Memjet MACH 8 Manuale utente

MACH 8

(HJ/AS-1180C)

HIGH CAPACITY

DIGITAL COLOR PRINTER

SERVICE MANUAL

Rev 05-27-14

PRELIMINARY

SAFETY PRECAUTIONS

THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY.

HOWEVER, CERTAIN SAFETY RULES SHOULD BE OBSERVED WHEN

OPERATING THE MACH 8 PRINTER.

BEFORE USING THE PRINTER, YOU SHOULD READ THIS MANUAL

CAREFULLY AND FOLLOW THE RECOMMENDED PROCEDURES, SAFETY

WARNINGS, AND INSTRUCTIONS:

Keep hands, hair, and clothing clear of rollers and other moving parts.

DO NOT place hands/feet or other body parts under the Feed Table or Receiving Tray.

Avoid touching moving parts or materials while the machine is in use. Before clearing a jam,

be sure machine mechanisms come to a stop.

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

any maintenance/service covered in this manual.

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

properly grounded, easily accessible wall outlet near the machine. Failure to properly ground

the machine can result in severe personal injury and/or fire.

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

power supply.

DO NOT use an adapter plug on the power cord or wall outlet.

DO NOT remove the ground pin from the power cord.

Do NOT use extension cords.

DO NOT route the power cord over sharp edges or trap it between furniture.

Avoid using wall outlets that are controlled by wall switches or shared with other equipment.

Make sure there is no strain on the power cord caused by jamming it between equipment,

walls or furniture.

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

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

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

for required service schedules.

To prevent overheating, do not cover the vent openings.

Use this equipment only for its intended purpose.

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

This manual is intended solely for the use and information of Neopost USA, its designated

agents, customers, and their employees. The information in this guide was obtained from several

different sources that are deemed reliable by all industry standards. To the best of our

knowledge, that information is accurate in all respects. However, neither Neopost USA, Inc. nor

any of its agents or employees shall be responsible for any inaccuracies contained herein.

Memjet®is a registered trademark.

All other trademarks are the property of their respective holders.

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

TABLE OF CONTENTS

Table of Contents

SECTION 1 – Before You Begin 4

Recommended Troubleshooting Supplies 4

Common Service Tools Needed: 4

Minimum Computer System Requirements 5

SECTION 2 – Troubleshooting 6

Print Quality Issues: 6

Examples of Print Quality Issues (including possible causes and solutions) 7

Air in Printhead Nozzle Area: 7

Clogged/Damaged/Dead Nozzles: 8

Color Mixing Issues: 9

Scuff Marks and Smudging Issues: 10

Fuzzy/Distorted Print 12

The Ink Tank(s) 13

The Printhead Cartridge 14

The Printer 16

Dots or Lines Printed on Media 16

Power (Power-Up) Problems 17

Service Station Problems 18

Interface Communication Problems 19

Feeding Problems 20

Feeding Problems (continued) 21

Errors and Warnings 22

Printer Alert Window Messages 22

Toolbox System Status Messages 23

Ink Accumulating in the Wrong Areas of the Printer 27

Jams in the Printer 28

Removing Jammed Media 28

SECTION 3 – Toolbox Service Features 30

Using the Printer Toolbox 30

Service Menu 32

SECTION 4 – Disassembly/Assembly Procedures 36

Printer Basic Disassembly 36

Service Disassembly Procedures 36

Left-hand Side (Operator Side) Covers 37

Right-hand Side (Non-Operator Side) Cover 38

Replacing the Feed Sensor 39

Adjusting the Feed Sensor 40

Replacing Feed Motor Drive Belt or Motor 41

Replacing the Clutch 41

Replacing the Feeder Encoder and/or Encoder Sensor 42

Replacing the Upper Limit Switch Assembly 43

Replacing the Feed Height Switch Assembly 45

Replacing the Hold Down Roller Assembly 47

Remove Media Table Lift Assembly Motor and Drive Belt 48

Replacing Media Table Lift Assembly Belt 49

Remove Media Table Lift Assembly 52

Replacing the Feed Rollers 57

Replacing Pull Out Rollers 59

Replacing Delivery Center Plate Assembly 62

Removing Delivery Rollers 65

Removing Separator Assembly 66

Replacing Interface PC Board 68

Replacing the Main PC Board (MPCA) 69

MPCA (Main Printed Circuit Assembly) Connections 89

Removing the Print Engine 90

Print Engine Basic Disassembly 95

TABLE OF CONTENTS

Removing the Print Engine Base 95

Replacing Peristaltic Pump Assembly 96

Replacing Dual Pinch Valve Assembly 96

Cleaning Dual Pinch Valve Sensors 97

Replacing Dual Pinch Valve Sensor PC Board 98

Replacing DPCA Board 100

Replacing Buffer Boxes (3 per machine) 101

Replacing QA Chip Assembly (3 per machine) 101

Removing the Pen Driver Printed Circuit Assembly (PCA) 102

Removing the Starwheel Assemblies 102

Replacing the Ink Tank Latches 104

Replacing the Printhead Lever Latch 104

Replacing the Printhead Lever Latch Solenoid 107

Replacing Upper and Lower Clamshell Latch Pins 109

Replacing Upper Latch Pins 109

Replacing Lower Latch Pins 114

Replacing the Ink Revolvers 117

Replacing Lifter Motor Assembly or Lifter Gear 119

Replacing Stepper Motor 120

Accessing Items Behind the Main Printed Circuit Assembly (MPCA) 122

Creating Access 122

Replacing Encoder or Encoder Sensor 123

Replacing Service Station Lifter Arm Sensor 123

Replacing Paper Path Motor or Drive Belt 124

Replacing Belt Drive Gear Pulleys 125

Reinstall Main Printed Circuit Board Assembly 126

Accessing Items Under the Clamshell Assembly 127

Removing Clamshell Assembly 127

Replacing Exit Sensor 127

Replacing Label Web Sensor 128

Replacing Service Station Sled Printed Circuit Boards 129

Replacing Wiper Motor Flex Cable PCA 129

Replacing Service Station Lifting Arms 130

SECTION 5 - Maintenance 138

Maintenance Schedule 138

Replacing the Ink Tanks 139

Cleaning Ink Tank Contacts 140

Cleaning/Replacing the Printhead Cartridge 142

Replacing the Printhead Cartridge 143

Printhead Storage & Shelf Life 144

Printhead Service Life 144

Printhead Disposal 144

Cleaning Pen Driver Printed Circuit Board Contacts 145

Inspecting & Cleaning the Lip of the Capping Station 146

Inspecting the Wiper Roller 147

Cleaning/Replacing Service Station Items 148

Removing the Service Station 148

Cleaning the Service Station 150

Wiper Roller Removal and Cleaning or Replacement 150

Wiper Motor Assembly Removal and Cleaning 151

Printing Platen and Capping Station Removal and Cleaning 152

Cleaning the Service Station Tray 152

Suggestion for High Volume Users: 152

Installing the Service Station 153

Still Experiencing Print Quality Issues? 156

Inspecting/Replacing the Waste Ink Tray 157

Replacing the Sheet Separators 158

Cleaning the Printer Body 159

Cleaning the Feed Rollers and Forwarding Rollers 159

Cleaning the Feed Sensor 160

TABLE OF CONTENTS

iii

Cleaning Other Items inside the Print Engine 161

Grit Rollers (Media Transport Rollers) 161

Media (Paperpath) Sensors 161

Capping Station Lip 161

Paperpath Surfaces 161

Printing Platen Surface 161

Cleaning the Ink Revolver Couplings 163

Preparing Printer for Transport 164

Local relocation 164

Remote relocation or shipping 164

Lubricating the Service Station 166

Reinstalling or Replacing the Service Station 168

Lubricating the Media Table Lift Assembly 171

Appendix A – Ink Delivery System (IDS) 173

Theory of Operation 173

Index 175

SECTION 1

BEFORE YOU BEGIN

SECTION 1 – Before You Begin

The following troubleshooting guides are provided to assist you in solving any problems that might occur

with the Digital Color Printer. We have tried to make them as complete as possible, but this section will

always be evolving.

Recommended Troubleshooting Supplies

Items that a Technician should have available to them, when they visit a “Digital Color Printer” customer

(in addition to standard tools):

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

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

M5K250-N, Black M5K250-N);

•Known good Printhead Cartridge (M5PRINT-N)

•Known good Service Station (123-2483)

•Lint-free cloths

•Distilled or Deionized water

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

system has been previously interfaced and tested with a Digital Color Printer. That way they should

have documents or jobs already setup to test with printer, drivers loaded, toolbox loaded.

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

•Service Manual

•Parts Manual

•Access to internet.

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

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

Common Service Tools Needed:

This list is in addition to standard tools.

•Spring Hook

•Needle Nosed Pliers

•Side Cutters

•Voltage Meter

•SAE set of Alan wrenches

•#1 and #2 Philips Screwdriver

•T-8/10/15 Torx drivers

•Carpenters Level (9” or smaller)

SECTION 1

BEFORE YOU BEGIN

Minimum Computer System Requirements

•Windows XP, Windows Vista, Windows 7 & *Windows 8/8.1

Supports 32 & 64 bit systems.

You must have administrative privileges on the system.

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

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

•At least 10 GB free hard-disk space.

•Microsoft Internet Explorer 6.0 or higher.

•Java version 6. (If you have Java 7 or higher installed; you may need to load Java 6 also, or the

Toolbox may not open properly.)

•CD/DVD drive

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

•Microsoft .Net Framework version 3.5 (for 32 bit systems) or Microsoft .Net Framework version 4 (for

64 bit systems) must be installed.

Note: Even if you have a higher .NET Framework version installed; version 3.5 or 4 must also be

installed, or the Toolbox will not open.

*Windows 8/8.1 is supported in “Desktop Mode” only. “Metro Apps” (applications for the Windows 8/8.1

environment only) are not supported.

How to check your system for the minimum system requirements, shown above:

Right click on "My Computer" and select Properties. The system information, including Operating System,

Processor Info and Memory info will be displayed under the "General" tab.

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

From the Control Panel; open "Add or Remove Programs" and look for "Microsoft .NET Framework 3.5..."

or "Microsoft .NET Framework 4..."in the list.

You can obtain "Microsoft .Net Framework 3.5 or 4" via the Microsoft website. http://www.microsoft.com

How to check your system for the version of "Java" installed.

From the Control Panel; open "Add or Remove Programs". Look for "Java(TM) ..." in the list.

You can obtain Java from the following website: www.java.com

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

installed.

SECTION 2

TROUBLESHOOTING

SECTION 2 – Troubleshooting

The following troubleshooting guides are provided to assist you in solving any problems that might occur

with the Digital Color Printer. We have tried to make them as complete as possible. The best advice we can

offer is to make sure that the system is set up properly, plugged in, and that it has an adequate supply of ink

before attempting to troubleshoot any problem.

WARNING

DO NOT REMOVE THE SIDE COVERS OF THE PRINTER!

THERE ARE HIGH VOLTAGES PRESENT BEHIND THE COVERS!

Print Quality Issues:

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

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

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

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

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

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

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

If not, check for a pinched color tube (finger on Forwarding Roller Guide Assembly may be pinching

tube), check related Ink Tank, and or the system may need to be re-primed. Please refer to the

Troubleshooting section for information on correcting these issues.

•Try removing air bubbles from printhead and system using the Toolbox utility feature “Circulate Ink”;

while lightly tapping on the ink tubes and printhead cartridge.

Note: Do not run the Circulate Ink feature more than twice in a row.

•Try removing or inserting the “Head Media Guide”.

•Try “Cleaning the Lip of the Printhead Cap”.

•Try “Cleaning/Replacing Service Station Items”.

•If you are still experiencing print quality issues; try “Replacing the Printhead Cartridge”.

Compatible Paper Types:(look for inkjet suitable stocks)

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

•Copier Paper

•Card Stock

•Kromekote

•Coated Paper - Gloss finish

•Coated Paper - Satin finish

•Coated Paper - Matte finish

Incompatible Paper Types:

•Color Laser Gloss

•Digital Printer Gloss

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

Compatible Graphic Types:

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

Note: Graphic types are not really printer dependent. They are dependent on the software program

being used to print the graphic, and what types of graphics that program can handle.

Incompatible Graphic Types:

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

SECTION 2

TROUBLESHOOTING

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

The Memjet printhead cartridge contains 70,400 inkjet nozzles. These nozzles are divided into ten rows;

two rows of nozzles for each color channel. Due to the high number of nozzles; it is not uncommon for

some nozzles to become contaminated, dehydrated or clogged.

The following examples were produced using a Five Band Color Purge YKCKM. A similar purge pattern

can be performed using the “Print Ink Channels” button; located in the Toolbox, Diagnostics Menu.

Air in Printhead Nozzle Area:

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

wider than one nozzle.

Possible Solutions:

•Press the “Full Clean Printhead” button, located in the Toolbox, User Interface screen, and lightly

tap on the ink tubes and Printhead Cartridge as the system is circulating ink. This can help

dislodge air bubbles within the Printhead and Ink Tubes.

Note:It is not a problem if air bubbles accumulate in the ink hoses at the non-operator side of the

printhead; since this is the outgoing side.

•Deprime and Reprime the system. Release the Printhead, using the “Release Printhead” button.

Remove and re-install the Printhead Cartridge. Then close printhead latch to re-prime the system.

Lightly tap on the ink tubes and Printhead Cartridge as the system is priming; to help dislodge air

bubbles.

•Inspect the system for possible air leaks (damage to ink tubes or ink revolver couplings).

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

perform automatic maintenance routines.

SECTION 2

TROUBLESHOOTING

Clogged/Damaged/Dead Nozzles:

Clogged/damaged/dead/ nozzles will normally show as thin, crisp, vertical lines of missing color. Multiple

adjacent nozzles, with same issue, will show as wider, crisp, vertical lines of missing color.

Clogged nozzles are normally due to Printhead nozzle dehydration or partial contamination.

Damaged nozzles are normally due to improper cleaning or debris on wiper roller causing damage to head.

Dead nozzles are normally due to the nozzle reaching its “end of life” (~50,000,000 ejections).

Possible Solutions:

•Press the “Full Clean Printhead” button, located in the Toolbox, User Interface screen

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

•Set the following Toolbox features to defaults to improve/increase head maintenance routines:

KWS Setting (Light) and Mid-Job Servicing (Default).

•Replace the printhead cartridge and wiper roller.

•Inspect/clean the service station and replace the wiper roller.

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

perform automatic maintenance routines.

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