Revised 05-12-2006 Printer Service Manual Chapter 1 Features Chapter 2 Setup Chapter 3 Networking Chapter 4 Software Suite Chapter

5 Calibrations Chapter 6 Operations Chapter 7 Routine Maintenance Chapt er 8 Cartridge Replacement Chapter 9 Firmware Download Chapter 10 Troubleshootin g Chapter 11 Disassembly Chapter 12 Mechanical Alignments Chapter 13 Illustrated Parts List NOTE: All button and video links shown in this manual are not active please proc eed to the Service Guide Presentation for interactive functions.

Service Guide Printer Information: Features Printer Components Printer Technology Ink System Dryer System Print Speeds Media Support System Software Interface Cartridge Warranty

Service Guide Printer Information: Features Printer Components Features Video 1) Ink Refill Bottles 2) Intermediate Reservoir 3) Carriage Assembly 4) Cartridg e/Printhead 5) Active Service Station 6) Rapid Drying System 7) Auto Clean Unit 8) Media Support System 9) Operator Control Panel 10) Pinch Roller Drive

Service Guide Printer Information: Features Printer Technology 1. Intelligent Mask Technology (IMT) A simple screen that is applied to image files by the printer to determine which dots are layed down during each swath or print pass when printing in a particul ar print mode. A different print mask is applied for each color plane. 3-pass pr inting with conventional masking tends to result in hue-shift banding, especiall y with pigment inks. The main reason is that 3-pass printing builds the printed image with two right-to-left swaths and one left-to-right swath. Consider a carr iage layout that has magenta and yellow sharing the same swath: This results in yellow ink drops landing on the media first with magenta on top when printing ri ght-to-left. When the carriage moves left-to-right magenta goes down first with yellow on top. This tends to result in two distinct alternating color bands a th ird of a swath high that are highly visible from a distance with pigment inks on certain media types. IMT makes it possible to achieve better image quality duri ng high speed printing. High speed printing is more difficult because of the hig her densities printed per swath and the short time interval between the printing of some ink drops before other drops are printed on top or nearby. Print maskin g controls and limits coalescence to even out the resultant density and color, a nd reduce banding and graininess. Animation

Service Guide Printer Information: Features Printer Technology

Service Guide Printer Information: Features Printer Technology 2. Rapid Evaporation Drying System The advanced dual-component drying system uses the principle of conducted heat t o dry printed images with much greater efficiency than can be achieved with hot air dryers. The media web is fed over a heated aluminum nose that is curved to m aintain intimate contact with the back of the web for effective heat transfer. T he nose is an isolated extrusion that incorporates three longitudinal fins with an electrical heating strip mounted to each fin inside the curve. This design ev ens out heat flow to minimize cold spots under high density printed areas across the web without the long warm-up time of a much thicker section. Ambient air fl ow is used to pull away moisture and improve drying efficiency by another 30% ov er that achieved with the heated nose alone. A fan driven air plenum is used to distribute air flow evenly across the print width. Air flow is downward, carryin g heat away from the print zone to improve nozzle reliability and to reduce the risk of edge curl. An intelligent control system regulates electrical power to a chieve and maintain temperature set points between 35 and 55 degrees C. Animation

Service Guide Printer Information: Features Ink System Ink Refill Bottles - 6 ink bottles (ML, CL, Y, K, M, C) - Refill bottles are easy to replace - Encr ypted for ink monitoring (740 ml shutoff) - One set of ink lines; switch over ca pability (Dye or Pigment) - Plug and Play ink refill bottle (700 ml) with septum /needle interface - Clean-hands installation - Mechanical color keying of bottle Intermediate Reservoir - Intermediate reservoir at reservoir base - provides consistent ink supply pres sure - Replace ink on-the-fly - Prevents job interruptions (52 ml capacity) - In k level LOW warning sensor (30 minutes) - Ink level OUT stop, protects cartridge

Service Guide Printer Information: Features Ink System Carriage Assembly - Robust carriage bushing design; thick bushings with spring loaded bias for bet ter dimensional stability - Bushings are grooved to minimize the effect of dirt and debris - Cartridge doors secure printheads in place - Ink is regulated to pr inthead via ink line dampers - One-step cartridge installation process Animation Cartridge/Printhead - Increased productivity with 640 nozzle printheads - Improved quality with 30% smaller drop size - Clean hands shipping and installation - Foam filled, elimina te tubing and needles - 2100 ml average life; 2800 ml shutoff

Service Guide Printer Information: Features Ink System Active Service Station - Clean hands ink line filling through service station - Motor controlled multiport color control selection valve - Eliminates ink prime devices - Clean hands cartridge maintenance through service station - Ink is deposited into a waste bo ttle Auto Clean Unit 1) Door Magnet 2) Suction motor (for priming ink lines) 3) Bottle full sensor 4) Ink Receptacle (bottle) 1) Color selection valve 2) Station Motor 5) Bottle present sensor

Service Guide Printer Information: Features Rapid Drying System 1) Air Plenum 2) Input air flow 3) Output air flow 4) Heated Nose (insulated) 5) Electrical heating strips (35-55 degrees C) 6) Platen (print zone) - The heated nose quickly warms the media up with 3 electrical heating strips th at provide even heat flow - The forced air plenum is used to remove moisture and heat from media surface to allow faster drying - 12 dryer modes are available f or a wide range of media types; air plenum can operate on or off. Ink dries 30% faster than hot air drying systems. May be rotated down for maintenance purposes ; may be removed for certain Bond media. System uses 25% less energy over other drying systems.

Service Guide Printer Information: Features Print Speeds Print Mode High Speed mode (2 pass) Productivity mode (3 pass) Fine mode (4 pass ) Enhanced mode (6 pass) High Quality (16 pass) Note: Printer ships with 64 MB S DRAM and is not up gradable; HPGL/2 is not supported. An additional 32 MB RAM re sides on the main board. 60 inch model 220 sfph (20.4 smph) 150 sfph (14.0 smph) 115 sfph (10.7 smph) 75 sfph (7.0 smph) 26 sfph (2.8 smph) Video 42 inch model 195 sfph (18.1 smph) 140 sfph (13.0 smph) 104 sfph (9.6 smph) 70 sfph (6.5 smph) 23 sfph (2.5 smph)

Service Guide Printer Information: Features Media Support System 1) Primary Feed Roll 2) Feed Sensor (bracket extended 2 inches) 3) Feed Roll 2 ( or TakeUp Roll) 4) TakeUp Sensor 5) AutoLoad Paper Sensor 6) Media Pinch Roller 7) Lower Roller - Four media supply modes are available: Sheet, Roll, Roll 2 and TakeUp - Media rolls can be easily exchanged with the removable media spindles. The Autoload pa per sensor has a 6 second delay when media is manually loaded at rear of printer . The lower roller and pinch rollers control paper travel. The Roll 2 mode allow s for a second roll of media to be loaded onto the lower roller (no takeup avail able). Note: 20,000 volt minimum protection is provided by 2 permanent rear elec trostatic discharge strips located in platen.

Service Guide Printer Information: Features Software Interface Setup Requirements: 1) Server workstation with RIP loaded; Windows 2000/XP/XP PR O/Windows 2003 Server, Network Card, 3.0 GHz Processor, 1 GB RAM, 160 GB hard dr ive 2) Printer Installation Software 3) Client workstation (not required) 4) Net work Switch/HUB; 100FD Capability 5) Printer (built-in 100baseT Network card) 6) Web Access (for Software Updates)

Service Guide Printer Information: Features Software Interface Setup Tasks: Software Installation: - Server/Client Control Setup (follow Typica l Setup) - Database Server (automatic) - Drivers, EFPU, and Custom Colors Utilit y (automatic) - Network Connectivity (automatic)

Service Guide Printer Information: Features Cartridge Warranty Cartridge Warranty Volume Cartridge Average Life Cartridge End of Life Warranty Coverage 700 ml 1400 to 2100 ml 2800 ml Verify ink throughput by selecting UTILI TY MENU - INK STATUS MENU - CART INFO Note: Nozzle failures are 100% filled bloc ks as observed in Prime pattern Ink Kit Configurations - Ink Refill Bottle (700 ml) - Ink and Cartridge Kit (700 ml)

Service Guide Installation/Operations: Printer Setup Printer Unpacking Install Takeup/Feed System Install Auto clean Unit/Raise Print er Initialization Load Media Install Ink Install Ink Cartridges Print Test Patterns Open Jet Compensation

Service Guide Installation/Operations: Printer Setup Printer Unpacking Step 1. Open printer head box flaps. Using two (2) people minimum, rotate box/pa llet over 90 degrees onto one side. Note: ensure the air plenum is facing up. Video WARNING: Printer head and packaging weigh up to 374 lbs (170 kilograms); only pe rform heavy lifts with two (2) or four (4) people as referenced by respective st ep. Also see video procedures. Approximately 3 x 4 square meters of space will b e required for setup. Note: A total of three boxes should be at installation site: printer head (on pa llet), stand box (contains Takeup System and Auto Clean Unit), and Ink Accessory Box. NOTE: If printer was in cold storage (below freezing) then allow 24 hours for printer to acclimate to new environment prior to assembling.

Service Guide Installation/Operations: Printer Setup Printer Unpacking Step 2. Using two (2) people minimum, pull printer free from packaging by grabbi ng shipping brackets (through plastic) and sliding printer away from box.

Service Guide Installation/Operations: Printer Setup Printer Unpacking Step 3. Remove power cord box and accessory box (contains screwdriver, ink line priming tools and software CD). Using the 6 (long and short) pieces of packing f oam (white foam strips); place in triangular formations (3 per pile) on the floo r directly in front of each printer cover. Note: ensure triangular foam piles ar e centered directly in front of each printer cover.

Service Guide Installation/Operations: Printer Setup Printer Unpacking Step 4. Using two (2) people minimum, lift each printer end onto the foam supports. NOTE : the protective metal shipping brackets must not be touching floor surface. Ver ify the printers air plenum is facing up (rear side of printer facing down).

Service Guide Installation/Operations: Printer Setup Printer Unpacking Step 5. Remove the plastic packaging from printer. Caution: verify printer is stable prior to stand installation.

Service Guide Installation/Operations: Printer Setup Install Takeup/Feed System Step 1. Remove the cross-support bracket by removing two bolts and wing nuts. At right side of printer (control panel end), remove the 2 shipping bracket bolts and wing nuts. One person will need to hold printer while the other person remov es the bracket to prevent from rolling. Video Remove right lower shipping bracket (4 screws) and upper shipping bracket.

Service Guide Installation/Operations: Printer Setup Install Takeup/Feed System Step 2. 1) Install and secure the right stand foot (4 screws) onto stand leg. Po sition the right stand leg and attach electrical plug connection (located inside leg) to printer base jack ensure the plug and jack are squarely aligned when co nnecting. Ensure restraining clips are secure. 2) Attach right stand leg with 4 screws - do not tighten screws down at this time. 3) Caution: do not pinch harne ss wiring when attaching to avoid damage.

Service Guide Installation/Operations: Printer Setup Install Takeup/Feed System Step 3. At left side of printer, remove the 2 shipping bracket bolts and wing nu ts. Remove left lower shipping bracket (4 screws) and upper shipping bracket. Set br ackets to one side.

Service Guide Installation/Operations: Printer Setup Install Takeup/Feed System Step 4. a) Secure stand foot to left stand leg (4 screws). Attach the left stand leg (4 screws) - do not tighten screws down at this time. b) Attach and secure crossbar to stand legs (4 screws). Tighten 8 (eight) stand leg screws at this ti me.

Service Guide Installation/Operations: Printer Setup Install Auto Clean Unit/Raise Printer 5 Step Process: Note: 4 short securing screws are pre-installed. 1) Connect 2 el ectrical connections; ensure plugs are securely seated into jacks. 2) Remove nip ple cover from pump. 3) Connect ink tubing connection to motor/pump nipple. Note : ink tubing connection should be located inside printer base. Caution: Do not l oosen quick connect valve. Video 4) Remove tape from securing screws. 5) Pitch unit to the right and secure over the 4 screws; tighten securing screws.

Service Guide Installation/Operations: Printer Setup Initialization Step 1. Lock two of the stand feet casters. WARNING: Installed printer can weigh up to 270 lbs (122 kilograms); only perform this heavy lift with four (4) peopl e. Using a four (4) person lift, grasp base of left and right bottom covers, rear s ide/edge of top cover; lift printer to standing position.

Service Guide Installation/Operations: Printer Setup Initialization Step 2. Remove remaining packaging materials including the center shipping brack et. To remove the center shipping bracket lower the dryer (air plenum) to the ma intenance position by removing the restraining pins at either side of dryer.

Service Guide Installation/Operations: Printer Setup Initialization Step 3. Ensure voltage selector switch is set to input line voltage (115 or 230 volts). Note: printer ships in the 230V position. Plug in printer and turn on pr inter power switch. Video Caution: For regions which experience intermittent voltage fluctuations a line c onditioner and surge protector are suggested to help protect the printers power supply.

Service Guide Installation/Operations: Printer Setup Initialization Step 4. After a 9 to 10 second power up delay, ensure the carriage traverses acr oss entire printing area and back without error during initialization process. T he main menu should be displayed when initialization is complete.

Service Guide Installation/Operations: Printer Setup Load Media Step 1. Install Feed Media/Roller 1) Unlock roll guide 2) Slide guide away from spindle 3) Install spindle into new roll of media 4) Install roll guide 5) Tight en roll guide against media edge 6) Install feed roller into printer; ensure gea rs mesh properly Video

Service Guide Installation/Operations: Printer Setup Load Media Step 2. Install Takeup Core/Roller 1) Install media core onto spindle 2) Install roll guide 3) Lock roll guide against media core 4) Install takeup roller into printer; ensure gears mesh properly

Service Guide Installation/Operations: Printer Setup Load Media Step 3. Pull media from feed roller; fully insert media edge into media path cha nnel. Align to white mark on left rear side of platen. After a 9 second delay me dia will be automatically pulled into the printer path. Media will be sensed and sized automatically. Verify media is sized correctly by selecting Utility Menu - Display Settings. Ve rify correct paper width is displayed. Adjust media guides to within two millime ters of media edges. Note: do not allow media guides to touch media or paper fee d drag/banding may be encountered. Note: media may also be manually loaded by selecting Feed Media Menu - Forward. Advance media until media is observed across the printing surface. Select Load M edia at control panel to load.

Service Guide Installation/Operations: Printer Setup Load Media Step 4. Use the takeup roller when multiple or long print jobs are going to be p rocessed and printed. Three inch core adapters are available if takeup roll is b eing loaded onto a laminator. For takeup operations, tape media edge to the medi a core; ensure media edges line up evenly with media core edges. Install Media Edge Holders (magnetic) onto Y-Arm side - the holders prevent medi a edges from lifting during low humidity conditions. Install left and right pape r guides over media edges - the guides will help media move through the air plen um.

Service Guide Installation/Operations: Printer Setup Install Ink Step 1. Video Note: Wait 5 minutes prior to performing line fill (must allow enough time for t he intermediate reservoirs to fill properly) Obtain the 6 new ink bottles remove the shipping caps from bottles. Open the lef t cover and install all 6 bottles. Ensure bottle fittings mate properly with eac h intermediate reservoir fitting.

Service Guide Installation/Operations: Printer Setup Install Ink Step 2. Lower air plenum and access cartridges (select Utility Menu - Access Cartridge). Obtain the Cartridge with Tube Assembly (and plug bar) from printer Accessory B ox. Connect Cartridge with Tube Assembly needle to septum fitting located on rig ht side plate (lift front access door). Install plug bar into service station if a yellow label is present at right front corner. Attach line fill cartridge int o the light Magenta stall. The Cartridge with Tube Assembly (and plug bar) is a setup tool for filling ink lines and may be used to help eliminate air bubbles from an ink line. Caution: d o not use for a complete flushing of ink lines unless a red star is present on a uto clean door or possible damage may result to auto clean motor/pump; a Flush K it will be required (P/N 222351-00 or 221984-01).

Service Guide Installation/Operations: Printer Setup Install Ink Step 3. Activate line pump. Select and hold Utility Menu - Prime Menu Service St ation Menu Pump On. Release Pump On when ink is observed in cartridge tubing lin e. The line fill process takes approximately 20 seconds per color. Repeat proced ure for remaining stall positions. Following ink line filling, disconnect the li ne fill cartridge from the last stall position but leave needle connected to sep tum fitting. Select Pump On to clean assembly of ink; disconnect priming assembl y when complete.

Service Guide Installation/Operations: Printer Setup Install Ink Cartridges Step 1. Open cartridge door. Video Step 2. Remove accumulator; remove blue tape from cartridge. Step 3. Slide cartridge into cartridge stall and close cartridge door. Door must be closed to properly bias cartridge position.

Service Guide Installation/Operations: Printer Setup Print Test Patterns Step 1. Print Color Test Select Utility Menu - Service Menu - Diagnostics Menu C olor Test. Choose All Colors, select Ok Video Verify solid rectangular print swaths are printed for each color with no visible ink starvation.

Service Guide Installation/Operations: Printer Setup Print Test Patterns Step 2. Print Prime Pattern Select Utility Menu - Prime Menu Prime All Verify printhead nozzle performance - ensure diagonal lines are smooth and clogg ed jets are not present.

Service Guide Installation/Operations: Printer Setup Print Test Patterns Step 3. Print the Test Print Select Utility Menu - Service Menu - Test Print Use this print to evaluate printer calibrations and general color output.

Service Guide Installation/Operations: Printer Setup Open Jet Compensation Step 1. Print Prime Pattern to verify nozzle performance. Video xxx To perform manual jet bypass select Utility Menu - Calibration Menu - Open Jet M enu - Edit List Menu. After inspecting the Prime pattern, select appropriate col or and toggle respective jet (s) off.

Service Guide Installation/Operations: Networking Automatic Configuration Manual IP Address Configuration

Service Guide Installation/Operations: Networking Automatic Configuration System Setup: 1) MAC design station 2) PC workstation 3) PC server with RIP load ed 4) Switch/hub 5) Printer; DHCP Disabled is the default setting Obtain User CD from Printer packaging and install CD onto Server/RIP workstation . After CD executes, load SOFTWARE UTILITIES (follow typical installation) and P RINTER SETUP (driver/networking portion). For more information refer to Software Control on this CD.

Service Guide Installation/Operations: Networking Manual IP Address Configuration Step 1. Set IP and network information. At printer select SETUP MENU - NETWORK M ENU - IP CONFIG MENU. Ensure host computer has the IP address, Subnet, and Gatew ay addresses assigned. Computer and Printer should be within the similar IP rang es (typically the first 3 numbers of IP address should be the same; both should have the same Subnet and Gateway addresses). Step 2. Check Network Info to ensur e network information is correctly setup. Note: Disable DHCP at Printers DHCP Cl ient screen for peer-to-peer configurations; enable DHCP for larger network conf igurations (IP address will be automatically assigned - use this IP address). St ep 3. Set this IP address within RIP or add Standard TCP printer port (generic) using this address.

Service Guide Installation/Operations: Networking Manual IP Address Configuration To download IP address directly to printer: Step 1. At the Command/DOS prompt en ter: arp -s IPaddress MACaddress (MAC address can be found under Printers Networ k Menu). For Example: arp -s 192.168.100.104 00-C0-EB-04-76-07 and then press En ter. Note: For NT systems enter MAC address with colons: i.e. 00:C0:EB:04:76:07 Step 2. Verify IP address download was successful by verifying IP address at Printers Network menu. Step 3. Ping IP address to ensure connection is valid. At the Com mand/DOS prompt enter: ping IPaddress (i.e. ping 192.168.100.104). Verify 4 REPL Y returns are displayed. Step 4. Set this IP address within RIP/Driver.

Service Guide Printer Information: Software Suite Software Installation Printer Installation Server Setup Datbase Server Client Co ntrol Job Accounting Technical Support Reporting Software Activation

Service Guide Printer Information: Software Suite Software Installation Software Suite Install Select the Typical installation for a first or single computer installation. For a second computer, select Advanced and install only the client portion of the s oftware. Note: Individual utilities may be installed if configuring onto a remote Client system only.

Service Guide Printer Information: Software Suite Printer Installation Printer Drivers Install Printer Installation will automatically detect printer on the subnet, install dr ivers and designate IP addresses. There are two types of installations. Complete the Server installation for a sin gle computer or server. Complete the Client printer installation for a second an d all sub-computer installations. Follow the screen prompts to complete the installation.

Service Guide Printer Information: Software Suite Server Setup Procedure: Stop server. Select settings to make changes to server configuration Walk throug h of connection to the server and printer information screens Software / Utilities Setup of the Client User Interface and 5 other packages. Requires only one server for all printers/computers

Service Guide Printer Information: Software Suite Database Server Runs in the background - Stores information on media type, ink cost and productions times. - Assist in cost reporting and print cost reporting.

Service Guide Printer Information: Software Suite Client Control Panel Platform Support: For use on Windows 2000, Server or Win XP/XP Pro - Remote Printer Control Center - Job Accounting - Ink Usage/Waste - Technical Support and Service Interface

Service Guide Printer Information: Software Suite Job Accounting Displayed Results: Output tracking features - User selectable fields for tracking all aspects of jo b costs. - Accurate reporting of media and ink used per job. - Accurate reportin g of time required to print jobs.

Service Guide Printer Information: Software Suite Technical Support Reporting - Used to export Database information - Information can be exported to a text fi le (csv) and sent to an email address - Can be customized to export specific inf ormation - Can be customized with user/contact information - Supports additional comments

Service Guide Printer Information: Software Suite Software Activation The printer software suite will expire the Job Accounting feature after 90 plot hours unless the printer software is registered. There are three ways to registe r: 1. Direct from the Registration page during software installation (web connec tion required from software installation location) or at Client Control Panel, c hoose Help Product Registration. 2. Through website (www.encad.com), printer ser ial number will be required. 3. Call directly into US Technical support with pri nter serial number. Encad San Diego will have a utility which will automatically generate a code (xxxx xxxx xxxx xxxx xxxx xxxx xxxx) upon registration and an e mail with the activation code will be forwarded back to the customer. From the C lient Control Panel select: Help - Product Activation - Add Key. Enter the code and select Ok.

Service Guide Installation/Operations: Calibrations Calibration Path Summary Printer Calibrations Prime Pattern Manual Jet Compensat ion

Service Guide Installation/Operations: Calibrations Calibration Path Summary For graphics printing (minimized microbanding) perform Graphics Calibration. For accurate line length accuracy perform the Line Accuracy Calibration. Either way , the 4 primary calibrations must be performed prior to conducting any printer o perations. Refer to Service Bulletin 1 or Technical Bulletin 1 for complete inst ructions. Graphics Calibration: 1. Perform Line Length Test; measure distance 2. Measure L ine Length Value (i.e. 33.06) 2. Modify Img Quality Value (i.e. 33.06) and press Ok. Save Calibration to User setting. 3. Perform Deadband Calibration 4. Perfor m Color Calibration Vertical 5. Perform Color Calibration Horizontal 6. Evaluate print performance (Demo image/6-pass mode) 7. If necessary perform micro-alignm ent, print the Printer Calibration Test Target.rtl (from Service CD). Adjust Pap er Calib Value to reduce microbanding. Perform Color Calibration Vertical Line A ccuracy Calibration: 1. Perform Line Length Test; measure distance 2. Adjust Lin e Length Value (i.e. enter 33.06) 3. Perform Deadband Calibration 4. Perform Col or Calibration Vertical 5. Perform Color Calibration Horizontal

Service Guide Installation/Operations: Calibrations Calibration Path Summary All printer calibrations are located in one menu. Note 1: the media feed/steppin g rate is determined by either the Paper Calib Value or the Line Length/Img Qual ity Value last entered, but not both. Calibration Menu Note 2: DO NOT use the PAPER CALIB TEST as results may vary. Paper Calib Menu

Service Guide Installation/Operations: Calibrations Printer Calibrations Step 1. Graphics Calibration a. Perform Line Length Test, select UTILITY MENU - CALIBRATION MENU - PAPER CALI B MENU - LINE LENGTH TEST. A line pattern will be printed in the center of the m edia; the pattern extends approximately 33 inches or 838.2 mm. Measure and enter true distance between lines (a 35 inch ruler may be printed from Service CD). b . Modify Img Quality Value (i.e. 33.06) and press OK. Save Calibration to User s etting. c. Perform Deadband Calibration, Color Calibration Vertical and Horizont al (see following pages). d. Activate the Deadband Test to verify printer calibrations, select Utility Men u - Service Menu - Calibration Menu - Deadband Test. This will check the electri cal and mechanical calibrations. All 6 colors should line up vertically across t he entire print. At both ends, check the next to last line.

Service Guide Installation/Operations: Calibrations Printer Calibrations Step 1. Graphics Calibration e. Evaluate print performance using a demo image in 6-pass mode. f. If banding i s unacceptable, then print the Printer Calibration Test Target.rtl (send file th rough EFPU) located on Service CD. g. Adjust Paper Calib Value to reduce microba nding. Analyze the calibration test target print for media overfeed or underfeed . If overfeed is observed as in example A below (white lines/gaps occurring), th en reduce the Paper Calib Value by one or two values and retest (i.e. change fro m 4806 to 4805). If underfeed is observed as in example B below (dark lines/over lap occurring), then increase the Paper Calib Value by one or two values and ret est (i.e. change from 4806 to 4807). Example A (need to decrease values). Example B (need to increase values). h. Perform Color Calibration Vertical (see following pages).

Service Guide Installation/Operations: Calibrations Printer Calibrations Step 1. Line Accuracy Calibration a. Perform Line Length Test, select UTILITY MENU - CALIBRATION MENU - PAPER CALI B MENU - LINE LENGTH TEST. Measure and enter true distance between lines (a 35 i nch ruler may be printed from Service CD). b. Adjust LINE LENGTH VALUE and selec t OK. Save Calibration to User setting. c. Evaluate the test pattern, cut media and remove from printer. Measure the distance between the horizontal lines and e nter the measured value under Line Length Value. Press OK, this will lock the me dia feed value. A line pattern will be printed in the center of the media; the pattern extends a pproximately 33 inches or 838.2 mm. Accuracy tolerance is +/- 0.2% over image le ngth. d. Perform Deadband Calibration, Color Calibration Vertical and Horizontal (see following pages).

Service Guide Installation/Operations: Calibrations Printer Calibrations Step 2. Deadband Calibrations Select UTILITY MENU - CALIBRATION MENU - COLOR DB MENU - COLOR DB TEST. For each color choose the best group of aligned vertical l ines. Note the compensation number below each group of vertical lines.

Service Printer Step 3. placed. TEST

Guide Installation/Operations: Calibrations Calibrations Color Calibration Vertical Perform whenever a cartridge is removed or re Select UTILITY MENU - CALIBRATION MENU - COLOR CALIB MENU - VERT. CALIB.

Choose number which best represents alignment between both colors for each field . Step 4. Color Calibration Horizontal. Perform Horiz Calib Test; repeat procedure as above.

Service Guide Installation/Operations: Calibrations Prime Pattern Check printhead nozzle performance by activating the Prime pattern. Select UTILI TY MENU - PRIME MENU - PRIME ALL. Verify diagonal lines are smooth and clogged j ets are not present. 1) Solid blocks represent failed jets; compensation engaged no user interaction is necessary. The cartridge warranty is provided from a des ignated number of these blocks observed in pattern and less than 700 ml ink thro ughput. Refer to regional cartridge warranty claim documentation from technical support. 2) Perform Manual Jet Compensation as necessary for: 3) Clogged Jets 4) Mis-directed Jets 5) Degraded Jets Video

Service Guide Installation/Operations: Calibrations Prime Script If a cartridge problem is suspected, check cartridge performance by selecting UT ILITY MENU - SERVICE MENU - DIAGNOSTICS MENU - PRIME SCRIPT. Select appropriate cartridge stall to check. A series of patterns will print: 1) Color Test; ink system pressure test, also u sed to help unclog print head nozzles 2) Prime pattern; test to check all 640 pr int head nozzles 3) PData patterns; Image data ports. Pdata 1 governs nozzles 1320. Pdata 2 governs nozzles 321640. 4) Fire patterns; Fire 1 and Fire 2 provide pulses. They are sampled to fire nozzles. 5) PWR1 through 8 patterns; indicates power lines. Each power line governs 2 primitives of nozzles. 6) A1 through A5 patterns; indicates address lines.

Service Guide Installation/Operations: Calibrations Manual Jet Compensation To bypass a clogged or misfiring jet select UTILITY MENU - CALIBRATION MENU - OP EN JET MENU EDIT LIST MENU. Select appropriate color. Scroll to appropriate jet and toggle the jet off. Compensated jets will appear a s 80 percent filled blocks the next time the Prime pattern is printed.

Service Guide Installation/Operations: Printer Operations Media Load and Verification Dryer Modes Humidity Control Printer Readiness Reser voir Replacement Ink Cartridge Replacement Ink Waste Disposal Printer Safety Ink Line Filling Cutter Replacement Printer Flushing

Service Guide Installation/Operations: Printer Operations Media Loading Install media onto spindle and attach the media guide and tighten the blue locki ng nut. Verify spindle gears mesh properly. Ensure left media guide is locked ne xt to the white alignment mark. Adjust right media guide to within 2 mm of media edge (guides should not touch media edges). Load media into the printer, align with white alignment mark. Note: when media reaches end of roll do not forward m edia through printer rollers. Sometimes the end of roll contains excess glue whi ch may cause frictional problems with the printer media transport system. Video -Complete Media Load Video -Quick Media Load Note: paper will be automatically advanced following a 6 second delay and then m easured.

Service Guide Installation/Operations: Printer Operations Media Loading Perfect Media Load 1. Load media at rear of printer. NOTE: Avoid damaging electr ostatic strip at rear. 2. Move the rear edge media guides aside so that the medi a can move freely, left to right. 3. At front of printer reach down and hold the feed roller guide (do not allow roller to move), at main menu press and hold Fe ed Media - Forward. 4. The feed gear will start to move in an attempt to drive t he media forward, but do not allow media to feed. 5. The media will begin to ali gn itself, observe media right edge until no side-toside motion is observed. 6. Release the Forward button after media stops moving sideways. Media should be al igned with feed roll edge. 7. At Main Menu select Load Media. 8. Move the left a nd right rear edge media guides to within 1-2 mm of media edges, but not touchin g. Install Paper Edge Guides (2) and Media Edge Holders (2). Video -Perfect Media Load

Service Guide Installation/Operations: Printer Operations Dryer Modes To activate the drying system select Setup Menu - Dryer Menu - Dryer Setting. Sc roll through available selections. Video Note: air plenum may be lowered to maintenance position by removing 2 locking pi ns and gently lowering plenum. Place in up postion for all printer operations. 12 dryer modes are available; refer to dryer matrix label affixed to printer top cover.

Service Guide Installation/Operations: Printer Operations Humidity Control Ideal humidity for printing is between 45 and 55 percent, at a temperature of 68 -72 degree F. (20-22.2 degrees C.). Refer to Service Bulletin 8. Low Humidity pr oblems: 1) Media warping and edge curl problems leads to visible carriage head s trike on media surface. Ensure paper guides/edge holders are properly affixed to printer. Caution: keep magnetic assemblies away from the control panel display or damage will result. 2) Inconsistent print quality is normally observed in sev ere low humidity environments. To compensate more ink must be used to balance th e color loss. High humidity problems: 1) Dry time drastically increases with hig h humidity levels. 2) Lamination issues often result; increasing time required t o finish jobs. 3) Color Shift from one day to the next may occur. Environmental Factors These problems can be avoided by maintaining proper temperature and humidity lev els (RH). The use of humidifiers will add more water to the air, resulting in a humidity level increase. This will help prevent heating season problems caused b y dry air.

Service Guide Installation/Operations: Printer Operations Printer Readiness To ensure the printer is ready prior to printing first activate the prime patter n by selecting Utility Menu Prime Menu - Prime All. Refer to Technical Bulletin 1 for complete Printer Calibrations. Video The Prime pattern checks the electrical firing capability of all 640 jets for al l six colors. Verify all cartridge nozzles are firing properly. If necessary per form open jet bypass, select Utility Menu - Calibration Menu - Open Jet Menu - E dit Jet List. Toggle misfiring or clogged jets off; select Ok to save changes. R efer to Technical Bulletin 6 for print and lamination guidelines.

Service Guide Installation/Operations: Printer Operations Printer Readiness End of Plot Edge Band Mode Edge Band is a special mode used to help eliminate in stances of First Drop (inconsistent small horizontal lines .2 mm to 10 mm appear ing at left or right edges of print) - refer to Troubleshooting. Select Setup Me nu - Paper Option Menu - Margins - Edge Band. Ensure the End of Plot mode is cor rectly setup. Select Setup Menu - Dryer Menu - End of Plot. Three modes are avai lable: On With Rewind (dries image and then rewinds print to save media) On With out Rewind (dries image, does not rewind the print) Off (no media advancement fo llowing printing, does not dry the remainder of print) The Edge Band mode employ s the same spacing as Normal Margins but prints a 6 color line within each norma l margin area. Note: This mode does not encroach/crop the printed image. Enhance d margins with the edge band mode is not available. Video - Edge Band

Service Guide Installation/Operations: Printer Operations Reservoir Replacement Firmly grasp the used reservoir bottle and pull straight up. Install new reservo ir by pushing reservoir firmly down into the intermediate reservoir at base of s tall. Video Note: if replacing a reservoir bottle during print operations, a print shutdown error will occur if bottle is not replaced within 30 seconds. The identification chip on reservoir must firmly make contact with intermediate reservoir sensor c ontacts. Check reservoir information: Utility Menu - Service Menu Bottle Status.

Service Guide Installation/Operations: Printer Operations Ink Cartridge Replacement To replace an ink cartridge: - Access cartridges by selecting Utility Menu Acces s Cartridges. - Lift the cartridge door by pulling on door lip up at a 45 degree angle. - Remove defective cartridge from carriage. - Remove tape from new cartr idge and install cartridge. - Close cartridge door by pressing down firmly until door locks. - Return carriage to service station. Video Caution: do not install/remove cartridges through the service station access doo r or damage to print heads or service station may result.

Service Guide Installation/Operations: Printer Operations Ink Waste Disposal To remove the ink disposal bottle open the auto clean unit door and remove ink d isposal bottle. Install empty waste disposal bottle and close auto clean unit do or. Video

Service Guide Installation/Operations: Printer Operations Printer Safety General operating tips to keep in mind: - Never touch the slide shaft while prin ter is operating or damage may occur to printer. - Never remove the service stat ion while printer is in operation or bodily harm may result. - Always keep top c over down to prolong carriage bushing life. - Never install or remove cartridges through the access door or damage to print heads or service station may occur. - Keep magnetic assemblies (Paper Guides/Media Edge Holders) away from the contr ol panel display or damage will result. Video

Service Guide Installation/Operations: Printer Operations Ink Line Filling Use this procedure to restore ink line pressure when a pressure loss occurs. Als o refer to Technical Bulletin 4. - Access Cartridges and remove cartridge for in k line to be primed. - Install the Plug Bar (for new service stations only - yel low label) into the service station and attach tubing needle to septum fitting. - Attach line fill cartridge into the cartridge stall position. - Select and hol d Utility Menu - Prime Menu Service Station Menu Pump On. Release Pump On when ink is observed in cartridge tubing line. The line fill process takes approximately 4-15 seconds. - When ink line is primed disconnect the line fill cartridge from stall position but leave tubing needle connected to septum fitting. Select Pump On to clean assembly of ink. Disconnect assembly when complete and remove plug bar from service station. Video

Service Guide Installation/Operations: Printer Operations Cutter Replacement Select Access Cartridges to move carriage assembly to maintenance position. At lef t side of carriage assembly, press down on cutter tab to remove cutter. Pull cut ter free. Install the new cutter by pushing cutter assembly into carriages left s ide until a click is heard. Return carriage to home position. Video

Service Guide Installation/Operations: Printer Operations Printer Flushing Refer to Technical Bulletin 3 for complete printer flushing/repacking instructio ns. - If an early model auto clean motor/pump assembly is installed, no red star i s present on auto clean unit door, then only use the EasyPrime equipped Printer Flush Kit P/N 222351-00 for flushing the ink lines or permanent damage to auto c lean motor/pump may result. - If the auto clean unit has a red star visible on i nside of auto clean unit door or the printer is equipped with the newer version of the auto clean unit pump (blue in color) then either the cartridge with tube assembly and/or plug bar assembly may be used in conjunction with Printer Flush Kit P/N 221984-01 for flushing the ink lines. Video

Service Guide Maintenance: Routine Maintenance Checking Plot Hours Cartridge Service Station Platen Surface Encoder Strip/Encod er Sensor Flex Driver Cables Slide Shaft Carriage Paper Sensor Carriage Bushing Replacement Note: strict adherence to plot hours listed is strongly recommended to reduce ti me between failures.

Service Guide Maintenance: Routine Maintenance Checking Plot Hours Routine Maintenance is based on plot hours. Obtain the Inkjet Printer Cleaning K it prior to performing routine maintenance, P/N 216883-XX USA and Canada; P/N 21 8439-XX International. Additionally, for preventive maintenance cleaning (i.e. e ncoder sensor) then obtain Domestic Cleaning Kit P/N 220970; International custo mers may order Cleaning Kit P/N 221191. NOTE: Use the printers control panel to check the plot hours. Select UTILITY MEN UDISPLAY SETTINGS. The plot time will be displayed at the bottom of the screen.

Service Guide Maintenance: Routine Maintenance Cartridge Step 1. Activate the Clean Function. Select UTILITY MENU-PRIME MENU-CLEAN. Selec t cartridge stall to clean. Step 2. Activate the Prime Pattern to verify jet per formance. Select UTILITY MENU-PRIME MENU-PRIME SINGLE. Select appropriate cartri dge stall to check. Video Step 3. Activate the Vacuum Prime Function one time only. Select UTILITY MENU-PR IME MENU-SERVICE STATION MENU-VACUUM PRIME. Select cartridge stall to prime. Ste p 4. Activate the Prime Pattern to verify jet performance. Select UTILITY MENU-P RIME MENU-PRIME SINGLE. Select appropriate cartridge stall to check. Step 5. To perform manual cleaning, remove cartridge from the carriage assembly. Dampen a lint-free cloth with NovaKlean solution or isopropyl alcohol; clean al l ink residues away by wiping cartridge bottom edges. Blot the jet plate surface thoroughly and wipe the cartridges rear electrical contacts. Clean flex driver cable to prevent ink residue transfer. Note: Verify surfaces are dry prior to re installing cartridge. Video

Service Guide Maintenance: Routine Maintenance Service Station NOTE: DO NOT REMOVE SERVICE STATION WHEN CLEANING Video Manual Cleaning Procedure Frequency: Every 40 plot hours. Move carriage out to m aintenance position by selecting UTILITY MENU-ACCESS CARTRIDGES. Open service st ation access door. Dampen a lint-free cloth with NovaKlean solution, apply to wi pers and seals. Clean all wipers and seals thoroughly. Ensure no lint fibers rem ain on surfaces. xxx xxx

Service Guide Maintenance: Routine Maintenance Platen Surface Frequency: Every 75 plot hours After removing power from the printer and lowerin g air plenum to maintenance position apply NovaKlean solution or De-Ionized wate r to a lint-free towel and wipe the entire surface area platen surface. Ensure n o ink residue or cloth fibers remain on the platen. Allow platen to dry complete ly before reinstalling media.

Service Guide Maintenance: Routine Maintenance Encoder Strip/Encoder Sensor Frequency: Clean strip every 20 plot hours; clean sensor every 200 plot hours. S ymptoms of dirty encoder strip/sensor include image shift as pictured below. Video To clean the encoder strip first remove power from printer. Dampen an industrial cotton swab with NovaKlean solution, clean the top and bottom surfaces of the e ntire length of the encoder strip. Several cotton swabs may be necessary to comp letely clean the encoder strip. Perform a second cleaning using isopropyl alcoho l. To clean the encoder sensor use Windex solution (obtain Domestic Cleaning Kit P/N P/N 220970; International customers order Cleaning Kit P/N 221191) and spra y directly onto sensor (behind Magenta stall). Clean area with canned air and li nt-free towels.

Service Guide Maintenance: Routine Maintenance Flex Driver Cables Frequency: Every 75 plot hours After removing power from the printer and lowerin g air plenum to maintenance position remove the cartridges from the carriage ass embly. Apply NovaKlean to a lint-free towel and wipe the entire surface area of each cable. Ensure no ink residue or cloth fibers remain on the cables. Allow ca bles to dry completely before reinstalling cartridges. Video

Service Guide Maintenance: Routine Maintenance Slide Shaft Frequency: Every 40 plot hours Video Apply NovaKlean solution to a lint-free towel and wipe the entire surface area o f the slide shaft including the service station area. Perform a second cleaning using isopropyl alcohol. Caution: never use lubricants or silicates on the slide shaft.

Service Guide Maintenance: Routine Maintenance Carriage Paper Sensor Frequency: During Preventive Maintenance or when a problem is encountered (i.e. Internal Shutdown - Carriage Axis Error). After removing power from printer pull carriage assembly away from service station area. Remove the black and magenta cartridges. Remove service station by removing shim at left side using needle no se pliers (new station design) and gently pulling on two tabs and lifting statio n out. Caution: do not force station tabs or damage may occur; control tab movem ent with two fingers. Slide carriage assembly over service station access hole. Apply NovaKlean solution to a lint-free cloth, gently blot the paper sensor loca ted directly behind the Magenta stall at base of carriage. Note: sensor is out o f view (see picture below), but can be felt with finger tips. Both the LED and r eceiver portions of the sensor need to be thoroughly cleaned. Video

Service Guide Maintenance: Routine Maintenance Carriage Bushing Replacement Step 1. Remove power from printer. Video Step 2. Remove the Ink Delivery System Carriage Cover support brackets by removi ng 4 securing screws.

Service Guide Maintenance: Routine Maintenance Carriage Bushing Replacement Step 3. Remove the left and right Bushing Retainers. Video Step 4. Remove the two screws securing the cutter actuator. Step 5. Remove both Carriage Bushings by prying away from carriage and sliding o ff of slide shaft.

Service Guide Maintenance: Cartridge Replacement Checking Cartridge/Bottle Status Cartridge Replacement Procedure Checking Prime Pattern Open Jet Bypass Procedure Printing Tips Ink Switch Over Procedure

Service Guide Maintenance: Cartridge Replacement Checking Cartridge/Bottle Status To check cartridge/bottle status select Utility Menu - Service Menu - Ink Status Menu Disp: Cart Info. (or Bottle Info.) Ink Type, Color and Ink Volume/Throughput will be displayed. Warranted ink throu ghput varies from region to region (i.e. Typically less than 700 ml ink throughp ut and 3-pass print mode is no longer supported). Verify warranty terms with technical support - see claim form.

Service Guide Maintenance: Cartridge Replacement Cartridge Replacement Procedure Step 1. Access cartridges via control panel (Utility Menu - Access Cartridge) Vi deo Step 2. Open respective cartridge door by pulling out, and then up. Remove cartr idge by pulling straight out.

Service Guide Maintenance: Cartridge Replacement Cartridge Replacement Procedure Step 3. Remove accumulator/septum assembly from cartridge by pulling assembly st raight out. Step 4. Remove tape from cartridge bottom and install into cartridge stall. Close cartridge door. Note: cartridge door must be closed and locked to properly bias cartridge position. Step 5. Select Access Cartridge to return carriage to home position. Refer to Se rvice Bulletin 7 if cartridge/bottle errors occur. Refer to Troubleshooting for all other problems.

Service Guide Maintenance: Cartridge Replacement Checking Prime Pattern To print the prime pattern select Utility Menu - Prime Menu Prime All Video The Prime pattern checks the electrical firing capability of all 640 jets. Verif y all cartridge nozzles are firing properly.

Service Guide Maintenance: Cartridge Replacement Open Jet Bypass Procedure Video -Cartridge Cleaning Verify all cartridge jets (nozzles) are firing properly. For random jet clogs or misfires perform open jet bypass manually. Select Utility Menu-Calibration Menu -Open Jet Menu-Edit List Menu. Select color and specific jet to bypass, Toggle t he jet off by depressing Toggle. The Auto Pass Correction feature will automatic ally step the printer into the next available print mode. In the example below 3 , 4, and 6 pass modes are not available in magenta - the printer will automatica lly switch to the 8 pass print mode regardless what mode was sent from the RIP. NOTE: This feature may be disabled by the customer. If multiple jets (observed i n groups) appear clogged, or excessive misfires are observed, cleaning of the ca rtridge and flex driver cables contacts may be necessary. Refer to Maintenance.

Service Guide Maintenance: Cartridge Replacement Printing Tips Caution: Do not replace a cartridge through service station access door or this may cause damage to both cartridge and/or service station seals. Video -Printer Cautions If cartridges are striking the media cease printer operations immediately. Only operate printer with suggested dryer setting, media types and at suggested humid ity ranges. Refer to Technical Bulletin 6 for detailed print and lamination guid elines. Verify Media Edge Holders, Paper Guides, and Media Edge Guides are posit ioned properly. Refer to Troubleshooting or contact technical support.

Service Guide Maintenance: Cartridge Replacement Ink Switch Over Procedure Video - Printer Flushing Step 1. Obtain Flush/Ink Switch Over Kit (P/N 222351-00 or 221984-01 - verify wi th technical support as to Flush Kit required). Remove all ink reservoirs and ca rtridges. Step 2. Attach Flush system components according to instructions (either use the EasyPrime with Cartridge with Tube Assembly or Cartridge with Tube Assembly/Plu g Bar). Attach needle end to the right side plate septum fitting. Activate the P ump On (Utility Menu - Prime Menu - Service Station Menu - Pump On) on the keypa d display until all ink is evacuated from ink line. Repeat for each stall positi on. Step 3. Place distilled water into Flush Reservoirs. Install into each reser voir position for 5 minutes (each intermediate reservoir should fill with water) . Remove Flush Reservoir. Activate the Pump On button on the keypad display unti l all ink is evacuated from ink line. Step 4. Remove disposal bottle and dispose of ink/water waste in accordance with regional regulations. Flush water from al l ink lines using above procedure. Step 5. Install the New Ink Reservoirs and Cartridges. Activate the Line Fill pr ocedure for each color until ink line is full. Remove Line Fill Cartridges. Inst all new cartridges and perform necessary printer readiness checks and calibratio ns prior to print operations.

Service Guide Maintenance: Firmware Download Checking Firmware Version Hardware/Software Requirements Software Control Downlo ad Procedure Stand Alone Download Procedure

Service Guide Maintenance: Firmware Download Checking Firmware Version Step 1. Select Utility Menu - Service Menu - About Step 2. Determine firmware level prior to downloading new firmware. Firmware lev el is indicated by the Vers. (version) line.

Service Guide Maintenance: Firmware Download Hardware/Software Requirements Operating Systems: Windows 2000/XP/XP Pro - Ethernet cable from server workstati on - Crossover ethernet cable from peer to peer workstation 1) Host Workstation 2) Software Control Panel Software (EFPU software) 3) Ethern et Cable (crossover cable required for peer-to-peer connection) 4) Printer Software Required: -Software Control Panel provided on CD with printer - EFPU (E ncad File Print Utility)

Service Guide Maintenance: Firmware Download Software Control Download Procedure Step 1. Open Printer Software Control panel, select Auto-Update. Step 2. Via web browser, latest firmware revision will be downloaded. If a web connection is no t available, obtain firmware from technical support and perform the Stand Alone Download Procedure. Step 3. Open EFPU (File Print Utility) software. - Create a new folder (i.e. printer download) - Add firmware .rom file (choose all files to view) to EFPU window Step 4. Download Firmware - Within EFPU program, highlight firmware file (.ROM f ile) and select Print. - Printer should emit a single audible beep after approxi matly 60 seconds. Step 5. Verify Download was successful. Cycle power to printer. - Check the Abou t screen for current firmware revision

Service Guide Maintenance: Firmware Download Stand Alone Download Procedure Step 1. System setup - Establish ethernet peer-to-peer connection to printer via crossover cable (set IP address at printers control panel) - Load EFPU (Encad F ile Print Utility) software - Create a new folder (i.e. printer download) - Sele ct TCP printer port (Note: an LPT port must be available for the EFPU to work pr operly. Load a Windows driver; setup for local port and LPT1 if necessary.) - Ad d firmware .rom file to EFPU window

Service Guide Maintenance: Firmware Download Stand Alone Download Procedure Step 2. Download Firmware - Within EFPU program, highlight firmware file and sel ect Print. - Printer should emit a single audible beep after approximatly 60 sec onds. Step 3. Verify Download was successful. Cycle power to printer. - Check the Abou t screen for current firmware version

Service Guide Troubleshooting: Advanced Analysis Prime Pattern Problems Error Messages Horizontal Banding Problems Vertical Bandi ng Problems Connectivity Failure xxx xxx ATTENTION: sample test prints (or digital photographs) mailed to technical suppo rt should contain arrows/marks indicating the problem area, media travel directi on, print pass mode used, and printer firmware level. Include the Prime pattern and Color Test (6 pass mode). Ink System/Pressure Failures Improper Print Output Printer Initialization Failure Carriage Movement Problems Media Feed/TakeUp Failure Media Drive/Image Skew Problems Dryer System Failure

Service Guide Troubleshooting: Advanced Analysis Prime Pattern Problems 1. Checking Prime Pattern Inspect and verify all cartridge nozzles are firing pr operly. To print the prime pattern select Utility Menu - Prime Menu Prime All. I f cartridge misfires or clogged jets are observed in the prime pattern activate the clean routine by selecting Prime Menu - Clean. Choose the appropriate cartri dge stall to clean. If necessary activate printhead suction. Select Prime Menu Service Station Menu - Vacuum Prime. Note: activating vacuum prime will remove approximately 1 ml of ink from cartridge. Video - Printer Readiness Note: typically up to 30 jets can be electrically damaged and/or compensated bef ore the Productivity mode (3-pass) support is no longer supported (indicated by a hyphen). Clean cartridges manually if necessary; ensure the bottom surfaces, j et plate, rear electrical contacts, and flex driver cable surfaces are thoroughl y cleaned. For severe jet failures (i.e. more than 160), with a new cartridge, r eplace respective flex driver cable.

Service Guide Troubleshooting: Advanced Analysis Prime Pattern Problems 2. Manual Jet Bypass/Cartridge Cleaning To perform Manual jet bypass (open jet c ompensation) select Utility Menu Calibration Menu - Open Jet Menu - Edit List Me nu. Choose the appropriate color to edit. Scroll to clogged/degraded jet, toggle jet to off position. Note: if jets appear clogged cleaning of the cartridge and flex driver cables contacts may be necessary. If 80 or 160 jets appear to be da maged, first try reseating cartridge and/or clean rear electrical contacts and f lex cable surfaces. Video - Cartridge Cleaning

Service Guide Troubleshooting: Advanced Analysis Prime Pattern Problems 3. Prime Script Test Pattern If an electrical failure in the cartridge is suspec ted verify performance by selecting Utility Menu - Service Menu Diagnostics Menu - Prime Script. Select appropriate cartridge stall to check. A series of patterns will print: 1) Color Test; ink system pressure test, also u sed to help unclog print head nozzles 2) Prime pattern; test to check all 640 pr int head nozzles 3) PData patterns; Image data ports. Pdata 1 governs nozzles 1320. Pdata 2 governs nozzles 321-640. 4) Fire patterns; Fire 1 and Fire 2 provid e pulses. They are sampled to fire nozzles. 5) PWR1 through 8 patterns; indicate s power lines. Each power line governs 2 primitives of nozzles. 6) A1 through A5 patterns; indicates address lines.

Service Guide Troubleshooting: Advanced Analysis Error Messages Possible Recoverable Error Condition: 1. Internal Error: Shutdown Carriage Axis Failure. 2. [Cl] Bottle Error! 3. Y:Max Ink Temp.! Abort Job? or Y:Overcurrent C artridge Shutdown! 4. K: Warning - Ink Reservoir Low! message appears but ink le vel is correct. 5. M: Ink Reservoir Low! message appears and ink level is below normal. 6. [Y] Pen Error!/Pen Error - Job Paused!/APC unavailable. Abort Job? 7. Warning: Empty Waste Bottle Now! (door is closed and bottle is empty) 8. Pen Er ror 10. Video - Carriage Axis Error Probable Cause: 1. Dirty slide shaft, bushings, or encoder strip; Unseated or da maged bushings/trailing cable. 2. Improper bottle contact with ID sensor. Damage d bottle IC and/or OEM bottle installed. 3. Improper Y cartridge ink level/press ure; air bubbles in ink line. Cartridge deprime. 4. Damaged K intermediate reser voir or sensor/connection. 5. Damaged M intermediate reservoir or air leak in li ne exists. Check tubing and damper. 6. Improper contact between cartridge and fl ex cable. Damaged cartridge/ID chip. 7. Damaged sensor/wiring connection. Motor/ pump is installed incorrectly. 8. Invalid ink type - change respective cartridge or bottle. Expanded Error Message List

Service Guide Troubleshooting: Advanced Analysis Error Messages

Service Guide Troubleshooting: Advanced Analysis Error Messages Common Operational Error Condition: 1. Paper Not Loaded!/Job Pause - Out of Pape r! 2. C: Warning - Ink Reservoir Low!/Job Pause - E.O.M. Detected! 3. Warning: E mpty Waste Bottle Now! 4. Reminder: Adjust Rear Paper Guides! 5. Warning: Reinst all Service Station! 6. Cartridge End of Life. 7. Dryer Warming Up, Print Anyway ? 8. Ethernet: 100HD (6.7E-01, etc.) seen under Network Menu Probable Cause: 1. Out of paper/Misfeed; Feed sensor alignment is incorrect. 2. Cyan ink reservoir is low or out of ink (Refer to Service Bulletin 7) 3. Auto Cl ean Unit ink bottle is full (or missing). 4. No error, just a friendly reminder to operator. 5. Service station failure - service station upgrade required. 6. C artridge/Printhead life has been terminated. A new printhead must be installed. 7. Nose heater is not completely heated, pressing Ok will bypass wait period. 8. Incompatible ethernet switch being used. Ethernet: 100FD is the normal indicati on. Note: Printer Operations/User Guide documentation should be consulted for any ot her operational problems encountered.

Service Guide Troubleshooting: Advanced Analysis Error Messages Service Required Error Condition: 1. Paper Sensor Failure. 2. Auto-Paper Sensor Failure. 3. Encoder Sensor Failure. 4. MBID Error - Code x (x = error code). 5. Carriage Paper Sensor is Unstable/TX Caller Error 6. Dryer Sensor Fault!/Dryer S ystem Fault - Dryer Off 7. No Display at control panel. Printer repeatedly reboo ts. 8. Carriage FPGA error. 9. Fatal PPC40X 11C.C128 error message 10. TSR error (all cartridges) 11. Ethernet Down Probable Cause: 1. Damaged carriage paper sensor (refer to Service Bulletin 7). 2. Damaged auto-load paper sensor (refer to SB7). 3. Damaged encoder sensor (ref er to SB7). 4. Damaged main PWA (refer to SB7/contact technical support). 5. Dam aged carriage paper sensor (refer to SB7). 6. Incorrect voltage switch position (115 vs. 230). Dryer circuitry damaged (refer to SB7 and SB6) 7. Improper connec tions. Damaged control panel display or power supply. 8. Loose or damaged traili ng cable connection (refer to SB7). 9. Damaged memory module. 10. Damaged carria ge PWA. 11. Damaged main PWA. Note: these conditions normally require parts replacement by a certified technic ian.

Service Guide Troubleshooting: Advanced Analysis Horizontal Banding Problems Videos 1. For general banding problems first ensure print ctly by checking the Prime pattern. Activate Clean to help clear nozzles. Perform color test. Clogged (check open jet detection) may produce single-band d image.

head nozzles are firing corre or Vacuum Prime (3x maximum) nozzles or misfiring nozzles (line) misfires in the printe

Note: dirty print heads or dirty cable surfaces can also cause cartridge misfire s. Thoroughly clean the printer, refer to Maintenance. Replace cartridge if seve re banding persists.

Service Guide Troubleshooting: Advanced Analysis Horizontal Banding Problems 2. Microbanding is defined as consistent bands spaced horizontally (spaced 0.5 m m to 14 mm) down the entire print or through a particular color space. Ensure lo wer rollers are free of residue and verify vacuum fan suction is present below p laten during printing. Check calibrations by activating the Paper Calib Test, Co lor Deadband, and Color Calibrations (vertical and horizontal). Refer to Calibra tions and/or Service Bulletin 1. Note: low pass print modes such as 2, 3, 4, or 6 may exhibit microbanding with h igh ink saturation levels or with light/solid color spaces. Increasing print pas s mode to 6 or 8-pass gradually eliminates the banding. Verify proper dryer sett ings and media compatibility.

Service Guide Troubleshooting: Advanced Analysis Horizontal Banding Problems 3. Scraping Bands appearing at media edges are likely caused by incompatible med ia type or media edge curl caused by low humidity in operating environment. Enab le the Edge Band Mode (or turn on Gutters at RIP) to help reduce Edge Spikes or First Drop from occurring. See video. Verify humidity levels are within specification (20 to 70 percent RH; 45 to 55 p ercent RH is optimum) and check the media compatibility list (i.e. some 3rd part y vinyl media has been known to leave glue on supply roller/lower rollers causin g banding). Proper operating temperature levels should also be adhered to for be st results (59 - 85 degrees F; 15 30 degrees C). Verify paper edge guides/magnet ic media holders are installed. If low absorption media (i.e. bond) is primarily used by customer verify paper g uides are in place (OEM4 customers should verify plastic guide is not interferin g with carriage). NOTE: the carriage head height may need to be raised (i.e. fro m 65/1000 to 85/1000 inches) for some bond/textile applications. Refer to Mechan ical Alignments. NOTE: The service station may need to be shimmed to correspond with any significant head height changes (i.e. over 85/1000).

Service Guide Troubleshooting: Advanced Analysis Horizontal Banding Problems 4. Severe Data shift combined with gradual image shift (at vertical border/edge of print) is either a dirty carriage encoder sensor or encoder strip. Clean all surfaces thoroughly using an ammonia based glass cleaner - refer to Maintenance. Refer to Technical Bulletin 5. 5. If severe horizontal bands appear every 1.25 or every 8.0 inches down the pri nt then the lower drive system is the likely cause. Check center support bracket alignment and orientation. Refer to Service Bulletin 4 and 17. Verify ESD prote ction. Replace the lower drive system, center support bracket and shaft/bearing assembly. 6. If micro banding cannot be corrected, check the Color Calibration Vertical Te st Pattern. Verify the horizontal lines are equally spaced apart - if lines appe ar inconsistent the stepper motor feed is severely out of tolerance. Check the P aper Calib Test/Line Length Test, enter only one value to reset stepper feed. Re fer to Service Bulletin 1.

Service Guide Troubleshooting: Advanced Analysis Horizontal Banding Problems 7. For color specific in-swath banding increase print pass mode (i.e. from 6-pas s to 16-pass; printer should not band in 16-pass). Check prime pattern; replace respective cartridge. Contact technical support for assistance. Download and ins tall the latest firmware - refer to Firmware Download. Note: right or left side banding may be caused by the rear paper guides being to o close to media edges; this will also affect paper feed values. Video 8. If one or two bands (apparent data shift) appear in the image the feed roller may be restricted. Check feed system sensor operation; clean lower rollers. Ref er to Media Drive/Image Skew Problems. Other causes include rear media guide int erference (should not press hard against media), ethernet data starvation, faili ng servo motor, improper printer grounding (ESD interference typically with 3rd party low cost PP or Self Adh PP), dirty encoder sensor, or dirty/damaged carria ge bushings. Replace bushings every 1000 print hours - refer to Maintenance.

Service Guide Troubleshooting: Advanced Analysis Vertical Banding Problems 1. Vertical banding across an image (printed on backlit/duratrans media) can be caused by excessive dryer temperature. Lower dryer temperature or turn dryer off and re-print image to verify. Follow media reference guidelines - refer to Tech nical Bulletin 6. 2. If a single vertical band results (from 0.3 cm to 2 cm wide) from the trailin g cable striking the chain shelf surface (cable has been recently replaced). Ens ure cable extends 6-7 inches maximum beyond clamp/restraint. Other causes of sin gle vertical bands/swath patterns include abnormal carriage obstructions (i.e. d amaged pinch roller); damaged encoder strip or teflon strip.

Service Guide Troubleshooting: Advanced Analysis Vertical Banding Problems 3. The absence of one color, producing printed image gaps in the vertical plane, normally indicates the trailing cable is damaged. Refer to step 5. For data shi ft problems verify proper printer grounding; refer to Service Bulletin 8. 4. Carriage head scrapes may be inadvertently described by customers as vertical banding, particularly when the cartridges lightly scrape the media surface. Oft en the scraping resembles scratches across the media surface. Check carriage hea d height and media type (some media types will cockle with ink oversaturation, i .e. bond). Note: verify carriage head height is correct (65/1000 of an inch clearance) usin g service Head Height Kit - refer to Mechanical Alignments.

Service Guide Troubleshooting: Advanced Analysis Vertical Banding Problems 5.If vertical swaths or gaps appears in image, the trailing cable/connector is p robably damaged. Inspect T-cable. Reseat trailing cable connections at carriage/ main board. Replace trailing cable assembly. 6.If two adjacent lines appear down the print then the lower roller may have a d efect causing the upper roller to deform the image. Verify carriage head height is correct. Check rollers for contamination or damage, replace as necessary. Video

Service Guide Troubleshooting: Advanced Analysis Ink System/Pressure Failures 1. Ink delivery failures are typically signified by a cartridge MAX INK TEMP err or. If one color fails to print verify ink system pressure is normal. Re-prime i nk line (s) using the Cartridge with Tube Assembly and the Pump On feature (or p ull ink directly into special service tool: pressure test cartridge/VacLok Syrin ge). No large air bubbles (gaps) should be present in main ink line. Verify all ink tubing connections are good. Video - Testing Ink Pressure 2. Replace printhead or cartridge. The internal cartridge ink level may not be p roper (chimney to foam separation has occurred). Replace ink bottle if discovere d leaking. Refer to Service Bulletin 7 for advanced troubleshooting. 3. Obtain the Ink System Test kit. Check damper pressure using the VacLok syring e connected to the pressure test cartridge. If ink cannot be pulled into syringe then an ink line is pinched; check for pinched ink line (behind intermediate re servoir). Check damper; replace damper if seal is broken.

Service Guide Troubleshooting: Advanced Analysis Ink System/Pressure Failures 4. Under DIAGNOSTICS MENU, select the INK RESERVOIR TEST. All values should indi cate a level 1 if ink is installed; the normal full level (the observer may note the level is slighly more than 50%; approximately 50 ml. If a sensor failure oc curs replace Intermediate Reservoir PwA. 5. Replace septum assembly (at carriage). A small leak may exist internal to ass embly. 6. Replace entire ink delivery system if ink tubing is suspected damaged. For OE M5 systems replace the ink delivery system tubing (cheaper option) if cracking o f ink lines is observed; it is suggested to also replace all 6 dampers.

Service Guide Troubleshooting: Advanced Analysis Ink System/Pressure Failures 7. For an auto clean unit sensor failure (i.e. EMPTY WASTE BOTTLE NOW or MISSING WASTE BOTTLE error message) reseat both wiring harness connections between auto clean unit and platen. Reseat wiring harness connections inside platen and at MPWA (J18 is connected to pump). Remove and clean any observed ink debris from plugs/connectors. Replace the auto clean unit sensor wiring harness assembly. NOTE: sensors cannot be replaced independently.

Service Guide Troubleshooting: Advanced Analysis Ink System/Pressure Failures 8. For an auto clean unit pump failure (i.e. ink is spitting out of service stat ion or complete pump failure occurs) replace pump assembly. Pump failures includ e improper operation during routine cap evacuation (normally occurs every 2.5 mi nutes during print operations) or during line filling (PUMP ON) operations. Pump should be heard when activated. To test pump select UTILITY MENU - PRIME MENU S ERVICE STATION MENU - PUMP ON. NOTE: If right-side spitting is observed onto the printed image and symptom only occurs during cap evacuation (every 2.5 minutes) this is NOT an auto clean unit pump failure. Refer to ESD control and print grounding guidelines as outlined i n Service Bulletin 8 to correct this problem. Pump Assembly with screws

Service Guide Troubleshooting: Advanced Analysis Improper Print Output 1. Ensure all cartridges are firing properly. 2. Verify relative humidity levels are between 40 and 60 percent. Install humidifier or de-humidifier as appropria te to prevent color shifting between tiles. Always bag media when not in use. Re fer to Technical Bulletin 6. 3. Check RIP (Raster Image Processor) ink/media out put profile settings; also check input ICC settings. Install new/updated profile s from RIP vendor (NOTE: this is the primary solution to correct color problems) . 4. Re-linearize ink/media profiles to maintain proper gray balance using RIP i nk/media color calibration software (i.e. Media Manager/Media Profiler) or 3rd p arty color calibration software. Contact RIP vendor or color specialist for assi stance. 5. Refer to Service Bulletin 7 for error code related problems. Video - Environmental Factors Incorrect color output Proper color output

Service Guide Troubleshooting: Advanced Analysis Improper Print Output 5. Activate Prime Pattern test. If cartridge jets are misfiring or are clogged/m issing (as observed in the prime pattern) reseat the cartridge. In the example i mage (at right) the Magenta cartridge was incorrectly seated into the carriage a ssembly. 6. Assuming printer calibrations have been performed properly, replace the cartridge if unacceptable image quality is observed from a ripped/external t est print. 7. Clean all flex driver cable contacts and rear cartridge surfaces of ink resid ue. Refer to Routine Maintenance. Reseat all flex driver cable connections at ca rriage board and retest. If severe jet failures persist replace respective flex driver cable. 8. Replace carriage board if excessive cartridge failures occcur (i.e. OVERCURRE NT errors) and related color problems persist.

Service Guide Troubleshooting: Advanced Analysis Improper Print Output 9. For sudden color shifts (i.e. observed during a tiling job), the TSR value ma y be reading incorrectly (TSR Found -; TSR error). Verify Cartridges TSR status. Power off printer and clean cartridge/flex driver cable connections - refer to maintenance. Replace cartridge if necessary. When a print head is installed it m ay appear to work fine (all jets firing, etc.) but the color output may be incor rect due to a mis-read of the temperature sensing resistor (TSR). This will caus e the cartridge to switch from an internal TEMP CONTROL mode to a PREHEAT MODE; there is no warning built-in to notify the operator of this situation. Verify th e cartridge status by selecting the adjacent F keys at Cartridge Status menu; ve rify signal level is detected (TSR Found +); TSR value is normally between 455 a nd 525. NOTE: If TSR ERROR is displayed for all cartridges then the carriage boa rd is probably damaged. Check trailing cable connections; Replace Carriage PWA. NOTE: ID should equal 6 after .10 ml of ink throughput; firmware dependent Cartridge Status - Advanced Menu Screen

Service Guide Troubleshooting: Advanced Analysis Improper Print Output 10. If printed data appears to be out of synchronization (in the horizontal/carr iage movement direction) or resembles ink overspray, combined with an abnormal c artridge failure rate (as low as 50 ml througput) then earth grounding to the pr inter will need to be verified. Refer to Service Bulletin 8. Using a polarity tester verify electrical outlet has the proper polarity and gro unding of the power source. Conduct standard grounding checks at printer, using an AC scale reading verify there is no voltage present on the printers rear meta l plate (plate on which the power switch is mounted against). If AC voltage (any thing higher than 2 volts is improper) is present at plate, platen surface or sl ide shaft then a faulty ground is present. 11. CAUTION: ground faults can cause up to half of the input/line voltage to app ear on the equipment. Exercise basic hardware electrical safety practices if a g round fault is suspected. Refer to Service Bulletin 8.

Service Guide Troubleshooting: Advanced Analysis Printer Initialization Failure 1. Check power connection and power source to printer. Check circuit breaker pos ition - if breaker is protruding out then the power supply is probably damaged. With power off, cycle 115V/230V voltage selector switch to ensure contact positi oning is good. Reboot printer to retest. Video 2. Reseat SDRAM module (64 MB) connection to Main PWA; reseat both trailing cabl e connections. If memory module is unseated, damaged, or missing the printer wil l not initialize completely (carriage will partially move to left side and will error with a carriage axis error). Note: Memory should not be substituted; memor y cannot be upgraded. Damaged memory may be indicated by error message FATAL PPC 40X 11C.C128 3. Check right base assembly internal power/wiring, and dryer board connections. If dryer board is not switching properly or air plenum fans fail to energize th en replace dryer board assy. (damaged transistor chip).

Service Guide Troubleshooting: Advanced Analysis Printer Initialization Failure 3. To help locate the problem, isolate loads by disconnecting connections to Dry er, takeup and feed system and Auto Clean Unit. If necessary, isolate motor load s: J13, J7, and J9. 4. If partial initialization occurs, check carriage board LED D1 (should illumin ate for 9-10 seconds then turn off). If LED does illuminate the the power supply is good but programming is faulty. Replace trailing cable, Memory module or Mai n PWA to correct. 5. If main board has intermittent or no LED activity, replace Power Supply.

Service Guide Troubleshooting: Advanced Analysis Printer Initialization Failure 6. For partial initializations (i.e. carriage stops at left side during power up ), replace memory module (SDRAM: 64MB) at Main PWA. 7. Replace main board. NOTE: If dryer fails to energize verify 115/230 volt sele ctor switch is in the correct position. Reseat all dryer board connections and m ain board SSR connection (J12). Check Dryer heater fuse resistance - refer to Se rvice Bulletin 6 for dryer system troubleshooting. Refer to Dryer System Failure . NOTE: If printer does initialize but will not process/print jobs the problem is normally the carriage paper sensor is not detecting the media. Check UTILITY MEN U - DISPLAY SETTINGS for NO PAPER LOADED indication. Thoroughly clean platen, cu tter groove, and carriage paper sensor - refer to Routine Maintenance. Verify th ere are no scratches in the cutter groove since the paper sensor seeks this zone when detecting paper. Repaint groove as necessary. Replace carriage paper senso r if failure persists.

Service Guide Troubleshooting: Advanced Analysis Printer Initialization Failure 8. If printer reboots repeatedly with the control panel message...CLEARING MACHI NE TYPE...then either the keypad connection (via green cable) is unseated or the keypad assy. is damaged. Replace keypad assy. (sheet switch). Video - Keypad/Display Removal NOTE: If, at anytime, navigation of the control panel display is not possible or navigation problems persist then the keypad connection is either unseated or th e keypad assy. is damaged. Replace keypad assy. (sheet switch) as appropriate.

Service Guide Troubleshooting: Advanced Analysis Carriage Movement Problems 1. Check printed image for skewing/data shift - clean encoder sensor/strip. Refe r to maintenance and Technical Bulletin 5. NOTE 1: No lubricants should be prese nt on the slide shaft, carriage belt or carriage bushings. Clean printer thoroug hly - refer to Maintenance. NOTE 2: For OEM4 printers verify the plastic guide ( 42 or 60 inch guide controlling media height) is not deformed and causing interf erence. Modify or replace guide as necessary. Video - Carriage Axis Error Video - Encoder Sensor/Strip Cleaning 2. Check SDRAM module at Main PWA; printer may partially initialize if memory mo dule is unseated. Perform soft NVRAM (Non-Volatile RAM) clear by holding bottom left control panel key and powering on printer until message...Clearing Machine Type..is displayed.

Service Guide Troubleshooting: Advanced Analysis Carriage Movement Problems 3. Remove carriage bushing retainers and carriage bushings. Inspect carriage bus hings and clean lint/excessive residue buildup from bushing as necessary. Replac e bushings if excessive wear is observed (see step 7) or at 1000 plot hours. Ins pect bushing shims (4 total) for wear and tear - replace shims if either the bus hing shims are missing or if the shim edges are lifting. Video - Carriage Bushing Removal 4. Check trailing cable connections at carriage and main board - reseat connecti ons at carriage board and main board. Inspect cable for surface breaks or burnt wire runs, refer to Vertical Banding symptoms. 5. If carriage stops in the same place everytime then check the autoload sensor wiring to plug - ensure all wires are connected. 6. Check encoder strip and teflon strip for visible damage. Repl ace if damaged.

Service Guide Troubleshooting: Advanced Analysis Carriage Movement Problems 7. Temporarily remove cutter and service station from the printer; retest to ver ify fault condition. Check UTILITY MENU - DISPLAY SETTINGS menu for logged plot hours. Replace service station if REINSTALL SERVICE STATION error message is obs erved; upgrade to non-geared station type if necessary. Refer to Service Bulleti n 10. 8. Clean the carriage paper sensor - refer to Routine Maintenance. This will hel p eliminate any overlapping problems from occurring. 9. Activate Servo PWM test under diagnostics, select UTILITY MENU - SERVICE MENU DIAGNOSTICS - SERVO CYCLE TEST. Perform for 10 cycles and press OK. The PWM Avg levels should typically be between 130 and 215; maximum levels are normally between 200 and 255. Carriage Axis Errors will occur above 242 on early model printers (prior to 07/2005) or a bove 312 on later model printers (post 07/2005). Replace the servo motor if inte rmittent failures are experienced (NOTE: assumes printer is clean of residues/lu bricants and carriage bushings have already been replaced); replace if more than 2000 plot hours have elapsed since last motor replacement. Verify motor winding resistance (At Main PWA J9) of approximately 2.9 ohms (+ 1 or 2 ohms); replace motor if zero (0) or greater than 80 ohms.

Service Guide Troubleshooting: Advanced Analysis Carriage Movement Problems 10. Replace the Trailing Cable. Refer to Disassembly. Video - Trailing Cable Removal 11. Activate SERVO CYCLE TEST and verify drive voltage of +24 volts dc (Main PWA R27 or U20-3). Refer to Main PWA schematics, sheet 6 of 14. Replace Main PWA if motor drive signal is absent. NOTE: the main board is rarely the cause for this type of error condition. Verify Steps 1 through 8 again. Contact technical supp ort to assist in making a final determination.

Service Guide Troubleshooting: Advanced Analysis Media Feed/TakeUp Failures Video - Legs Testing 1. Perform LEGS TEST. Tape media onto feed roller so both sensors are NOT blocke d by media (both sensors should be illuminated red). Select UTILITY MENU SERVICE MENU - DIAGNOSTICS MENU - ACCESSORY MENU - LEGS TEST. Both rollers should slowl y pulse in one direction only. Block one sensor at a time and verify the respect ive roller reverses direction. If both or either sensor test fails proceed to st ep 2, otherwise check SETUP MENU - PAPER SUPPLY OPTION. Verify the supply mode i s not set to SHEET (disables both sensors). 2. Check bracket alignment to ensure optic sensor is aligned with reflective tap e. Bend bracket as necessary until LED illuminates red in color. Replace if seve rely bent (NOTE: optic diaphram tape must also be transferred to new assembly). NOTE: During legs test control panel display values should change from a 0 to 1 when sensor is blocked. 3. If problem occurs during a new printer installation, then check wiring harness connection between the right stand leg and platen. Ver ify plug is properly seated and retest.

Service Guide Troubleshooting: Advanced Analysis Media Feed/TakeUp Failures 4. Check wiring harness connection between the platen and main PWA (check for lo ose or disconnected wires). Verify wiring resistances; if damaged replace wiring harness assembly. Inspect for ink contamination at plug (from service station); clean/flush connections thoroughly if ink is present in connector. 5. Verify sensor connections to right stand leg; reseat both connections. Check sensor electrical resistance (BLU and BLK is 2.3 M ohm., BRN and BLK is O.L or i nfinite). For single sensor failure (no red LED indication) replace respective s ensor. Refer to leg drive schematics. NOTE: If smoke/alarm comes from the printer then inspect Main PWA U26 (located b ehind trailing cables) and U2 I/Cs for damage (visible melting of I/Cs). If dama ge is observed at Main PWA replace Main PWA and both feed and takeup sensors (an d possibly carriage board if U26 damage was severe enough). One of the sensors l ikely fused bringing +24V up to U26 main pwa sensor input, then over to the U2 F PGA).

Service Guide Troubleshooting: Advanced Analysis Media Feed/TakeUp Failures 6. If sensors are functioning correctly but gear/shaft (s) fails to turn (no mot or drive), verify electrical resistance of feed/take-up motor. Check resistance levels between motor gear and ground, values should be between 0 and several hun dred Kohms (5 to 70 ohms is typical). Values in the Mohms indicate the motor bea rings are probably damaged or printer is not grounded properly. Swap motor posit ions to isolate problem; replace motor if out of range. 7. Check electrical resistance across motor windings (remove motor housing via 4 screws, disconnect wires to motor and check across motor input leads). Range is typically 29 to 36 ohms. Replace motor if greater than 120 ohms. Swap motor ass embly positions to isolate failure. 8. Check strike plate condition to help avoid future imaging problems. Carbon fi bers should be present and standing upright on strikeplate. Replace as necessary .

Service Guide Troubleshooting: Advanced Analysis Media Feed/TakeUp Failures 9. While running LEGS TEST verify drive signals to motor (i.e. pulsing 24.0 volt s dc, 0.0 volts dc when not active). Swap or replace respective motor if determi ned damaged. 10. For problems which cannot be resolved replace entire right stand leg assembl y or replace leg drive harness (lower cable within right stand leg). 11. Perform resistance checks across dryer/winder harness (upper cable) wiring. Refer to le g drive schematics. Replace harness if damaged. 12. At MPWA verify motor drive DC outputs (+24 vdc) while running the legs test. Feed Motor (J11 7 or U19-4); TakeUp Motor (J11 9 or U19-7). Refer to leg drive schematic. Replace main PWA if motor drive signal is absent.

Service Guide Troubleshooting: Advanced Analysis Media Drive/Image Skew Problems 1. Ensure media is loaded properly following Technical Bulletin 1 guidelines; ch eck rear paper guides. NOTE: maximum compatible media thickness is 0.024 inches or 0.6 mm. Clean lower rollers of vinyl adhesive residues if present. 2. Perform diagnostic tests as outlined in Service Bulletin 17 to verify the lower roller and center support shaft/bearing assembly are functioning properly. This include s a lower roller gear/drive test, mechanical alignment test, lower roller skew t est, and a lower drive inspection. NOTE: Both the lower roller and new support s haft/bearing assembly (pictured at right) should be replaced at the same time if a damaged lower roller is discovered. Video -Perfect Media Load NOTE: Refer to Technical Bulletin 5 for image skew related problems (this is dif ferent from media skew; the printed border skews/shifts while the media is align ed properly).

Service Guide Troubleshooting: Advanced Analysis Media Drive/Image Skew Problems 3. If tile lengths are drastically inconsistent throughout entire job (i.e. tile to tile) and/or severe banding/inconsistent banding then the lower drive roller may have insufficient/improper drive compression (applied from the center suppo rt shaft/bearing assy). Remove center support shaft/bearing assy and inspect low er roller for damage. If damage is observed then the lower drive system and cent er support shaft/bearing assy. will need replacement. CAUTION: refer to SB17 for evaluating lower drive performance and for complete lower drive system replacem ent instructions. - Inconsistent banding - tile length differences NOTE: It is common to experience length problems with the first tile (Tile #1) o n many media types; problems may be experienced with all tiles on certain vinyl media due to humidity exposure vs. inherent media properties (expansion control) . Refer to Technical Bulletin 7 for proper tiling guidelines.

Service Guide Troubleshooting: Advanced Analysis Media Drive/Image Skew Problems 4. If the media does not advance or banding is spaced every 1.33 (or every 8) in ches consistently down print this typically indicates a stepper motor failure. V erify motor winding resistance across Main PWA J7 (pins 1 - 2 is normally 2.3 oh m, pins 1 - 3 is normally 4.2 ohm.). Replace the lower drive system for either f ailure - refer to Service Bulletin 17. (NOTE: stepper motor cannot be replaced i ndependently) 5. Check Main PWA signal drives during FEED MEDIA FOWARD/BACKWARD tests. Verify +24 volts dc at Main PWA R13/R18 (refer to Main PWA schematic, she et 6 of 14). Replace Main PWA if drive signals are not present. 6. If the lower roller is not visibly damaged but image to image lengths continue to fluctuate d rastically (combined with severe banding), then the large press-fitted gear (at right end of lower roller) may be defective. Run four (4) line length tests to v erify media slip is occurring. Replace the lower drive system - refer to Service Bulletin 17. There is no reliable way to test this gear independent of the rest of the system. NOTE: In either case, first inspect the center support bracket and inspect for m etal debris inside bracket or below lower roller position. Ensure shims are pres ent on the center support bracket, these are normally required to prevent excess ive pressure onto the lower roller shaft. Thoroughly clean inside of bracket of metal shavings/residues and reinstall into printer and re-test.

Service Guide Troubleshooting: Advanced Analysis Media Drive/Image Skew Problems 7. Check roller heights and platen compression levels. Refer to Service Bulletin 17. The carriage and Y-Arm will need to be removed. Verify L/R/C lower roller h eights and C1/C2 compression values (do not rely on the platen profile label bel ow service station - values should be measured for field installation accuracy!) . If values are incorrect then shim or adjust the lower drive system as necessar y. Typical In-Field Alignment Example: Roller Height (in) above Platen Left 7 6 5 4 3 2 Right 0.011 0.008 0.006 0.010 0.009 0.010 0.011 0.018 NOTE: LOW is 0.006, HIGH is 0.018, RANGE is 0.012; this example used a smile pro file of 0.003

Service Guide Troubleshooting: Advanced Analysis Dryer System Failure 1. Power off printer. Cycle voltage selector switch (i.e. 230v to 115v to 230v; set to region). Power on Printer; activate the dryer and check dryer status: Sel ect SETUP MENU - DRYER MODE MENU - DRYER SETTING (select 4), press Ok. Select UT ILITY MENU - SERVICE MENU - DIAGNOSTICS MENU ACCESSORY MENU - DRYER STATUS. Norm ally the T1 and T2 values (temperature sensors) should drive up to 40C after app roximately 5 minutes. If not, refer to Service Bulletin 6 and the following step s. 2. Remove power from printer and remove right-rear cover. Check dryer connect ion at Main PWA (J12). Remove bottom right cover. Reseat all dryer board connect ions, including dryer connection at Dryer PWA (J12); verify dryer SSR connection at Dryer PWA (J4). 3. NOTE: If the circuit breaker is blown (protruding outward s) there is usually a reason why it is blown, such as an electrical short. Verif y circuit breaker continuity between TB1-1 and SSR-1 - refer to AC wiring schema tic. If open, then the circuit breaker is open/blown and will need replacement. Following CB replacement, first verify electrical continuity across all wiring h arnesses/heater strips/sensors prior to power up. Video - Printer Initialization

Service Guide Troubleshooting: Advanced Analysis Dryer System Failure 4. For a dryer system only failure (heat portion only; air plenum is operational ) check SSR (solid state relay located below the power supply) activation signal (from Main PWA) for 4.5 to 15 volts dc at SSR-3. Refer to AC wiring schematic. When the SSR is enabled it allows AC to pass to the 6 (six) heater strips (at ap proximately 3/4 of input AC source voltage). Activation signal, HTR ON signal (a lso at Dryer PWA J4-2) only occurs at the time of dryer activation (best to acti vate this by placing DRYER SETTING TO 0, press Ok; set DRYER SETTING TO 6, press Ok. Simultaneously look for dc signal when pressing Ok). If activation does not occur, then an error condition has occurred (DRYER SENSOR FAULT). Replace SSR i f damaged. 5. Check for AC power coming into Dryer PWA J7 (measure across pins 1 and 3). Ve rify proper wiring orientation if a new installation or previously repaired. 6. For an air plenum only failure (heating system is functional) first check dry er board air plenum fan connections. Replace the dryer board assembly (damaged t ransistor).

Service Guide Troubleshooting: Advanced Analysis Dryer System Failure 7. Conduct electrical resistance checks. Power off printer. Verify electrical re sistance across both thermocouple sensors (J8 and J9) for approximately 10K ohms . Verify electrical resistance across dryer fuse (J6), for approximately 0.3 to 0.9 ohms (possibly up to 2 ohms), but not open. If discovered open, place fuse i n freezer (below 0C for 25 minutes to reset). Retest fuse assembly. 8. Disconnect J1, J2, and J3 from Dryer board; verify electrical resistance betw een pins 1-2 and 2-3 for 89 ohms (80.1 mininum/97.9 maximum). If any of the resi stances are faulty then replace dryer heater (nose) assembly. 9. Check electrical resistance at soldered connections between dryer board/volta ge selector switch harness assembly. If any of the resistances are faulty then r eplace dryer board assy.

Service Guide Troubleshooting: Advanced Analysis Dryer System Failure 10. Replace any wiring harness with faulty resistance values (greater than 0.6 o hms across wiring/jacks). 11. Replace Main PWA if failure persists. NOTE: Ensure the air plenum is properly grounded in accordance with Service Bull etin 8.

Service Guide Troubleshooting: Advanced Analysis Connectivity Failure 1. Ensure network is within IP range of printer (i.e. first three sets of number s are the same) and port is assigned/configured (For Windows systems ensure the Windows driver is loaded with active IP address). Verify SUBNET and GATEWAY addr esses; typically the same as the computer/server. Check IP CONFIG MENU refer to NETWORKING section. 2. Verify DHCP (Dynamic Host Control Protocol) configuration ; normally disabled for most installations Check printers network LED status at rear of printer. 3. Check cable type for respective configuration. Use regular R J45 patch Ethernet cable when connecting to HUB or Switch; use crossover cable i f going direct from computer to printer. Verify HUB/Switch operation; swap ports to verify function. 4. Attempt to ping the printer - refer to the NETWORKING section. 5. Replace Main PWA if no network activity is observed (LEDs do not illuminate), but other printer functions are active (i.e. power is present, internal test pr ints function, etc.)

Service Guide Service: Disassembly Right Covers Left Covers Keypad and Display Main PWA and Clone Procedure Carriag e Assembly Ink Delivery/Trailing Cable Assembly Intermediate Reservoir Assembly Service Station/Station Upgrade Auto Clean Unit Encoder Strip Assembly Pinch Roller Assembly Media Drive System Nose Heater Assembly Air Plenum Assembly Media Takeup/Feed System Trailing Cable Power Supply/Cooling Fan Power Components Dryer PWA and Voltage Switch Servo Motor Ink Dampers/Septums Ca rriage Bushings Carriage PWA

Service Guide Service: Disassembly Right Covers Video Step 1. Remove power from printer. Step 2. Remove the Right Rear Cover by removing 2 securing screws. Note: The Printer Service Tool Kit prior is required for performing most major s ervice actions.

Service Guide Service: Disassembly Right Covers Step 3. Disconnect the Air Plenum. Step 4. Remove the Right Lower Cover. Ensure inner clips securing Right Lower Co ver are disengaged. Note: to aid in lower cover removal gentle twisting of cover may be necessary.

Service Guide Service: Disassembly Left Covers Video Step 1. Remove 2 screws securing top-left cover. Step 2. Remove 6 screws securing left cover. Note: gently twist left cover to aid in removal; 4 clips secure cover to reservo ir bay.

Service Guide Service: Disassembly Keypad and Display Video Step 1. Remove power from printer. Step 2. Remove the Right Rear Cover by removing 2 securing screws. Caution: keep magnetic assemblies (i.e. Paper Guides/Media Edge Holders) away fr om the control panel display or damage will result.

Service Guide Service: Disassembly Keypad and Display Step 3. Disconnect the Air Plenum. Step 4. Remove the Right Lower Cover. Ensure inner clips securing right lower co ver are disengaged. xxx

Service Guide Service: Disassembly Keypad and Display Step 5. Disconnect the keypad from J5 on the MPWA. Step 6. Disconnect the display from J4 on the MPWA.

Service Guide Service: Disassembly Keypad and Display Step 7. Remove the Display Mount Cover Assembly. Note: during assembly ensure grounds are properly attached.

Service Guide Service: Disassembly Keypad and Display Step 8. Remove the EMI shield. Step 9. Remove the Display Assembly and/or Keypad Assembly.

Service Guide Service: Disassembly Main PWA and Clone Procedure Video Step 1. Remove power from printer. Step 2. Remove the Right Rear Cover by removing 2 securing screws. xxx

Service Guide Service: Disassembly Main PWA and Clone Procedure Step 3. Remove all connections to the Main PWA. Caution: ensure that the locking clip is released before removing the Trailing C able connection (J1). xxx

Service Guide Service: Disassembly Main PWA and Clone Procedure Step 4. Remove the Memory Module. Step 5. Remove the Main PWA. xxx

Service Guide Service: Disassembly Main PWA and Clone Procedure Step 6. Main PWA Clone Procedure A) Replacement of a main board in the field wil l require either the customer to be running Server/Client Control software or th e technician to have the printer software available on a laptop computer. There is no dongle or password for this operation. The software has a hidden service p age (Note: will only be displayed when connected to a non-serialized main board) . The only way to activate the page is to connect to the PC running the software with a main board that has no serial number. A serial number present will disab le the control channel functions required to clone a board. B) When this conditi on exists, the service page can be activated by launching Client Control Panel; select TOOLS - SHOW SERVICE PAGE. In the current version, this activation method is always present. When the software releases, the Show Service Page menu item will be hidden until the main board with no serial number is detected.

Service Guide Service: Disassembly Main PWA and Clone Procedure C) The SHOW SERVICE PAGE has two simple choices: 1. If the customer is running C lient software with the database, a list of potential clones will be displayed. The service tech will select the appropriate one and press a button to send the settings and serial number to the new main board. 2. If the customer is not runn ing our software, the service tech can connect a laptop computer to the printer via cross-over, select the service page as described above and type in the seria l number manually then send it to the printer. Caution: Ensure the printers alph anumeric serial number (exact letter/number combination) is downloaded or the Ma in PWA will need to be returned to an Encad service center for re-initialization . D) If it is determined the new main board does not fix the problem, do not clo ne the main board or reset the serial number. Clear Machine Type by holding bott om-left key and powering up printer; Clearing Machine Type should be displayed a fter approximately 20 seconds. Remove Main PWA and replace with original Main PW A.

Service Guide Service: Disassembly Power Supply/Cooling Fan Video Step 1. Remove power from printer. Step 2. Remove the Right Rear Cover by removing 2 securing screws. xxx

Service Guide Service: Disassembly Power Supply/Cooling Fan Step 3. Disconnect the Air Plenum. Remove the Right Lower Cover. Ensure inner cl ips securing right lower cover are disengaged. xxx

Service Guide Service: Disassembly Power Supply/Cooling Fan Step 4. Remove the Display Mount Cover Assembly. Note: during assembly, ensure grounds are properly attached. xxx

Service Guide Service: Disassembly Power Supply/Cooling Fan Step 5. Remove all connections to the Main PWA. Caution: ensure the locking clip is released before removing the Trailing Cable connection (J1).

Service Guide Service: Disassembly Power Supply/Cooling Fan Step 6. Remove all connections to the Dryer PWA.

Service Guide Service: Disassembly Power Supply/Cooling Fan Step 7. Remove the PWA Mounting Bracket Assembly. Step 8. Rotate the PWA Mounting Bracket Assembly 90 towards the back of the print er. xxx

Service Guide Service: Disassembly Power Supply/Cooling Fan Step 9. Remove connections to the Power Supply and/or Cooling Fan. Step 10. Remove the Power Supply and/or Cooling Fan. NOTE: During reassembly ensure the power supply connections to the power supply are correct, wiring should be connected from, as observed from left to right, wh ite, black, and green

Service Guide Service: Disassembly Power Components Video Step 1. Remove power from printer. Step 2. Remove the Right Rear Cover by removing 2 securing screws. xxx

Service Guide Service: Disassembly Power Components Step 3. Disconnect the Air Plenum. Remove the Right Lower Cover. Ensure inner cl ips securing right lower cover are disengaged. xxx

Service Guide Service: Disassembly Power Components Step 4. Remove the Display Mount Cover Assembly. Note: during assembly, ensure grounds are properly attached. xxx

Service Guide Service: Disassembly Power Components Step 5. Remove all connections to the Main PWA. Caution: Ensure that the locking clip is released before removing the Trailing C able connection (J1).

Service Guide Service: Disassembly Power Components Step 6. Remove all connections to the Dryer PWA. Note: during assembly, thermal sensor connections (J8-J9) air plenum fan connect ions (J10J11) and nose heater connections (J1-J3) plug order is not critical sin ce sensors, fans and heaters energize together respectively.

Service Guide Service: Disassembly Power Components Step 7. Remove the PWA Mounting Bracket Assembly. Step 8. Rotate the PWA Mounting Bracket Assembly 90 towards the back of the print er.

Service Guide Service: Disassembly Power Components Step 9. Disconnect and remove the Power Entry Module. Note: during assembly, ensure that the ground is properly connected. Step 10. Disconnect and remove the Circuit Breaker. During assembly, ensure that the Circuit Breaker is depressed.

Service Guide Service: Disassembly Power Components Step 11. Disconnect and remove the Nose Heater Switching Relay (10 amp Solid Sta te). Note: during assembly, ensure the wiring harnesses are properly oriented.

Service Guide Service: Disassembly Dryer PWA Video Step 1. Remove power from printer. Step 2. Remove the Right Rear Cover by removing 2 securing screws. xxx

Service Guide Service: Disassembly Dryer PWA Step 3. Disconnect the Air Plenum. Step 4. Remove the Right Lower Cover. Ensure inner clips securing right lower co ver are disengaged. xxx

Service Guide Service: Disassembly Dryer PWA Step 5. Remove the Display Mount Cover Assembly. Note: during assembly ensure grounds are properly attached. xxx

Service Guide Service: Disassembly Dryer PWA Step 6. Remove all connections to the Main PWA. Caution: ensure the locking clip is released before removing the Trailing Cable connection (J1).

Service Guide Service: Disassembly Dryer PWA Step 7. Remove all connections to the Dryer PWA. Note: during assembly, thermal sensor connections (J8-J9) air plenum fan connections (J10-J11) and nose heater connections (J1-J3) plug order is not critical since sensors, fans and heaters e nergize together respectively.

Service Guide Service: Disassembly Dryer PWA Step 8. Remove the PWA Mounting Bracket Assembly by removing 4 screws and removi ng two nuts which secure the two ground wires. Step 9. Rotate the PWA Mounting Bracket Assembly 90 towards the back of the print er. xxx

Service Guide Service: Disassembly Dryer PWA Step 10. Disconnect and remove the Voltage Selector Switch. Caution: during assembly ensure the voltage selector switch is properly configur ed to the local power source, 115V or 230V. Step 11. Remove the Dryer PWA. Note: during assembly ensure grounds are properly attached.

Service Guide Service: Disassembly Servo Motor Video Step 1. Remove power from printer. Step 2. Remove the Right Rear Cover by removing 2 securing screws. Note: It is strongly recommended to obtain the Printer Service Tool Kit prior to performing major service actions.

Service Guide Service: Disassembly Servo Motor Step 3. Remove the Auto Clean Unit. CAUTION: Ensure the waste disposal bottle ha s been previously removed from the auto clean unit or ink may spill. Note: Loosen the 4 securing screws to remove unit; removal of the securing screw s are not required. Caution: hold assembly while disconnecting 2 electrical conn ections or damage may occur to wiring harnesses/plugs. xxx

Service Guide Service: Disassembly Servo Motor Step 4. Remove Servo Motor Connector from J9 on the MPWA. xxx xxx

Service Guide Service: Disassembly Servo Motor Step 5. Slide the Carriage Assembly towards the center of the printer. Belt Removal Tool Step 6. Release carriage belt tension using the Belt Removal Tool (P/N 216688-00 ); insert and twist tool between the frame tensioner and left-side plate.

Service Guide Service: Disassembly Servo Motor Step 7. Remove the Belt from the Servo Motor Pulley. Step 8. Remove the Servo Motor by removing 2 securing screws; lower through plat en access hole. xxx

Service Guide Service: Disassembly Ink Dampers/Septums Video Step 1. Remove power from printer. Step 2. Lower the Air Plenum to the service position. Caution: damper and septum fittings can be easily damaged. Carefully remove ink tubing from connection points using pliers/flathead screwdriver to gently pry tu bing free.

Service Guide Service: Disassembly Ink Dampers/Septums Step 3. For Septum assembly removal, remove the Cartridge, Cartridge Door and Sp ring. Note: when cartridge is removed place on a flat surface so the needle poin ts upwards to avoid possible leaking. Tip: to re-install the cartridge door spring first place spring into the positio n shown (with door installed). With a flat-head screwdriver gently force the rea r spring tab all the way down until it snaps into place. This will need to be re peated until sucessful. Test spring installation by unlocking the door, the cart ridge door should pop up to the fully open position. Door Spring position

Service Guide Service: Disassembly Ink Dampers/Septums Step 4. Remove the septum pressure restraint and E-Clip securing the Septum Asse mbly. Hose Clamp Tool Step 5. Clamp ink tubing above septum assembly; gently pry ink tubing free using needle nose pliers. Cut ink tubing if tube end is flared too large. Remove the Septum Assembly.

Service Guide Service: Disassembly Ink Dampers/Septums Step 6. For Damper Assembly removal, remove the Ink Delivery System Carriage Cov er by removing 4 screws and the 2 Supporting Brackets. Note: the Ink System Test Kit is required for this procedure. Step 7. Disconnect the Trailing Cable conne ction from J1 on the Carriage PWA. Caution: verify the connection locking clip is released before removing the Trai ling Cable connector.

Service Guide Service: Disassembly Ink Dampers/Septums Step 8. Clamp the tube supplying ink to the Damper and cut both tubing lines to the Damper Assembly. Note: do not use flared tube ends or air leaks into line tu bing may occur. Step 9. Remove damper by removing 2 securing screws. Caution: new Damper assemblies are extremely fragile - do not drop ink delivery cover or compress damper assembly or damage may occur (leaking). Step 10. Following septum/damper replacement, use the Primer tool (VacLok syring e/cartridge) to restablish ink line pressure. Ensure no air bubbles are present in ink line or head failures/error messages will be encountered during printing. Videos

Service Guide Service: Disassembly Carriage Bushings Video Step 1. Remove power from printer. Step 2. Remove the Ink Delivery System Carriage Cover support brackets by removi ng 4 securing screws.

Service Guide Service: Disassembly Carriage Bushings Step 3. Remove the left and right Bushing Retainers. Step 4. Remove 2 screws securing cutter actuator. Step 5. Using a small flat-head screwdriver, remove bushings by gently prying aw ay from carriage and sliding off of slide shaft. Step 6. If bushing shims are da maged then replace all 4 shims (0.004 inches thick; self-adhesive vinyl).

Service Guide Service: Disassembly Carriage Board Video Step 1. Remove power from printer. Step 2. Remove the Ink Delivery System Carriage Cover and 2 Support Brackets by removing 4 securing screws. Step 3. Lift cover and disconnect the Trailing Cable connection from J1 on the C arriage PWA using a small flathead screwdriver. Move the Carriage Cover aside. Caution: verify that the locking clip is released before removing the Trailing C able connection (J1).

Service Guide Service: Disassembly Carriage Board Step 4. Remove Electronics Cover by pulling plastic cover clips outward. Carriage Assembly xxx

Service Guide Service: Disassembly Carriage Board Step 5. Disconnect remaining connections on the Carriage PWA. J4-J9 Flex Driver Cables J2 Paper Sensor; J3 Encoder Sensor

Service Guide Service: Disassembly Carriage Board Step 6. Remove one screw securing Carriage PWA. Caution: always wear electrostatic discharge (ESD) protection when working with ESD sensitive electronic assemblies or components.

Service Guide Service: Disassembly Carriage Assembly Video Step 1. Remove power from printer and lower air plenum to maintenance postion. S tep 2. Remove the Ink Delivery System Carriage Cover and 2 Support Brackets by r emoving 4 securing screws. Note: It is not necessary to break ink line integrity (disconnect tubing connect ions) or remove the reservoir chassis for this procedure. Caution: to avoid dama ging lock do not twist plug from connector J1. Step 3. Disconnect trailing cable from carriage board by pressing on lock with a small blunt tool.

Service Guide Service: Disassembly Carriage Assembly Step 4. Open 6 cartridge doors and remove cartridges from carriage. Step 5. Remo ve 6 door assemblies by first removing the 6 pressure restraints. Remove each do or support by depressing clips on both sides of door support. Step 6. Place cart ridges on a flat surface so the needle points upwards to avoid leaking. Note: do not disconnect ink line from septum assembly or repriming of ink lines will be necessary following this procedure.

Service Guide Service: Disassembly Carriage Assembly Step 7. Place cartridge door assemblies onto a drop cloth Caution: Do not drop ink delivery system or damage to dampers may occur; ink may leak out of the ink tubes if accidently disconnected from the septum assemblies . Step 8. Remove cutter from left side of carriage assembly.

Service Guide Service: Disassembly Carriage Assembly Step 9. Install belt removal tool by twisting between left side plate and frame tensioner to release carriage belt tension. Step 10. Slide the Belt off of the Servo Motor Pulley. Remove the Belt Removal T ool. Step 11. Remove 2 screws securing cutter actuator and remove actuator.

Service Guide Service: Disassembly Carriage Assembly Step 12. Remove 1 screw securing each bushing retainer; remove carriage bushings from carriage. Step 13. Remove the Frame Tensioner, Idler Assembly and the Compression Spring. Caution: Ensure that the Idler Assembly is oriented correctly on installation. Step 14. Disconnect Ink Reservoir Chassis by removing 6 screws and moving 3 to 4 millimeters toward rear (left covers do not need to be removed).

Service Guide Service: Disassembly Carriage Assembly Step 15. Remove Carriage Belt and Carriage Assembly from slide shaft - gently mo ve reservoir chassis as needed to aid in removal. Caution: During re-installation verify the Encoder Strip is between the Encoder Sensor edges. Damage to the Encoder Strip is possible if care is not observed wh en sliding carriage back onto the slide shaft. Step 16. If ink line becomes separated during carriage removal/replacement the i nk line (s) will need to be reprimed using the Primer tool (VacLok syringe/cartr idge).

Service Guide Service: Disassembly Carriage Assembly Step 17. If replacing the Encoder Sensor disconnect J3 at Carriage PWA; for pape r sensor replacement disconnect J2 at Carriage PWA. To clean the encoder sensor, lightly dampen a lint-free towel with distilled water or an isopropyl alcohol c leaning pad. Apply to sensor surfaces by gently rubbing towel back and forth unt il residue is gone. To clean the paper sensor, lightly dampen a lint-free towel with distilled water or an isopropyl alcohol cleaning pad. Apply to transmitter and receiver surfaces and flex cable surface. Gently dab until residue is gone. Repeat procedures as necessary.

Service Guide Service: Disassembly Carriage Assembly Step 18. Remove the Paper Sensor; needle nose pliers may be necessary to help re move paper sensor board from guide channel. Caution: paper sensor flex cable is extremely fragile, only make gentle bends wh en re-installing. Step 19. Remove the Encoder Sensor by gently working sensor fr ee from carriage restraining clip. NOTE: If removing the carriage flex driver ca bles please note that two small clear plastic shims (adhesive) are to be reinsta lled at the base of each cable - see picture at right for proper positioning. Fa ilure to do so will result in cartridge recognition type errors. Caution: encoder sensor carriage housing clip is extremely fragile, do not push too hard on housing clip when removing sensor.

Service Guide Service: Disassembly Ink Delivery/Trailing Cable Assembly Video - Ink Delivery Removal Step 1. Remove power from printer and lower air plenum to maintenance postion (i f attached). The ink lines may be flushed using the ink system kit; evacuate and flush ink lines with distilled water. Step 2. Remove the Ink Delivery System Ca rriage Cover and 4 screws securing 2 Support Brackets. Remove support brackets. Step 3. Lift cover and disconnect the Trailing Cable connection from J1 on the C arriage PWA. Caution: ensure locking clip is depressed prior to removing; do not twist plug f rom connector or damage will result.

Service Guide Service: Disassembly Ink Delivery/Trailing Cable Assembly Step 4. Remove the Right Rear Cover by removing 2 securing screws. Remove 2 scre ws securing trailing cable grounding plate. Step 5. Disconnect the Trailing Cable connection from J1 on the Main PWA. Remove double-sided stick tape from cable and pull trailing cable free. Caution: verify the locking clip is released before removing the Trailing Cable connection (J1). Note: trailing cable cannot be easily replaced and overstress t o new cable will result in permanent damage. Video - Trailing Cable Removal Go to Trailing Cable Removal procedure

Service Guide Service: Disassembly Ink Delivery/Trailing Cable Assembly Step 6. Open cartridge doors and remove cartridges. Step 7. Remove 6 door assemb lies by first removing door blocker, then removing door support by depressing 2 clips on either side of door support. Step 8. Place ink delivery carriage cover onto a drop cloth. Step 9. Disconnect the Chain Shelf by removing 2 screws at rear of printer.

Service Guide Service: Disassembly Ink Delivery/Trailing Cable Assembly Step 10. Disconnect tubing lines from 6 septum assemblies using small needle nos e pliers. Lift ink delivery cover up for 2 minutes to allow ink lines to complet ely drain back to intermediate reservoirs. Step 11. After removing the left bottom cover, loosen ink tube restraining clamp s at reservoir chassis. Step 12. Clamp 6 ink tubing lines with 12 hose clamp tools on both sides of tubi ng butt-splice. Disconnect tubing lines at butt splices. Remove the Ink Delivery Assembly. Step 13. Following ink delivery system replacement re-establish ink line pressur e using cartridge with tube assembly and plug bar or service primer tool (VacLok syringe/cartridge; part of Ink System Test Kit). Clean the primer tool between each ink color usage.

Service Guide Service: Disassembly Intermediate Reservoir Assembly Videos Step 1. Remove power from printer; evacuate ink from defective intermediate rese rvoir using special service tool only (VacLok syringe and Pressure Test Cartridg e). Step 2. Gently disconnect the Intermediate Reservoir Sensor Board connector. Step 3. Clamp vent tube - it is attached to the underside of the reservoir chass is. Caution: carefully disconnect the vent tube or damage may occur to cover.

Service Guide Service: Disassembly Intermediate Reservoir Assembly Step 4. Clamp off the ink tubing line on both sides of the service butt-splice w ith hose clamp tool. Caution: Ink may leak out of the tubes when disconnected or cut. Always Use of a drop cloth or other material is recommended to control ink leaks. Step 5. Separate tube from the tube butt splice by pulling apart or cut the ink tube between the service splice and the Intermediate Reservoir (cut/separate lin e between hose clamps only).

Service Guide Service: Disassembly Intermediate Reservoir Assembly Step 6. Remove intermediate reservoir from chassis by removing 4 securing screws . Step 7. Remove 1 screw securing reservoir identification contactor (T7 star-head driver) and 4 screws securing restraining clips. Note: part of identification s ensor PWA. * = Reservoir restraining clips

Service Guide Service: Disassembly Intermediate Reservoir Assembly Step 8. Remove Identification Sensor PWA by removing 4 screws (two T7 starhead a nd two cross head screws). Note: ink may leak from assembly; use drop cloth to control ink discharge. Basic replacement assembly does not contain the ID housing, restraining clips or sens or PWA. These items will need to be transferred to the new intermediate reservoi r. Video - Repriming Ink Line Video - Cleaning Primer Tool Step 9. Following assembly replacement use the Primer tool (VacLok syringe/cartr idge) to restablish ink line pressure. Ensure no air bubbles are present in ink line or head failures/error messages will be encountered during printing.

Service Service Video Step 1.

Guide Service: Disassembly Station Service Station Replacement Remove power from printer.

Step 2. Remove the Right Rear Cover by removing 2 securing screws. NOTE: Refer t o Service Bulletin 10 or the video below to replace an early model station (gear ed) with the new station model (non-geared). Video - Service Station Upgrade

Service Guide Service: Disassembly Service Station Step 3. If replacing an early model station (geared) with a new service station (non-geared) then remove the disposal bottle from Auto Clean Unit and remove the Auto Clean Unit Assembly. Disconnect two wiring connections. Caution: only loosen the securing screws, removal of the securing screws is not required. Damage to electronic cables may occur if assembly is dropped.

Service Guide Service: Disassembly Service Station Step 4. Lift out the Service Station by releasing both locking clips. Step 5. If replacing the Service Station, disconnect the tubing disposal line by twising luer fittings in opposite directions. This tube is connected to the Aut o Clean Unit disposal bottle. Note 1: For new service stations - When re-install ing the service station verify shim is properly located and station tabs are sea ted flush against platen. Note 2: The valve vent line should not be pinched or o bstructed check positioning.

Service Guide Service: Disassembly Service Station Step 6. If replacing a geared service station with a new service station version then disconnect the station motor/sensor connection from J13 on the Main PWA. I nstall jumper into J13 to bypass sensor operations. Refer to Service Bulletin 10 for complete instructions. Perform steps 7 and 8.

Service Guide Service: Disassembly Service Station Step 7. Disconnect plug adjacent to sensor connection. Note: The new service station design no longer uses the motor or sensor function s. Firmware version 1.4.2 must be loaded and a jumper (J13) must be installed to allow operation of the new service station. Step 8. Remove the 2 securing screws and remove the station motor/sensor assembl y (including bracket). xxx

Service Guide Service: Disassembly Auto Clean Unit Video Step 1. Remove power from printer. Step 2. Remove disposal bottle from auto clea n unit. Caution: do not drop unit or damage to plug connections/wir ing may occu r. Note: Loosen the securing screws and lower unit approximately 15 cm. Removal of the securing screws are not required.

Service Guide Service: Disassembly Auto Clean Unit Step 3. Clamp the tubing going to the Suction Motor. If necessary cut the tubing off of the Suction Motor is tubing end is severly flared or leaking ink. Step 4. Disconnect both electrical connections. Station may be disassembled furt her to gain access to motor and sensors. - Suction Pump/Motor Assembly; see vide o. - Bottle Full Sensor - Bottle Load (present) Sensor Assembly Video

Service Guide Service: Disassembly Encoder Strip Assembly Video Step 1. Remove power from printer. Step 2. Remove the Right Rear Cover by removing 2 securing screws. xxx

Service Guide Service: Disassembly Encoder Strip Assembly Step 3. Remove the Ink Delivery System Carriage Cover and 2 Support Brackets. Step 4. Lift cover and disconnect the Trailing Cable connection from J1 on the C arriage PWA. Move the Carriage Cover out of the way. Caution: Ensure that the locking clip is released before removing the Trailing C able connection (J1).

Service Guide Service: Disassembly Encoder Strip Assembly Step 5. Remove Carriage Assembly - refer to carriage assembly removal procedures . Step 6. Disconnect 6 cartridge door assemblies from carriage by removing door re straints and pushing on door support clips to release each assembly.

Service Guide Service: Disassembly Encoder Strip Assembly Step 7. Move the Carriage Cover to one side. xxx Step 8. Remove carriage bushings from carriage by removing the bushing retainers at each side (1 screw secures each retainer).

Service Guide Service: Disassembly Encoder Strip Assembly xxx Step 9. Install the Belt Removal Tool (P/N 216688-00) between frame tensione r and left side plate. Twist to release carriage belt tension. Step 10. Slide the Belt off of the Servo Motor Pulley. Remove the Belt Removal T ool.

Service Guide Service: Disassembly Encoder Strip Assembly Step 11. Remove the Frame Tensioner, Idler Assembly and the Compression Spring. xxx Caution: Ensure that the Idler Assembly is oriented correctly before installatio n. Step 12. Remove the Cutter Actuator by removing 2 securing screws.

Service Guide Service: Disassembly Encoder Strip Assembly Step 13. Disconnect Ink Reservoir Chassis by removing 6 screws. Note: left cover s do not need to be removed to remove carriage assembly. Step 14. Remove Belt and Carriage Assembly - the ink reservoir chassis may need to be moved slightly toward the rear to aid in removal. Caution: Ensure that the Encoder Strip is between the Encoder Sensor as the Carr iage Assembly is positioned back onto the Slide Shaft. Damage to the Encoder Str ip is possible if care is not observed.

Service Guide Service: Disassembly Encoder Strip Assembly Step 15. Using a pen, draw position marks above the old encoder stablizer bracke t assembly. Remove Stabilizer Bracket/Encoder Strip Assembly. Note: following the repair action, a carriage head height adjustment may be requ ired. Refer to Service Bulletin 3 or Mechanical Alignments. The printer service tool kit contains the carriage head height adjustment tools required.

Service Guide Service: Disassembly Pinch Roller Replacement Step 1. Remove the Rear/Back Cover by removing 12 securing screws. Video - Pinch Roller Replacement Step 2. Pitch the back cover toward the rear slightly. Pinch roller eclips can b e removed and replaced once the back cover is positioned to provide assembly rem oval (clearance provided is approximately 0.5 inch/2.5 cm) Caution: Do not remove Y-Arm for this procedure. Only remove on OEM4 printers wh en the long media guide requires replacement. The 8 crescent springs at left sid e allow the Y-Arm to float when dryer is on for proper operation.

Service Guide Service: Disassembly Pinch Roller Replacement Step 3. While holding the Pinch Roller, remove the EClip and pull the Pinch Roll er back through the Y-Arm Bracket. Remove the Compression Spring using spring pl iers or spring hook tool at the rear end of Pinch Roller. Step 4. Carefully tilt the back of the Pinch Roller upwards; this lowers the fro nt of the Pinch Roller, away from the Slide Shaft. Carefully remove the spring t hat is going into the Slide Shaft. Step 5. Remove the Pinch Roller. NOTE: To reinstall pinch roller, place spring i nto base of pinch roller, maneuver pinch roller at an angle under the slide shaf t and compress spring using fingers - orient spring into spring hole at base of slide shaft.

Service Guide Service: Disassembly Media Drive System Video NOTE: Refer to Service Bulletin 17 for complete replacement instructions. Step 1 . Remove power from printer. Step 2. Remove the Right Rear Cover by removing 2 securing screws. Step 3. Remove the Left Top Cover by removing 4 screws.

Service Guide Service: Disassembly Media Drive System Step 4. Disconnect Ink Reservoir Chassis by removing 6 screws; move assembly cle ar. Caution: do not over extend reservoir chassis or damage to ink tubing may occur. It is suggested to place chassis onto a small table beside printer. Do not disa ssemble intermediate reservoirs from ink reservoir chassis. xxx

Service Guide Service: Disassembly Media Drive System Step 5. Disconnect the Stepper Motor connector from J7 on the MPWA. Step 6. Disconnect the Vacuum Fan connectors from J15 and J16 on the MPWA. xxx

Service Guide Service: Disassembly Media Drive System Step 7. Remove Service Station by first removing station shim at left side (new stations only). Reinstall shim once station has been removed from printer. Step 8. Disconnect the Stepper Motor wire clamp and ground located in service St ation access opening (auto clean unit may need to be removed for reinstallation) . Remove Right Foam Block. CAUTION: Do not tear Foam Block or proper vacuum/suct ion may not exist for normal operations. Stepper Motor Ground

Service Guide Service: Disassembly Media Drive System Step 9. Disconnect Vacuum Fans (3 screws each) and Exhaust Grills (4 screws each ). Remove the Exhaust Grills. Step 10. Remove Platen Plug by prying out with one hand and screwdriver assistan ce from the other. Note: Four inner tabs secure Platen Plug to the Platen. Plug may have to be brok en for removal if technicians hands are too large for removal.

Service Guide Service: Disassembly Media Drive System Step 11. Disconnect the Lower Roller Assembly from the Platen by removing 6 secu ring screws. Step 12. Remove the Center Support through the hole on the bottom of the Platen. Note: Front side of center support bracket is labeled FRONT, ensure this sides faces toward the dryer/air plenum upon re-installation. Note: Ensure proper orientation of the Center Support Bracket during installatio n or low quality output may result. The thick arm faces towards the front of pri nter.

Service Guide Service: Disassembly Media Drive System Step 13. Remove the Left Base Plate by removing 9 securing screws. xxx Step 14. Remove the top cover by removing 4 securing screws. Step 15. Remove the Left Side Plate by removing 5 securing screws.

Service Guide Service: Disassembly Media Drive System Step 16. Remove Left Foam Block. Do not tear Foam Block or proper vacuum may not be obtained. Step 17. Recess the 4 screws securing the Left Leg Assembly until they are flush with the inside of the Platen. CAUTION: do not move printer until the left stand leg screws are secure or print er may collapse.

Service Guide Service: Disassembly Media Drive System Step 18. Remove the Lower Roller Assembly and Vacuum Fans. Note: To ease in assembly removal gently shake and lift assembly while pulling o ut left side of platen. Step 19. To remove the stepper motor remove two securing screws, nuts and spring . NOTE: the correct shims (differentiated by color) will need to be installed on to new lower roller support brackets and center support bracket refer to Service Bulletin 17 for instructions.

Service Guide Service: Disassembly Nose Heater Assembly Video Step 1. Remove power from printer. Step 2. Remove the Right Rear Cover by removing 2 securing screws. xxx

Service Guide Service: Disassembly Nose Heater Assembly Step 3. Disconnect the Air Plenum. Step 4. Remove the Right Lower Cover. Ensure inner clips securing right lower co ver are disengaged. xxx

Service Guide Service: Disassembly Nose Heater Assembly Caution: Ensure that the Air Plenum is locked in the operational position. Step 5. Remove both pivoting screws. Step 6. While firmly holding the Air Plenum, release both position locking pins. Remove the Air Plenum.

Service Guide Service: Disassembly Nose Heater Assembly Step 7. Disconnect the Heater Element connectors from J1, J2 and J3 on the Dryer PWA. Step 8. Disconnect the Thermocouple connectors from J8 and J9 on the Dryer PWA. Step 9. Disconnect the Thermal Fuse connector from J6 on the Dryer PWA.

Service Guide Service: Disassembly Nose Heater Assembly Step 10. Remove the (rear) screws securing the Nose Spacers to the Platen. xxx Step 11. Remove Nose Heater Assembly. Note: once the nose heater has been removed the thermocouple sensors and thermoc ouple fuse may be removed.

Service Guide Service: Disassembly Air Plenum Assembly Video Step 1. Remove power from printer. Step 2. Remove the Right Rear Cover by removing 2 securing screws. xxx

Service Guide Service: Disassembly Air Plenum Assembly Step 3. Disconnect the Air Plenum. Step 4. Remove the Right Lower Cover. Ensure inner clips securing right lower co ver are disengaged. xxx

Service Guide Service: Disassembly Air Plenum Assembly Caution: Ensure that the Air Plenum is locked in the operational position. Step 5. Remove both pivoting screws. Step 6. While firmly holding the Air Plenum, release both position locking pins. Remove the Air Plenum. Disassemble air plenum completely to remove defective fa n assembly. Note: 4 fans are present in the 42 inch printer, 6 fans are present in the 60 inch printer.

Service Guide Service: Disassembly Media Takeup/Feed System Video Step 1. Remove power from printer. Step 2. Remove Drive Cradle Assembly by removing 4 securing screws. Remove ESD s trike plate. Note: motor is secured to motor mount via 2 tie-straps, 3 screws and an e-clip.

Service Guide Service: Disassembly Media Takeup/Feed System Note: Inspect the Carbon Fiber Brushes on the ESD Strike Plate for wear. Carbon fiber brushes should not be worn or bent. Replace strike plate (s) if defective. Step 3. Cut the Motor tie-strap and disconnect the Motor. Note: An additional 3 screws and an E-Clip will need to be removed to seperate t he Motor from the Motor Mount.

Service Guide Service: Disassembly Media Takeup/Feed System Step 4. Disconnect Sensor. Cut tie-straps and unscrew the Sensor from the bracke t to remove.

Service Guide Service: Disassembly Trailing Cable Video Step 1. After removing printer power, right rear cover and lowering air plenum, remove 4 screws securing ink delivery carriage cover support brackets. Remove 2 support brackets. Step 2. Disconnect trailing cable from carriage board by pressing on lock with a small blunt tool. Caution: to avoid damaging lock do not twist plug from connector. Connector tab will need to be depressed to release lock.

Service Guide Service: Disassembly Trailing Cable Step 3. Remove ink chain restraint by removing two #8 star-head screws. Use a To rque #8 driver. Step 4. Remove 2 chain shelf screws. Step 5. Pry 2 restraining tabs securing ink chain to carriage cover. Step 6. Separate ink chain links by prying or pulling ink chain links apart ever y 10-15 cm along entire chain length.

Service Guide Service: Disassembly Trailing Cable Step 7. Tape trailing cable lock to protect connector lock. Step 8. Remove trail ing cable from chain by removing cable slack and pulling free. Gently pry up on each chain link with a small flathead screwdriver to allow cable connector to mo ve past each link. Caution: do not overstress cable (s) during installation or damage to cable (s) will result.

Service Guide Service: Disassembly Trailing Cable Step 9. Remove 2 screws securing trailing cable grounding plate. Step 10. Disconnect trailing cable from main board. Note: Depress lock with a small blunt tool to release trailing cable. Step 11. Remove double-sided tape from cable and remove trailing cable from prin ter. Note: when reinstalling cable ensure carriage side of cable extends only 67 inches beyond the last link.

Service Guide Service: Mechanical Alignments Alignment Theory Tools Required Special Notes Slide Shaft Adjustment Carriage He ad Height Adjustment

Service Guide Service: Mechanical Alignments Alignment Theory XXX Head to Platen Height Relationship The distance between the bottom of the cartridge (print head) and the platen sur face should be equal to 0.065 inches (65/1000 of an inch). The carriage head hei ght normally requires adjustment following an encoder strip replacement or if pr int head scraping occurs on multiple media types.

Service Guide Service: Mechanical Alignments Tools Required Head Height Adjustment Kit (221955-00): - Modified test cartridge with dual tens ion bands - Micrometer dial gauge - Shaft mounting block - Extension tip (for di al gauge stem) - Service station plate (221816-01) - 1/16 and 7/64 inch hex-key wrench tools - 1/4 inch open-ended wrench Cross-head screwdriver, no. 2

Service Guide Service: Mechanical Alignments Special Notes Note 1: A special tool kit is required to perform the mechanical adjustments. Re fer to Service Bulletin 3 for complete procedures/updates. Note 2: Only perform mechanical adjustments if carriage head scraping is observed on media surface, i f the color deadband adjustment cannot be calibrated, or if the encoder strip/st abilizer bracket is moved or replaced. Note 3: Remove power and media from printer before beginning adjustments. Lower the air plenum by removing the two locking pins.

Service Guide Service: Mechanical Alignments Slide Shaft Adjustment Step 1. Obtain the Head Height Alignment Kit. Step 2. Assemble the shaft mountin g block to the micrometer dial gauge using 1/16 inch hexkey wrench; ensure the e lbow is flush to the front. Tighten the set-screw at the rear of the shaft mount ing block. Step 3. After moving air plenum to maintenance position, place shaft mounting block and gauge over the slide shaft on the left most printable surface (above slide shaft supports), zero the gauge at this first location. Step 4. Mo ve the shaft mounting block and dial gauge to the right end (above slide shaft s upports) and take a measurement. Video Step 5. Move to the center position (directly over turnbuckles) and calculate th e average between the left side and the right side. Step 6. Using a open ended wr ench adjust the turn buckle (or turn buckles - 60 inch unit) for the average com puted value.

Service Guide Service: Mechanical Alignments Carriage Head Height Adjustment Video Step 1. Obtain tools: head height test cartridge, dial gauge, extension tip, 1/1 6 and 7/64 inch hexkey wrenches. Step 2. Attach extension tip to dial gauge. Ass emble the test cartridge and micrometer dial gauge using 1/16 hex-key wrench too l. Step 3. Ensure or 6 mm of the measuring tip extends beyond the cartridge base. Rotate gauge so it faces towards the left side, tighten the set screw securely. Step 4. Place the dial micrometer gauge on a flat surface and adjust gauges fac e plate so needle reads 90-10 (left of zero); Tighten gauge face screw. Step 5. Moving air plenum to maintenance position. Remove 5 printer covers (left top and bottom, right rear and bottom, and top cover). Check slotted insulator plates s crews, 1/2 turn CCW. Activate dryer to heat setting of 5, select access cartridg es to activate vacuum fans.

Service Guide Service: Mechanical Alignments Carriage Head Height Adjustment Step 6. Remove media from the printer. Remove all 6 cartridges. Remove the foam pad from K cartridge stall position. Step 7. Install the test cartridge into the K cartridge stall position; gauge should be facing toward left side of printer. Step 8. Measure in front of each adjustment screw for 65 +/- 3; only observe th e gauges inner set of numbers. Firmly force encoder stabilizer bracket up or down with tool and tighten 7/64 screws at rear of printer. Step 9. To adjust at the service station area, remove the service station. Place service station plate in to the access hole (towards right side) and move gauge/cartridge onto plate surf ace. Adjust for 65 +/- 3.

Service Guide Service: Mechanical Alignments Carriage Head Height Adjustment Adjustment Tips 1. Loosen all screws prior to making adjustments and working towards the center of printer makes the adjustments easier. 2. When adjustment is complete ensure t he carriage is parallel to the platen surface - by observing the small dial on t he gauge for a consistent reading at all adjustment positions. 3. If a crossbar or stand assembly is adjusted or installed perform all mechanical adjustments ag ain. Print Deadband (fast) to verify adjustments are correct - perform Service B ulletins 2, 3, 1, and 4 (in this order) if any problems are encountered with the Deadband print pattern.

Revised 05-12-2006 Service: Illustrated Parts List: Part Number Listing Pages 1-6 Illustrated Parts List (Reference) Pages 7-29 Part Number Listing (by part name): Illustrated Parts Cross Reference # B-8 B-4a B-4b D-2 E-7a E-14 E-12a E-2 K-4b K -5a D-7 A-1 C-13 H-3 F-1 KODAK 1200iNJ1000i Part Number: 222703-00 220540-00 220 468-00 208987-1 222038-00 220236-150 221584-04 220131-065 221986-00 220708-00 22 3682-00 220854-02 219127-00 207659-01 221781-00 Part Name/Description AUTOLOAD S ENSOR BELT, 42" BELT, 60" BRACKET, LOWER DRIVE SUPPORT BUSHING SET (2), Kodak 12 00i-NJ1000i CARRIAGE ASSY, COMPLETE, Kodak 1200i-NJ1000i CARRIAGE FLEX, 640J CAR RIAGE PCB, 640J CARTRIDGE GARAGE CASE, EQUIP, WATER PROOF CENTER SUPPORT BRACKET ASSY CHASSIS, INK RESERVOIR CIRCUIT BREAKER, 13A CLAMP, PAPER GUIDE CONNECTOR, 1/8 ID TO 3/32 ID TUBE

1200i/1000i Illustrated Parts List Part Number Listing (by part name): K-5b H-10 A-5 E-1 C-12 A-4 C-1 H-6 B-6c E-11 E-11 F-3 C-4 E-13a 222169-00 207673 -1 220266-02 220302-00 220231-03 220472-04 220850-02 207667 200507 215644-01 215 643-01 221282-01 210068-06 222563-150 CONTAINER, PARTS STORAGE CORE, PAPER, 60" COVER, BOTTOM, LEFT COVER, CARRIER ELECTRONICS COVER, DISPLAY MOUNT COVER, TOP L EFT COVER, TOP RIGHT, REAR CRADLE IDLER (TAKE UP) C-RING, (PINCH ROLLER) CUTTER ASSY, WHITE - 5 PACK CUTTER BLADE, WHITE, SINGLE DAMPER, ASSY DISPLAY DOOR & SEP TUM ASSY (INCLUDES COMPLETE DOOR ASSEMBLY, DOOR SUPPORT MOUNT, DOOR SPRING & BLO CKER CLIP) DOOR ASSY, SINGLE DOOR, RIGHT COVER DRYER PCB (INCLUDES SLIDE SWITCH) ELBOW BARB 1/8 TO 3/32 ENCODER SENSOR W/FLEX ENCODER STRIP LAMINATED, 89.7" (EN CODER STRIP ONLY - NO TAPE OR STABILIZER BRACKET INCLUDED) ESD BRUSH, 42"-6, ASS Y (QUANTITY OF 6) ESD BRUSH, 60"-6, ASSY (QUANTITY OF 6) E-13b C-2 C-7 F-2 E-5 B-3c B-2a B-2b 220461-01 220985-03 220441-02 222016-00 209578-101 217236-00 220959-150 220639-1 50 2

1200i/1000i Illustrated Parts List Part Number Listing (by part name): D-6 I-6 C-11 D-5 D-4 B-5a I-5a H-8 B-9 H-2 D-9 H-4 A-2d / F-2d I-5b B-7a / I-1a B-7b / I-1b A-2b / F-2b B-5c B-1b / F-3b B-1a / F-3a A-2a / F-2a C-3 H-9 K-4a 20 4976 220668-00 215566-00 214402-01 214401-01 203870-1 221696-01 207666 215158-02 207644 220272-01 221427-00 220688-02 220673-00 220537-150 220503-150 221248-00 217269-02 220535-150 220249-150 220853-04 209096-3 211170 221984-01 EXHAUST, GRI LL FAN, ASSY, DRYER FAN, COOLING (POWER SUPPLY) FAN, VACUUM (LEFT), 60" PRINTER ONLY FAN, VACUUM (RIGHT) FRAME TENSIONER ONLY FUSE, THERMAL CUT-OFF (84C) GEAR, MOTOR DRIVE (FEED & TAKE-UP) GUIDE, CENTER, COMMON (OEM4 PRINTER) GUIDE, PAPER A DJUSTABLE (FEED & TAKE-UP) HARNESS, DRYER/WINDER (MAIN PWA - LEG) HARNESS, LEG D RIVE (INNER LEG) HARNESS, RESERVOIR SENSOR HARNESS, THERMAL FUSE HEATED NOSE, AS SY 42" HEATED NOSE, ASSY 60" HOUSING, SENSOR IDLER ONLY INK DELIVERY ASSY 42" IN K DELIVERY ASSY 60" INTERMEDIATE RESERVOIR, ASSY KEYPAD KIT, 2 STRIKEPLATES + 2 BRUSHES KIT, FLUSH KIT ASSY 3

1200i/1000i Illustrated Parts List Part Number Listing (by part name): K-1 K-2 B-10a K-6b K-6a A-3 A-6a A-6b D-3a D-3b B-10d C-6 C-5 H-7 J-2 K-7a K-7b K-7c K-7d K-7e B-10b B-10b B-10c 221955-00 222185-00 221555-00 221945-00 22199300 221338-00 223071-01 222370-00 221855-610 221857-610 222007-00 220111-165 2163 91-00 207767 220695-00 222824-00 222823-00 215631-01 215627-01 215628-02 22149801 222191-00 221496-01 KIT, HEIGHT ALIGNMENT, Kodak 1200i-NJ1000i KIT, INK SYSTE M TEST KIT, MEDIA GUIDES ASSY KIT, SERVICE SPARES PREMIUM, Kodak 1200i-NJ1000i K IT, SERVICE SPARES STANDARD, Kodak 1200i-NJ1000i KNIFE DELATCHER LINE FILLING CA RTRIDGE w/PLUG BAR LINE FILLING CARTRIDGE ONLY LOWER DRIVE ASSY, 42" (INCLUDES S TEPPER MOTOR) LOWER DRIVE ASSY, 60" (INCLUDES STEPPER MOTOR) MAGNET, MEDIA WEIGH T MAIN PWA, Kodak 1200i-NJ1000i (OEM1 PRINTER ONLY) MEMORY - SDRAM DIMM, 8 X 64 MOTOR, FEED & TAKE-UP OPTICAL SW ASSY, (WASTE UNIT WIRING HARNESS & SENSOR ASSY) PACKAGING, 42" PRINTER HEAD (BOX 1) PACKAGING, 60" PRINTER HEAD (BOX 1) PACKAGI NG, SPACER, BASE POSITIONER (P/O BOX 2) PACKAGING, SPACER, END (P/O BOX 2) PACKA GING, SPACER, HOLDER (P/O BOX 2) PAPER GUIDE, LEFT PAPER GUIDE, LEFT (LONG; OEM 4 PRINTER) PAPER GUIDE, RIGHT 4

1200i/1000i Illustrated Parts List Part Number Listing (by part name): B-10c E-10 B-6a B-6d D-8 C-10 C-8 J-3 A-2c / F-2c E-8 E-6 E-9b / F-8b H-5 E-9a / F-8a G-2 D-1 H-1a H-1b E-7b E-12b A-3b B-11 B-12 D-10a 222190-00 220391-02 2218 81-00 222116-00 215189-00 220667-03 220647-02 221231-150 221500-01 220550-01 220 374-01 220460-00 207727-02 220420-00 220258-260 221825-00 219681-00 219682-00 22 1981-00 221964-01 222182-00 221991-00 221992-00 212427-00 PAPER GUIDE, RIGHT (LO NG; OEM 4 PRINTER) PAPER SENSOR W/FLEX PINCH ROLLER ONLY PINCH ROLLER ONLY (OEM 4 PRINTER) PLUG, PLATEN POWER ENTRY MODULE POWER SUPPLY (275W) PUMP ASSY, WASTE RESERVOIR RESERVOIR DATA BOARD, PWA RETAINER, BUSHING, LEFT RETAINER, BUSHING, R IGHT RING, RETAINING, E-TYPE, 5/16 (FOR SEPTUM) SENSOR ASSY, TAKE-UP & FEED SEPT UM, ASSY SERVICE STATION ASSY (UPGRADE KIT/REPLACEMENT) SERVO MOTOR, CARRIAGE SH AFT, W/FIXED RT ROLLGUIDE 42 (FEED & T/U) SHAFT, W/FIXED RT ROLLGUIDE 60 (FEED & T/U) SHIM, BUSHING (SINGLE) SHIM, CARRIAGE FLEX (144 PER SHEET) SHIM, KNIFE DEL ATCHER SHIM, SHAFT SUPPORT SHIM, Y-ARM SHIM, .005 THICK, LOWER DRIVE (AS REQUIRE D) 5

1200i/1000i Illustrated Parts List Part Number Listing (by part name): D-10b D-10c I-7a I-7b E-4 E-3 C-9 E-15 B-5b B-6b B-3b B-3a I-2 I-3 I-4 K-3 B-13a / F-4b B-13b / F-4a J-1 J-4 G-1 212428-00 212429-00 220768-04 220758-05 204804 204654 220596-00 220248-02 215348-00 212542-00 220530-150 220216-150 220510-02 2 20605-00 220603-00 222088-00 220875-02 220269-02 220558-00 220835-05 220265-01 S HIM, .010 THICK, LOWER DRIVE (AS REQUIRED) SHIM, .020 THICK, LOWER DRIVE (AS REQ UIRED) SHROUD, PLENUM, 42-6 SHROUD, PLENUM, 60-6 SLIDER LOWER (CARRIAGE) SLIDER UPPER (CARRIAGE) SOLID-STATE RELAY, 25A SPRING PAD (CARRIAGE) SPRING, COMPRESSIO N (IDLER) SPRING, COMPRESSION (PINCH ROLLER) STABILIZER ASSY, 42" (WITH ENCODER STRIP) STABILIZER ASSY, 60" (WITH ENCODER STRIP) THERMISTOR, COMMON THERMISTOR, 42" THERMISTOR, 60" TOOL, BELT REMOVAL TRAILING CABLE, SHIELDED, 42" TRAILING CA BLE, SHIELDED, 60" WASTE CONTAINER (ONLY) WASTE INK RES., ASSY COMPLETE WIPER, S ERVICE STATION 6

5 4 3 2 1 TRAILING CABLE MAIN BOARD +24V, GND 6 INK BOTTLES WITH DATA CHIPS LVDS DIFF. PAIRS 2 VACUUM FANS A/D CONVE RTER LVDS BCKCHL CARRIAGE BOARD PRINT HEADS D D LVDS INTF. FPGA HEAD DRIVERS LM LC M Y K C HEATERS FIRE FIRE DRYER BOARD DRYER INTERFACE PROGRAM INTF. CPROGRAM BLOWERS PAPER SENSOR ENCODER POWER SUPPLY

C POWER SUPPLY FAN FAN DRIVERS 24V POWER SUPPLY 1.8V 3.3V 5V 7V - 11V FIRING VOLTAGE C AC 120 / 240 3.3V @ 10A 2.5V @ 0.9A POWER SUPPLY 1.5V @ 2A 5V @ 0.1A SERVO MOTOR 24V FPGA MOTOR DRIVERS AUTOLOAD SENSOR INTERFACE WINDER / UNWINDER INTERFACE STEPPER MOTO R CRYSTAL B AUTOLOAD SENSOR B WINDER / UNWINDER ETHERNET CONNECTOR ETHERNET PHY CLOCK WASTE BOTTLE INTERFACE WASTE BOTTLE 2K EEPROM POWERPC 405GP SERVICE STATION INTERFACE DISPLAY / KEYPAD INTERFACES 256K X 18 ZB T RAMS DISPLAY / KEYPAD SERVICE STATION JTAG PORT NJ1000i Block Diagram A 4M FLASH SDRAM 32M MAIN MEMORY SDRAM DIMM 64M RASTER MEMORY Title Size A Block Diagram, NJ1000i Document Number Thursday, February 26, 2004 1 Custom 222052-00

Sheet 1 of 1 Rev AA Date: 5 4 3 2