Page 1
DA80F and DA95F
AddressRight™ Fixed Head Printers
DA80F (WF81)
DA95F (WF96)
Service Manual
Page 2
FCC Compliance
This equipment had been tested and found to comply with the limits for a Class A digital device,
pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection
against interference when the equipment is operated in a commercial environment. This equipment
generates, uses, and can radiate radio frequency energy, and if not installed and used in accordance
with the users manuals, may cause harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interference in which case the user will be
required to correct the interference at his own expense.
Shielded cables must be used with this unit to insure compliance with Class A limits.
Canadian DOC Compliance
This digital apparatus does not exceed in the Class A limits for radio noise emissions from digital ap-
paratus set out in the Interference-causing Equipment Regulations (Standard ICES-003) of the Canadian Department of Communications.
Le present appareil numerique n’emet pas de bruits radioelectriques depassant les limites applicables aux appareils numeriques de la class A prescrites dans le Reglement sur le brouillage radioelectrique edicte par le ministere des Communications du Canada.
NOTE: This equipment has been tested and found to comply with the U.S. Standard for Safety
UL1950, Third Edition, Safety of Information Technology Equipment including Electrical Business
Equipment and Canadian Standards C22.2 No 950-95, Third Edition, Safety of Information Technology Equipment including Electrical Business Equipment
First Edition, December 2007
SV61962 Rev. A
©2007 Pitney Bowes Inc.
All rights reserved. This book may not be reproduced in whole or in part in any fashion or stored in a
retrieval system of any type or transmitted by any means, electronically or mechanically, without the
express written permission of Pitney Bowes Inc.
We have made every reasonable effort to assure the accuracy and usefulness of this manual, however, we cannot assume responsibility for errors or omissions or liability for the misuse or misapplication of our products.
Page 3
Table of Contents
Chapter 1 – Introduction
1.1 Purpose of this Manual .............................................................. 1-1
1.2 Related Publications .................................................................. 1-1
1.3 Book Organization ..................................................................... 1-2
1.4 Safety ........................................................................................ 1-2
Chapter 2 – Specifi cations
2.1 Product Description ................................................................... 2-1
2.2 System Requirements ............................................................... 2-1
2.3 Physical Equipment Specifications ............................................ 2-2
2.4 Print Specifications .................................................................... 2-3
2.5 Material Specifications............................................................... 2-7
Chapter 3 - Theory
3.1 Changes From Earlier Models .................................................. 3-1
3.2 Printer Architecture .................................................................... 3-2
3.3 Operating Sequence.................................................................. 3-6
Chapter 4 - Troubleshooting/Diagnostics
4.2 Block Diagrams ........................................................................ 4-2
4.3 Main Controller Board Diagnostics ........................................... 4-4
4.4 Error Codes ............................................................................... 4-9
4.5 Print Samples for Troubleshooting .......................................... 4-12
4.6 Feeding Issues ........................................................................ 4-14
4.7 Printing Issues ......................................................................... 4-19
4.8 Display Issues ......................................................................... 4-23
4.9 Miscellaneous Issues .............................................................. 4-23
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
iii
Page 4
Table of Contents
Chapter 5 - Removal & Replacement
5.1 List of Procedures...................................................................... 5-1
DA80F (WF81) Parts Removal
5.2 Rear Cover and Keyboard/LCD Display Board ......................... 5-3
5.3 Main Processor Board ............................................................... 5-4
5.4 Encoder Assembly .................................................................... 5-6
5.5 Paper Top Sensor Assembly (Emitter) ...................................... 5-9
5.6 Paper Bottom Sensor Assembly (Receiver) .............................. 5-9
5.7 Feeder Sensor Assembly (Emitter and Receiver) ................... 5-10
5.8 Front Bottom Cover Assembly ..................................................5-11
5.9 Transport Timing Belt .............................................................. 5-12
5.10 Feed Motor Timing Belt ......................................................... 5-13
5.11 Feed Roller Pulley and Feed Roller Assembly ...................... 5-14
5.12 Feed Motor Assembly and Encoder Harness Assembly........ 5-16
5.13 Transport Motor Assembly ..................................................... 5-18
5.14 H-Block Assembly (Media Separators) .................................. 5-20
5.15 Print Head Cables and Print Head Boards ............................ 5-21
5.16 Entry Idler Roller Arm ............................................................ 5-28
5.17A Feed Deck ............................................................................ 5-30
5.17B Front Plate Assembly ........................................................... 5-32
5.18 Transport (Metal Grit) Roller .................................................. 5-34
5.19 Exit (Rubber) Roller ............................................................... 5-35
5.20 Power Supply ........................................................................ 5-36
5.21 Print Head Access Door ........................................................ 5-38
DA95F (WF96) Parts Removal
Standard Feeder (WF9S)
5.22 Rear Cover/Side Guides ....................................................... 5-39
5.23 Lower Sensor Receiver Assembly ......................................... 5-41
5.24 Feeder Top Sensor (Emitter) Assembly ................................. 5-42
5.25 “H Block” Roller (Media Separator) ...................................... 5-43
5.26 Feed Belts and Rollers .......................................................... 5-44
5.27 Motor/Drive Assembly............................................................ 5-46
iv DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 5
Table of Contents
Chapter 5 - Removal & Replacement (continued)
DA95F (WF96) Parts Removal
Printer Section
5.28 Printer Top Cover ................................................................... 5-48
5.29 Front Cover and Keyboard/LCD Display Board..................... 5-49
5.30 Rear Cover and Processor Board ......................................... 5-51
5.31 Paper Sensor and Sensor Bar............................................... 5-54
5.32 Entry Roller Support Assembly .............................................. 5-55
5.33 Intermediate Idler Rollers Assembly ...................................... 5-56
5.34 Idler Roller Support (“Module A”) Assembly .......................... 5-57
5.35 Idler Roller Support (“Module B”) Assembly .......................... 5-58
5.36 Print Head Cables and Print Head Boards ............................ 5-59
5.37 Belt Drive Assembly............................................................... 5-67
5.38 Media Belts ............................................................................ 5-69
5.39 Encoder Assembly ................................................................. 5-71
5.40 Drive Belt/Motor Assembly .................................................... 5-74
5.41 Power Supply ........................................................................ 5-75
Chapter 6 - Adjustments
6.1 List of Adjustments ................................................................... 6-1
Adjustments for All Models
6.2 LCD Display .............................................................................. 6-2
6.3 Feeder Sensor Test and Calibration ......................................... 6-2
DA80F (WF81) Adjustments
6.4 Leveling the Print Head Assembly to Deck (Belts) .................. 6-3
DA95F (WF96) Adjustments
6.5 Leveling the Print Head Assembly to Deck............................... 6-5
6.6 Adjustable Thickness Knob and Eccentric Sprockets ................ 6-6
Chapter 7 - Maintenance Procedures
7.1 General Maintenance ................................................................ 7-1
7.2 Specific Maintenance ............................................................... 7-2
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
v
Page 6
Table of Contents
Appendix A – Printer Control Panel Menus and Utilities
A.1 Control Panel Menus for the Printer ..........................................A-1
A.2 LCD Control Panel Menu .........................................................A-3
A.2 LCD Main Menu .......................................................................A-4
A.3 LCD Setup Menu ......................................................................A-9
A.4 LCD Service Menu ................................................................. A-19
A.5 Setting Factory Defaults (from LCD Menu) ............................. A-24
A.6 Updating Firmware .................................................................A-26
Appendix B – Printer Communications
B.1 Communication Scenarios ........................................................B-1
B.2 Troubleshooting Tables .............................................................B-4
B.3 Testing Printer Communications Within a Network ...................B-6
Appendix C – Schematics
Main Processor Board for Both Printers ...........................................C-2
DA80F (WF81) Printer Block Diagram .............................................C-3
DA95F (WF96) Printer Block Diagram .............................................C-4
Appendix D – Print Head Alignment
D.1 Reason for this Appendix ..........................................................D-1
D.2 Print Head Alignment Procedure...............................................D-2
Appendix E – Printing Standards
E.1 USPS® Delivery Point Barcode (DPBC) ...................................E-1
E.2 USPS® PLANET Code Barcode ...............................................E-3
Index ..........................................................................I-1
vi DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 7
1 • Introduction
1.1 Purpose of
this Manual
1.2 Related
Publications/
Information
This manual contains instructions for troubleshooting and site repair of DA80F
(WF81) and DA95F (WF96) AddressRight™ fixed head printers. It also includes
complete product specifications and a section on theory for training purposes.
For reference, the table below shows the predecessor fixed head models.
New
Marketing
Model
DA80F WF81 Black and
DA95F WF96 Black and
DA80F Operator Guide SV61722
DA80F Parts List SV62033
DA95F Operator Guide SV61749
New
PCN
Printing
Capability
spot color
spot color
Speed Predecessor
Marketing
Model
Up to 22,000
#10 or DL
envelopes
per hour
Up to 30,000
#10 or DL
envelopes
per hour
DA400 W400
DA950 W803
Predecessor
PCN
DA95F Parts List SV62034
DA80/DA95F Hardware Install (US/Canada only) SV61747
DA80/DA95F Hardware Install (outside of US/Canada) SV61774
AddressRight Printer Drivers and
Envelope Designer™ Plus Software Install SV61108
Customer Tutorial for Setting up a DAxxx Series Printer
Using the AddressRight Printer Control Panel Application SV61986
For other information on the printers, refer to these sources:
• Software Control Panel Application (on the host PC) - see the help sys-
tem on the software.
• FAQs document - see the Customer Service website under the product
page for AddressRight™ printers.
• Training - see Enhanced AddressRight™ Fixed Head Printers Self-Directed Course (GMS-MC-03248) at My Portfolio on the Pitney Bowes intranet.
• Training Job Aids - print the job aids for the software control panel appli-
cation (GMS-MC-03248JA) at My Portfolio on the Pitney Bowes intranet.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
1-1
Page 8
1 • Introduction
1.3 Book
Organization
1.4 Safety
Chapter 1: Introductory and safety information
Chapter 2: Product specifications
Chapter 3: Theory of operation
Chapter 4: Troubleshooting and Diagnostics
Chapter 5: Removal and replacement procedures
Chapter 5: Adjustment procedures
Chapter 7: Maintenance procedures
Appendix A: Printer Control Panel Menus
Appendix B: Printer Communications
Appendix C: Schematics/Diagrams
Appendix D: Print Head Alignment
Appendix E: Printing Standards
Warning messages appear throughout this manual to alert you to potentially
hazardous con di tions. Two designations indicate their relative seriousness:
WARNING! Calls attention to improper practices that
could result in a potentially serious, even lethal injury to
you or the customer.
CAUTION! Calls attention to practices that could
cause minor injury to you or a customer or that could
damage equipment or material.
Familiarize yourself with proper procedures and methods before you install,
operate or re pair the equipment to avoid personal injury or damage to the
equipment. If you train service peo ple or equip ment operators, it is important to
explain safety precautions to your students and en cour age safety awareness.
Personal Safety
Follow these precautions for your own safety:
• Treat every circuit like a gun that may be loaded. It may not be “live,” but be
sure. Check with a neon tester or voltmeter, or simply unplug the machine.
• Know how to turn off power in the work area and get help in an emer gen cy.
• Don’t un der es ti mate the danger of shock: 1 mA (1/1000 amp) is un com fort able; 5 mA is dan ger ous —you may jump back and be injured; 12 mA
causes hand muscles to con tract, so you can not free your self; 24 mA has
proven fatal; and 100 mA (1/10 amp) is likely to be fa tal.
1-2 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 9
Introduction • 1
1.4 Safety
Personal Safety (continued)
• Don’t work on equipment under power unless it’s absolutely necessary.
If you must, use extreme cau tion. Don’t grasp two sides of a live circuit
at the same time—use one hand when reach ing into a cir cuit, touching
a ground ed case or chas sis with that wrist or el bow if pos si ble. This pre vents cur rent from passing through vital organs. Observe this rule when
con nect ing or dis con nect ing plugs or leads, or mak ing any adjustments
on a live cir cuit.
• Use the right tools for the job. A tool which slips can cause a short—or a
shock. Don’t reach into a circuit with metal tools, or while wearing rings or
a watch. Even in low voltage cir cuits, a metal object can short circuit two
terminals. When work ing on live cir cuits, use tools with in su lat ed handles
and try to keep your tool hand grounded.
• Don’t bypass safety devices, particularly fuses. Three-wire outlets (120
Vac) are designed to ground equipment to make it safe. If a hot wire
shorts to a grounded frame, the only result is an open fuse. If a hot wire
shorts to an ungrounded frame, the frame itself be comes hot and po ten tial ly dangerous. A fuse is a weak link in a circuit, de signed to break down
before any thing else does. The maximum safe cur rent in a circuit is de ter mined by the de sign ers. Too large a fuse can pass excessive current,
dam ag ing expensive equipment.
• For electrical fires, use Type C, BC or ABC extinguishers only. Don’t use
soda acid or other liq uid stream extinguishers. They will damage elec tri cal equipment and present a shock hazard to the user.
• Digital equipment can be easily damaged or destroyed by static charges.
Mi cro pro ces sors and other integrated circuits con tain tiny transistors not
much more than a mil lionth of an inch across, which operate at 5 to 12
volts.
• Be extremely careful when lifting heavy equipment. Follow the guidelines
below:
a. Squat to lift and lower. DO NOT bend at the waist.
b. Keep your low back bowed in while bending over.
c. Keep the weight as close to you as possible.
d. Bow your back in and raise up with your head first.
e. If you must turn, turn with your feet, not your body.
f. Never jerk or twist!
g. Put the weight down by keeping your low back bowed in.
h. Keep your feet apart, staggered if possible.
i. Wear shoes with non-slip soles.
j. Get help if you need it.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
1-3
Page 10
1 • Introduction
1.4 Safety
Electrostatic Discharge (ESD) Procedures
Follow these guidelines to protect sen si tive equipment from static damage:
• Always use a wrist grounding strap and anti-static mat when working on
equipment sensitive to electrostatic discharge. These items are furnished
in the ESD Field Service Kit, L-8351.
• Ground yourself before reaching into the equip ment, or touch ing any
circuit board or other electrical component. Just touch ing a doorknob or
metal work bench may be enough, but the best guarantee is to turn the
machine off but leave it plugged in, and ground your self on the chassis,
which is grounded through the three-wire power cord.
• Be careful of rugs—even a few steps can recharge you. Re-ground yourself whenever you’ve walked away and re turned to the ma chine. Rugs
are a major source of static build up in the body.
• Take greater precautions as the objects you handle get smaller. A board
in the machine is better protected than one that is not plugged in; a chip
on a board is better protected than one in your hand.
• Stay away from metal conductors. The plastic and resin that chips and
boards are made of are much better insulators than metal. It’s most important to keep your hands away from any metal which contacts the data.
In particular, this means the long connector along the bottom of each
board, and the pins coming out of the chips. These signal and data lines
are directly connected to the fragile inner circuits of the chips. When handling a board, try not to touch the connector; when handling a chip, try
not to touch the pins.
1-4 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 11
2 • Specifications
2.1 Product
Description
2.2 System
Requirements
The DA80F (WF81) and DA95F (WF96) ink jet printers are fixed head type
desktop models used to print addresses, graphics and other information, in
black ink and spot color on a wide range of material sizes, construction and
composition. The operator can define the font, placement, print quality and bar
code characteristics for the printed addresses.
Customer PCs must meet the following minimum requirements:
• CPU: Pentium III 500MHz. or greater, 500MB RAM or more preferred
• USB Cable/Ethernet Cables cable are supplied with the printer. If the
customer chooses to use another USB cable, it must be no longer than
15 feet (5 meters).
• Windows 2000 SP4, Windows XP Pro SP2, Windows Server 2003 SP1
w/latest Service Pack, and Windows Vista
• Dot Net v2.0
• 5MB Disk space
• Administrative rights to install software
2.3 Physical
Equipment
Specifications
Physical Dimensions
DA80F
17.9" (455mm) high; 18.5" (470mm) wide; 17.7" (450mm) deep
DA95F:
15” (380mm) high; 24” (609.6mm) wide; 27” (685.8mm) deep
Weight
DA80F:
53 lbs. (24 kg), including print cartridges and output stacker.
DA95F:
88 lbs. (39.9 kg), Feeder 28 lbs. (12.7 kg), Printer/Feeder 116 lbs. (52.6 kg)
Electrical
Domestic: 100-240 VAC, 50/60 Hz, 5.0 A
Power Consumption: 575 Watts, 1962 BTU/hr.
Agency Approvals
TUV/UL/cUL/VDE-GS - Refer to the FCC and CE statements at the front of
this manual for more information.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
2-1
Page 12
2 • Specifications
2.3 Physical
Equipment
Specifications
Interface
USB, Ethernet
Control Language
PCL5, enhanced
Environmental Limits
Operating Conditions and Longterm Storage
• Temperature: 55 to 95°F (10 to 35°C)
• Humidity: 8 to 80%
• Maximum Wet Bulb Temperature: 80°F (27°C)
Shipment Conditions
• Temperature (Printer): -4 to 140°F (-20° to 60°C)
• Humidity (Supplies): 5 to 85%
• Maximum Wet Bulb Temperature: 85°F (29°C)
Noise Level
DA80F
The sound pressure level at the operator’s position for this equipment as measured in any mode using ANSI and ISO Standards is no more than 75 dB(A).
DA95F
The sound pressure level at the operator’s position for this equipment as measured in any mode using ANSI and ISO Standards is no more than 76 dB(A).
2-2 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 13
Specifications • 2
2.4 Print
Specifications
Print Modes (Print Resolution)
The printers have four print resolutions; they are Executive (600 DPI), Letter
(300 DPI), Draft (200 DPI), and Super Draft (150 DPI), which represent the
horizontal density. Additionally, there are two Light Mode settings (ON and
OFF), which represent the vertical density. When Light Mode is “ON”, the
vertical density setting is 300 DPI; when Light Mode is “OFF” the vertical density setting is 600 DPI. Refer to the table below for print mode options.
Print Quality With Light Mode set to
"ON"
Executive 600 x 300 DPI 600 x 600 DPI
Letter 300 x 300 DPI 300 x 600 DPI
Draft 200 x 300 DPI 200 x 600 DPI
Super Draft 150 x 300 DPI 150 x 600 DPI
With Light Mode set to
"OFF"
Fonts
Resident Fonts
Arial, Comic Sans MS, Courier New, Georgia, Impact, Kino, MSLogo, Symbol, Tahoma, Times New Roman, Trebuchet MS, Verdana, Webdings, Wingdings, plus there must be included one OCR and one Code 39 font. (All fonts
are scalable from 4 to 108 pt size.)
Resident Font Enhancements
Bold, Underline, Italic
Downloadable Fonts
Supports TrueType and Bitmapped fonts.
Downloadable Graphics
Supports Bitmap and PCL Raster images up to 40 sq in. (258 sq. cm). This
translates to images up to 3" x 13.3" (76mm x 338mm) for the DF95.
User-Definable Parameters
• Font Characteristics
• Address Placement
• Barcode Characteristics
• Print Quality
Barcode Printing Position
The printer can print a barcode in one of three positions:
• Above the address block
• Below the address block
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
2-3
Page 14
2 • Specifications
2.4 Print
Specifications
✍
TIP: Do not attempt
to print "high density"
barcodes, that is, those
barcodes whose narrow elements are less
than 0.010" (.254mm).
Barcode Printing Types Position
All the printers in the DA Series can print the following barcodes:
1-Dimensional
• USPS Certified POSTNET barcode. All types of barcodes can be printable including FIM, 3 of 9, 4 state barcode (USPS, UK, Canadian, Euro,
Australia, etc.) and others.
• Planet barcode for delivery confirmation services.
• The printer is also capable of printing any barcode rendered by a Windows® True Type font.
2-Dimensional
The printers are capable of printing a USPS Certified IBIP barcode as well as
all types of 2-D barcodes defined for the UK, Canada, Europe, Australia, etc.,
and others to the defined standards. Reference applicable Postal Standards.
NOTE: Do not attempt to print "high density" barcodes. The narrow elements
should not be less than 0.010" (.254mm).
Special Note on FIM Barcode
FIM (Face Identification Marking) barcode was developed by the USPS as
part of their POSTNET barcoding system. It is normally used by high-volume
mailers to put on return envelopes for their customers’ invoices.
When the invoices are mailed back in their return envelope, the USPS sorts
and processes this mail according to what version of FIM barcode is used on
the envelope: FIM A (Postage required, POSTNET bar code included), FIM
C (Postage prepaid, POSTNET bar code included), and FIM D (Postage required, POSTNET bar code not included).
One of the requirements of the FIM barcode is that it needs to be printed on
the edge of the envelope (typically printed in the top right corner). Any attempt to print to the exact edge of the envelope is liable to "miss" the edge
occasionally. Because of these issues, we cannot guarantee full USPS
compliance for printing FIM barcode. As a result, some of our high-volume
customers used pre-printed envelopes containing the FIM barcode that meet
USPS printing specifications.
However, if you want to try printing the FIM using our printers, the Pitney
Bowes Envelope Designer Plus software allows you to place a FIM graphic
on the envelope. You can obtain photo-ready graphics directly from the
USPS (the Envelope Designer software itself can not create the FIM barcode
graphic).
2-4 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 15
Specifications • 2
2.4 Print
Specifications
Effective Print Area
The printable width is the width of the piece measured from the right side of
the piece of mail. The printable height is 1.5" (38mm) for the DA80F and 3”
(76mm) fro the DA95F.
NOTES:
• All envelopes should be loaded so the side to be printed faces up, flap
faces down, stacked to feed with the left or right edge first. See example
that follows.
Example of Normal Orientation
This Side Prints
This Side Prints
Flap down, close to operator
Feed Edge
feeds into
printer.
Flap down, close to operator
• If running an inverted job (image prints upside down on media) your envelopes will load like the example below.
Feed Edge
feeds into
printer.
Example of Inverted Orientation
Feed Edge
feeds into
printer.
This Side Prints
Flap down, and away
from operator
Feed Edge
feeds into
printer.
This Side Prints
Flap down, and away
from operator
• All edges are viewed from the front surface of the material.
• Two clear zones, each 0.3" (7.6mm) wide, are required on the piece of
mail to allow clearance for the exit rollers.
• Printing is allowed to the top edge of the media, however print quality will
be degraded.
Print Heads
Able to produce spot color by swapping a black cartridge with a color cartridge on any head.
DA80F: 3 head capacity
DA95F: 6 head capacity
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
2-5
Page 16
2 • Specifications
2.4 Print
Specifications
Inkjet Cartridges
Cartridges are operator replaceable. The ink supply cartridges for the
DA80F and DA95F are the same ones used on their predecessor models
(see table on page 1-1). The table below lists some common order numbers for replacement cartridges. For a complete list of ink cartridges, go to
http://www.pb.com/supplies. In the Find Your Supplies field on the left pan-
el, select “AddressRight” from the dropdown list provided. Follow the links for
the model of your printer from the web page that displays.
Model Printing Capability Black Cartridge Color Cartridge
DA80F Black and Spot Color
DA95F Black and Spot Color
HP Versatile Black
C8842A
HP Versatile Black
C8842A
HP 45 Spot Color Cartridges
Approved
HP 45 Spot Color Cartridges
Approved
Useful Life
User replaceable black and color ink jet cartridges. A cartridge printing 3 line
addresses with "light" mode off will provide approximately 30,000 pieces in
executive mode, 60,000 letter, 90,000 draft and 120,000 super draft, depending printer settings, materials and image density.
Print Position Accuracy
For a #10 or DL envelope (Acclaim #10 WW Commercial, Regular):
• Horizontal: within +/- 1.5 mm
• Vertical: within +/- 1.5 mm
• Skew: within +/- 1 degree
For other media:
• Horizontal: within +/- 3.0 mm
• Vertical: within +/- 3.0 mm
• Skew: within +/- 2-1/2 degrees
Recommended Usage
The printers have been tested under many different conditions. Use of the
printer should fall within these piece usage recommendations:
Monthly Piece Usage Product Life
Typical Maximum
DA80F 176,000 240,000 5 years or 14,400,000 cycles
(whichever comes first)
DA95F 480,000 1,000,000 5 years or 60,000,000 cycles
(whichever comes first)
NOTE: Usage beyond the maximum monthly pieces is not covered by the
Equipment Maintenance Agreement (EMA).
2-6 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 17
Specifications • 2
2.4 Print
Specifications
✍
TIP: Any network
the print data has to
flow through to reach
the printer may affect (reduce) printer
throughput.
2.5 Material
Specifications
Throughput
DA80F: 22,000 envelopes hour
DA95F: 30,000 envelope per hour
Based on:
• "Super Draft" mode print quality
• 3-line destination address
• 18 characters per line
• 12-point character size
• Time New Roman font
NOTE: Adding graphics and/or printing at a higher resolution (e.g., Draft, Let-
ter, Executive mode) will decrease throughput.
For envelope addressing purposes, the printer is compatible with any word
processor or database application that can print a mailing label.
The paper types listed below are approved for use with the printer. Please note
that the dimensional limits above apply in all cases, and that all media (enve-
lopes, postcards, flats, etc.) should be without windows.
• White Wove
• Bond paper
• Recycled paper
• Coated paper
• Card stock
• Brown kraft
• Manila
• Perforations
Refer to the table below for media size specifications.
Media Sizes
DA80F DA95F
Min. width 5" (127 mm) 5" (127 mm)
Max. width 14" (355 mm) 14" (355 mm)
Min. height (length) 3.5" (89 mm) 3.5" (89 mm)
Max. height (length) 15.5" (393 mm) 15.5" (393 mm)
Min. thickness 0.003" (0.08 mm) 0.003" (0.08 mm)
Max. thickness 0.25" (6.3 mm) 0.50" (12.7 mm)
Input Feeder Capacity
DA80F/DA95F: 500 #10 or DL Envelopes
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
2-7
Page 18
2 • Specifications
2.5 Material
Specifications
Approved Media
• Envelopes normally have a flap along the long edge and are processed
by the printer non-flap edge first (see illustration)
Non-flap
Lead Edge
Flap Edge
(flap faces down)
Envelopes may have either a diagonal or straight edge along the enve-
lope flap. Envelopes may have either a diagonal or straight edge along
the envelope flap. Stuffing materials must be machine folded (C, Z, or 1/2
folded) or cut sheets.
• Booklets are defined as media having physical dimensions 6" x 9”
(152mm x 229mm) or larger. Booklets have an opening along their long
edge which is covered by a flap with an adhesive seal.
• Catalog Envelopes have an opening along their short edge which is
closed by a flap with an adhesive seal. A catalog may consist of multiple
pages bound by adhesive or tabs on the feed edge or at 90 degrees with
respect to the feed edge. Material that is too stiff will cause feed problems.
• Postcards have no folds or bends. The printable side may have a higher
surface roughness than the non-printable side.
• Self-mailers may be of “C,” “Z,” or half-folded construction. They may not
exceed the maximum allowable thickness as specified on the previous
page and must be tabbed per postal regulations. Half-folds and tri-folds
must be machine produced.
• A catalog may consist of multiple pages bound by adhesive or tabs on
the feed edge or at 90 degrees with respect to the feed edge.
2
• Sheet stock may consist of 20 to 28 lb. (75 to 105g/m
) bond as well as
60 to 80 lb. (220 to 300g/m2) coated stock. The size and thickness constraints specified above apply.
2-8 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 19
Specifications • 2
2.5 Material
Specifications
Unapproved Material
• Contaminants – material with visible material loss (loose powder, ink, sur-
face glaze, etc.) when hung free over a clean surface and struck sharply
with a standard wood ruler.
• NCR paper
• Special Materials – materials that are sensitive to heat such as thermal
papers, any pressure-sensitive materials, and materials that are sensitive
to minor magnetic fields.
• Excessively Glossy Paper – this is material whose surface frictions falls
outside the guidelines given here (and in chart below).
- Material shall not slide when placed on a 18% slope (10.2 degrees).
- Envelopes shall not slide when placed on a 33% slope (18.2 degrees).
- Material shall slide when placed on a 70% slope (35 degrees).
To test material for proper surface friction (a clipboard is ideal for this test):
1. Secure bottom piece to slope and place ten pieces on top of the bot-
tom piece. Material shall be tested with short edge leading.
2. Raise the clipboard until any portion of the stack begins to slide. The
height to length ratio of the clipboard is the % slope. .
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
2-9
Page 20
2 • Specifications
2.5 Material
Specifications
✍
*Chou #3 Yoko, Chou
#4 Tate, and Hagaki
sizes cannot be used
with DA80F/DA95F
because they do not
meet the minimum
envelope width of
127mm (5 inches)
when run through the
printer in their usual
orientation.
Common Envelope/Paper Sizes
Paper Name Displayed in List Size (Width) Size (Height)
US/Canada Envelope/Paper Sizes
ENV_9 Envelope #9 8⅞"3⅞"
ENV_10 Envelope #10 9½" 4⅛"
ENV_11 Envelope #11 10⅜" 4½"
ENV_12 Envelope #12 11" 4¾"
PPR_Booklet_9_12 Booklet 9 x 12 12" 9"
ENV_MONARCH Envelope Monarch 7½" 3⅞"
PPR_Card_4_6 Card 6 x 4 6" 4"
PPR_Card_5_7 Card 7 x 5 7" 5"
LETTER Letter 8½" 11"
LEGAL Legal 8½" 14"
EXECUTIVE Executive 7¼" 10½ in
European Envelope/Paper Sizes
ENV_B4 Envelope B4 353mm 250mm
ENV_B5 Envelope B5 250mm 176mm
ENV_B6 Envelope B6 176mm 125mm
ENV_C4 Envelope C4 324mm 229mm
ENV_C5 Envelope C5 229mm 162mm
ENV_C6 Envelope C6 162mm 114mm
ENV_C65 Envelope C65 229mm 114mm
PG_ENV_C76 Envelope C76 162mm 81mm
PG_ENV_C7 Envelope C7 114mm 81mm
ENV_DL Envelope DL 220mm 110mm
ENV_DLX Envelope DLX 235mm 120mm
ENV_DLE Envelope DLE 225mm 114mm
A4 A4 210mm 297mm
A5 A5 148mm 210mm
Asian Envelope/Paper Sizes
Envelope 12JE 140mm 265mm
Envelope 9JE 190mm 265mm
Envelope 6JE 215mm 305mm
Envelope ZL [China] 230mm 120mm
Chou #3 Yoko* 120mm 235mm
Chou #4 Tate* 90mm 205mm
Hagaki* 100mm 148mm
Postcard #3 165mm 102mm
Postcard #4 183mm 100mm
Maximum Paper Size 14" (356mm) 15.5" (394mm)
2-10 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 21
3 • Theory
3.1 Changes
From Earlier
Models
The DA80F (three print heads) and DA95F (six print heads) are fixed head,
ink jet desktop printers. The DA80F (WF81) and DA95F (WF96) printers are
based on the previous Pitney Bowes fixed head printers (DA400 and DA950,
respectively). For those familiar with the older models, the changes implemented include:
• Updated Main Board, as well as LCD/Keyboard Board/Print Head Driver
Board. Same Main Board used in both DA80F/DA95F models. Now
100% RoHS compliant.
• Elimination of Centronics (parallel) connector; replaced by Ethernet connector (USB port kept)
• Improved paper sensor calibration now accessible via LCD Service menu
• New options on the LCD control panel menus for greater flexibility and
control
• Introduction of a Pitney Bowes “software control panel” (running under
Windows on a separate PC) which mimics the features of the printer’s LCD
control panel while also adding more diagnostic and administrative features
• Control panel menu supports bulk cartridge ink management (“low ink“
warning now works when using these types of cartridges)
• Removed large transformer and replaced with heavier duty power supply
(allows a graceful shutdown of the printer and for the software parameters
to be saved). Same supply as used in DA5xx/DA7xx shuttle-head printers.
• Print heads now raise up straight (instead of to the side) which allows
easier access to wipe and clean the print heads
• One printer software for all functionality (uses PB monolithic driver)
• Support for 18 languages in the Operator Guide, soft control panel, and
drivers
DA95F-Specific Improvements
• Removed feeder board (used in predecessor DA950 model)
• New exit sensor and new feeder deck extension
• New “feet” on bottom of feeder allows better alignment of feeder
• Two new idler roller assemblies provide better control of the media
through the print path resulting in better print quality and more accurate
placement of printed items
DA80F-Specific Improvements
• New feeder clutch added
• Added auto-tensioner on drive belts.
• Media thickness range increased from 1/8” to ¼”
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
3-1
Page 22
3 • Theory
3.2 Printer
Architecture
The printer system is made up of several sub-systems (see also Figure 3-1):
• Universal Power Supply - The universal power supply has auto sensing/
switching for input voltage and intelligent shutdown capability. It ensures
proper parking of the cartridges in the maintenance station and proper
shutdown of the software. (It is the same supply used in the midrange
DM series mailing machines.)
• System Controller - The system controller is comprised of the overall op-
erating system in the firmware that controls the behavior of the system
and coordinates activities between the other sections.
• User Interface - The user interface is the LCD display, the buttons, and
the software to drive it within the firmware.
• Feeder and Transport Motion Control - The feeder and transport motion
control is responsible for feeding and positioning the envelope beneath
the printer for printing. All material motion is controlled by the transport
motor and firmware.
• Head Management - The head management controls the proper operation
of the print cartridges.
• Communications - The communications hardware and firmware are re-
sponsible for the interface to the host PC through which print streams are
received and passed to the system controller for parsing and rendering.
Power
Universal Power
Supply
Communications
USB Ethernet
Busy/Error
System
Controller
Head
Management
Display
Te xt
User Interface
Motion Control
Operator
Input
Feeder
and
Transport
LED
3-2 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Figure 3-1 Printer System Functional Architecture
Page 23
Theory • 3
3.2 Printer
Architecture
✍
TIP: Module A =
Print Heads 1, 2, 3
Module B =
Print Heads 4, 5, 6
Throughput
Cycle Time
Values
Material #10 Envelope
Model
22828
0.158
60.000
50.000
40.000
30.000
20.000
10.000
0.000
-10.000
0.0000 0.1000 0.2000 0.3000 0.4000 0.5000 0.6000 0.7000
WF81
Figure 3-2 DA80F (WF81) Printer Timing Diagram
Throughput 32230
Cycle Time 0.112
90.000
70.000
Print Sensor
50.000
Values
30.000
pcs/hr
sec
Module A Printing
Feeder Sensor
pcs/hr
sec
Exit Sensor
Module A Printing
Module B Printing
Print Sensor
Timing Diagram
Piece 1 Piece 3Piece 2
Time
Timing Diagram
Feeder Sensor
Piece 1 Piece 3
Piece 2
1.5
1
0.5
0
-0.5
-1
-1.5
-2
-2.5
2.5
2
1.5
1
0.5
0
-0.5
-1
10.000
-10.000
Material #10 Envelope
Model WF96
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
-1.5
-2
-2.5
0.0000 0.1000 0.2000 0.3000 0.4000 0.5000 0.6000 0.7000
Time
Figure 3-3 DA95F (WF96) Printer Timing Diagram
3-3
Page 24
3 • Theory
3.2 Printer
Architecture
On Line
_
Menu Enter
+
Test Env.
Figure 3-4 User Interface ( Control Panel) on Printer
The buttons on the control panel perform the following functions:
Button Description
ON LINE
_
(minus)
Menu
Enter
(plus)
+
Test Env
• Toggles (switches) between ON LINE (communicates with host
PC) and OFF LINE (no communications with host PC).
• Exits the menu system.
• Decrements a value.
• Moves backwards through a choice list.
• Negative response to query.
• Enters the menu system when OFF LINE.
• Exits a submenu.
• Selects and/or saves the displayed value.
• Causes system to perform described action.
• Advances to next screen.
• Increments a value.
• Moves forward through a choice list.
• Affirmative response to a query.
• Prints a test piece when OFF LINE.
• Prints a report for specific menu items.
NOTE: See Appendix A, Printer Control Panel Menus for a full explanation of
all the menu options.
3-4 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 25
Theory • 3
3.3 Operating
Sequence
When the printer is either, “off line” (led is unlit) and the [test] button is depressed, or the printer is “on line” (led is lit) and a valid address is received
from the computer, the belt drive motor will be energized. A belt, driven by
the motor, drives the belt drive roller assembly which in turn drives the media
belts.
The printer motor will be energized. The printer belt connects the printer motor to the transport roller and exit roller. The processor board will compare
the speed of the encoder on the transport roller to calculate the desired
speed.
The feed motor will be energized, and the feed rollers and feed belt will rotate, pushing the bottom piece of media between the rollers and the “h” block
media separators. The frictional design of the “h” block media separator is to
restrict all but the bottom piece of media.
The feed roller moves the piece of media between the entry idler rollers and
the transport rollers. The speed differential between the transport rollers and
the feed rollers will create a gap between the moving pieces. The feeder
photo sensor assembly is energized as the piece of media is pushed out.
The transport roller continues to push the leading edge of the media into the
path of the printer sensor. When the leading edge of the media is detected
by the printer sensor assembly, two things occur:
• Position counting begins so that printing will occur at the preprogrammed
position on the media. This pre-programmed position is set in the address layout or is controlled by the software driver.
• The media is captured between the exit roller and the exit idler roller
where it is ejected from the printer. In the DA95F, an exit sensor captures
the piece exit data.
This process is repeated until all the records in the file are printed.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
3-5
Page 26
3 • Theory
3-6 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 27
4 • Troubleshooting/Diagnostics
4.1
Troubleshooting
Overview
✍
TIP: See Appendix B
- Printer Communications, for troubleshoot-
ing problems relating to
networking and printer
communications.
This chapter discusses printer troubleshooting in the following sections:
4.2 Block Diagrams ........................................................................ 4-2
4.3 Main Controller Board Diagnostics ........................................... 4-4
4.4 Error Codes ............................................................................... 4-9
4.5 Print Samples for Troubleshooting .......................................... 4-12
4.6 Feeding Issues ........................................................................ 4-14
4.7 Printing Issues ......................................................................... 4-19
4.8 Display Issues ......................................................................... 4-23
4.9 Miscellaneous Issues .............................................................. 4-23
When You Start Y our Troubleshooting
When any paper handling/printing errors begin to occur frequently, perform
the following standard printer setup procedures in the order given. There is
a high likelihood that performing these procedures will correct the error. If
these procedures do not correct the problem, then refer to the troubleshoot-
ing tables starting on page 4-14 for further actions, including part removal/
replacement.
Standard Printer Setup Procedures
(see DA80F or DA95F Operator Guides for specific instructions)
1. Verify that the output stack is not backing up into paper path
2. Recheck standard feeder setup procedures:
a. Adjust the “H” blocks
b. Adjust input ramp
c. Adjust feed guide
d. Verify stack weight limits
e. Adjust side guides
f. Check feed roller/belt surface for glazing
3. Check the thickness adjustment on the print heads
4. Check all adjustable nips for position and tension
5. Clean the paper path
6. Sensors:
a. Clean Sensors
b. Calibrate Sensors
c. Check Sensor Operation
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
4-1
Page 28
4 • Troubleshooting/Diagnostics
4.2 Block
Diagrams
Control Panel &
Display Board
WS82002
Paper Sensor
Emitter
Receiver
Feeder Sensor
Emitter
Receiver
Universal
AC Fan
Power Input
Power Supply
WS80001
Shaft
Encoder
M
Feeder Motor
Figure 4-1 DA80F (WF81)
Printer Block Diagram
Transport Motor
M
PB Stacker
Bryce Stacker
Feeder
Encoder
Control Panel &
Display Board
WS82002
Paper Sensor
Emitter
Receiver
Exit Sensor
Emitter
Receiver
Universal
AC Fan
Power Input
Power Supply
WS80001
Shaft
Encoder
M
Feeder Motor
External Feeder
Figure 4-2 DA95F (WF96)
Printer Block Diagram
Transport Motor
M
PB Stacker
Hi Speed Feeder
Feeder
Encoder
Emitter
Receiver
Feeder Sensor
4-2 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 29
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4.2 Block
Diagrams
Troubleshooting/Diagnostics • 4
Figure 4-3 DA80F (WF81)/DA95F (WF96) Printer Detailed Block Diagram
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
4-3
Page 30
4 • Troubleshooting/Diagnostics
4.3 Main Controller
Board Diagnostics
Figure 4-3 Main Controller Board Mounted in DA80F (WF81) Printer
Figure 4-4 Main Controller Board Mounted in DA95F (WF96) Printer
4-4 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 31
Troubleshooting/Diagnostics • 4
4.3 Main
Controller
Board
Diagnostics
J10 (Serial
Debug Port)
J6 (Print Head 6)
J5 (Print Head 5)
J4 (Print Head 4)
[J4, J5, J6 used
with DA95F only]
J12 (ThirdParty Stacker/
Conveyor for
DA80F)
J18 (LAN)
J20 (USB)
CR15
J21 (External High
Speed Feeder for
DA95F)
J22 (Feeder Sensor Emitter,
DA80F)
J24 (Feeder Sensor Receiver,
DA80F)
J25 (LCD Display)
CR27
J34 (Shaft Encoder)
CR28
J33 (Paper Sensor Receiver)
J32 (Paper Sensor Emitter)
J31 (Feeder Motor Encoder,
DA80F)
J30 (not used currently)
CR4, CR3, CR2,
CR1, CR5, CR25
J3 (Print Head 3)
J2 (Print Head 2)
J1 (Print Head 1)
[J1, J2, J3 used
with both DA80F
and DA95F]
J11 (for W98X
Series Stacker)
J29 (Exit Sensor Emitter,
DA95F)
J28 (Exit Sensor Receiver,
DA95F)
J27 (Transport Motor)
CR12
J26 (Feeder Motor,
DA80F)
CR11
J23 (Input Power)
Figure 4-5 Main Controller Board With Service-Related Components Called Out
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
J15 (Feeder Motor Sensor, Feeder
Motor Encoder Sensor, DA95F)
4-5
Page 32
4 • Troubleshooting/Diagnostics
4.3 Main
Controller
Board
Diagnostics
✍
TIP: See Appendix B
- Printer Communications, for troubleshoot-
ing problems relating to
networking and printer
communications.
Table 4-1 Main Board Connectors
Location Description Comments/Models Used On
J1 Print Head 1 Bank A
J2 Print Head 2
J3 Print Head 3
J4 Print Head 4 Bank B
J5 Print Head 5
J6 Print Head 6
J10 Serial Debug Port (Engineering use
only)
J11 W98x Series Stacker Allows communication to
J12 Third Party Stacker/Conveyor DA80F only
J15 Feeder Motor
Feeder Motor Encoder
Feeder Sensors
J18 LAN
J20 USB
J21 External High Speed Feeder (only
used if you are replacing the stan-
dard WF9S feeder)
J22 Feeder Sensor Emitter DA80F only
J23 Input Power
J24 Feeder Sensor Receiver DA80F only
J25 LCD Display
J26 Feeder Motor DA80F only
J27 Transport Motor
J28 Exit Sensor Receiver DA95F only
J29 Exit Sensor Emitter DA95F only
J30 Not used currently
J31 Feeder Motor Encoder DA80F only
J32 Paper Sensor Emitter
J33 Paper Sensor Receiver
J34 Shaft Encoder
DA95F only
Allows attachment of a serial
device to communicate with the
board
Pitney Bowes stackers: W980,
W981, W983, W984, W985,
W986
DA95F only
DA95F only
4-6 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 33
Troubleshooting/Diagnostics • 4
4.3 Main
Controller
Board
Diagnostics
✍
TIP: Device name
is unique to each
printer’s main board.
Therefore, replacing
an existing main board
in the printer gives that
printer a new device
name.
Table 4-2 Main Board LED Designations
LED Color
When
Lit
CR1 Red General purpose software
CR2 Red General purpose software
CR3 Green General purpose software
CR4 Green General purpose software
CR5 Green Configuration Complete for
CR11 Red Feeder Motor Current
CR12 Red Transport Motor Current
Description Normal State Error State
programing (during booting blinks once)
programing (during booting blinks once)
programming (during booting blinks once)
programming (during booting blinks once, then three
times, then stays ON)
the FPGA (Field Programmable Gate Array - U14).
The FPGA receives its
configuration program
from the processor and
must be programmed on
every power up.
Limit
Limit
LED is lit if the
transport motor
is running
LED is lit when
feeder motor is
on
LED not lit LED stays lit
LED is lit LED stays off
LED is lit (FPGA
programming is
complete)
LED is lit from
time-to-time
when printer is
printing
LED is lit from
time-to-time
when printer is
printing
LED stays lit
(indicates a
board/software
problem)
LED stays
lit under ALL
printer states
(indicates a
board/software
problem)
(indicates a
board/software
problem)
(indicates a
board/software
problem)
LED stays off
(indicates a
board/software
problem)
LED stays
lit (indicates
feeder motor
over-current
detected)
LED stays
lit (indicates
feeder motor
over-current
detected)
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
4-7
Page 34
4 • Troubleshooting/Diagnostics
4.3 Main
Controller
Board
Diagnostics
Table 4-2 Main Board LED Designations (continued)
LED Color
When
Lit
CR15 Green USB connection detected LED is lit when
CR25 Red Exit Sensor [DA95F only] LED lit when
CR27 Red Feeder Sensor LED lit when
CR28 Red Paper Sensor LED lit when
Description Normal State Error State
LED stays off
USB connection is detected;
blinks when USB
is active
sensor is
blocked
sensor is
blocked
sensor is
blocked
after connect-
ing a USB de-
vice (indicates
a bad USB
connection)
LED not lit
when sensor is
blocked
LED not lit
when sensor is
blocked
LED not lit
when sensor is
blocked
Main Controller Board Voltage Checks
When you need to troubleshoot the Main Controller Board, measure the voltages (with power applied) using a digital voltmeter at these points (see table
below).
Table 4-3 Main Board Test Points With Voltage Ranges
Voltage With
Normal Range
1.5V ±5% Generated from main board TP27
3.3V ±5% Generated from main board TP25
5V ±5% Generated from main board TP38
40V ±5% Input from power supply TP39
Ground Ground for 3.3V measurement TP26
Ground Ground for 1.5V measurement TP28
Ground Ground for 40V measurement TP40
Ground Ground for 5V measurement TP37
Where It Comes From/Going Location
4-8 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 35
Troubleshooting/Diagnostics • 4
4.4 Error
Codes
Table 4-4 Power-Up Printer Errors
Error Text Possible Resolution
00 Internal error 1. Power down and up to see if it clears
2. Replace main board
01 Bad OS Version 1. Check all cables
2. Attempt firmware flash (download)
3. Replace main board
02 Bad FPGA Version 1. Reboot printer (power down and up)
2. Reset printer to factory default settings
(see section A.4).
3. Attempt firmware flash (download)
4. Replace main board
03 Language File Error 1. Check all cables
2. Attempt firmware flash (download)
3. Replace main board
05 No J33/Transport Sensor Cable 1. Check J33 cable
2. Replace transport sensor
11 Newport Board X Not Present Newport Board = print head board
1. Check all cables
2. Replace print head board “X”
3. Replace main board
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
4-9
Page 36
4 • Troubleshooting/Diagnostics
4.4 Error
Codes
✍
TIP: Device name
is unique to each
printer’s main board.
Therefore, replacing
an existing main board
in the printer gives that
printer a new device
name.
Table 4-5 Printer Error Codes
Error Text Probable Cause Solution
Paper Too Short Material length speci-
fied incorrectly
Sensors Blocked Material in paper path Remove paper and clean sensors
Stream Feed Error Feeder out of adjust-
ment
NVRAM Not Valid Electronic failure on
Main Board
Sensor Dirty Paper dust on sensor Clean and calibrate sensors
Sensor Failure Sensor not functioning
properly
Black Ink Empty HDx Cartridge “x” (1-6) is
empty
Conveyor Full Conveyor is full of
material
PROM Failure Electronic failure on
Main Board
Feeder Stall Error Stack is too heavy or
material is jammed
Jam At Exit Clear jam
Jam At Feeder Clear jam
Jam At SOP SOP = Paper Sensor Clear jam
Jam To Exit Clear jam
Jam To SOP SOP = Paper Sensor Clear jam
Out Of Memory Power down and up printer. Break
Paperout At SOP SOP = Paper Sensor Add material to or adjust the ex-
Paper Too Long Adjust feeder and clean sensors
Paper Trans Err #x Paper Transport Error
“x” (1-8, for various
conditions)
Paper Out At Feeder Add material to or adjust feeder
Stacker Full Remove material from stacker
Transport Stall Err Remove jam from transport (also
Unknown Error Clear all material from paper path
Check job settings on paper size
Adjust feeder
Reboot printer. Reset settings to
factory default (see section A.4).
Download new firmware. Replace
Main Board if problem persists.
Reboot printer; clean and calibrate sensors. If persists, check
cables and replace sensor if need
be.
Replace cartridge
Clear conveyor
Reboot printer. Replace Main
Board if problem persists.
Remove jam and reduce stack
weight (also see troubleshooting
tables)
job into pieces or reduce complexity of piece with overlays
ternal feeder
Do standard printer setup (page
4-1)
see troubleshooting tables)
and resume if message reoccurs
call service
4-10 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 37
Troubleshooting/Diagnostics • 4
4.4 Error
Codes
Table 4-6 Internal Errors
Number
that
Displays
on LCD
8000 Unspecified Internal Error Msg
8004 System Assert Event
8008 Internal Feeder Logic Error
8012 Internal SOP Logic Error
8016 Internal Unused error
8020 Internal Renderer Logic Error (Renderer State Machine Error)
8024 Internal SES Motor Start Failed
8025 Internal SES Motor Start Failed
8026 Internal SES Motor Start Failed
8028 Internal Power Manager Abnormal Error
8032 Internal IP Comm IO Socket In Use Error
8036 Internal IP Comm IO Socket Accept Error
8040 Internal IP Comm IO Socket Connect Error
8044 Internal IP Comm IO Socket Write Error
8048 Internal IP Comm IO Socket Read Error
8052 Internal Buffer Manager Logic Error
8056 Internal FIFO push error in the push media of Media Object Collection
8060 Internal Get Next Error in the push media of Media Object Collection
8064 Internal Rendering Engine Logic Error
8068 Internal Rendering Engine Bad Image Error
8072 Newport Thread Fail to Acknowledge
8076 Internal IP Comm Errors Data Server
8077 Internal IP Comm Errors Command Server
8078 Internal IP Comm Errors Ctrl Panel Protocol Glossary
What Error Means
Troubleshooting Internal Errors
When you encounter an internal error, try the following in the order given:
1. Power down and up the printer. Re-run job.
2. If that doesn’t work, run a standard simple job to see if it runs through OK.
If the simple job runs OK, there maybe an issue with the initial job. Send
the problem job to Pitney Bowes Engineering for escalation resolution.
3. If the simple job and problem job both have issues, check all main board
connectors. If that fails, download new firmware. If that fails, replace the
main board.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
4-11
Page 38
4 • Troubleshooting/Diagnostics
4.5 Print
Samples for
The print samples below are provided to help troubleshoot printing problems
you may encounter.
Troubleshooting
Table 4-7 Sample Prints
Sample Print What It Indicates How to Fix
Good test print
Poor printing due to
Replace ink cartridge
low ink
Smudging Multiple causes. See 4.7
Printing Issues, Streaking on
media.
ABCDE F GH I J K LMNO
Head 1
Head 2
Head 3
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
Satellite Print Need to lower printer heads,
or clean or replace heads if
needed.
“Stitching” Issue
(multiple print heads
used to print a barcode)
Move barcode location on
mailpiece so barcode marks
are not printed across multiple print heads
Shadow Print Do standard printer setup
(see page 4-1)
4-12 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 39
Troubleshooting/Diagnostics • 4
4.5 Print
Samples for
Troubleshooting
All 3 versions of FIM
Return Address
Figure 4-6 Sample Envelope Printed with a Variety of Options
Barcode (USPS)
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
4-13
Page 40
4 • Troubleshooting/Diagnostics
4.6 Feeding
Issues
IMPORTANT:
If you have a DA95F printer and are NOT using the standard feeder
(WF9S), this section (4.6 Feeding Issues) will NOT apply. This reason
for this is that the feed sensor on a non-standard feeder is not an integral part of the printer, and hence, will behave according to its own
characteristics. Consequently, please refer to the documentation supplied with your external feeder for troubleshooting feeding issues.
Material (Media) Issues that Affect Feeding
• All mailpieces with loose contents should be tamped toward the lead
edge of the mailpiece before being fed into the printer. Otherwise, there
is chance that the two pieces may be fed at once and cause a jam.
• Material processed too many times (roughly more than three) by automatic machinery (inserters, mailing machines, other printers, etc.) before
it reaches this printer may cause the material to get too glazed to be processed properly by this printer.
• It is possible for material to wind up in the machine base cavity. When
this happens, you may encounter strange noises, blocked sensors, and
other symptoms not readily visible when you are troubleshooting the
printer.
4-14 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 41
Troubleshooting/Diagnostics • 4
4.6 Feeding
Issues
✍
TIP: If you have a
DA95F printer and are
NOT using the standard feeder (WF9S),
the Feeding Issues
tables on these pages
will NOT apply. Please
refer instead to the
documentation supplied with your feeder.
Table 4-8 Feeding Issues
Symptom Possible Cause Solution
Multiple/stream
feeds
Motor on; main
feed roller doesn’t
turn
“Paper Too Long”
Error on LCD
Display
“Paper Too Short”
Error on LCD
Display
Stack too high Reduce stack
Material too sticky; out of
spec
Feeder misadjusted Review standard setup for
Worn “fingers” or rollers on
“H” block assembly
“H” block roller not locked
(DA95F)
“H” block roller needing advancement (DA95F)
“H” block separators improperly set
Lead/trail edge sensors dirty
or bad
Material processed too many
times by other machines
before reaching the printer
Worn feed roller Replace feed roller
Bad main board Replace bad main board
Loose setscrew on drive pul-
leys (see photos)
Drive belt (s) Check for loose or broken belt,
One way clutch bad or broken
Slippage in feeder or transport
Actual paper length does not
match paper length in job
setup
Actual paper length does not
match paper length in job
setup
Verify against material specs,
(see section 2.5 for testing
material)
feeder
Replace fingers or rollers
Slide blue mechanism to lock
position
Advance roller and relock
Adjust separators to thickness
of material
Blow sensors with clean air;
replace if necessary
Do not process more than
three times before placing on
printer
Tighten screw
adjust spring tensioner screw
Rotate drive belt (DA95F) or
feed rollers (DA80F) in both
directions; check that they turn
in one direction. If not, replace
one way clutch.
Clean drive rollers. Review
standard setup for feeder.
Verify material against job
setup
Actual paper is shorter than
job defined, or is shorter than
minimum spec, or material is
translucent, making the machine think that the paper is
shorter than it is.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
4-15
Page 42
4 • Troubleshooting/Diagnostics
4.6 Feeding
Issues
✍
TIP: If you have a
DA95F printer and are
NOT using the standard feeder (WF9S),
the Feeding Issues
tables on these pages
will NOT apply. Please
refer instead to the
documentation supplied with your feeder.
Table 4-8 Feeding Issues
Symptom Possible Cause Solution
Fails to feed Not enough material Add more material
Stack too high or low for feed
rollers to grab properly
Separation thickness adjustment set incorrectly incorrect
Material too sticky or too
glossy; out of spec
Material out of spec
Feed rollers glazed or contaminated with paper dust
Feed ramp assembly and
media support wedge is positioned or being used incorrectly
Feed gap or transport speed
not set correctly
Pulley is loose Tighten set screw on drive pul-
Bad motor encoder Verify proper transition of
Bearing in feed roller
pulley broken or doesn’t turn
the shaft
Broken clutch Replace the clutch
Broken belt Replace the belt
Bad feed motor Replace bad motor
Adjust stack accordingly
Adjust “H” blocks to thickness
of material, review standard
setup for feeder
Verify material meets spec, see
section 2.5 Material Specs.
Min. thickness 0.003" (0.08 mm)
Max: 0.25" (6.3 mm) (DA80F)
Max: 0.50" (12.7 mm) (DA95F)
No staples, paper clips, etc., on
media
Clean with water and plastic
scouring pad
Reposition feed ramp assembly and media support wedge
to transfer the weight of media
onto feed rollers
Adjust feed gap or transport
speed to avoid blank envelopes feeding
ley
encoder. Replace bad motor
encoder.
Manually move the feed rollers
to see if the feed pulley grabs
the shaft and turns
4-16 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 43
Troubleshooting/Diagnostics • 4
4.6 Feeding
Issues
Table 4-8 Feeding Issues
Symptom Possible Cause Solution
Motor runs for a
moment, turns
off, LCD display
indicates “Transport Stall Error”
Printer runs for
a moment, turns
off, LCD display
indicates “Feeder
Stall Error”
Media Jammed Remove jammed media. Press
Test button or On-Line to reset
printer.
Incorrect thickness adjustment
Belt Jam Manually fix belt by gently pull-
Bad motor or seized
bearing
Damaged encoder cable Replace cable
Faulty Encoder Check the voltages on the
Bad Main Board Replace Main Board
Media Jam Clear jam and reset “H” blocks
Media sticking together Fan media before placing on
“H” Block separators improperly adjusted
Media out of spec
Belt Jam Move belt back onto pulleys
Bad bearing on roller or
bearing in pulley assembly
Damaged encoder cable Replace encoder cable
Faulty Encoder Check the voltages on the
Bad Motor Replace bad motor
Bad Main Board Replace Main Board
Adjust lever so head height is
above media
ing on belt side to side
Manually rotate roller in both
directions. Verify rollers turn
freely. Replace roller or bearing when it resists turning. Replace bad motor.
Main Board. Slowly turn the
transport Belt and check for a
transition when checking the
voltage on the encoder.
feed rollers
Adjust as necessary
Min. thickness 0.003" (0.08 mm)
Max: 0.25" (6.3 mm) (DA80F)
Max: 0.50" (12.7 mm) (DA95F)
and check alignment of motor
pulleys
Move rollers to check resistance. Replace bad bearing(s).
Main Board. Slowly turn the
transport belt and check for a
transition when checking the
voltage on the encoder.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
4-17
Page 44
4 • Troubleshooting/Diagnostics
4.6 Feeding
Issues
✍
TIP: If you have a
DA95F printer and are
NOT using the standard feeder (WF9S),
the Feeding Issues
tables on these pages
will NOT apply. Please
refer instead to the
documentation supplied with your feeder.
Table 4-8 Feeding Issues
Symptom Possible Cause Solution
Envelope jams,
resulting in Jam
at xxxx” Errors
Media jam Paper path obstructed; clear
jam
Media sticking together Fan media before placing on
feed rollers
Media out of spec Min. thickness 0.003" (0.08 mm)
Max: 0.25" (6.3 mm) (DA80F)
Max: 0.50" (12.7 mm) (DA95F)
“H” Block separators improperly adjusted
Faulty or dirty sensor Clean sensors with canned air
Adjust to thickness of material
or soft cotton cloth, replace if
necessary
4-18 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 45
Troubleshooting/Diagnostics • 4
4.7 Printing
Issues
✍
TIP: See Appendix B
- Printer Communications, for troubleshoot-
ing problems relating to
networking and printer
communications.
Table 4-9 Printing Issues
Symptom Possible Cause Solution
Ink Print Quality not Sharp
Non-Uniform
Print
Quality
Envelope thickness adjustment incorrect
Material out of spec Change to typical white wove bonded
Contaminated print car-
tridge
Print Cartridge problems
(e.g., gap appears in test
pattern)
Multiple print nozzles not
working
Loose or bad print head
Cable Assembly
Print Head Holder broken Check the print head holder for
Adjust lever to lower print head
Clean and wipe with damp cloth or
paper towel
Purge print cartridge
Clean cartridge with soft cotton cloth
and water
Change to a known good cartridge
Run “Purge Print Head“ from Main
Menu, then run “Print Head Adjust”
from Service Menu . If not helpful, swap ink cartridge with known
good one. If the same nozzles are
out, check the ribbon cable going to
print head cartridge (it may have lost
power to nozzles). If cable is fine,
check print head board.
Replace bad cable or print head assembly (see section 5.15 for WF81 or
section 5.36 for WF96)
broken pins. Replace print head
drive board if pins are broken. Check
for crimped or torn cable assembly.
Check that cable assembly is secured in Main Board and in the print
head assembly.
NOTE: When trying to decide if print
head driver board should be replace
or not, run “Print Head Adjust” from
Service Men, replace the ink cartridge with a new one, then run the
print head test again. If the gaps are
consistent with different ink cartridge,
then the print head driver board
needs to be replaced (when there is
no physical sign that the print head
driver board is damaged). See sec-
tion 5.15 for WF81 or section 5.36 for
WF96.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
4-19
Page 46
4 • Troubleshooting/Diagnostics
4.7 Printing
Issues
Table 4-9 Printing Issues
Symptom Possible Cause Solution
Print is Skewed Feeder ramp not set cor-
rectly
Side guides not set correctly
Takeaway Rollers not set
correctly [on DA95F]
Check setup of the Entry
Rollers.
Roller is running along
the edge of the media
Addresses
“walking” to
next piece
Ink streaking
on Media
Number of lines of address varies. No Form
Feed used for address
termination.
Incorrect address setup Count carriage returns and line feeds
Thickness and Takeaway
Rollers [on DA95F]
Envelope thickness adjustment incorrect
The print cartridge is dirty Clean the cartridge
Print head needs purging Run “Purge Print Head“ from Main
Print heads not level to
deck (floor)
Exit idler rollers dirty Clean rollers with water to remove ink
Adjust ramp so it is centered with
respect to material (see standard
printer setup on page 4-1)
Adjust fence to within 1/16” of material. Check that fence is square
with respect to material (assuming
material is rectangle). See standard
printer setup on page 4-1.
Adjust rollers to appropriate tension
and location using thickness adjustment (see Operator Guide)
Redo the setup of the Entry Rollers
(see Operator Guide).
Move print head bank to different
area over media.
Check Line Termination CRCR,LF=LF. Address Termination
should be Form Feed.
of address field; should match address setup
Adjust rollers to appropriate tension
using thickness adjustment (see
Operator Guide)
Adjust lever to raise print head
Menu.
Level print heads (see section 6.4 for
WF81 and section 6.5 for WF96)
4-20 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 47
Troubleshooting/Diagnostics • 4
4.7 Printing
Issues
✍
TIP: See Appendix B
- Printer Communications, for troubleshoot-
ing problems relating to
networking and printer
communications.
Table 4-9 Printing Issues
Symptom Possible Cause Solution
No Printing on
Material
Blanks between printed
media
Unwanted
Bolding
Garbage print Incorrect Software Driver Use correct AddressRight driver.
Print cartridge issues or
out of ink
Address location set off
the media (printing on
belts or deck)
Sensor is dirty or bad Blow sensor clean; recalibrate sensor
USB not plugged into correct connector
Print Head Holder broken Check for crimped or torn flex circuit.
Loose or bad Cable Assembly.
Power supply voltage out
of specifications
Wrong setting in Lines
Per Address
Sending media too
quickly
Faulty or dirty sensor Clean sensors with canned air or soft
LCD Main Menu setting
of Bold is enabled
ESC sequence turning
bold on, located before
the address
Wrong Symbol Set
selected in printer
Purge print cartridge
Clean cartridge with soft cotton cloth
and water
Change to a known good cartridge
Correct position in software or in Ad-
dress Layout Menu
via Test System option on Service
Menu on LCD (see section A.5);
replace if necessary
Verify USB cable
Replace bad Print Head Holder.
Check for crimped or torn Cable As-
sembly. Check that Cable Assembly
is secured in Main Board and the
Board in the Print Head Assembly.
Verify the LED’s on back of Print
Head Board are lit when printing.
Replace bad cable or Print Head Assembly.
Check voltages on main board (see
section 4.3). Replace Main Board if
necessary.
Increase settings in Lines Per Address to match software.
Slow the transport speed or increase
the gap between pieces in the menu
(see section A.4, LCD Setup Menu)
cotton cloth.
Press Test Button. A bold Standard
Office Systems Address is printed.
Turn Bold setting off in Main Menu.
Do a HEX Dump of the problem address. Examine for ESC sequence
(1B) before the start of the line.
Reference printer command codes
to find ESC Sequence. Remove the
ESC Sequence from the address.
Select correct Symbol Set from printers Setup Menu.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
4-21
Page 48
4 • Troubleshooting/Diagnostics
4.7 Printing
Issues
Table 4-9 Printing Issues
Symptom Possible Cause Solution
Printer keeps
stopping and
starting every
few pieces
(unwanted)
Postal Bundle Break
Pause or Tray Break
Pause is enabled or set
incorrectly
Feeder may stop while
waiting for data from PC
Transport speed and/or
feed gap may need adjusting
Disable Bundle Break or Tray Break
Pause or correct the settings in the
LCD Setup Menu or Software Control
Panel
Try the following:
- Turn “Advanced Printing Features”
off in the driver when submitting the
job.
- If you are using TCP/IP, try swapping to USB (If possible) and see if
the problem is resolved. If it is, then
the network capability or settings
are the problem.
- If the problem still persists, try and
reduce complexity of the print piece
by either removing elements from
the layout or placing fixed portions
into an overlay to load into the machine before the job starts.
Manually adjust (via the LCD Setup
Menu or Software Control Panel) the
transport speed down or increase
the between-piece feed gap until the
feeder does not stop regularly during
the job. Proper adjustment improves
machine throughput and provides
longer lasting operation.
4-22 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 49
Troubleshooting/Diagnostics • 4
4.8 Display
Issues
Table 4-10 Display Issues
Symptom Possible Cause Solution
Blank LCD display
OR
LCD display shows
solid black boxes
OR
LCD display shows
solid line of erroneous characters
LCD out of adjustment Adjust the potentiometer on the
back of keyboard/LCD board until
the LCD display is legible (see section 6.2)
Cable loose at the display or Main Board
Bad keyboard/LCD
display board
Bad Print Head Board Replace blown print head board
Bad Main Board Replace main board (see section
Power supply problem Check J23 (provides power to board
Check that P25 cable to LCD display is secured at both ends
Replace the keyboard/LCD board
(see section 5.2 for WF81 or section
5.29 for WF96)
(see section 5.15 for WF81 or section 5.36 for WF96)
5.30 for WF81 or section 5.36 for
WF96)
from power supply). Replace power
supply if necessary (see section
5.20 for WF81 or section 5.41 for
WF96)
4.9
Miscellaneous
Issues
Table 4-11 Miscellaneous Issues
Symptom Possible Cause Solution
No Barcode Invalid Zip Code or
more data following
Zip Code in job setup
No Planet Code
Printed
Nothing happens
when power is
switched on
Invalid Code or more
data following the
PLANET Code.
No power to AC inlet
of printer
J23 on Main Board
disconnected
Fuse blown in Power
Supply
Check Zip Code and correct, remove any data following the Zip
Code. (See Appendix E for valid
DPBC format)
Check Planet Code and correct, remove any data following the PLANET Code. (See Appendix E for valid
PLANET code format)
Check power cord and AC outlet to
which it is plugged in
Connect J23 (provides power to
board from power supply)
Replace power supply - no service
replaceable parts inside (see section 5.20 for WF81 or section 5.41
for WF96)
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
4-23
Page 50
4 • Troubleshooting/Diagnostics
4-24 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 51
5 • Removal and Replacement
5.1 List of
procedures
This chapter contains parts removal instructions and is divided into two sections; one for the DA80F model and one for the DA95F model.
Tools Required
• Ball end square (quadrax) drives. Sizes used:
#0 for 4-40 screws
#1 for 6-32 screws
#2 for 8-32 screws
NOTE: Phillips head screwdrivers of the same size work but not as well if
you are at an angle.
• Allen wrenches (imperial standard sizes). NOTE: The extra small encoder Allen (.050 inch) is taped inside each printer.
• 5/16” imperial socket (for WF81)
• Cutters
• Pliers
• Feeler gauges
DA80F (WF81) Parts Removal
5.2 Rear Cover and Keyboard/LCD Display Board ......................... 5-3
5.3 Main Processor Board ............................................................... 5-4
5.4 Encoder Assembly .................................................................... 5-6
5.5 Paper Top Sensor Assembly (Emitter) ...................................... 5-9
5.6 Paper Bottom Sensor Assembly (Receiver) .............................. 5-9
5.7 Feeder Sensor Assembly (Emitter and Receiver) ................... 5-10
5.8 Front Bottom Cover Assembly ..................................................5-11
5.9 Transport Timing Belt .............................................................. 5-12
5.10 Feed Motor Timing Belt ......................................................... 5-13
5.11 Feed Roller Pulley and Feed Roller Assembly ...................... 5-14
5.12 Feed Motor Assembly and Encoder Harness Assembly........ 5-16
5.13 Transport Motor Assembly ..................................................... 5-18
5.14 H-Block Assembly (Media Separators) .................................. 5-20
5.15 Print Head Cables and Print Head Boards ............................ 5-21
5.16 Entry Idler Roller Arm ............................................................ 5-28
5.17A Feed Deck ............................................................................ 5-30
5.17B Front Plate Assembly ........................................................... 5-32
5.18 Transport (Metal Grit) Roller .................................................. 5-34
5.19 Exit (Rubber) Roller ............................................................... 5-35
5.20 Power Supply ........................................................................ 5-36
5.21 Print Head Access Door ........................................................ 5-38
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
5-1
Page 52
5 • Removal and Replacement
5.1 List of
procedures
(continued)
DA95F (WF96) Parts Removal
Standard Feeder (WF9S)
5.22 Rear Cover/Side Guides ....................................................... 5-39
5.23 Lower Sensor Receiver Assembly ......................................... 5-41
5.24 Feeder Top Sensor (Emitter) Assembly ................................. 5-42
5.25 “H Block” Roller (Media Separator) ...................................... 5-43
5.26 Feed Belts and Rollers .......................................................... 5-44
5.27 Motor/Drive Assembly............................................................ 5-46
Printer Section
5.28 Printer Top Cover ................................................................... 5-48
5.29 Front Cover and Keyboard/LCD Display Board..................... 5-49
5.30 Rear Cover and Processor Board ......................................... 5-51
5.31 Paper Sensor and Sensor Bar............................................... 5-54
5.32 Entry Roller Support Assembly .............................................. 5-55
5.33 Intermediate Idler Rollers Assembly ...................................... 5-56
5.34 Idler Roller Support (“Module A”) Assembly .......................... 5-57
5.35 Idler Roller Support (“Module B”) Assembly .......................... 5-58
5.36 Print Head Cables and Print Head Boards ............................ 5-59
5.37 Belt Drive Assembly............................................................... 5-67
5.38 Media Belts ............................................................................ 5-69
5.39 Encoder Assembly ................................................................. 5-71
5.40 Drive Belt/Motor Assembly .................................................... 5-74
5.41 Power Supply ........................................................................ 5-75
5-2 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 53
DA80F (WF81) Parts Removal
Removal and Replacement • 5
5.2 Rear
Cover and
Keyboard/
LCD Display
Board
WARNING!
Always wear anti static wrist straps (L-8258) whenever handling the main
processor board or keyboard /LCD Board. Static discharge will damage
the IC chips.
1. Turn the power off and unplug the AC power cord. Remove extension
bins (two thumbscrews) and wireform media holder.
2. Unfasten the two screws securing the rear cover.
<-Two
Screws
for Rear
Cover
(Circled)
Rear ->
Cover
Removed
3. Lift up to free the two tangs on the bottom of the cover from the slots in
the floor of the rear chassis assembly and remove the rear cover.
4. Disconnect the ribbon cable from the keyboard/LCD board (bottom left
figure) and green ground screw from frame (bottom right figure).
Green
Ground
Cable
Keyboard/LCD Board
5. Remove the keyboard overlay from the top of the rear chassis assembly
to gain access to the screws beneath.
6. Support the keyboard/LCD board from inside the rear chassis assembly,
then unfasten the three screws securing the keyboard/LCD board.
Ribbon Cable
Keyboard
Overlay
Screws Under
Overlay (dotted
circles)
7. Reinstall in reverse order.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
5-3
Page 54
5 • Removal and Replacement
J1 J2 J3
DA80F (WF81) Parts Removal
5.3 Main
Processor
Board
✍
TIP: Device name
is unique to each
printer’s main board.
Therefore, replacing
an existing main board
in the printer gives that
printer a new device
name.
WARNING!
Disconnect power to processor board before removing or connecting the
print head assemblies or damage to components may occur.
WARNING!
Always wear anti static wrist straps (l-8258) whenever handling the main
processor board or keyboard /LCD board. Static discharge will damage
the IC chips.
1. Turn the power off and unplug the AC power cord.
2. Follow procedures in section 5.2 to remove the rear cover.
3. Disconnect the cables from the processor board and move them out of
the way. When disconnecting the print head cables at J1, J2, and J3,
lift up blue piece on main board connector with fingernail before removing
cable from connector (uses zero insertion force).
J1 J2 J3
Disconnecting Print Head Cables
(use fingernail to lift up blue
piece and release pressure on
cable to remove)
4. Remove EMI shields and grounding straps to board by disconnecting two
screws and clamp.
5. Unfasten the five screws (white circles in figure below) securing the processor board and metal ground plate (behind board) to chassis. Remove
the processor board and metal plate together.
Screws that
hold Board and
Ground Plate to
Chassis (white
circles)
Main Processor
Board with Ground
Plate Behind
5-4 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 55
DA80F (WF81) Parts Removal
Removal and Replacement • 5
5.3 Main
Processor
Board
(continued)
6. Unfasten the three screws (yellow circles in figure below) securing the
processor board to metal ground plate and remove board.
Main Processor
Board
Screws that
hold Board to
Ground Plate
(yellow circles)
7. Install new board and reconnect the cables to the board as shown below.
Junction Description
J1 Print Head 1
J2 Print Head 2
J3 Print Head 3
J11 W98x Series Stacker
J12 Third Party Stacker/Conveyor [DA80F only]
J18 LAN
J20 USB
J22 Feeder Sensor Emitter [DA80F only]
J23 Input Power
J24 Feeder Sensor Receiver [DA80F only]
J25 LCD Display
J26 Feeder Motor [DA80F only]
J27 Transport Motor
J31 Feeder Motor Encoder [DA80F only]
J32 Paper Sensor Emitter
J33 Paper Sensor Receiver
J34 Shaft Encoder
8. Reinstall in reverse order.
NOTE: Every time the main processor board is changed or removed, the
printer must be powered down and powered on.
IMPORTANT! Be careful when re-connecting the ribbon print head ca-
bles (J1, J2, J3) on the main processor board. Make sure each cable is
aligned straight before fully seating; otherwise, some pins may touch and
cause damage to the print head (Newport) boards inside the print head
assembly upon powering up.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
5-5
Page 56
5 • Removal and Replacement
DA80F (WF81) Parts Removal
5.4 Encoder
Assembly
✍
TIP: Make sure you
have the encoder
alignment bushing tool
(PN# WS71001) handy when you remove
the encoder. You will
need this tool if you
wind up replacing the
encoder backing plate.
1. Remove the rear cover (see section 5.2), the main processor board (see
section 5.3), and the front bottom cover (see section 5.8).
2. Remove encoder allen wrench taped inside the chassis.
Encoder Allen Wrench
Encoder
3. Use a screwdriver to turn the encoder disc lock screw counter-clockwise
from two-dot stop (locked position) to one-dot stop (unlocked). The screw
recesses and exposes the hole where the allen wrench goes in on top.
Two Dot Position
(Locked)
One Dot Position
(Unlocked, exposes hole for
allen wrench)
4. Insert encoder allen wrench into the exposed slot. Rotate the transport
roller pulley (on the non-operator side of the chassis which rotates the
encoder) until you feel the set screw hole. Wiggle the wrench until it is
seated. You may have to bias the of top of the wrench towards the encoder base to find the set screw while turning the shaft.
Insert Allen Wrench into
Exposed Hole
Transport
Roller Pulley
(circled)
5-6 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 57
DA80F (WF81) Parts Removal
Removal and Replacement • 5
5.4 Encoder
Assembly
(continued)
5. Loosen set screw by turning the wrench counterclockwise a turn or two
to loosen (do NOT remove the set screw).
6. Unplug ENC harness from encoder.
ENC Harness
7. Using a small screwdriver, separate the main body cover of encoder from
encoder mounting backing at the various "pry points" (see figures below).
Pry
Points
Pry Points
Pry Points
8. Carefully remove the encoder from its backing plate. Try not to damage
the housing or the backing plate if possible because it is placed by the
factory in a precise position.
• If the encoder was removed intact, skip to step 10.
• If the encoder or backing plate does get damaged, you need to re-
place the backing plate as well as the encoder. You also need to have
on hand the special encoder alignment bushing tool (PN#
Continue with step 9.
Backing Plate
WS71001).
<-Two
Screws
Holding
Backing
Plate
(Circled)
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
5-7
Page 58
5 • Removal and Replacement
DA80F (WF81) Parts Removal
5.4 Encoder
Assembly
(continued)
✍
TIP: Make sure you
have the encoder
alignment bushing tool
(PN# WS71001) handy when you remove
the encoder. You will
need this tool if you
wind up replacing the
encoder backing plate.
9. On the replacement (new) encoder, remove the backing plate (if it isn't already). Install new backing plate with the two screws removed from step
8. Place the alignment bushing tool over the center shaft to ensure the
encoder plate is centered around the shaft. Remove bushing after fastening backing plate.
Alignment Bushing Tool
10. On the replacement encoder, remove the backing plate (if it isn't already).
Place (snap on) new encoder onto backing plate. Tighten allen screw
with wrench, but do NOT overtighten. As the set screw is tightened, push
the top of the wrench towards the base of the encoder. This will properly
align the encoder disk within its housing.
11. Remove the allen wrench from the encoder and re-tape it back inside the
chassis (see figure from step 2).
12. Use a screwdriver to rotate the encoder disc lock screw clockwise to the
two dot (locked) position.
Two Dot Position
(Locked)
13. Connect the encoder cable assembly to the encoder.
14. Reinstall all components in reverse order except covers.
15. From the LCD menu, go to the Service menu. Select 2 “Test System”, Select Belt by pressing Enter. Press + twice to adjust the speed to 2 ips. If
the roller moves slowly (2 ips) then the install is correct. If it turns rapidly
and proclaims “Transport Stall Err”, then there is an issue with the encoder.
First start by ensuring that the encoder is plugged in and restart the process again if needed.
16. If functioning properly, reinstall remaining covers.
5-8 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 59
DA80F (WF81) Parts Removal
Removal and Replacement • 5
5.5 Paper
Top Sensor
Assembly
(Emitter)
1. Remove the rear cover (see section 5.2) and the main processor board
(see section 5.3).
2. Disconnect the paper top sensor (emitter) from the processor board connector (J32).
3. Cut the tie wrap holding the cable inside the rear chassis assembly.
4. Unfasten the screw securing the top sensor assembly and remove sensor assembly.
Paper Top Sensor
Assembly
Screw for Assembly
5. Reinstall in reverse order.
NOTE: Replacing the paper top entry sensor assembly will require an
adjustment. Refer to section 6.3 Feeder Sensor Test and Calibration for
more information.
5.6 Paper
Bottom
Sensor
Assembly
(Receiver)
1. Remove the rear cover (see section 5.2) and the main processor board
(see section 5.3).
2. Disconnect the paper bottom sensor (receiver) from the processor board
connector (J33).
3. Cut the tie wrap holding the cable inside the rear chassis assembly.
4. Unfasten the screw securing the bottom sensor assembly and remove
sensor assembly.
Paper Bottom
Sensor Assembly
Screw for Assembly
5. Reinstall in reverse order.
NOTE: Replacing the paper bottom sensor assembly will require an
adjustment. Refer to section 6.3 Feeder Sensor Test and Calibration for
more information.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
5-9
Page 60
5 • Removal and Replacement
DA80F (WF81) Parts Removal
5.7 Feeder
Sensor
Assembly
(Emitter and
Receiver)
1. Remove the rear cover (see section 5.2) and the main processor board
(see section 5.3).
2. Disconnect both feeder sensor assembly cables from the processor
board connectors (J22 and J24).
3. Cut the tie wrap holding the cables inside the rear chassis assembly.
4. Unfasten the two screws (circled in white in figure below) securing the
feeder sensor assembly and remove sensor assembly.
Feeder Sensor
Assembly
Screws
Circled in
White
5. Reinstall in reverse order.
NOTE: Replacing the feeder sensor assembly will require an adjustment.
Refer to section 6.3 Feeder Sensor Test and Calibration for more infor-
mation.
5-10 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 61
DA80F (WF81) Parts Removal
Removal and Replacement • 5
5.8 Front
Bottom Cover
Assembly
1. Turn the power off and unplug the AC power cord.
2. Open print head station door.
3. Unfasten five screws on top deck and one on side.
Screws for
Front Bottom
Cover (Circled)
4. Slide the printer to the edge of the table so it completely overhangs the
edge. Unfasten the three screws on the bottom of the front bottom cover
assembly.
Front Bottom Cover
Assembly
Three
Screws,
Circled
5. Pull the cover away from the printer.
6. Reinstall in reverse order.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
5-11
Page 62
5 • Removal and Replacement
DA80F (WF81) Parts Removal
5.9 Transport
Timing Belt
1. Remove the front bottom cover (see section 5.8).
2. Loosen the auto-tension screw.
Transport Timing Belt
Auto-Tensioner
Screw for Auto-Tensioner
3. Slide auto-tensioner back to release tension on belt, then re-tighten
screw. Slowly walk the belt off the feed pulley assembly.
4. Install new belt. Loosen screw, tension new belt, then re-tighten screw.
5. Replace cover.
5-12 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 63
DA80F (WF81) Parts Removal
Removal and Replacement • 5
5.10 Feed
Motor Timing
Belt
1. Remove the rear cover (see section 5.2) and main processor board (see
section 5.3).
2. Loosen the auto-tensioner screw.
Screw for Auto Tensioner
Auto Tensioner
Feed Motor
Timing Belt
3. Slide auto-tensioner back to release tension on belt, then re-tighten
screw. Slowly walk the belt off the feed pulley assembly
4. Install new belt. Loosen screw, tension new belt, then re-tighten screw.
5. Reinstall main board and rear cover.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
5-13
Page 64
5 • Removal and Replacement
DA80F (WF81) Parts Removal
5.11 Feed
Roller Pulley
and Feed
Roller
Assembly
1. Remove the rear cover (see section 5.2), the main processor board (see
section 5.3), front bottom cover (see section 5.8), and transport timing
belt (see section 5.9).
2. Raise the H-block assemblies by lifting the lever assemblies up and lock
into place.
Lever
Assemblies
Lifted Up
“H” Block
Assemblies
3. On the front side, unfasten the two screws each with a split lock washer
and a bearing retainer that secure the feed rollers flanged bearing on the
front plate assembly.
Feed Roller (on top, not shown)
Two Screws Holding
Bearing, Circled in White
Bearing/Brake Assembly
4. Loosen top screw and unfasten bottom screw on brake assembly. Swing
brake assembly to the side. Pop bearings out and remove break assembly.
Top Screw (loosen)
Brake Assembly
Bottom Screw (remove)
5-14 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 65
DA80F (WF81) Parts Removal
Removal and Replacement • 5
5.11 Feed
Roller Pulley
and Feed
Roller
Assembly
(continued)
5. On the back side, unfasten the four screws to separate the feed roller
mounting plate with bearing from the rear chassis assembly. Remove the
retainer and the flanged bearing from the feed roller assembly.
Feeder Roller
Mounting Plate
Screws
Circled in
White
6. Remove assembly from back side.
Roller Assembly
7. Peel the worn crepe tires from the hub of the feed roller assembly.
Rough Crepe
Grain Direction
8. Reinstall in reverse order.
NOTE: When replacing the tires on the feed roller assembly, check that
the cut of the crepe tires runs so the smoother cut is running forward.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Crepe Tire
Direction of Paper Flow
5-15
Page 66
5 • Removal and Replacement
DA80F (WF81) Parts Removal
5.12 Feed Motor
Assembly and
Feed Motor
Encoder Harness
Assembly
1. Remove the rear cover (see section 5.2), main processor board (see section 5.3), and feed motor timing belt (see section 5.10)
2. Cut the tie wrap holding cable J31 to encoder.
3. Remove the front bottom cover (see section 5.8) to prevent the chance of
damaging the cover when laying the printer on its side.
4. Turn the printer onto the side. Unfasten the six screws securing the power supply access cover and partially remove power supply.
Screws for Power Supply
Access Cover (Circled)
Partial Removal of
Power Supply
5. Unplug encoder cable (J26) from feed motor and cut cable tie.
Encode Cable and Cable
Tie to Feed Motor
5-16 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 67
DA80F (WF81) Parts Removal
Removal and Replacement • 5
5.12 Feed
Motor Assembly
and Feed
Motor Encoder
Harness
Assembly
(continued)
6. Unfasten four screws holding motor assembly to back chassis plate.
Keep the back of the motor from dropping.
Four Screws Holding
Feed Motor Assembly
(Circled)
7. Carefully remove feed motor assembly through power supply access hole.
Feed Motor Assembly
8. When positioning the new motor pulley on the back chassis plate, make
sure you leave a 0.180” space between the pulley and motor face.
Motor Face
Pulley
9. Reinstall in reverse order.
NOTE: Connect encoder cable on new motor before inserting motor into
place. Push the cable through the openings in the rear chassis assembly.
Hook up the feed motor encoder cable to the processor board at connector J31.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
5-17
Page 68
5 • Removal and Replacement
DA80F (WF81) Parts Removal
5.13 Transport
Motor
Assembly
1. Remove the rear cover (see section 5.2) and the front bottom cover (see
section 5.8).
2. Unplug the transport motor assembly cable (J27) from main board. Push
the cable through the opening in the rear chassis behind main board.
Opening in Rear
Chassis to Push
Cable Through
Opening
Close up
(Behind Main
Board)
3. Turn the printer onto the side. Unfasten the four screws securing the bottom access cover.
Screws for
Bottom Access
Cover (Circled)
4. Unfasten the four screws securing the transport motor assembly to the
front plate assembly. Keep the back of the motor from dropping.
Four Screws Holding
Transport Motor Assembly
5-18 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 69
DA80F (WF81) Parts Removal
Removal and Replacement • 5
5.13 Transport
Motor
Assembly
(continued)
5. Carefully pull the printer motor assembly through access hole in bottom.
Transport
Motor
Assembly
in Access
Hole on
Bottom
6. When positioning the new motor pulley on the front plate assembly, make
sure you leave a 0.200” space between the pulley and motor face.
Motor Face
7. Reinstall in reverse order.
Pulley
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
5-19
Page 70
5 • Removal and Replacement
DA80F (WF81) Parts Removal
5.14 H-Block
Assembly
(Media
Separators)
1. Lift the lever assemblies halfway up on the “H” block assemblies to release them.
Lever
Assemblies
Lifted Up
Screw for “H”
Blocks are Circled
“H” Block
Assemblies
2. Unfasten the screw in the middle of the “H” block assembly. Remove the
lever assembly and the “H” block assembly from the printer.
3. Turn the “H” block over and unfasten the screw securing the separator
finger on the “H” block.
5. Reinstall in reverse order.
5-20 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Separator Fingers
on “H” Block
H Block Flipped Showing Screws
for Separator Fingers (Circled)
Page 71
DA80F (WF81) Parts Removal
J1 J2 J3
Removal and Replacement • 5
5.15 Print
Head Cables
and Print Head
Boards
WARNING!
Disconnect power to processor board before removing or connecting the
print head assemblies or damage to components may occur.
1. Turn the power off and unplug the AC power cord.
2. Remove the rear cover (see section 5.2).
3. Disengage appropriate print head cables (J1 to J3) from the main board (see
figures below). Pull out slightly the blue piece on main board connector with
fingernail and simply remove cable (uses zero insertion force).
Main Board Showing all Three Print Head Cable Connections
J1 J2 J3
Location
on Main
Board
J1 Print Head 1 Bank (Set)
J2 Print Head 2
J3 Print Head 3
Description Comments
A
Blue Piece on Main Board
Connector (use fingernail to
pull out slightly and release
pressure on cable so cable
can be removed)
4. Unfasten two screws from clamp above main board to release print head
ribbon cable stiffener.
Clamp for Print Head Ribbon Cable
Stiffener (Screws Circled)
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
5-21
Page 72
5 • Removal and Replacement
DA80F (WF81) Parts Removal
5.15 Print
Head Cables
and Boards
(continued)
5. Slide the print head assembly away from control panel. Unfasten the
black screw and washer (at the pivot point), and then the print head locking thumb screw on the print head lift bracket assembly.
Print Head Lift Bracket Assembly
Black Screw
Thumbscrew
Print Head
Assembly
6. Remove the print head assembly and pull print cables through opening.
Opening for
Cables
Print Head
Assembly
7. Remove four screws (small allen size) for print head metal cover.
Print Head Cover
Screws for Print
Head Cover
(circled)
5-22 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 73
DA80F (WF81) Parts Removal
Removal and Replacement • 5
5.15 Print
Head Cables
and Boards
(continued)
8. Slide metal cover up the ribbon cable.
Screw for Metal
Clamp (Circled)
9. Unfasten one screw (see figure above) and slide out and remove metal
clamp holding all three print head cables. NOTE: This clamp has tape on
one side.
Metal Clamp for Print Head Cables
10. Pull out slightly the tan locking piece on the edge of the connector with
your fingernail and simply remove cable (uses zero insertion force).
Tan Locking
Piece
Edge of
Connector
Tape on Other Side of Metal Clamp
Removing Cable from
Print Head Board
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
5-23
Page 74
5 • Removal and Replacement
DA80F (WF81) Parts Removal
5.15 Print
Head Cables
and Boards
(continued)
11. Loosen the two star screws on the print head board about four turns (but
do not remove).
Print Head Board
(aka “Newport board”)
Star Screws
(Circled)
12. Insert a screwdriver between the retainer plate and print head stall and
gently pry the retainer plate outwards.
Retainer
Plate
13. Remove print head (Newport) board.
Print Head Board
5-24 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 75
DA80F (WF81) Parts Removal
Removal and Replacement • 5
5.15 Print
Head Cables
and Boards
(continued)
14. (Optional) If you need to remove the print head stall, unfasten three
screws (figures below are looking from the top down).
NOTE: When reinstalling the stall, ensure that the plastic pins on the bot-
tom of the stall engage the locating holes (see figure, below right).
Print Head
Stall
<--Three
Screws
(Circled)
Locating Holes for Stall (Circled)
15. When installing the new print head (Newport) board, do the following:
• Ensure the two locator pins on the back side of the print head board
are aligned to the black print head stall.
• When reassembling the bottom retainer plate, engage the tabs on
one side of the part to the print head stall and then pivot it into position. The engagement tabs on the other side of the plate will “snap”
into position on the opposite side of the cartridge stall. Tighten the
screws lightly once plate has been snapped into position.
Print Head Stall
Locator Pins
for Print Head
Board (Circled)
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
5-25
Page 76
5 • Removal and Replacement
DA80F (WF81) Parts Removal
5.15 Print
Head Cables
and Boards
(continued)
16. Attach (new) print head ribbon cables, starting at print head side. Apply a
light push to the cable while inserting to allow it to seat fully and straight
into the connector socket. Make sure the cable end is marked "PH" for
print head, and the black tab at the cable end is pointing upwards as it is
being inserted into the print head connector. After inserting cable, press the
tan locking piece inwards (toward the connector) to lock cable into place.
Black Tab Facing Up
17. Route the three print head ribbon cables through metal print head cover
and clamping mechanism (has tape on one side) and fasten clamp with
cables to print head assembly (one screw). Make sure there is enough
slack (see figure) when in final position.
Tan Locking Piece Edge of
Connector
Metal Clamp for
Print Head Cables
18. Re-attach print head metal cover (four screws, small allen size).
19. Route new cables through black stiffener saved from the original print
head cables and clamp above main board. Use the two screws to clamp
down on the cable stiffener.
Clamp for Print Head Ribbon Cable
Stiffener (Screws Circled)
5-26 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 77
DA80F (WF81) Parts Removal
J1 J2 J3
Removal and Replacement • 5
5.15 Print
Head Cables
and Boards
(continued)
20. Attach print head cables to main board connectors (see figures below).
Apply a light push to the cable while inserting to allow it to seat fully and
straight into the connector socket. Make sure the cable end is marked
"MMC" for main board and the black tab at the cable end is facing down
as it is being inserted into the print head connector. After inserting cable,
press down on blue connector piece to lock cable into place.
CAUTION: Partial or crooked insertion of print head cable can result in
main board, print head board, and/or cable damage!
Main Board Showing all Three Print Head Cable Connections
J1 J2 J3
Location
on Main
Board
J1 Print Head 1 Bank (Set)
J2 Print Head 2
J3 Print Head 3
Description Comments
A
Blue Piece on
Main Board
Connector
Black Tab at End of
Cable is Facing Down
21. Reassemble covers and parts as needed.
IMPORTANT! Keep in mind the following points when reassembling:
• Attach the correct end of the ribbon cable to the print head board and
the correct end to the main board. Failure to do so can blow out
the print head board, the main board, or both!
• Be careful when reconnecting the ribbon print head cables (J1 to
J3) at the main processor board and at the print head side. Make
sure each cable is aligned straight before fully seating; otherwise,
some pins may touch and cause damage to the print head (Newport)
boards upon powering up.
22. Power up the machine. Do a print test from the control panel to confirm
proper operation of print heads.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
5-27
Page 78
5 • Removal and Replacement
DA80F (WF81) Parts Removal
5.16 Entry Idler
Roller Arm
1. Remove the rear cover (see section 5.2) and print head assembly (see
section 5.15).
2. Unfasten two screws securing the front top cover and remove the cover.
Front
Top
Cover
Screws
for Top
Cover
(Circled)
3. Remove two springs, one for each entry idler roller (see figures below).
Entry Idler
Roller Shaft
Entry Idler Roller
Springs (Circled)
Removing Entry Idler Roller Spring
4. [Only if idler roller shaft is to be replaced] - Unfasten screw (circled in figures below) on either end of idler roller shaft and remove shaft.
Screws
for Idler
Roller
Shaft
(Circled)
5. Remove the e-ring from the shaft and entry idler roller from the shaft.
NOTE: The nylon washer between the roller and the entry idler arm assembly may fall off when the roller is removed.
5-28 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Entry Idler Rollers
E-ring
Page 79
DA80F (WF81) Parts Removal
Removal and Replacement • 5
5.16 Entry Idler
Roller Arm
(continued)
✍
TIP: If you have
replaced the lower
shaft (the shaft that
the idler rollers rest
on), you need to per-
form the idler roller
height adjustment.
6. [Only if lower shaft is to be replaced] - Unfasten screw (circled in figures be-
low) on either end of lower shaft and remove shaft. See tip note at left.
Lower Shaft
Screws
for Lower
Roller
Shaft
(Circled)
7. Reinstall in reverse order.
Idler Roller Height Adjustment (If Lower Shaft has Been Replaced)
Entry idler roller height is determined by the height of the lower shaft on
which the idler rollers rest on, not the shaft on which the idler arm is at-
tached. Consequently, if the lower shaft has been replaced, you need to
verify the height of the idler rollers because they rest on it.
A. The height between the idler rollers and transport roller on deck should
be between 0.170” and 0.210”. If you don’t have a tool with the proper
gap, you can use 50 sheets of 20 lb. bond paper.
B. Adjust the lower shaft using the two screws at either end (see step 6
above) until you reach the proper height.
Idler Roller
Shaft
Lower
Shaft
Idler Roller
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Transport
Roller
Height for Adjustment
(must be between
0.170” and 0.210”)
5-29
Page 80
5 • Removal and Replacement
DA80F (WF81) Parts Removal
5.17A Feed
Deck
1. Remove the rear cover (see section 5.2), and front bottom cover (see
section 5.8),
2. Remove wireform feed ramp input guide by unscrewing input guide knob
all the way and lifting up guide from deck. Remove side guide by sliding it
all the away out from the printer.
Wireform Feed
Ramp Input Guide
Knob for
Input Guide
3. Unfasten two thumbscrews for extension bin and remove bin.
Extension Bin
Side Guide
Thumbscrews
for Extension
Bin (circled)
4. Unfasten screw on side of deck and on top (see figures below).
Screw on Side of Deck
Screw on Feed Deck
5-30 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 81
DA80F (WF81) Parts Removal
Removal and Replacement • 5
5.17A Feed
Deck
(continued)
5. Remove two feed deck mounting screws on back of chassis.
Feed Deck
Mounting
Screws on
Back of
Chassis
(circled)
6. Remove three feed deck mounting screws on front of chassis.
Feed Deck Screws
on Front Chassis
(Circled)
7. Lift out feed deck.
8. Reinstall in reverse order.
Feed Deck
Removed
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
5-31
Page 82
5 • Removal and Replacement
DA80F (WF81) Parts Removal
5.17B Front
Plate Assembly
1. Remove the rear cover (see section 5.2), front bottom cover (see section
5.8), transport timing belt (see section 5.9), and feed deck (see section
5.17A).
2. Unplug the printer motor assembly from the processor board connector
(J26).
3. Cut the tie wrap holding the cable inside the rear chassis assembly. Push
the cable through the openings in the rear chassis assembly.
4. On the front side, unfasten the two screws each with a split lock washer
and a bearing retainer that secure the feed rollers flanged bearing on the
front plate assembly.
Feed Roller (on top, not shown)
Two Screws Holding
Bearing, Circled in White
Bearing/Brake Assembly
5. Loosen top screw and unfasten bottom screw on brake assembly. Swing
brake assembly to the side. Pop bearings out and remove break assembly.
Top Screw (loosen)
Brake Assembly
Bottom Screw (remove)
6. Remove two timing pulleys (two set screws per each) and pulley spacers.
Timing Pulleys
5-32 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 83
DA80F (WF81) Parts Removal
Removal and Replacement • 5
5.17B Front
Plate Assembly
(continued)
7. Unfasten the nine screws (see figure below) securing the front plate as-
sembly to the main chassis and floors of the printer. Slowly remove the
front plate assembly from the printer. Check for the end of the wire harness; it may snag on the other cables located in the main chassis, preventing the removal of the front plate assembly from the printer.
NOTE: Lay the plate face down to keep the back end of the motor from
dropping and hitting the bottom of the chassis. The motor encoder is easily damaged or destroyed if the motor is dropped.
Screws Holding Front
Plate (Circled)
8. Reinstall in reverse order.
NOTE: Make certain to set the tensioner on the transport timing belt (see
section 5.9).
TIP: Work the printer motor harness through the main chassis before the
front plate assembly is reinstalled.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
5-33
Page 84
5 • Removal and Replacement
DA80F (WF81) Parts Removal
5.18 Transport
(Metal Grit)
Roller
1. Remove the rear cover (see section 5.2), encoder assembly (see section
5.4), front bottom cover (see section 5.8), transport timing belt (see section 5.9), feed motor timing belt (see section 5.10), feed deck (see section 5.17A), and front plate assembly (see section 5.17B).
2. Raise the print head assembly and “H” blocks fully up.
3. Remove print deck by unfastening three screws behind main board.
Print Deck (Shown with Print
Head Assembly Removed)
4. On the rear chassis side of the roller, remove the bearing holding the roller.
The encoder should have been removed already.
Three Screws Behind
Main Board (Circled)
NOTE: Use care when removing the transport roller, as the bearing lo-
cated in the rear chassis may not come out with the roller and could get
damaged in the course of removal.
Rear Chassis
Side of Roller
(under Encoder)
5. Remove transport (metal grit) roller.
Transport
(Metal Grit)
Roller
5-34 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 85
DA80F (WF81) Parts Removal
Removal and Replacement • 5
5.18 Transport
(Metal
Grit) Roller
(continued)
6. When re-installing the new transport roller on the front plate assembly
and before the encoder is locked into place, make sure you leave a
0.010” space (three sheets of 20 lb. paper may be used if feeler gauges
are not available) between the roller pulley and white spacer as shown in
the figure below. This setting controls the amount of side-to-side play in
the transport roller and is a critical adjustment. If the amount of play is
not controlled, encoder damage will occur.
Also, the roller needs to be pushed and held to the operator side of ma-
chine while securing the pulley setscrews.
Spacer
Transport
Roller Pulley
7. Reinstall remaining components in reverse order.
NOTE: Make certain to set the tensioner on the transport timing belt (see
section 5.9) and feed motor timing belt (see section 5.10).
TIP: Work the printer motor harness through the main chassis before the
front plate assembly is reinstalled.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
5-35
Page 86
5 • Removal and Replacement
DA80F (WF81) Parts Removal
5.19 Exit
(Rubber) Roller
1. Remove the rear cover (see section 5.2), front bottom cover (see section 5.8), transport timing belt (see section 5.9), feed deck (see section
5.17A), and front plate assembly (see section 5.17B).
2. Raise the print head assembly and “H” blocks fully up.
3. Remove exit roller, including spacer (see figure below).
NOTE: Use care when removing the exit roller assembly or one of the
bearings may get damaged in the course of removal. The bearing located
in the rear chassis assembly may not come out with the roller.
Exit Roller
4. When re-installing the new exit roller on the front plate assembly, make
sure you leave a 0.010” space (three sheets of 20 lb. paper may be used
if feeler gauges are not available) between the roller pulley and white
spacer as shown in the figure below. This setting controls the amount of
side-to-side play in the exit roller and is a critical adjustment.
Also, the roller needs to be pushed and held to the operator side of ma-
chine while securing the pulley setscrews.
Spacer
Exit Roller
Pulley
5. Reinstall remaining components in reverse order.
NOTE: Make certain to set the tensioner on the transport timing belt (see
section 5.9).
TIP: Work the printer motor harness through the main chassis before the
front plate assembly is reinstalled.
5-36 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 87
DA80F (WF81) Parts Removal
Removal and Replacement • 5
5.20 Power
Supply
1. Turn off power and unplug printer.
2. Remove the front bottom cover (see section 5.8) to prevent the chance of
damaging the cover when laying the printer on its side.
3. Turn the printer onto its side. Unfasten the six screws securing the power
supply mounting panel.
Screws for Power Supply
Mounting Panel (Circled)
4. Unfasten power supply harnesses from tie wraps/twist ties. Gently remove power supply and hold with hand (do not let hang).
Power Supply
5. Remove power supply cover fastened with four screws. NOTE: The fan
comes off with the cover.
6. Unplug two harnesses (see below) to separate power supply from chassis.
7. Unfasten four screws holding power supply to mounting panel and remove supply.
8. Reinstall in reverse order.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Power Supply Cover
Cover Removed,
Harness Connectors
Circled
5-37
Page 88
5 • Removal and Replacement
DA80F (WF81) Parts Removal
5.21 Print
Head Access
Door
1. Remove the rear cover (see section 5.2).
2. Loosen two nuts holding cover arms.
Two Nuts
Metal Hinge
Bracket
Push Down
Here
3. Push down with fingers on metal hinge bracket and remove door.
Door
3. Reinstall in reverse order, but make sure you push the hinge bracket towards the operator side of machine when installing the door.
5-38 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 89
Removal and Replacement • 5
DA95F (WF96) - Standard Feeder (WF9S) Parts Removal
5.22 Rear
Cover/Side
Guides on
Standard
Feeder
1. Lift up the feeder assembly and unhook it from the printer. Pull the feeder
assembly away from the printer.
2. Disconnect the feeder signal cable from the printer.
Feeder
Signal
Cable
3. Remove the quick release pin from the feed ramp assembly. Raise the
feed ramp assembly up and remove the support bar completely from the
feed assembly (see figure on bottom right). Remove feed ramp.
Quick
Release
Pin
Feed
Ramp
Assembly
4. Push the lever up to raise the separator H-block to the uppermost position and secure in place.
5. Pull the side guides (sliding fences) wide open on the feeder assembly.
Optionally, remove the side guides should they hinder the removal of the
feeder deck (two screws per side guide).
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Side Guides
Lever for
“H” Block
5-39
Page 90
5 • Removal and Replacement
DA95F (WF96) - Standard Feeder (WF9S) Parts Removal
5.22 Rear
Cover/Side
Guides on
Standard
Feeder
(continued)
6. Using a regular screwdriver, release the four 1/4 turn studs on the feeder
deck. Turn each stud counterclockwise a quarter turn. NOTE: The four
1/4 turn studs are permanently attached and cannot be removed.
1/4 Turn
Studs for
Feeder Deck
(Circled)
7. Lift the deck assembly. Unhook the front of the deck and slide it beneath
the side guides.
Feeder With Deck
and Side Guides
Removed
8. Locate and remove from the inside of the feeder assembly the four
screws that secure the rear cover. Remove the rear cover.
Screws For
Rear Cover
(Circled)
5-40 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 91
Removal and Replacement • 5
DA95F (WF96) - Standard Feeder (WF9S) Parts Removal
5.23 Lower
Sensor
(Receiver)
Assembly
on Standard
Feeder
1. Disengage the feeder assembly from the printer and remove the deck
and rear cover (see section 5.22).
2. Remove “H” block by lifting up tab and sliding assembly up and out.
“H” Block
3. Cut the wire tie holding the sensor cables.
Wire Tie
Feeder Lower
Sensor Assembly
with Screw
4. Unfasten the screw securing the feeder lower sensor assembly and remove the sensor.
5. Pull the sensor harness through the hole in the bottom of the feeder assembly.
6. Reinstall in reverse order.
NOTE: Replacing the feeder lower sensor assembly will require an ad-
justment. Refer to section 6.3 Feeder Sensor Test and Calibration for
more information.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
5-41
Page 92
5 • Removal and Replacement
DA95F (WF96) - Standard Feeder (WF9S) Parts Removal
5.24 Top
Sensor
(Emitter)
Assembly
on Standard
Feeder
1. Disengage the feeder assembly from the printer and remove the side
guides, deck, and rear cover (see section 5.22).
2. At the rear, loosen the four quick screws securing the feeder cover sub
assembly on the feeder assembly. Pull the feeder cover sub assembly
out from the feeder assembly.
Screws For
Feeder Cover
Sub Assembly
(Circled)
3. From inside, disconnect the feeder top sensor assembly (emitter) from
the harness.
4. Cut the wire tie holding the sensor cables.
5. Unfasten the screw securing the feeder top sensor assembly (emitter)
and remove the sensor from the feeder assembly.
Top Sensor
Emitter
6. Reinstall in reverse order.
NOTE: Replacing the feeder top sensor assembly will require an adjust-
ment. Refer to section 6.3 Feeder Sensor Test and Calibration for more
information.
5-42 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 93
Removal and Replacement • 5
DA95F (WF96) - Standard Feeder (WF9S) Parts Removal
5.25 “H Block”
Roller (Media
Separator)
on Standard
Feeder
1. Remove “H” block by lifting up tab and sliding assembly up and out.
“H” Block
2. Slide the blue ring to the lock position for the H block roller. Unfasten
shoulder screws (one on either end) to remove H block roller. The shaft
and separators will drop off the H block. Remove the H block roller from
the shaft.
Blue Ring to
Lock Roller
Shoulder
Screw
3. Reinstall in reverse order. NOTE: The installation of the new assembly
and may require a strong push down on the H block roller.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
“H” Block Roller
Shoulder Screws
Removed
5-43
Page 94
5 • Removal and Replacement
DA95F (WF96) - Standard Feeder (WF9S) Parts Removal
5.26 Feed
Belts and
Rollers on
Standard
Feeder
1. Disengage the feeder assembly from the printer and remove the side
guides, deck, and rear cover (see section 5.22).
2. Located the feeder assembly and the handle of the swing arm near the
floor of the chassis (see figures below). Insert a long screwdriver or a
long sturdy metal bar behind the handle. Pull the screwdriver against the
belt and feed pulley to use as a fulcrum. This will release the tension on
the belt created by the extension spring.
Feeder Assembly
in Standard Feeder
3mm Belt
Extension Spring
Swing Arm Handle
3. Remove the 3 mm belt from around the other feed pulley and idler pulleys. Release the swing arm to finish removing the belt.
✍
TIP: If pulleys were
removed from the
shafts, you need to
perform the gap adjustment procedure
on the next page.
Handle (in
up position)
3mm
Belt
Extension
Spring
4. Pull the belt drive upper or lower shaft assembly from the printer. The
feed belts and a bearing will come out with the shaft assemblies. Remove these parts from the printer.
5. The tires and feed belts may be removed by pulling them from the hubs.
Tires
3mm Belt
Fulcrum
Screwdriver
Handle
Hub
Extension
Spring
3mm Belt
Tire
3mm Belt
5-44 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 95
Removal and Replacement • 5
DA95F (WF96) - Standard Feeder (WF9S) Parts Removal
5.26 Feed
Belts and
Rollers on
Standard
Feeder
(continued)
6. Replace in reverse order.
NOTE: If upper and/or lower shafts were removed, do the following gap
adjustments below.
Gap Adjustment Procedures (if Pulleys have Been Removed from
Shafts)
A. Gap Between Tensioner and Pulley
Place 0.010” shim between tensioner and pulley when reinstalling upper
shaft.
Pulley
Shim
Tensioner
B. Gap Between Pulley and Motor Face
Place 0.150” shim between pulley and motor face when reinstalling the
lower drive shaft.
Motor Face
Pulley
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
5-45
Page 96
5 • Removal and Replacement
DA95F (WF96) - Standard Feeder (WF9S) Parts Removal
5.27 Motor/
Drive
Assembly
on Standard
Feeder
1. Disengage the feeder assembly from the printer and remove the side
guides, deck, and rear cover (see section 5.22).
2. (Optional) carefully, turn the feeder assembly onto the side. Hold the feed
roller assembly to keep it from falling. Unfasten the four screws securing
the feeder roller assembly. Remove the feeder roller assembly.
Screws
(Circled)
3. Remove the 3 mm belt from around the two feed pulleys and remove the
upper and lower feed shaft assembly from the feed roller assembly (see
section 5.26).
4. Locate the idler pulley assembly on the belt tensioner lever. Remove the
e-ring securing the pulley on the idler pulley shaft. Remove the nylon
washer and idler pulley assembly.
Spacer
Nylon Washer
✍
TIP: You need to per-
form the gap adjustment procedures on
the next page when
re-installing shafts
and pulleys.
Idler
Pulley
Assembly
5. Keep the motor assembly from falling while unfastening the four screws
securing the motor assembly. Remove the motor assembly and cables
from the feed roller assembly. NOTE: If the sensor needs replacement,
this is the level to do it.
Screws
Motor Assembly
Feed Roller
Assembly
Idler
Pulley
Assembly
Encoder Disc
and Sensor
E-Ring
Screws
Motor Assembly
5-46 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 97
Removal and Replacement • 5
DA95F (WF96) - Standard Feeder (WF9S) Parts Removal
5.27 Motor/
Drive
Assembly
on Standard
Feeder
(continued)
7. Replace in reverse order.
NOTE: When reassembling the shafts, you need to do the adjustments
below.
Gap Adjustment Procedures (if Pulleys have Been Removed from
Shafts)
A. Gap Between Tensioner and Pulley
Place 0.010” shim between tensioner and pulley when reinstalling upper
shaft.
Pulley
Shim
Tensioner
B. Gap Between Pulley and Motor Face
Place 0.150” shim between pulley and motor face when reinstalling the
lower drive shaft.
Motor Face
Pulley
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
5-47
Page 98
5 • Removal and Replacement
DA95F (WF96) - Printer Parts Removal
5.28 Printer
Top Cover
1. Lift top plexiglass cover up to access shock support arm. Unfasten two
screws where support arm attaches to cover.
Top Cover
Shock Support Arm for Cover
Two Screws
Holding Shock
Support Arm
2. While holding cover, unfasten two screws at either end where cover attaches to chassis. Remove cover.
Screws (Circled) Holding Top Cover to Chassis
5-48 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
Page 99
Removal and Replacement • 5
DA95F (WF96) - Printer Parts Removal
5.29 Front
Cover and
Keyboard/LCD
Display Board
WARNING!
Always wear anti static wrist straps (L-8298) whenever handling the LCD
Display Board or Processor Board. Static discharge will damage the IC chips.
1. Turn the power off and unplug the AC power cord.
2. Disengage the feeder assembly from the printer (see section 5.22).
3. Lift printer cover up to full extension.
4. Turn the adjustment knob to loosen the print head brake. Slide the print
head assemblies away from the front cover.
5. From the feeder side of the printer, unfasten the two screws holding the
front cover to the entry roller support frame.
Two Screws on Exit
Frame Side (obscured
in figure)
Front
Cover
Two Screws on
Feeder Side
6. From inside the printer on the exit side, unfasten the two screws holding
the front cover to the exit frame, including the green ground strap.
7. Slide the printer to the edge of the table so the front cover completely
overhangs the edge. Unfasten the three screws on the bottom of the front
cover, while hanging onto the cover to keep it from dropping.
IMPORTANT: The figure below is presented to show the location of the
bottom screws only. Do NOT rest the printer on the cover side that has
the hand held because the cover may crack from the weight of the printer.
Front Cover
Screws for
Front Cover
(circled)
8. Pull the cover away from the printer.
DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
5-49
Page 100
5 • Removal and Replacement
DA95F (WF96) - Printer Parts Removal
5.29 Front
Cover
Assembly and
Keyboard/LCD
Display Board
(continued)
9. Disconnect the ribbon cable from the keyboard / LCD display board and
green ground screw from frame.
Keyboard/
LCD Board
Ribbon
Cable
Green Ground
Cable
Green Ground
Cable Fastened
at Frame
10. Remove the keyboard overlay from the top of the rear chassis assembly
to gain access to the screws beneath.
Keyboard
Overlay
Screws Under
Overlay (dotted
circles)
11. While supporting the keyboard/LCD board from inside the rear chassis
assembly, unfasten the three screws securing the keyboard/LCD board.
12. Reinstall in reverse order. Remember to fasten the green ground strap
removed in step 6.
5-50 DA80F/DA95F AddressRight™ Printers Service Manual (SV61962 Rev. A)
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