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MACH 5
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SECTION 6
DISASSEMBLY AND ASSEMBLY
83
13.
Verify that All C
ables Are Installe
d
NOTE: There will
be 10 open
sockets after all cables h
ave been installed
.
Open Socket
s: J550, J554, J553,
J750,
J706, J504, J353,
J400, J37, P900.
84
86
Table of Contents
Main Page
Default Chapter
1
Service Guide
1
Safety Precautions
2
Table of Contents
3
SECTION 1 - before You Begin
7
Recommended Troubleshooting Supplies
7
Common Service Tools Needed
7
Minimum Computer System Requirements
8
Print Engine Reference Note
8
If You Have Setup-Operations Questions
8
SECTION 3 - Troubleshooting
9
Print Quality Issues
9
Examples of Print Quality Issues (Including Possible Causes and Solutions)
10
Scuff Marks and Smudging Issues
13
Fuzzy/Distorted Print
15
The Ink Tank(S)
16
The Printhead Cartridge
17
The Printer
19
Dots or Lines Printed on Media
19
Power (Power-Up) Problems
20
Service Station Problems
21
Interface Communication Problems
22
Feeding Problems
23
Error's and Warnings
25
Alert Window Messages
25
Toolbox System Status Messages
26
Ink Accumulating in the Wrong Areas of the Printer
31
Jams in the Printer
32
Removing Jammed Media
32
How to Zero the Tilt Sensor
33
SECTION 4 - Toolbox Service Features
34
Using / Opening the Printer Toolbox
34
Firmware Download Feature
35
Diagnostics Menu
35
Network Configuration Menu
36
Service Menus
36
Printer Maintenance Configuration Screen
37
Printer Control Configuration Screen
38
Scan Sensors Screen
39
Commands Help Screen
40
Exit Service Menus
40
SECTION 5 - Measurements and Adjustments
41
Drive Belt Tension Adjustment
41
Power Supply
42
Media Sensors
43
Feed Sensor
43
Print Engine Sensors
45
Feeder Encoder Sensor and Encoder Wheel
46
Dust Exhaust Fans
47
Feeder Motor (Feed Section)
47
Clutch (Feed Roller Drive)
48
Feed Roller Drive Pulley Test
49
Print Engine Open Switch
49
Dual Pinch Valve Connection
50
Interface (I/O) Board Test Points
52
Section 6 - Disassembly/Assembly Procedures
53
Preparing the Printer for Service
53
Installation and Service Videos (Where to Find)
54
Basic Disassembly
54
Service Disassembly Procedures
54
Left-Hand (Operator) Side Covers
55
Right-Hand (Non-Operator) Side Cover
56
Replacing Motor Drive Belt or Motor
57
Replacing the Clutch
57
Replacing the Feeder Encoder And/Or Encoder Sensor
58
Replacing Feed Rollers
59
Replacing Delivery Rollers
62
Replacing Interface (I/O) Board
66
Replacing the Main PC Board (MPCA)
67
MPCA (Main Printed Circuit Assembly) Connections
87
Removing the Print Engine
88
Print Engine Basic Disassembly
93
Removing the Print Engine Base
93
Replacing Peristaltic Pump Assembly
94
Replacing Dual Pinch Valve Assembly
94
Cleaning Dual Pinch Valve Sensors
95
Replacing Dual Pinch Valve Sensor PC Board
96
Replacing DPCA Board
99
Replacing Buffer Boxes (3 Per Machine)
100
Replacing the Ink Tank Interface Boards
100
Removing the Pen Driver Printed Circuit Assembly (PCA)
101
Removing the Starwheel Assemblies
101
Replacing the Ink Tank Latches
102
Replacing the Printhead Lever Latch
102
Replacing the Printhead Lever Latch Solenoid
105
Replacing the Clamshell Latch Pins
107
Upper Clamshell Latch Pin Replacement - Kit
107
Lower Clamshell Latch Pin Replacement Kit
112
Replacing the Ink Revolvers
115
Replacing Lifter Motor Assembly or Lifter Gear
117
Replacing Stepper Motor
118
Accessing Items Behind the Main Printed Circuit Assembly (MPCA)
119
Replacing Encoder or Encoder Sensor
120
Replacing Service Station Lifter Arm Sensor
120
Replacing Paper Path Motor or Drive Belt
121
Replacing Belt Drive Gear Pulleys
122
Reinstall the Main Printed Circuit Assembly
123
Accessing Items under the Clamshell Assembly
124
Replacing Paperpath Exit Sensor
124
Replacing Paperpath Entry Sensor
125
Replacing Service Station Sled Printed Circuit Boards
126
Replacing Wiper Motor Flex Cable PCA
126
Replacing Service Station Lifting Arms
127
Section 6 - Service Maintenance
135
Maintenance Schedule
135
Replacing the Ink Tanks
136
Cleaning Ink Tank Contacts
137
Cleaning the Printhead Cartridge
139
Replacing the Printhead Cartridge
140
Printhead Storage & Shelf Life
141
Printhead Service Life
141
Printhead Disposal
141
Cleaning Pen Driver Printed Circuit Board Contacts
142
Inspecting & Cleaning the Lip of the Capping Station
143
Inspecting the Wiper Roller
144
Cleaning/Replacing Service Station Items
145
Removing the Service Station
145
Cleaning the Service Station
147
Wiper Roller Removal and Cleaning or Replacement
147
Wiper Motor Assembly Removal and Cleaning
148
Printing Platen and Capping Station Removal and Cleaning
149
Cleaning the Service Station Tray
149
Suggestion for High Volume Users
149
Installing the Service Station
150
Still Experiencing Print Quality Issues
153
Inspecting/Replacing the Waste Ink Tray
154
Replacing the Sheet Separators
155
Cleaning the Printer Body
156
Cleaning the Feed Rollers and Forwarding Rollers
156
Cleaning the Feed Sensor
157
Cleaning the Ink Revolver Couplings
158
Cleaning the Encoder Wheel - Z2I Engine
158
Cleaning the Lift Arm Sensor
159
Cleaning the Encoder Wheel on the Lift Motor
160
Cleaning Other Items Inside the Print Engine
161
Grit Rollers (Media Transport Rollers)
161
Media (Paperpath) Sensors
161
Paperpath Surfaces
161
Printing Platen Surface
161
Preparing Printer for Transport
163
Local Relocation
163
Remote Relocation or Shipping
163
Lubricating the Service Station Friction Points
165
Lubricating the Grit Roller Ground Clips/Springs
169
Reinstalling or Replacing the Service Station
170
Appendix Section
174
Appendix A -Specifications
174
Appendix B - Supplies and Optional Hardware
175
Appendix C - Service Station Guide Installation Instructions
176
Remove the Service Station
177
Appendix D - Ink Delivery System (IDS)
182
Theory of Operation
182
Appendix E - Z2I Wiring Diagram
184
Appendix F - Z3/Z4/MR Wiring Diagram
185
Appendix G -Interface (I/O) Board (42-500-30) Schematic
186
Appendix H -Interface (I/O) Board (42-500-30 Rev B) Schematic
187
Appendix I -Side Frame Modification
188
Index
189
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