TABLE OF CONTENTS
ii
Print Engine Drive Belt Tension Adjustment 55
Interface (I/O) Board Test Points 57
Section 5 – Disassembly/Assembly Procedures 58
Preparing the Printer for Service 58
Installation and Service Videos (where to find) 59
Basic Disassembly 59
Service Disassembly Procedures 59
Left-hand (Operator) Side Covers 60
Right-hand (Non-Operator) Side Cover 61
Replacing Digital Counter 62
Replacing Motor Drive Belt or Motor 65
Replacing the Clutch 65
Replacing the Feeder Encoder and/or Encoder Sensor 66
Replacing Feed Rollers 67
Replacing Delivery Rollers 70
Replacing Interface (I/O) Board 74
Replacing the Main PC Board (MPCA) 75
MPCA (Main Printed Circuit Assembly) Connections 95
Removing the Print Engine 96
Print Engine Basic Disassembly 101
Removing the Print Engine Base 101
Replacing Peristaltic Pump Assembly 102
Replacing Dual Pinch Valve Assembly 102
Cleaning Dual Pinch Valve Sensors 103
Replacing Dual Pinch Valve Sensor PC Board 104
Replacing DPCA Board 107
Replacing Buffer Boxes (3 per machine) 108
Replacing the Ink Tank Interface Boards 108
Removing the Pen Driver Printed Circuit Assembly (PCA) 109
Removing the Starwheel Assemblies 109
Replacing the Ink Tank Latches 110
Replacing the Printhead Lever Latch 110
Replacing the Printhead Lever Latch Solenoid 113
Replacing the Clamshell Latch Pins 115
Upper Clamshell Latch Pin Replacement - Kit (42-900-35) 115
Lower Clamshell Latch Pin Replacement Kit (42-900-30) 120
Replacing the Ink Revolvers 123
Replacing Lifter Motor Assembly or Lifter Gear 125
Replacing Stepper Motor 126
Accessing Items Behind the Main Printed Circuit Assembly (MPCA) 127
Replacing Encoder or Encoder Sensor 128
Replacing Service Station Lifter Arm Sensor 128
Replacing Paper Path Motor or Drive Belt 129
Replacing Belt Drive Gear Pulleys 130
Reinstall the Main Printed Circuit Assembly 131
Accessing Items Under the Clamshell Assembly 132
Replacing Paperpath Exit Sensor 132
Replacing Paperpath Entry Sensor 133
Replacing Service Station Sled Printed Circuit Boards 134
Replacing Wiper Motor Flex Cable PCA 134
Replacing Service Station Lifting Arms 135
Section 6 – Service Maintenance 143
Maintenance Schedule 143
Replacing the Ink Tanks 144
Cleaning Ink Tank Contacts 145
Cleaning the Printhead Cartridge 147
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