HP DESIGNJET L26500 October 2011
For HP Internal Use Only Warranty WARNING ©Copyright Hewlett-Packard Company 2011 The information contained in this document is subject to change without notice. The procedures described in this manual are to be performed by HP-qualified service personnel only. This document contains proprietary information that is protected by copyright. All rights are reserved.
HP Designjet L26500 Printer series Service manual
Table of Contents Printer System 1-7 Troubleshooting 2-41 System Error Codes 3-89 Service Test, Utilities and Calibrations 4-135 Print Quality 5-249 Ink Supplies 6-277 Service Parts and Diagrams 7-291 Removal and Installation 8-313 Preventive Maintenance 9-619 Safety 10-629 1
Using this Manual Purpose This Service Manual contains information necessary to test, calibrate and service: • HP Designjet L26500 61-inch Printer (Model CQ869A) • HP Designjet L26500 61-inch Printer (Model CR030A, Japan) For information about using these printers, refer to the corresponding User Guide or Maintenance and Troubleshooting Guide.
Ink Supplies Troubleshooting In this chapter we describe the components of the ink supply system. 7 Service Parts The purpose of this chapter is to detail all of the available service parts of the printer. This information is presented in tables, organized by subsystem, and includes the following: • Official service part names • Part numbers • Graphics of the service parts Use this chapter whenever you need to order a service part.
Printer Systems 1 Printer systems • • • • • • • Electrical system .....................................................................................................8 Substrate path ..................................................................................................... 16 Ink Delivery System (IDS) ....................................................................................... 22 Scan Axis and Carriage................................................................................
Printer systems Electrical system Description The electrical system controls all the printing systems and the heating systems inside the printer. Most parts of the control electronics are placed inside the ’E-box’. Components The electronics can be divided into different functional subsystems and will be described in such a way. There are 7 functional subsystems within the electronics, Front panel, Substrate path, Scan axis, Service Station, Waste Management, Ink Supply and Dryer and Curing.
Description The E-Box contains all the electronics except for the Ink Supply and the control of the firing of the Printheads which take place outside the Ebox.
Printer systems Printmech The ‘Printmech’ PCA is mainly used to control motors and fans but it also controls the following: • Scan motor • Top fans • Paper motor • Dryer fans • Rewinder motor • Curing fans • Ink valves • Web-wipe • Ink pressurizing pumps • IR sensor • IR Fan The Interconnect PCA The Interconnect PCA controls several motors and is also used as a connections board for some of the functionality that resides in Printmech board.
Printer systems Circuit diagram The following diagram shows the connections between the components and the ebox. Carriage Electronics The Carriage contains the electronics for controlling and firing the Printheads. It also contains electronics for controlling the external sensors (SOL and Tetris) as well as the Scan Axis Encoder. The electronics of the Carriage receives power and data from the Trailing cables, which conveys both Power (+45V) and Data (LVDS) cables.
Printer systems Before taking any color measurement, the SOL must be initialized. The SOL initialization process takes approximately 7min. This process consists of three steps: • Sensor switch on • Sensor warm up • Sensor calibration. When the initialization process has finished, the shutter opens automatically and the Carriage is moved along the Scan Axis to place the SOL on top of each sample to take a color measurement.
Below is a picture showing the connections and components located at the rear of the ISS.
Printer systems O expander also controls the multiplexers for the PILS measurement circuitry and the Acumen interface. The device contains 16 I/O ports. • ADC: This measures the PILS signal, and the signals coming from all the sensors on the PCA, i.e. temperature, humidity and air pressure sensors. It is a 12-bit, 8-channel A/D converter. • EEPROM: 32KByte memory for storage of tubes and system back-up information (NVM).
Printer systems Circuit diagrams A simplified block diagram: Related tests, utilities, and calibrations • Electrical system Menu Page 141. Service parts • Electronics Module Page 295. • Carriage PCA Page 301. • Left Hand Assemblies Page 300 Removal and installation • Electronics Module Page 495. • ISS Upper and Lower PCAs Page 404. • ISS to Cartridge Cables Page 397. • Carriage PCA Page 415. • Carriage Flex Cables Page 418. • Interconnect PCA Page 448.
Printer systems Substrate path Description The substrate path moves the substrate from the input spindle to the take-up reel, through the print path, while the Carriage prints on the substrate.
NOTE: The OMAS sensor cannot see the fibers on some substrates, such as transparent media or very dark or very reflective substrates. In these cases, the OMAS sensor can be disabled. To disable the OMAS sensor See page 212. Startup, substrate load, substrate selection During startup, the printer checks that the substrate path components are functioning correctly. When shutting down, if a substrate is loaded, the printer remembers the substrate definition.
Printer systems Loading table Loading table You can use the loading table as a working surface to load the substrate roll onto the spindle In order to position the spindle, use the two slots on the right hand side. Right hub should go inside one of them. Then, by rotating the table towards the machine, the roll will go to its final position with a small amount of effort. The user is asked to check that both spindle ends have entered into the final positions.
The window of the OMAS sensor must be cleaned of dust and ink to functioning correctly. The cleaning procedure for this is described in the customer document ‘Maintenance and Troubleshooting guide’, in the section called ‘Clean the substrate advance sensor window’. During the substrate load, the printer detects that the substrate has reached the print platen when the OMAS captures its image.
Printer systems The HP Designjet L26500 printers requires a hot print zone (with additional airflow) to allow the evaporation of the majority of the water in the latex inks. This feature, plus the new media supported, changes a little the main contributors of the cockle control and media expansion from the former products and also adds new issues such as the thermal marks. The platen gives a convenient shape to the heated media, avoiding differential temperatures because of platen conductivity.
• Rewinder Page 372. • Vacuum Fan Page 380. • OMAS Page 437. • TOMAS Page 444. • Output Platen Page 552. • Center Platen Page 556. • Input Roller Page 568. • Output Roller Page 570. • Media Sensor Page 573. • Pinchwheel AssemblyPage 583. • Center GuidePage 589. • Driver RollerPage 591. • Rollfeed Modules Page 597. • Take-up reel Page 600.
Printer systems Ink Delivery System (IDS) Ink Delivery System The ink deliver system (IDS) is located in the left enclosure of the printer (inside the left covers) and delivers a continuous supply of ink to the printheads. It can detect an ink leakage anywhere in the system, including inside an Ink Cartridge. It also tracks and determines when an Ink cartridge needs replacing.
The upper and lower ISS both contain PCAs, although the top PCA contains more functionality, such as the pressure sensor, see Page 12. Non-return valves The two non-return valves are only for the inks on the lower IDS. This is to ensure that when the pump stops and the cartridges are nearly empty, that the ink does not flow back to the cartridge. If a cartridge is nearly empty, with no pressure from the pump, the cartridge bag might increase, and air might enter the printhead.
Printer systems Scan Axis and Carriage Scan Axis The Scan Axis System is the part of the Scan Axis subsystem designed to move the carriage backwards and forwards for printing and servicing. This subsystem moves the carriage with a motor, belt, and pulley system. Furthermore the scan axis has features to open and close the Spectrophotometer shutter (SOL) and to enable/disable the cutter. Scan Axis Components Scan Beam: It is an extruded aluminum part.
SOL Spectrophotometer SOL is a color sensor and it is placed in the left side of the carriage, covered by a metal sheet that protects it from the heater’s high temperatures. The main function of SOL is to measure color samples that have been printed on the loaded media and are placed on the print platen zone. Before taking any color measurement, SOL must be initialized. The SOL initialization process lasts for about 7min.
Printer systems Felts, these parts help to lubricate the rod and they also avoid dirt going in between the carriage. They block four degrees of freedom (Z and Y translation and rotation over the primary rod) SOL protectors, these parts help to avoid the SOL shutter breaking after a paper jam Plastic rear bushing: this blocks one degree of freedom (the X rotation over the primary rod). The dam protector, are Mylar and stainless steel, and they stop the aerosol.
The main function of the Service Station is to maintain the Printheads of the Carriage assembly and to manage the Waste Ink. The Service Station and Waste Management can be split into three subsystems: • PHC servicing: Comprising Cap, wiping and priming functions • Waste Management: Contains ink spit/aerosol ink collection and the aerosol filter.
Printer systems Web Wipe Printhead Maintenance Cartridge Drop Detector channel Spittoon Platen Web Wipe The Web Wipe Advance mechanism engages/disengages the advance gear of the Printhead Cleaner Cartridge. The actual advance is achieved by moving the Printhead Cleaner Cartridge once the gear has been engaged by this mechanism.
• Ink Funnel: It collects both the ink and aerosol waste during the spitting printhead servicing operation. • Tubes: Each type of waste (ink and aerosol) is driven downwards through its own tube, before being processed in the Waste Management module. The tubes are fitted inside a guiding tube that provides the proper routing. • Waste Management Module: This external subsystem collects both types of waste coming from the upper part of the system and stores each of them in its consumable.
Printer systems 30 • Aerosol Fan and Filter: Page 385. • Drop Detector: Page 387. • Primer Assembly: Page 366.
The type of ink used in this printer (Latex) require heating in order for the ink to be cured. The heating system applies this heat through a Dryer Assembly and a larger Curing assembly. Temperatures are kept at a target level depending on the type of substrate and amount of ink fired via a temperature sensor, which feeds back information to the Heater Control assembly (Petisa) located at the rear of the printer.
Printer systems Curing Module The Curing Module fixes the latex ink (cures) at typically around 80-120ºC, depending on the substrate for satisfactory durability. The two independent resistors provide a total 1900W split as follows: 1200W (Curing overdrive, closest to the printer) and 700W (Curing Output, furthest from the printer).
There are two infrared sensors, one for each module, these sensors detect the temperature and feedback the information to the Heater Control Assembly (Petisa), the power supplied to each module is then adjusted according to target levels. In the following picture a closer view of both sensors can be seen. Dryer Module: Curing Module: The dryer module has a unique resistor, the maximum power level is 2400W(61”) while the curing module has two separate resistors for a power level of 1900W(61”).
Printer systems The following diagram summarizes the electronics involved in the heaters control: The power comes to the heating system via two different power cords, one is supplying energy just to the Dryer and the other sharing its energy between the Curing heaters and the rest of the printer electronics. Both AC lines are internally protected by RCDS (Residual Current Sensor), that will trip and cut the AC power going into the heating system if there is a leakage to Ground above 30mA.
This the block diagram shows further the interaction between the different elements. Printer systems 35 Printer systems PrintMech PCA This PCA is used for several I/O activities between the Power Control PCA, the Control Logic PCA and the firmware.
Printer systems Cabling System Heaters and electronics are connected by a cabling system: In this cabling drawing it can be seen the connections between the main components of the heating system. Due to the physical printer structure, an interconnect is required between the lines coming from the Power Control PCA and the heating elements. Note the green line in the diagram, this cable goes across all these intermediate connectors which allow you to detect if any of them are disconnected.
Printer systems Heating and Curing PCA and connections Related tests, utilities, and calibrations • Heating and Curing service tests Page 188. • Heating and Curing Temperature Page 219. Service parts • Front Covers Page 293. • Dyer and Curing Modules Page 302. Removal and installation • Heating Control Assembly Page 473. • Dryer (IR) Heater Sensor Page 510. • Dryer Heater Assembly Page 515. • Curing Temperature Sensor Page 520. • Curing Fans Page 520.
Printer systems Front Panel Description Direct printer interactions are made through the Front Panel. The Front Panel is a small screen display and array of button controls located on the right side of the printer. The Front Panel is frequently used by Service Engineers. In general most things requiring direct mechanical interaction with the printer, such as tests or calibrations, are performed using the Front Panel. The Front Panel communicates with the Formatter via the Main Interconnect Board.
• Printer systems Related tests, utilities, and calibrations Front Panel Service Test Page 139 Service parts • Front Panel Page 296. Removal and installation • Front Panel Page 364. Front Panel Electronics Diagram NOTE: The front panel is connected to the Formatter Board through a USB BUS and 5V standby & reset line. The standby and reset line is what enables you to start the Main Power Supply from the ON/OFF button of the front panel.
Printer systems 40 Printer systems
Troubleshooting 2 Troubleshooting • • • • • • • • • • • • • • • • • • • • • • • • • Troubleshooting the printer.................................................................................................42 • Printer Education and Training ....................................................................................42 • Firmware upgrade .....................................................................................................42 Troubleshooting system error codes ...................
Troubleshooting Troubleshooting the printer Refer to Section 6 for troubleshooting Image Quality issues. Printer Education and Training Before any attempt is made to troubleshoot the printer, it is critical that you have the relevant training on the HP Designjet L26500 Printer series. If you are not trained on this printer, please contact HP Education or HP Training to enquire about becoming ‘HP Service Qualified’ for this printer.
Performing the necessary service calibrations Is the printer calibrated correctly after replacing a component? For information on the Service Calibrations and how to use them refer to Chapter 4, Service Tests, Utilities & Calibrations See page 135. NOTE: Remember that certain Calibrations are required even if an Assembly has been disassembled to gain access to another Assembly or Component.
Troubleshooting Cover sensors are not working To resolve cover sensor problems, do the following: 1. Perform the Sensors Test See page 195. 2. Check if the cable for the faulty sensor is not damaged and is connected correctly. 3. Replace the faulty Sensor. The line sensor has problems detecting media To resolve line sensor media detection problems, do the following: 1.
In order to minimize the problem, check the top edge of the substrate for damage or excessive curling. If the substrate is a self-adhesive type of substrate, check that the backing paper (the liner) has not become detached. • Check that the substrate has been correctly adjusted following the ‘Add new Substrate procedure’ in the User´s Guide. 2. Check that the Vacuum Fan works correctly. 3. If necessary use the edge holders provided with the printer.
Troubleshooting Vacuum suction much lower at high altitudes At altitudes above 3,000 meters, the vacuum force holding down the media will be lower, therefore the media will not be held in place sufficiently causing: • Ink Smearing on the Media. • Printhead crashes against the Media. • Roll Media loading problems (low probability). The level of Vacuum applied to the substrate can be adjusted from the RIP.
Use this section to troubleshoot failures with the take-up reel. Take-up reel LED status information LED status Issue Print job interrupted Possible cause Print job interrupted? Blinking quickly Take-up reel not winding Yes Sensor beam blocked for more than 3 seconds Ensure the take-up reel sensors are not blocked by a strip of paper, the collection bin or other objects. Also ensure the take-up reel power switch is in the On position.
Troubleshooting Checking the take-up reel is correctly installed Many system error codes are displayed as a result of the take-up reel not being installed correctly or because parts have moved or become dislodged from their correct positions. This troubleshooting procedure checks the mechanical installation of the take-up reel. 1. Check that the take-up reel sensor unit is correctly installed on the right foot. 2. To correctly install the foot, the wheel has to be positioned as shown. 3.
How to enable the take-up reel: The take-up reel must be enabled and operated from the front panel. When the take-up reel is enabled, the “Take-up reel enabled” message appears on the Substrate tab on the front panel. Select the substrate icon and then select Take-up reel >Enable take-up reel. How it works? When the bottom of the 'loop' is lower enough and it cuts the signal between the 2 sensors, the take-up reel starts to move the motor until the signal between the 2 sensors is passing through again.
Troubleshooting Number of Beeps Problem Description Corrective Action • • • Check that the Front Panel cable is not damaged and is correctly connected between the Front Panel and the Interconnect PCA.
Troubleshooting Step Initialization Process 23 • • Set the hostname. Initialize USB controller and HID devices 22 • • • Set variables for options to be later used for filesystem check Turn Off DMA on CD-ROMs Turn On Hard Disk optimization 21 Perform file system check on root volume. 20 Update quotas if fsck was run on root 19 Setup pnp 18 • • • • • • • Remount the root filesystem read-write. LVM initialization. Clear mtab.
Troubleshooting Step Initialization Process 3 Engine startup, start EE and Mechanical initialization. 2 HPGL/PS parsers startup. 1 All subsystems launched. Wait for Front Panel application to clear the Front Panel and start signaling the initialization sequence. Corrective Actions for Power-Up Problems To resolve power-up problems, use the following corrective actions: 1.
#Error LEDs Description/Corrective Action • 1 • Problem description: Not possible to power on the printer with the power button located in the front panel Corrective action: Follow standard troubleshooting to determine the part that it is failing. • 2 Problem description: Voltages 12V, 5V and 3V3 are not correct in Main PCA Formatter. • Corrective action: • reconnect cables of power connector in Main PCA Formatter • Replace Main PCA Formatter See page 460. • Replace PSU See page 464.
Troubleshooting #Error LEDs Description/Corrective Action • • • • • 10 Problem description: Power Button in front panel doesn’t reach PSU, but it is possible to boot turning on the PSU switch Corrective action: Replace Front Panel See page 364. Replace Sausalito PCA See page 457. Replace Main PCA Formatter See page 460. Troubleshooting OMAS problem A problem with the OMAS board may cause the printer to display a 50.2:10 service error, this can be fixed by checking the following connections. 1.
Check the LEDs under the OMAS board. Troubleshooting 3. This LED only comes on for the first 20 seconds after the printer is turned On. When the firmware has successfully loaded into the memory the LED will switch OFF. These LEDs come On and stay On. LED=3.3 volts LED=24 volts LED=5 volts Using the Power Switch LEDs to Troubleshoot In certain circumstances, the LEDs located on top of the power switch (located at the rear of the Printer) can help to troubleshoot the Printer.
Troubleshooting 2. When the Blue LED is On: Deliver standard “ATX” power for the Electronics Module PCAs (+12V, +5V, -5V, -12V, etc...). All the functions of the Electronics Module are fully operational (EWS, etc...). 3. When the Green LED is On: Deliver “analog” 24V and 42V to enable printing. The Printer monitors and reports different signals: PSU fan issues, 24V and 42V delivery failures (specific System Error reported pointing to PSU failure).
Troubleshooting PrintMech PCA The following illustration shows the locations of the LEDs on the PrintMech PCA. DS2: 5V DS1: 3V3 DS5: VAUX=12V DS3: VPOWER2 42V DS4: 24V Note: LED DS7: 5Vsb is a little difficult to see, however if you look into the printmech from the position shown here, you should see it. DS7: 5Vsb DS1: 3V3 - Comes from the Power Supply Unit. DS2: 5V - Comes from the Power Supply Unit. DS3VPOWER2 - Comes from the PSU (42V) after a fuse on the PrintMech PCA.
Troubleshooting Signal LED on Interconnect PCA LED on PrintMech PCA Power Switch LED Corrective Action • 5Vsb OFF OFF Amber or no LED • • 2. If the Printer starts (after having pressed the ON button on the Front Panel) but the front Panel remains black: Signal LED on Interconnect PCA LED on PrintMech PCA Power Switch LED Corrective Action • 5V OFF ON Blue • • 5V 3. Check the connection between the PSU and the PrintMech PCA and Interconnect PCA.
24V 4. LED on Interconnect PCA ON LED on PrintMech PCA Power Switch LED OFF Blue and Green Corrective Action • • Check the connection between the PSU and the PrintMech PCA. If connection OK, run the Electronics Module Test to further diagnose the problem. If the Power Switch LED is Green and the 3V3 LED is ON, 5V LED is ON, VAUX LED is ON and the VPOWER2 LED is OFF, then try the following: • Check the connection between the PSU and the PrintMech PCA.
Troubleshooting LEDs +24v Present Relays Active Relays Enabled Halt +5v present +24v Present Relays Active Relays Enabled Halt +5v present Status Normal operation. This is the normal functioning status of the Heaters Control Assembly PCA. Troubleshooting • This is the normal functioning status of the Heaters Control Assembly PCA. • Check the printer connected to the power source. Are the switches of the power inputs in the on position.
Status +24v Present Relays Active Relays Enabled Halt +5v present Error Status. The relays have been enabled during a HALT condition. +24v Present Relays Active Relays Enabled Halt +5v present Abnormal status. No 5 volts available. There is 24v present, but the 5volts from the PrintMech is not arriving +24v Present Relays Active Relays Enabled Halt +5v present A HALT condition is present, but the relays are active (Warning). Although the HALT signal is active, the relays are enables and active.
Troubleshooting Checking the resistance values Part of troubleshooting some of the system error codes related to the Dryer and Curing Assemblies involves checking the resistance values. In the tables shown below are the resistance values that would typically be seen when the resistors have not been used for 1 hour. Resistance values as seen in P1 and P2 connectors on the Power Control PCA Japan Japan Type of resistor Dryer resistance value (± 5% ohms) Upper spec Lower Spec Steady 27.0 28.4 25.
Use a voltage current tester to measure between the pins 1 and 4. Troubleshooting 3. Pin 4 Check the values are within specification Pin 1 4. Use a voltage current tester to measure between the pins 2 and 3. Pin 3 Check the values are within specification Pin 2 5. Open the window. 6. Remove two T-20 screws that secure the Left Cable Plate to the printer and remove the cover. 7. Disconnect the Dryer and Curing Power Cables. 8. The dryer connector has 8 female pins.
Troubleshooting 10. Use a voltage current tester to measure between the pins 1 and 3. Pin 1 Check the values are within specification Pin 3 If all the resistances are within specification, the fault is in the path from the Heaters Control Assembly to the connectors in the arc. It could be a failed cable or the 8 pin connector has failed. 1. Check the connectors and cables are not damaged, disconnect and reconnect them, test the pins again. 2. Replace the Dryer Heater See page 515. 3.
Remove two T-20 screws that secure the Left Cable Plate to the printer and remove the cover. 6. Disconnect the Dryer and Curing Power Cables. 7. The curing connector has 2 connectors female pins, one connector has 4 female pins and another one with 6 female pins. The drawing below shows the connectors pins numbering by looking from the connection side and holding the clip down. 8. Use a voltage current tester to measure between pins 4 (4 pin) and 6 (6 pin) as shown in the pic- Troubleshooting 5.
Troubleshooting 10. Use a voltage current tester to measure between pins 3 (4 pin) and 6 (6 pin) as shown in the pic- ture. Pin 6 Check the values are within specification Pin 3 11. Use a voltage current tester to measure between pins 3 (6 pin) and 6 (6 pin) as shown in the pic- ture. Pin 6 Check the values are within specification Pin 3 • • If all the resistances are within specification, the fault is in the path from the Heaters Control Assembly to the connectors in the arc.
Troubleshooting How to Interpret the Service Information Pages The Service Information Pages contain the following information: • Current Configuration • Current Information. • Usage Information. • Event Logs. • Calibration Status. • Connectivity Configuration • All Pages. It is possible to print the Service Information Pages either through the Front Panel or through the Embedded Web Server: • Front Panel: Setup menu Internal Prints Service Information Prints.
Troubleshooting Current Configuration This page contains full details of the current configuration of the Printer.
The first section, is generic information and is available in every tab, it displays information such as the current level of firmware installed, the serial number of the printer etc. This page is in two parts: The first part displays information on the following: • Current Printer Configuration. • Substrate Loaded Information. • Current Printhead Kit Information.
Troubleshooting Current Information (2 of 2) The second part displays information on the following: • Current Ink Cartridge Information • Printhead Cleaning Kit.
Troubleshooting Printer Usage Information (1 of 3) This page contains the following information: • Printer Usage. • Usage per Printhead Slot. • Usage per Cartridge Slot. • Media Usage per Media Type. Printer Usage: The total amount of media used in the Printer Total Insertions: This is linked with the crane of the Ink Supply Tubes. When the Ink Supply Tubes or ISS PCAs are replaced, the total insertions amount will be reset to zero (0).
Troubleshooting Printer Usage Information (2 of 3) • Spittoon Usage • Component Usage. • Preventive Maintenance Usage. • Job Accounting I. • Job Accounting II Component Usage: A cycle is counted when the Carriage makes one movement to the left of the Printer and then returns to the right will be reset to zero (0). Maintenance Usage: Once the value reaches 100%, the corresponding Preventive Maintenance Kit should be used.
• Job Accounting III. • Job Accounting I • Job Accounting V Troubleshooting Printer Usage Information (3 of 3) Event Logs This page contains the following information: • Last 20 System Error Codes (which prevented the Printer from booting). • Last 20 System Warnings (which did not prevent the Printer from booting, but which required the user to acknowledge the problem). • Printhead Error log. • GPIO Sensor Status. In this section the printer is reporting the status of all the sensors.
Troubleshooting Same for the sensors inside the ink cartridges. System/Warning Error • The Line and Internal Code do not provide much information, but are useful in the case of escalating a problem to the division (different internal error codes can point to the same error code (e.g. 01.10:10)). • Media Usage (in square meters) and Date (from the Printer’s Internal Clock (RTC)) help you to understand if the Printer has been used (media usage) and how much time has passed since the last error.
1 or higher: At least one Printhead recovery has been performed.
Troubleshooting Calibrations Status This page contains the following information: • General Calibrations (performed by Service Engineers). • Diagnostic Log • Provide information about the internal NVM values. • You could check if the real measured values of the dryer heaters are equal to the ones in the printer NVM. • After installing a new Heaters Control Assembly and introducing the values using the diagnostic test, you could check if the values have been correctly saved.
Troubleshooting Connectivity Configuration This page contains full details of the current configuration of the Printer. How to troubleshoot the 79:04 System Error Introduction The System error 79:04 is a generic firmware error (equivalent to a blue screen in Windows). It’s the System Error that the printer will display when an unknown exception occurs that cannot be pointed to by any specific subsystem of the printer. Since this is a generic error, there can be multiple causes behind it.
Troubleshooting usually be applied by either correctly configuring a selection, updating the printer’s firmware/software that is being used or by fixing an error in the code). Possible causes Since the 79:04 system error is a generic error, the number of possible causes behind it is large.
Perform an 2.11 EEROM reset Important note: It is possible that the corrupt data came to be in the printer as a consequence of some activity in the customer’s workflow. In this case, it is possible that the issue will happen again. In these cases, it is very important to understand the sequence of events in the customer’s workflow that led to the error occurring. Once the error can be traced in the customer’s workflow, escalate the issue to the GBU (through the GCC).
Troubleshooting These errors will most likely only happen in very specific corner cases that have not been identified during the development or the qualification of the printer, so normally, they do not severely impact the customer, as they do not affect their regular working flows. Symptoms The symptoms here are as numerous as the number of possible interactions between the user and the printer.
Workarounds and solutions Random 79:04 errors are, by far, the most complex ones to diagnose and to fix. The only solutions available in these cases are: 1. Identify the root cause (either in the files or in the firmware) and fix it in the code, which requires the intervention of the GBU. 2. Test any options available to modify the customer’s workflow and see if any combination of them solves the issue. In both cases, a profound understanding of the customer’s workflow is necessary.
Troubleshooting • 79:04 during start up. Rebooting the printer may or may not solve the problem • 79:04 while processing or printing a job. Rebooting the printer and printing the same job does not always produce the error. Solutions and workarounds In the following procedure perform each step as it appears in the list and only move on to the next step once you are sure the 79:04 error has not been cleared: 1.
The results of the previous 8 steps • The System Error detailed information (this can be obtained by pressing CANCEL + Down) • The printer logs. Front panel displays 79:04 during printer operation – not while sending jobs 1. Reboot the printer. 2. Upgrade the printer’s firmware. Even if the currently installed firmware version is the latest one, reinstall it. 3. Reset the printer to factory defaults: Go to the Setup icon>Resets>Restore Factory Settings. 4.
Troubleshooting 2. Upgrade the printer’s firmware. Even if the currently installed firmware version is the latest one, reinstall it. 3. Escalate the issue, providing the following information: • Unit information: S/N, P/N, accessories • Conditions where the problem occurs and conditions prior to the first occurrence of the issue.
One of the electronic boards or connections processing the carriage movement signal is defective, so the printer cannot detect the actual movement, and causing an 86:01. From the list above, it is possible to establish two main groups of causes for a system error 86:01: • Mechanical: When the motors and electronics are working as expected, but still the carriage does not move due to an obstacle or too high a friction.
Troubleshooting - If the motor does not move, the error is electrical, refer to page 87. - If the motor moves when not attached to the carriage the error is Mechanical, refer to page 86. • If the carriage moves the error is mechanical, refer to page 86. Take note of the values of the PWM test. After performing the actions described below, the average PWM should show a lower value .
If the printer is still showing issues at this point, it is possible that the carriage bushings are dirty or that they are worn out, affecting the friction between the carriage and the rod. Disassemble the carriage and check the bushings. If they are dirty, try to clean them and lubricate them.
Troubleshooting 88 Chapter 2 Troubleshooting
System Error Codes • • • Introduction...................................................................................................................... 91 System Error Codes and Warnings - Explanation ..................................................................92 Continuable and Non-Continuable Error Codes ....................................................................95 • 01.0:03 - Error impact I2C channel..............................................................................95 • 01.
System Error Codes • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 24.03:00 - One of the Top Cover Fans not connected................................................... 113 26.0:10 - Contact failure with Magenta Ink Cartridge.................................................... 114 26.1:10 - Contact failure with Yellow Ink Cartridge ........................................................ 114 26.
Introduction Firmware upgrade If the error with the printer does not allow you to upgrade the firmware using the normal process, try upgrading the firmware using the emergency .plt file procedure page 202 What are System Error codes? System error codes are hexa-decimal based numbers generally caused by internal system errors. The following pages contain a list of system error codes and their respective descriptions and recommended corrective actions.
System Error Codes and Warnings - Explanation System Error Codes explain which component/system is failing and what action should be taken to resolve the problem. System Error Codes System Error Codes are displayed directly on the front panel (but can also be seen on the Information Page) and have been defined in the format XX.YZ. or XX.n:YZ.m. • XX: Service Part (2 digits). • n: Service Part Index (if more than one used in the product) - Optional. • e.g. Identify the Ink Supply (color and number).
Component/System 50 51 51.01 52 53 54 55 56 58 61 61.1 61.
System Error Codes Code Recovery Action Response 10 11 12 13 14 15 16 17 18 19 Replace Reseat/Reconnect/Clean/Adjust (manually) Calibrate/Adjust (using Automatic Process) Power OFF Upgrade System Firmware Upgrade Driver or Computer Software Add Accessory Escalate Send Plot Again Wrong Part Installed hp qualified personnel assistance required 94 Chapter 3 System Error Codes
Continuable and Non-Continuable Error Codes Some of the Error Codes are continuable, which means you can press Enter on the front-panel and continue working with the Printer. Non-Continuable Error Codes do not allow you to continue working with the Printer, in this case power the Printer OFF and ON again and see if the System Error disappears. If the Error Code reappears, then the Printer requires an on-site visit in order to resolve the problem.
System Error Codes Corrective Action: • Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer. • Check the connections of the ISS PCAs (Upper and Lower) are correctly connected and not damaged. • Check with another set of Ink Cartridges, to ensure the error is not with the Ink Cartridges. • Replace the ISS PCAs (Upper and lower) Page 404. SE Code: 02.
SE Code: 05.3:10 - Main memory size failure Problem Description: This is a service test failure and will only be displayed while in the process of testing a part. • Check that at least 256 megabytes of memory is installed in the Printer. • Check that the Memory Module is installed correctly. • Try installing the Memory Module in the other Memory slot and check if the system error is still displayed. • If the System Error reappears, replace the Memory Module Page 460.
System Error Codes • Check that the cables between the Interconnect PCA and the Main PCA are not damaged and are correctly connected. • Check that the cables between the Hard Disk Drive and the Power Supply Unit and the Main PCA are not damaged and are correctly connected. • Check that the cable between the Power Supply Unit and the Main PCA is not damaged and is correctly connected. • Check that the Printer has the latest Firmware version, if not, update the firmware to the latest version.
• Replace the Heaters Control Assembly Page 473. • If the heater resistor value is too low, locate which of the heaters and replace: • Change the heaters in the Dryer Assembly Page 515. • Change the heaters in the Curing module Page 534 SE Code: 14.02:00 - Current too high on the Dryer Assembly Over current in Dryer assembly. The level of amps is over 18 amps, or the amount of current requested from the Dryer assembly is too high.
• Troubleshoot the Dyer Assembly Page 62. • Replace the Heater Control Assembly Page 473. SE Code: 14.06:00 - One or more heaters are not connected Problem Description: System Error Codes There is a communication failure between the Heaters Control Assembly and the Curing Module or Dryer Assembly. Corrective Action: • Check all the cables are correctly connected from the Heaters Control assembly to the Curing module and the Dryer Assembly around the left arc.
Check the connections of the cables from the Heater Control PCA to the PrintMech PCA and the Sausalito PCA. • The halt condition in the Heaters Control PCA can also be displayed as a 14.08:00 system error. Check it by looking at the Heaters Control PCA LEDs, refer to page 59. • This condition could happen with incorrectly connected drying and curing systems, at the level of the Heaters Control module and/or under the left arc.
SE Code: 14.11:00 - Open circuit in the Curing Module Problem Description: Power is applied to the Curing module and then the current is measured, if the flow of current is not as expected, the system error is displayed System Error Codes Corrective Action: • Troubleshoot the Curing Assembly Page 64.
SE Code: 14.15:00 - Generic failure with the Heaters Control Assembly Problem Description: There is a failure with the Heaters Control assembly. • Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer. • Check all the cables are connected in the Electronics module. • Replace the Heaters Control assembly Page 473.
System Error Codes Corrective Action: • Check if the environmental ambient temperature is low. Check the surrounding temperature is within the printer´s operating specifications; it should be higher than 15C for printer operation. If this is the case, increase the ambient temperature of the printer´s location. • Check if the input voltage is in the range of 198v to 205v, ensure the ambient temperature is higher than 20C for the correct functioning of the printer.
The cooling fans intake is blocked, check there are no obstructions on any of the cooling fans: Dryer, Curing, Top Cover Fans, Rear Fans. • Check if the Dryer IR sensor is dirty and requires cleaning, observe all safety precautions while working in the area of the heaters. • Check the power going to the IR sensor. • Check the position of the IR sensor is correct, if it is pointing to a position other than the substrate this will cause an error. • Perform the IR sensor diagnostic check 8.
System Error Codes Corrective Action: • The ink density is too high, check the User´s Manual for the recommended ink density levels. • Check if the input voltage is in the range of 198v to 205v, ensure the ambient temperature is higher than 20C for the correct functioning of the printer. • Check if the substrate loaded on the printer is too transparent or reflective for the IR sensor to detect the surface temperature. Check this by loading another type of substrate.
SE Code: 15.10:00 - Drying Assembly resistors incorrect Problem Description: The firmware measures the current through the Burst resistor and the steady resistor, and it checks that one is greater than the other. If the measurements detected are not as expected this could indicate that the heaters have been swapped in error. Corrective Action: Replace the Dryer Assembly Page 515. SE Code: 16.
• The environmental ambient temperature is too hot or is outside the operational specification of the printer. Make sure there are no external sources of heat, such as strong lights, direct sunlight, heaters etc. SE Code: 16.03:00 - Curing system temperature too high Problem Description: Curing System has exceeded the upper temperature level (150C). System Error Codes Corrective Action: • Check there are no obstructions on any of the cooling fans: Curing, Top Cover Fans, Rear Fans.
SE Code: 16.05:00 - Problem with the Curing System Temperature Sensor Problem Description: Signal error detected with the Curing System Temperature Sensor. Corrective Action: Check the Curing IR Sensor Fan is turning and is correctly installed with the fan in the correct orientation. • Check the cables are connected and not damaged. • Replace the Curing IR Sensor & Fan Page 528. • Replace the Printmech Page 494.
SE Code: 16.08:00 - Curing System fans not connected Problem Description: The array of Curing System fan(s) is not connected. System Error Codes Corrective Action: • To confirm that none of the fans are working perform the service test 2.4 Page 147. • Check the cables from the Curing Fans to the Printmech are not damaged and are connected. • Replace the PrintMech Page 494. SE Code: 16.
SE Code: 21.3:10 - Electrical problem in the Web Wipe Motor Problem Description: Error detected in the area of the Web Wipe Assembly (Rack engage motor electrical) • Switch the Power OFF from the back of the Printer, manually pull the Printhead Maintenance Cartridge to the position and power On the Printer.
• Make sure that the Service Station path is clear. Remove any visible obstacles (e.g. foam from the printer’s packaging, screws, plastic parts, etc...) restricting the movement of the Service Station. • If the System Error continues, replace the Service Station Page 375. SE Code: 21:13 - Problem in the Service Station Problem Description: System Error Codes Problem with the Service Station. Corrective Action: • Switch the Power OFF from the back of the Printer and disconnect the Power cord.
• Try purging the Ink Supply Tubes again when the Printer has been rebooted. If the printer does not automatically go into the purge process, use the service test procedure “1.4.1 Purge tubes” Page 214. • Install new Ink Cartridges in to the Printer and try purging the Printer again. If the printer does not automatically go into the purge process, use the service test procedure “1.4.1 Purge tubes” Page 214. Problem Description: A broken bag has been detected in one of the Ink Cartridges.
• If all the cables from the Printmech to the fans are connected, replace the Printmech Page 494. • If at least one of the fans is working, check if the failed fans are connected to the array, if it is connected replace the failed fan (Top Cover Fans Page 360. • If the error is not cleared, check all the cables from the failed fan to the PrintMech. SE Code: 26.0:10 - Contact failure with Magenta Ink Cartridge System Error Codes Problem Description: Bad contact detected in ISS slot 0 floater.
Corrective Action: Remove the Black Ink Cartridge and reinstall it in to the Printer. • Check the Ink supply tube to this Ink Cartridge has not been forced laterally causing a misalignment of the floater (Ink supply connector). • Check the floater spring is functioning correctly. • Replace the Black Ink Cartridge. • Check that the ISS to Cartridge cable (Black Ink Cartridge) is not damaged and is correctly connected to the Ink Supply Tubes PCA.
• Replace the ISS PCA Page 404 • Replace the Ink Supply Tubes and Trailing Cable Page 392. SE Code: 26.5:10 - Contact failure with Light Cyan Ink Cartridge Problem Description: Bad contact detected in ISS slot 7 floater. System Error Codes Corrective Action: • Remove the Light Cyan Ink Cartridge and reinstall it in to the Printer. • Check the Ink supply tube to this Ink Cartridge has not been forced laterally causing a misalignment of the floater (Ink supply connector).
Corrective Action: • Reseat the Printhead Cleaning Cartridge. • Replace the Printhead Cleaning Cartridge if the error continues. SE Code: 32:01.1 - Early Take Up Reel paper jam This system error happens when there is a small amount of paper printed (less than 79 inches long), and the Take Up Reel sensor detects that the loop shaper is (incorrectly) at the bottom of its path, even though the spindle motor has been rotating for more that 3 seconds.
• If not, manually unload the paper from the Take Up Reel. Remember to cut the paper before. SE Code: 32:02 - Take Up Reel disconnected at initialization Problem Description This message is shown during initialization of the printer and indicates a warning that the Take Up Reel has been disconnected while the printer was off. This error is also shown if the user tries to enable the Take Up Reel but it is not connected to the Printer.
• Open the Window and check for any visible obstacles restricting the movement of the Carriage Assembly. If there is a wrinkled mass of media blocking the Carriage Assembly, then clear the obstruction. • Perform the Scan Axis Service Test Page 176. • Replace the Scan Axis Motor Page 432. • If the System Error continues, replace the PrintMech PCA Page 472. Problem Description: Electrical fault in Carriage Motor or starting the Scan Axis or Homing Scan Axis.
System Error Codes • Check that the cable of the waste management system is correctly connected to the connector at the EBOX (this check can be done by the customer). • Check that the cable from the EBOX to the interconnect PCA is correctly connected. • Check that the cables going from the interconnect PCA to the printmech PCA are correctly connected. • If the previous action did not work then, replace the interconnect PCA Page 448.
SE Code: 44.3:00 - Waste management cable short circuited Problem Description: There is a short circuit in the waste management system cable, and maybe also in the Interconnect PCA. • Replace the Waste Management module (this part can be changed by the customer). This is the most probable failure. • Check that the cable of the waste management system is correctly connected to the connector at the EBOX (this check can be done by the customer).
• Replace the Rewinder Motor Page 372. SE Code: 45.2:10 - Rewinder inverse polarity Problem Description: Rewinder inverse polarity. This message is only displayed when the printer is initializing Corrective Action: System Error Codes • Swap over the power cables of the Rewinder motor. SE Code: 45.3:10 - Rewinder driver system fault Problem Description: There is a system fault with the Rewinder driver.
• Replace the Interconnect PCA Page 448. SE Code: 46:10 - Electrical fault in the Primer motor Problem Description: Electrical fault in Primer motor. Corrective Action: Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer. • Check to make sure there is not obstruction in the Primer mechanism. • Replace the Primer Assembly Page 366. • Replace the PrintMech PCA Page 472.
System Error Codes Corrective Action: • There is a tendency for this system error to being displayed because of cables becoming disconnected. Check all relevant cables are correctly connected, especially the cables from the OMAS Controller and the Main PCA and the Sausalito PCA. • Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer.
• Check that the Printer has the latest Firmware version, if not, update the firmware to the latest version. • Check that the OMAS Module cable is not damaged and is correctly connected to the OMAS Controller PCA. • Replace the OMAS Controller Card Page 450 • Replace the OMAS Module Page 437 Problem Description: FW version mismatch between the controller fw and the version of the file in the Engine disk.
SE Code: 51.1:10 - Problem with the Service Station door sensor Problem Description: Error detected with the sensor on the Service Station Door. System Error Codes Corrective Action: • Check that the Printhead Maintenance Cartridge Door Sensor cable is not damaged and is correctly connected to the Interconnect PCA. • Perform the Sensors service test Page 195. • Replace the Printhead Maintenance Cartridge Door Sensor Page 572.
Corrective Action: • Check that the Media Sensor cable is not damaged and is connected correctly to the Interconnect PCA. • Perform the Substrate Path Sensor service test Page 157. • Replace the Media Sensor Page 573. SE Code: 54:10 - Problem with the Media lever sensor System Error Codes Problem Description: Pinch Lever sensor error detected. Corrective Action: • Check that the Media Lever Sensor cable is not damaged and is correctly connected to the Interconnect PCA.
System Error Codes • If the error is displayed during the printer’s initialization, perform the “6.2 Color Sensor service test” page 181. • If the error is displayed after the printer has initialized, for example when performing a Color Calibration/Linearization, perform the 5.6.3. Open/Close SOLPage 246. – If the Color Sensor Shutter opens and closes, but the error is still displayed, replace Color Sensor Assembly Page 502.
SE Code: 63:04 - Network problem Problem Description: Input/Output problem through the Network Connector. • Check that the network cable is correctly connected to the network connector. • Check that the Printer has the latest Firmware version, if not, update the firmware to the latest version. • If the System Error continues, replace the Main PCA Page 460.
Corrective Action: • Resend the file to be printed on the current paper type. • Change the paper type to the type that was loaded when the file was originally sent. SE Code: 71:19 - Mis-match of printer information Problem Description: System Error Codes Different serial numbers detected in Main NVM (hard disk) and the Backup NVM (in ISS PCA). Corrective Action: • Perform the Error 71:19 Recovery Page 149.
SE Code: 74:04 - Request to upgrade the firmware Problem Description: This error is displayed when the current firmware does not support the installed PrintMech PCA. Corrective Action: • Install the latest firmware through the Embedded Web Server. Problem Description: Embedded Web Server internal software error. Corrective Action: • Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer.
SE Code: 79:04 - Generic firmware error II Problem Description: Generic Firmware error. System Error Codes Corrective Action: • Switch the Power OFF from the back of the Printer and disconnect the Power cord. Reconnect the power cord and power On the Printer. • Check that the Printer has the latest Firmware version, if not, update the firmware to the latest version. • Try using different selections in the RIP to print the image.
• Perform the Substrate Path service test Page 151. • Replace the Media-Axis Motor Page 435. SE Code: 82:01 - Media jam in the platen Problem Description: Media jam detected in the Print Platen area. • Open the window observing all safety procedures and clear the Print Platen of any obstruction. Check especially around the area of the media jam sensor, on the left end of the platen. • Check the cable from the Media Jam Sensor is connected and not damaged.
SE Code: 98:03 - Printhead Nozzles Out Problem Description: None of the 1056 nozzles of one of the printheads is firing. Corrective Action: System Error Codes • Perform the Printhead Nozzles health test Page 224. • Replace the Printhead if the test detects an error. • Perform the Drop Detector calibration, if the calibration fails replace the Drop Detector Page 387.
Service Tests, Utilities & Calibrations Introduction.............................................................................................. 138 • Diagnostics - Self Test ................................................................................... 138 • Phone Support ............................................................................................ 138 Service Tests .............................................................................................
Tests, Utilities & Calibrations • • • • 8.2 Curing ........................................................................................ 190 8.3 Heating (Dryer) IR Sensor ...............................................................191 8.4 Curing IR Sensor .......................................................................... 192 8.6 Heating Resistance ....................................................................... 193 • 9. Cover sensor test ...............................................
2.2.4.1 Print Pattern .........................................................223 2.2.4.2 Manual Alignment Settings....................................223 • 2.3 Substrate Advance ........................................................................223 • 2.3.1 Substrate Advance Adjustment .............................................223 • 2.3.2 Print Adjustment Plot...........................................................223 • 2.3.3 Reset Substrate Advance...............................................
Introduction This chapter explains how to use the Service Tests, Utilities and Calibration. Each part is shown step by step in order that it is displayed on the Front Panel. If the Test, Utility or Calibration should fail and display a system error, we explain where to go in the Service Manual to either troubleshoot the error of fix it directly. NOTE: If possible, always perform the related Service Test on a component that you are about to replace, to confirm it has failed.
3. For On-Site Engineers, hold the Up arrow key and the Cancel key down and switch the printer ON using the front power switch. Wait until you hear one beep (usually after 5 seconds) before releasing ALL three keys. ON AI R REP E -SIT Hold UP key Switch Printer ON Hold Cancel key 4. Once inside the Service Tests Menu use the Arrow keys to scroll through the “Service Tests” selections. Press the OK key to select the highlighted option.
Tests, Utilities & Calibrations 3. Press any key to continue. 4. The printer verifies that all the keys on the Front Panel are working correctly. Ensure the keys are pressed firmly. The printer asks you to push all the key on the Front Panel to verify that they are working, and updates the screen every time you push a key 5. Within 30 seconds, push all the buttons on the Front Panel multiple times. 6. Press any key to continue. 7.
11. The screen displays a white image. 12. After a few seconds the screen displays a black image. 13. The printer asks you to confirm that the two displays were white and black, with no pixelation. 14. Press Cancel to fail the test. If the display was correct, press OK to pass the test. Tests, Utilities & Calibrations 15. Press any key to finish the test. 2. Electrical System Menu 2.
Tests, Utilities & Calibrations 2. A message will display on the Front Panel asking whether you would like to check the Formatter. Select Yes, and press OK to confirm your selection. 3. The printer will get the CPU information and display the information on the Front Panel. Press any key to continue the test: 4. The printer will now get the CPU Fan Speed and display the information on the Front Panel.
7. The Printer will start the CDS and the following information will be displayed on the Front Panel: • Starting CDS. If there is a failure at this point, the Front Panel will display system error code 79:03 page 131. 8. The printer will then check the Serial Number and Part Number and display the information on the Front Panel.
13. A message will display on the Front Panel asking whether you would like to check the PrintMech. Select Yes and press OK to confirm your selection. 14. The Printer will check various electrical subsystem, if there is an error at any time, use the information on chapter 3 page 89, to solve the issue. 15. A message will display on the Front Panel stating that the delSol has been detected and asking whether you would like to Continue. Press any key to continue: 16.
At this stage, the Printer reads and checks the default GPIO values in the Interconnect PCA when all the cables are connected and all the sensors give the default value or the current state. The results will be displayed on the Front Panel and you can press any key to scroll through the information. If any of the channels cannot be read, the Front Panel will display system error code 01.0:10 page 95. 18.
If there is a failure at this point, the Front Panel will display system error code 02.1:10 see page 96. Check also system error code 11:10 see page 98 or system error code 01.0:10 (refer to page 95). • Checking Carriage rev. If there is a failure at this point, the Front Panel will display system error code 02.1:10 see page 96. Check also system error code 11:10 see page 98. 21. A message will display on the Front Panel asking whether you would like to check the ISS Communication.
The front panel displays the following message, use the up and down keys to set the Calibration Value and press the OK key. 3. The following screen is displayed, press the OK key to confirm the selection. 4. The following screen is displayed, press any key to finish. 2.4 All Fans Description This test checks the Printer’s cooling fans. • Curing Fans, • Dryer Fans (Top Cover Fans) • Cover Fans.
3. The following is displayed on the front Panel, the printer tests all the fans are functioning correctly. 4. Check the fans are all rotating, if there are any that are not, stop the test, by pressing the Cancel key, and perform the appropriate troubleshooting procedure. 2.
• Getting Interface info. If there is a failure at this point, the Front Panel will display an error. If no active interface is found, the Front Panel will display “No active interface found. Press any key to finish”. 3. Once the IO information is obtained, it is displayed on the Front Panel. Press any key to exit. 4. Once the process is completed, OK will be displayed on the Front Panel. 2.
Procedure 1. Go to Diagnostic test>2. Electrical System Menu>2.8 SE 71:19 Recovery, and press Ok. 2. The Printer will check if the system error code 71:19 has been recorded and the following message will display on the Front Panel: • Checking SE log. If the Printer fails to find the system error code 71:19, the Front Panel will display Error: Utility not available. In this case press any key to exit. 3.
4. Use the Up and Down keys to go through the digits and press the OK key to go to the next digit. You can press the Cancel key at any time to exit the utility without making any changes. The printer displays the new serial number and part numbers for confirmation. At this point, they are not saved. 5. Double check that the values displayed are what you wanted to enter. If the values are not the correct, press Cancel to reenter them. If the values are correct, press OK to confirm.
Tests, Utilities & Calibrations 3. The following screen is displayed, remove the media and spindle from the printer. 4. Press any key to continue. 5. The printer will now test the Rewinder without the Spindle, moving in an open loop in one direction, after the test the following message is displayed: 6. Press any key to continue. 7. The printer will now test the Rewinder without the Spindle moving in a open loop in the opposite direction, after the test the following message is displayed: 8.
10. The printer will now test the Rewinder with the Spindle, moving in an open loop in one direction, after the test the following message is displayed: 11. Press any key to continue. 12. The printer will now test the Rewinder with the Spindle moving in a open loop in the opposite direction, after the test the following message is displayed: 14. Press OK to continue. The front panel displays the following test, the printer now tests the friction in rewinder with media loaded.
3.2 Drive Roller Description The purpose of this test is to diagnose a failure in the operation of components related to the Driver roller. You must perform the Paper Drive Test after: • System Error Code 81:YX. • System Error Code 41:YX. • System Error Code 73:YX. NOTE: IF POSSIBLE ALWAYS PERFORM THIS TEST BEFORE REPLACING ANY COMPONENT OF THE MEDIA-AXIS. Procedure 1. Go to Diagnostic test>Substrate Path Menu>3.2 Drive Roller. 2.
6. The Printer will now test the Paper Drive moving in an open loop in one direction and the following message will be displayed on the Front Panel. Press any key to continue the test: Check that the movement done is more than 100 encoder units (in absolute value). If the movement done is less than 100 encoder units then open the Window and check for any visible obstacles restricting the movement of the Drive Roller or the Overdrive Assembly. In this case, press any key to finish the test. 7.
Once the Analog Encoder calibration is completed, the Front Panel will display the results: Acceptable values are: • Gain: between 0 and 5 • DGain between 0 and 15 • Offset: between -80 and 80 If the results are acceptable, press OK. If the results are unacceptable, then press the Back/ Cancel key and the Front Panel will display system error code 56:10 page 127. • Starting media Path. • Homing and repeat. test.
If there is a failure at this point, the Front Panel will display: 12. Once the test is completed, OK will be displayed on the Front Panel and then you will be prompted to press any key to shut down the Printer. 13. Press any key to finish the test. 3.3 Substrate Path Sensor Description The purpose of this test is to verify the operation of the following Sensors: • Left and Right Window lock sensors. • Media Lever. • Maintenance Cartridge Door Sensor. • Media Sensor.
6. The Window Sensor will be tested first. When the following message is displayed on the Front Panel, open the Window and press any key to continue. 7. If the Window Sensor passes the test, the following message is displayed on the Front Panel. Close the Window and press any key to continue. Tests, Utilities & Calibrations If the Window Sensor fails the test, the Front Panel will display system error code 51:10 page 125. 8. The Maintenance Cartridge Door Sensor will be tested next.
10. The Media Lever Sensor will be tested next. When the following message is displayed on the Front Panel, raise the Paper Lever and press any key to continue. 11. If the Media Lever Sensor passes the test, the following message is displayed on the Front Panel. Lower the Paper Lever and press any key to continue. If the Paper Lever Sensor fails the test, the Front Panel will display system error code 54:10 page 127. 12. The Media Sensor will be tested next.
If there is an error with the Media Jam sensor, the system error 82:01 is display page 133. 15. If the test passes OK the following message is displayed on the Front Panel, press any key to continue. 16. The following message is displayed. Make sure the parts inside the printer are not too hot. Cover the reflector on the left side of the carriage and at the same time press any key to continue. This verifies that the light going to the sensor is from the reflector and not from another light source.
3.4 Vacuum Description The purpose of this test is to verify the operation of the Vacuum Fans, to check that they are connected and working. 2. The printer asks you to confirm that you want to perform the Vacuum Diagnostic test, select Yes. 3. The printer tests various electrical subsystems and the Vacuum fans. 4. If the Vacuum fans are functioning correctly the following is display. 5. Press and key to finish the test. 3.
The printer displays the OMAS sensor serial number. The format of the OMAS version should be YY WW NNNN Day Week Year If the OMAS is not correctly connected the format of the version number will not be correct. 4. Press any key to finish the test. 3.6 Rewinder Motor Polarity Description The objective of this procedure is to rapidly check that the rewinder motor has been installed correctly.
If there is an error with the Media Jam sensor, the system error 82:01 is display page 133. 3. If the test passes OK the following message is displayed on the Front Panel, press any key to continue. 4. The following message is displayed. Make sure the parts inside the printer are not too hot. Cover the reflector on the left side of the carriage and at the same time press any key to continue. This verifies that the light going to the sensor is from the reflector and not from another light source. 5.
3.8 Solve Media Jam Description We recommend using this test in case you cannot remove the media from the media path after a media jam. This test allows you to move the media motor in both directions. It may help to “push” the media in the direction you want while you are pulling the media to remove it. Procedure 1. Go to Diagnostic test>3. Substrate Path Menu>3.8 Solve Media Jam.
4. Ink system Menu 4.1 ISS Electronics Description The ISS Electronics service test checks the Upper and Lower ISS PCA are connected correctly and functioning. If a failure is found, a system error is displayed which can be used to troubleshoot the error using the information in Chapter 3. Procedure 1. Go to Diagnostic test>4. Ink System Menu>4.1 ISS Electronics. 2. The Printer will check the ISS Communication and the following information will be displayed on the Front Panel: • Starting Sausalito.
Tests, Utilities & Calibrations the system error using Chapter 3: System Error codes page 89. 5. The Printer will pressurize the APS and the Front Panel will display the following message: 6. The Printer will hold the pressure in the APS and the Front Panel will display the following message: 7. The Printer will pressurize the APS and the Front Panel will display the following message: If there is a failure starting the Pump, the Front Panel will display a system error code.
• Starting AcumenSupplies. If there is a problem while reading the Acumen, the Front Panel will display one of the system error codes: • 26.n:10 page 114 • 01.2:10 page 95 • 01.0:10 page 95 If there is a failure at this point, the Front Panel will display the message “Replace failing ink supplies after running this utility”. 3. Once the Ink Supplies information is obtained, it is displayed. Press any key to exit.
4.4.1 Clean Air Tubes Procedure The procedures and menu selections must be performed if there is ink visible in the air tubes of the APS. 1. Remove the Left Cover and check if the tubes from the APS to the ISS are clean. If the tubes are clean of ink this procedure does not need to be performed, go to page 171 and perform the Refill Ink Tubes to clear any air bubbles from the ink tubes.
6. The following message is displayed on the Front Panel, use the up and down keys to select “Yes“ and press “Ok“. 7. The following message is displayed on the Front Panel. 8. The following message is displayed on the Front Panel. 9. Remove the dummy ink cartridge with the two holes and insert it into the other slots that may also have ink in their air tubes, press “OK“ to continue removing ink from the other air tubes.
4.4.2 Recover Broken Bag Description This option recovers the printer to a ready status after a broken bag has been detected in one of the Ink Cartridges. NOTE: This option should only be selected if the following has been performed: • The Ink Cartridge with the broken bag has been replaced with a new Ink Cartridge • The Air Tubes have been cleaned of any ink Tests, Utilities & Calibrations Procedure 1. Go to Diagnostic test>4. Ink System Menu>4.3 Broken Bag Recovery Menu>4.4.
5. The following message is displayed on the Front Panel if no broken bags are found in the Ink Cartridges, press any key to finish the recovery procedure. 4.4.3 Refill Ink Tubes CAUTION: This procedure must only be performed after performing the procedure “4.4.2 Recover Broken Bag” Description The procedures and menu selections must always be performed if a broken bag has been detected by the printer.
Tests, Utilities & Calibrations 6. Check the new Ink Cartridges are installed, press ok to continue. 7. The following message is displayed on the Front Panel, open the Front Cover and Carriage Cover and press OK. 8. The following message is displayed on the Front Panel. 9. Remove the two Printheads of the color affected by the broken bag error, in the example shown below it is Magenta. Press any key on the Front Panel to continue. 10. The following message is displayed on the Front Panel.
11. Insert the needle connected to the syringe into the FI tower of the color affected. Use the FI of the color which is to the rear of the Carriage, as shown. Press “Ok“ to continue. Use this FI Tower Not this FI Tower 12. The following message is displayed on the Front Panel. Tests, Utilities & Calibrations Ink is now pumping through the ink tube, pushing any air bubbles, from the Ink Tubes into the syringe. The amount of ink pumped through the Ink Tube into the syringe is 33cc + air. 13.
14. The following message is displayed on the Front Panel, press any key to continue. 15. The following message is displayed on the Front Panel, press any key to continue. Tests, Utilities & Calibrations 16. The following message is displayed on the Front Panel, press any key to continue. 17.
18. Remove the needle from the FI tower, press any key to continue. TIP: Ink from the syringe can be emptied into the Printhead Cleaning Container. 19. Reinstall the Printheads into the Carriage. Tests, Utilities & Calibrations 20. Close the Carriage and close the Front Window.
5. Scan axis 5.1 Scan Axis Test Description The purpose of this test is to diagnose a failure in the operation of components related to the Scan Axis. Perform the Scan-Axis Test after: • System Error Code 86:YX. • System Error Code 42:YX. • System Error Code 73:YX. • System Error Codes related to Scan-Axis shutdown or Carriage jam. WARNING!: All the cover sensors are disabled when in the service tests menu.
If you select No at this point, the Front Panel will display system error code 02.1:10 see page 96. Check also system error code 11:10 see page 98 If you select Yes, then the Front Panel will display: • Booting up the Carriage. If there is a failure at this point, the Front Panel will display system error code 02.1:10 see page 96. Check also system error code 11:10 see page 98 or system error code 01.1:10 (refer to page 95).
9. At the end of 10 Carriage movements, the Front Panel will display the maximum and minimum length (in encoder units) of the 10 movements and the overall average. If Carriage movement has not been detected or if Carriage movement was very short, the Front Panel will ask you “Did the motor move?”. If the answer is Yes (the Carriage had moved) press OK. If the answer is No (the Carriage had not moved) press the Back key.
12. The Printer will now check the Scan-Axis PWM and the following information will be displayed on the Front Panel: • Starting Scan Axis. • PWM test. If there is a failure at this point, the Front Panel will display a system error code. 13. The Printer will test the PWM at 61 ips and display the results on the Front Panel. If some of the results are incorrect, the Front Panel will show “High Friction”.
The following is displayed indicating the number of cycles of the Scan Axis. Tests, Utilities & Calibrations 2.
6. Carriage Menu 6.1 Carriage PCA Description This test performs specific routines on the Carriage PCA to check for any problems. If a failure is detected, the printer will display a system error code which can be used to troubleshoot the problem. Procedure 1. Go to Diagnostic test>6. Carriage Menu>6.1 Carriage PCA. 2. The Front Panel message is displayed. 6.2 Color Sensor Description The purpose of this test is to troubleshoot an error with to the Color Sensor Test.
4. The Color Sensor information is read and the following message is displayed on the Front Panel, press any key to continue. 5. The Printer will read the Red Reference and the Front Panel will display the following messages: Tests, Utilities & Calibrations 6.
2. The printer retrieves the Carriage Sensors PCA revision and displays it on the Front Panel. 3. Press any key to continue. 4. The printer checks that the Line Sensor NVM reads and writes correctly. To do this, the printer temporarily writes a new serial number on the line sensor NVM then reads the new serial number to verify that the change was made. The printer retrieves the line sensor serial and part numbers and displays them on the Front Panel. 5. Press any key to finish the test. 7.
Tests, Utilities & Calibrations 4. Push the Service Station back a little to the rear, but not all the way, press OK. 5. Pull the Service Station a little to towards the front of the printer, but not all the way, and press OK. 6. Move the Carriage Assembly to the middle of the Scan axis, and press OK. The front panel displays the following message. 7. If the Service Station has moved automatically to the front of the printer press OK. The front panel displays the following message.
8. The front panel displays the results of the test in encoder units. 9. Close the window and press any key to finish the test. 7.2 Drop Detector Test Description The purpose of this test is to check the connection and functionality of the Drop Detector by testing to see if it correctly detects the beam of light used when it s checking the Printhead. 2. The printer checks that the Drop Detector is functioning correctly. 3. If there is a communication error, the following screen is display.
4. If there is an obstruction in the light beam of the Drop Detector, the following message is displayed. Try to clear the obstruction, if this cannot be done replace the Drop Detector page 387. 7.3 Web Wipe Motor Description The purpose of this test is to check the functionality of the Web Wipe Motor and the connection with the Printmech. If a failure is found the appropriate system error is displayed, which can be used to troubleshoot the issue. Procedure 1. Go to Diagnostic tests>7.
3. The following message is displayed, select the pen number (0 to 5) by using the Up and Down keys and press OK to confirm your selection. 0: C-Lc 1: C-Lc 2: Y-B 3: Y-B 4: M- Lm 5: m-Lm 4. The Printer will prime the selected pen and the Front Panel will display the following messages: • Setting pens operational. • Preparing fluid manager. • Priming... • Terminating fluid manager. • Allowing pens not operational.
Tests, Utilities & Calibrations 2. The test detects the 5 measurements of the signal (in milivolts). This is the expected values for a working module in regular status (fan OK and All switches OK). 3. In the same module, after opening the waste door, the reported values are (Fan OK and Fail some switch): 4. When the signal is not arriving to the interconnect PCA (maybe because the waste management is not connected) the voltages detected by the test are: 5.
• The heaters in the Dryer Assembly. • The complete servo system. In order for the test to run, there must be media loaded in the media path. NOTE: In order to obtain an accurate test of the Dryer heating system, the printer must be in a stable temperature condition. Procedure 1. Go to Diagnostic tests>8. Heating and Curing>8.1 Heating Test. The following message is displayed, confirm there is media loaded. 3.
8. The front panel displays the following screen, close the window and press Ok. 9. The printer sets a target temperature of 45C and tries to achieve and sustain the target temperature. In order to achieve this, the closed loop system must work correctly. 10. The printer heats up the print zone to the target temperature, and maintains it there until Ok is Tests, Utilities & Calibrations pressed. 11. Press OK to finish the test, some extra time will now be required while the printer cools down. 8.
The following message is displayed, confirm there is media loaded. 3. The temperature is detected and checked that it is stable. 4. The following message is displayed, remove the Curing IR Sensor from its place in the printer, but do not disconnect it. Press Ok. 5. Point the Curing IR temperature sensor at your hand and check that the temperature changes. 6. Press OK to continue or Cancel if the value did not change or is not as expected. The printer sets a target temperature of 80C.
Tests, Utilities & Calibrations 2. The following message is displayed, confirm there is media loaded. 3. The printer displays the current temperature detected by the temperature sensor and checks that the temperature is stable. If the readings are not immediately stable, the printer turns on the vacuum and the fans and checks again for one minute (up to 4 times) before displaying a failure. 4. The front displays the following message. Open the window and press OK. 5.
The following message is displayed, confirm there is media loaded. 3. The temperature is detected and checked that it is stable. 4. The following message is displayed, remove the Curing IR Sensor from its place in the printer, but do not disconnect it. Press Ok. 5. Point the Curing IR temperature sensor at your hand and check that the temperature changes. 6. Press OK to continue to finish the test or Cancel if the value did not change or is not as expected. 8.
Tests, Utilities & Calibrations 3. The following message is displayed on the front panel, use the up and down arrows to change the resistor value to match with the resistor value of the ‘Burst’ resistor. This value is also provided with the part from the factory. Press enter when finished. 4. Confirm that the values have been correctly entered and press the OK key. 5. Press enter to finish and shut down the printer. The resistor values will come with the service part from the factory.
9. Cover sensor test 9.1 Cover Switch Sensor Description The printer checks the functionality of the sensors of the covers. 2. The Printer will initialize the sensors 3. The Front Panel will display the various electrical subsystems being initialized in order to perform the test, if there is a failure at this point the Front Panel will display a system error, troubleshoot the system error using Chapter 3: System Error codes. 4.
7. The Maintenance Cartridge Door Sensor will be tested next. When the following message is displayed on the Front Panel, open the Maintenance Cartridge Door Sensor and press any key to continue. 8. If the Maintenance Cartridge Door Sensor passes the test, the following message is displayed on the Front Panel. Maintenance Cartridge Door Sensor and press any key to continue. If the Maintenance Cartridge Door Sensor fails the test, the Front Panel will display system error code 51.1:10 page 126.
11. The Media Sensor will be tested next. When the following message is displayed on the Front Panel, raise the Media Lever, load paper, lower the Media Lever, and press any key to continue. 12. If the Media Sensor passes the test, the following message is displayed on the Front Panel, raise the Media Lever, unload paper, lower the Media Lever, and press any key to continue. If the Paper Lever Sensor fails the test, the system error 53:10 is displayed page 126 13.
If there is an error with the Media Jam sensor, the system error 82:01 is display page 133. 16. If the test passes OK the following message is displayed on the Front Panel, press any key to continue. 17. The following message is displayed. The carriage assembly moves along the Carriage path testing the Media Jam Sensor as it goes along the scan axis. If there is an error with the Media Jam sensor, the system error 82:01 is display page 133. Tests, Utilities & Calibrations 18.
10. Diagnostic Utilities 10.1 Force Normal Boot Description This selection must be made after you no longer want the printer to constantly boot in diagnostic mode. After this selection is made the printer will boot as normal This feature is also included in the Service Menu. Procedure 1. Go to Diagnostic tests>10. Diagnostic Utility Menu>10.1 Force Normal Boot. The printer changes the configuration. 2. Press any key to finish. 10.
Procedure 1. Go to Diagnostic tests>10. Diagnostic Utility Menu>10.2 Report Tests Version. 2. The printer displays the diagnostic menu version. 3. Press any key to finish the test. 10.4 Enable/Disable Logs Description Enabling logs is a useful tool when troubleshooting any error with the printer when the cause of the error is not obvious, the printer can log all printer activity up until the error occurred, this can give clues as to the cause and solution to the error.
5. Press any key to finish and shut down the system. 10.5 Hard Disk Recovery Description Use this test to reinstall the firmware in the HDD of the printer. It may be useful when the printer cannot initialize or it “hangs” from time to time without any clear cause. This will fix all the possible issues related to “data/file” corruption.
4. This screen shows a warning and warns you if you continue; the test will format the main partition of the Hard Disk and reinstall the firmware stored in a secondary partition of the Hard Disk. Emergency Firmware Upgrade Tests, Utilities & Calibrations The following procedure can be used if the printer cannot be turned on in normal mode because of an error, or if the EWS has been disabled in the Front Panel.
Service Menu 1. Service Test and Utilities Menu page 204 2. Image Quality Plots page 222 3. Inks On Substrate Test page 225 4. Reset Life Counters page 226 5. Service Calibration menu page 227 These service utilities help you to service, maintain, and clean the printer. This section guides you through the service utility procedures and provides information about each utility. Entering the Service Utilities Menu 1.
4. Use the Arrow keys to scroll to the “Service Utilities” menu and press the OK key. 5. Use the Arrow keys to scroll through the “Service Utilities” selections and press the OK key to begin a specific operation when the required Service Utility is highlighted. 1. Service Tests and Utilities Menu 1.0 Boot Mode Menu Tests, Utilities & Calibrations 1.0.
3. Press OK to change the bootmode. Press Cancel to make no changes and to exit. 1.0.2 Force normal Mode Description This selection must be made after you no longer want the printer to boot in diagnostic mode. After this selection is made the printer will boot as normal. This feature is also included in the Diagnostic Menu. 2. The printer asks you to confirm. 3. Press ok to change to the boot mode. 1.0.3 Force Firmware Upgrade Description This test changes the boot mode of the unit.
2. The printer asks you to confirm, press Enter. 3. On next reboot you must reinstall new firmware. 1.1 Report Tests Version Description Some parts of the FW can be upgraded independently than the rest. Tests, Utilities & Calibrations For example, if we consider that a service test must be changed but the FW of the unit (for regular customer work) is stable and not need any change, it’s possible to release a new FW file that contains ONLY a new version of the test files.
2. The Printer displays the current time (HH:MM:SS) and date (MM:DD:20YY) and a space for you to enter the new time and date. 3. Use the Up and Down keys to go through the digits and press the OK key to go to the next digit. You can press the Cancel key at any time to exit the utility without making any changes. Once the new time has been entered, the Front Panel displays the time that you have entered. 4.
2. The utility checks to see if the firewall is enabled or disabled, and then prompts you to enable or disable the firewall. 3. Use the Up and Down keys to choose to enable/disable and press the OK key to confirm your selection. If the utility exits correctly, OK is displayed on the Front Panel. 1.2.3.
5. If the utility exits correctly, OK is displayed on the Front Panel. The printer must be rebooted to enable the logs 1.2.4 Input/Output Description This test is checking the performance of the LAN chip in the formatter. Is does NOT check the external LAN components, in fact you could run this test even with the LAN cable not connected and the results will be exactly the same. If the test fails you must change the formatter PCA. 2.
5. The front panel displays the following message. 6. The front panel displays the following message. 1.2.5 Set Serial Number Description The purpose of this Service Utility is to set the Serial Number and Part Number of the Printer. Tests, Utilities & Calibrations Procedure 1. Go to Service Test Menu >1.2.5 Set Serial Number. 2. The Printer will display the current Serial Number and the new Serial Number of the Printer.
Procedure 1. Go to Service Test Menu >1.2.6 Sleep Mode. 2. When the following message displays on the front panel, use the Up and Down arrow keys to either disable or enable the sleep mode. Press the OK or Cancel key to confirm the selection. If the current sleep mode cannot be read, it could point to a possible Firmware error. 3. Once the selection is confirmed, the Front Panel will display the new sleep mode state: If the current sleep mode cannot be set, it could indicate a possible Firmware error.
3. The Drive Roller begins to turn slowly and the following message is displayed on the Front Panel: 4. Refer to the Cleaning Instructions on page 620. 5. Once you have finished cleaning the Drive Roller and the Overdrive, press the Cancel key to exit. NOTE: Please remember to remove the piece of paper from the window sensor before closing the window as this could damage the window and the sensor. 1.3.2.
2. Shows the temperature measured by the TOMAS sensor: 3. The test asks to place a standard paper sheet over the OMAS window:. 4. It tries to calibrate the level of illumination needed to navigate the paper. At this point, if it is not able to find the correct illumination the test will display the FAIL message and will finish. In that case, it could be that the OMAS module is defective or that the power from the OMAS controller PCA is not reaching the OMAS module. 5.
1.4 Ink System Menu 1.4.1 Purge Tubes Description The purpose of this is to Prime the Tubes when the Ink Tubes are NOT new and they need to be re-primed or automatic priming was not completed correctly. NOTE: Make sure that NEW Ink Cartridges are installed or that the ink volume remaining in the Ink cartridges is below 88% before starting to prime the tubes. If you do not comply, you will get a warning message. Tests, Utilities & Calibrations Procedure 1. Go to Service Menu >1.4 Ink System Menu>1.4.
6. Once ALL the Printheads have been removed, the Front Panel will instruct you to install the Setup Printheads into the Carriage. 7. Once all the Setup Printheads are installed, the following message will display on the front panel. Close the carriage cover and close the window. 8. The printer will begin to purge the tubes system. 9. Once the tubes system has been purged, the following message will instruct you to open the Window: 11.
3. The printer asks you to check that the ink is ready and all the pinch lever is closed. 4. Check that the ink is ready, and the pinch lever is in the closed position. Press any key to continue, the following message is displayed. Tests, Utilities & Calibrations The printer performs a drop detection and displays the drop detector values on the Front Panel. NOTE: The drop detector values for nozzles out should be below 150 nozzles per printhead. If they are not print the “2.4.
The printer tells you that it will begin to warm up the color sensor, press any key to continue The printer warms up the Color Sensor for ten minutes, and displays the time remaining. The printer performs the calibration. The results are displayed on the front panel, press any key to finish the test. 1.6.2 Replace Cutter Description The purpose of this Service Utility is to move the Carriage to a position where the Cutter can be replaced easily. Procedure 1. Go to Service Menu >1.6 Carriage Assembly>1.
3. 4. The Carriage will move to the Cutter replacement position and the following message will be displayed on the Front Panel. After a few seconds the Printer will begin to shutdown. Before replacing the Cutter, make sure that you switch the Printer OFF from the rear. 1.7 Service Station 1.7.1. Prime Pen X Description The purpose of this is to prime a specific pen. Tests, Utilities & Calibrations Procedure 1. Go to Service Menu >1.7 Service Station>1.7.1 Prime Pen X. 2.
1.7.2 Ink Funnel Roller Description Use this test to visually check if the ink funnel roller rotates. If it does not rotate, it could be because the ink funnel is defective or because the transmission from the overdrive has failed. 2. Open the front door. 3. Check if the Spit roller is turning. 4. Close the front door to finish the Test. 1.8 Heating and Curing 1.8.
1.8.2 Enable Heating and Curing Description This setting enables you to disable the heating system of the printer. This setting is useful for example if you want to print a quick print to test the printer’s functionality, but did not want to wait for the printer to heat up to the target temperature. Tests, Utilities & Calibrations Procedure 1. Go to Service Menu >1.8 Heating and Curing Menu>1.8.2 Enable Heating and Curing. 2.
2. Press the OK key to exit. 1.12 Force Firmware Upgrade Description With this option selected the firmware of the printer must first be updated before it will initialize. Procedure 1. Go to Service Menu >1.12 Force Mandatory FW upgrade. 2. Press OK to accept the mandatory firmware upgrade mode. 1.14 Hard Disk Recovery Description Use this test to reinstall the firmware in the HDD of the printer.
3. Select OK. 4. This screen shows a warning and warns you if you continue; the test will format the main partition of the Hard Disk and reinstall the firmware stored in a secondary partition of the Hard Disk. 2. Image Quality Plots 2.1 Print ALL Plots Tests, Utilities & Calibrations Description The Print ALL Plots allows you to print at once all three basic diagnostic prints in order to diagnose an image quality defect. These are the Printhead Alignment, the Printheads Health and Substrate advance.
Procedure 1. Go to Service Menu >2. Image Quality Plots>2.2 Printheads Alignment Menu>2.2.3 Automatic Printhead Alignment. 2.2.4 Manual Printhead Alignment Menu Description Automatic printhead alignment may not produce optimal registration under certain conditions. Substrate texturing, elasticity and the behavior of the substrate under different temperatures may lead to some imperfections with regards to printhead registration. In these circumstances select the Manual Printhead Alignment instead. 2.2.4.
Procedure 1. Go to Service Menu >2. Image Quality Plots>2.3 Substrate Advance>2.3.3 Reset Substrate Advance. 2.4 Printheads Health 2.4.1 Print Test Plot Description The purpose of this Service plot is to show the overall health of the printheads nozzles by visual inspection. Refer to Chapter 5 for detailed information. Procedure 1. Go to Service Menu >2. Image Quality Plots>2.4 Printheads Health>2.4.1 Print Test Plot. 2.4.
Procedure 1. Go to Service Menu >2. Image Quality Plots>2.4 Printheads Health>2.4.5 Clean LM-M Printheads 2.5 Geometry Check Description The purpose of this Service plot is to provide a template for checking the printer's length accuracy and figure distortion. Refer to page 262 for further information on this procedure. Procedure 1. Go to Service Menu >2. Image Quality Plots>2.5 Geometry Check. 2.
4. Reset Life Counters (NEVER DONE BY CUSTOMER) 4.0 Reset Maintenance Kit Usage Description The purpose of this Service Utility is to check the maintenance kit usage and/or reset the life counter of all the components included in the maintenance kit. Procedure 1. Go to Service Menu >4. Reset Life Counters>4.0 Reset Maintenance Kit Usage. 2. Select the Service Maintenance Kit for which you want to reset the life counters. • 4.0.
4.6 Reset Carriage Menu Description The purpose of this Service Utility is to check the service part usage and/or reset the life counter for the Carriage: • • • • • 4.6.1 Carriage Cycles: Reset the cycles of the Carriage 4.6.2 New Line Sensor: Reset the Line Sensor (hours) 4.6.3 Cutter Cycles: Reset the cutter cycles (number of times substrate has been cut) 4.6.4 Color Sensor: Reset the SOL (hours) 4.6.5 Carriage Lubrication: Resets the Carriage lubricant 4.
5.3 Substrate Path Menu 5.3.1 Substrate Advance Calibration Description The purpose of this Service Calibration is to calibrate the nominal advance of the media. This calibration is necessary to control the exact movement of the media in order to avoid print quality problems like banding. Perform the Service Accuracy Calibration whenever: • Banding is detected in prints. • Drive Roller is disassembled or replaced. • Paper-axis Assembly is disassembled or replaced.
4. When the Paper Motor has been initialized, the printer starts to perform the series of paper advances. During this process, the front panel displays the current iteration number and the total number of iterations. You can cancel the calibration process at any time by pressing Cancel. In this case, the previous calibration values are restored and the cancelled process has no effect on the printer. 5. If the calibration process finishes without errors, the new calibration values are checked.
Tests, Utilities & Calibrations 2. Select Check Advance Calibration. 3. At the end of the process, the printer checks whether the current calibration values are valid, using the data obtained during the paper advances. If the values are considered valid, then the following message will be shown. 4. If they are not valid, the front panel displays the reason (for example, the AMP1 parameter value is greater than the maximum allowed). 5. Press OK to return to the main screen. 6.
The Printer will begin the Drive Roller Cleaning procedure. This could take several minutes during which the following message will be displayed on the Front Panel. 8. Reboot the printer after performing the tests. 5.3.2 OMAS calibration Description The purpose of this Service Calibration is to calibrate the OMAS Module. The calibration process consists of printing a special calibration plot and then scanning it with the printer.
3. If media is already loaded, the following message displays on the front panel and the media is unloaded. 4. If the media cannot be unloaded automatically, the Front Panel will show the following message. 5. Follow the instructions and unload the media. 6. The Front Panel prompts you to load media. Tests, Utilities & Calibrations NOTE: During this calibration process you have to load the media with the Carriage positioned in the print path. • Raise the Media Lever. • Load the media.
9. The Front Panel then prompt you to unroll 1 meter of media to avoid back tension. Unroll 1 meter of media and press OK. 10. The Printer will start to print the OMAS Calibration Pattern. This could take several minutes during which the following message will be displayed on the Front Panel. 11. Once the OMAS Calibration Pattern has been printed successfully, the following message will be If the OMAS Calibration fails for any reason, a warning message will display on the Front Panel.
Tests, Utilities & Calibrations 2. When the following message displays on the front panel, you must select whether you would like to continue with the calibration by pressing the OK key. Press Back or Cancel to exit the calibration. 3. A message will display advising you that you will need to load the OMAS Calibration Pattern in to the Printer. Make sure that you rotate the printed pattern 90° clockwise and reload it printed-side down. Press the OK key to continue. 4.
6. The Printer will scan the OMAS Calibration Pattern which could take several minutes. Once the calibration is completed successfully, the following message will be displayed on the Front Panel. Press the OK key to continue. If the OMAS Calibration fails for any reason, a warning message will display on the Front Panel. In this case, try the following: • Check that the OMAS Calibration Pattern was not incorrectly cut (trimming the actual pattern) during the media load process.
5.3.4 Rewinder Voltage Calibration Description This test must be performed whenever the Rewinder Assembly has been replaced or one of the rewinder gears have been replaced. The test calculates the optimum power required to move the rewinder system. Procedure 1. Go to Service Menu >5. Service Calibration Menu>5.3 Substrate Path Menu>5.3.5 Rewinder CO Voltage Calib. 2. The front panel displays the following screen, press ok to continue.
• Center Platen is disassembled or replaced. NOTE: Make sure you load one of the following media into the Printer before performing this calibration. If none of them are available use the service part Q1273-60296: • HP Bond Paper. • HP Glossy Media. • HP Coated Paper. • HP Productivity Photo Gloss. • HP Heavyweight Coated Paper. • HP Super Heavyweight Coated Paper. • HP Bright White Inkjet Paper. NOTE: Disabling the Heaters ‘1.8.2’ will significantly speed up this procedure 2.
WARNING!: Make sure you keep your hands away from the Print Platen as the Carriage will be moving at high speed and you could injure yourself or damage the Carriage Assembly. 4. The Printer will start to check the PWM. Once the PWM has been checked, the results will be displayed on the Front Panel. Press OK to continue or press Back or Cancel to exit the calibration. 5. The Printer will start to calibrate the Line Sensor.
8. The Printer will now perform the Printhead Alignment. 9. When the following message displays on the front panel, you must select whether you would like to continue with the calibration by pressing the OK key. Press Back or Cancel to exit the calibration. 10. Once the Printhead Alignment is completed, the following message will be displayed on the Front If the Printhead Alignment fails for any reason, a warning message will display on the Front Panel.
2. When the following message displays on the front panel, you must select whether you would like to continue with the calibration by pressing the OK key. Press Back or Cancel to exit the calibration. 3. The Printer will start to calibrate the Drop Detector. Once the Drop Detector has been calibrated, the results will be displayed on the Front Panel. Press any key on the Front Panel to finish the calibration. 4. Once the calibration is completed, OK will be displayed on the Front Panel. 5.
Procedure 1. Go to Service Menu >5. Service Calibration Menu>5.6 Carriage Menu>5.6.1 Line Sensor Calibration. 2. When the following message displays on the front panel, you must select whether you would like to continue with the calibration by pressing the OK key. Press Back or Cancel to exit the calibration. 3. If media is not loaded, the following message displays on the front panel. Load media in to the Printer and start again from step 1. • The Media Lever is in the lowered position.
Tests, Utilities & Calibrations 5. The Printer will start to calibrate the Line Sensor position to the Black Printhead. It will print a line of black dots and then scan them: 6. Once the Line Sensor has been calibrated, the results will be displayed on the Front Panel. Press OK to finish the calibration or press Back or Cancel to exit the calibration. 7. The Printer will now perform the Printhead Alignment. When the following message displays on the front panel, select the OK key. 8.
5.6.2 Primer Calibration Description The purpose of this Service Calibration is to find the optimum position of the Primer Assembly with respect to the Carriage. The calibration is a visual procedure so you will have to remove the Right Hand cover before starting. 2. Remove the Right Cover page 331). 3. Block the Printhead Cleaning Cartridge door switch in the closed position. 4. When the following message displays on the front panel, press any key to continue. 5.
8. Use the Up (move left) and Down (move right) keys to move the Carriage until the RIGHT edge of the Left Alignment Mark is correctly aligned with the Primer Positioning Indicator and press ENTER.
10. Once the Right Scan-Axis Offset has been calculated the Front Panel prompts you use the Up/ Down keys to move the carriage until the LEFT edge of the Right Alignment Mark is correctly aligned with the Primer Positioning Indicator and press ENTER. 11. Use the Up and Down keys to move the Carriage until the LEFT edge of the Right Alignment Mark is correctly aligned with the Primer Positioning Indicator and press ENTER.
While the Carriage is moving the Front Panel shows the actual position and the direction of movement and prompts you to press ENTER when done. 12. The Front Panel shows the actual right offset value. 13. The calibration process continues and front panel shows the following messages as the new nominal Tests, Utilities & Calibrations offset value is read and saved to NVM: • Reading Nominal Offset. • New Nominal Offset is [ActualValue]. • Saving to nvm. • Saved. 14.
• Opening SOL Shutter • Reading Lab values with SOL Shutter Open • Analyzing SOL Shutter Open status. If there is a failure at this point, the Front Panel will display system error code 58:10 page 127. If the utility exits correctly, OK will be displayed on the Front Panel. Tests, Utilities & Calibrations 4.
Tests, Utilities & Calibrations 248 Chapter 4 Service Tests, Utilities & Calibrations
Print Quality • Print Quality 5 Initial Print Quality Troubleshooting Actions ........................................................................250 • How to Use the Image Quality Plots...........................................................................250 • 2.2.1 Printhead Alignment Test Plot ............................................................................ 251 • 2.4.1 Printheads Health Test Plot................................................................................
Print Quality Initial Print Quality Troubleshooting Actions For the vast majority of print quality problems, a Call Agent should request that the customer performs the troubleshooting actions in the Maintenance and Troubleshooting Guide in the section ‘Troubleshooting print-quality issues. Most problems can be resolved using these procedures without the need for an on-site visit.
If you do not see any problems with the Image Quality Test, then the problem may not be with the printer itself. The problem may be with the RIP. The following is printed when ‘Print all plots’ is selected. 2.2.1 Printhead Alignment Test Plot To print this test plot go to Menu List>2. Image Quality Plots>2.2 PH Alignment Menu>2.2.1 Test Plot. This test is designed to check the accuracy of the current printhead alignment. The plot consists of five different areas: 1.
Print Quality The die 1 and die 2 of the black printhead is used as a reference to which the rest of the pens are compared. The substrate does not move while the pattern is being printed. If the Printer is experiencing horizontal misalignment problems, the Alignment Test will print the lines in the orientation shown below (A). If the Printer is experiencing vertical misalignment problems, the Alignment Test will print the lines in the orientation shown below (B): B A 2.
3. Nozzle check and Paper Axis Die to Die Registration The colors are printed with a halftone, low-ink area fill, in a one pass printmode. The small arrows point to the place where two different printhead dies meet. No significant light or dark lines should be seen at this point. Manual Alignment reset the alignment back to factory defaults. The patches also provide a basic judgment about the printhead nozzle status. Horizontal bands indicate weak or missing nozzles.
Print Quality choose to use the Manual Printhead Alignment instead, refer to page 223. Correct Incorrect 5. Scan Axis Angular Check The small arrow point to the place where the lines printed in subsequent passes meet using unidirectional printmode. The registration must be checked at that point. The check should be done for the MLm, KY and CLc printheads. Note that the substrate advances between the upper and lower parts of the plot. This test mainly relies on the changing surface of the substrate.
In this example of the plot the print shows a nozzles health pattern without any failing nozzles. In this case, the case shown corresponds to the black color. This is an example of nozzles outs. You can see the broken or the skewed line, in this case marked in yellow to help you to understand the issue. In the service plot there are no yellow marks. This is an example of nozzles mis-positioned or malfunctioning.
Print Quality 2.3.2 Print Adjustment Plot Printing direction (paper axis) To print this test plot go to Menu List>2. Image Quality Plots>2.3 Substrate Advance>2.3.2 Print Adjustment Plot. This plot enables you to visually determine the accuracy of the media advance, if there are any advancement issues they will appear in this diagnostic plot. The plot can be used to precisely measure the media advance error with a one dot row accuracy to verify the stability of the media advance.
Print Quality A perfectly calibrated printer will show a straight vertical lighter line in the 0 column. If the lighter line is printed in any of the other columns, this would indicated there is a constant advance offset along the entire plot. If the offset is bigger than ± 2.95mm per meter (the lighter column is not the center one), this can be adjusted by using the button on the front panel to change the compensation of the substrate advance as the printer prints.
Print Quality 2.4.2 Advanced Printhead Health Test Plot The Advanced Printhead Health Test Plot is not part of the large diagnostic print, but it is similar to the Printhead Health Test Plot described previously. With this plot however you will be able to identify which of the Printhead Nozzles is actually failing. To print this test plot go to Menu List>2. Image Quality Plots>2.4 Printheads Health>2.4.2 Advanced Test Plot.
This example on the left has many nozzle outs. The unfilled white rectangles indicate the nozzle is not firing. In this example, the zoomed area has 6 faulty nozzles. The corresponding nozzle number can be seen directly from the print. This is an example of good nozzle health. All rectangles are perfectly filled with the printhead’s color.
Print Quality 2.2.2 Advanced Alignment Diagnostic Print This plot helps you to visually check any alignment problems of the printer, it is similar to the process already described on Page251, but in more detail. You use it to precisely measure the alignment error with a one dot row accuracy. To print this test plot go to Menu List>2. Image Quality Plots>2.2 PH Alignment Menu>2.2.2 Advanced Test Plot The plot is split into two main areas.
In this area there are four checks for the pen to pen alignment in the scan axis direction (Pen2PenFwd or Pen2Pen-Rev). It is forward and reverse. • The top pattern is related to the front printhead (nearest to the user when doing the pen replacement). • The bottom pattern is related to the rear printhead (furthest from the user when doing the pen replacement). The area to check is the junction (marked with a “-”) of the black with the rest of colors. 2.
Print Quality 2.4.3 Plot for escalation only To print this test plot go to Menu List>2. Image Quality Plots>2.4 Printheads Health>2.4.3 Only For Escalations. There are two identical plots to this test and each plot has three parts to it. The first plot refers to the rear printheads (number 1, 3, 5), while the second plot refers to the front printheads (2, 4, 6).
Find the vector length accuracy by selecting parallel vectors and/or figure distortion by measuring the diagonals in the selected area. 4. Note the measurements to access the printer’s performance. It will help to keep the measured vectors identified by using the name convention marked on the plot i.e. A1, A3. This makes it easier to identify exactly the areas of the plot where the measurements were taken.
Print Quality The test plot consists of six horizontal color bands with a black pattern mask on top of them. Each band is split in to two horizontal areas corresponding to the die 0 and die 1 for the specific color. The plot is printed in unidirectional mode at 40ips. Corrective action If an fault is found with the encoder strip, replace the Encoder Strip page 412. 2.
Select the appropriate one according to the following table. Selection When to select Low Ink 30-50 inches RIP profile ‘Low Ink’, roll width between 30-50 inches. Low Ink 50-60 inches RIP profile ‘Low Ink’, roll width between 50-60 inches. High Ink 30-50 inches RIP profile ‘Low Ink’, roll width between 30-50 inches. High Ink 50-60 inches RIP profile ‘Low Ink’, roll width between 50-60 inches. 3. Print Quality 2. At the next screen select confirm to print.
Print Quality Find below an image of the plot and when during the printing the vacuum levels can be checked (red) and when during the printing they should be changed (blue). Recommendations to modify the vacuum level during the plot Print the first pattern with the default vacuum level for the Front Panel family. This way you can know if the default value is good. IMPORTANT NOTE: The default family vacuum level is not necessarily the one selected in the RIP profile.
Corrective Action • • • • • • • • • • Vacuum is TOO LOW. Substrate cockle-like shape does NOT follow the same shape as the platen ribs. This may produce Vertical Banding with a similar shape as the cockle. Increase the vacuum +20 mm H2O. Vacuum is OK – it could also be too high. Substrate cockle-like shape follows the same shape as the platen ribs. The vacuum level should be set at the minimum vacuum level that shows this shape. If vacuum level is excessive the shape is the same.
Print Quality Checking the Main substrate advance pattern Pattern Corrective Action • • • Substrate advance is OK. Light band is uniformly centered on the pattern. Max deviation acceptable is ±1 band. • • • Substrate advance is NOT OK. Light band is uniform but not centered on the pattern. The printer can provide good Image Quality but the substrate advance setting needs to be adjusted.
Secondary • • • • Both vacuum level and substrate advance are OK. Secondary pattern looks similar to main pattern: uniform and centered. • Print Quality Comparing the Secondary substrate advance pattern with the Main one Main Substrate advance is OK Vacuum level is NOT OK This is named differential substrate advance. Secondary pattern is different than the main pattern, typically non-uniform, with a smooth oscillation, while the main pattern should be uniform and centered.
Print Quality Other plot information The pictures below show some other features of this plot that can be useful for diagnostic. 2.8 Misregistration Check This plot helps you to visually check any alignment problems of the printer caused by media expansion. You use it to precisely measure the media expansion error with 2 dots row accuracy. To print this test plot go to Menu List>2. Image Quality Plots>2.8 Misregistration Check. The plot is split into two main areas, the left (B) and the right (A) areas.
3.1 Inks on Substrate Test The Inks on Substrate Test plot is used to determine the level of performance of the Drying and Curing Assemblies and to determine if they are performing as expected. To print this test plot go to Menu List>3. Inks On Substrate Test>3.1 Print Ink Test Plot. At the beginning of the plot is an area used to stabilize the printing system before the diagnostic print is printed, this area can be ignored.
Print Quality To evaluate the Curing test plot look at the squares that show ink smudge when touched (see picture) or that show an ‘oily finish’ (which is more likely). The following table shows the maximum quantity of ink (the darkest patch) that can be printed using HP Permanent Gloss Adhesive Vinyl without producing any of the issues previously stated.
Upon approximately 60cm of the job done, increase Curing Temperature +5°C (105°C) through the Front Panel, mark the 105°C step on the job. To do this go to Ink Menu> Image quality Maintenance> Adjust Curing Temperature. 5. Wait for 40cm more of the job done and then increase Curing Temperature +5°C (110°C), mark the 110°C on the job. 6. Wait for 40cm more of the job done and then increase Curing Temperature +5°C (115°C), mark the 115°C on the job. 7.
Print Quality Substrate advance issues The vast majority of issues concerning the advancement of the substrate can be solved by asking the customer to clean the ‘Substrate-advance sensor window’. This procedure is described in the customer document ‘Maintenance and Troubleshooting Guide’. If after performing this, the customer is still experiencing image quality issues related to the advancement of the media, use the following procedure. 1.
There is an advance issue a List of types of media which are NOT used (non navigable) by the OMAS media sensor: Replace the TOMAS HP or HP Approved Clear Film HP or HP Approved Backlit Clean OMAS and reload the paper HP or HP Approved types of Matt film Print Quality Advance error with the Substrate or with OMAS? NO Perform the TOMAS check HP or HP Approved types of Polypropylene A non HP or HP Approved Media Test passed YES b Launch the user advance calibration adjustment In order to perform
Print Quality 276 Chapter 5 Print Quality
Ink Supplies • • • • • • • • • • What are Ink Supplies?.......................................................................................278 General Information About the Ink Supplies ........................................................... 281 General Precautions When Handling Ink Supplies ..................................................282 Priming the Ink System ........................................................................................
What are Ink Supplies? For each of the six ink colors used in the printer, there are three separate components, the Printhead, the Maintenance Cartridge, and the Ink Cartridge. All of these components are called Ink Supplies.
Ink Cartridges The printer's six Ink Cartridges provide yellow, magenta, light magenta, light cyan, cyan, and black ink to the Printheads. There’s NO Introductory Ink Cartridges supplied with the printer. The ‘Host’ Ink Cartridges which are purchased hold approximately 775ml. The Ink Cartridges for the HP Designjet Printer series require no maintenance or cleaning. As long as each Ink Cartridge is inserted correctly into its slot, the ink will flow to the Printheads.
Waste Management System Printhead Cleaning kit The Printhead cleaning kit for the HP Designjet L26500 Printer series is the HP 792 Printhead cleaning kit P/N CR278A. It consists of three main items: Printhead Cleaning Cartridge, Ink Funnel and the Ink Filter. Printhead Cleaning Cartridge Use the Printhead cleaning kit to clean and maintain the Printheads, ensuring the best possible print quality, and to seal the Printheads when they are not in use, preventing them from drying out.
Ink Maintenance Kit To maintain the status of the printhead nozzles, the printer expels a few drops of ink from each nozzle of each printhead into the Waste Ink Collection System. This is done at the start of each print job, during printing, whenever a printhead is replaced, and whenever you request a printhead check. It consists of three main items: Ink Funnel and the Ink Filter (shown above).
• The Ink Cartridges should never be removed while the printer is printing. They should only be removed when the printer is ready for you to replace them. The front panel will guide you through the removal and installation procedure. General Precautions When Handling Ink Supplies Ink Supplies CAUTION: Do not touch, wipe or attempt to clean the printhead nozzles. This can damage the printhead. • Handle the ink supplies with care.
The Printer will also display the ink level and will tell you when the ink supply is low on ink. This means you have constantly updated information about the ink supplies. Printhead guarantied life is 1000 ml although the printheads usually last much longer. See the section about the ‘Warranty Information for Ink Supplies’ page 290. ”Obtaining Ink Cartridge Information”. Use the following procedure to obtain Ink Cartridge information: 1. Scroll to the Ink Menu icon and press OK.
• The color of the Ink Cartridge. • The product name (HP no.792 is recommended). • The product number of the Ink Cartridge. • The serial number of the Ink Cartridge. • The current status of the Ink Cartridge. • The current ink level of the ink cartridge in milliliters. • Original capacity of the ink cartridge in milliliters. • The expiration date of the Ink Cartridge. • The warranty status of the Ink Cartridge. • The manufacturer of the Ink Cartridge (HP is recommended).
4. The front panel displays information on the selected printhead. The information supplied is: • The color • The product number of the Printhead (hp no. 792 is recommended). • The serial number of the Printhead. • The current status of the printhead. • How much ink has been fired (consumed) by the printhead. Note: It is possible for a printhead to consume more than one Ink Cartridge. • The current warranty status of the Printhead. Status Bars The front panel displays four horizontal bars.
Missing The Ink Cartridge has not been installed or is installed incorrectly. The Printer will not print until ALL Ink Cartridges have been installed correctly. Reseat Replace The Ink Cartridge is having continuity problems. Try removing the Ink Cartridge from the Printer and inserting it in again. The Ink Cartridge is faulty and needs to be replaced before the printer can continue printing. Wrong Cartridge The Ink Cartridge installed is not the expected one (different color or different ink).
Printhead Status Messages While Replacing The following are the Printhead status messages that may be displayed while replacing the Printheads. Reseat Remove Missing In this situation, select the Printhead replacement option through the Front Panel but do NOT remove the Printheads. If this status message continues to appear then remove the Printheads and install them again. The Printhead is not a suitable type for use in printing (for example, a Setup Printhead).
Cannot insert an Ink Cartridge 1. Use the correct procedure to change Ink Cartridges, through the Front Panel. Refer to the User´s Guide for further details. 2. Check that there is no obstruction in the Ink Cartridge connector. 3. Check that the Ink Cartridge is the correct color. A connector of an Ink Cartridge will refuse to connect to a cartridge of an incorrect color 4. Ensure that the Ink Cartridge is the correct orientated (compare it with the others). Cannot insert a Printhead 1.
The error code is ALREADY CONVERTED TO HEXADECIMAL and you could go directly to the table below. In the example we can see several pens rejected reporting error code (0x00010 TEMP EXTREMELY HIGH). The following table explains the meaning of the different hexadecimal values: • In the Error Code you may see some “combined” numbers, like for example (80010). In that case you have 2 combined in one number 80000 means Expired and 10 means Temp extremely high.
• Most probable cause the line sensor is dirty and cannot read the white label on the cleaning cartridge. In that case the solution is to change/clean the line sensor. Review that the aerosol extraction system is working, if it does not work the aerosol will go again on to the line sensor and the customer will have the same problem sooner or later. • In some extreme cases even after changing the line sensor, the counter of the Cleaning Cartridge was not reseated.
Parts and Diagrams • • • • • • • • • • • • • • • • • • • • Printer Support...................................................................................................292 Front Covers ......................................................................................................293 Top & Rear Covers .............................................................................................294 Electronics Module ................................................................................
Printer Support Parts and Diagrams Part Number Part Description Page 1 CQ869-67041 Leg Cover N/A 2 CQ869-67015 Foot Assembly N/A 3 CQ869-67042 Foot Brace Assembly N/A 4 CQ869-67039 Legs Assembly N/A 5 CQ869-67034 Cross-Brace Assembly N/A 6 Q6651-60264 Stand Supports (left and Right) N/A 7 CQ869-67065 SPI Load Accessory Parking N/A - CQ869-67040 Stand Hardware Kit (Includes screws for Legs Assembly) N/A 292 Chapter 7 Parts and Diagrams
Front Covers Part Description Page 1 CQ869-67029 Window Assembly 323 2 CH956-67037 Window Mylar 3 CH956-67016 Transparent Window 4 CH955-67047 Window Locks 5 CQ869-67017 Left & Right Curing Cover 342/ 340 6 CH955-67046 Window Lock Sensor 356 7 CQ869-67057 Window Hinges 328 8 CH956-67034 Window Lock Sensor Cable Front Covers 293 Parts and Diagrams Part Number
Top & Rear Covers Parts and Diagrams Part Number Part Description Page 1 Q6652-60124 Rear Cover 344 2 CQ869-67044 Right Connector Cover 353 3 CH955-67048 Top Cover Fan (with grill) 360 4 CQ869-67028 Top Cover 346 5 CH955-67050 Top Cover Fan Diffusors (all fan diffusors are included) 6 CH956-67015 Top Cover Fans Cable 7 CH955-67088 Rear Dryer Fan (contains 1 fan) 8 CH956-67033 Dryer Fans Cable 294 Chapter 7 Parts and Diagrams 362
Electronics Module Part Description Page 1 CQ869-67007 Electronics Module Cables Kit N/A 2 CH955-67021 Sausalito PCI PCA 457 3 CQ869-67061 OMAS PCA 450 4 CQ869-67043 Main PCA Formatter (Includes Processor, Heatsink & Fan).
Right Cover Parts and Diagrams Part Number Part Description Page 1 CQ869-67006 Right Cover (without Right Door) 331 2 CQ869-67012 Printhead Maintenance Cartridge Door 571 3 CH955-67025 Right Trim 334 4 Q1273-60240 Front Panela 364 5 CQ869-67011 Front Panel Bezel 364 6 Q6651-60343 Quick Reference Guide Holder CM765-67001 Svs Door Sensor Assy w Screws a.
Left Cover Part Number Part Description Page CQ869-67005 Left Cover 337 2 CQ869-67010 Left Trim 339 Parts and Diagrams 1 Left Cover 297
Right Hand Assemblies Parts and Diagrams Part Number Part Description Page 1 Q1273-60086 Right Scan-Axis Bracket 2 CQ869-67026 Service Station Assemblya 375 3 Q6651-60266 Primer Valves and Primer Tubes Assembly 368 4 CQ869-67071 Service Station Cable (Includes Printhead Cleaning Cartridge Door Sensor) 375 5 CH955-67095 Vacuum Fan Assembly 380 6 Q6651-60265 Primer Assembly 366 7 CH955-67053 Web Wiper Motor Assembly 378 8 CH955-67064 Rewinder Motor and Gears a.
Waste Management System Part Description Page 1 CQ869-67052 Waste Ink Tube Guide 385 2 CQ869-67060 Drop Detector and Funnel Transmission 387 3 CQ869-67053 Ink Funnel 387 4 CQ869-67063 Waste Tubes (with Ink Funnel) 387 5 CQ869-67038 Ink Waste Management 387 Waste Management System 299 Parts and Diagrams Part Number
Left Hand Assemblies Parts and Diagrams Part Number Part Description Page 1 CH955-67028 Cartridge Trays 566 2 CH955-67014 Lower Ink Supply Station (without APS Assembly but including Cartridge Tray) 400 3 CH955-67013 Upper Ink Supply Station (without APS Assembly but including Cartridge Tray) 400 4 CQ869-67009 Left Scan-Axis Bracket N/A 5 Q1273-60245 ISS to Cartridge Cable N/A 6 CQ111-67002 APS Assemblya 408 7 Q6651-60272 Color Sensor Actuator 506 8 CH955-67054 ISS PCAs 9
Carriage Assembly Part Description Page 1 CQ869-67062 Line Sensor Assemblya 498 2 CH956-67005 Encoder Sensor (Includes Encoder Strip) 412 3 CQ869-67004 Carriage Assemblyb 421 4 CH955-67007 Cutter Assembly 398 5 Q6651-60341 Carriage Bumper (includes Carriage Bumper Screw and MediaAxis Motor Bracket) 421 6 CH955-67101 Color Sensor (SOL) 502 7 Q6651-60335 Setup Printhead Kit N/A 8 CH955-67099 Carriage Flex Cables 418 9 Q6651-60338 Carriage PCA 415 10 CH955-67083 SOL Shut
Dryer Assembly Part Number Page 515 CQ869-67035 Dryer Module (includes thermal switch, resistors) CR030-67001 Dryer Module (includes thermal switch, resistors) (Japan) 2 CH956-67030 Dryer Grill 508 3 CH956-67018 Dryer IR Temperature Sensor 510 4 CH955-67103 CAL Thermal Switch Dryer SERV 5 CQ869-67054 SPI Dryer Plastic Isolators 6 CQ869-67051 SPI Dryer Enclosure 1 Parts and Diagrams Part Description 302 Chapter 7 Parts and Diagrams
Curing Assemblies Part Description Page 1 CQ869-67032 Curing Module base (without Heaters & Fans) 544 2 CH955-67089 Curing Holder Bracket 554 3 CQ869-67019 Curing Trims (Left and Right) 544 4 CH955-67104 Curing Thermal Switch 534 5 CH956-67036 IR Curing Sensor Fan 528 6 CH956-67021 IR Curing Sensor 528 CH956-67041 Curing Resistors 534 CQ162-67001 Curing Resistors (Japan) 534 8 CH956-67031 Curing Grill 534 9 CH956-67028 Curing Resistor Holders 534 - CH956-67043 Barri
Curing Fans Assembly Part Number Part Description Page CQ869-67033 Curing Fans Cover (without fans) 544 2 CH955-67062 Curing Fan 544 3 CH956-67023 Curing Fan cable 4 CQ869-67064 SPI AirCURTAIN Deflector Parts and Diagrams 1 304 Chapter 7 Parts and Diagrams
Scan-Axis Assemblies Part Description Page 1 CH956-67005 Encoder Strip and Encoder Sensor Kit 412 2 Q6652-60128 Scan-Axis Motor 432 3 CQ869-67037 SRK and TC (Ink Supply Tubes and Trailing Cable) 392 4 CH955-67002 Ink Supply Tubes Clips 392 5 Q6652-60126 Rear Tube Shelf and Brackets 392 6 CQ111-67003 Belt and Tensioner Assembly 421 - CH955-67111 Broken Bag Fixing Tools 170 - CH955-67123 Carriage shutdown kit (Includes Belt and Tensioner, Lubrication Felts, oil and spittoon che
Drive Roller and Media-Axis Motor Parts and Diagrams Part Number Part Description Page 1 Q6652-60123 Drive Roller Encoder Kit 432 2 Q1273-60242 Drive Roller Gears and Drive Roller Brake Kit 591 3 Q6652-60109 Drive Roller 591 4 Q6652-60108 Media Advance Drivea a.
Media Path Assemblies Part Description Page 1 CQ869-67027 Center Platena 556 2 CH956-67004 Output Platen 552 3 CH955-67065 Output Roller Support (& Pins) 570 4 Q1273-60103 Input Roller Lever 568 5 CQ869-67045 Entry Roller 568 6 Q6651-60270 OMAS Module 437 7 Q6651-60269 OMAS Cable 452 8 CH955-67066 TOMAS Assembly 444 9 Q6652-60114 Entry roller SERV 60” CQ869-67049 Media Edge Holder a.
Center Guide and Pinchwheel Assembly Parts and Diagrams Part Number Part Description Page 1 CH956-67047 Complete Pinchwheel Assemblya 583 2 Q6652-60130 Center Guide 589 3 CQ869-67021 Media Presence Sensor 573 4 Q6651-60319 Media Lever Assembly 578 5 Q1273-60082 Media Lever Sensor 581 6 Q6651-60066 Pinchwheel Kit (spare Pinchwheels and interpinches are also included in the User Maintenance Kit) 583 a.
Media Entry Assemblies 1 Part Description Page 597 CH955-67040 Right Rollfeed Module Assembly CQ869-67036 SPI 2 inch Spindle Support CQ869-67030 SPI 3 inch Spindle Support 3 CQ869-67016 Right Rollfeed Housing Cover 597 4 CH955-67037 Spindle Hub N/A 5 CQ869-67003 Left Rollfeed Module Assembly 598 6 CH955-67107 Cal Spindle Left Endcap - CQ869-67048 Media Loading Accessory 2 Media Entry Assemblies 309 Parts and Diagrams Part Number
Take-Up Reel Assembly Parts and Diagrams Part Number Part Description Page 1 CQ869-67066 Take-Up Reel Deflector Support Assembly 603 2 CQ869-67022 Take-Up Reel Left Hand Module (includes Motor) 600 3 Q6706-60910 Thumbscrew 608 4 CQ869-67023 TUR sensor module SERV 608 5 CQ869-67031 Take-Up Reel Spindle Assembly 6 CQ869-67059 Take-Up Reel Shelf (Deflector) 7 Q6652-60902 Take-Up Reel Tubes Assembly 8 CQ869-67025 Take-Up Reel Spindle Hubs, Deflector Supports, TUR Screws +cable ti
Miscellaneous Parts Part Number Part Description Page CH955-67114 Right Arc 597 2 CH955-67115 Left Arc 597 - CH615A HP 792 Black Latex Designjet Ink Cartridge CH616A HP 792 Cyan Latex Designjet Ink Cartridge CH617A HP 792 Magenta Latex Designjet Ink Cartridge CH618A HP 792 Yellow Latex Designjet Ink Cartridge CH619A HP 792 Light Cyan Latex Designjet Ink Cartridge CH620A HP 792 Light Magenta Latex Designjet Ink Cartridge CH612A HP 792 Yellow/Black Printhead CH613A HP 792 Cyan/Light
Parts and Diagrams 2 312 Chapter 7 Parts and Diagrams 1
Removal & Installation Two contents lists are provided for this chapter to help you to quickly find the service part you want to replace. The first list is provided in Service Part Order and the second in Disassembly Order. Service Part Order • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Introduction ....................................................................................................... 319 Screw Types .....................................................................
Removal & Installation Service Part Order (Continued) • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Front Panel ........................................................................................................364 Hard Disk Drive (HDD)........................................................................................462 Heaters Control Assembly ...................................................................................
Service Part Order (Continued) Right Trim ......................................................................................................... 334 Sausalito PCI PCA ............................................................................................. 457 Scan-Axis Motor................................................................................................ 432 Service Station ..................................................................................................
Removal & Installation Disassembly Order • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Introduction ....................................................................................................... 319 Screw Types ..................................................................................................... 320 Window ...........................................................................................................323 Hinge Brakes ...................
Disassembly Order (Continued) Scan-Axis Motor................................................................................................ 432 Media-Axis Motor ............................................................................................. 435 Optical Media Advance Sensor (OMAS) .............................................................. 437 TOMAS: Temperature Optical Media Advance Sensor ........................................... 444 TOMAS Cable ........................................
Disassembly Order (Continued) Media Lever Sensor............................................................................................ 581 Pinchwheel Assembly..........................................................................................583 Individual Pinchwheel Rollers ...............................................................................586 Center Guide ....................................................................................................589 Drive Roller ...........
Introduction This chapter is a step-by-step guide to the removal and installation of the key components of the printer. You may find it useful to tick off the steps as they are performed. Use the illustrations for each procedure to identify the parts referred to in the text. The procedures appear in order of removal. So the whole machine can be stripped down by starting at the beginning of this chapter and working through the subsequent procedures.
Removal & Installation Screw Types Type Torx Length (mm) Head Type Thread Type Part Number A B C D E F G H I J K L M N O P Q R S T-20 T-20 T-10 T-8 T-15 T-15 T-15 T-15 T-10 T-15 T-8 T-8 T-20 T-20 T-20 T-15 T-20 T-15 T-15 17 10 7.0 5.5 9.5 12.7 12.7 8.0 20 9.5 12.7 35 12.7 11.6 18.
Opening the Window WARNING!: Before opening the Window, observe all safety precautions when working in the area of the Dryer Assembly. Make sure that the temperature of the print zone has sufficiently cooled down. 1. Switch off the printer from the on/off switch and remove both power cables from the back of the printer. Removal & Installation 1. Unlock the two Window Locks 2. Open the Window.
Removal & Installation 3. Wait five minutes for the printer to cool down.
Window Removal WARNING!: Switch off the printer and remove the power cable. 1. Open the Window See page 321. 4. Loosen two screws on the connector of the Dryer IR Temperature Sensor cable, by hand or with a flat screwdriver, and disconnect. 5. Remove one T25 screw, one lock washer, one normal washer that secures the grounding cable. WARNING!: To ensure the electrical safety of the Printer, it is very important that this grounding cable is reinstalled after the new part has been installed.
WARNING!: When reinstalling the grounding cable, it is an important safety point that the washer is installed between the printer and the grounding cable. Plain washer Black locking washer Removal & Installation 6. Push the grounding cable to one side. 7. Remove one T-20 screw from a cable clamp that secures the grounding and Dryer Temperature Sensor cable to the left Arc. 8. Remove two T-20 screws that secure the Left Cable Plate to the printer.
9. Rotate (1) and remove (2) the Left Cable Plate. Removal & Installation 10. Disconnect the Dryer Power Cable. 11. Rest all the disconnected cables on the Platen. 12.
13. Disengage the Right Hinge Brake. TIP: To disengage the brake, slowly open the Window, at the same time, insert an Wrench Key or small screwdriver into a hole in the Hinge Shaft and slide it to the left. You may have to open and close the Window several times to gain access the hole. 14. Slide the shaft all the way to the left until its Removal & Installation disengaged. 15. The right side of the Window is now loose. 16.
Removal & Installation 17. Remove the Window.
Hinge Brakes Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover See page 337. Removal & Installation 2. Remove the Window See page 323. 3. Remove two T-15 screws from the Right Hinge Brake. 4. Remove one T-15 screw from the back of the Right hinge Brake. NOTE: A long screw driver attachment is required to remove this screw 5. Remove the Right Hinge Brake.
6. Remove four T-20 screws from the grill of the Top Cover Left Fan. 8. Leave the Top cover Left Fan and diffuser on the platen. 9. Remove two T-15 screws from the Left Hinge Brake. Hinge Brakes 329 Removal & Installation 7. Remove the grill of the Top Cover Left Fan.
10. Remove one T-15 screw from the back of the Left hinge Brake. NOTE: A long screw driver attachment is required to remove this screw. Removal & Installation 11. Remove the Left Hinge Brake.
Right Cover Removal WARNING!: Switch off the printer and remove the power cable. 1. Using a suitable small flat-blade screwdriver, unclip the 2. Remove the Front Panel Bezel from the Right Cover. 3. Remove two T-15 screws (Type G) that secure the Front Panel to the Right Cover. 4. Remove one T-15 screw. 5. Remove the metallic part. Right Cover 331 Removal & Installation Front Panel Bezel from the Right Cover.
6. Open the Maintenance Cartridge Door. 7. Remove one T-15 screw (Type J) that secures the Right Removal & Installation Cover. 8. Open the Window See page 321. 9. Remove one T-15 screw (Type J) that secures the Right Cover.
10. Remove one T-15 screw (Type J) that secures the Right Cover. 11. Remove one T-15 screw (Type J) and one T-20 screw (Type A) that secure the Right Cover from the rear of the Printer. Type A 12. Remove the Right Cover from the Printer. CAUTION: When installing the Right Cover, make sure you leave the Printhead Maintenance Cartridge Door open, otherwise you could damage the sensor of the door.
Right Trim Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. Removal & Installation 2. Remove the Output Platen See page 552. 3. Raise the Media Lever. 4. Remove one T-15 screw (Type F) that secures the Media Lever to the Linkage. 5. Disconnect the Media Lever from the Linkage.
6. Remove one T-20 screw (Type F) that secures the Media Lever to the Right Trim. 8. Unroute the cable of the Media Lever Position Sensor from its clip to avoid putting strain on the Media Lever Position Sensor connections during the removal of the Right Trim. 9. Remove two T-20 screws that secure the Right Trim. Right Trim 335 Removal & Installation 7. Remove the Media Lever from the Printer.
10. Carefully remove the Right Trim sufficiently to gain access to the Media Lever Position Sensor. 11. Unclip the Media Lever Position Sensor of its mounting Removal & Installation lugs on the Right Trim. 12. Remove the Right Trim from the Printer.
Left Cover Removal WARNING!: Switch off the printer and remove the power cable. 2. Remove one T-15 (Type J) screw that secures the Left Cover at the top. 3. Remove one T-15 (Type J) screw that secures the Left Cover at the bottom. Left Cover 337 Removal & Installation 1. Open the Window See page 321.
4. Remove one T-20 screw (Type J) that secures the Left Cover. 5. Remove one T-15 screw (Type J) that secures the Left Removal & Installation Cover. 6. Remove one T-20 screw (Type J) that secures the Left Cover. 7. Remove the Left Cover from the Printer.
Left Trim Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Remove the Output Platen See page 552. 2. Remove three T-20 screws that secure the Left Trim. 3. Carefully remove the Left Trim from the Printer.
Left Curing Cover Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Open the Window See page 321. 2. Remove three T-20 screws from the Left Curing Cover. 3. Remove one T-10 screw from the Left Curing Cover.
Removal & Installation 4. Remove Left Curing Cover by sliding it off.
Right Curing Cover Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Open the Window See page 321. 2. Remove three T-20 screws from the Right Curing Cover. 3. Remove one T-10 screw from the Right Curing Cover.
Removal & Installation 4. Remove Right Curing Cover.
Rear Cover Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 344 2. Remove the Left Cover See page 337. 3. Remove seven T-20 screws (Type G) and the four T-15 screws (Type X) from the Rear Cover. Type X NOTE: Each Type X screw includes a washer (part number 3050-1267). Removal & Installation Type X 4. Open the Rear Cover slightly (as shown, approximately 30 degrees). 5.
Removal & Installation 6. Remove the Rear Cover from the Printer.
Top Cover Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Remove the Left Cover See page 337. 3. Remove the Rear Cover See page 344. 4. Release the clip securing the Ink Supply Tubes and the Removal & Installation Trailing cable to the Top Cover. 5. Release the Ink Supply Tubes and Trailing Cable from the clip underneath the Top Cover. 6. Press the clip to release it from the Top Cover.
7. Remove the clip from the Top Cover. 9. Position the Ink Supply Tubes so they are resting on the Platen. 10. Remove four T-20 screws from the grill of the most Left Top Cover Fan. Top Cover 347 Removal & Installation 8. Unroute the Trailing Cable from the Top Cover.
11. Remove the grill. Removal & Installation 12. The Left Top Cover Fan and Diffuser is now loose. 13. Disconnect the cable from the Left Top Cover Fan. 14. Remove the Left Top Cover Fan and Diffuser.
15. Remove two T-20 screws that secure the front plate to the front of the Top Cover. 16. Remove the front plate 17. Remove one T-10 screw that secures the earth cable to the left side of the printer. 18. Disconnect the cable of the Top Cover Fans. Top Cover 349 Removal & Installation Tip: Close the Window a small amount.
19. Remove the cable of the Top Cover Fans from a 2nd clip on the rear of the Left Arch. Removal & Installation 20.Remove the two locking plates. 21. Lift up the right end of the Top Cover to release it from the right arch. 22. Close the Window.
2 23. Slide the Top cover to the Left (1) and then raise the Top Cover (2). 1 24.Slide the Top Cover in the direction of the arrow to Removal & Installation release the two locking clips. 25. Remove the clip from the right arch. 26. Move the cable to the side.
27. Push the cable of the Top Cover Fans through a hole in the right Arch. Removal & Installation 28.Remove the Top Cover.
Right Connector Cover Removal WARNING!: Switch off the printer and remove the power cable. 2. Unroute the TUR cable from the Right Connector Cover. 3. Disconnect the TUR Module Cable. Right Connector Cover 353 Removal & Installation 1. Disconnect the TUR connector.
4. Remove two T-20 screws (Type B) from the Right Connector Cover. 5. Rotate the Right Connector Cover a few degrees Removal & Installation counter-clockwise so it can be removed completely. 6. Remove the Right Connector Cover from the Printer.
Electronics Module Extension Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove ten T-20 screws (Type B) from the Electronics 2. Rotate the Electronics Module Extension approximately 90 degrees counter-clockwise. 3. Remove the Electronics Module Extension from the Printer. Electronics Module Extension 355 Removal & Installation Module Extension.
Window Lock Sensor Left Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Remove the Left Curing Cover See page 340. 2. Disconnect the Left Window Lock Sensor. 3. Remove the cable of the Left Window Lock Sensor from a holding point on the Left Curing Cover. 4. Remove two T-8 screws that secure the Left Curing Sensor.
5. Remove a metal plate from the Left Curing Sensor. Removal & Installation 6. Remove the Left Window Lock Sensor.
Window Lock Sensor Right Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Remove the Right Curing Cover See page 342. 2. Disconnect the Right Curing Sensor. 3. Remove the cable of the Right Window Lock Sensor from a holding point on the Right Curing Cover. 4. Remove two T-8 screws that secure the Right Curing Sensor.
5. Remove a metal plate from the Right Curing Sensor. Removal & Installation 6. Remove the Right Window Lock Sensor.
Top Cover Fans Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Open the Window See page 321. Top Left & Middle Fans 2. Remove four T-20 screws that secure the Top Cover Fan to the Top Cover, 3. When the last T-20 screw is being removed, support the Fan Assembly underneath with your hand to catch it.
4. Slide the Fan and Diffuser assembly towards you. 6. Remove the four T-15 screws that secure the Fan to the Diffuser Assembly. Top Cover Fans 361 Removal & Installation 5. Disconnect the cable from Fan and Diffuser Assembly.
Rear Fans Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Remove the Rear Cover See page 344. 2. Disconnect Rear Fan Cable. 3. Remove three T-20 screws that secure the Rear Fan. 4. Remove the Rear Fan.
5. To remove the Rear Fan Array Cable, remove two Removal & Installation plastic clamps to release the cable from the array of Fans.
Front Panel Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Remove the Right Connector Cover See page 353. 3. Disconnect the Front Panel Cable from the Interconnect Removal & Installation PCA. 4. Disconnect the Ferrite clip (located on the rear of the Electronics Module) from the front of the Printer. 5. Move the Front Panel Cable (including the ferrite) out of the Electronics Module.
6. Release the Front Panel Cable from the Right Arc. 8. Remove two T-15 screws (Type G) that secure the Front Panel to the Printer. 9. Remove the Front Panel from the Printer. Front Panel 365 Removal & Installation 7.
Primer Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Remove the Right Connector Cover See page 353. 3. Remove the Front Panel See page 364. 4. Disconnect Primer Assembly cable from the from Removal & Installation Interconnect PCA. 5. Unroute the Primer Assembly cable from the from cable clamp. 6. Disconnect the two Primer Assembly tubes.
7. Remove four T-10 screws that secure the Primer Assembly to the Service Station. NOTE: Use a short screw driver, less than 10 cm in length. 8. Remove the Primer Assembly from the Service Station. Installation of the Primer Assembly 1. When installing the new Primer Assembly, it is important to note that the internal tube (red) is shorter than the external tube (green). 2. Reset “4.7.7. Primer Cycles” See page 227. 3. Perform the Calibration “5.6.2 Primer Calibration” See page 243.
Primer Valves Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Remove the Right Connector Cover See page 353. 3. Disconnect both Primer Valves from the from Interconnect PCA. Removal & Installation NOTE: The upper connection is identified as number 5 and the lower connection as number 6. These identification numbers correspond to the actual Primer Valves identification. 4. Unroute the Primer Valves cables from the from cable clamp. 5.
6. Disconnect the two Primer Assembly Tubes. Removal & Installation 7. Unclip the Primer Valve Tubes from the Service Station. 8. Disconnect the Primer Valve Tubes at the Y-Piece. 9. Unclip the lower Primer Valve.
10. Remove the lower Primer Valve (identified as 5). 11. Unclip and remove the upper Primer Valve (identified Removal & Installation as 6 and with an identification mark on the tube). 12. Remove the Primer Valves from the Printer. NOTE: When installing the Primer Valves, use the identification marks on the Primer Assembly Tubes and the identification numbers to ensure they are correctly connected. 13. Remove two T-15 screws that secure the Primer Valves Mounting Plate from the printer.
14. Remove Primer Valves Mounting Plate from the printer Installation of the Primer Assembly 1. When installing the new Primer Assembly, it is Removal & Installation important to note that the internal tube (red) is shorter than the external tube (green).
Rewinder Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Remove the Right Cover See page 331. 2. Lift up the Spindle lock and remove the Spindle 3. Remove the Right Leg Cover. 4.
5. Disconnect the power cable from the Rewinder motor. 6. Disconnect the Black Cable from the Left side of the 7. Disconnect the Red Cable from the Right side of the Rewinder Motor. 8. Remove two T-20 screws from the left side of Rewinder Assembly.. NOTE: A long screwdriver is required to reach the screws.
9. Remove two T-20 screws from the right of Rewinder Assembly. NOTE: A long screwdriver is required to reach the screws. 10. Remove the Rewinder Assembly making sure that you do not drop the gears.y. Removal & Installation NOTE: The gears of the Rewinder assembly are loose and could fall as you remove the assembly. Installation 1. Important: Note the position of the gears when installing the Rewinder Assembly, as they can fall from the assembly while being installed. 1.
Service Station Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Primer Assembly See page 366. 3. Primer Valves See page 368. 4. Remove the Drop Detector See page 387. 5. Remove the Printhead Maintenance Cartridge See the User’s Guide. 7. Disconnect the cable from the Maintenance Cartridge Door Switch. Service Station 375 Removal & Installation 6. Disconnect the Web Wipe Motor cable.
8. Disconnect the Service Station cable from the Interconnect PCA. Removal & Installation 9. Unroute the Service Station. 10. Unroute the Primer Assembly Valves tube from the Service Station. 11. Remove two T-15 screws (Type J) that secure the rear of the Service Station to the Chassis.
12. Remove two T-15 screws (Type J) that secure the Service Station to the Chassis. CAUTION: When removing the screws, be very careful NOT to damage the Encoder Strip. CAUTION: When removing the screws that secure the Service Station to the X-Axis, hold the Service station as it could fall when the screws are removed. 13. Remove the Service Station from the Printer. NOTE: After installing the NEW Service Station, make sure you perform the following Service Utility: • Reset “4.7.
Web Wipe Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Remove the Right Connector Cover See page 353. 3. Remove the Primer Assembly See page 366. 4. Remove the Primer Valves See page 368. 5. Remove the Printhead Maintenance Cartridge See the User’s Guide. 6. Remove the Service Station See page 375. 7. Release two clips on the right side of the Service Removal & Installation Station. 8.
9. Remove the Web Wipe Assembly. 10. Reset “4.7.5 Service Station cycle counter” Removal & Installation page 227.
Vacuum Fan Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Remove the Right Connector Cover See page 353. 3. Remove the Primer Assembly See page 366. 4. Remove the Primer Valves See page 368. 5. Remove the Printhead Maintenance Cartridge See the User’s Guide. 6. Remove the Service Station See page 375. 7. Release the Pinch Lever Sensor Cable from the Vacuum Removal & Installation Fan. 8.
9. Unclip the cables from the cable clamp. 10. Unroute both Vacuum Fan cables from the Interconnect 11. Remove four T-20 screws (Type B) that secure the Vacuum Fan to the Printer. 12. Remove the OMAS cable clamp from the printer. Vacuum Fan 381 Removal & Installation PCA.
13. Lower then lift the Vacuum Fan out of its attachment. 1 2 Removal & Installation 14. Remove the Vacuum Fan from the Printer. Cable 2 Cable 1 NOTE: When connecting the Vacuum Fan cables to the Interconnect PCA, make sure you connect the cable with the label marked Vacuum Fan 1 to connector 1 and the cable with the label marked Vacuum Fan 2 to connector 2. You can verify if both cables are labelled correctly by the actual markings on the Vacuum Fan.
Waste Ink System Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Remove the Printhead Cleaning Container. 2. Disconnect the Waste Ink Tube. 3. Put a cap on the end of the Waste Ink Tube to prevent waste ink leakage.
4. Disconnect the Waste Ink System cable. 5. Remove one T-15 screw from underneath the Waste Ink Removal & Installation System 6. Open the top of the Waste ink System (1), remove two T-15 screws from the Waste Ink System. 7. Lift up the Waste Ink System (1) and remove (2).
Waste Ink Tube Guide Removal WARNING!: Switch off the printer and remove the power cable. 1. Open the Window See page 321. 1. Remove the Right Cover See page 331. 2. Remove the Drop Detector See page 387. 3. Remove two T-8 screws that secures the top of the Drain 4. Remove one T-10 screw that secures the Waste Ink Tube Guide. 5. Slide off the retaining ring from the Waste Ink Tube Guide.
Removal & Installation 6. Slide off the assembly from the Service Station.
Drop Detector, Funnel Transmission, Waste Ink Tube Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Open the Window See page 321. 3. Pull out the Printhead Cleaning Cartridge fully from the 4. Slide the Carriage Assembly into the print path so you access the Drop Detector. 5. Pull the bottom of the Waste Ink Tube assembly from the Printhead Cleaning Container.
6. Cover the end of the old ink tube with the cap or a cloth to stop ink leaking out. 7. Pull the slider with one finger (1) while removing the Ink Removal & Installation Funnel with the other hand (2). 8. Pinch the sides of the Funnel Transmission (1) and lift up the assembly (2). 9. Lift up the Waste Ink Tube Assembly.
10. Remove the Waste Ink Tube Assembly. Removal & Installation 11. Remove two T-8 screws. 12. Remove the blue slider and Drop Detector Cover. 13. Disconnect the Drop Detector Cable from the Service Station Cable.
14. Release the Drop Detector Cable from the Service Station. Removal & Installation 15. Disconnect the spring. 16. Remove the spring. 17.
18. Remove the Drop Detector from the Printer. NOTE: After installing a new Drop Detector, perform the following: • “5.5.2 Drop Detector Calibration” page 239. • Reset “4.7.4 Drop detector cycle” Removal & Installation page 227.
Ink Supply Tubes and Trailing Cable Removal WARNING!: Switch off the printer and remove the power cable. CAUTION: You MUST NEVER replace both the Hard Disk Drive and the ISS PCAs (or the Ink Supply Tubes and Trailing Cable) at the same time. If these parts need to be replaced, you MUST first replace one part and then power ON the Printer until it completely initializes. Then power OFF the Printer and replace the other part. 1. Remove the Right Cover See page 331. 2. Remove the Left Cover See page 337.
9. Release the two plastic clips securing the Trailing Cable to the Right Arc. 10. Press the two side of the Carriage PCA Cover and unclip from the Carriage Assembly. 2 11. Disconnect the Trailing Cable from the Carriage PCA. 12. Open the Carriage Cover and remove ALL the Printheads from the Carriage Assembly.
13. Remove three T8 screws from the metal plate on the right side of the carriage. 14. Remove five T-15 screws (Type G) that secure the Ink Removal & Installation Supply Tubes to the Carriage Assembly. 15. Remove the Ink Supply Tubes from the Carriage Assembly and safely place to one side of the Printer. 16. Remove one T-20 screw (Type B) from two plastic holders at the rear of the Printer.
17. Disconnect the Air Tubes from the Ink Cartridge Tube Connector. 18. Disconnect the Electrical Cable from the rear of the Ink 19. Unroute the Electrical Cable and Air Tubes from the rear of the Ink Cartridge Tube Connector. 20.Twist the four latches at the rear of the Ink Cartridge Tube Connector and release the complete assembly. NOTE: Be careful not to damage the interconnecting cable. Ink Supply Tubes and Trailing Cable 395 Removal & Installation Cartridge Tube Connector.
21. Remove one T-20 Screw from the Sideplate (grounding cable). 22. Carefully slide the Ink Cartridge Tube Connector off the Removal & Installation Ink Supply Station. 23. Remove the Ink Supply Tubes and Trailing Cable from the Printer. Installation of the Ink Supply Tubes and Trailing Cable NOTE: After installing the NEW Ink Supply Tubes and Trailing Cable, reset the life counter “4.5.2 Tubes/Trailing Cable” page 226.
ISS to Cartridge Cables Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover See page 337. 2. Disconnect the ISS to Cartridge Cable from the ISS 3. Release the clips securing the ISS to Cartridge Cable. 4. Remove the ISS to Cartridge Cable from the Printer. ISS to Cartridge Cables 397 Removal & Installation PCA.
Cutter Assembly Removal 1. Select “Replace Cutter” from Service Menu (refer to Chapter 4) and follow the instructions on the Front Panel. 2. Open the Window. Removal & Installation 3. Open the Carriage Cover. 4. Remove one T-15 screw (Type G) that secures the Cutter Assembly to the Carriage Assembly.
5. Slide the Cutter Assembly to the left and remove from the Printer. Removal & Installation NOTE: After installing the NEW cutter, reset the life counter “4.6.4 cutter cycles” page 227.
Ink Supply Station (ISS) Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover See page 337. 2. Remove the Scan-Axis Motor See page 432. 3. Pull out the top row of Cartridge Trays and remove the Ink Cartridges. 1 Removal & Installation 2 4. Close the top row of Cartridge Trays and pull out the bottom row. 5. Pull out the bottom row of Cartridge Trays and remove the Ink Cartridges.
6. Disconnect the top and bottom Air Tubes from the Ink Supply Tubes. 7. Disconnect the Electrical Cable from the rear of the Ink Removal & Installation Cartridge Tube Connector. 8. Unroute the Air Tubes and Electrical Connector. 9. Remove one T-20 Screw from the Sideplate (grounding cable).
10. Twist the four latches at the rear of the lower Ink Cartridge Tube Connector and release the complete assembly. 11. Lift the Cartridge Tube Connector off the Ink Supply Removal & Installation Station. 12. Remove the Cartridge Tube Connector from the Ink Supply Station. 2 1 13. Unhook Ink Supply Station cables from the printer.
14. Remove the complete Ink Supply Station (upper and lower assemblies) from the Printer.
Ink Supply Station PCAs (Upper and Lower) Removal WARNING!: Switch off the printer and remove the power cable. NOTE: You MUST NEVER replace both the Hard Disk Drive and the ISS PCAs (or the Ink Supply Tubes and Trailing Cable) at the same time. If these parts need to be replaced, you MUST first replace one part and then power ON the Printer until it completely initializes. Then power OFF the Printer and replace the other part. 1. Remove the Left Cover See page 337. 2.
5. Twist the four latches at the rear of the lower Ink Cartridge Tube Connector and release the complete assembly. 6. Slide the Upper and Lower Cartridge Tube Connectors Removal & Installation out of the ISS Assembly (but do not remove) to gain access to the Upper ISS PCAs. 7. Disconnect the Air Tube from the Upper ISS PCA. 8. Disconnect the Electrical Cable from the Upper ISS PCA.
9. Disconnect the Electrical Cable from the Upper ISS PCA. Removal & Installation 10. Remove two T-10 screws from the Upper ISS PCA. 11. Disconnect four connectors from the Upper ISS PCA. 12. Tip: To make the removal easier you can remove the two Ink Valves located at the rear of the Upper Cartridge Tube Connector from holders, by turning them in a clockwise direction.
13. Slide out the Lower Carriage Tube Connector to gain access to the Lower ISS PCA (but do mot remove). You may need to slide in the Upper Carriage Tube Connector. 14. Disconnect the Electrical Cable from the Lower ISS 15. Remove two T-10 screws from the Lower ISS PCA (one screw also secures a grounding cable). Grounding cable 16. Disconnect the two Electrical Cables from the Lower ISS PCA. Ink Supply Station PCAs (Upper and Lower) 407 Removal & Installation PCA.
APS Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover See page 331. 2. Remove the Electronics Module Extension See page 355. 3. Remove the Scan-Axis Motor See page 432. 4. Remove the ISS See page 400. 5. Disconnect the APS 1 (Top unit) valve electrical Removal & Installation connectors from the PCA. 6. Unclip the APS 1 electrical cables from the cable clamps in the left connector panel 7.
8. Unroute the electrical connections from the printer. 10. Remove one T-20 attachment screw from APS 1 (Top unit). 11. Remove APS 1 (Top unit) from the printer. 2 1 12. Remove the ISS See page 400. APS Assembly 409 Removal & Installation 9. Disconnect both air tubes from APS 1.
13. Disconnect the APS 2 (Top unit) valve electrical connectors from the PCA. 14. Unclip the APS 2 electrical cable from the cable clamps Removal & Installation in the left connector panel 15. Unroute the APS 2 electrical connection from the Media Path Cover Encoder. 16. Unroute the APS 2 electrical connection from the printer.
17. Disconnect both air tubes from APS 2. 18. Remove one T-20 attachment screw from APS 1 (Top 19. Remove APS 2 (Bottom unit) from the printer. NOTE: After installing the NEW APS pumps, reset the life counter “4.4.1 APS cycles” page 226. 2 1 APS Assembly 411 Removal & Installation unit).
Encoder Strip and Encoder Sensor Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Remove the Left Cover See page 337. 3. Uncap the Carriage Assembly by manually pulling out Removal & Installation the Printhead Maintenance Cartridge tray. 4. Lift the Primer and hold the Primer to its maximum position to avoid damaging it when you move the Carriage Assembly in the next step. 5. Move the Carriage Assembly out of the Service Station.
6. Remove one T-10 screw (Type I) that secures the Encoder Strip on the right hand side of the Printer. 7. Release the Encoder Strip from the locating pins on the 8. Release the Spring Clip from the Bracket on the left hand side of the Printer. 1 2 9. Carefully pull the Encoder Strip out of the left hand side of the Printer. 10. Remove the Carriage PCA See page 415. Encoder Strip and Encoder Sensor 413 Removal & Installation right hand side of the Printer.
11. Remove one T-8 (Type L) screw that secures the Encoder Sensor to the Carriage Assembly. 12. Slide the plastic cover to the left and remove it from the Removal & Installation Encoder Sensor. 13. Remove the Encoder Sensor from the Printer. NOTE: After installing the NEW Encoder Strip and Encoder Sensor, perform the following Service Calibration: • “5.5.1 Scan Axis Calibration”page 236. • Reset the life counter “4.5.4 Encoder Strip cycles” page 226.
Carriage PCA Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Press the two side of the Carriage PCA Cover and unclip from the Carriage Assembly. 1 2 3. Disconnect the Trailing Cable from the Carriage PCA. 4. Use a flat bladed screwdriver to release ALL the clips, securing the Carriage Flex Cables to the Carriage Assembly, by pulling upwards.
5. Disconnect the Flex Cables from the Carriage PCA. 6. Disconnect the Line Sensor Cable and the Encoder Removal & Installation Sensor Cable from the Carriage PCA. 7. Unlock the connector and disconnect the Color Sensor Cable from the Carriage PCA. 8. Push inwards the four clips that secure the Carriage PCA.
Removal & Installation 9. Remove the Carriage PCA from the Printer.
Carriage Flex Cables Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Remove the Front Panel See page 364. 3. Remove the Primer Assembly See page 366. 4. Press the two side of the Carriage PCA Cover and 1 unclip from the Carriage Assembly. 2 Removal & Installation 1 5. Use a flat bladed screwdriver to release ALL the clips, securing the Carriage Flex Cables to the Carriage Assembly, by pulling upwards. 6.
7. Remove eight T-8 screws (Type L) that secure the Carriage Flex Cables to the Carriage Assembly. 8. Open the Carriage Cover and remove ALL the 9. The two unused spaces of the Carriage Assembly have dummy printheads installed. To remove them, insert a thin bladed tool into a small hole on the left to release them from a latch located underneath. 10. Remove the dummy Printheads. Carriage Flex Cables 419 Removal & Installation Printheads from the Carriage Assembly.
Removal & Installation 11. Remove the Carriage Flex Cable from the Printer.
Carriage Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Remove the Front Panel See page 364. 3. Remove the Left Cover See page 337. Removal & Installation 4. Remove the Encoder Strip See page 412. 5. Pull out the Printhead Maintenance Cartridge tray. 6. Lift the Primer and hold the Primer to its maximum position to avoid damaging it when you move the Carriage Assembly in the next step. 7.
8. Press the two side of the Carriage PCA Cover and unclip from the Carriage Assembly. 1 2 1 Removal & Installation 9. Disconnect the Trailing Cable from the Carriage PCA. 10. Open the Carriage Cover and remove ALL the Printheads from the Carriage Assembly. 11. Remove five T-15 screws (Type G) that secure the Ink Supply Tubes to the Carriage Assembly.
12. Remove the Ink Supply Tubes from the Carriage Assembly and safely place to one side of the Printer. 13. Remove one T-20 screw (Type A) that secures the Belt Removal & Installation Tensioner to the Chassis. 14. Lift the Primer and hold the Primer to its maximum position to avoid damaging it when you move the Carriage Assembly in the next step. 15. Move the Carriage Assembly slightly away from the right Scan-Axis Bracket.
16. Release the Carriage Belt from the Scan-Axis Motor on the left hand side of the Printer. 17. Remove one T-10 screw (Type C) that secure the Removal & Installation Encoder Strip. 18. Remove four T-20 screws (Type N) that secure the right Scan-Axis Bracket. NOTE: Note that these are Chassis screws and in normal circumstances should NEVER be removed, but in this case we need to remove them in order to remove the Carriage Assembly. 19. Remove the right Scan-Axis Bracket from the Printer.
20.Remove the Carriage Stopper Screw (T-20) from the Chassis. 22. Slide the Carriage Assembly (including the belt) to the right and out of the Printer. 23. If the Carriage Assembly is to be replaced, make sure that you remove the Belt, the Carriage PCA, Color Sensor, Encoder and Line Sensors and the Cutter Assembly (in order to install them on the new Carriage Assembly). NOTE: After installing the NEW Carriage Assembly, perform the following: • “5.5.1 Scan-Axis Calibration” See page 236. • “5.6.
Media Jam Sensor, cable & Carriage Reflector Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover page 337. 2. Remove the Rear Cover Removal & Installation 3. Remove the Left Connector Cover See page 355. 4. Remove two T-15 screws from the Media Jam Sensor. 5. Remove the Media Jam Sensor Plate. 6. Remove the Media Jam Sensor from the clip on the Left Scan-Axis Bracket.
7. Disconnect the Media Jam Sensor from the cable by unscrewing. 8. Remove two T-15 screws from cable clamps securing the 9. Unroute the cable of the Media Jam Sensor through the Service Station. 10. Push the cable of the Media Jam Sensor through the upper cavity in the chassis. Media Jam Sensor, cable & Carriage Reflector Assembly 427 Removal & Installation cable of the Media Jam Sensor to the Left Scan-Axis bracket.
11. Pull the rest of the cable through the cavity in the chassis. 12. Release the cable of the Media Jam Sensor from the Removal & Installation bundle of cables held with cable clamps. 13. Pull the cable through the cavity at the top of the electronics enclosure. 14. Release the cable of the Media Jam Sensor from the bundle of cables held with cable clamps along the top of the Electronics Enclosure.
15. Disconnect the cable of the Media Jam Sensor from the cable on top of the Electronics Enclosure. 17. Pull out the Printhead Maintenance Cartridge tray. 18. Slide the Carriage to the center of the platen. Media Jam Sensor, cable & Carriage Reflector Assembly 429 Removal & Installation 16. Open the Printhead Maintenance Cartridge Door.
19. Remove two T-8 screws from the side of the Reflector Assembly. 20.Remove the Carriage Reflector Assembly. NOTE: After installing the NEW Jam Sensor Assembly, perform the following to test the functionality: Removal & Installation • “3.7 Media Jam sensor test”.
Belt Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Remove the Left Cover See page 337. 3. Remove the Top Cover See page 346. 4. Remove the Encoder Strip See page 412. 5. Remove the Carriage Assembly See page 421. 6. Release the Belt from the bottom of the Carriage NOTE: After installing the NEW Belt Assembly, make sure you perform the following Service Utility: • Reset the life counter “4.5.
Scan-Axis Motor Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Remove the Left Cover See page 337. 3. Remove the Electronics Module Extension See page 355. 4. Uncap the Carriage Assembly by manually pulling out Removal & Installation the Printhead Maintenance Cartridge tray. 5. Lift the Primer and hold the Primer to its maximum position to avoid damaging it when you move the Carriage Assembly in the next step. 6.
7. Remove one T-15 screw that secures the Belt Tensioner to the Chassis. 8. Release the Carriage Belt from the Scan-Axis Motor on Removal & Installation the left hand side of the Printer. 9. Disconnect the Scan-Axis Motor cable from the PrintMech PCA. 10. Unroute the Scan-Axis Motor cable from the chassis.
11. Remove two T-20 screws (Type A) that secure the Scan-Axis Motor. NOTE: Make sure you hold the Scan-Axis Motor securely when removing the screws. 12. Remove the Scan-Axis Motor from the Printer. NOTE: After installing the NEW Scan-Axis Motor, make sure you perform the following Service Utility: • Reset the life counter “4.5.3 Scan Axis Removal & Installation motor” See page 226.
Media-Axis Motor Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover See page 337. 2. Remove the Rear Cover See page 344. 3. Remove the Electronics Module Extension See page 355. 4. Disconnect the Media-Axis Motor cable from the 5. Detach the clamp of the ferrite core of the Media-Axis Motor cable from the printer chassis. 6. Remove the T-15 screws (Type R) identified (A) and loosen the T-15 screws (Type R) identified (B) that secure the Media-Axis Motor.
7. Remove the Media-Axis Motor Bracket. 8. Remove two T-20 screws (Type B) that secure the Removal & Installation Media-Axis Motor Bracket. 9. Remove the Media-Axis Motor from the Printer. NOTE: When reinstalling the parts, make sure you apply the grease (included with the support part) to the gears. NOTE: After installing the NEW Media-Axis Motor, make sure you perform the following Service Calibration: • “5.3.1 Paper Advance Calibration” See page 228. • “4.3.2 Drive Roller Motor” See page 226.
Optical Media Advance Sensor (OMAS) Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover See page 337. 2. Remove the Right Cover See page 331. 3. Remove the Rear Cover See page 344. 4. Remove media if installed. 5. Remove one T-10 screw from the Media sensor Removal & Installation holding bracket. 6. Remove the Media Loading tool holder 7. Unclip the Media sensor from the platen underside.
8. Let the Media Sensor hang below the Center Guide. This is to ensure it does not get damaged by the ribbon cable of the OMAS during the removal procedure. Removal & Installation 9. Squeeze the corners of the OMAS Access Cover release it from the bottom of the printer. 10. Remove the OMAS Access Cover the printer. 11. Insert the T-20 thin bladed torx screwdriver (supplied with the replacement OMAS) into the access hole at the rear of the printer.
12. Remove and discard one T-20 screw which secures the OMAS horizontally to the printer. 13. From the bottom of the printer, remove and discard 14. Carefully lower the OMAS from the printer as far as you can with the large ribbon cable still connected. 15. Release the two locking clips of the large ribbon cable connector. Optical Media Advance Sensor (OMAS) 439 Removal & Installation one T-20 screw which secures the OMAS vertically to the printer.
16. Disconnect the large ribbon cable from the OMAS. Removal & Installation 17. Remove the OMAS Sensor from the printer. Installation NOTE: To simplify the installation of the OMAS an Attachment Screw Retainer has been added to hold the two T-20 attachment screws. This part is delivered attached to the replacement OMAS unit with the two attachment screws. It is also delivered as a separate part with the Center Platen in case the OMAS is completely removed during its replacement. 1.
Position the OMAS under the Printer and connect the large ribbon. 3. Lock the clips of the large ribbon cable connector. 4. FULLY tighten the T-20 vertical attachment screw. 5. While installing the OMAS, take care not to trap the cable of the TOMAS. Optical Media Advance Sensor (OMAS) 441 Removal & Installation 2.
6. Carefully push the OMAS fully up into its mounting so that the OMAS window protrudes slightly ABOVE the Center Platen (approximately 0-2 mm). To ensure the OMAS is correctly positions, slide a sheet of paper over the Platen Ribs until it is stopped by the OMAS. This ensures the OMAS is protruding slightly above the platen. CAUTION: Make sure the OMAS is pushed completely up into its mounting or you will encounter an error during the OMAS calibration because it will not be able to focus on the paper. 7.
10. Clip the Media Sensor to the Center Guide. 12. Install one T-10 screw into the Media sensor holding bracket. 13. Clip the OMAS access cover back into place by sliding one edge of the cover into the slot and then applying enough pressure to it so you can clip it into the other slot. NOTE: After installing the NEW OMAS, perform the following Service Calibration: 1 • “5.3.2 Calibrate the OMAS” See page 231. 2 • Reset the life counter “4.3.3.Reset OMAS Sensor cycle” See page 226.
TOMAS: Temperature Optical Media Advance Sensor Removal WARNING!: Switch off the printer and remove the power cable. NOTE: To simplify the installation of the TOMAS an Attachment Screw Retainer has been added to hold the two T-20 attachment screws. This part is delivered attached to the replacement TOMAS unit with the two attachment screws. It is also delivered as a separate part with the Center Platen in case the TOMAS is completely removed during its replacement. 1.
7. Pull out the TOMAS and cable from the underside of the platen, and disconnect the cable. 8. For installing the new TOMAS a screw is held in the 9. Insert the new TOMAS into the hole underneath the platen. 10. Tighten the screw held by the bracket into the platen. 11. There are some important notes on installing the OMAS if it has been removed while removing the TOMAS See page 440. 12. Install the screw holder onto the OMAS and reinstall it.
TOMAS Cable Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Primer Assembly See page 366. 3. Primer Valves See page 368. 4. Remove the Drop Detector See page 387. 5. Remove the Service Station See page 375. 6. Remove OMAS See page 437. 7. Remove TOMAS See page 444. 8. Unroute the TOMAS Cable from the right side of the Removal & Installation chassis. 9. Remove the TOMAS cable from the hole in the chassis.
10. Disconnect the TOMAS cable from the Interconnect Removal & Installation board.
Interconnect PCA Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Connector Cover See page 353. 2. Remove three T-20 screws (Type A) that secure the Removal & Installation Main PCA cover. 3. Remove the Main PCA Cover from the Printer. 1 2 4. Remove six T-10 screws (Type I) that secure the Interconnect PCA Cover.
5. Remove the Interconnect PCA Cover from the Printer. Removal & Installation 6. Disconnect ALL cables from the Interconnect PCA. 7. Remove five T-10 screws (Type I) that secure the Interconnect PCA. 8. Remove the Interconnect PCA from the Printer.
OMAS Controller Card Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Connector Cover See page 353. 2. Remove three T-20 screws (Type A) that secure the Removal & Installation Main PCA cover. 3. Remove the Main PCA Cover from the Printer. 1 2 4. Disconnect the OMAS Controller Card to OMAS ribbon cable.
5. Disconnect the OMAS Controller Card to PrintMech and Sausalito PCI connection cables (Three connectors). 6. Remove one T-10 screw (Type I) that secures the 7. Disconnect the OMAS Controller Card from the Main PCA and remove from the Printer. CAUTION: To remove the OMAS Controller Card without damaging it on the Emodule cover, you will need disconnect it first and then rotate it slightly in the direction indicated. NOTE: After installing a new OMAS Controller Card, perform the following: • “1.3.
OMAS Cable Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Remove the Right Connector Cover See page 353. 3. Remove the Service Station See page 375. 4. Remove the OMAS See page 437. 5. Remove one T-15 screw that secures the OMAS Cable Removal & Installation clamp from the printer. 6. Remove the OMAS Cable clamp from the printer. 7. Carefully Pull the OMAS Cable out of the Vacuum Beam.
8. Disconnect the OMAS Cable form the OMAS Controller Card. 10. Unroute and remove the OMAS Cable from the Printer. OMAS Cable 453 Removal & Installation 9. Unroute the OMAS Cable from the Ferrite Core.
Installation CAUTION: It is critical that the OMAS Cable is correctly positioned in the Vacuum Beam so that it does not cause physical interference to the Media Sensor. The following illustration shows a cross-section of the Vacuum Beam with the OMAS Cable correctly routed to avoid interference to the Media Sensor. Platen OMAS Cable Removal & Installation OMAS Media Sensor OMAS Controller Card OMAS 1.
2. Position the OMAS Cable in the Vacuum Beam slot so that the blue reinforcement enters first. 3. Carefully feed the OMAS cable through the Vacuum 4. Slide the Ferrite Core and its associated Attachment Plate (on the top) onto the OMAS Cable. 5. Push the Attachment Plate into its slot in the Vacuum beam until it is level with the edge of OMAS installation position. OMAS Cable 455 Removal & Installation Beam sufficiently to have approximately 20 cm hanging from the OMAS installation position.
6. Carefully pull the OMAS Cable back into the Vacuum Beam (from the Service Station end) until the straight fold immediately before the first diagonal fold (from the OMAS sensor end) is aligned with the slot, fold the OMAS Cable across the diagonal fold, and install the cable clamp to lock the OMAS Cable in the correct position. 7. Route the OMAS Cable to the Ferrite Core in the Right Removal & Installation Interconnect panel. 8. Feed the OMAS Cable through Ferrite Core. 9.
Sausalito PCI PCA Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Connector Cover See page 353. 2. Remove three T-20 screws (Type A) that secure the Removal & Installation Main PCA cover. 3. Remove the Main PCA Cover from the Printer. 1 2 4. Disconnect the Trailing Cable from the Sausalito PCI PCA.
5a.Disconnect ALL cables connected to the Sausalito PCI PCA. 5b. Disconnect ALL cables connected to the Sausalito PCI Removal & Installation PCA 6. Remove one T-10 screw (Type I) that secures the Sausalito PCI PCA. 7.
Removal & Installation 8. Remove the Sausalito PCI PCA from the Main PCA.
Main PCA Formatter Removal WARNING!: Switch off the printer and remove the power cable. CAUTION: Do NOT remove the Fan or the Processor (located under the Fan) from the Main PCA Formatter - The Fan and the Processor are part of the Main PCA Formatter support part and should be replaced as one assembly. 1. Remove the Sausalito PCI PCA See page 457. 2. Remove the OMAS Controller Card See page 450. 3. Disconnect ALL cables connected to the Main PCA Removal & Installation Formatter. 4.
5. Release the plastic locating pin that secures the Main PCA Formatter. NOTE: When installing the Main PCA Formatter, make sure that you first locate it on the plastic locating pin and then install the screws. Main PCA Formatter 461 Removal & Installation 6. Remove the Main PCA Formatter from the Printer.
Hard Disk Drive (HDD) Removal WARNING!: Switch off the printer and remove the power cable. Before removing the HDD, download the latest version of FW from the HP web site: www.hp.com/go/ L26500/support. Copy it to a portable device such as a USB Pen Drive or a CD and take it to the repair site. NOTE: You MUST NEVER replace both the Hard Disk Drive and the ISS PCAs (or the Ink Supply Tubes and Trailing Cable) at the same time.
4. Disconnect two cables from the Hard Disk Drive. 6. Slide the Hard Disk Drive upwards and remove from the Printer. NOTE: It is not necessary to remove the screws securing the HDD inside the metal casing. 7. Switch on the printer and the printer will initialize normally. The printer will not request the new firmware. 8. Connect the printer to the customer’s network, retrieve the IP address. 9.
Power Supply Unit (PSU) Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Connector Cover See page 353. 2. Remove the Electronics Module Extension See page 355. 3. Remove three T-20 screws (Type A) that secure the Removal & Installation Main PCA cover. 4. Remove the Main PCA Cover from the Printer. 1 2 5. Remove three T-20 screws (Type A) that secure the PSU cover.
6. Remove the PSU Cover from the Printer. 1 2 7. Remove one T-20 screw from underneath the AC Dryer Removal & Installation Input Assembly 8. Remove two T-20 screws from the AC Dryer Input Assembly. 9. Slide the AC Dryer Assembly to the left.
10. Pull out (but do not remove) the AC dryer Input Assembly from the rear of the printer. Removal & Installation 11. Locate the cable shown. 12. Disconnect the cable shown. 13. Locate the cable shown.
14. Disconnect the cable shown. 16. Remove the bundle of cables from two cable clamps. 17. Remove one T-20 screw from next to the Circuit Breaker. Power Supply Unit (PSU) 467 Removal & Installation 15. Disconnect one cable from the Interconnect PCA.
18. Slide out the Dryer Circuit Breaker. Removal & Installation 19. Disconnect the Curing Module Circuit Breaker Cable. 20.Unroute the cable. 21. Slide out the Curing Circuit Breaker.
22. Remove the Circuit Breakers but do not disconnect them. 23. Disconnect the Power Supply cable from the PrintMech 24.Remove two T-10 screws (Type I) from the back of the PSU Assembly. 25. Remove two T-10 screws (Type I) from the PSU Assembly. Power Supply Unit (PSU) 469 Removal & Installation PCA.
26. Disconnect the cable from the Sausalito PCA. 27. Push the cable through the cavity in the Electronics Removal & Installation Module. 28.Pull out slightly the PSU Assembly from the Electronics Module. 29. Push the bundle of cables attached to the PSU Assembly, through a cavity at the back of the Electronics Module.
30.Pull the bundles of cables attached to the PSU Assembly through the other side. Removal & Installation 31. The PSU Assembly can now be removed.
Formatter Battery Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Connector Cover See page 353. 2. Remove three T-20 screws (Type A) that secure the Removal & Installation Main PCA cover. 3. Remove the Main PCA Cover from the Printer. 1 2 4. Push the clip down (1) and release the battery (2) from the Main PCA.
Heaters Control Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Electronics Module Extension See page 355. 2. Remove four T-20 screws (Type A) that secure the PSU Removal & Installation cover. 3. Remove the PSU Cover from the Printer. 1 2 4. Remove two T-20 screws from the AC Dryer Input Assembly.
5. Remove one T-20 screw from underneath the AC Dryer Input Assembly. Removal & Installation 6. Slide the AC Dryer Input Assembly to the left. 7. Pull out (but do not remove) the AC Dryer Input Assembly from the rear of the Printer. 8. Disconnect the connector Curing Heaters Power connector below the Heaters Control Assembly Fan.
9. Disconnect one connector (Dryer Heaters power connector) above the Heaters Control Assembly Fan. 11. Disconnect two connectors located next to the Circuit Breakers (Sausalito & PrintMech cables). for information refer to Printer Systems page 37. 12. Remove one T-20 screw from inside the chassis, above the Heaters Control Assembly Fan. Heaters Control Assembly 475 Removal & Installation 10. Disconnect the Window Lock Sensors connector.
13. Remove one T-20 screw from underneath the 60 extension. Removal & Installation 14. Remove one T-20 screw next to the Circuit Breaker. 15. Slide out the Dryer Circuit Breaker indicated. 16. Hold the Circuit Breaker upside down in one hand.
17. Loosen with a flat end screwdriver two screws from the circuit breaker. 18. Remove the two cables (brown and blue) from below 19. Leave the Dryer AC Input and Dryer Circuit Breaker loose hanging from the Printer. 20.Disconnect the cable of the Curing Circuit Breaker. Heaters Control Assembly 477 Removal & Installation the Circuit Breaker.
21. Unroute the cable. Removal & Installation 22. Slide out the Curing Module Circuit Breaker indicated. 23. Hold the Circuit Breaker up side down in one hand. 24.Loosen with a flat end screwdriver two screws from the circuit breaker.
25. Remove the two cables (brown and blue) from below the Circuit Breaker. 26. The Curing Module Circuit breaker can now be 27. Gently open up the top part and the bottom part of the extension. 28.Pull out slightly (but do not remove) the Heaters Control Assembly. Heaters Control Assembly 479 Removal & Installation removed from the Printer.
29. Remove the Heaters Control Assembly with the Dryer AC Input and Dryer Circuit Breaker from the Printer. 30.Remove one T-20 screw securing the cable of the Dryer Removal & Installation AC Input Assembly to the Heater Control Assembly. Installation Use the following installation procedure to avoid damaging exposed parts on the PrintMech PCA. 1. There are two screws shown here that attach the Electronics Enclosure Extension to the Electronics Enclosure. It is important to loosen these two screws.
HC Side Plate HC Side Plate 2. The Heaters Control module (HC) has a groove at the top and another one at the bottom of the side plate. These grooves must be correctly inserted into the guides of the Electronics Enclosure (EE). HC Side Plate 3. The pictures and drawing show the bottom part of the 4.
5. The following graph shows the correct position. 6. The following graph shows the incorrect position. 7. An incorrect installation is clearly visible that the Heaters Control module is 1 mm or more to the inner side of the Electronics Enclosure than it should be: the thickness of the Electronics Enclosure sheet metal and the nut. Even worse, a misaligned screw could push it even further in. Removal & Installation Plain washer 8.
10. In the event of an incorrect installation, it is very easy to damage the C22 or the C21 capacitor. Symptoms the printer will show with this damage are the following: • System error 03:10, indicating error with the Removal & Installation • Power Supply when it is actually functioning correctly. 42:03, 42:10, and 86:01 errors have been observed, indicating errors in the carriage servo or scan axis motor.
Heaters Control Assembly Fan Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Connector Cover See page 355. 2. Remove the Heaters Control Assembly Fan by gently pulling it from three rubber stand-offs. Removal & Installation release battery 3. Disconnect the cable of the Heaters Control Assembly Fan. release battery Installation 4. Remove the four screws from the old Heaters Control Assembly Fan.
5. Install three rubber stand-offs into the side of the Heaters Control Assembly. release battery Removal & Installation 6. Use a screw driver to push them through the holes. release battery 7. Stand-offs correctly installed. release battery 8. Install the fan onto the three rubber stand-offs. With the type of fan currently installed on the printer, make sure the label shown here is facing to the printer when it is being installed.
9. Connect the cable of the new fan.
Circuit Breakers Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Electronics Module Extension See page 355. 2. Remove four T-20 screws (Type A) that secure the PSU Removal & Installation cover. 3. Remove the PSU Cover from the Printer. 1 2 4. Remove one T-20 screw next to the Circuit Breaker.
5. Slide out the Dryer Circuit Breaker. 6. Loosen four screws with a flat end screwdriver on the Removal & Installation Dryer Circuit Breaker and remove the Circuit Breaker. 7. Disconnect the Curing circuit Breaker. 8. Unroute the cable.
Removal & Installation 9. Slide out the Curing Circuit Breaker.
AC Input Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Electronics Module Extension See page 355. 2. Remove four T-10 screws (Type A) that secure the PSU Removal & Installation cover. 3. Remove the PSU Cover from the Printer. 1 2 4. Remove two T-20 screws from the AC Input Assembly.
5. Remove one T-20 screw from underneath the AC Input Assembly. 7. Pull out (but do not remove) the AC Input Assembly from the rear of the Printer. 8. Remove one T-20 screw next to the Circuit Breaker. AC Input Assembly 491 Removal & Installation 6. Slide the AC Input Assembly to the left.
9. Slide out the Dryer Circuit Breaker to remove. 10. Loosen two screws on the Dryer Circuit Breaker with a Removal & Installation flat end screw driver. 11. Remove the two cables from the Dryer Circuit Breaker. 12. Remove one T-15 screw from the safety Grounding Cable inside the Printer Chassis.
13. Note the location of the washers for when you are reinstalling this part Black locking washer 14. Remove the AC Input Assembly.
PrintMech PCA Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Electronics Module Extension See page 355. 2. Remove the Heaters Control Assembly See page 473. Removal & Installation 3. Disconnect ALL cables from the PrintMech PCA. 4. Remove eight T-10 screws (Type I) that secure the PrintMech PCA. 5. Remove the PrintMech PCA from the Printer.
Electronics Module Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Connector Cover See page 353. 2. Remove the Left Connector Cover See page 355. 3. Disconnect ALL the cables connected to the right 4. Unroute all the disconnected cables so they are clear of the Electronics Module. x 5. Remove two T-20 screws (Type B) that secure the right side Electronics Module. Electronics Module 495 Removal & Installation Interconnect PCA and the Sausalito PCI PCA.
6. Remove three T-20 screws (Type A) that secure the PSU cover. 7. Remove the PSU Cover from the Printer. Removal & Installation 1 2 8. Disconnect ALL cables from the PrintMech PCA. 9. Remove two T-20 screws (Type B) that secure the left side Electronics Module.
10. Lift the Electronics Module sufficiently (approximately 2 cm) to release it from the attachments. CAUTION: Be careful not to damage the cables on top of the Electronics Module as you remove it. Removal & Installation 11. Remove the Electronics Module from the Printer.
Line Sensor Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Press the two side of the Carriage PCA Cover and 1 unclip from the Carriage Assembly. 2 Removal & Installation 1 3. Release the clip and disconnect the Line Sensor cable from the Carriage PCA. 4. Remove two T-8 screws from the metal part.
5. Uncap the Carriage by manually pulling out the Printhead Maintenance Cartridge 6. Lift the Primer and hold the Primer to its maximum 7. Move the Carriage away from the Service Station. 8. Remove one T-8 screw from the metal Carriage Cover.
9. Move the Carriage into the Service Station. Removal & Installation 10. Remove the Metal Carriage Cover. 11. Pass the Line Sensor Cable through the hole. 12. Remove one T-15 screw (Type G) that secures the Line Sensor to the carriage Assembly.
13. Remove the Line Sensor from the Carriage Assembly. 14. Remove the protective foam from around the sensor. NOTE: After installing the NEW Line Sensor, perform the following Service Calibrations: • “5.6.1 Line Sensor Calibration” page 240. • Reset the life counter “4.6.2 Line Sensor Removal & Installation cycle” page 227.
Color Sensor Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Open the Window. 2. Remove the Right Cover See page 331. 3. Press the two side of the Carriage PCA Cover and 1 unclip from the Carriage Assembly. 2 Removal & Installation 1 4. Release the clip and disconnect the Color Sensor cable from the Carriage PCA. 5. Uncap the Carriage Assembly by manually pulling out the Printhead Maintenance Cartridge tray.
6. Lift the Primer and hold the Primer to its maximum position to avoid damaging it when you move the Carriage Assembly in the next step. 7. Move the Carriage away from the Service Station, into Removal & Installation the center of the platen. 8. Remove two T-8 screws that secure the Reflector Assembly to the side of the Carriage Assembly. 9. Remove the Reflector Assembly.
10. Remove one T-10 screw from the front of the Color Sensor. 11. Remove one T-10 screw from the Rear of the Color Removal & Installation Sensor. 12. Tilt the Color Sensor so it can be removed. 13. Remove the Color Sensor from the Carriage Assembly. NOTE: After installing the NEW Color Sensor, perform the following Service Calibrations: • “5.6.3 Open Close SOL” page 246. • Perform the safety test “3.3 Substrate Path Sensor ” page 157. • Reset the life counter “4.6.5 Color sensor” page 227.
Installation 1. When installing the T-10 screw to the front of the Color Sensor, make sure you do not over-tighten the screw. 2. When installing the T-10 screw to the Rear of the Color Removal & Installation Sensor, make sure you do not over-tighten the screw.
Color Sensor Actuator Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover See page 337. 2. Slide out the top row of Ink Cartridges from the Ink Removal & Installation Supply Station 3. Disconnect the Color Sensor Actuator Assembly. 4. Remove one T-15 screw (Type G) that secures the Color Sensor Actuator Assembly to the printer.
5. Remove the Color Sensor Actuator Assembly to the printer.
Dryer Grill Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Open the Window See page 321. 2. Open the Dryer Grill Protection 3. Remove two T-10 countersunk screws securing one section of Dryer Grill.
4. Tilt the Dryer Grill downwards. Removal & Installation 5. Remove the Dryer Grill.
Dryer (IR) Temperature Sensor Removal WARNING!: Switch off the printer and remove the power cable. 1. Twist the Window Locks and open the Dryer Window. 2. Remove the Left Cover See page 337. 3. Disconnect the Dryer Temperature Sensor cable from Removal & Installation the left side of the printer. 4. Remove one T20 screws from the cable clamp. 5. Remove all the T20 screws from cable clamps that secure the Temperature Sensor Cable to the inside of the Dryer Window Assembly.
6. Remove two thin nuts from the Dryer Temperature Sensor. 8. Remove the Dryer Temperature Sensor Cable from the cable clamps. 9. Remove the Dryer Temperature Sensor and cable from the printer. NOTE: After installing the NEW Dryer IR temp sensor, perform the following Service Calibrations: • Reset the life counter “4.8.4 Reset Heating Sensor” page 227. Dryer (IR) Temperature Sensor 511 Removal & Installation 7. Remove the Dryer Temperature Sensor from the holder.
Dryer Enclosure Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Open the Window See page 337. 2. Remove two T-10 screws from the left of the Dryer Enclosure. 3. Remove two T-10 screws from the right of the Dryer Enclosure.
4. Remove the Dryer Enclosure. 5. Remove three T-10 screws from the right Dryer Enclosure 6. Remove the right Dryer Enclosure Support Bracket. 7. Remove three T-10 screws from the left Dryer Enclosure Support Bracket. Dryer Enclosure 513 Removal & Installation Support Bracket.
Removal & Installation 8. Remove the left Dryer Enclosure Support Bracket.
Dryer Heater Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover See page 337. 1. Remove the Dryer EnclosureSee page 512. 2. Remove one T-10 screw from a clamp that secures the 3. Loosen two screws on the connector of the Dryer IR Temperature Sensor cable, by hand or with a flat screwdriver, and disconnect. 4. Remove one T25 screw, one lock washer, one normal washer that secures the grounding cable.
WARNING!: When reinstalling the grounding cable, it is an important safety point that the washers are installed as shown here. Removal & Installation 5. Push the grounding cable to one side. 6. Remove one T-20 screw from a cable clamp that secures the grounding and Dryer Temperature Sensor cable to the left Arc. 7. Remove two T-20 screws that secure the Left Cable Plate to the printer.
8. Rotate (1) and remove (2) the Left Cable Plate. 10. Remove one T-20 screw from a cable clamp that secures the Dryer Heater Power cables to the left side. 11. Remove one T-20 screw from a cable clamp that secures the Dryer Heater Power cables in the Window cavity. Dryer Heater 517 Removal & Installation 9. Disconnect the Dryer Power Cable.
12. Remove the cable of the Dryer IR Temperature Sensor from the cable clamp. 13. Push the Dryer power cable and grounding cable back Removal & Installation through the cavity of the Window Assembly. 14. Remove the cable from inside the cavity of the Window assembly. 15. Remove all the T-20 screws that secure the Dryer Assembly to the inside of the window. The number of screws will depend on the Printer size. CAUTION: We recommend that the last screw to be removed is one of the central screws.
16. When all of the T-20 screws have been removed, you can remove the Dryer Assembly from inside the Window. NOTE: After installing the NEW Dryer Heater perform the following: • “8.6 Heating Resistance resist” page 193. • Reset the life counter “4.8.3Heating Lamps” Removal & Installation page 227.
Curing Fans & Cover Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover See page 337. 2. Remove the Left Curing Cover See page 340. 3. Remove the Right Curing Cover See page 342. 4. Disconnect the Curing Fans Cable from the left of the Removal & Installation printer. 5. Disconnect the Left Window Sensor Cable. 6. Remove one T-20 screw from the left side of the Curing Module (screw closest to the printer).
7. Remove one T-20 screw from the top of the Left Curing Trim. 8. Remove one T-10 screw from the bottom of the Left Removal & Installation Curing Trim. 9. Remove the Left Curing Trim. 10. Disconnect the Right Window Sensor Cable.
11. Remove one T-20 screw from the Right Curing Trim (screw furthest from the printer). 12. Remove one T-20 screw from the top of the Right Curing Removal & Installation Trim. 13. Remove one T-10 screw from the bottom of the Right Curing Trim. 14. Remove the Right Curing Trim.
15. Remove two T-20 screws that secure the Left Cable Plate to the printer. Removal & Installation 16. Rotate (1) and remove (2) the Left Cable Plate. 17. Push the cable of the Curing Fans back through underneath the left arch. 18. Unroute the cables from the Cable Protector.
19. Leave the cable of the Curing Fans loose on the Curing Module. 20.Remove five the T-10 screws that secure the front of the Curing Fans Cover to the Printer. Removal & Installation Do not remove the screws that secure the Curing Grill to the Curing Module, these do not need to be removed. 21. Remove six T-20 screws from the top of the Curing Fans Assembly. CAUTION: We recommend that the last screw to be removed is one of the central screws.
23. Place the Curing Fans Cover on the floor or a flat surface. Removal & Installation 24.Unroute the Fans cable from inside the Fans Cover. 25. Disconnect the Fans Cable. 26. Remove the Fans Cable from the clip in the Fans Cover.
27. Remove two T-10 screws from the Fan Deflector. Removal & Installation 28.Remove the Fan Deflector. 29. Remove four T-20 screws from the Fans Assembly. 30.Remove the Fan from the Fan mounting.
31. Remove the Fan Assembly. Installation Removal & Installation One of the Fan Deflectors is different from the others, it contains a notch to pass the fan cable through.
Curing IR Temperature Sensor & Fan Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover See page 337 2. Remove the Left Curing Cover See page 340. 3. Remove the Right Curing Cover See page 342. 4. Remove the Curing Fans Cover See page 520. 5. Loosen two screws on the connector of the Curing IR Removal & Installation Temperature Sensor cable, by hand or with a flat screwdriver. 6. Disconnect the Curing Temperature Sensor Cable. 7.
8. Push the cables of the Curing Temperature Sensor and Fan back through underneath the left arch. 9. Unroute the cables from the cable protector. 10. Leave to one side the cables of the Curing Temperature Sensor and Fan. 11. Remove four T-20 screws that secure the cables of the Curing Temperature Sensor and Fan to the front of the curing Module.
TIP: Not all of the cable clamps need to be removed, only those that hold the cables of the Curing Temperature Sensor and the Fan. 12. Remove only the cables of the Curing Temperature Removal & Installation Sensor and the Fan from the cable clamps. The cables of the curing heater and right window sensor can stay in the cable clamps. 13. Remove four T-10 screws securing the cover of the Curing Temperature Sensor. 14. Remove the cover.
15. Pull off the ferrite clamp from the Curing Cover. 17. Remove the Curing Temperature Sensor Fan from the black plastic holder. 18. Remove two thin nuts securing the Curing Temperature Sensor to the black plastic bracket. Curing IR Temperature Sensor & Fan 531 Removal & Installation 16. Slide the black plastic holder to the left.
19. Slide out the Curing IR Temperature sensor. 20.Remove the Curing Temperature Sensor Fan through Removal & Installation the hole in the Curing cover. 21. Remove the Curing Temperature Sensor through the hole in the Curing cover. Installation 1. When installing the Curing Temperature Sensor fan, it is important that the label of the fan is not visible.
2. In this example the fan is correctly installed. NOTE: After installing the NEW Curing IR Temp sensor & Fan perform the following: • Reset the life counter “4.8.2 Reset Curing Removal & Installation Sensor” page 227.
Curing Heaters Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover See page 337. 2. Remove the Left Curing Cover See page 340. 3. Remove the Right Curing Cover See page 342. 4. Remove the Curing Fans Cover See page 520. 5. Loosen two screws on the connector of the Curing IR Removal & Installation Temperature Sensor cable, by hand or with a flat screwdriver. 6. Disconnect the Curing Temperature Sensor Cable. 7.
8. Disconnect the cable of the Curing Temperature Sensor Fan. L 9. Push the cables of the Curing Temperature Sensor (1), the Sensor Fan (2) and the Left Windows Lock Sensor (3) back through underneath the left arch. 1 2 10. Disconnect the Curing Heater Cables from the left side (upper and lower connectors). 11. Remove one T-15 screw that secures the Output Roller to the right side of the Curing module, and remove the roller.
12. Slide the Output roller from the pin located on the left side of the curing Module. Removal & Installation 13. Remove the Output roller. 14. Remove the Electrical Block Cover by squeezing the holding pins together and sliding it off. 15. Loosen three screws on the Electrical Block with a flat end screw driver.
16. Remove the three cables from the Electrical Block. Take care not to lose the holders underneath the terminal cables. 17. Remove one T-20 screw from a cable clamp that Removal & Installation secures the heater cables. 18. Remove the cable clamp from around the heater cables. 19. Remove two T-10 screws from the cover of the Curing Thermal Switch.
20.Pull out the cover of the Curing Thermal Switch. 21. The Curing Thermal Switch is located on the underside Removal & Installation of the cover. Disconnect the connector shown. 22. Remove both together the Cover and the Curing Thermal Switch. 23. Remove the cable shown from inside the Curing Module.
24.Remove all the T-20 screws from the cable clamps that secure cables to the front of the Curing Module. The number of cable clamps will depend of the version of the Printer. 25. Remove one cable clamp on the left side of the curing 26. Remove two T-10 safety grounding screws from the right side of the Heaters. To ensure the electrical safety of the printer, it is critical that these screws are reinstalled at the installation. 27. Remove two T-10 screws from the left side of the Heaters.
28.Remove the two holding brackets on the left side of the resistors. 29. Remove one T-20 screw from the left of the Curing Removal & Installation Module. D 30.Remove two T-20 screws from the right side of the Curing Module. 31. Remove one T-20 screw from the top right of the Curing Module.
32. Remove the Curing Module by lifting off the left and right locating pins. 33. Turn upside down and place on a flat even surface. 34.Remove all the T-10 screws that secure the sections of Curing Heater Grills to the Curing Module. 35. Remove the Heater Grills by lifting up the free end and removing. Curing Heaters 541 Removal & Installation NOTE: When placing on the flat surface take care not to damage the terminals of the Heaters.
36.Remove all T-15 screws that secure the heater holders to the Curing Module. 37. Twist the heater holders to remove them all. Removal & Installation NOTE: The Output Heater Holders are different to the Overdrive Heater Holders 38.Remove the left end of the Output Heater taking care not to damage the Isolation fiber. 39. Remove the right end of the Output Heater taking care not to damage the Isolation fiber.
40.Be careful when removing the end of the Output heater cable as there is a connector on the end, and this could damage the isolation fiber. 41. Remove the Overdrive Heater taking care not to Removal & Installation damage the Isolation fiber. 42. Remove the other end of the Overdrive Heater Installation 1. The ends of the two types of Curing Heaters are different to avoid incorrectly installing them. If the Heaters are installed swapped over, this will trigger a system error.
Curing Module & Curing Fans Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover See page 337. 2. Remove the Left Curing Cover See page 340. 3. Remove the Right Curing Cover See page 342. 4. Loosen two screws on the connector of the Curing IR Removal & Installation Temperature Sensor cable, by hand or with a flat screwdriver. 5. Disconnect the Curing Temperature Sensor Cable. 6. Disconnect the cable of the Left Windows Lock Sensor.
7. Disconnect the cable of the Curing Fans. 8. Disconnect the cable of the Curing Temperature Sensor 9. Remove two T-20 screws that secure the Left Cable Plate to the printer. 10. Rotate (1) and remove (2) the Left Cable Plate. Curing Module & Curing Fans Assembly 545 Removal & Installation Fan.
11. Unroute the cables from the Cable Protector Removal & Installation L 12. Push all the cables through the left arch and out the other side. 13. Disconnect the Curing Heater Cables from the left side (upper and lower connectors). 14.
15. Remove one T-20 screw from the left side of the Curing Module (screw closest to the Printer). 16. Remove one T-20 screw from the top of the Left Curing Removal & Installation Trim. 17. Remove one T-10 screw from the bottom of the Left Curing Trim. 18. Remove the Left Curing Trim.
19. Disconnect the Right Window Sensor Cable. 20.Remove one T-20 screw from the Right Curing Trim Removal & Installation (screw furthest from the printer). 21. Remove one T-20 screw from the top of the Right Curing Trim. 22. Remove one T-10 screw from the bottom of the Right Curing Trim.
23. Remove the Right Curing Trim. 24.Remove one T-15 screw that secures the Output Roller to 25. Slide the Output roller from the pin located on the left side of the curing Module. 26. Remove the Output roller. Curing Module & Curing Fans Assembly 549 Removal & Installation the right side of the Curing module, and remove the roller.
D 27. Remove two T-20 screws from the right side of the Curing Module. 28.Remove one T-20 screw from the top right of the Curing Removal & Installation module. 29. Remove one T-20 screw from the left of the Curing module. 30.Remove the Curing Module by lifting off the left and right locating pins.
31. Turn upside down and place on a flat even surface. NOTE: When placing on a flat surface take care not to damage the terminals of the Curing Heaters. Installation 1. When installing the Left and Right Curing Trims back Removal & Installation onto the printer, ensure they are installed into the alignment holes, located on the sides.
Output Platen Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover See page 337. 2. Remove the Left Curing Cover See page 340. 3. Remove the Right Curing Cover See page 342. 4. Remove the Curing Module & Curing Fans See page 544. 5. Remove one T-20 screw from the right side of the Removal & Installation Output Platen. 6. Remove one T-20 screw and washer from the left side of the Output Platen. 7.
8. Remove one T-15 screw +washer from below right of the Output Platen. 9. Remove one t-10 screw from below the Output platen in 10. Lift the Output Platen off the locating pins and remove. Output Platen 553 Removal & Installation the middle.
Curing Holders Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Remove the Curing Module See page 544. 3. Remove the Output Platen See page 552. 4. Cut the cable clamp to release the bundle of cables on Removal & Installation the front of the left arch. 5. Remove one T-20 screw that secures the Left Curing Holder to the left arch. 6. Remove two T-15 screws from the Left Curing Holder.
7. Remove the Left Curing Holder. 8. Remove one T-20 screw that secures the right Curing Holder to the right arch. 10. Remove two T-15 screws from the Right Curing Holder. 11. Remove the Right Curing Holder Curing Holders 555 Removal & Installation 9.
Center Platen Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Remove the Left Cover See page 337. 3. Remove the Top Cover See page 346. 4. Remove the Service Station See page 375. 5. Remove the Rear Cover See page 344. 6. Remove three or one T-25 screws from the Media Removal & Installation Loading Tool holder. 7. Remove the Media Tool holder. 8. Unclip the Media sensor.
9. Removal & Installation 10. 11. Squeeze the corners of the OMAS Access Cover release it from the bottom of the printer. 12. Remove the OMAS Access Cover from the printer.
13. Insert the T-20 thin bladed torx screwdriver (supplied with the replacement OMAS) into the access hole at the rear of the printer. 14. Loosen approximately two turns the T-20 screw which Removal & Installation secures the OMAS horizontally to the printer. 15. From the bottom of the printer, loosen approximately two turns the T-20 screw which secures the OMAS vertically to the printer. 16. Carefully lower the OMAS from the printer as far as you can with the large ribbon cable still connected.
17. Release the two locking clips of the large ribbon cable connector. Removal & Installation 18. Disconnect the large ribbon cable from the OMAS. 19. Remove the OMAS Sensor from the Printer. 20.Remove one T-15 screw (Type P) that secures the Center Platen Gear.
21. Remove the Center Platen Gear from the Printer. Removal & Installation 22. Remove one T-15 screw that secures the small Gear. 23. Remove the small Gear from the Printer. 24.Remove the two small Platen Gears by releasing the clips.
25. Remove two T-20 screws (Type Q) that secure the Gear Bracket. Removal & Installation 26. Remove the Gear Bracket from the Printer. 27. Move the Carriage Assembly fully to the right. 28.
29. Remove the Center Platen from the Printer. OMAS Attachment Screws Completely Removed during Center Platen Removal 30.Completely remove OMAS from the Printer See page 437. Installation of the Foam 1. Make sure you take note of the positions of the Foams Removal & Installation located underneath the center Platen. NOTE: When reinstalling the parts, make sure you apply the grease (included with the support part) to the gears.
2. Position the Attachment Screw Retainer on the OMAS and secure it with the T-8 attachment screw provided with Center Platen. 3. Verify that the two T-20 attachment screws are correctly 4. Position the OMAS under the Printer and connect the large ribbon. 5. Lock the clips of the large ribbon cable connector. Center Platen 563 Removal & Installation positioned in the Attachment Screw Retainer.
6. Fully tighten the T-20 vertical attachment screw. 7. While installing the OMAS, take care not to trap the Removal & Installation cable of the TOMAS. 8. Carefully push the OMAS fully up into its mounting so it protrudes slightly (approximately 0.1 mm) above the Center Platen. To ensure the OMAS is correctly positions, slide a sheet of paper over the Platen Ribs until it is stopped by the OMAS. This ensures the OMAS is protruding slightly above the platen.
10. Insert the T-20 thin bladed torx screwdriver into the access hole at the rear of the printer. 11. Fully tighten the T-20 horizontal attachment screw 12. Clip the OMAS access cover back into place by sliding one edge of the cover into the slot and then applying enough pressure to it so you can clip it into the other slot. 13. Calibrate the following: • 1.3.5 OMAS See page 212. • 5.3.1 Paper Advance Calibration See 1 page 228.
Cartridge Tray Removal WARNING!: Switch off the printer and remove the power cable. 1. Release the Tray Lever of the required color and pull Removal & Installation out the Tray. 2. Remove the Ink Cartridge if installed. 3. Press down on the Tray clip.
4. Pull the Tray completely out of the Printer. Removal & Installation NOTE: Note that each Cartridge Tray is different even though they look very similar. When selecting the Cartridge Tray from the Support Part (it contains eight Cartridge Trays), choose the Tray that exactly matches the one that you have just removed.
Input Roller Removal WARNING!: Switch off the printer and remove the power cable. 1. Raise the right lever to release the right hand end of the Removal & Installation Input Roller. 2. Pull out the right hand end of the Input Roller from the Printer. 3. Move the Input Roller to the right to disengage it from the Printer.
Removal & Installation 4. Remove the Input Roller from the Printer.
Output Roller Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Curing Cover See page 340. 2. Remove one T-15 screw from the left side of the Output Removal & Installation Roller, and remove the Roller.
Printhead Maintenance Cartridge Door Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Open the Printhead Maintenance Cartridge Door. 2. Unclip and remove the Printhead Maintenance Cartridge Door from Right Cover.
Printhead Maintenance Cartridge Door Sensor Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Disconnect the Printhead Maintenance Cartridge Door Removal & Installation Sensor cable. 3. Release one T-10 screw the attaches the Printhead Maintenance Cartridge Door Sensor assembly to the printer. 4. Remove the Printhead Maintenance Cartridge Door Sensor assembly from the printer.
Media Sensor Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Rear Cover See page 344. 2. Remove the Right Connector Cover See page 353. 3. Disconnect the Media Sensor cable from the 4. Release the Media Sensor cable from the clip located on the Electronics Module. 5. Remove the Input Roller to gain access to the following part See page 568. 6. Remove one T-10 screw from the Media sensor holding bracket.
Removal & Installation 7. Remove the holder of the Media Sensor.
Encoder Disc and Sensor Removal WARNING!: Switch off the printer and remove the power cable. CAUTION: Please handle the Encoder Disc very carefully since any finger prints, scratches or stains could cause the Printer to malfunction. 1. Remove the Left Cover See page 337. 2. Remove the Electronics Module Extension See page 355. 3. Remove the Ink Supply Station See page 400. 4. Disconnect the Encoder Sensor cable from the 5.
6. Release the Encoder Sensor cable from the clip located on the Encoder Disc Cover. 7. Unclip the Encoder Disc Cover and remove from the Removal & Installation Printer. 8. Remove one T-8 screw (Type D) that secures the Encoder Sensor to the Chassis. 9. Remove the Encoder Sensor from the Printer.
Removal & Installation 10. Carefully peel the Encoder Disc from the Drive Roller.
Media Lever Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. Removal & Installation 2. Remove the Rear Cover See page 344. 3. Raise the Media Lever. 4. Remove one T-15 screw (Type F) that secures the Linkage to the Spring. 5. Remove the Linkage from the Spring.
6. Remove one T-20 screw (Type A) that secures the Spring to the Spacer. 8. Raise the Media Lever to gain access to the linkage attachment screw. 9. Remove one T-15 screw (Type F) that secures the Media Lever to the Linkage. Media Lever Assembly 579 Removal & Installation 7. Remove the Spring and plastic washer.
10. Remove the Media Lever Linkage from the Printer. 11. Remove one T-20 screw (Type O) that secures the Removal & Installation Media Lever to the Right Trim. 12. Raise the Media Lever. 13. Remove the Media Lever from the Printer.
Media Lever Sensor Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Remove the Right Trim See page 334. 3. Remove the Right Connector Cover See page 353. 4. Remove the Output Platen See page 552. 5. Disconnect the Media Lever Sensor cable from the 6. Unroute the Media Lever Sensor cable from the cable clamp. 7. Release the Media Lever Sensor Cable from the three clips on the Vacuum Fan.
Removal & Installation 8. Remove the Media Lever Sensor from the Printer.
Pinchwheel Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Remove the Rear Cover See page 344. 5. Remove one T-20 screw that secures the Linkage to the Spring. 6. Disconnect the linkage from the Pinchwheel cam-arm. Pinchwheel Assembly 583 Removal & Installation 3. Remove the Service Station See page 375. 4. Raise the Media Lever.
7. Disconnect the spring from the Pinchwheel cam-arm. 8. Remove one T-20 screw that secures the Cam to the Removal & Installation Cam Lever. 9. Insert a plastic stud in to each Pinchwheel Subassembly (the Plastic Studs can be found in the replacement Pinchwheel Assembly kit). 10. Remove one T-20 screw that secures the attachment plate to the center Pinchwheel Subassembly.
11. Remove the attachment plate from the center Pinchwheel Subassembly. 12. Remove two T-20 screws (Type M) from each 13. Remove the complete Pinchwheel Assembly (including the Cam and Cam Lever) from the Printer. NOTE: Before installing the NEW Pinchwheel Assembly, insert the plastic studs in to each Pinchwheel subassembly. This will make it easier to install the complete Pinchwheel Assembly.
Individual Pinchwheel Rollers Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Open the Window See page 337. 2. Raise the Media Lever. 3. Going from right to left use a screw driver to push apart all the pins that secures the Inter-Pinchwheel roller.
4. Remove the two inter-Pinchwheel rollers from both sides of the Pinchwheel. Remove first the left one (1) and then the right one(2). You need to go from right to left, doing this until you reach the individual Pinchwheel that you need to remove 5. When you have reached the individual Pinchwheel Removal & Installation roller, push apart the metal part that secures the Pinchwheel roller. 6. Pull out the individual Pinchwheel roller. Installation of the Drive Roller 1.
2. When the new Pinchwheel roller has been installed, Removal & Installation check that the rollers move freely.
Center Guide Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Remove the Left Cover See page 337. 3. Remove the Primer Assembly See page 366. 4. Remove the Right Connector Cover See page 353. 5. Remove the Electronics Module See page 495. 6. Remove the Service Station See page 375. 8. Remove the Media Sensor See page 581. 9.
11. Remove one T-15 screw (Type S), that secures the Center Guide, from underneath the Printer. Removal & Installation 12. Remove the Center Guide from the Printer.
Drive Roller Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Right Cover See page 331. 2. Remove the Left Cover See page 337. 3. Remove the Right Connector Cover See page 353. 4. Remove the Electronics Module Extension See page 355. 5. Remove the Service Station See page 375. 6. Remove the Ink Supply Station See page 400. 7. Remove the Media-Axis Motor See page 435. page 575. 9. Remove the Media Lever Assembly See page 578. 10.
14. Remove one T-20 screw (Type B) that secures the cover on the right hand side of the Printer. Removal & Installation 15. Remove the Cover. 16. Remove three T-20 screws that secure the cover on the left hand side of the Printer. 17. Remove the Cover.
18. Remove T-20 screws that secure the Media-Axis Motor Bracket to the side-plate. 19. Remove two T-20 screws (Type A) that secure the 20.Remove the Media-Axis Motor Bracket from the Printer. 21. Use a flat bladed screwdriver to unclip the Roller Middle Support Cover. Drive Roller 593 Removal & Installation Media-Axis Motor Bracket to the Chassis.
22. Rotate the Roller Middle Support Cover vertically. 23. Release the Roller Middle Support Cover from its Removal & Installation attachment point. 24.Remove the Roller Middle Support Cover. 25. Remove the Drive Roller by sliding it to the right, then downwards and then out of the Printer. 1 2 NOTE: When reinstalling the parts, make sure you apply the grease (included with the support part) to the gears.
Installation of the Drive Roller When installing the Drive Roller, several different datums have to be met in order to ensure that the Drive Roller has no axial play. Use the following illustrations to ensure that ALL the datums are met: Media-Axis Motor Bracket Drive Roller Bearing Sideplate 1 2 1 1. Datum between Media-Axis Motor Bracket and Drive Roller Bearing 2. Datum between Media-Axis Motor Bracket and Sideplate 3 Removal & Installation 3.
instructions: 1. Place the Media-Axis Motor Bracket in the correct position on the Printer. Make sure you keep it pushed down (as shown in the illustration) until the first screw has been installed and fully tightened. 2. Install the first screw (T-15) in the position shown. Make Removal & Installation sure you tighten the screw fully so that the Media-Axis Motor Bracket cannot be moved. 3. Check that there is no play (movement) between the Media-Axis Motor Bracket and the Drive Roller.
Right Rollfeed Module Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Input Roller See page 568. 2. Remove the Media Spindle (if installed). 3. Remove four T-20 screws that secure the Right Rollfeed 4. Remove the Right Rollfeed Module from the Printer. Right Rollfeed Module Assembly 597 Removal & Installation Module.
Left Rollfeed Module Assembly Removal WARNING!: Switch off the printer and remove the power cable. 1. Remove the Left Cover See page 337. 2. Remove the Ink Supply Station See page 400. 3. Remove the Input Roller See page 568. 4. Remove the APS Assembly See page 408. 5. Remove the Media Spindle (if installed). 6. Remove one T-15 screw that secures the APS Mounting Removal & Installation Plate to the Printer. 7. Tilt out the top of the APS Mounting Plate support. 8.
9. Remove four T-20 screws that secure the Left Rollfeed Module to the Printer. Removal & Installation 10. Remove the Left Rollfeed Module from the Printer.
Take-Up Reel Motor Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Remove the Take Up Reel Spindle. 2. Disconnect the Take-Up Reel Motor from the Parallel Port on the rear of the printer. 3. Disconnect the Take-Up Reel Sensors from the Take-Up Reel Motor.
4. Remove the three T-20 screws that attach the Take-Up Reel Motor to the Right Leg Assembly. 5. Remove the Take-Up Reel Motor from the Right Leg Removal & Installation Assembly.
Take-Up Reel Left Hand Module Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Remove the Take UP Reel Spindle. 2. 1. Remove the three front T-20 screws that attach the TakeUp Reel Left Hand Module to the Left Leg Assembly. 2. 3. Remove the Take-Up Reel Left Hand Module.
Take-Up Reel Deflector Supports Removal WARNING!: Switch off the printer and remove the power cable. 2. Remove the Take-Up Reel Deflector from the printer. 3. Remove the two T-20 screws that attach the Left Hand Deflector Support to the Left Leg Assembly. Take-Up Reel Deflector Supports 603 Removal & Installation 1. Disconnect the Take Reel cable.
4. Remove the Left Hand Deflector Support. 5. Remove the two T-20 screws that attach the Right Hand Removal & Installation Deflector Support to the Right Leg Assembly. 6. Remove the Right Hand Deflector Support.
Take Up Reel Dancer Removal 1. Remove the retaining clip on the right side. 2. Remove the T-10 screw securing the earthing cable to WARNING!: Ensure when installing the TUR Dancer the earth cable is reinstalled. 3. Remove three T-10 screws that secure the left side of the TUR Dancer to the legs of the printer. Take Up Reel Dancer 605 Removal & Installation the legs of the printer.
4. Remove the left side of the TUR Dancer. 5. Remove the Dancer Bracket shown from the left side of Removal & Installation the TUR Dancer. 6. Remove the right side of the TUR Dancer from the legs of the printer. 7. Remove three T-10 screws that secure the right Dancer Bracket to the legs of the printer.
8. Remove the Dancer Bracket shown from the right side Removal & Installation of the printer.
Take-Up Reel Sensors Removal WARNING!: Switch off the printer and remove the power cable. Removal & Installation 1. Disconnect the Take-Up Reel Sensors. 2. Remove the blue thumbscrew that attaches the Take-Up Reel Sensors to the Right Foot Assembly. 3. Slide the Take-Up Reel Sensors off the Right foot Assembly.
4. Remove one T-15 screw that attaches the cover of the receiver sensor to the housing. 5. Remove the cover of the receiver sensor to the housing. 6. Disconnect the connector from the receiver sensor. 7. Remove the receiver sensor from the housing. Take-Up Reel Sensors 609 Removal & Installation .
8. Unroute the Take-Up Reel Transmitter Sensor cable. 9. Unclip and remove the Take-Up Reel Transmitter Sensor Removal & Installation from the X-Brace Assembly.
Electronic Cables routing This section can be used as a reference section, to check the original routing of the cables Rear Service Station Cables routing Removal & Installation Rear of the Service Station Electronic Cables routing 611
Removal & Installation Interconnect PCA Cables routing Interconnect PCA 612 Chapter 8 Removal & Installation
Removal & Installation Electronics Main PCA Cavity Cables routing Electronic Cables routing 613
Removal & Installation Printmech PCA Cables routing (behind Heaters Control Assembly) 614 Chapter 8 Removal & Installation
Removal & Installation Left Interconnect Cables routing Electronic Cables routing 615
Removal & Installation Left End Rear Chassis Cables routing 616 Chapter 8 Removal & Installation
Removal & Installation Rear ISS Cables routing Electronic Cables routing 617
Removal & Installation Circuit Breakers Cables routing 618 Chapter 8 Removal & Installation
Preventive Maintenance • • • • • • Preventive Maintenance ......................................................................................620 • Moisture on the Printer .................................................................................620 • Belt Swelling ...............................................................................................620 Cleaning the Printer............................................................................................
Preventive Maintenance Moisture on the Printer Users should use the Printer in an environment between 20% and 80% relative humidity. To recover from moisture condensation, turn the Printer Off, and, using the main roller as a reference, wait until the Printer is completely dry before using it again. Belt Swelling To prevent new belts from swelling incorrectly, keep them in their bags with desiccant until you need to install them.
Clean the Platen The printer’s platen should be cleaned every few months, or when necessary NOTE: If a wide substrate is used to print after printing on a narrower substrate, you may find that the left hand side of the platen has become dirty. If this contaminated section of the platen is not cleaned, it might leave marks on the back of the substrate. CAUTION: Be careful not to damage the substrate advance sensor (OMAS) when cleaning the platen.
6. Slightly dampen the used cloth with 95% ethanol to wipe the remaining dry ink deposits from the platen. (Methyl Acetate is not supplied in the Maintenance Kit). NOTE: 95% ethanol is not supplied in the Maintenance Kit. CAUTION: Ethanol is highly flammable. Observe the manufacturer’s safety precautions. Preventive Maintenance CAUTION: Do not use commercial cleaners or abrasive cleaners. Do not wet the Center Platen directly because you will leave too much moisture behind. 7.
Clean after the porous substrates If a porous substrate is used (through which ink can pass), clean the platen immediately after each printing session. Do not, for instance, leave the printer overnight or load a new roll without cleaning the platen first. When printing on a textile or thin substrate, you may find condensation in the input area of the printer. You are recommended to wipe it away with a dry cloth, at least before loading a new roll.
Preventive Maintenance 2. Locate the small holes in the platen near some of the rollers. 3. Put three drops of oil into each hole in the platen. 4. If oil spills onto the platen, wipe the platen by using the cloth that was supplied within the User Maintenance guide kit. But do not wipe the rollers. 5. Close and lock the printer window.
Unlock and open the printer window and apply a few drops of oil (bottle of oil can be found in the Maintenance Kit) to the pads on either side of the Carriage Assembly. 3. Apply a few drops of oil directly to the Slider Rod on either side of the Carriage Assembly. 4. Press Ok when the lubrication procedure has finished. 5. Clean the substrate jam reflector using a lint-free cloth dampened with distilled water.
One of the EEROM counters is assigned to counting the number of carriage cycles. When certain components of the Printer exceed this amount, the front panel displays the following message: “Service Maintenance #1 required” The following message is triggered depending on the number of Service Station cycles. “Service Maintenance #2 required” The following message is triggered depending on the total quantity of ink that has gone into the Ink Funnel.
• Lubrication felts • 2 lubricant oil bottles. Preventive Maintenance Clean the IR sensors with a lint free cloth and solvent. Clean the IR sensors with a lint free cloth and solvent. Reset the Maintenance Counter, refer to page 226. Perform all maintenance procedures after the replacement: lubrication, cleaning.
Preventive Maintenance 628 Chapter 9 Preventive Maintenance
• • • • • • • • • Safety General Safety Guidelines ................................................................................. 630 Electrical shock hazard ...................................................................................... 630 Heat Hazard .................................................................................................... 630 Fire Hazard ...................................................................................................... 630 Mechanical Hazard.....
General Safety Guidelines Before servicing the printer, read the following safety precautions to make sure that you work on the printer safely. • Refer to installation instructions removing and replacing parts. • Whenever servicing the printer, turn off the printer, disconnect both power cords from the power sockets.
• Do not load substrates with auto-ignition temperatures below 300°C (572°F). See note below Test method based on EN ISO 6942:2002; Evaluation of materials and material assemblies when exposed to a source of radiant heat, method B. The test conditions, to determine the temperature when the substrate starts ignition (either flame or glow) were: Heat flux density: 30 kW/m², copper calorimeter, K type thermocouple.
Warning Labels Label Description Safety Risk of burns. Do not touch the internal enclosures of the drying and curing modules. Risk of burns. Do not touch the drying enclosure of the printer. Even after opening the window latch, which disconnects the power to the drying and curing modules, the internal surfaces could be hot. Electric shock hazard. The printer has two input power cords. A voltage is still present in the drying and curing modules after the main switch is turned off.
Safety Safety 633
Safety 634 Safety
