Rena MACH 5, HJ950C, AS-950C Service Manual

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Page 1

MACH 5, AS-950C, HJ950 C

DIGITAL COLOR PRINTER

SERVICE GUIDE

Rev 5-22-12

Page 2

SAFETY PRECAUTIONS

THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY. HOWEVER, CERTAIN SAFETY RULES SHOULD BE OBSERVED WHEN OPERATING THE RENA MACH 5 PRINTER.

BEFORE USING THE PRINTER, YOU SHOULD READ THIS MANUAL CAREFULLY AND FOLLOW THE RECOMMENDED PROCEDURES, SAFETY WARNINGS, AND INSTRUCTIONS:

 Keep hands, hair, and clothing clear of rollers and other moving parts.  Avoid touching moving parts or materials while the machine is in use. Before clearing a jam, be

sure machine mechanisms come to a stop.

 Always turn off the machine before making adjustments, cleaning the machine, or performing any

maintenance covered in this manual.

 The power cord and power supply supplied with the machine should be plugged into a properly

grounded, easily accessible wall outlet located near the machine. Failure to properly ground the machine can result in severe personal injury and/or fire.

 The power cord and wall plug is the primary means of disconnecting the machine from the power

supply.

 DO NOT use an adapter plug on the line cord or wall outlet.  DO NOT remove the ground pin from the line cord.  DO NOT route the power cord over sharp edges o r t r ap it between furniture.  Avoid using wall outlets that are controlled by wall switches, or shared with other equipment.  Make sure there is no strain on the power cord caused by jamming between equipment, walls or

furniture.

 DO NOT remove covers. Covers enclose hazardous parts that should only be accessed by a

qualified service representative. Report any cover damage to your service representative.

 This machine requires periodic maint enance. Contact your authorized service representative for

required service schedules.

 To prevent overheating, do not cover the vent openings.  Use this equipment only for its intended purpose.

In addition, follow any specific occupational safety and health standards for your workplace or area.

This manual is intended solely for the use and information of Neopost USA, its designated agents, customers, and their employees. The information in this guide was obtained from several different sources that are deemed reliable by all industry standards. To the best of our knowledge, that information is accurate in all respects. However, neither Neopost USA nor any of its agents or employees shall be responsible for any inaccuracies contained herein.

Memjet All other trademarks ar e the pro per ty of their respective hold ers . All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electron i c or mechanical,

including photoc opying, recording, or any inform a t i on storage and ret rieval system, without permission in writing from the publisher

is a registered trademark.

Page 3

TABLE OF CONTENTS

Table of Contents

Section 1 – Getting Acquainted 5

SAFETY PRECAUTIONS 5 Front View 6 Rear View 7 Print Engine Area 8 Behind the Ink Tank Door 9 Accessory Box Contents 10 Control Panel Functions 11

Printer Status Light Indicators 12

Recommended Troubleshooting Supplies 1 Common Service Tools Needed: 1 Minimum Computer System Requirements 1 Installing the Printer Software (Driver and Toolbox) 3

Connecting the Digital Color Printer via Network (Ethernet Port) 6

Printer Driver Properties 8

General Tab 8 Layout Tab 9 Media Tab 10 Services Tab 11

Using the Toolbox Utility 12

User Interface 12 Diagnostics 16 Ink Usage 16 Network Config 17 Service Menu 18

Section 2 – Installation 21

Tools Needed for Installation 21 Choosing the Location 21

Work-Table Surface Must be Level 21

Removing Service Station Transport Tab 21 Installing the Service Station 22 Install the Ink Tanks 26

Ink Tank Anatomy 26 Procedure (Installing the Ink Tanks): 27

Installing the Printhead Cartridge 29

Printhead Cartridge Protective Packaging 29 Procedure (Installing the Printhead): 31

SECTION 3 – Troubleshooting 36

Print Quality Issues: 36

Examples of Print Quality Issues (including possible causes and solutions) 37

The Printhead Cartridge 40 The Printer 42

Dots or Lines Printed on Media 42 Power Problems 42 Service Station Problems 43 Interface Communication Problems 44 Feeding Problems 45

Error’s and Warnings 46

Control Panel Light Sequences 46 Alert Window Messages 46 Toolbox System Status Messages 47

Ink Accumulating in the Wrong Areas of the Printer 49

Page 4

TABLE OF CONTENTS

Clearing Media Jams 50 How to Zero the Tilt Sensor 51

SECTION 4 – Measurements and Adjustments 52

Drive Belt Tension Adjustment 52 Power Supply 53 Media Sensors 54

Feed Sensor 54 Print Engine Sensors 55

Feed Encoder Sensor and Encoder Wheel 56 Print Engine Open Switch 57 Dust Exhaust Fans 57 Clutch (Feed Roller Drive) 58

Feed Roller Drive Pulley Test: 58

Dual Pinch Valve Connection 59 Interface Board Test Points 61

Section 5 – Disassembly/Assembly Procedures 62

Preparing the Printer for Service 62 Installation and Service Videos (where to find) 62 Basic Disassembly 63 Service Disassembly Procedures 63

Left-hand Side Covers 64 Right-hand Side Cover 65 Replacing Motor Drive Belt or Motor 66 Replacing the Clutch 66 Replacing the Feeder Encoder and/or Encoder Sensor 67 Replacing Feed Rollers 68 Replacing Delivery Rollers 71 Replacing Interface PC Board 75 Replacing the Main PC Board (MPCA) 76 MPCA (Main Printed Circuit Assembly) Connections 96 Removing the Print Engine 97

Print Engine Basic Disassembly 102

Removing the Print Engine Base 102 Replacing Peristaltic Pump Assembly 103 Replacing Dual Pinch Valve Assembly 103 Replacing DPCA Board 104 Replacing Buffer Boxes (3 per machine) 105 Replacing QA Chip Assembly (3 per machine) 105 Removing the Pen Driver Printed Circuit Assembly (PCA) 106 Removing the Starwheel Assemblies 106 Replacing the Ink Tank Latches 107

Removing the Main Printed Circuit Assembly (MPCA) Cover 108

Replacing Encoder or Encoder Sensor 109 Replacing Paper Path Motor or Drive Belt 110 Replacing Belt Drive Gear Pulleys 111 Replacing Lifter Motor Assembly or Lifter Gear 112 Replacing Stepper Motor 113

Removing the Clamshell Assembly 115

Replacing Paperpath Exit Sensor 115 Replacing Paperpath Entry Sensor 116 Replacing Service Station Sled Printed Circuit Boards 117 Replacing Wiper Motor Flex Cable PCA 117

Reinstall Main Printed Circuit Board Assembly 118

Section 6 – Service Maintenance 119

Maintenance Schedule 119 Replacing the Ink Tanks 120 Cleaning/Replacing the Printhead Cartridge 121

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TABLE OF CONTENTS

Cleaning/Replacing the Ink Revolvers 123 Cleaning Pen Driver Printed Circuit Board Contacts 125

Cleaning/Replacing the Service Station 126

Removing the Service Station 126 Cleaning the Service Station 128 Replacing Wiper Roller 128 Removing the Wiper Motor Assembly 129 Replacing Service Station Lifting Arms 130

Replacing the Clamshell Latch Pins 137

Lower Clamshell Latch Pin Replacement Kit (42-900-30) 137 Upper Clamshell Latch Pin Replacement Kit (42-900-35) 140 Lubricating the Service Station 145 Reinstalling or Replacing the Service Station 147

Replacing the Ink Waste Tray 149 Replacing the Sheet Separators 149 Cleaning 150

Feed Rollers and Forwarding Rollers 150 Encoder Wheel 150 Feed Sensor 151 Print Engine 152

Grit Rollers 152 Media Sensors 152 Capping Station Seal and Squeegee 152 Printing Platen 152

Appendix Section 153

Appendix A –Specifications 153 Appendix B – Supplies and Optional Hardware 154 Appendix C – Service Station Guide Installation Instructions 155 Appendix D – Z2i Wiring Diagram 162 Appendix E – Z3/Z4 Wiring Diagram 163 Appendix F –Side Frame Modification 164

Index 165

iii

Page 6

TABLE OF CONTENTS

NOTES

______________________________________________________

Page 7

SECTION 3

OPERATING THE PRINTER

Section 1 – Getting Acquainted

SAFETY PRECAUTIONS

THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY. HOWEVER, CERTAIN SAFETY RULES SHOULD BE OBSERVED WHEN OPERATING THE DI GITAL COL OR PRI NT E R .

BEFORE USING THE PRINTER, YOU SHOULD READ THIS MANUAL C ARE FUL LY AND FOLLOW THE RECOMMENDED PROCEDURES, SAFET Y WARNINGS , AND INSTRUCTIONS:

 Keep hands, hair, and clothing clear of rollers and other moving parts.  Avoid touching moving parts or materials whil e t he machine is in use. Before clearing a jam, be sure machine

mechanisms come to a stop.

 Always turn off the machine before making adjustments, cleaning the machine, or performing any maintenance

covered in this manual.

 The power cord, supplied with the machine, should be plugged into a properly grounded wall outlet located near

the machine and easily accessible. Failu r e t o properly ground the machine can result in severe personal injury and/or fire.

 The power cord and wall plug is the primary means of disconnecting the machine from the power supply.  DO NOT use an adapter plug on the line cord or wall outlet.  DO NOT remove the ground pin from the line cord.  DO NOT route the power cord over sharp edges or trap between furniture.  Avoid using wall outlets that are controlled by wall switches or shared with other equipment.  Make sure there is no strain on the power cord caused by jamming between the equipment, walls or furniture.  DO NOT remove covers. Covers enclose h azardous parts that should only be accessed by a qualified service

representative. Report any damage of covers to your service representative.

 This machine requires periodic maintenance. Contact your authorized service representative for required service

schedules.

 To prevent overheating, do not cover the vent openings.  Use this equipment only for its intended purpose.

In addition, follow any specific occupational safety and health standards for your work place o r ar ea.

This manual is intended solely for the use and information of Neopost USA, its designated agents, and their employees. The information i n th is g ui de was o btai ned fro m sever al d ifferen t so urces th a t are d eemed reliable by all industry standards. To the best of our knowledge, that information is accurate in all respects. However, neither Neopost USA nor any of its agents or employees shall be responsible for any inaccuracies contained herein.

Memjet All other trademarks ar e the pro per ty of their respective hold ers . All rights reserved. No part of t hi s book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including

photocopying, recording, or any i nformation storage and retrieval system, without permission in writing from the publisher

is a registered trademark of Memjet Labels, Inc.

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SECTION 3

Exit Roller Cover – This cover plate must be removed to install the Service Station.

Control Panel – Provides printer controls. See “Control Panel Functions” section.

Side Guide Locking Knob – Used to secure the position of the side guide.

10.

OPERATING THE PRINTER

Front View

Rear Media Support Guide – Provides the proper angle to enhance paper feeding and

separation. Media Support Wedge – Allows for adjustments in stack angle, based on media type and

length. Helps to force the media against the separation area. Narrow and wide wedges are provided with the printer, to accommodate different media widths.

Adjustable Media Side Guide – Adjusts to hold the media against the Media Registration Side Guide.

Media Registration Side Guide– All media is registered against this guide. It has two positions. Inner position for media measuring 3” to 8.5” in width. Outer position for media measuring 8.6” to 9.5” in width.

Sheet Separator Locking Screws – These thumb screws (four total) are used to secure the positions of the four sheet separators.

Top Cover – Provides access to the Print Engine. Ink Tank Door – Hinged door provides access to the Ink Tanks and Waste Ink Tray.

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Rear View

SECTION 3

OPERATING THE PRINTER

Main Power Switch, Receptacle and Fuse – Plug in AC power cord here. Switch turns main power on or off. Fuse provides over-current protection. Fuse rating: 2.5A, 250V, slow blow.

CAUTION: Make sure power cord is disconnected from printer before checking/replacing fuse.

WARNING: Press the ON/OFF Button, located on control panel, to properly shut-down the print

engine. Wait until all control panel lights turn off, before you turn off the main power switch.

Tip: Starting with S/N 100027598; to power-up the print engine you must press the control panel’s ON/OFF button after turning ON the Main Power Switch. In earlier units, the print engine would automatically power-up after turning on the main power switch.

USB Port Connection – (USB 2.0) The USB cable attaches to the printer here.

Network Connection – (Ethernet) The network cable plugs in here.

Sheet Separators – Used to separate a single piece of media from the stack. There are four sheet

separators on this printer.

Feed Rollers – Delivers the bottom piece of media, from the stack, through the separation area

and under the forwarding rollers. There are eight feed rollers on this printer.

Media Support Wedge Thumb Screw – Used to secure the Media Support Wedge to the Rear

Media Support Guide.

Counter – LCD displays number of pieces run for a given job. Reset button zeros counter.

Rear Media Support Guide Knob – Attaches the Rear Media Support Guide to the printer body.

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SECTION 3

1 5 2 3 4

Print Engine with printhead cartridge

OPERATING THE PRINTER

Print Engine Area

installed and printhead latch closed.

Antistatic Brush Assembly – This assembly contains a conductive brush that is used to help reduce static energy and remove paper dust f rom t he media. This assembly also contains upper

pressure rollers and fingers that help guide the paper into the print engine.

Printhead Latch – When lowered and locked this device connects the Ink Couplings with the Printhead Cartridge. Note: The printhead latch on your printer may be blue or black. WARNING! Never attempt to open the printhead latch manually, when in the closed/locked

position. Sever damage will result. Use the Printhead Release function from the Toolbox utility on your PC or press the Printhead Latch Rel ease b utton if a computer is not available.

Clean Printhead Button – The button located below this opening can be used to enable a “Level 1 Cleaning” cycle. Insert a non-conductive tool (i.e. plastic pen) into the opening provided, and

lightly press the button. Additional levels of cleaning can be enab l ed from the M Series Driver services.

Ink Couplings – These devices connect the ink tubes to the printhead cartridge. The printhead

latch is used to engage or disengage these devices fr om the printhead cartridge.

Printhead Latch Release Button – The button, l oc a t e d below t hi s ope ning, can be used to initiate the printhead latch release cycle. Insert a non-conductive tool (i.e. plastic pen) and lightly press the

button. If the system is primed it will run a deprime c ycle befo r e r eleasing the latch. Thi s featur e can also be initiated from the Toolbox utility and M Series Driver services.

Print Engine Latches – Lift up on both latches, at the same time, to release and swing open the top section of the Print Engine. CAUTION! Do NOT open the Print Engine while the printer is operating.

Make sure the Print Engine is closed and locked before operating. Do NOT open the Print Engine to an angle greater than 60º.

Printhead Cartridge – Memjet® printhead; produces an 8.5” wide, full color, print area.

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Behind the Ink Tank Door

SECTION 3

OPERATING THE PRINTER

Ink Tank Securing Latches – Used to hold the Ink Tanks in the slots.

NOTE: Please be sure that both sides, at the bottom part of the latch, are engaged.

Ink Tanks – Five I nk Tanks are used in the printer.

Cyan (C), Yellow (Y), Magenta (M), Black (K), Black (K)

Waste Ink Tray –The purpose of this tray is to catch any waste ink produced by the system. This

tray is filled with absorbent material.

The tabs located at the left and right sides o f the t r ay; secu r e t he tray to the print engine f rame. Please be sure the tabs “click” into the frame to secure the tray’s position.

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SECTION 3

B C D E F G H I J

Items contained in the Accessories Box

OPERATING THE PRINTER

Accessory Box Contents

The following items are included with your printer:

Qty [Image Reference] Description

5 [A] Ink Tanks

- Cyan, Magenta, Yellow, Black, Black 1 [B] Printhead Cartridge and packaging 1 [C] Rear Media Support Guide

- thumb screw attached to printer 1 [D] Service Station 1 [E] Wide Media Support Wedge

- mounting hardware attached to item C 1 [F] Narrow Media Support Wedge

- mounting hardware attached to item C 1 [G] Media Registration Side Guide

- mounting screws attached to printer 1 [H] Adjustable Media Side Guide

- mounting screws attached to printer 1 [I] USB Cable 1 [J] Power Cord 1 [K] Operation CD

contains printer software and pdf manual

Note: Ink Tanks and Printhead Cartridges can be purchased through your local Dealer.

Page 13

Control Panel Functions

BUTTON FUNCTION(s)

Press to power-up or power-down the print engine. Note: The Main Power Switch must be ON, to power-up the print engine. Printer S/N 1000274898 and lower will automatically power-up after turning on the main power switch.

POWERING-UP: It takes approximately 45 seconds for the print engine to power-up; after pressing this button. All lights blink simultaneously during power-up sequence.

The ON/OFF button will change to a steady illumination condition, once the print engine is fully powered-up.

SECTION 3

OPERATING THE PRINTER

Tip: You can launch (open) the Toolbox utility after the lights come on.

ON/OFF

PAPER/RESUME

PAUSE/CANCEL

POWERING-DOWN: Before turning off the printer, using the Main Power Switch; please be sure to power-down the print engine using this button. When the print engine has completed its power-down cycle, all lights in the control panel will turn off safe to turn off the Main Power Switch. WARNING! Power-down printer, using the ON/OFF button before removing/inserting Ink Tank(s), performing operator maintenance (cleaning), or powering off the Main Power Switch. If this power-down process is not followed; Ink Tanks may be damaged, ink color mixing and printhead nozzle clogging may result.

IMPORTANT: To provide proper printhead and ink system maintenance; the printer should remain powered on (ON/OFF light illuminated) at all times.

PAPER (Paper Feed Test): Before sending data to the printer; you can perform a paper feed test by pressing and holding this button for 4 seconds. The printer will feed a single page.

RESUME: If an “Out of Paper” condit i on is detected; reload media and press this button to resume printing. If the printer was paused using the PAUSE/CANCEL button, press this button to resume printing.

PAUSE: If you are in the process of printing and you want to pause the print job, press this button once. If the printer was paused, using the PAUSE/CANCEL button, press the RESUME button to resume printing.

CANCEL: If you want to cancel a paused print job, press this button again. The print job will be cleared from the printer. You must manually clear job from computer’s print queue.

Please see “Printer Status Light Indicators”, for additional information.

. It is now

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SECTION 3

PAPER

RESUME

PAUSE

CANCEL

OPERATING THE PRINTER

Printer Status Light Indicators

Valid with Beta Firmware 110928_u or higher installed. The lights on the three buttons, shown below, indicate the status of the printer.

LEGEND (For the Status Light Indicator chart on the next page.):

Description

ON steady OFF steady  or 

Flashing (1/second) / or / Fast Flash (3/second) / fast or / fast



Description POWER

Simultaneous Flash (1/second) Simultaneous Fast Flash (3/second) Alternating Flash (1/second)

Alternating Fast Flash (3/second) Power-Up and Power-Down Cycle / / /

  

 / fast / fast

/ /

/ fast / fast

/ /

Please see the “Status Light Indicator Chart” on the following pages.

Page 15

SECTION 1

GETTING ACQUAINTED

Printer Status Light Indicator Chart (see legend)

Valid with Beta Firmware 110928_u or hi g h e r installed.

ON/OFF

PAPER

RESUME

PAUSE

CANCEL

Printer Status corresponding Toolbox message

Additional Details, Possible Solution or Action



OFF



OFF



OFF

Print engine is powered-OFF

In this condition, it is safe to turn the Main Power Switch OFF or ON. IMPORTANT: To provide proper printhead and ink system

maintenance; the printer should remain powered on (ON/OFF light illuminated) at all times.





OFF



OFF

Print engine is powered-ON and ready

Printer is Ready

/

Print engine powering-up

It takes approximately 45 seconds for the print engine to power-up; after pressing this button. All lights blink simultaneously during power-up sequence.

The ON/OFF button will change to a steady illumination condition, once the print engine is fully powered-up.

TIP: You can launch (open) the Toolbox after the lights come on.

Print engine powering-down

All lights blink simultaneously during power-down sequence. Wait until all lights go out before turning OFF the Main Power

Switch.



/

Busy: Job Loading Wait for lights to stop blinking. Printer is Performing Maintenance

(Cleaning, Circulating Ink, etc..) Toolbox = MAINTENANCE_BUSY

Wait for lights to stop blinking.

Canceling Job. CANCEL key was pressed Toolbox = MECH_CANCELJOB

Wait for lights to stop blinking.



/

/

Printer is Printing

Press PAUSE, to pause printing. TIP: If the printer doesn’t try to feed media; check for paper jam in print engine and clean the PaperPath sensors.

Please see the “Toolbox System Status Messages” section for more details on Toolbox messages.

Simultaneous Flash (1/sec)

Alternating Flash (1/sec)

Page 16

SECTION 1 GETTING ACQUAINTED

Printer Status Light Indicator Chart (continued) (see legend)

Valid with Beta Firmware 110928_u or higher installed.

ON/OFF

PAPER

RESUME

PAUSE

CANCEL

Printer Status corresponding Toolbox message

Additional Details, Possible Solution or Action



/

FLASH



OFF

Printing Paused PAUSE button was pressed.

Press the RESUME button to continue printin g . Job can also be resumed by clicking on the “Clear Error” button in the Toolbox. Press the CANCEL button to cancel the job, and then manually clear the job from the computer’s print queue. Job can also be canceled by clicking on the “Cancel Job” button in the toolbox.



/ fast

Fast FLASH



OFF

Paper Time-Out (Out of Paper) Toolbox = PAPERPATH_FEED_TIMEOUT

Load Paper.

Press RESUME, to resume printing. Press the CANCEL button to cancel the print job. If job was canceled; manually clear job from the computer’s print

queue. Errors can also be cleared using Toolbox Interface.





OFF



Ink Tank(s) Empty Toolbox = INK_OUT_... Example: INK_OUT_YELLO W

Power-down the printer and then replaced empty Ink Tank(s). Verify that Ink Tanks are seated firmly and latches are fully closed, before powering-up the printer. TIP: If INK_OUT_ANY is displayed; contact service to update printer firmware to 110928_u or higher.

Ink Tank(s) Missing Toolbox = CARTRIDGE_MISSING_... Example: CARTIRDGE_MISSING_Y

Power-down the printer and then insert missing Ink Tank(s). Verify that Ink Tanks are seated firmly and latches are fully closed, before powering-up the printer. TIP: If problem persists the Ink Tank contacts could be dirty/corroded, or the chip on the Tank may have been damaged by installing removing Tank while printer was powered-on. Contact service.

Please see the “Toolbox System Status Messages” section for more details on Toolbox messages.

Page 17

SECTION 1

GETTING ACQUAINTED

Printer Status Light Indicator Chart (continued) (see legend)

Valid with Beta Firmware 110928_u or higher installed.

ON/OFF

PAPER

RESUME

PAUSE

CANCEL

Printer Status corresponding Toolbox message

Additional Details, Possible Solution or Action





OFF

Paper Jam Detected Toolbox = PAPERPATH_PAPERJAM

Any of the following conditions could exist: Paperpath: Entry : Yes Exit: Yes or Paperpath: Entry : No Exit: Yes or Paperpath: Entry : Yes Exit: No

Printer has detected that one of the media (PaperPath) sensors is blocked (interrupted).

Carefully remove jam and or clean PaperPath sensors. Make sure the clamshell is closed and securely latched.

If the PaperPath sensors are clear; the toolbox “PaperPath” line should change to Paperpath: Entry: No Exit: No No = not blocked (not interrupted), Yes = blocked (interrupted)

After you fix the condition you can;

- Press the RESUME button on the printer or press the “Clear Error” button in the Toolbox; to continue printing

- Press the CANCEL button to cancel the job, and then manually clear job from the computer’s print queue.



/ fast / fast

Printhead Missing Toolbox = PRINTHEAD_MISSING

Replace missing Printhead.

Printhead Not Primed Toolbox = PRINTHEAD_UNPRIMED

Follow Printhead Priming procedures. If you continue to have trouble; check for kinked or pinched ink color tubes or call for service.

Clamshell Open Toolbox – DOOR_OPEN_FRONT

Make sure the clamshell is fully closed and latched. If problem persists call Service and have them check the clamshell switch. Note: This switch is not present on printer S/N 100027598 or lower.

Other Errors – See Toolbox

Open Toolbox to view error. Fix condition then press “Clear Error” button in the Toolbox.

Please see the “Toolbox System Status Messages” section for more details on Toolbox messages.

Simultaneous Fast Flash

(3/sec)

Page 18

SECTION 1 GETTING ACQUAINTED

Printer Status Light Indicator Chart (continued) (see legend)

Valid with Beta Firmware 110928_u or higher installed.

ON/OFF

PAPER

RESUME

PAUSE

CANCEL

Printer Status corresponding Toolbox message

Additional Details, Possible Solution or Action



/ fast

/ fast

Tilt Error Toolbox = TILT_ERROR

Verify that printer is on a sturdy, level table (front to back and

left to right). Level the table, NOT the printer body. Do NOT use the printer’s tilt values to level the printer or table. Use an 18” or longer carpenters level to level the table. WARNING: If the printer is not placed on a sturdy level table, damage to the printer may result. If just powered on, wait a few minutes; tilt readings may settle into normal range. Once tilt readings drop into a normal range (Tilt values are no longer RED) the error can be cleared using the “Clear Error” feature in the Toolbox.

If problem persists; see “How to Zero the Tilt Sensor”.

Please see the “Toolbox System Status Messages” section for more details on Toolbox messages.

Alternating Fast Flash

(3/sec)

Page 19

SECTION 1

INSTALLATION

Recommended Troubleshooting Supplies

Items that a Technician should have avail able to them, when they visit a “Digital Color Printer” custo mer (in addition to standard tools):

• A box or ream of “inkjet suitable” media.

• Known good set of Ink Tanks (Cyan M5C250-N, Magenta M5M250-N, Yellow M5Y250-N, Black

M5K250-N, Black M5K250-N);

• Known good Printhead Cartridge (M5PRINT-N)

• Known good Service Station (123-2483)

• Lint-free cloths

• Distilled or Deionized water

• Computer (Win XP, Vista, Win 7, with USB 2.0 port) and USB cable. It would be best if the computer

system has been previously interfaced and tested with AS-950C. That way they should have documents or jobs already setup to test with printer, drivers loaded, toolbox loaded.

• Operations CD (contains printer software, drivers, operators guide, etc...)

• Service Manual

• Parts Manual; when available.

• Access to internet.

Note: Part numbers, shown above (with “-N”), are for Neopost.

Remove “-N” for Rena Systems. Add “-H” for Hasler.

Common Service Tools Needed:

This list is in addition to standard tools.

• Spring Hook

• Needle Nosed Pliers

• Side Cutters

• Voltage Meter

• SAE set of alan wrenches

• #1 and #2 Philips Screwdriver

• T-10 Torx driver

• Carpenters Level (18” or longer)

Minimum Computer Syst em R eq uire m ents

• Windows XP, Windows Vista, Windows 7. Supports 32 and 64 bit systems.

• You must have administrative privileges on the system.

• Pentium II, 2 GHz minimum (Pentium Dual Core, 2.5 GHz or better, is optimal)

• System memory – 2 GB minimum; or as recommended for your operating system.

• At least 10 GB free hard-disk space.

• Microsoft Internet Explorer 6.0 or higher.

• Java version 6 or higher

• CD/DVD drive

• USB 2.0 port (ports will be identified as “USB2” or “Enhanced” in the Device Manager)

• "Microsoft .NET Framework 3.5" installed (Even if you have a higher version installed, version 3.5

must also be installed.).

IMPORTANT: Before installing the printer software (Toolbox and Driver); you should temporarily disable all Antivirus programs and Firewalls. In addition; you must be logged onto the system with full administrative privileges (admin rights).

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SECTION 1

INSTALLATION

How to check your system for the minimum syst em requirements, shown above: Right click on "My Computer" and select Properties. The system information, including Operating System, Processor Info and Memory info will be displayed under the "General" tab.

How to check your system for the versions of "Microsoft .NET Framework” installed.

From the Control Panel; open "Add or Remove Programs" and look for "Microsoft .NET Framework 3.5..." in the list. You can obtain "Microsoft .Net Framework 3.5" via the Microsoft website. http://www.microsoft.com/net/download

How to check your system for the version of "Java" installed. From the Control Panel; open "Add or Remove Programs". Look for "Java(TM) 6 .." in the list. You can obtain Java from the following website:

www.java.com

There are also tools on the Java site to help you detect if you have java installed and what version is installed.

Page 21

SECTION 1

INSTALLATION

Installing the Printer Software (Driver and Toolbox)

During this process the M Series Driver and M Series Toolbox utility will be installed onto your computer system.

NOTE: If you are updating the Mach 5 (M Series) printer software (printer driver and toolbox utility); please be sure to Uninstall the old software before installing the new software. Use the “Uninstall” feature found on your computer system under All Programs, “Memjet”, “M Series Driver”.

PROCEDURE

1. Disconnect the USB cable connection from the printer; if you plugged it in already.

2. Insert the CD, supplied with the printer, into your CD drive. If the “Launch Menu” window does

not automatically open in your browser. Locate and run the “MENU_LAUNCH.htm” file, located on the root directory of the CD.

3. When the Mach 5 Operation CD “Launch

Menu” window opens on the computer screen; Click “Install Printer Software”.

NOTE: If you receive a Windows security or authorization warning, click on “YES” or “Continue Anyway”.

Tip: If you are unable to start the software installation using the button in the “Launch Menu”: Browse to the CD. Locate and open the Printer Drivers folder. Located and run “Install.exe” to start the install.

4. When the License Agreement window opens.

Carefully read the “End User Agreement”. If you agree to the terms, check “I accept…” then click Next>.

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5. When the Printer Connections window opens.

Select the USB choice and then click Next>.

NOTE: If you plan to connect the printer to a Network; first you need to install via USB. After this process is complete; please refer to the section title “Connecting the Digital Color Printer via Network (Ethernet Port)”.

NOTE: If you receive a Windows securit y or authorization warning, click on “YES” or “Continue Anyway”.

6. After a few moments the “Connect your device

now” window will appear. Turn the printer’s Main Power Switch ON; then press the control panel’s ON/OFF button. Wait about 45 seconds for the Print Engine to powerup (ON/OFF button will illuminate). Then connect the USB cable.

click on the <Back or Cancel buttons. The

Don’t software will automatically begin installing, once it recognizes that the printer has been connected.

7. You may receive two Windo ws security warnings during the software installation process. One for

the “USBCOMM Device Driver” and one for “Printers”. Be sure to click on Continue Anyway.

8. The necessary files will be copied to your

computer system.

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9. When the “Finished software installation” window ope n s ; uncheck the “Print Test Page” box.

Since the printer still requires the installation of the ink tanks and the printhead cartridge; you do not want to print a test page at this time. Select if you want to set the printer as default o r not.

If the button displayed at the bottom of the window shows “Finish”. Then click Finish>. If the buttons displayed show “No Reboot” and “Reboot”; then make sure all other programs have been closed and click Reboot>.

The “M Series Driver” should now be avai lable in your “Printer and Faxes” or “Devices and Printers” folder.

Tip: After you have completed printer setup (service station installed, ink tanks installed, printhead cartridge installed, media feed setup); it is a good idea to print a test page from the printer driver to confirm that the printer driver and printer are communicating. This is done by right-clicking on the “M Series Driver” and selecting “Properties” (Printer properties in Win7). Then click on the “Print Test Page” button.

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Connecting the Digital Color Printer via Network (Ethernet Port)

Valid for printer models Mach 5, AS-950C and HJ950C; with firmware version 110928_u or higher

installed. For printers with older firmware; please update the fir mwar e and driver before proceeding.

The following procedure is written for network systems that do not provide an automatic IP Address. In this case a static IP Address must be entered into the printer's "network status and configuration" window.

Note: For network systems that automatically provide the IP Address: Connect the printer to the network via the Ethernet connection, then run the Printer Software (Printer Driver) installation. Once you are prompted to choose the Printer Connection, skip to Step 8 below.

1. Run the Printer Software (M Series Driver and Toolbox) installation (R9.1 or higher). When prompted

to choose the Printer Connection, select “Configure to print via USB”. Then click Next. Note: Initially the USB connection is needed in order to configure the printer’s network settings. Once the software installation is co mplete; you can proceed to the next step.

2. Open the M Series “Toolbox” utility.

The Toolbox will open in a Web Browser (Example: Internet Explorer) window.

3. From the User Interface window of the Toolbox; click

on “Network Config”. Note: Your Toolbox layout may look different then shown.

4. When the “Network Configuration” window appears;

configure the printer's network settings as needed. See example. Check with your IT support person for help with these settings. Be sure to click on “Submit” after entering new information. Network Setting Tips: The information shown on this page is just an example. You must use settings that are compatibl e with your network and settings that are not in direct conflict with other devices on the network. Running "ipconfig" from a Command Prompt may help you determine some of these settings. In general you can use the same "Subnet Mask" and "Default Gateway" that are shown in the "Windows IP Configuration", but you need to provide a unique "IP Address" for the printer. For example if the "Windows IP Configuration", IP Address for your computer's connection is shown as 192.168.100.222 you may be able to use 192.168.100.223 for the printer; if this IP Address is not in use by some other device. If you want to check for an open IP Address you can ping the address before you save the settings and con nect the printer. Type "ping your-ip-address" (Example: ping

192.168.100.223) at the command prompt. An open IP Address will show "Request timed out". An IP address that is working and in-use

will show replies (Reply from 192.168.100.223:....)

Check with your IT support person for he lp w i th thes e settings.

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5. Using a Cat5 network cable; connect the printer to your network via the Ethernet port.

6. Click on “Diagnostics”.

The “Diagnostics” window will open; displaying a lot of information about the printer. This information will include the Network Status and configuration settings.

7. If the “Network Status:” is shown as

“disconnected”; click on the refresh button in the browser window. If you have entered compatible network settings for your network and the printer; the "Network Status:" line in the Diagnostics window should change from "disconnected" to "connected". If the status doesn’t change to “connected” please contact your IT support person for help with the network settings.

8. Run the Printer Software ( M Series Driver, R9.1 or higher) installation again; but this time choose

"Add another printer".

9. When prompted to choose the Printer Connection; select "Configure to print over the Network".

Then click Next.

The install program will search the netwo r k for printers. It should automatically locate the "M Series" printer at the IP address provided by the network or that you configured in step 4. In this example the M Series printer has the IP Address 192.168.100.251.

Note: If the driver install program cannot locate the printer automatically, then you will be presented with a window to enter the Host name and IP Address for the printer. Enter the IP Address for the printer and click Next (You do NOT need to enter a Host name). If the printer is found at the IP Address provided; the driver install will continue automatically (skip to 10). If the printer is not

found then, in general, you have not provided a valid IP Address or network configuration for the printer. In thi s case CANC EL the driver install and repeat from Step 1. Please obtain help from your IT support people.

10. Select the "M Series" printer that is displayed. Then click Next

When the “Finished software installation ” window appears; displaying “Network Connecti on Successful”; select if you want to “Print Test Page” or “Set this printer as the default printer”. Then click Finish. If selected, a test page will be sent to the printer t o be printed.

Opening (launching) the “M Series Toolbox” utility from an Ethernet connection:

Valid for M Series Driver version R9.1 and printer firmware version 110928_u or higher.

To open the Toolbox utility; click on Start, All Programs, Memjet, M Series Driver, Toolbox. Improvement: During the driver installation process, the Toolbox connection is now automatically configured to the selection you provided (USB or Network) during the installation process. In other words if you selected “Network” during your most recent driver install, the Toolbox will automatically connect to the printer’s EWS (Embedded Web Server) via the network connection. If you selected “USB” during your most recent driver install, the Toolbox will automatically connect to the printer’s EWS via the USB connection. Tip: With driver version R9.1 you can no longer connect to the printers Toolbox utility, via the network, by typing the network address into the browser window. You must select the desired connection (USB or Network) during the driver installation process.

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NOTE – Reverse Order is set

page loads.

INSTALLATION

Printer Driver Properti es

Valid with driver version R9.1 or highe r . The Printer Driver for the RENA Mach 5 works the same as any other Pr i nter Driver for Windows. It does

have some enhancements to help you maximize the ability of the Printer to print variable addressed pieces quickly and efficiently.

Windows XP, Vista, Windows 7: Once the job is set up, click F The window on the right will open. Make sure the M Series Driver is the selected Printer. Clicking on P “Properties” window.

ile, then Print.

roperties opens the

General Tab

The General tab lets you select:

• Orientation – Portrait (Default),

Landscape, Rotate 180° and Mirrored.

• Page Buffering – Allows the entire print

job to load before printing starts.

• Copies – Lets you choose the number of

copies to be printed.

as the default. This means the job starts printing from the last page. The entire job will load into the Printer before printing starts. Large jobs may take some time to load. Unchecking the box prints the job starting with the first page. Printing starts as soon as first

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MEDIA TYPE

MEDIA PROFILE

Plain Paper

Transparency Film

Premium Photo Paper Glossy

Label Glossy

Photo Greeting Cards Glossy

Brochure Glossy

Photo Paper Matte

Postcards Matte

INSTALLATION

• Media

Type: Chart at right lists the media profiles

associated with the type of media chosen. Sizes: Select for the given media that you are

Bright White Paper

Plain Paper

using. If the size is not present use Custom Sizes.

Photo Paper Glossy

Premium Glossy Label

In some programs (i.e. Adobe Acrobat®) this feature also allows you to choose a different size paper than the document was originally designed for, and the document image is

Photo Paper Semi-gloss Postcards Glossy

Glossy Label

automatically resized to fit the new media. Important: When designing a custom size; do not

exceed the printer’s maximum print width (8.5”). Custom sizes can only be created for locally-attached printers. Borderless Print – Also known as “full-bleed” printing. Select this option to allow the image

Label Matte Photo Greeting Cards Matte Brochure Matte Premium Inkjet Paper Presentation P aper Other Inkjet Paper

Matte Coated L a bel

to overlap all edges of the media. The image being sent must be slightly larger than the media (a 1/8” bleed is typical). Tip: You may need to have your support person adjust the tof_adjustment setting in the Toolbox (Service Menu, Printer Control Conf., under Printout Control) to align the “full bleed” image with the physical page.

• Color Selection – Set Printing for Color or Monochrome.

Monochrome + Normal Print Quality = Black Only (image produced using only the black Tanks) Monochrome + Best Print Quality = Composite Black (uses CMYKK to make the darkest black)

• Print Quality – Select Normal or Best.

Normal provides 1600 x 800 dpi at 12 ips (inches per second). If you also select the Half Speed, box; media transport and printing is slowed, for higher print accuracy. Best provides 1600 x 1600 dpi, at 6 ips. Use when high quality images are required.

• My Print Settings – Allows you to save or recall (select) your custom driver settings for various

jobs.

Layout Tab

Layout allows you change how the document

prints without changing the original document.

• Resizing

Original Size – no changes Custom Resize - lets you resize the

original as a % of normal size. The printer will print the document in the size you selected regardless of the size of the paper selected. Print on: Lets you specify the particular size of paper that you want to print on regardless of the size of the original document. Checking “Scale to Fit” automatically resizes the document to fi t on the new page size.

• Printing Adjustments – Allows you to

make minor positioning changes to the print area in relation to the media if needed. Note: Only works on jobs using less than the full print area (less than 8.5 " wide).

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• Watermark – Prints background text onto the media along with the original document. A few

selections (SAMPLE, Draft, COPY, Confidential) are provided with the driver. First page only – When a watermark is selected; the “First page only” option is available. Selecting this option prints the watermark on the first page, but not subsequent pages. Un-checking this option prints the watermark on all pages. Custom – This button lets you create a new watermark or edit an existing watermark, including font selection, color, size and printing angle.

• My Print Settings – Allows you to save or recall (select) your custom driver settings for various

jobs.

Media Tab

The Media tab provides the following features:

• Position Adjustment – This feature will

allow you to make small corrections in the horizontal and vertical position of the image. Horizontal Offset – allow you to set a plus or minus number. Vertical Offset – allows you to set a plus o r minus number.

Inches – Not available Millimeters – Not available Pixels – value in dots (very small)

• Top of form indicator –Please be sure

“None” is selected or the printer will not operate properly. The other choices are not valid for this printer model.

• Page Cutting – Please be sure neither of

these boxes are checked off, or the printer may not operate properly. These choices are not valid for this printer model.

• My Print Settings – Allows you to save or recall (select) your custom driver settings for various

jobs.

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Services Tab

Services allows you to:

• Print Configuration Page – Prints out the

current configuration of the Printer including current Firmware Version, Network Connection, Printer Engine Serial Number and more.

• Print Colorbar Page – Prints type and color

bands to check print quality.

• Print Diagnostic Page – Shows basic printer

information, memory, Network Settings, Event Log and RAM partitions.

• User Maintenance, Levels 1 to 3

Level 1 – Circulates ink, wipes and cleans the

Printhead Cartridge. Level 2 – Runs cleaning and wiping routine twice for better flushing and cleaning. Level 3 – Runs the cleaning routine multiple times for the most thorough flushing and cleaning of the Printhead. NOTE: If the Printer is connected to a network and the Driver buttons fail to activate the cleaning process, you can perform the same functions from the Toolbox User Interface.

• Wipe Printhead – Wipes and cleans excess ink from the Printhead Cartridge.

• Printhead Release – Use this feature to prepare the printer for the installation or removal of the

Printhead Cartridge. This feature pumps some releases (opens) the Printhead Latch. Same as using the Printhead Latch Release Button. See “Installing Printhead Cartridge” or “Replacing Printhead Cartridge” for more details

• System Deprime – Use this feature to prepare the printer for service or transport to a remote

location. This feature pumps most Printhead Latch. See A ppe n dix “Preparing the Printer for Transport” for more details.

of the ink back into the Ink Tanks and then releases (opens) the

of the ink back into the Ink Tanks and then it

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Using the Toolbox Utility

Valid with firmware 110928_u. Once the M Series Printer Driver is install ed you h ave access to the M Series Toolbox. The Toolbox lets

you monitor ink usage, perform diagnostic checks, print reports and run maintenance tasks on the Printer from your computer.

To open the Toolbox: Click Start from the Windows taskbar, go to All Programs, open the “Memjet” folder, select the “M Series Driver” folder, and then click on “Toolbox”. When the “User Interface” window opens you will find a series of Menu Options you can click on at the lower left of the screen. You can check the Printer Status in the upper l ef t part of the screen.

NOTE: The Toolbox utility uses your web browser to communicate with the printer’s EWS (Embedded Web Server). If you receive warning that Windows Firewall has blocked some features of this program. Please select Private Networks and then click on Allow Access. Tip: If you receive a “Printer not responding” message in your browser; check to be sure the printer is turned on and the USB cable is connected. Then click on Retry.

User Interface

[A] User Interface Buttons: Let you perform

maintenance and operating tasks. You can use these buttons to Clear Errors, Cancel a Job, Reset the Job Counter, and Reset the Page Counter. You can also perform some maintenance and operating tasks such as:

Clear Error – Clears some printer errors t hat are displayed in the Toolbox.

Cancel Job – Clears the current job from the print engine. Job must be manually cleared from computer’s print queue.

Reset Job Counter – Resets the job count. Reset Page Counter – Resets the page cou nt.

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Cleaning Buttons: Provide 3 levels of cleaning for the Printhead Cartridge. These work the same way as the 3 Maintenance Level Buttons in the Printer Driver:

Quick Clean Printhead – Circulates ink, wipes and cleans the Printhead Cartridge. Normal Clean Printhead – Runs cleaning and wiping routine twice for better flushing and cleaning. Full Clean Printhead – Runs the cleaning routine multiple times for the most thorough flushing and

cleaning of the Printhead.

Wipe Printhead – Activates the Service Station to wipe the Printhead. Circulate Ink – Can be used to help purge air from the printhead and ink system. Caution! Don’t run

this feature more than two times in a row. Doing so can build-up too much pressure in the system which may cause excessive ink waste and ink spill s to occur.

Release Printhead – Use this feature to prepare the printer for the installation or removal of the Printhead Cartridge. This feature pumps some

of the ink back into the Ink Tanks and then it releases (opens) the Printhead Latch. Same as using the Printhead Latch Release Button. See “Installing Printhead Cartridge” or “Replacing Printhead Cartridge” for more details

System Deprime – Use this feature to prep ar e t he printer for service or transport to a remote location. This feature pumps most

of the ink back into the Ink Tanks and then releases (opens) the Printhead Latch.

See Appendix “Preparing the Printer for Transport” for more details. Eject Maintenance Station – Ejects the Service Station from the printer. This feature should only be

used by a qualified technician during maintenance. Install Maintenance Station – Pulls the Service Station into the printer. This feature should only be used

by a qualified technician during installation or maintenance.

[B] Basic Printer Settings – Lets you adjust automated service and cleaning intervals, adjust the feeder speed for a job and adjust the Printer for pre-printed media.

KWS Setting – The Keep Wet System (KWS) incorporates an algorithm to periodically fire all printhead nozzles in order to keep all nozzles wet; thereby reducing nozzle clogging and print quality issues. In general the dots produced on the media by this nozzle firing algorithm are hardly noticeable. However in some case the dots produced are not acceptable for the application and the user may wish to turn this feature off. None = Intrapage spitting is turned off. No dots sprayed onto media. Light (Default) = Intrapage spitting frequency is set to the "default" level. Dots are sprayed onto media to help reduce nozzle clogging and print quality issues. Heavy = Intrapage spitting frequency is increased. More dots sprayed onto media to further reduced nozzle clogging and print quality issues.

WARNING: Selecting “None” will increase the chance for nozzle clogging and print quality issues. PLEASE BE SURE TO HIT "SUBMIT" AFTER CHANGING THESE SETTINGS

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Mid Job Servicing – Allows user to adjust the frequency of printhead cleaning (servicing) during a print job. Based on the linear meters of media transpo r ted through the system.

OFF = 32,000 meters (This distance is so large that it should never be reached) Level 1 = 500 meters Level 2 = 375 meters Level 3 = 250 meters Level 4 = 100 meters Default = 14 meters (14,000 millimeters)

NOTE: This feature will revert to default if power is cycled or printer is reset. WARNING: Changing from "default" may cause print quality issues and reduced printhead life.

Service interval examples for the “default” (14 meters) setting:

Feeding 8.5" x 11" media (length= 11”= 0.28 meters). Printer stops to clean about every 50 pieces. Feeding #10 envelopes (length= 4.13”= 0.10 meters). Printer stops to clean about every 140 pieces.

Cutsheet Feeding Mode – Allows user to select between more accurate media feed control or better throughput.

Safe_Feed = Larger gap between pieces p r ovides slower throughput, but less chance for blan ks (unprinted pieces) to be fed.

Max_Throughput = Smaller gap between pieces provides higher throughput, but more chance for blanks (unprinted pieces) to be fed.

NOTE: These two settings can be changed “on the fly” without stopping the job. Example: While running a job in “Max-Throughput” you find that the media is jamming excessively due to speed. Open the Toolbox, check “Safe Feed” and click “Submit”. The Printer will automatically adjust without having to pause or stop the job.

Ignore Exit Sensor – Allows use of medi a that i s non-reflective to the Paperpath Exit sensor. When this feature is NOT selected; non-reflective media may cause a "Paperpath_Paperjam" condition.

After you select this feature and click on Submit; you will see the "Paperpath Exit" condition, shown in the Toolbox, change to "Exit: Disabled" ; allowing you to run non-reflective media.

NOTE: Please try cleaning sensors; as outlined in the user's guide and service guide; before selecting this feature. This feature will not solve issu es cau sed by media transport (slipping, hesitating, jamming).

PLEASE BE SURE TO HIT "SUBMIT" AFTER CHANGING THESE SETTINGS

[C] Shutdown – Turns the Printer OFF from your computer.

[D] Display Language – S el ects the language the Printer will operate in.

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INSTALLATION

[E] Firmware Download – This feature is used to update the main firmware in the printer.

WARNING: This process should only be performed by a qualified support representative. In some cases firmware must be loaded using the “Firmware Migration Tool”. If this process is not performed properly, it can render the printer inoperable.

How to download new firmware:

1. When you are notified that new firmware

is available for your Printer, download the *.fbf file and save it to your desktop.

2. Open the Toolbox. On the “User

Interface” page, find Firmware

Downloads.

3. Click the “Browse” button and find the file you just saved to your desktop.

4. Click “Submit”. DO NOT touch the Printer until the firmware is loaded! A message will

appear on your screen warning you not to unplug or shut off the Printer.

5. Once the firmware finishes l oading (about 10-30 minutes), the printer will automatically power-

down (control panel li ghts will go out). After two minutes; if the printer doesn’t automatically power-up, press the ON/OF button to restart the printer, to complete the process.

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Diagnostics

From this screen you can see the current st at us of your Printer. You can also:

Print Sample Page – Prints type and color bands to check print quality.

Print Configuration Page – Shows the current configuration of the Printer including Firmware Version, Network Connection, Printer Serial Number and more.

Print Diagnostic Page – Shows basic Printer information, memory, Network Settings, Event Log and RAM partitions.

Print Demo Page – Prints a 4-color sheet. Print Ink Channels – Prints 5 solid block of color bars (1 block/bar from each Ink Tank CMYKK) to

show how well the nozzles are performing , in each colo r chan nel of the Printhead. Print Color Bars Page – Prints 7 solid blocks of color bars to show how well the Printhead is mixing

colors and printing. Prints four blocks of mixed color (black, red, green, purple) along with three blocks representing the cyan, magenta, and yellow ink channels.

Ink Usage

Provides the estimated volume (nL) of ink used, from each Ink Tank, for each print job that was completed.

• Does not include ink used during

maintenance cycles.

• Pieces printed during the job will be separated

by any maintenance cycles and pauses that occurred during the run.

• This information is cleared whenever the

printer is reset (turned off/on) .

Ink Estimation Mode – Allows for estimation of ink usage; without actually feeding or printing on media. After selecting “Enabled” and clicking on "Submit", the text “Ink Estimation Mode” should appear at the left side of the Toolbox screen. Send your job to the printer. The printer will accept the job, but will not feed or print. When the job has finished being sent to printer; check the Ink Usage page to obtain results. NOTE: Don’t forget to unselect “Enabled” and click on “Submit” when you are finished using this Ink Estimation Mode. Tip: The estimating process will take as long as the job would take to print (i.e., if the job would take 1 hour to print, the estimate will take 1 hour to display.). To reduce estimation time, only send part of the job for estimation purposes. For example: If you have a 200,000 piece job. Send only 200 records, and multiply the Ink Usage by 1,000.

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Network Config

Permits you to view, enter or change settings to connect the Printer to your network.

Network Connection Set Up:

This is a brief description of the processes. For more details see: “Connecting the Digital Color Printer via Network (Ethernet Port)”

1. Connect the printer to the computer via USB.

NOTE: To initially access the Toolbox and

make the necessary Network settings; the printer must be connected to the computer via the USB cable (during driver install, the USB choice was selected).

2. Open the Toolbox. On the “User Interface” page,

click Network Config.

3. The “Network Configuration” page opens. Your

IT person can choose the Network Settings box to enter the correct settings for your network.

4. Connect Ethernet cable to Network Port on Rear Panel of Printer.

5. Re-install the M Series Driver, but this time choose the Network

choice during the installation process .

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Service Menu

For authorized personnel only (password protected). Provides access to more advanced Printer Control and Maintenance menus. Enter password to view the Service menus.

Firmware 110928_? and higher PW = 630

Firmware 110513_? and lower PW = servicepw

Once you gain access to the Service Menu, y ou will notice that several new menu options become available: “Printer Maint Config,” “Printing Control Config, ” “Exit Service Menu,” and “Commands Help.”

Printing Control Config Screen: Allows you to make fine adjustments as to how a job is fed int o and through the Printer and how it will print.

NOTE: The Memjet print engine is manufactured as a universal device; therefore many of these features do not pertain to the Digital Color Printer model.

WARNING: To avoid accidently causing problems with the function of the printer; features that are not described below, sho uld not be touched, unless you have been instructed to do so by Tech Support.

Make sure you make a note of your current settings, before you make adjustments.

Media Feed:

• Feed must be set to “cutsheet”.

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Printout Control

The following settings will vary from unit to unit. The unit value (measurement) used in the following features is microns (1000 units = 1mm). NOTE: You must press Submit for the change to take effect in the printer.

• tof_adjustment: Provides fine adjustment for the starting print position, TOF (Top of Form)

• bof_adjustment: Provides fine adjustment for the ending print position (where media ends),

BOF (Bottom of Form)

• left_adjustment: Provides fine adjustment for the left print position.

Printing Parameters

The settings, shown in the screen-shot above, are the normal settings for the Digital Color Printer. With exception to the disable_tilt feature (check box); we do not suggest adjustment to these settings.

• disable_tilt: checked (default). Unchecked = disregard tilt errors.

Note: This item will default beck to unchecked if you cycle printer power.

Printer Maint Config Screen: Allows you to

enable or disable certain maintenance functions, zero the tilt sensor and print-out configuration/diagnostic information.

Active Maintenance Tasks The settings, shown are the normal setting s for the Digital Color Printer. Everything should be checked except “disable_maint”.

WARNING: To avoid accidently causing problems with the function of the printer; do NOT

alter these settings unless you have been instructed to do so by Technical Support. BUTTONS:

• Zero Tilt Sensor: Pressing this button will reset the base-line of tilt sensors (the current

physical level will become zero). The printer must be on a level surface to operate properly. Do NOT press this button unless you are sure the table, the printer has been placed on, is perfectly level and sturdy. See “How to Clear a Tilt Error”. NOTE: After zeroing the Tilt Sensor; restart the printer using the ON/OFF button. This will insure that the settings get saved. Tip: With firmware 110928_u and higher, the Tilt Sensor can be zeroed by pressing and holding the PAPER and CANCEL buttons simultaneously, for 5 seconds.

• Print Sample Page: Prints-out current pri nt e r settings including Firmware version, MAC

Address, IP Address, Tilt Reading s, etc… on colored background.

• Print Configuration Page: Prints-out current printer configuration including Firmware

version, Device (print engine) serial number, Language, Internal memory, Print Settings (Paper Type, Paper size), IP Configuration, etc.

• Print Diagnostics: Prints-out a System Diagnostics Page which shows: Firmware version,

Device (print engine) serial number, Number of pages printed in each print quality (color and mono), Network Settings, and Event Log.

• Print Demo Page: Prints-out Memjet demo page.

• Print Ink Channels: Prints 5 solid block of color bars (1 block/bar from each Ink Tank

CMYKK) to show how well the nozzles are performing, in each color channel of the Printhead.

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• Print Color Bars Page: Prints 7 solid blocks of color bars to show how well the Printhead is

mixing colors and printing. Prints four blocks of mixed color (black, red, green, purple) along with three blocks representing the cyan, magenta, and yellow ink channels.

Commands Help Screen: Provides a list of available EWS service com mands. These commands can be used to help troubleshoot issues within the print engine.

WARNING: To avoid accidently causing problems with the function of the printer; do NOT

alter these settings unless you have been instructed to do so by Technical Support.

Service Command Example: If you are trying to verify the funct i on of the P inc h Valve you can use the following process:

1. In the search box; type “ids_valve” and click on

Submit.

2. Click on the “/config/ids_valve” link.

3. The “ids_valve: Set Valve Position” screen will

appear. A pull down box with selections for the valve positions (openink, openair, closed, idle) is provided.

4. Select “openink” and click on Submit. If you have the entrance cover off the printer, you may hear

and see the valve respond. When looking into the printer from the entrance side; the pinch valve is located to the right of the five channel pump. It is d ifficult to see because it is behind the l ower fan shrouding.

5. Take a look at the “Valve:” condition, displayed at the left side of the Toolbox window.

It should have changed to “openink”.

6. Select “closed” and cl ick on Submit.

7. Take a look at the “Valve:” condition, displayed at the left side of the Toolbox window.

It should have changed to “closed”.

8. Select “openair” and click on Submit.

9. Take a look at the “Valve:” condition, displayed at the left side of the Toolbox window.

It should have changed to “openair”.

10. Select “idle” and click on Submit; to give the printer control over the valve. Valve Troubleshooting Tip: If you find that the pinch valve is not responding then this could indicate

a problem with the valve or valve sensor. Check connections to valve and valve sensor. NOTE: If the Toolbox is showing other errors (Reason: ink_error); it is possible that it will not

respond to the service commands until the pre-existing condition is fixed and the error is cleared.

Service Tip: If the printer will not feed/print (Toolbox may show “Valve: Error” or constantly show

“Maintenance Busy”); click on “nvm_h w ” and make sure the settings are as follows: mpcarev (don’t touch) Wiper_motor = E Pump_motor = B Then press “Submit”. Then restart the printer using the ON/OFF button. This will insure that the settings get saved.

Exit Service Menus

Closes the Service Menu options and takes you back to the "Printer User Control" screen.

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SECTION 1

CAUTION

INSTALLATION

Section 2 – Installation

This section provides a few of the critical installation items. Please refer to the “Operator’s Guide” for complete Installation and Operation instructions.

Tools Needed for Installation

• Knife and scissors to open packaging

• #2 Philips head Screwdriver

• Carpenters Level (recommend using 18” or longer level)

• Protective gloves should be worn to avoid getting ink on hands when removing protective packaging

materials from the ink coupling areas, the Ink Tank areas, and when installing/removing Printhead Cartridge and Ink Tanks.

Choosing the Location

The Digital Color Printer should be placed on a sturdy, level, worktable or cabinet at least 9 inches from any walls. Protect the Digital Color Printer from excessive heat, dust, and moisture – avoid placing it in direct sunlight.

Work-Table Surface Must be Level

The surface that the printer is placed upon must be level, front to back and side to side. Use a carpenter’s level to verify that the surface is level . If the surface is not level the printer will not perform properly. Level the table surface, NOT the printer. Do NOT move the printer while the power is on.

Operation should take place under the following conditions:

- At temperatures between +15°C and +35°C (59 °F to 95 °F).

- At a relative air humidity between 20% and 80%, non-condensing.

- At an atmospheric pressure between 70 kPa and 105 kPa. Exposure to conditions that are not permissible may lead to damage which is not externally visible. Allow the printer, printhead and ink tanks to acclimate to ambient temperature before using the printer

Removing Service Station Transport Tab

1. Open the Top Cover.

2. Release the two latches (on e on ei ther side of the

Print Engine). Open the top half of the Print Engine by lifting both levers at the same time.

OPERATE AND HOLD ONTO BOTH LATCHES WHEN OPENING AND CLOSING THE CLAMSHELL COVER TO PREVENT DAMAGE.

DO NOT ALLOW THE ASSEMBLY TO DROP BY ITSELF WHEN CLOSING.

TO PREVENT DAMAGE TO THE INK LINES, A STOP LIMITS RAISING THE ASSEMBLY MORE THAN 60°.

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SECTION 1

Ribbon

Cable

Service Station

Ink Tank

INSTALLATION

3. Pull up on the two tabs to remove the cardboard

Transport Tab from the Service Station.

4. Carefully close and relatch the Upper Print

Engine. Then close the Top Cover.

Installing the Service Station

Note: New printers are shipped with the Service Station pre-installed. In this case all you need to do is remove the cardboard shipping insert as described above. Removing the “Service Station Transport Tab”

CAUTION

THIS PROCESS MUST BE PERFORMED BY A

QUALIFIED TECHNICAL SUPPORT PERSON.

Due to the technical nature of this procedure; t his process should only be performed by a qualified t echn i cal support person. This process is normally performed when the printer is first instal led or when technical maintenance is needed on the printer.

The Service Station fits in the slot immediately above the Ink Tank slots. The Service Station contains three separat e areas/devices that are used to perform the following tasks.

• Cleaning. The wiper roller cleans the Printhead nozzles of excess ink and debris.

• Printing/Purging. This area acts as a base to support media during printing. It also contains a purging

area; which captures and absorbs ink that is purged, to help keep nozzles clear.

• Capping. This area seals and protects th e printhead nozzles when not in use.

PROCEDURE:

1. Make sure the printer is po w ered OFF.

If the printer is not engine to power off (all control panel light’s off). Then turn the Main Power Switch OFF.

2. Open the Ink Tank Door (hinged at bottom).

3. Open the Top Cover.

4. Remove the Exit Roller Cover by removing the four (4) screws.

The Service Station Slot and Ribbon Cable will be exposed.

powered off, press the ON/OFF button once and wait about 45 seconds for the print

Slot

Door

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INSTALLATION

CAUTION!

Closed

Opened

Open

Check the latch at each end of

5. Carefully remove the Service Station from its packaging.

NOTE: Loose parts may fall out. Keep wiper roller si de facing up, when removing the packaging.

Make sure latches on the Wiper Roller are fully latched before installing the Service Stat ion.

the wiper roller.

6. Slide the Cable Securing Latch open on the Service Station Circuit Board; as shown below.

SECTION 1

7. Insert the Ribbon Cable (blue side up) into the space under the Cable Securing Latch [1].

Make sure the ribbon cable is pushed in all the way and is NOT crooked. Then close the Cable Securing Latch [2].

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SECTION 1

Wiper Roller end of

Ribbon Cable

Connected to Service

INSTALLATION

8. Once the Ribbon Cable is properly connected to the Service Station Circuit Board; gently slide the

Service Station, wiper roller end first, into the Service Station Slot until it stops. The Service Station fits into the slot immediately above the Ink Tank slots. NOTE: The Ink Tank Door must be open

to perform this procedure.

Service Station

Station Circuit Board

9. Look down through open area of the Printhead

Cartridge compartment, in the top of the Print Engine, to make sure the Service Station is align ed wit h the “Bar”; as shown.

IMPORTANT! Service Station must perfectly ali gned with “Bar” to prevent misalignment and jamming of the service station.

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SECTION 1

You don’t need to open the Print Engine.

Ink Tank

INSTALLATION

10. GENTLY push in on the Service Station with one hand, while slowly turning the “Large Gear”

clockwise with the other hand. It should b e easy to tu r n this gear and the service station should start to drive into the print engine squarely. Once the Service Station moves about ¼ inch past the “Bar” (shown in previous step), stop turning the gear. Do NOT manually drive the Service Station into the print engine beyond this point.

NOTE: The “Large Gear” is located on the non-operator side of Print Engine; as shown below. You don’t

need to open the Print Engine to access this gear.

Shown for clarification purpose only.

Service Tip: Verify that the Service Station Guide (42-900-25) is installed. In addition; before

powering-on the printer, make sure the service station moves free. Manually drive the Service Station all the way into the back wall, until it stops. Then drive the Service Station almost all the way back out; but be sure to stop when the leading edge of the Serv ice Station is about ¼” past the drive shaft (still engaged with drive shaft). If the Service Station does not move free anywhere along its travel, this issue must be corrected before you power-up the printer.

11. Turn the printer’s Main Power Switch ON; then press the control panel’s ON/OFF button.

After printer initialization (~45 seconds) the Print Engine will automatically pull the Service Station the rest of the way in. NOTICE: If the Service Station should get jammed during this process (you hear motor stall noise or gear slipping noise); immediately turn OFF the printer’s Main Power Switch. This is one of the only exceptions for turning off the printer using the main power switch, before properly powering-down the print engine. Remove the Service station by turning the Large Gear counter-clockwise. Re-check that the Wiper Roller is properly installed and latched at each end. Then re-install the Service Station starting from step 8 above.

Tip: The “Eject Service Station” button, located in the M Series Toolbox, should be used if the service station needs to be removed in the future.

12. Re-install the Exit Roller Cover plate, using the 4

screws. Make sure the cover is installed in the proper orientation. Tip: Since the Exit Roller Cover is also an integral part of the frame structure; you may need to push in on the outer frames to get the screw holes in the Ex it Roller Cover to align. Close the Top Cover and the Ink Tank Door.

Door

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The ink used in this system may be harmful if swallowed.

INSTALLATION

Install the Ink Tanks

The Digital Color Printer uses five Ink Tanks (two Black, one Cyan, one Magenta, and one Yellow) . The Ink Tank is a delicate, precision device. Handle with extreme care to avoid damage.

Ink Tank Anatomy

Keep new and used printhead cartridges and ink tanks out of reach of children.

Discard unwanted printhead cartridges and empty ink tanks immediately.

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SECTION 1

CYAN (C)

YELLOW (Y)

MAGENTA (M)

BLACK (K) x 2

INSTALLATION

Procedure (Installing the Ink Tanks):

This procedure assumes that you are installing Ink Tanks into a printer that doesn’t have any Ink Tanks installed. If you are replacing an empty Ink Tan k, please refer to the “Replacing the Ink Tanks” section.

1. Plug in the printer. Turn the printer’s Main Power Switch ON; then press the control panel’s ON/OFF

button. Wait about 45 seconds for the print engine to power-up (ON/OFF button will illuminate).

2. Open the M Series Toolbox. Go to All Programs, select the

“Memjet” folder, select the “M Series Driver” folder and Open the “Toolbox”. A web browser will open and display the “Printer User Control” screen. On the left side of the screen you will see information about the System Status and Ink levels. With no Ink Tanks installed all Ink status levels will all be displayed with a question mark (?) below each color position.

Tip: If you receive a “Printer not respond ing” mess age in your browser; check to be sure the printer is turned on and the USB cable is connected. Then click on Retr y.

NOTE: If you receive warning that Windows Firewall has blocked some features of this program. Please select Private Networks and then click on Allow Access.

3. Turn the printer OFF with the ON/OFF Button.

Wait about 45 seconds for the print engine to shut-down (ON/OFF button light will turn off). Note: You may loose communication with the “M Series Toolbox” at this time.

4. Open the Ink Tank Door (hinged at bottom).

Unlock and Open the three Ink Tank Securing Latches [A].

5. Remove the new Ink Tanks from their

packaging.

6. Slide the new Ink Tanks (label side up) into their appropriate color slots.

INSTALLATION TIP – To make sure the Ink Tank seats properly (sept um needles penetrate the

seals on the tank and the tank contacts make a good el ectr ical connection with the system): Insert the

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SECTION 1

INSTALLATION

Ink Tank firmly. Then pull the Ink Tank back out about an inch. Then push the Ink Tank back in, firmly.

7. Close and lock all three Ink Tank Securing Latches.

IMPORTANT: Make sure both sides of the Latch are engaged at the bottom.

8. Turn the printer’s Main Power Switch ON; then press the control panel’s ON/OFF button. Wait about

45 seconds for the print engine to power on (ON/OFF button will illuminate).

9. Refresh your web browser window. Watch the Toolbox

screen on your computer; you will see the ink colors fill in as the Ink Tanks are recognized.

Tip: If the Toolbox utility does not respond; verify that the printer is powered on and that the USB cable is connected. Then try closing and opening the Toolbox utility again.

Tip: If an ink color does not fill in after a few minutes; power-down the print engine, using the ON/OFF button. Then reseat the Ink Tank by popping it in and out; as described in Step 6 “Installation Tip”. Then repeat from Step 8.

10. Close the Ink Tank Door.

11. Close the Top Cover.

12. If a Printhead Cartridge is not installed the Systems Status line in the Toolbox will display “MISSING

PRINTHEAD message. To inst al l the Printhead Cartridge; please proceed to the section t itled “Installing the Printhead Cartridge”.

Tip: It is planned for the next revision of firmware (above 110928_u) to have a new Toolbox feature (button located in the User Interface screen) that will allow the operator to put the printer into a state where it will be safe to insert/remove Ink Tanks while the printer is still powered on. Until that time, please be sure to power-down the printer before installing/removing Ink Tanks. If this procedure is not followed damage to the chip on the Ink Tanks may result. This will render the Tank useless.

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The ink used in this system may be harmful if swallowed.

INSTALLATION

Installing the Printhead Cartridge

The Digital Color Printer uses a single Memjet® printhead cartridge. The Printhead Cartridge is a delicate, pr ecision device. Handle with extreme care to avoid damage an d issues that could degrade print quality.

Printhead Cartridge Protective Packaging

NOTE: Discard protective tape once it is removed . Do NOT reuse protective tape.

Keep all other packaging to store/dispose of old printhead cartridge.

Keep new and used printhead cartridges and ink tanks out of reach of children.

Discard unwanted printhead cartridges and empty ink tanks immediately.

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SECTION 1

CAUTION!

CAUTION

INSTALLATION

• Use electrostatic discharge (ESD) handling preca utions.

• Hold the Printhead Cartridge by the handles ONLY.

• DO NOT touch the ink couplings, nozzle surface or electrical contacts.

• DO NOT unpack the Printhead Cartridge until the Printer is ready for

installation. Once unwrapped, delay in installing the Printhead can compromise print quality due to dehydration.

• DO NOT place an unwrapped Printhead on any surface before installing.

Protect the Printhead at all times from dust, fibers, dirt and other contaminants.

DO NOT PRY OR MANUALLY LIFT THE PRINTHEAD COVER OR THE COVER MAY BREAK. ONLY OPEN THE COVER USING THE RELE ASE BU T TONS ON THE PRINTER OR THE PRINTHEAD RELEASE COMMANDS IN THE SERVICES TAB OR M SERIES TOOLBOX.

NOTICE! Read this procedure, in its entirety, before proceeding!

Before you begin this process, you will need to obtain some deionized or distilled water and some lint free cloths. These items will be used to wet the printhead nozzles. NOTE: Do NOT use tap water or paper towels to w et or clean the printhead nozzles. Doing so may cause dama ge to the printhead cartridge and possible contamination to the ink system. Why is it necessary to wet the printhead nozzles? During the priming process a vacuum is created at the non-operator side of the printhead cartridge. If the printhead nozzles are dry (open); air is pulled in through the printhead nozzles causing the priming process to fail (printer is unable to create a vacuum to pull ink into the cartri dge). By wetting the printhead nozzles this creates a temporary “water seal”, which prevents ai r fro m getting sucked into the printhead during the priming process.

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INSTALLATION

Procedure (Installing the Printhead):

This procedure assumes that you are installing a Printhead Cartridge into a printer that does NOT have a Printhead Cartridge installed. If your printer already has a Printhead Cartridge installed, and you wish to replace the Printhead Cartridge; please refer to the section titled “Replacing the Printhead Cartr idg e”.

1. Plug in the printer. Turn the printer’s Main Power Switch ON; then press the control panel’s ON/OFF

button. Wait about 45 seconds for the print engine to power-up (ON/OFF button will illuminate).

2. Open the Top Cover.

3. If the Printhead Latch [2] is closed; press the “Printhead Latch

Release” button [1]; as shown. Use a non-metallic item (example: plastic pen) to reach through the hole and lightly press the button.

The printer will run a routine and then the Printhead Latch [2] will release so it can be opened.

WARNING! If the printhead latch fails to release do not force the latch open. Severe damage will result.

Tip: You can perform this same function from your computer by clicking “Printhead Release” from the “Services” tab of the “M Series Driver” properties, or the “User Interface” screen of the M Series “Toolbox” utility.

4. Open the Printhead Latch all the way to fully retract the Ink Couplings

[3].

WARNING! Do not force the latch open or severe damage will result. Use the “Printhead Latch Release” button .

5. Be sure that all protective packaging materials [4] are removed from

the Ink Coupling [3] areas.

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INSTALLATION

6. Prepare the printhead cartridge.

Carefully remove the Printhead Cartridge from the foil vacuum packaging. Tear at notch or cut end with scissors.

CAUTION: DO NOT touch the ink couplings, printhead

nozzle surface or electrical contacts.

[A] Remove the protective plastic cov er. Hold the Printhead cartridge by the handle. Unclip the ink port covers [1, 2], then unclip the cover from the center point of the cartridge [3]. Grasp the protective cover firmly, then rotate the top of the cartridge away from the ink port side of the cover and lift at the same time. Save this protective cover for future u se.

CAUTION: DO NOT touch the ink couplings, printhead nozzle surface or electrical contacts.

[B] Remove protective strip from the Printhead Electrical Contacts.

Dispose of the removed strip immediatel y.

CAUTION: DO NOT allow removed strip to touch the electrical contacts. DO NOT try to re-apply the removed strip.

[C] Remove protective strip from the Printhead Nozzles.

Hold the Printhead by the handle with one hand. With the other hand; grasp the strip tab and slowly peel the strip, at an angle (90° to 45°), from the printhead nozzles. DO NOT pull the strip off at an angle less than 45° with the printhead surface. Dispose of the removed strip immediately.

CAUTION: DO NOT allow removed strip to touch the electrical contacts or printhead nozzles. DO NOT try to reapply the removed strip.

NOTE: Keep packaging to store/dispose of printhead cartridge.

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Printhead Nozzle Area

Fig A

Fig B

WARNING: Be careful not to damage

media.

INSTALLATION

7. Carefully insert the printhead cartridge into the compartment at an angle, with the print nozzle surface

facing down and the ink receptacles facing towards the Ink Couplings and hoses; as shown [Fig A].

8. Once the cartridge is fully insert ed, gently but firmly rotate the top of the

cartridge to a vertical position; as shown [Fig B]. DO NOT FORCE the cartridge into position. If it does not rotate, check to be sure it is fully inserted.

9. DO NOT close the Printhead Latch at this time. First, open the clamshell with

both hands. Using a lint-free cloth soaked with deionized or distilled water, wet the entire Printhead Nozzle area. Be liberal with the amount of water you leave behind on the nozzles (the thin dark line on bottom of printhead cartridge). See images below.

the “star rollers” when wiping the printhead. These rollers are designed so they can roll across a wet image, without damaging the image. If the rollers are bent, they will not turn free; causing media feed issues (jamming) and possible damage to the image or

10. Immediately after wetting the no zzl es surface, GENTLY close the clamshell.

CAUTION: To prevent damage, hold onto, then lift and release both latches

when closing. If you force it closed without holding the latches open, you will eventually damage the latches and clamshell switch (door switch).

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INSTALLATION

11. Slowly close the Printhead Latch until it locks. It will be resistant, but apply

consistent pressure and the ink couplings will ease into the ink ports on the printhead. Once latch is closed, the printer will automatically start running a “printhead priming routine”. See “What to Expect” below.

WHAT TO EXPECT:

• After closing the Printhead Latch there will be a ~15 second pause (no

noise or motion).

• Then you will hear the Service Station move to the capping position.

• Then you will hear the ink pump start to run.

• At this time, ink should start flowing through all the tubes, in and out of the printhead. If you

see this occurring, then the priming process is working and you can skip to Step 12.

a. If ink doesn’t start filling all tubes during the first 5-seconds of the first ink pump cycle:

Using deionized or distilled water; re-wet your lint-free cloth generously. Don’t wait for the pump to stop, open the clamshell and wipe along the Nozzles with the cloth, back and forth twice. Immediately after re-wetting the nozzles, carefully close the clamshell. The ink tubes should begin filling. Tip: To save time; prepare a pre-wetted lint free cloth before you begin the priming process.

WHAT TO EXPECT:

• The first cycle of the ink pump will run for about 15 seconds.

At this time, ink should start flowing through all the tubes, in and out of the printhead. If you see this occurring, then the priming process is working and you can skip to Step 12.

b. If ink still doesn’t start filling all tubes after the first 15-seconds of the first ink pump cycle:

Using deionized or distilled water; re-wet your lint-free cloth generously. Open the clamshell and wipe along the Nozzles with the cloth, back and forth twice. Immediately after re-wetting the nozzles, carefully close the clamshell. The i nk tubes should be filling at this point. If not, re-wet your lint free cloth and repeat as needed, even while the pump is running, until ink fills all the tubes.

WHAT TO EXPECT:

• After the ink pump runs the first time for 15 seconds, it will stop for about 10 seconds and

then it will restart and run for another 30 seconds.

• At this time, ink should start flowing through all the tubes, in and out of the printhead. If you

see this occurring, then the priming process is working and you can skip to Step 12.

c. If you reach the end of the second pump activation cycle and the printhead still fails to prime (one

or more of the ink tubes have not filled):

i. Release the printhead (using the Release Printhead feature from the Toolbox), but don’t

remove the printhead.

ii. Repeat the process from Step 9. See Caution below .

DO NOT REPEAT THIS PRIMING PROCEDURE MORE THAN TWICE IN A ROW.

DAMAGE TO THE INK SYSTEM MAY RESULT.

AFTER TWO ATTEMPTS, LET THE PRINTER SIT FOR AT LEAST 1 - 2 HOURS

BEFORE YOU ATTEMPT TO PRIME THE PRINTER AGAIN. CONTACT TECHNICAL

SUPPORT FOR ASSISTANCE IF PROBLEMS PERSIST.

CAUTION

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INSTALLATION

12. Once the printhead priming process is successful (all ink tubes are filled, in and out of the printhead); it

will take an additional 5 - 10 minutes for the printer to complete the process. During this time the printer will emit a number of chirps, whirrs and other noises.

13. Watch the Toolbox screen on your computer. Notice that

some of the information is in red. As the printer circulates ink and primes the system these fields should al l tur n black. This may take a few minutes.

NOTE: If any Ink Tank is less than 30% full, the Printhead Cartridge priming process may fail (not enough ink to completely fill the system). In this case you will need to replace the tank(s) containing low ink and repeat the printhead priming process. After the Printhead is primed, you can re-install the original Ink Tank(s) to use up any remaining ink. Please refer to the section titled “

the Ink Tanks”.

14. When the printer stops processing , and all the fields in System Status are black, the printer is ready for

use. When the printer is ready for use you will also observe the following printer Control Panel condition: ON/OFF button light ON, Paper/Resume light OFF, Pause/Cancel light OFF.

Replacing

15. Close the top cover.

16. IMPORTANT! Whenever a printhead cartr i dge is installed or re-installed, it must be conditioned to

perform properly. Before printing a live print-job; please refer to the section titled “

Conditioning”.

Printhead Cartridge

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SECTION 3

WARNING

DO NOT REMOVE THE SIDE COVERS OF THE PRINTER!

THERE ARE HIGH VOLTAGES PRESENT BEHIND THE COVERS!

TROUBLESHOOTING

SECTION 3 – Troubleshooting

The following troubleshooting guides are provided to assist you in solving any problems that might occur with the Digital Color Printer. We have tried to make them as complete as possible, but this section will always be evolving.

Print Quality Issues:

Many things can contribute to print quality issues. Here is a list of things to check:

• To reduce print quality issues, the print engine should remain powered-on. Even in its standby state,

the printer will run routine maintenance cycles t o help keep the printhead nozzles hydrated and clean.

• Verify that the media you are printing on is an “inkjet suitable” media. See Paper Types below.

• Verify that the “graphic” you are printing is of a high quality. See Graphic Types below.

• Check to be sure the printer has an adequate supply of ink (30% or more) in all five Ink Tanks.

• Check to be sure all five color tubes, at both sides of the printhead cartridge, have ink filling them. If

not, the cartridge will need to be removed, the printhead nozzle surface re-wetted using deionized or distilled water, and the cartridge reinst al led. Please refer to the appropriate sections in this manu al f or removing and installing the printhead cartridge.

• Try removing air bubbles from printhead and system using the “

routine or Toolbox utility feature “Circulate Ink”. Note: Do not

• Replace the Printhead Cartridge. Generally when the ink supply is adequate and the print quality

remains poor, even after cleaning; the printhead cartridge should be replaced. Please refer to “Replacing the Printhead Cartridge”.

Compatible Paper Types: (look for inkjet suitable st ocks)

• Inkjet Paper - all types (recommended for best color output).

• Copier Paper

• Card Stock

• Kromekote

• Coated Paper - Gloss finish

• Coated Paper - Satin finish

• Coated Paper - Matte finish

Incompatible Paper Types:

• Color Laser Gloss

• Digital Printer Gloss

• Any Post Print Coated Substrate (aqueous, gravure or UV)

Compatible Graphic Types:

• In general; scalable, vectorized art will produce the best images and color.

Note: Graphic types are not really printer dependent. They are dependent on the software program being used to print the graphic, and what types of graphics that program can handle.

Incompatible Graphic Types:

• Low resolution and web images will not produce quality output and should not be used.

run the Circulate Ink feature more than twice in a row.

Printhead Cartridge Conditioning”

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SECTION 3

TROUBLESHOOTING

Examples of Print Quality Issues (including possible causes and solutions)

The Memjet printhead cartridge contains over 70,000 inkjet nozzles. These nozzles are divided into ten rows; two rows of nozzles for each color channel. Due to the high number of nozzles; it is not uncommon for some nozzles to become contaminated or clog ged.

The following examples were produced using a Five Band Color Purge YKCKM. A similar purge pattern can be performed using the Services tab within the M Series Driver properties. Click on the “Print Demo Page” button.

Air in Printhead Nozzle Area:

Air in the printhead nozzles will show as jagged, irregular shaped lines of missing color. Lines are normally wider than one nozzle.

Possible Solutions:

• Run “User Level Maintenance 3” from the M Series Driver’ s Services tab. Tapping on the ink

tubes and printhead cartridge, during this process, may also help dislodge air bubbles.

• Deprime the system. Then close printhead latch to r e-prime the system.

• Instead of powering the printer off , when not in use, leave the print engine powered-up; so it can

perform automatic maintenance routines.

• Don’t lift the print engine to an angle greater than 60º.

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TROUBLESHOOTING

Clogged Nozzles: Clogged/dehydrated nozzles will normally show as thin, crisp, vertical lines of missing color. Multiple adjacent clogged nozzles will show as wider, crisp, vertical lines of missing color. Clogged nozzles are normally due to Printhead nozzle dehydration or partial contamination.

Possible Solutions:

• Run “User Level Maintenance 3” from the M Series Driver’s Services tab.

• Manually clean the printhead nozzles using distilled water and a lint free cloth.

• Clean/replace the wiper roller and or service station.

• Replace the printhead cartridge.

• Instead of powering the printer off, when not in use, leave the print engine powered-up; so it can

perform automatic maintenance routines.

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TROUBLESHOOTING

Color Mixing Issues:

Color mixing will show as muddy, mottled or distorted (grainy) colors. Color mixing occurs when the ink from one color channel crosses over into another color channel. Since the inkjet nozzle rows are located very close to one another (ten rows of ~7,000 nozzles, located within a

0.8 mm space), it is easy for partials or fibers to create bridges across color channels. These bridges allow ink to flow (wick) from one color channel to another; resulting in a “localized” color mixing event; as shown in the examples below.

Color mixing can occur for a number of reasons (here are some common ones)

• Ink wicking due to fibers bridging (crossing) inkjet nozzles.

• Wiper roller saturation (too much ink on wiper roller).

• Ink flooding on the nozzle plate; due to printer not being level or excessive back-pressure in the

ink system. Excessive back-pressur e can occur during the time the printer is switched off (pinch valve closed). During this time; temperatur e or barometric pressure variations can create excessive back-pressure. For this reason, it is best to keep the print engine powered-up. Even when the printer is in standby mode; the pinch valve (valve that pinches ink tubes to keep ink from flowing) is cycled periodically to relieve the buildup of back-pressure in the system. This issue may also be caused or enhanced by a print er that is not level.

Tip: Muddy, mottled, distorted (grainy) colors can also be caused by the media you are printing onto. Test the printer, using a compatible “inkjet suitable” media, to determine if this could be the cause.

Possible Solutions:

• Make sure printer is on a sturdy, level table.

• Run “User Level Maintenance 3” from the M Series Driver’s Services tab.

• Clean/replace the Service Station.

• Instead of powering the printer off, when not in use, leave the print engine powered-up; so it can

perform automatic maintenance routines.

• Don’t lift the print engine to an angle greater than 60º.

NOTE: The above examples show “localized” co l or mixing events. “Broad” color mixing events can be caused by an over-saturated wiper roller, or by flooding on the nozzle plate (ink pooling) due to too much back-pressure in the system. They can also b e caused by a deformed “purge wick” (ridge of absor bent material) within the capping area. If the “purge wick” touches the printhead nozzles it will cause major ink wicking and color mixing.

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SECTION 3

The ink used in this system may be harmful if swallowed.

may not have been stabilized.

Replace the Printhead.

greater than 60º.

to angle greater than 6 0º.

or buckled.

software program.

TROUBLESHOOTING

The Printhead Cartridge

CONDITION PROBLEM SOLUTION

Mixed, mottled, muddy or distorted colors.

Thin, crisp vertical line(s) of missing color.

Irregular or Jagged vertical line(s) of missing color.

Black scuff marks on media or image smudging occurs.

Ink color channel mixing within the printhead cartridge/nozzles.

Print Engine was opened to angle greater than 60º.

Incompatible media. Table is not level.

Printer was not powered-down properly. Printhead may not have been cleaned or capped. Ink system

Clogged printhead nozzle(s). Electrical failure or poor electrical

connection at printhead. Air in the system. Air bubbles

blocking nozzle(s ) . Print Engine was opened to angle

Media is making contact with the printhead surface.

Refer to “Printhead Cartridge

Conditioning”.

Do NOT open Print Engine to angle greater than 6 0º.

Use inkjet suitable media Make sure table, that printer

is placed on, is level. Make sure to power-down

the printer using the ON/OFF button, before shutting off the Main Power Switch.

Clean/replace the Printhead. Reseat the Printhead.

Refer to “Printhead Cartridge

Conditioning”.

Do NOT open Print Engine

Install the Envelope Printing Attachment (42-110-52).

Run the media in a different orientation.

Incompatible media. Use media that is not bent, bowed

Blurry/Grainy Images

Keep new and used printhead cartridges and ink tanks out of reach of children.

Discard unwanted printhead cartridges and empty ink tanks immediately.

Partially clogged nozzle(s). Incompatible media. Low quality image being sent to

printer.

Clean/replace the Printhead. Use inkjet suitable media. Use high quality graphics

that are compatible with your

Page 59

pressure in the system.

The Printhead Cartridge (continued)

CONDITION PROBLEM SOLUTION

SECTION 3

TROUBLESHOOTING

System will not prime the printhead after installing Printhead Cartridge

(One or more of the ink color tubes are not filling with ink.)

Ink leaking from the printhead nozzles

Printhead nozzles dry (air pulled through nozzles; not allowing system to create vacuum)

Capping station not making good seal against the printhead.

Damaged Ink Coupling (revolver)

Toolbox displays …Low_Ink or Ink_Out… message.

Toobox displays Ink_Error or Ink Valve Error.

Pinched/kinked ink tube(s)

Ink Tanks may be 1/3 full or less. Ink Tank Issue Printhead ink channel(s) are clogged

Print Engine was opened to angle greater than 60º.

Table is not level.

Excessive back-pressure within ink system.

Wet the Printhead nozzles using distilled water and a wet, lint-free cloth.

Check for obstruction. Is the Envelope Printing Attachment in the way?

Check/replaced damaged Ink Revolver.

Replace Ink Tanks.

See Service Menu, Commands Help “nvm_hw” settings. Check to be sure Wiper_motor = E and Pump_motor = B.

Check ink tubes. Is the Antistatic Brush Assy pinching tubes?

Replace ink tanks. Replace the Ink Tank Replace the printhead.

Do NOT open Print Engine to angle greater than 6 0º.

Manually clean printhead. Make sure table, that printer

is placed on, is level. Allow print engine to remain

powered-up, when not in use, so it can routinely cycle the pinch valve to equalize back-

Page 60

SECTION 3

length of the media.

width of 8.5”.

Set bof_adjustment to 3000.

used to adjust the Level of spitting.

not illuminate.

Replace Processor Board

TROUBLESHOOTING

The Printer

Service Tip: If you recently replaced the Main Board, please see “Replacing the Main PC Board (MPCA)”

and “MPCA (Main Printed Circuit Assembly) Connections”; to verify your connections. Also check for damaged wires and loose connections.

NOTE: The printer will not print if any of the five ink tanks are empty or missing.

Dots or Lines Printed on Media

CONDITION PROBLEM SOLUTION

Multiple horizontal black lines are printed down the

A single horizontal black line is printed at or near the trailing edge of the media.

Very small dots (gray overspray) are being printed down length of media.

You have exceeded the maximum print

Intrapage nozzle spitting is hitting trailing edge of media.

These dots are formed by interpage nozzle spitting (KWS Setting).

Reduce paper width to 8.5” to avoid exceeding the max print width of printer.

Intrapage (between pages) nozzle spitt ing (purge) is used to help keep nozzles from drying (clogging). If piece is hesitating in transport or printer’s bof_adjustment is not set properly; this purge line may hit the trailing edge of the media. Test using 8.5 x 11 paper. If issue does not occur then issue is being caused by media hesitation. If issue still occurs, check/adjust bof_adjustment value in Toolbox Service Menu.

Interpage (on the page) nozzle spitting is normal. This feature is used to help keep nozzles from drying (clogging). With firmware version 110928_u and hi ghe r t he Toolbox provides a “KWS Setting” that can be

Power Problems

CONDITION PROBLEM SOLUTION

Main Power Switch is ON, but the ON/OFF button does

No power being delivered to printer.

Check that the power cord is plugged in. Check that the wall power outlet is live.

Problem within printer.

Press the ON/OFF button and wait 45 seconds. Check fuse in Receptacle.

Replace AC Receptacle. Check power Supply inputs and outputs. Replace Power Supply. If power is being delivered to Processor board:

Run Dead Board Fix Reload Firmware

Page 61

Service Station Drive

Service Station was not installed

Eject Service Station. Cycle print

Wiper Motor doesn’t turn

Cable not connected.

Verify ribbon cable and motor

Color mixing occurs after

Wiper Roller is saturated.

If saturated, clean/replace roller.

Service Station cannot be

Wiper Roller Latches were not

Carefully unhook Latches from

Service Station Problems

CONDITION PROBLEM SOLUTION

SECTION 3

TROUBLESHOOTING

Motor stalls.

or stalls

wiper roller performs a cleaning

properly. Wiper roller securing latches are not closed; preventing Service Station sled from moving properly. Jammed gear train due to broken post or improperly seated gears.

Damaged Service Station Damaged Lifting Arm Damaged Motor

Squeegee blade wedged, not seated properly.

Debris build-up on blade and rollers, increasing friction.

Bad wiper roller motor

Squeegee blade is wedged, not seated properly or bowed.

engine off/on. If drive motor turns without stalling then motor is OK. Before re-installing Service Station, make sure: wiper roller latches are closed and not damaged, reseat the roller gears and/or squeegee, clean debris from blade and rollers.

Replace Service Station. Replace damaged Lifting Arm. Replace Motor

cable are properly connected to board on side of Service Station.

Reseat squeegee blade.

Clean rollers and blade.

Replace Service Station.

Reseat wiper roller squeegee. If squeegee is bowed, replace Service Station.

removed from the Print Engine

completely closed when the Station was installed. Latches now hooked on bottom of paper path.

Damaged Lifting Arms

bottom of paper path and secure latches. If wiper roller latches are damaged; replace Service Station.

Replace Lifting Arms.

Page 62

SECTION 3

computer tested/serviced.

USB Cable connection issue.

Check/replace USB cable.

pump motors.

Help “nvm_hw” settings.

energy.

Printer OFF and ON.

TROUBLESHOOTING

Interface Communication Problems

CONDITION PROBLEM SOLUTION

M Series Driver does not respond to printer being connected via USB.

Driver shows printer off-line, even with printer connected and powered-up.

No communication with Toolbox utility.

Wrong USB port selected in “M Series Driver”.

System is hung-up.

USB Port, or Cable Connection problem

Computer system does not meet minimum requirements.

Java not installed or version not supported.

Printer’s EWS (Embedded Web Server) not responding.

Firewall is blocking communication with EWS.

System is hung-up.

Verify that you are selecting the appropriate USB port in the driver Ports Tab. Note: During driver install the USB port was automatically assigned. However if someone changes the port setting in the driver you will need to manually reassign the port.

Clear spooler; then turn printer and computer OFF and ON.

Test using known good USB cable; replace cable if necessary. If still no communication; check printer using another known good system (computer, software, cable). If printer works with known good systems then problem is outside the printer. Have

Check that computer system meets minimum requirements.

Install/Update Java to version 6 or higher.

Close and reopen Toolbox utility.

Change firewall settings to allow access.

Reboot printer/com p uter.

Job is sent, but printer does not feed or print.

Erratic output

(printing garbage, feeding blanks, etc.)

Printer not connected to computer.

Printer Error

Media Sensor is covered in Print Engine.

Improper Driver Config. System is hung-up. Incorrect settings for wiper &

Problem with software

Improper driver selected. System was disrupted by static

Connect printer cable to computer and resend job.

Open Toolbox utility to view errors. Open print engine and remove media.

Uninstall, Re-install Driver. Reboot printer/computer. See Service Menu, Commands

Test from another software program. Contact software vendor.

Use M Series Driver Close the software, then turn

Page 63

TROUBLESHOOTING

Uneven mail piece.

Tap inserts to front of envelopes and retry.

Media stuck together.

Fan the media before loading in Printer.

No power.

See Power Problems in this Section.

Feed Encoder dirty / misadjusted.

Check/adjust Feed Encoder

Right edge of media

Media is hitting the limits inside

Make sure Adjustable Media Side Guid e

Feeding Problems

CONDITION PROBLEM SOLUTION

SECTION 3

Intermittent feeding

Multiple feeds (double feeding)

Failure to feed

Media Support Wedge not used.

Side Guides set too tight to media. Dirty Feed Rollers.

Paper stuck together.

Separator gap not set properly.

Side Guides set too tight to media. No power to Printer.

Feed gap too tight. Feed gap too loose. Material is out of specification.

Motor on, Rollers not turning.

Clutch not engaging (forwarding rollers turning, but paper feed rollers not turning)

Motor not driving

The Media Support Wedge adds a slope to the stack and helps feeding.

Readjust Side Guides. Clean the Feed Roller with distilled water

and a cloth. DO NOT use any solvents or detergents as they may damage Rollers.

Fan media before placing it in Printer.

Adjust Separators to thickness of media.

Readjust Side Guides. Check that power is ON (Main Power

Switch and ON/OFF button) and that the power cord is plugged i n.

Adjust Separator to thickness of media Adjust Separator to thickness of media. Maximum thickness is 0.020".

Check for broken Drive Belt and replace. Check for loose set screws on Drive Pulley or Belt Drive Roller Pulley.

Check drive to clutch. Replace Clutch.

Check that motor is receiving power from the power supply.

Jams

being damaged as it travels through print engine area

Paper path obstructi o n .

Paper not loaded properly.

Media Support Wedge not adjusted properly.

Separators improperly adjusted. Media curled or bent. The Separators are worn. PaperPath Exit sensor is having

trouble seeing the underside of the media (non-reflective colors).

the print engine.

Clear jam and remove pieces remaining under Printhead.

Instruct operator in proper loading of media.

Adjust Media Support W e dge .

Adjust Separators to thickness of medi a. Uncurl media. Replace Separator tip. In Toolbox, select (check) “Ignore Exit

Sensor”. Feature added with firmware version 110928_u and hi ghe r .

is at least 1/8” away from side frame. If stock is over 9.5” wide; you need to use narrower stock.

Page 64

SECTION 3

…. Ink Low

Example: Black Ink Low

Reorder Ink

Multiple Inks Low

Reorder Ink

…. Out of Ink

Example: Cyan Ink Out

Replace empty Ink Tank Multiple Ink Tanks Out

Replace empty Ink Tanks

Paper Jam

Clear media from system and close print engin e.

Cleaning in Progress

Wait until the message disappears. The printer will not respond until the cleaning has completed.

Incorrect … Ink Tank

Clean electrical contacts and re-seat I nk Tank.

Unauthorized … Ink Tank Installed

Clean electrical contacts and re-seat I nk Tank. Ink Tanks must be purchased from authorized supplier for this printer model.

Multiple Unauthorized Ink Tanks

Clean electrical contacts and re-seat I nk Tank. Ink Tanks must be purchased from authorized supplier for this printer model.

The … Ink Tank is missing

Insert missing Ink Tank. Clean electrical contacts and re-seat I nk Tank.

Multiple Ink Tanks are missing

Insert missing Ink Tanks. Clean electrical contacts and re -seat I nk Tanks.

Printhead Latch Open

Ensure printhead cartridge has been inserted properly then closer the printhead latch so it locks.

Excessive Tilt Error

See details under “Toolbox System Status Messages” section.

Load Paper

Load paper into printer and press the PAPER/RESUME button.

Incompatible Printhead

Remove and re-insert your printhead cartridge. Printhead cartridges must be purchased from authorized supplier for this printer model.

Missing Printhead

Remove and re-inse r t your printhead cartridge. Printhead cartridges must be purchased from authorized supplier for this printer model.

Unauthorized Printhead

Remove and re-insert your printhead cartridge. Printhead cartridges must be purchased from authorized supplier for this printer model.

Paper Jam

Remove jammed media. Check for and remove obstruction.

and higher.

Mechanical Jam

Check for and remove obstruction. Reboot your printer.

TROUBLESHOOTING

Error’s and Warnings

Control Panel Light Sequences

See Section titled “Printer Status Light Indicators”.

Alert Window Messages

Messages sent from the driver and displayed on PC screen in a small popup window.

MESSAGE SOLUTION

Check for proper feed setup. If stock has non-reflective colors on underside; in the Toolbox, select (check) “Ignore Envelope Sensor”. Feature add ed with firmware version 110928_u

Page 65

PAPERPATH_FEED_TIME

Out of Paper

Load media into printer and press the

Yes = blocked (interrupted)

Paper Jam

Carefully remove jammed Media from

DOOROPEN_FRONT

Printer has detected that

Verify that the print engine is closed

DATA_PATH_UNDERRUN

Printer was paused by

Press the RESUME button to continue

Error appears without

Check for dirty grit rollers within print

X_INK_LOW

X = Color.

Ink Tank replacement will be necessary

INK_OUT_X

X = Color or “Any”

Replace empty Ink Tank(s)

Toolbox System Status Mes s ages

Displayed, in red, in the M Series Toolbox utility.

SYSTEM STATUS PROBLEM SOLUTION

SECTION 3

TROUBLESHOOTING

OUT

PAPERPATH_PRINTZONE _BLOCKED

PAPERPATH_PAPERJAM

Paperpath: Entry:Yes Exit:Yes or Paperpath: Entry: No Exit:Yes or Paperpath: Entry:Yes Exit:No

No = not blocked

No media is reaching the print engine.

Media jam detected. Printer has detected that

one of the media sensors is blocked (interrupted).

the top section of the print engine is open.

the user pressing the PAUSE button.

PAPER/RESUME button. If media is present; check/adjust the

guides and separators.

printer and close the print engine. The toolbox “Paperpath” line should

change to: Paperpath: Entry: No Exit: No

After you clear the jam you can; Press RESUME button to continue printing. Press the CANCEL button to cancel the job, and then manually clear the job from the computer’s print queue. Check/adjust the Feeder Encoder.

and securely latched at both sides.

printing. Press the CANCEL button to cancel the job, and then manually clear the job from the computer’s print queue.

Example: CYAN_ INK_LOW

Example: INK_OUT_MAGENTA

PAUSE being pressed. Print engine has detected discrepancy between paper transport rate and encoder feedback

One or more Ink Tanks are low on ink.

One or more Ink Tanks are out of ink

Any = more than one.

engine. If media is slick (slippery), try a different media. Units with Uncovered Encoder Wheel: Carefully clean the Encoder Wheel, located at the operator side of the print engine, using a lint free cloth dampened with distilled water. Install the Encoder Shield Kit (part # 42-900-20).

soon. Reorder Ink

Verify that Ink Tanks are seated firmly and latches are fully closed. Clear error by cycling print engine power, using ON/OFF button.

Page 66

SECTION 3

[Fatal 71 02-? offline

Possible problem with

Check for mechanical bind in Service

CARTRIDGE_MISSING_X

Missing Ink Tank, or Ink

X = Color (CYMKK)

PRINTHEAD_MISSING

No printhead installed or

If just powered on, wait a minute; error

PRINTHEAD_UNPRIMED

Printhead priming

If just powered on, wait a minute; error

TILT_ERROR

The printer’s electronics

If just powered on, wait a few minutes;

TROUBLESHOOTING

cancelpage] See additional information shown in Toolbox. Reason: “service station failed to home 3 times”

“maintenance lift failed three times”

“ids valve failed to home 3 times”

INK_TANK_MISSING_X

drive, movement or position sensing of the:

Service Station (Maintenance Module)

Lifting Arms

Dual Pinch (ids) Valve.

Tank not being recognized

printhead not making proper connections.

Station movement or lifting arm movement.

Check Service Station positioning and Lifting Arm positioning sensors.

Check drive components to Service Station and Lifting Arms.

See section titled “Dual Pinch Valve Connection” for details.

Insert missing Ink Tank or pop tank in and out to improve connection. Clear error by cycling print engine power, using ON/OFF button.

may clear by itself. Install Printhead Cartridge. Remove and reinstall printhead. Replace printhead.

Refer the appropriate sections in this manual for removing and installing the printhead cartridge.

EXCESSIVE_TILT_ERROR

process has failed.

have detected that the print engine is too far out of level.

Tilt sensor needs to be re-calibrated.

may clear by itself. Remove Printhead Cartridge, wet print

nozzles using deionized or distilled water and re-install printhead cartridge. Refer the appropriate sections in thi s manual for removing and installing the printhead cartridge. If you continue to have trouble priming printhead; check for kinked or pinched color tubes.

error may clear by itself. Once Tilt level reading changes to “black” you can clear the error using the “Clear Error” feature in the Toolbox.

Make sure printer is placed on sturdy, level, worktable. Do NOT level the printer, level the table. Do NOT move the printer while the power is on.

If problem persists; see “How to Zero the Tilt Sensor”.

Page 67

MECH_CANCELPAGE

Job was canceled by

Wait until print job has cleared from

INK_VALVE_ERROR

Bad connection

See section titled “Dual Pinch Valve

Toolbox System Status Messages (continued)

SYSTEM STATUS PROBLEM SOLUTION

SECTION 3

TROUBLESHOOTING

user pressing the CANCEL button.

Improper wiper motor and pump settings

Tip: The printer will not print if any of the five ink tanks are empty or missing. With firmware version 110513_d and lower: When viewing the Toolbox utility; the right-most “Ink level” graphic represents the black (K) ink tank, which is physically located in the slot closest to the operator side of the printer.

printer. Then manually clear job from computer’s print queue. Then send new print job.

Connection” for details. See Service Menu, Commands Help

“nvm_hw” settings.

Ink Accumulating in the Wrong Areas of the Printer

Ink deposited into the Service Station during purging, cleaning, capping travels from the service station into a trough below the service station, where it is channeled down into the Waste Ink Tray. If ink is accumulating in areas that are not normal waste ink paths please check the following possibilit ies.

Ink Accumulating Under the Wiper Motor, in the Service Station Tray.

Wiper motor gearbox may pick up this ink and thrown it inside the Service Station Slot and onto the lower rollers in the Print Engine. This ink will then be transferred onto the upper rollers and onto the media as it is fed through the printer.

• Check to be sure the printer is on a Level Surface.

• Replace the Service Station

Ink Accumulating under the Service Station (on base of Service Station Slot).

Waste ink from the Service Station flows through the wicking material and out the hole, located on the bottom of the service station. In some cases the wicking material that hangs out this hole may not be directed into the trough located below the Service Station. If this occurs ink will build up on the base of the Service Station Slot.

• Check to be sure the wick is hanging in the waste ink trough.

Ink Accumulating in the Body of the Printer or Under the Printer.

If you find ink below the Waste Ink Tray, in the lower body of the printer, or outside the printer.

• Proper Shipping/Service precautions may not have been followed. For example if printer was

tilted and there was ink in the un-sealed ink system, it could end up anywhere inside the printer.

• Check to be sure the printer is on a Level Surface

• Check to be sure the service station wick is hanging in the waste ink trough.

• Check to be sure the Waste Ink Tray is properly install ed.

• If the absorbent material is saturated, repl ace the Waste Ink Tray.

• Check for damage to the ink delivery system. Damaged Ink Tubes, Ink Tanks, Ink Couplings

(revolvers), etc…

Page 68

SECTION 3

CAUTION

BE CAREFULL NOT TO PINCH OR CUT THE INK HOSES WHEN RE-INSTALLING THE ANTISTATIC BRUSH ASSY.

TROUBLESHOOTING

Clearing Media Jams

When the printer detects a media jam, it will stop automatically. The control panel PAPER/RESUME and PAUSE/CANCEL lights will blink simultaneously. The message “PAPERPATH_PRINTZONE_BLOCKED” or “PAPERPATH_PAPERJAM” will be displayed in the Toolbox. Once the jam has been removed from the system and the print engine is closed; press the PAPER/RESUME button to continue printing.

Some possible causes for jamming are:

1. Feeding more than one piece of media at a time (double-feeding), due to improper sheet separation

adjustment, improper media loading, or nested media (envelopes that are caught under the flap of another envelope or stick to one another).

2. Damaged media, such as do g-eared (turned down corners), curled or bowed media.

3. Media that is not stiff enou gh may not be usable. Media that meets Postal st i f f ness requirements for

automated feeding is acceptable in the Digital Color Printer.

4. Media that is too thick for the printer.

5. Media that is too wide for th e pri nter or media that skews as it travels through the printer.

Removing Jammed Media

Clearing a jam depends on where the jam o ccurred. From the Feed Section: Remove media stack. Loosen and lift the sheet

separators to clear the jam. Then re -adjust the sheet separators as described in this manual.

Under the Antistatic Brush Assembly: If necessary, remove th e Antistatic Brush Assembly [A] to access jammed material. U nlatch the two latches (one on either side of the Assembly) and lift the assembly off the four mounting pins as shown. Do not bend the guide fingers! Clear the jam, and then carefully reinstall the Antistatic Brush Assembly. Make sure brush assembly is correctly reinstalled and aligned before starting to print. Assembly should sit flat on transport area surface

From the Print Engine Area: Open the Top Cover. Lift up on the two latches (one on each side of the print engine assembly) and raise (swing open) the Print Engine Assembly [C]. Clear the jam, then lower and re-latch the Print Engine Assembly. Then close the Top Cover.

CAUTION: Do NOT open the Print Engine Assembly to an angle greater than 60º. Damage to the ink color tubes and other issues will result.

Page 69

SECTION 3

TROUBLESHOOTING

Misfeeds

Misfeeds can be corrected by readjusting the Sheet Separators to the media or replacing them. See “Replacing the Sheet Separators”.

How to Zero the Tilt Sensor

CAUTION! Prior to using this option, verify that your printer is on a sturdy, level surface. This is of utmost importance, since being out of level can cause the printer to perform poorly. Level the table surface, Not the printer. If the printer was recently powered on, wai t at least 20 minutes before performing this task. This will allow the printer’s electronics time to warm -u p and its tilt sensor values to settle. NOTE: If the Tilt error can be cleared by clicking on the “Clear Error” button in the Toolbox, then there is no need to proceed.

Once you verify that the printer is on a sturdy level surface; proceed with the appropriate procedure below, to reset the printer’s baseline to zero.

Using the PAPER and CANCEL buttons to Zero the Tilt Readings. Valid for Printers with Firmware 110928_u or higher installed.

1. Open the Toolbox utility.

2. Simultaneously press and hold the PAPER and CANCEL buttons for 5 seconds. Then r elease

the buttons.

3. In the “User Control” screen; v erify that the Tilt readings have been zeroed (0.0 + or – 0.20).

NOTE: If you are unable to zero the Tilt readings using this procedure; please use the process described below “Using the Service Men u Features to Zero the Tilt Readings”.

4. If the Tilt readings have been zeroed but a “Tilt Error” is still showing at the top of the

Toolbox screen; click on the “Clear Error” button. This should clear the Tilt Error.

5. Hit the printer’s ON/OFF button to power-down the printer.

6. After the printer shuts down completely (all lights off), hit the ON/OFF button again to

power-up the printer. NOTE: These last two steps are done to insure that the printer saves the settings.

Using the Service Menu Features to Zero the Tilt Readings. Valid for printers with all firmware versions.

1. Open the Toolbox utility.

2. Click on “Service Menus”.

3. Type password (servicepw or 630). Try both.

4. Click on “Printer Maint Config”.

5. Click on the “Zero Tilt Sensor” button.

6. Go to “User Control” and verify that the Tilt readings have been zeroed (0.0 + or – 0.20).

7. If the Tilt readings have been zeroed but a “Tilt Error” is still showing at the top o f the

Toolbox screen; click on the “Clear Error” button. This should clear the Tilt Error.

8. Hit the printer’s ON/OFF button to power-down the printer.

9. After the printer shuts down completely (all lights off), hit the ON/OFF button again to

power-up the printer. Note: These last two steps are done to insure that the printer saves the settings.

Page 70

SECTION 4

ADJUSTMENT

SECTION 4 – Measurements and Adjustments

CAUTION

ALWAYS WEAR A WRIST STRAP THAT IS GROUNDED WHEN

TOUCHING ELECTRONIC DEVICES.

Drive Belt Tension Adjustment

REQUIREMENT:

To ensure the Drive Belt has the proper tension, use the 42-101-33T Belt Tension Tool to properly adjust Motor Belt Drive tension without guesswork.

ADJUST BELT TENSION:

[A] Unplug the Printer. Remove the right-hand Side Cover (5 screws).

[B] Loosen the two screws that mount the Main Drive Motor to the Frame.

[C] Install the Tool so the two ears fit around the outer edges

of the Drive Belt. Then fit the other end into the gap between the Clutch Assembly and Belt Pulley.

[D] Reach inside the Frame to hold the Motor in place and retighten the Motor mounting screws.

[E] REMOVE the Belt Tension Adjustment Tool.

[F] Reinstall the right-hand Side Cover.

Page 71

Power Indicator LED

+V Adjustment Pot

RED

Engine

White

Board (J1)

Black

Board (J1)

Black

Engine

Green/Yellow

Ground

Blue

Receptacle

Brown

Receptacle

V+

24 VDC

V-

Logic Ground (GND)

Earth Ground

Neutral

Line

Power Supply

The Power supply converts the incoming AC voltage into 24 VDC. The DC output provides power to the electronics for the entire printer.

SECTION 4

MAINTENANCE

Power Supply Measurements: Input: 100 – 240 VAC (This is an auto-switching power supply)

Output: 24 VDC (+ or – 0.2 VDC)

Adjustment: There is normally no need to adjust the power supply output. However, if the voltage

reading is out of the tolerance range; an adjustment can be done using the +V Adjustment Pot shown in the image below.

Connections:

N/C

to Print

to Interface

to Print

N/C

to Frame

from AC

Troubleshooting Tip: If you don’t get any DC output (measuring 0 VDC and Power Indicator light is off); check the AC Input to the power supply. If you have proper AC input, but no DC output, then the power supply may be bad. Test the supply with the output connections disconnected, to be sure nothing is shorting-out the supply. Cycle power before re-testing. If you don’t measure a proper AC input (110-240 VAC) then you may have a blown fuse in the receptacle, a bad receptacle (check to be sure switch is ON), or no power from wall outl et .

Page 72

SECTION 4

ADJUSTMENT

Media Sensors

Feed Sensor

The feed sensor detects the media as it feeds between t he sheet separation area and the print engine. This is a retro-reflective sensor. The sensor is located below the deck of the printer ( see i mage below). The sensor looks up at a reflector, which is attached to the underside of the plate on the center pressure rollers. When the paper passes between the sensor and r ef l ect or, the light beam is broken and the sensor responds as being interrupted (paper present).

Feed Sensor Tests

Remove the non-operator side cover to access the Feed Sensor and Interface Board. There are three ways you can test the Feed Sensor.

1 - Measure sensor output at the Interface Board: between GND and TP4:

0 V open (no paper); 7.5 VDC interrupted (paper present)

2 - Check the LED conditions at the sensor:

Open (no paper) = Both Green & Orange LEDs are illuminated Interrupted (paper present) = On ly the Green LED is illuminated

3 - You can use the resettable job counter to test sensor f unction. As paper interrupts this sensor the job counter will increment by one.

Feed Sensor Adjustment

The potentiometer, located on the bottom of the feed sensor (see red arrow in the image abo ve) is used to adjust the intensity of this sensor. In general, the intensity will be set to MAX. However if you have a glossy piece of media that is being seen as open (no paper), when it is over the sensor; you can try to adjust the sensor intensity lower until the sensor reads correctly.

Troubleshooting Tip: If the sensor is always reading interrupted, when no p aper is present; check to be sure the sensor and reflector are clean. Check the intensity adjustment. Replace the sensor.

Cleaning Note: The Feed Sensor should be cleaned using compressed air and a soft bristled brush. To avoid splattering ink through-out the print engine; do NOT blow air into the capping station or onto the wiper roller. Tip: If cleaning and adjustment does not cure issue, as a last effort befor e replacement, you can try to clean with a damp cloth or cotton swab.

Page 73

SECTION 4

Entry Sensor

Transmitter

Entry Sensor

Receiver

Entry Sensor

Exit Sensor

Mark Sensor

(not used)

MAINTENANCE

Print Engine Sensors

There are two media sensors within the feed path of the print engine that are used to monitor paper entering and exiting the print engine area. There is also a Margin sensor in the paper f eed p at h, but this sensor is not active (not used).

Measurement: Use the Toolbox utility to view the condition of the Print Engine Sensors.

Entry Sensor

The entry sensor is an interruptive sensor. It consists of a receiver (below) and a transmitter (above). When nothing is in this sensor the sensor should read open (Toolbox shows “Paperpath: Entry: No”) . If paper breaks this sensor beam, the sensor should read interrupted (Toolbox shows “Paperpath: Entry: Yes”).

Entry Sensor Test: (viewed in Toolbox utility) Paperpath: Entry: No = interrupted (paper present) Paperpath: Entry: Yes = open (no paper)

Exit Sensor

The exit sensor is a reflective sensor . It consists of a single device located below the feed deck. It emits ligh t that is reflected off the bottom side of the media and back to the sensor. When nothing is above this sensor area the sensor should read open (Toolbox shows “Paperpath: Exit: No”). If paper or something reflective is position ed ab ove the sensor area the sensor should read interrupt ed (Toolbox shows “Paperpath: Exit: Yes”).

Exit Sensor Test: (viewed in Toolbox utility) Paperpath: Exit: No = interrupted (paper present) Paperpath: Exit: Yes = open (no paper)

Troubleshooting Tip: If these sensors are always reading interrupted (Yes), tr y cleaning them. Cleaning Note: Media sensors should be cleaned using compressed air and a soft bristled brush.

To avoid splattering ink through-out the print engine; do NOT blow air into the capping station or onto the wiper roller. If cleaning does not cure issue, as a last effort before replacement, you can t r y to clean with a damp cloth or cotton swab.

Receiver

Page 74

SECTION 4

ADJUSTMENT

Feed Encoder Sensor and Encoder Whe e l

The Feed Encoder is responsible for matchi ng the speed of the feed section with the speed of the print engine. If a problem develops with this sensor (example: encoder wheel gets dirty), then you will normally see issues with the transition of media from the feed section to the print engine.

Possible Symptom: Frequent paper jams at entrance side of print engine.

• Media crashing into the entrance side of print engine. Media

is being delivered too fast.

• Media getting held back by the feed section. Feed section

seems to stop prematurely; with media part ially fed into the print engine.

• The following messages may appear in the Toolbox utility.

PAPERPATH_PRINTZONE_BLOCKED

PAPERPATH_PAPERJAM

Cleaning: Clean the sensor using compressed air. Clean the encoder wheel using a soft damp cloth. If the encoder wheel becomes discolored or damaged it may need to be replaced. If cleaning and adjustment does not cur e i ssue, as a last ef f ort before replacement, you can try to clean the encoder sensor with a damp cloth or cotton swab.

Adjustment:

The position of the encoder can be adjusted by loosening the two screws that secure the sensor to the mounting posts. Normally the encoder sen sor is adjusted so it sits at the highest point. However if you experience feeding issues; try adjusting it lower.

Feed Encoder Sensor and Wheel (Side View)

Page 75

SECTION 4

Switch Closed

Latch Closed/Locked

Switch Open

Latch Open/Unlocked

MAINTENANCE

Print Engine Open Switch

The Print Engine Open Switch is activated by the Print Engine Latch on the non-operator side. When the latch is released, to open the top section of the Print Engine, the switch position is toggled.

Note: This switch is not on early printer models. It was added to printers starting with S/N 100027599.

Measurement: Use the Toolbox utility to view the condition of this switch.

Symptom: If a problem develops with this switch the Toolbox will display the message

“DoorOpen_Front”. You will not be able to print until this issue is resolved.

Possible Solutions: Check that the latch arm is activating the switch. Replace th e swi tch.

Dust Exhaust Fans

In conjunction with the Antistatic Brush Assemb ly the fans and air plenums are used to remove dust and debris from media. This is done to reduce the amount of dust and debris that enters the printengine area. One fan is attached to the printer’ s bottom frame and one is attached to the non-operator side frame.

Measurement: Fans are turned on/off with the same control as the feed roller drive clutch signal. Clutch on = fans on. Clutch off = fans off. You can use the Paper Feed test (press and hold the PAPER button for 4 seconds) to activate.

Input: 24 VDC

Cleaning: Dust can be cleaned from the fans using a

vacuum and soft brush. To avoid damage; disconnect the fans from the Interface board before cleani ng. A spinning fan will generate voltage which could cause damage to the electronics. Don’t forget to r econ nect.

Troubleshooting Tip: If the fan is receiving 24 VDC, but not turning, then check for obstructions and or replace the fan.

Page 76

SECTION 4

ADJUSTMENT

Clutch (Feed Roller Drive)

The clutch is used to engage/disengage drive to the feed rollers. When the fee d motor is driving and the clutch is engaged; the feed rollers are d r iven to deliver media into the print engine.

Measurement: To check the clutch for proper operation: Measure from TP3 to the bottom pin on J8 (Clutch Out), on the Interface Board, while perfor mi ng a Paper Feed test (press and hold the PAPER button for 4 seconds).

- You should measure 24 VDC when the clutch is engaged.

- You should measure 0 VDC when the clutch is disengaged.

Clutch Resistance Check:

Measure with the clutch disconnected from Interface Board.

- A good clutch will read ~225 Ohms

- A bad clutch or bad connection to the clutch will read open.

Troubleshooting Tips:

• The Clutch turns on/off with the same control signal that

drives the Dust Exhaust Fans. Fans On = Clutch On. Fans Off = Clutch Off.

• If you are NOT getting any drive to the Clutch or the Dust Exhaust Fans, during the Paper Feed

Test; then the Interface Board (Clutch In) may NOT be receiving a drive signal from the electronics. In this case the issue may be as simple as the Paper Path Sensors being interrupt ed. Toolbox will normally show PaperPath_PaperJam or PaperPath_PrintZone_Blocked. This issue, with the PaperPath sensors, needs to be resolved before the system will engage the clutch.

• If the Dust Exhaust Fans are turning on but the Clutch and Feed Rollers are not engaging; then the

electronics are providing the proper signal t o the Interface Board (Clutch In). In this case, you can temporarily connect one of the Fans to the “Clutch Out” connection on the Interface Board to verify that the Interface Board is providing a Clutch signal. If both fans still drive during the Paper Feed Test then the Interface Board is OK and the problem is with the Clutch and or Feed Roller Drive Pulley. If the Fan, connected to the “Clutch Out” connection, does not drive, but the other Fan does, then this indicates a problem with the Interface Board. In this case, replace the Interface Board. Don’t forget to return the Fan to its proper location on the Interface Board; after performing the above tests.

Feed Roller Drive Pulley Test:

With the clutch removed; rotate the Feed Roller Drive Pulley (sprocket) counter-clockwise. The cen ter section (clutch drive spline) should also drive counter-clockwise with the rotation of the Pulley. If the center section does not drive with the counter-clockwise rotation of the Pulley; then the Feed Roller Drive Pulley may need to be replaced.

Tip: There have been a few cases where a Feed Roller Driv e Pulley was improperly assembled by the facto r y. In this case the center section (clutch driv e spine) will NOT be driven when the Feed Roller Drive Pulley is rotated counter-clockwise. However the center drive spline will be driven wh en the Feed Roller Drive Pulley is rotated clockwise. If this is the case; remove the Pulley from the shaft. Remove the snap-ring that secures the clutch d r ive spline. Remove the clutch drive spline from the assembly. Flip the clutch drive spline over and insert it back into the Pulley. Reinstall the snap-ring. Reinstall the Feed Roller Drive Pulley (clutch drive splines facing out) and test for proper operation.

Page 77

SECTION 4

MAINTENANCE

Dual Pinch Valve Connection

If you should receive the [System Status: Fatal 71 02-? offline cancelpage] message in the Toolbox utility window; along with the message “Reason: ids valve failed three times” the printer has detected a problem with the Dual Pinch Valve. It is possible that the Dual Pinch Valve’s Printed Circuit Assembly connector may be loose or disconnected. Please use the following procedure to reso lve.

This message appears in the "System Status" and "Mech Status" lines in the top left corner of the Printer Control Screen in the Printer Toolbox.

1. Shut off the Printer.

[A] Press the Power Button on

the Control Panel. [B] Wait for the Printer to Stop Processing. [C] Press the Main Power Switch on the Rear Panel.

[D] Unplug the power cable .

2. Remove the Non-Operator Side Cover.

Remove the (2) screws at the top of the Cover. Then remove the (3) screws from the bottom of the Cover.

Page 78

SECTION 4

ADJUSTMENT

3. Look through the open side of the

Printer. The Dual Pinch Valve connector (white) is located just behind the metal duct, for the lower dust exhaust fan.

4. Use a long-blade flat-tip

screwdriver to carefully reach across the print engine and push in or reconnect the small white PCA connector.

5. Reinstall the Non-Operator Side

Cover.

Page 79

Interface Board

Interface Board Test Points

This board is located on the non-operator side of the printer

GND: Logic Ground

Connect your ground lead here for all measurement s except TP3 (clutch).

12VDC: Power In

Improperly tagged; should be 24VDC. Hopefully this will be corrected in a future revision.

TP2: Counter

3 VDC open (no paper); 0 V interrupted (paper present) Count should also increase, by one digit, each t ime the Feed Sensor is interrupted.

TP3: Clutch

Must measure from TP3 to the bottom pin on J8 (Clutch Out).

24 VDC = on (engaged), 0 VDC = off (disengaged)

You can also tell if clutch signal is being received at the Interface Board by monitoring the Fans.

- Fans will turn on when clutch is being driven (engaged).

- Fans will turn off when clutch is not being driven (disengaged).

TP4: Sensor (Feed Sensor)

0 V open (no paper); 7.5 VDC interrupted (paper present) You can also use the counter to verify that the Feed Sensor is working. Count will increase each time the Feed Sensor is i nterrupted.

SECTION 4

MAINTENANCE

Page 80

SECTION 1

GETTING ACQUAINTED

Section 5 – Disassembly/Assembly Procedures

Preparing the Printer for Service

Whenever the printer needs to be tilted, for servicing, you must follow the procedure, as outlined below, before performing these tasks.

NOTE: We suggest the use of protective gloves during this process.

Please complete the following to prep ar e t he printer for service.

1. Plug in the printer. Turn the printer’s Main Power Switch ON; then press the control panel’s ON/OFF

button. Wait about 45 seconds for the print engine to power-up (ON/OFF button will illuminate).

2. Open the Toolbox utility.

3. Deprime system using the “System Deprime” feature located in Toolbo x utility.

NOTE: Use the System Deprime feature, NOT

4. Remove the Service Station from the printer, using the “Eject Service Station” feature in the Toolbox

utility. Refer to “Installing the Service Station”, located in the Operator’s Guide, for help with this process. Follow the sequence in reverse.

5. Wrap the Service Statio n in paper towels and place into resealable bag.

6. Power-down the system using the ON/OFF button and wait until all lights are off.

7. Turn off the Main Power Switch. Then disconnect the power cable from the printer and wall outlet.

IMPORTANT! Do NOT switch off the power at the power outlet or remove the power cable until all lights are off. Failure to do so may damage your printer.

8. Disconnect the USB or Ethernet cable from your printer

9. Remove the Printhead Cartridge and install protective covers on printhead. Store Printhead Cartridge

in a sealed plastic bag with a damp cloth. B e careful t o avoid spills or stains during this process. CAUTION: Make sure contacts are dry before re-installing print he a d.

10. Remove all five Ink Tanks. Be careful to avoid spills or stains during this process. Wrap each ink tank

in a clean, lint-free, absorbent material and place them in a sealed plastic bag as a precaution against any spillages during transport.

11. Place paper towels into each Ink Tank slot, making sure the towels make contact with the back o f the

slots. This is done to absorb any ink that may leak from septum needles. NOTE: Even though the system is deprimed, some ink will remain in the lower areas of the tubing. In transit, this residual ink may drain out.

12. Keep the printer as level as possible du r i ng service.

CAUTION! During the service process the printer should remain semi-level at all times. Failure to do

so may cause the printer to leak ink.

13. When you have finished servicing the printer; please refer to Section 2 of the Operator’s Guide for

details on how to properly install the Service Station, Printhead Cartridge, Ink Tanks, etc. Remember the printhead cartridge “nozzle surface” needs to be wetted using distilled water and a lint free cloth or the priming process may fail.

Installation and Service Videos (where to find)

the Release Printhead feature.

Installation and Service Videos are also available for this product.

Neopost/Hasler Technicians: Please see the Knowledgebase or NeoU for Installation and Service Vid eos. Rena Systems Technicians: Please see the Rena Dealer Net area for Install at ion and Service Videos.

Page 81

DISASSEMBLY AND ASSEMBLY

WARNING!

CAUTION

Basic Disassembly

Turn off Power Disconnect Power Cord Disconnect Interface Cable

Service Disassembly Procedures

THE FOLLOWING DISASSEMBLY SHOULD ONLY BE DONE BY A QUALIFIED,

TRAINED SERVICE REPRESENTATIVE.

ALWAYS POWER DOWN THE PRINTER BEFORE CONNECTING OR DISCONNECTING ANY WIRING HARNESSES OR CABLE CONNECTIONS TO AVOID SERIOUS SHOCK OR INJURY.

SECTION 5

• ALWAYS USE APPROPRIATE PERSONAL PROTECTION EQUIPMENT (PPE).

• DISPOSE OF ALL MAINTENANCE WASTE IN ACCORDANCE WITH LOCAL

REGULATIONS.

USE ELECTROSTATIC DISCHARGE (ESD) PROTECTION WHEN WORKING AROUND ELECTRONIC DEVICES:

• USE STATIC-FREE WORKSTATIONS WHEN UNIT COVERS ARE REMOVED.

• WEAR GROUNDED WRIST STRAPS WHEN WORKING ON UNIT.

• TRANSPORT ELECTRONIC SUBASSEMBLIES IN SEALED STATIC-

SHIELDING PACKAGING

Page 82

SECTION 5

DISASSEMBLY AND ASSEMBLY

Left-hand Side Covers

1. Remove (2) screws at the

top and bottom of the Lefthand Rear Side Cover. Remove the Cover.

2. Remove (2) screws at the

top and bottom of the Lefthand Front Side Cover. Pull Cover away from machine and set aside.

3. Reassemble in reverse

order.

Components under Left-Hand Side Covers

1. Main Print Engine

Printed Circuit Board

2. Printed Circuit Board

USB Connector

3. Printed Circuit Board

Network Connector

4. Printed Circuit Board

Main Power Connector

5. Wiring harness for

Control Panel Buttons

6. LCD Counter

7. Control Panel Buttons

Page 83

Right-hand Side Cover

1. Remove the (2) screws at

the top of the Cover. Then remove the (3) screws from the bottom of the Cover.

SECTION 5

DISASSEMBLY AND ASSEMBLY

Major Components under Right-Hand Side Cover

1. Main PC Board

2. Main Power Plug,

Switch, Fuse

3. USB Connector

4. Network Connector

5. Feed Clutch and Feed

Roller Assembly

6. Encoder

7. Encoder Sensor

8. Drive Belt

9. Drive Motor & Roller

Drive Pulley

Page 84

SECTION 5

CAUTION

DRIVE BELT.

DISASSEMBLY AND ASSEMBLY

Replacing Motor Drive Belt or Motor

1. Remove Right-hand Side Cover.

NOTE: To remove the motor, remove the five screws holding the right-hand side cover.

2. [1] Loosen the (2) motor mounting screws to

relieve tension on the Motor Drive Belt. [2] Then remove the (2) screws ] and t he Encoder Sensor.

NOTE: To remove the Motor, disconnect the wires and remove the two mounting screws.

DO NOT SCRATCH OR OTHERWISE DAMAGE THE ENCODER WHEEL WHEN REMOVING THE MOTOR

3. Carefully remove the Motor Drive Belt by

lifting it over and around the Encoder Wheel.

4. Replace the belt in reverse or der, and then adjust the belt per the adjustment instr uctions in Section 4.

Replacing the Clutch

1. Remove Right-hand Side Cover.

2. Disconnect the Clutch from the wiring harness.

Page 85

3. Push the Clutch toward the pulley to get access to the

mounting pin. Remove the retaining pin.

4. Remove the Clutch from the Feed Roller Shaft.

SECTION 5

DISASSEMBLY AND ASSEMBLY

5. Reassemble in reverse order.

Replacing the Feeder Encoder and/or Encoder Sensor

1. Remove the Encoder Sensor from the Rear

Side Frame. [A] Remove the (2) Screws holding the Encoder

Circuit Board to the two standoffs. [B] Remove the Encoder Sensor by carefully moving the Sensor down and away from the Encoder Wheel. NOTE: Be very careful not to damage Encoder Wheel.

2. Remove the Encoder Wheel A ssembly from

the Pull Out Shaft Assembly.

Remove Screw and Washer from the center of Encoder Wheel. Do not bend or damage the

Encoder during removal.

3. To Reinstall: Insert Screw with Washer throug h

the Encoder Wheel. Apply Blue Loctite to threads. Insert Screw into threaded end of the Pull Out Shaft.

4. Reassemble in reverse order. NOTE: Check that Encoder Wheel and Drive Belt turn freely.

Page 86

SECTION 5

CAUTION

DISASSEMBLY AND ASSEMBLY

Replacing Feed Rollers

1. Unplug the Printer from power.

2. Follow the instructions above and remove the Right-

hand Side Cover, Drive Belt and Clutch before beginning the replacement of the Feed and Forwarding Rollers.

3. Remove the Rear Left-hand Side Cover and set aside.

4. Remove the Side Pap er Gui des and the Rear Paper

Support.

5. Move the Sheet Separators t o the up position. Remove

two screws from each side of the Separator Guid e Assembly and remove it from the machine.

6. Remove Antistatic Bru sh Assembly [A] from mounting

studs. Unlatch the two latches (one on either side of the Assembly) and lift the assembly off the four mounting pins as shown. Do not bend the brushes!

DO NOT BEND, PINCH OR CUT THE INK LINES LOCATED DIRECTLY IN FRONT OF THE BRUSH ASSEMBLY.

NOTE: Make sure Brush Assembly is correctly reinstalled and aligned before starting to print. Assembly should sit flat on transport area surface.

7. Remove the (3) screws on each side of the machine that

hold the Center Plate in place. Then remove the (2) screws on the Rear Panel.

Page 87

8. Lift the Center Plate Assembly from

the machine and set aside.

9. Remove the screw holding the Clutch Support Bracket

and remove the bracket.

SECTION 5

DISASSEMBLY AND ASSEMBLY

10. Remove the Rear Feed Roller Drive Pulley.

NOTE: The spring and washer keep tension on the clutch so that the pin holding the clutch remains in place. Reassemble these parts as shown.

Page 88

SECTION 5

DISASSEMBLY AND ASSEMBLY

11. Remove the washer and spring from th e Feed Roller

Shaft.

NOTE: The spring and washer keep tension on the clutch so that the pin holding the clutch remains in place. Reassemble these parts as shown.

12. Remove the two screws holding the Bearing Housing to

the Side Frame. Push the Rear Feed Roller Assembly toward you to release it from the bearing on the other side of the machine. Carefully remove the belt. Then lift the Roller and Shaft Assembly from the machine.

13. The Front Feed Rollers and Pull Out

Rollers and Shafts can be removed in the same manner as the Rear Feed Rollers and Shaft. Remove the bearing cap on the Side Frame, slide the Roller and Shaft toward you, carefully remove the belts and lift out of the machine.

14. The Rollers are attached to the

Shafts with Allen screws. Loosen the screws to slide the Rollers off the Shafts.

15. Reassemble in reverse order. Take

care to reinstall the belts that drive the Rollers during assembly.

Page 89

SECTION 5

DISASSEMBLY AND ASSEMBLY

Replacing Delivery Rollers

The Delivery Rollers are part of the Front Center Assembly on the feed end of the Print Engine.

1. Remove the Left hand Rear

Side Cover. Remove (2) screws at the top and bottom of the Rear Lefthand Side Cover. Remove the Cover.

2. Remove (2) screws at the

top and bottom of the Front Left-hand Side Cover. Pull Cover away from machine slightly.

3. Remove the Right-hand Side Cover.

Remove the (2) screws at the tof the Cover. Then remove the (3) screws from the bottom of the Cover.

Page 90

SECTION 5

CAUTION

DISASSEMBLY AND ASSEMBLY

4. Remove Top Cover. Remove mounting screw on

left-hand side (Control Panel Side). Remove Top Cover and set aside.

5. Remove Antistatic Brush Assembly [A] from

mounting studs. Unlatch the two latches (one on either side of the Assembly) and lift the assembly off the four mounting pins as shown. Do not bend the brushes!

DO NOT BEND, PINCH OR CUT THE INK LINES LOCATED DIRECTLY IN FRONT OF THE BRUSH ASSEMBLY.

NOTE – Make sure Brush Assembly is correctly reinstalled and aligned before starting to print. Assembly should sit flat on transport area surface.

6. Unplug Network, USB and Main Power

connectors from Print Engine Circuit Board. Disconnect the wires attached to the Power, Paper and Cancel Buttons at connectors. NOTE: Wires are labeled to simplify reconnection.

Page 91

7. Remove Ink Station Door. Carefully unhook the

(2) springs (one on each side), then remove the mounting screw from the left-hand side (Control Panel Side). Remove Door and set aside.

8. Remove Left hand Inner Side

Frame (3 screws). Remove the

Ink Tank Door mounting screw. First remove the Door Spring attached to the screw under the Base Plate. Then remove the screw. NOTE: Be careful not to

lose the Ink Door Spring.

SECTION 5

DISASSEMBLY AND ASSEMBLY

9. Remove (2) Screws holding Front Center

Plate Assembly to the Intermediate Side Frame on right hand side.

Page 92

SECTION 5

DISASSEMBLY AND ASSEMBLY

10. Remove Side Fan (2 screws).

[A] Remove Media Bracket Stud #1 (1 screw) and

the small screw holding the Assembly on left-hand side. [B] Take the Front Center Plate by sliding it off the alignment studs on the Print Engine.

11. Remove Front Center Plate Assembl y. Remove the

(2) screws holding the Delivery Roller Shaft to the Assembly. NOTE: you will have to remove the Bearing to remove Shaft from the Assemb ly. The Rollers are attached to the shafts with Allen screws. Loosen the screws to slide the rollers off the shafts.

12. Reassemble in reverse order. Take care to reinstall

the belt that drives the Rollers during assembly.

Page 93

CAUTION

Replacing Interface PC Board

1. Remove the Right hand Side Cover.

2. Unplug the PC Board power cord [1] from the Power Inlet

on the PC Board.

3. Unplug (9) Connectors for Clutch, Sensors, Motor, Encoder

and Counter wires. NOTE: Wires are labeled for easy reconnection.

DO NOT DAMAGE THE WIRES WHEN

REMOVING THEM.

SECTION 5

DISASSEMBLY AND ASSEMBLY

4. Remove the (4) screws that at t ach the PC Board to the Side

Frame and remove the PC Board.

MAKE SURE THAT YOU ARE PROPERLY

GROUNDED BEFORE HANDLING THE PC

BOARD. STATIC ELECTRIC ITY CAN DAMAGE

THE BOARD.

5. Reassemble in reverse order.

Page 94

SECTION 5

Number Range

Z3/Z4 Print Engine” in the Service Guide.

SG126Z3#####

Higher than SG126Z3#####

DISASSEMBLY AND ASSEMBLY

Replacing the Main PC Board (MPCA)

Valid for Z3 and Z4 Print Engines.

WARNING

THE FOLLOWING PROCEDURE SHOULD ONLY BE DONE BY A

QUALIFIED, TRAINED SERVICE REPRESENTATIVE.

Before you Begin:

Verify that you have ordered and received the proper version board for the Print Engine that is installed, in your printer. See chart below.

Part #

42-110-02

42-500-200

42-500-300

For Print Engine Serial

SG09CZ1#####

SG10KZ1##### to SG10UZ1#####

& SG11FZ3##### to

Description

Main Boards are no longer available for the Z2i engine. In this case, you must replace the Print Engine. In addition, please see “Side Frame Modification to Accommodate

Main PCB for Z3 Print Engine

Main PCB for Z4 Print Engine

When ordering a new board; please be sure to provide the serial number of the printer and the print-engine with your order. This info is needed in or der for the print-engine serial number to be programmed into the new board.

CAUTION

ALWAYS WEAR A WRIST STRAP THAT IS GROUNDED WHEN

TOUCHING ELECTRONIC DEVICES.

Page 95

Operator

Control Panel

Procedure:

1. Turn off the Printer

CAUTION

WHENEVER POWERING DOWN UNIT, ALWAYS:

1. PRESS THE POWER BUTTON ON THE CONTROL PANEL.

2. WAIT FOR THE PRINTER TO STOP PROCESSING.

3. THEN PRESS THE MAIN POWER SWITCH ON THE REAR PANEL.

2. Disconnect Power Cord

3. Disconnect Interface Cable

4. Remove Control Panel Side

Cover. Remove (2) screws at the top and bottom of the Control Panel Side Cover. Pull cover away from machine and set aside. Tip: Keep track of where screws are removed from. They are different.

5. Remove Operator Side Cover.

Remove (2) screws at the top and bottom of the Operator Side Cover. Remove the Cover.

SECTION 5

DISASSEMBLY AND ASSEMBLY

Side Cover

6. Unplug USB, Network and

Power Supply cables from the Main Print Engine PCB.

Page 96

SECTION 5

DISASSEMBLY AND ASSEMBLY

7. Remove the Main PCB Cover

Using a T10 Torx driver remove the screws that secure the cover. There will be 4 or 5 screws, depending on print-engine version. Tip: The top section of this cover wraps around the backside of the enclosure. Once the screws are removed, lift the cover up and then towards you; so the cover clears the back side of the enclosure.

8. Carefully disconnect all connections from Main PCB

IMPORTANT! Do not pull on wires to disconnec t; pull on connector. Before

you disconnect; check to be sure each connection is tagged so you know where to re-attach it.

NOTE: This image shows a Main PCB from a printer with a Z2i print engine installed. The board layout and connections are different in printers with Z3 or higher print engines installed.

9. Remove the T10 screws that secure the Main PCB to the frame.

10. Carefully remove the Main PCB.

Page 97

DISASSEMBLY AND ASSEMBLY

11. Install the New Main PCB to the frame using the T10 screws.

SECTION 5

12. Carefully reconnect all connections to the New Main PCB, in the following

order.

Please follow this process, step by step, to be sure each connection is installed into the appropriate socket.

WARNING: The images shown in the following process are valid for the

installation of a board into a Z3, Z4 or higher print-engine. If you have a Z2i engine; do NOT use the following images to guide you through the connection process. The cables and socket (connection) positions are different on Z2i boards. We have not developed a docum ent with Z2i images. If you have a Z2i boa rd installation you will need to carefully read the tags on the cables and locate the corresponding socket loc ation on the board (they are labeled).

Tip: Triple check that all connections have been properly made before installing the Main PCB Cover.

CAUTION

ALWAYS WEAR A WRIST STRAP THAT IS GROUNDED WHEN

TOUCHING ELECTRONIC DEVICES.

Page 98

SECTION 5

DISASSEMBLY AND ASSEMBLY

a. J1002 Cable

J1002 Socket Location (Connection)

Page 99

SECTION 5

DISASSEMBLY AND ASSEMBLY

b. J1000 Cable

J1000 Socket Location (Connection)

Page 100

SECTION 5

DISASSEMBLY AND ASSEMBLY

c. J551 Cable

J551 Socket Location (Connection)

Rena MACH 5, HJ950C, AS-950C Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual