NJ1000i-1200i Printer Service Manual - 05122006

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
Chapter 8 Cartridge Replacement
Chapter 9 Firmware Download
Chapter 10 Troubleshooting
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 proceed 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 Components
1) Ink Refill Bottles

2) Intermediate Reservoir
3) Carriage Assembly
4) Cartridge/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
Features Video
Service Guide
Printer Technology
Animation
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 particular print mode. A
different print mask is applied for each color plane. 3-pass printing with conventional
masking tends to result in hue-shift banding, especially 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 carriage 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 right-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
third 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 during high speed printing. High
speed printing is more difficult because of the higher 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 masking controls and limits coalescence to even out the resultant
density and color, and reduce banding and graininess.
Service Guide
Printer Technology
Service Guide
Printer Technology
2. Rapid Evaporation Drying System
The advanced dual-component drying system uses the principle of conducted heat
to 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
maintain intimate contact with the back of the web for effective heat transfer. The
nose is an isolated extrusion that incorporates three longitudinal fins with an
electrical heating strip mounted to each fin inside the curve. This design evens 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 flow is used to
pull away moisture and improve drying efficiency by another 30% over 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, carrying 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 achieve and maintain temperature set points between 35 and 55
degrees C.
Animation
Service Guide
Ink System
Ink Refill Bottles
- 6 ink bottles (ML, CL, Y, K, M, C)
- Refill bottles are easy to replace
Intermediate Reservoir
- Encrypted for ink monitoring (740 ml shutoff)
- Intermediate reservoir at reservoir base
- One set of ink lines; switch over capability (Dye or

Pigment)
- provides consistent ink supply pressure
- Plug and Play ink refill bottle (700 ml) with

septum/needle interface
- Clean-hands installation
- Mechanical color keying of bottle
- Replace ink on-the-fly

- Prevents job interruptions (52 ml
capacity)
- Ink level LOW warning sensor (30
minutes)
- Ink level OUT stop, protects cartridge
Service Guide
Ink System
Animation
Carriage Assembly
Cartridge/Printhead
- Robust carriage bushing design; thick bushings with spring

loaded bias for better dimensional stability
- Increased productivity with 640 nozzle printheads
- Bushings are grooved to minimize the effect of dirt and

debris
- Clean hands shipping and installation
- Improved quality with 30% smaller drop size
- Cartridge doors secure printheads in place
- Foam filled, eliminate tubing and needles
- Ink is regulated to printhead via ink line dampers
- 2100 ml average life; 2800 ml shutoff
- One-step cartridge installation process
Service Guide
Ink System
Active Service Station
Auto Clean Unit
- Clean hands ink line filling through service station

- Motor controlled multi-port color control selection valve
- Eliminates ink prime devices
- Clean hands cartridge maintenance through service station
- Ink is deposited into a waste bottle
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
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 that 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 for 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
Print Speeds
Video
Print Mode
60 inch model
42 inch model
High Speed mode (2 pass)
220 sfph (20.4 smph)
Productivity mode (3 pass)
Fine mode (4 pass)
104 sfph (9.6 smph)
Enhanced mode (6 pass)
75 sfph (7.0 smph)
70 sfph (6.5 smph)
High Quality (16 pass)
26 sfph (2.8 smph)
23 sfph (2.5 smph)
Note: Printer ships with 64 MB

SDRAM and is not up gradable; HPGL/2 is not supported. An additional
32 MB RAM resides on the main
board.
Service Guide
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 paper 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 allows for a second roll of media
to be loaded onto the lower roller (no takeup available).
Note: 20,000 volt minimum protection is provided by 2 permanent rear
electrostatic discharge strips located in platen.
Service Guide
Software Interface
Setup Requirements:
1) Server workstation with RIP
loaded; Windows 2000/XP/XP
PRO/Windows 2003 Server,
Network Card, 3.0 GHz Processor, 1
GB RAM, 160 GB hard drive
2) Printer Installation Software
3) Client workstation (not required)
4) Network Switch/HUB; 100FD
Capability
5) Printer (built-in 100baseT
Network card)
6) Web Access (for Software
Updates)
Service Guide
Software Interface
Setup Tasks:
Software Installation:
- Server/Client Control Setup (follow
Typical Setup)
- Database Server (automatic)
- Drivers, EFPU, and Custom Colors
Utility (automatic)
- Network Connectivity (automatic)
Service Guide
Cartridge Warranty
Cartridge Warranty Volume
700 ml
Cartridge Average Life
1400 to 2100 ml
Cartridge End of Life
2800 ml
Warranty Coverage
Verify ink throughput by selecting UTILITY MENU - INK

STATUS MENU - CART INFO
Note: Nozzle failures are 100% filled blocks 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 Printer
Initialization
Load Media
Install Ink
Install Ink Cartridges
Print Test Patterns
Open Jet Compensation
Service Guide
Printer Unpacking
Video
Step 1.
Open printer head box flaps. Using two (2)
people minimum, rotate box/pallet over 90
degrees onto one side. Note: ensure the air
plenum is facing up.
WARNING:
Printer head and packaging weigh up to 374 lbs (170
kilograms); only perform heavy lifts with two (2) or four (4)
people as referenced by respective step. Also see video
procedures. Approximately 3 x 4 square meters of space will
be required for setup.
Note: A total of three boxes should be at installation site: printer head (on pallet), 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
Printer Unpacking
Step 2.
Using two (2) people minimum, pull printer free from
packaging by grabbing shipping brackets (through
plastic) and sliding printer away from box.
Service Guide
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
foam (white foam strips); place in triangular
formations (3 per pile) on the floor directly in
front of each printer cover.
Note: ensure triangular foam piles are
centered directly in front of each printer cover.
Service Guide
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.
Verify the printers air plenum is facing
up (rear side of printer facing down).
Service Guide
Printer Unpacking
Step 5.
Remove the plastic packaging from printer.
Caution: verify printer is stable prior to stand installation.
Service Guide
Video
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 removes the bracket to prevent from rolling.
Remove right lower shipping bracket (4 screws) and

upper shipping bracket.
Service Guide
Step 2.
1) Install and secure the right stand foot (4
screws) onto stand leg. Position 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 connecting. 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 harness
wiring when attaching to avoid
damage.
Service Guide
Step 3.
At left side of printer, remove the 2 shipping bracket
bolts and wing nuts.
Remove left lower shipping bracket (4 screws) and

upper shipping bracket. Set brackets to one side.
Service Guide
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 time.
Service Guide
Install Auto Clean Unit/Raise Printer
Video
5 Step Process:
Note: 4 short securing screws are pre-installed. 1) Connect 2 electrical connections; ensure
plugs are securely seated into jacks. 2) Remove nipple 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 loosen
quick connect valve.
4) Remove tape from securing screws. 5) Pitch unit to the right and secure over the 4 screws; tighten
securing screws.
Service Guide
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) people.
Using a four (4) person lift, grasp base of

left and right bottom covers, rear side/edge
of top cover; lift printer to standing position.
Service Guide
Initialization
Step 2.
Remove remaining packaging materials
including the center shipping bracket. To
remove the center shipping bracket lower the
dryer (air plenum) to the maintenance
position by removing the restraining pins at
either side of dryer.
Service Guide
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 printer power switch.
Caution: For regions which experience intermittent

voltage fluctuations a line conditioner and surge
protector are suggested to help protect the printers
power supply.
Video
Service Guide
Initialization
Step 4.
After a 9 to 10 second power up delay, ensure the carriage
traverses across entire printing area and back without error
during initialization process.
The main menu should be displayed when initialization is
complete.
Service Guide
Load Media
Video
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) Tighten roll guide against media edge
6) Install feed roller into printer; ensure gears mesh properly
Service Guide
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
Load Media
Step 3.
Pull media from feed roller; fully insert media edge into
media path channel. Align to white mark on left rear side
of platen. After a 9 second delay media 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. Verify correct paper width is
displayed.
Adjust media guides to within two
millimeters of media edges. Note: do
not allow media guides to touch media
or paper feed 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 Media
at control panel to load.
Service Guide
Load Media
Step 4.
Use the takeup roller when multiple or long print jobs are going to be
processed and printed. Three inch core adapters are available if takeup
roll is being loaded onto a laminator. For takeup operations, tape media
edge to the media core; ensure media edges line up evenly with media
core edges.
Install Media Edge Holders (magnetic) onto Y-Arm side - the

holders prevent media edges from lifting during low humidity
conditions.
Install left and right paper guides over media edges - the guides
will help media move through the air plenum.
Service Guide
Install Ink
Video
Step 1.
Obtain the 6 new ink bottles remove the shipping caps from
bottles.
Open the left cover and install all 6
bottles. Ensure bottle fittings mate
properly with each intermediate
reservoir fitting.
Note: Wait 5 minutes

prior to performing line
fill (must allow enough
time for the intermediate
reservoirs to fill properly)
Service Guide
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 Box. Connect Cartridge with Tube Assembly needle to
septum fitting located on right 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 into 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: do not use for a complete flushing of ink lines unless a red star is present
on auto clean door or possible damage may result to auto clean motor/pump; a
Flush Kit will be required (P/N 222351-00 or 221984-01).
Service Guide
Install Ink
Step 3.
Activate line pump. Select and hold 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 20 seconds per color.
Repeat procedure for remaining stall
positions.
Following ink line filling, disconnect the
line fill cartridge from the last stall position
but leave needle connected to septum
fitting. Select Pump On to clean assembly
of ink; disconnect priming assembly when
complete.
Service Guide
Install Ink Cartridges
Step 1.
Open cartridge door.
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.
Video
Service Guide
Print Test Patterns
Video
Step 1. Print Color Test

Select Utility Menu - Service Menu - Diagnostics Menu Color Test. Choose All Colors, select Ok
Verify solid rectangular print swaths are printed for each color with no visible ink
starvation.
Service Guide
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 clogged jets are not present.
Service Guide
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
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 Menu - Edit List Menu. After
inspecting the Prime pattern, select appropriate color and toggle respective jet (s) off.
Service Guide
Installation/Operations: Networking
Automatic Configuration
Manual IP Address Configuration
Service Guide
Automatic Configuration
System Setup:
1) MAC design station
2) PC workstation
3) PC server with RIP loaded
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
PRINTER SETUP (driver/networking
portion). For more information refer to
Software Control on this CD.
Service Guide
Step 1. Set IP and network information. At printer select
SETUP MENU - NETWORK MENU - IP CONFIG MENU.
Ensure host computer has the IP address, Subnet, and
Gateway addresses assigned. Computer and Printer
should be within the similar IP ranges (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 ensure network information
is correctly setup.
Note: Disable DHCP at Printers DHCP Client screen for
peer-to-peer configurations; enable DHCP for larger
network configurations (IP address will be automatically
assigned - use this IP address).
Step 3. Set this IP address within RIP or add Standard
TCP printer port (generic) using this address.
Service Guide
To download IP address directly to printer:
Step 1. At the Command/DOS prompt enter: arp -s IPaddress
MACaddress (MAC address can be found under Printers Network
Menu). For Example: arp -s 192.168.100.104 00-C0-EB-04-76-07
and then press Enter.
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 Command/DOS prompt enter: ping IPaddress
(i.e. ping 192.168.100.104). Verify 4 REPLY 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 Control
Job Accounting
Technical Support Reporting
Software Activation
Service Guide
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 software.
Note: Individual utilities may be

installed if configuring onto a remote
Client system only.
Service Guide
Printer Installation
Printer Drivers Install
Printer Installation will automatically detect printer on the
subnet, install drivers and designate IP addresses.
There are two types of installations. Complete

the Server installation for a single computer or
server. Complete the Client printer installation
for a second and all sub-computer installations.
Follow the screen prompts to complete the installation.
Service Guide
Server Setup
Procedure:
Stop server. Select settings to make
changes to server configuration
Walk through 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
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
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
Job Accounting
Displayed Results:
Output tracking features
- User selectable fields for tracking all
aspects of job costs.
- Accurate reporting of media and ink used
per job.
- Accurate reporting of time required to
print jobs.
Service Guide
Technical Support Reporting
- Used to export Database information
- Information can be exported to a text
file (csv) and sent to an email address
- Can be customized to export specific
information
- Can be customized with user/contact
information
- Supports additional comments
Service Guide
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 register:
1. Direct from the Registration page during
software installation (web connection required
from software installation location) or at Client
Control Panel, choose Help Product
Registration.
2. Through website (www.encad.com), printer
serial number will be required.
3. Call directly into US Technical support with
printer 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 email with the activation code will be forwarded
back to the customer. From the Client 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 Compensation
Service Guide
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 operations. Refer to Service Bulletin 1 or Technical Bulletin 1 for complete instructions.
Graphics Calibration:
1. Perform Line Length Test; measure distance
2. Measure Line Length Value (i.e. 33.06)
2. Modify Img Quality Value (i.e. 33.06) and press Ok. Save
Calibration to User setting.
Line Accuracy Calibration:

1. Perform Line Length Test; measure
distance
2. Adjust Line Length Value (i.e. enter 33.06)
3. Perform Deadband Calibration
3. Perform Deadband Calibration
4. Perform Color Calibration Vertical
4. Perform Color Calibration Vertical
5. Perform Color Calibration Horizontal
5. Perform Color Calibration Horizontal

6. Evaluate print performance (Demo image/6-pass mode)
7. If necessary perform micro-alignment, print the Printer
Calibration Test Target.rtl (from Service CD). Adjust Paper
Calib Value to reduce microbanding. Perform Color Calibration
Vertical
Service Guide
All printer calibrations are located in one menu.
Calibration
Menu
Note 1: the media feed/stepping

rate is determined by either the
Paper Calib Value or the Line
Length/Img Quality Value last
entered, but not both.
Note 2: DO NOT use the PAPER

CALIB TEST as results may vary.
Paper Calib
Menu
Service Guide
Step 1. Graphics Calibration
a. Perform Line Length Test, select UTILITY MENU - CALIBRATION MENU - PAPER CALIB
MENU - LINE LENGTH TEST. A line pattern will be printed in the center of the media; 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 setting.
c. Perform Deadband Calibration, Color Calibration Vertical and Horizontal (see following
pages).
d. Activate the Deadband Test to verify printer calibrations, select Utility Menu - Service
Menu - Calibration Menu - Deadband Test. This will check the electrical and mechanical
calibrations. All 6 colors should line up vertically across the entire print. At both ends, check
the next to last line.
Service Guide
Step 1. Graphics Calibration
e. Evaluate print performance using a demo image in 6-pass mode.
f. If banding is unacceptable, then print the Printer Calibration Test Target.rtl (send file
through EFPU) located on Service CD.
g. Adjust Paper Calib Value to reduce microbanding. Analyze the calibration test
target print for media overfeed or underfeed. If overfeed is observed as in example A
below (white lines/gaps occurring), then reduce the Paper Calib Value by one or two
values and retest (i.e. change from 4806 to 4805). If underfeed is observed as in
example B below (dark lines/overlap occurring), then increase the Paper Calib Value
by one or two values and retest (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
Step 1. Line Accuracy Calibration
a. Perform Line Length Test, select UTILITY MENU - CALIBRATION MENU - PAPER
CALIB MENU - LINE LENGTH TEST. Measure and enter true distance between lines (a 35
inch ruler may be printed from Service CD).
b. Adjust LINE LENGTH VALUE and select 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 enter the measured value under Line Length Value. Press
OK, this will lock the media feed value.
A line pattern will be printed in the center of the media; the pattern extends
approximately 33 inches or 838.2 mm. Accuracy tolerance is +/- 0.2% over
image length.
d. Perform Deadband Calibration, Color Calibration Vertical and Horizontal (see following
pages).
Service Guide
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 lines.
Note the compensation number below each group of vertical lines.
Service Guide
Step 3. Color Calibration Vertical
Perform whenever a cartridge is removed or replaced.
Select UTILITY MENU - CALIBRATION MENU - COLOR
CALIB MENU - VERT. CALIB. TEST
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
Prime Pattern
Check printhead nozzle performance
by activating the Prime pattern.
Select UTILITY MENU - PRIME
MENU - PRIME ALL.
Verify diagonal lines are smooth and
clogged jets are not present.
1) Solid blocks represent failed jets;
compensation engaged no user
interaction is necessary. The
cartridge warranty is provided from a
designated number of these blocks
observed in pattern and less than
700 ml ink throughput. 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
Prime Script
If a cartridge problem is suspected, check cartridge 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 used to help unclog print head nozzles
2) Prime pattern; test to check all 640 print head nozzles
3) PData patterns; Image data ports. Pdata 1 governs nozzles 1-320. 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
Manual Jet Compensation
To bypass a clogged or misfiring jet select UTILITY
MENU - CALIBRATION MENU - OPEN JET MENU EDIT LIST MENU. Select appropriate color.
Scroll to appropriate jet and toggle the jet

off. Compensated jets will appear as 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
Reservoir Replacement
Ink Cartridge Replacement
Ink Waste Disposal
Printer Safety
Ink Line Filling
Cutter Replacement
Printer Flushing
Service Guide
Media Loading
Video -Complete Media Load
Install media onto spindle and attach the media guide and
tighten the blue locking nut. Verify spindle gears mesh properly.
Ensure left media guide is locked next 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.
Video -Quick Media Load
Note: when media reaches end of roll do not forward media

through printer rollers. Sometimes the end of roll contains
excess glue which may cause frictional problems with the
printer media transport system.
Note: paper will be automatically advanced

following a 6 second delay and then
measured.
Service Guide
Media Loading
Video -Perfect Media Load
Perfect Media Load

1. Load media at rear of printer. NOTE: Avoid damaging electrostatic strip at
rear.
2. Move the rear edge media guides aside so that the media 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 Feed Media - Forward.
4. The feed gear will start to move in an attempt to drive the media forward, but
do not allow media to feed.
5. The media will begin to align 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 aligned with feed roll edge.
7. At Main Menu select Load Media.
8. Move the left and right rear edge media guides to within 1-2 mm of media
edges, but not touching. Install Paper Edge Guides (2) and Media Edge
Holders (2).
Service Guide
Dryer Modes
To activate the
drying system select
Setup Menu - Dryer
Menu - Dryer
Setting. Scroll
through available
selections.
12 dryer modes are available; refer to dryer matrix label

affixed to printer top cover.
Video
Note: air plenum may be lowered to
maintenance position by removing 2 locking
pins and gently lowering plenum. Place in up
postion for all printer operations.
Service Guide
Humidity Control
Environmental Factors
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 problems:
High humidity problems:
1) Media warping and edge curl problems leads to visible carriage head
strike 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.
1) Dry time drastically increases with high humidity

levels.
2) Inconsistent print quality is normally observed in severe low humidity

environments. To compensate more ink must be used to balance the
color loss.
These problems can be avoided by maintaining proper temperature and

humidity levels (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 by dry air.
2) Lamination issues often result; increasing time

required to finish jobs.
3) Color Shift from one day to the next may occur.
Service Guide
Printer Readiness
To ensure the printer is ready prior to printing first
activate the prime pattern by selecting Utility Menu Prime Menu - Prime All. Refer to Technical Bulletin 1 for
complete Printer Calibrations.
The Prime pattern checks the electrical firing capability of all

640 jets for all six colors. Verify all cartridge nozzles are
firing properly. If necessary perform open jet bypass, select
Utility Menu - Calibration Menu - Open Jet Menu - Edit Jet
List. Toggle misfiring or clogged jets off; select Ok to save
changes.
Refer to Technical Bulletin 6 for print and lamination
guidelines.
Video
Service Guide
Printer Readiness
End of Plot
Video - Edge Band

Edge Band Mode
Edge Band is a special mode used to help eliminate instances
of First Drop (inconsistent small horizontal lines .2 mm to 10
mm appearing at left or right edges of print) - refer to
Troubleshooting.
Select Setup Menu - Paper Option Menu - Margins - Edge
Band.
Ensure the End of Plot mode is correctly setup.

Select Setup Menu - Dryer Menu - End of Plot.
Three modes are available:
The Edge Band mode employs the same spacing as Normal

Margins but prints a 6 color line within each normal margin
area.
On With Rewind (dries image and then rewinds

print to save media)
Note: This mode does not encroach/crop the printed image.

Enhanced margins with the edge band mode is not available.
On Without Rewind (dries image, does not rewind

the print)
Off (no media advancement following printing, does
not dry the remainder of print)
Service Guide
Reservoir Replacement
Firmly grasp the used reservoir bottle and pull straight up.
Install new reservoir by pushing reservoir firmly down into
the intermediate reservoir at base of stall.
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 contacts.
Check reservoir information: Utility Menu - Service Menu Bottle Status.
Video
Service Guide
Ink Cartridge Replacement
Video
To replace an ink cartridge:

- Access cartridges by selecting Utility Menu
Access 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 cartridge and install
cartridge.
- Close cartridge door by pressing down firmly
until door locks.
- Return carriage to service station.
Caution: do not install/remove cartridges through the service station access door or damage
to print heads or service station may result.
Service Guide
Ink Waste Disposal
To remove the ink disposal bottle open the auto clean
unit door and remove ink disposal bottle. Install empty
waste disposal bottle and close auto clean unit door.
Video
Service Guide
Printer Safety
General operating tips to keep in mind:
- Never touch the slide shaft while printer is operating
or damage may occur to printer.
- Never remove the service station while printer is in
operation or bodily harm may result.
- Always keep top cover 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 control panel display or
damage will result.
Video
Service Guide
Ink Line Filling
Use this procedure to restore ink line pressure when a
pressure loss occurs. Also refer to Technical Bulletin 4.
- Access Cartridges and remove cartridge for ink line to be
primed.
- Install the Plug Bar (for new service stations only - yellow
label) into the service station and attach tubing needle to
septum fitting.
- Attach line fill cartridge into the cartridge stall position.
- Select and hold 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
Cutter Replacement
Select Access Cartridges to move carriage assembly
to maintenance position.
At left side of carriage assembly, press down on cutter
tab to remove cutter. Pull cutter free.
Install the new cutter by pushing cutter assembly into
carriages left side until a click is heard.
Return carriage to home position.
Video
Service Guide
Printer Flushing
Refer to Technical Bulletin 3 for complete printer
flushing/repacking instructions.
- If an early model auto clean motor/pump
assembly is installed, no red star is 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 clean motor/pump
may result.
- If the auto clean unit has a red star visible on
inside 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/Encoder Sensor
Flex Driver Cables
Slide Shaft
Carriage Paper Sensor
Carriage Bushing Replacement
Note: strict adherence to

plot hours listed is
strongly recommended
to reduce time between
failures.
Service Guide
Checking Plot Hours
Routine Maintenance is based on plot hours. Obtain the Inkjet Printer Cleaning Kit prior to performing routine
maintenance, P/N 216883-XX USA and Canada; P/N 218439-XX International. Additionally, for preventive
maintenance cleaning (i.e. encoder sensor) then obtain Domestic Cleaning Kit P/N 220970; International
customers may order Cleaning Kit P/N 221191.
NOTE: Use the printers control panel to check the plot hours. Select UTILITY MENUDISPLAY SETTINGS. The plot time will be displayed at the bottom of the screen.
Service Guide
Cartridge
Step 1. Activate the Clean Function. Select UTILITY MENU-PRIME MENU-CLEAN. Select
cartridge stall to clean. Step 2. Activate the Prime Pattern to verify jet performance. Select
UTILITY MENU-PRIME MENU-PRIME SINGLE. Select appropriate cartridge stall to check.
Video
Step 3. Activate the Vacuum Prime Function one time only. Select UTILITY MENU-PRIME MENU-SERVICE
STATION MENU-VACUUM PRIME. Select cartridge stall to prime. Step 4. Activate the Prime Pattern to verify jet
performance. Select UTILITY MENU-PRIME 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 all 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 reinstalling cartridge.
Video
Service Guide
Service Station
xxx
NOTE: DO NOT REMOVE SERVICE STATION WHEN CLEANING

Video
Manual Cleaning Procedure
Frequency: Every 40 plot hours.
Move carriage out to maintenance position by selecting UTILITY
MENU-ACCESS CARTRIDGES. Open service station access
door. Dampen a lint-free cloth with NovaKlean solution, apply to
wipers and seals. Clean all wipers and seals thoroughly. Ensure no
lint fibers remain on surfaces.
xxx
Service Guide
Platen Surface
Frequency: Every 75 plot hours
After removing power from the printer and lowering air
plenum to maintenance position apply NovaKlean solution or
De-Ionized water to a lint-free towel and wipe the entire
surface area platen surface.
Ensure no ink residue or cloth fibers remain on the platen.
Allow platen to dry completely before reinstalling media.
Service Guide
Encoder Strip/Encoder Sensor
Frequency: Clean strip every 20 plot hours; clean sensor
every 200 plot hours. Symptoms of dirty encoder
strip/sensor include image shift as pictured below.
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 entire
length of the encoder strip. Several cotton swabs may be
necessary to completely clean the encoder strip. Perform a
second cleaning using isopropyl alcohol.
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 spray
directly onto sensor (behind Magenta stall). Clean area
with canned air and lint-free towels.
Video
Service Guide
Flex Driver Cables
After removing power from the printer and lowering
air plenum to maintenance position remove the
cartridges from the carriage assembly.
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 cables to dry completely before reinstalling
cartridges.
Video
Service Guide
Slide Shaft
Apply NovaKlean solution to a lint-free towel and

wipe the entire surface area of 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.
Video
Service Guide
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 nose pliers (new station design) and gently pulling
on two tabs and lifting station out. Caution: do not force
station tabs or damage may occur; control tab movement
with two fingers.
Slide carriage assembly over service station access hole.
Apply NovaKlean solution to a lint-free cloth, gently blot the
paper sensor located directly behind the Magenta stall at
base of carriage.
Note: sensor is out of view (see picture below), but can be
felt with finger tips. Both the LED and receiver portions of
the sensor need to be thoroughly cleaned.
Video
Service Guide
Step 1. Remove power from printer.
Video
Step 2. Remove the Ink Delivery System

Carriage Cover support brackets by removing
4 securing screws.
Service Guide
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 off 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
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 throughput varies from
region to region (i.e. Typically less than
700 ml ink throughput and 3-pass print
mode is no longer supported).
Verify warranty terms with technical

support - see claim form.
Service Guide
Step 1. Access cartridges via
control panel (Utility Menu - Access
Cartridge)
Step 2. Open respective

cartridge door by pulling out,
and then up. Remove cartridge
by pulling straight out.
Video
Service Guide
Step 3. Remove accumulator/septum
assembly from cartridge by pulling
assembly straight 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 Service Bulletin 7 if
cartridge/bottle errors occur. Refer to
Troubleshooting for all other problems.
Service Guide
Checking Prime Pattern
Video
To print the prime pattern select Utility Menu - Prime Menu Prime All
The Prime pattern checks the electrical

firing capability of all 640 jets. Verify all
cartridge nozzles are firing properly.
Service Guide
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 the jet off by depressing Toggle.
The Auto Pass Correction feature will automatically 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 automatically 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 in groups) appear clogged, or excessive misfires are observed, cleaning of the cartridge
and flex driver cables contacts may be necessary. Refer to Maintenance.
Service Guide
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.
If cartridges are striking the media cease printer

operations immediately. Only operate printer with
suggested dryer setting, media types and at suggested
humidity ranges. Refer to Technical Bulletin 6 for
detailed print and lamination guidelines.
Verify Media Edge Holders, Paper Guides, and Media
Edge Guides are positioned properly. Refer to
Troubleshooting or contact technical support.
Video -Printer Cautions
Service Guide
Ink Switch Over Procedure
Video - Printer Flushing
Step 1. Obtain Flush/Ink Switch Over Kit (P/N 222351-00 or 221984-01 - verify with technical support
as to Flush Kit required). Remove all ink reservoirs and cartridges.
Step 2. Attach Flush system components according to instructions (either use the EasyPrime with
Cartridge with Tube Assembly or Cartridge with Tube Assembly/Plug Bar). Attach needle end to the
right side plate septum fitting. Activate the Pump On (Utility Menu - Prime Menu - Service Station
Menu - Pump On) on the keypad display until all ink is evacuated from ink line. Repeat for each stall
position.
Step 3. Place distilled water into Flush Reservoirs. Install into each reservoir position for 5
minutes (each intermediate reservoir should fill with water). Remove Flush Reservoir.
Activate the Pump On button on the keypad display until 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 all ink lines using above procedure.
Step 5. Install the New Ink Reservoirs and Cartridges. Activate the Line Fill procedure for each color
until ink line is full. Remove Line Fill Cartridges. Install new cartridges and perform necessary printer
readiness checks and calibrations prior to print operations.
Service Guide
Maintenance: Firmware Download
Checking Firmware Version
Hardware/Software Requirements
Software Control Download Procedure
Stand Alone Download Procedure
Service Guide
Checking Firmware Version
Step 1. Select Utility Menu - Service Menu - About
Step 2. Determine firmware level prior to downloading new firmware. Firmware level
is indicated by the Vers. (version) line.
Service Guide
Hardware/Software Requirements
Operating Systems:
Windows 2000/XP/XP Pro
- Ethernet cable from server workstation
- Crossover ethernet cable from peer to peer
workstation
Software Required:
-Software Control Panel provided on CD
with printer
- EFPU (Encad File Print Utility)
1) Host Workstation
2) Software Control Panel
Software (EFPU software)
3) Ethernet Cable (crossover
cable required for peer-to-peer
connection)
4) Printer
Service Guide
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 not
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 file) and select Print.
- Printer should emit a single audible beep after approximatly 60 seconds.
Step 5. Verify Download was successful. Cycle power to printer.

- Check the About screen for current firmware revision
Service Guide
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 File Print Utility) software
- Create a new folder (i.e. printer download)
- Select TCP printer port (Note: an LPT port must
be available for the EFPU to work properly. Load
a Windows driver; setup for local port and LPT1 if
necessary.)
- Add firmware .rom file to EFPU window
Service Guide
Step 2. Download Firmware
- Within EFPU program, highlight firmware file and select Print.
- Printer should emit a single audible beep after approximatly 60
seconds.
Step 3. Verify Download was successful. Cycle power to printer.

- Check the About screen for current firmware version
Service Guide
Troubleshooting: Advanced Analysis
Prime Pattern Problems
Connectivity Failure
Error Messages
xxx
Horizontal Banding Problems
xxx
Vertical Banding Problems
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
ATTENTION: sample test prints (or digital photographs)

mailed to technical support should contain arrows/marks
indicating the problem area, media travel direction, print
pass mode used, and printer firmware level. Include the
Prime pattern and Color Test (6 pass mode).
Service Guide
Video - Printer Readiness
1. Checking Prime Pattern

Inspect and verify all cartridge nozzles are firing properly. To
print the prime pattern select Utility Menu - Prime Menu Prime All. If cartridge misfires or clogged jets are observed
in the prime pattern activate the clean routine by selecting
Prime Menu - Clean. Choose the appropriate cartridge 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.
Note: typically up to 30 jets can be electrically damaged and/or compensated

before the Productivity mode (3-pass) support is no longer supported
(indicated by a hyphen). Clean cartridges manually if necessary; ensure the
bottom surfaces, jet plate, rear electrical contacts, and flex driver cable
surfaces are thoroughly cleaned. For severe jet failures (i.e. more than 160),
with a new cartridge, replace respective flex driver cable.
Service Guide
2. Manual Jet Bypass/Cartridge Cleaning
To perform Manual jet bypass (open jet
compensation) select Utility Menu Calibration Menu - Open Jet Menu - Edit List
Menu. 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
damaged, first try reseating cartridge and/or
clean rear electrical contacts and flex cable
surfaces.
Video - Cartridge Cleaning
Service Guide
3. Prime Script Test Pattern
If an electrical failure in the cartridge is suspected 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 used to help unclog print head nozzles
2) Prime pattern; test to check all 640 print head nozzles
3) PData patterns; Image data ports. Pdata 1 governs nozzles 1-320. Pdata 2 governs nozzles 321-640.
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
Error Messages
Video - Carriage Axis Error
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 Cartridge
Shutdown!
4. K: Warning - Ink Reservoir Low! message appears but ink
level 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 Error 10.
Probable Cause:
1. Dirty slide shaft, bushings, or encoder strip; Unseated or
damaged bushings/trailing cable.
2. Improper bottle contact with ID sensor. Damaged bottle
IC and/or OEM bottle installed.
3. Improper Y cartridge ink level/pressure; air bubbles in ink
line. Cartridge deprime.
4. Damaged K intermediate reservoir or sensor/connection.
5. Damaged M intermediate reservoir or air leak in line
exists. Check tubing and damper.
6. Improper contact between cartridge and flex 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
Error Messages
Service Guide
Error Messages
Common Operational Error Condition:
1. Paper Not Loaded!/Job Pause - Out of Paper!
2. C: Warning - Ink Reservoir Low!/Job Pause - E.O.M.
Detected!
3. Warning: Empty Waste Bottle Now!
4. Reminder: Adjust Rear Paper Guides!
5. Warning: Reinstall 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 Clean 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. Cartridge/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 indication.
Note: Printer Operations/User Guide documentation should be consulted for any other operational
problems encountered.
Service Guide
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 System Fault - Dryer Off
7. No Display at control panel. Printer repeatedly reboots.
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 (refer to SB7).
4. Damaged main PWA (refer to SB7/contact technical support).
5. Damaged carriage paper sensor (refer to SB7).
6. Incorrect voltage switch position (115 vs. 230). Dryer circuitry
damaged (refer to SB7 and SB6)
7. Improper connections. Damaged control panel display or power
supply.
8. Loose or damaged trailing cable connection (refer to SB7).
9. Damaged memory module.
10. Damaged carriage PWA.
11. Damaged main PWA.
Note: these conditions normally require parts replacement by a certified technician.
Service Guide
Videos
1. For general banding problems first ensure print head nozzles are firing correctly by checking the Prime
pattern. Activate Clean or Vacuum Prime (3x maximum) to help clear nozzles. Perform color test.
Clogged nozzles or misfiring nozzles (check open jet detection) may produce single-band (line) misfires in the
printed image.
Note: dirty print heads or dirty cable surfaces can also cause cartridge misfires. Thoroughly
clean the printer, refer to Maintenance. Replace cartridge if severe banding persists.
Service Guide
2. Microbanding is defined as consistent bands spaced horizontally (spaced 0.5 mm to 14 mm) down the entire
print or through a particular color space.
Ensure lower rollers are free of residue and verify vacuum fan suction is present below platen during printing.
Check calibrations by activating the Paper Calib Test, Color Deadband, and Color Calibrations (vertical and
horizontal). Refer to Calibrations and/or Service Bulletin 1.
Note: low pass print modes such as 2, 3, 4, or 6 may exhibit microbanding with high ink saturation
levels or with light/solid color spaces. Increasing print pass mode to 6 or 8-pass gradually eliminates
the banding. Verify proper dryer settings and media compatibility.
Service Guide
3. Scraping Bands appearing at media edges are likely caused
by incompatible media type or media edge curl caused by low
humidity in operating environment.
Enable 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 percent RH is optimum) and check the media compatibility list (i.e.
some 3rd party vinyl media has been known to leave glue on supply
roller/lower rollers causing banding). Proper operating temperature
levels should also be adhered to for best results (59 - 85 degrees F; 15 30 degrees C). Verify paper edge guides/magnetic media holders are
installed.
If low absorption media (i.e. bond) is primarily used by customer verify

paper guides are in place (OEM4 customers should verify plastic guide
is not interfering with carriage). NOTE: the carriage head height may
need to be raised (i.e. from 65/1000 to 85/1000 inches) for some
bond/textile applications. Refer to Mechanical 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
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 print 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
protection. Replace the lower drive system, center support
bracket and shaft/bearing assembly.
6. If micro banding cannot be corrected, check the

Color Calibration Vertical Test Pattern. Verify the
horizontal lines are equally spaced apart - if lines
appear inconsistent the stepper motor feed is
severely out of tolerance. Check the Paper Calib
Test/Line Length Test, enter only one value to reset
stepper feed. Refer to Service Bulletin 1.
Service Guide
Video
7. For color specific in-swath banding increase

print pass mode (i.e. from 6-pass to 16-pass;
printer should not band in 16-pass). Check prime
pattern; replace respective cartridge.
Contact technical support for assistance.
Download and install the latest firmware - refer to
Firmware Download.
Note: right or left side banding may be caused by the rear paper
guides being too close to media edges; this will also affect paper
feed values.
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.
Refer to Media Drive/Image Skew Problems.
Other causes include rear media guide interference
(should not press hard against media), ethernet data
starvation, failing servo motor, improper printer
grounding (ESD interference typically with 3rd party
low cost PP or Self Adh PP), dirty encoder sensor, or
dirty/damaged carriage bushings. Replace bushings
every 1000 print hours - refer to Maintenance.
Service Guide
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 Technical Bulletin 6.
2. If a single vertical band results (from 0.3 cm to 2

cm wide) from the trailing cable striking the chain
shelf surface (cable has been recently replaced).
Ensure cable extends 6-7 inches maximum beyond
clamp/restraint. Other causes of single vertical
bands/swath patterns include abnormal carriage
obstructions (i.e. damaged pinch roller); damaged
encoder strip or teflon strip.
Service Guide
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 shift
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. Often the scraping resembles scratches across the
media surface. Check carriage head 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) using service Head Height Kit - refer to Mechanical
Alignments.
Service Guide
5.If vertical swaths or gaps appears in
image, the trailing cable/connector is
probably 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 defect
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
Video - Testing Ink Pressure
1. Ink delivery failures are typically signified by a cartridge MAX

INK TEMP error. If one color fails to print verify ink system
pressure is normal. Re-prime ink line (s) using the Cartridge with
Tube Assembly and the Pump On feature (or pull ink directly into
special service tool: pressure test cartridge/VacLok Syringe). No
large air bubbles (gaps) should be present in main ink line. Verify
all ink tubing connections are good.
2. Replace printhead or cartridge. The internal cartridge ink level may

not be proper (chimney to foam separation has occurred). Replace ink
bottle if discovered leaking. Refer to Service Bulletin 7 for advanced
troubleshooting.
3. Obtain the Ink System Test kit. Check damper pressure using the
VacLok syringe 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 reservoir).
Check damper; replace damper if seal is broken.
Service Guide
4. Under DIAGNOSTICS MENU, select the INK RESERVOIR TEST. All
values should indicate 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 occurs replace Intermediate Reservoir PwA.
5. Replace septum assembly (at carriage). A small leak may

exist internal to assembly.
6. Replace entire ink delivery system if ink tubing is suspected damaged. For OEM5
systems replace the ink delivery system tubing (cheaper option) if cracking of ink lines is
observed; it is suggested to also replace all 6 dampers.
Service Guide
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
8. For an auto clean unit pump failure (i.e. ink is
spitting out of service station or complete pump
failure occurs) replace pump assembly. Pump
failures include improper operation during routine cap
evacuation (normally occurs every 2.5 minutes during
print operations) or during line filling (PUMP ON)
operations. Pump should be heard when activated.
To test pump select UTILITY MENU - PRIME MENU SERVICE 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 in Service Bulletin 8 to correct this
problem.
Pump
Assembly
with screws
Service Guide
Video - Environmental Factors
1. Ensure all cartridges are firing properly.

2. Verify relative humidity levels are between 40
and 60 percent. Install humidifier or de-humidifier as
appropriate to prevent color shifting between tiles.
Always bag media when not in use. Refer to
Technical Bulletin 6.
3. Check RIP (Raster Image Processor) ink/media
output profile settings; also check input ICC
settings. Install new/updated profiles 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 ink/media color calibration
software (i.e. Media Manager/Media Profiler) or 3rd
party color calibration software. Contact RIP vendor
or color specialist for assistance.
5. Refer to Service Bulletin 7 for error code related
problems.
Incorrect color
output
Proper color
output
Service Guide
5. Activate Prime Pattern test. If cartridge jets are misfiring
or are clogged/missing (as observed in the prime pattern)
reseat the cartridge. In the example image (at right) the
Magenta cartridge was incorrectly seated into the carriage
assembly.
6. Assuming printer calibrations have been performed
properly, replace the cartridge if unacceptable image quality
is observed from a ripped/external test print.
7. Clean all flex driver cable contacts and rear cartridge

surfaces of ink residue. Refer to Routine Maintenance.
Reseat all flex driver cable connections at carriage board
and retest. If severe jet failures persist replace respective
flex driver cable.
8. Replace carriage board if excessive cartridge failures

occcur (i.e. OVERCURRENT errors) and related color
problems persist.
Service Guide
9. For sudden color shifts (i.e. observed during a tiling job), the TSR value may 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 may appear to work fine (all jets firing, etc.) but the color output may be incorrect
due to a mis-read of the temperature sensing resistor (TSR). This will cause 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 the cartridge status by selecting the adjacent F keys at Cartridge Status menu; verify signal level
is detected (TSR Found +); TSR value is normally between 455 and 525.
NOTE: If TSR ERROR is displayed for all cartridges then the carriage board 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
10. If printed data appears to be out of synchronization (in the
horizontal/carriage movement direction) or resembles ink
overspray, combined with an abnormal cartridge failure rate (as
low as 50 ml througput) then earth grounding to the printer will
need to be verified. Refer to Service Bulletin 8.
Using a polarity tester verify electrical outlet has the proper

polarity and grounding 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 metal plate (plate
on which the power switch is mounted against). If AC voltage
(anything higher than 2 volts is improper) is present at plate,
platen surface or slide shaft then a faulty ground is present.
11. CAUTION: ground faults can cause up to half of the input/line voltage to appear on the
equipment. Exercise basic hardware electrical safety practices if a ground fault is
suspected. Refer to Service Bulletin 8.
Service Guide
Video
1. Check power connection and power source to printer.

Check circuit breaker position - if breaker is protruding out
then the power supply is probably damaged. With power off,
cycle 115V/230V voltage selector switch to ensure contact
positioning is good. Reboot printer to retest.
2. Reseat SDRAM module (64 MB) connection to Main

PWA; reseat both trailing cable connections. If memory
module is unseated, damaged, or missing the printer will not
initialize completely (carriage will partially move to left side
and will error with a carriage axis error). Note: Memory
should not be substituted; memory cannot be upgraded.
Damaged memory may be indicated by error message
FATAL PPC40X 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 then replace dryer board assy. (damaged transistor chip).
Service Guide
3. To help locate the problem, isolate loads by disconnecting
connections to Dryer, takeup and feed system and Auto Clean
Unit. If necessary, isolate motor loads: J13, J7, and J9.
4. If partial initialization occurs, check carriage board LED D1

(should illuminate 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 Main PWA to
correct.
5. If main board has intermittent or no LED activity, replace

Power Supply.
Service Guide
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 selector switch is in the
correct position. Reseat all dryer board connections and main board SSR
connection (J12). Check Dryer heater fuse resistance - refer to Service 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
MENU - DISPLAY SETTINGS for NO PAPER LOADED indication. Thoroughly
clean platen, cutter groove, and carriage paper sensor - refer to Routine
Maintenance. Verify there are no scratches in the cutter groove since the
paper sensor seeks this zone when detecting paper. Repaint groove as
necessary. Replace carriage paper sensor if failure persists.
Service Guide
8. If printer reboots repeatedly with the control panel
message...CLEARING MACHINE TYPE...then either the
keypad connection (via green cable) is unseated or the
keypad assy. is damaged. Replace keypad assy. (sheet
switch).
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 the keypad assy. is damaged.
Replace keypad assy. (sheet switch) as
appropriate.
Video - Keypad/Display Removal
Service Guide
Video - Carriage Axis Error
1. Check printed image for skewing/data shift - clean encoder

sensor/strip. Refer to maintenance and Technical Bulletin 5.
NOTE 1: No lubricants should be present on the slide shaft,
carriage belt or carriage bushings. Clean printer thoroughly - 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
interference. Modify or replace guide as necessary.
2. Check SDRAM module at Main PWA; printer

may partially initialize if memory module 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.
Video - Encoder
Sensor/Strip Cleaning
Service Guide
3. Remove carriage bushing retainers and carriage bushings.
Inspect carriage bushings and clean lint/excessive residue
buildup from bushing as necessary. Replace bushings if
excessive wear is observed (see step 7) or at 1000 plot hours.
Inspect bushing shims (4 total) for wear and tear - replace
shims if either the bushing shims are missing or if the shim
edges are lifting.
4. Check trailing cable connections at carriage and main board - reseat

connections 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. Replace if
damaged.
Video - Carriage
Bushing Removal
Service Guide
7. Temporarily remove cutter and service station from the printer;
retest to verify fault condition. Check UTILITY MENU - DISPLAY
SETTINGS menu for logged plot hours. Replace service station
if REINSTALL SERVICE STATION error message is observed;
upgrade to non-geared station type if necessary. Refer to
Service Bulletin 10.
8. Clean the carriage paper sensor - refer to Routine Maintenance. This will
help 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 above 312 on later model printers (post 07/2005). Replace the servo motor if intermittent
failures are experienced (NOTE: assumes printer is clean of residues/lubricants 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
10. Replace the Trailing Cable. Refer
to Disassembly.
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 support
to assist in making a final determination.
Video - Trailing Cable Removal
Service Guide
Media Feed/TakeUp Failures
Video - Legs Testing
1. Perform LEGS TEST. Tape media onto feed roller so both sensors are NOT
blocked by media (both sensors should be illuminated red). Select UTILITY MENU SERVICE MENU - DIAGNOSTICS MENU - ACCESSORY MENU - LEGS TEST. Both
rollers should slowly pulse in one direction only. Block one sensor at a time and verify
the respective roller reverses direction. If both or either sensor test fails proceed to
step 2, otherwise check SETUP MENU - PAPER SUPPLY OPTION. Verify the supply
mode is not set to SHEET (disables both sensors).
2. Check bracket alignment to ensure optic sensor is aligned with reflective tape.
Bend bracket as necessary until LED illuminates red in color. Replace if severely 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. Verify plug
is properly seated and retest.
Service Guide
4. Check wiring harness connection between the platen and main PWA (check for loose
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 infinite). For
single sensor failure (no red LED indication) replace respective sensor. Refer to leg
drive schematics.
NOTE: If smoke/alarm comes from the printer then inspect Main PWA
U26 (located behind trailing cables) and U2 I/Cs for damage (visible
melting of I/Cs). If damage is observed at Main PWA replace Main PWA
and both feed and takeup sensors (and possibly carriage board if U26
damage was severe enough). One of the sensors likely fused bringing
+24V up to U26 main pwa sensor input, then over to the U2 FPGA).
Service Guide
6. If sensors are functioning correctly but gear/shaft (s) fails to turn
(no motor drive), verify electrical resistance of feed/take-up motor.
Check resistance levels between motor gear and ground, values
should be between 0 and several hundred Kohms (5 to 70 ohms is
typical). Values in the Mohms indicate the motor bearings are
probably damaged or printer is not grounded properly. Swap motor
positions 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 assembly positions to isolate
failure.
8. Check strike plate condition to help avoid future imaging problems.

Carbon fibers should be present and standing upright on strikeplate.
Replace as necessary.
Service Guide
9. While running LEGS TEST verify drive signals to motor
(i.e. pulsing 24.0 volts dc, 0.0 volts dc when not active). Swap
or replace respective motor if determined damaged.
10. For problems which cannot be resolved replace entire right

stand leg assembly or replace leg drive harness (lower cable
within right stand leg).
11. Perform resistance checks across dryer/winder harness
(upper cable) wiring. Refer to leg 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
1. Ensure media is loaded properly following Technical Bulletin 1
guidelines; check 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 includes a lower roller
gear/drive test, mechanical alignment test, lower roller skew
test, and a lower drive inspection. NOTE: Both the lower roller
and new support shaft/bearing assembly (pictured at right)
should be replaced at the same time if a damaged lower roller is
discovered.
NOTE: Refer to Technical Bulletin 5

for image skew related problems (this
is different from media skew; the
printed border skews/shifts while the
media is aligned properly).
Video -Perfect Media Load
Service Guide
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 support shaft/bearing assy).
Remove center support shaft/bearing assy and inspect
lower roller for damage. If damage is observed then the
lower drive system and center support shaft/bearing assy.
will need replacement. CAUTION: refer to SB17 for
evaluating lower drive performance and for complete lower
drive system replacement instructions.
NOTE: It is common to experience length

problems with the first tile (Tile #1) on
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.
- Inconsistent
banding
- tile length
differences
Service Guide
4. If the media does not advance or banding is spaced every 1.33 (or
every 8) inches consistently down print this typically indicates a stepper
motor failure. Verify motor winding resistance across Main PWA J7 (pins
1 - 2 is normally 2.3 ohm, pins 1 - 3 is normally 4.2 ohm.). Replace the
lower drive system for either failure - refer to Service Bulletin 17. (NOTE:
stepper motor cannot be replaced independently)
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, sheet 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 drastically (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 verify 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 metal
debris inside bracket or below lower roller position. Ensure shims are present on the
center support bracket, these are normally required to prevent excessive pressure
onto the lower roller shaft. Thoroughly clean inside of bracket of metal
shavings/residues and reinstall into printer and re-test.
Service Guide
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 heights and C1/C2 compression values (do not rely on the platen
profile label below service station - values should be measured for field installation accuracy!). If values are
incorrect then shim or adjust the lower drive system as necessary.
Typical In-Field Alignment Example:
Roller Height (in) above Platen
Left
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 profile of 0.003
Service Guide
Video - Printer Initialization
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: Select SETUP MENU - DRYER MODE
MENU - DRYER SETTING (select 4), press Ok. Select UTILITY
MENU - SERVICE MENU - DIAGNOSTICS MENU ACCESSORY MENU - DRYER STATUS. Normally the T1 and T2
values (temperature sensors) should drive up to 40C after
approximately 5 minutes. If not, refer to Service Bulletin 6 and the
following steps.
2. Remove power from printer and remove right-rear cover.
Check dryer connection at Main PWA (J12). Remove bottom
right cover. Reseat all dryer board connections, including dryer
connection at Dryer PWA (J12); verify dryer SSR connection at
Dryer PWA (J4).
3. NOTE: If the circuit breaker is blown (protruding outwards) there is usually a reason why it is blown, such as an
electrical short. Verify circuit breaker continuity between TB1-1 and SSR-1 - refer to AC wiring schematic. If open,
then the circuit breaker is open/blown and will need replacement. Following CB replacement, first verify electrical
continuity across all wiring harnesses/heater strips/sensors prior to power up.
Service Guide
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 approximately 3/4 of input AC source voltage). Activation
signal, HTR ON signal (also at Dryer PWA J4-2) only occurs at
the time of dryer activation (best to activate 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 if
damaged.
5. Check for AC power coming into Dryer PWA J7 (measure

across pins 1 and 3). Verify proper wiring orientation if a new
installation or previously repaired.
6. For an air plenum only failure (heating system is functional)

first check dryer board air plenum fan connections. Replace the
dryer board assembly (damaged transistor).
Service Guide
7. Conduct electrical resistance checks. Power off printer.
Verify electrical resistance 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 in freezer (below 0C for 25 minutes to reset).
Retest fuse assembly.
8. Disconnect J1, J2, and J3 from Dryer board; verify

electrical resistance between pins 1-2 and 2-3 for 89 ohms
(80.1 mininum/97.9 maximum). If any of the resistances are
faulty then replace dryer heater (nose) assembly.
9. Check electrical resistance at soldered connections

between dryer board/voltage selector switch harness
assembly. If any of the resistances are faulty then replace
dryer board assy.
Service Guide
10. Replace any wiring harness with faulty resistance
values (greater than 0.6 ohms across wiring/jacks).
11. Replace Main PWA if failure persists.
NOTE: Ensure the air plenum is

properly grounded in accordance
with Service Bulletin 8.
Service Guide
Connectivity Failure
1. Ensure network is within IP range of printer (i.e. first three sets of numbers 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
addresses; 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 RJ45 patch Ethernet cable when connecting to HUB or Switch; use
crossover cable if 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 prints function, etc.)
Service Guide
Service: Disassembly
Right Covers
Carriage Assembly
Left Covers
Ink Delivery/Trailing Cable Assembly
Keypad and Display
Intermediate Reservoir Assembly
Main PWA and Clone Procedure
Service Station/Station Upgrade
Power Supply/Cooling Fan
Auto Clean Unit
Power Components
Encoder Strip Assembly
Dryer PWA and Voltage Switch
Pinch Roller Assembly
Servo Motor
Media Drive System
Ink Dampers/Septums
Nose Heater Assembly
Carriage Bushings
Air Plenum Assembly
Carriage PWA
Media Takeup/Feed System

Trailing Cable
Service Guide
Right Covers
Video
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 service
actions.
Service Guide
Right Covers
Step 3. Disconnect the Air Plenum.
Step 4. Remove the Right Lower Cover. Ensure inner clips

securing Right Lower Cover are disengaged.
Note: to aid in lower cover removal gentle twisting of cover

may be necessary.
Service Guide
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 reservoir bay.
Service Guide
Keypad and Display
Video

securing screws.
Caution: keep magnetic assemblies (i.e.

Paper Guides/Media Edge Holders) away
from the control panel display or damage
will result.
Service Guide
Keypad and Display
Step 4. Remove the Right Lower Cover.

Ensure inner clips securing right lower cover
are disengaged.
xxx
Service Guide
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
Keypad and Display
Step 7. Remove the Display Mount Cover Assembly.
Note: during assembly ensure grounds are properly

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

Keypad Assembly.
Service Guide
Video
Step 2. Remove the Right Rear Cover by removing

2 securing screws.
xxx
Service Guide
Step 3. Remove all connections to the Main
PWA.
Caution: ensure that the locking

clip is released before removing
the Trailing Cable connection
(J1).
xxx
Service Guide
Step 4. Remove the Memory Module.
Step 5. Remove the Main PWA.
xxx
Service Guide
Step 6. Main PWA Clone Procedure
A) Replacement of a main board in the field will require either the
customer to be running Server/Client Control software or the
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 page (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 disable the control channel
functions required to clone a board.
B) When this condition 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
C) The SHOW SERVICE PAGE has two simple choices:
1. If the customer is running Client 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 running 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 serial number manually then send it to the
printer.
Caution: Ensure the printers alphanumeric serial number (exact letter/number combination) is downloaded or the
Main 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 clone the main board or reset the serial
number. Clear Machine Type by holding bottom-left key and powering up printer; Clearing Machine Type should
be displayed after approximately 20 seconds. Remove Main PWA and replace with original Main PWA.
Service Guide
Video

2 securing screws.
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Service Guide
Step 3. Disconnect the Air Plenum. Remove the Right Lower
Cover. Ensure inner clips securing right lower cover are
disengaged.
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Service Guide
Note: during assembly, ensure grounds are properly

attached.
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Service Guide
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
Step 6. Remove all connections to the Dryer PWA.
Service Guide
Step 7. Remove the PWA Mounting Bracket
Assembly.
Step 8. Rotate the PWA Mounting Bracket Assembly

90 towards the back of the printer.
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Service Guide
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, white, black, and green
Service Guide
Power Components
Video

2 securing screws.
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Service Guide
Power Components
Step 3. Disconnect the Air Plenum. Remove the Right
Lower Cover. Ensure inner clips securing right lower
cover are disengaged.
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Service Guide
Power Components
Note: during assembly, ensure

grounds are properly attached.
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Service Guide
Power Components
PWA.
Caution: Ensure that the

locking clip is released before
removing the Trailing Cable
connection (J1).
Service Guide
Power Components
Note: during assembly, thermal

sensor connections (J8-J9) air
plenum fan connections (J10J11) and nose heater
connections (J1-J3) plug order is
not critical since sensors, fans
and heaters energize together
respectively.
Service Guide
Power Components
Step 7. Remove the PWA Mounting Bracket Assembly.
Step 8. Rotate the PWA Mounting Bracket

Assembly 90 towards the back of the printer.
Service Guide
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
Power Components
Step 11. Disconnect and remove the Nose Heater Switching
Relay (10 amp Solid State).
Note: during assembly, ensure the

wiring harnesses are properly
oriented.
Service Guide
Dryer PWA
Video

2 securing screws.
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Service Guide
Dryer PWA

securing right lower cover are disengaged.
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Service Guide
Dryer PWA
Note: during assembly

ensure grounds are properly
attached.
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Service Guide
Dryer PWA
PWA.
Caution: ensure the

locking clip is released
before removing the
Trailing Cable
connection (J1).
Service Guide
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 energize
together respectively.
Service Guide
Dryer PWA
Step 8. Remove the PWA Mounting Bracket
Assembly by removing 4 screws and removing
two nuts which secure the two ground wires.
Step 9. Rotate the PWA Mounting Bracket

Assembly 90 towards the back of the
printer.
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Service Guide
Dryer PWA
Step 10. Disconnect and remove the Voltage Selector Switch.
Caution: during assembly ensure the

voltage selector switch is properly
configured to the local power source, 115V
or 230V.
Step 11. Remove the Dryer PWA.
Note: during assembly ensure grounds are properly attached.
Service Guide
Servo Motor
Video

securing screws.
Note: It is strongly recommended

to obtain the Printer Service Tool
Kit prior to performing major
service actions.
Service Guide
Servo Motor
Step 3. Remove the Auto Clean Unit.
CAUTION: Ensure the waste disposal bottle has 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 screws
are not required.
Caution: hold assembly while disconnecting
2 electrical connections or damage may
occur to wiring harnesses/plugs.
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Service Guide
Servo Motor
Step 4. Remove Servo Motor Connector from J9 on
the MPWA.
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xxx
Service Guide
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
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 platen access hole.
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Service Guide
Ink Dampers/Septums
Video
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 tubing free.
Service Guide
Ink Dampers/Septums
Step 3. For Septum assembly removal,
remove the Cartridge, Cartridge Door and
Spring.
Note: when cartridge is removed place on a
flat surface so the needle points upwards to
avoid possible leaking.
Tip: to re-install the cartridge door spring first place

spring into the position shown (with door installed).
With a flat-head screwdriver gently force the rear
spring tab all the way down until it snaps into place.
This will need to be repeated until sucessful. Test
spring installation by unlocking the door, the cartridge
door should pop up to the fully open position.
Door Spring
position
Service Guide
Ink Dampers/Septums
Step 4. Remove the septum pressure restraint and
E-Clip securing the Septum Assembly.
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
Ink Dampers/Septums
Step 6. For Damper Assembly removal, remove the Ink Delivery
System Carriage Cover 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 connection
from J1 on the Carriage
PWA.
Caution: verify the connection

locking clip is released before
removing the Trailing Cable
connector.
Service Guide
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 tubing 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
syringe/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
Carriage Bushings
Video
Step 2. Remove the Ink Delivery System

Carriage Cover support brackets by removing 4
securing screws.
Service Guide
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 away from carriage and sliding off
of slide shaft.
Step 6. If bushing shims are damaged
then replace all 4 shims (0.004 inches
thick; self-adhesive vinyl).
Service Guide
Carriage Board
Video
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
Carriage PWA using a small
flathead screwdriver. Move the
Carriage Cover aside.
Caution: verify that

the locking clip is
released before
removing the
Trailing Cable
connection (J1).
Service Guide
Carriage Board
Step 4. Remove Electronics Cover by pulling plastic cover
clips outward.
Carriage Assembly
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Service Guide
Carriage Board
Step 5. Disconnect remaining
connections on the Carriage PWA.
J4-J9 Flex Driver

Cables
J2 Paper Sensor; J3 Encoder

Sensor
Service Guide
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
Carriage Assembly
Video
Step 1. Remove power from printer and lower air plenum to maintenance
postion.
Step 2. Remove the Ink Delivery System Carriage Cover and 2 Support
Brackets by removing 4 securing screws.
Note: It is not necessary to break ink line integrity (disconnect tubing

connections) or remove the reservoir chassis for this procedure.
Step 3. 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 J1.
Service Guide
Carriage Assembly
Step 4. Open 6 cartridge doors and remove cartridges from carriage.
Step 5. Remove 6 door assemblies by first removing the 6 pressure restraints. Remove
each door support by depressing clips on both sides of door support.
Step 6. Place cartridges 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
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
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 Tool.
Step 11. Remove 2 screws securing

cutter actuator and remove actuator.
Service Guide
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
Carriage Assembly
Step 15. Remove Carriage Belt and Carriage Assembly
from slide shaft - gently move 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 when sliding carriage back onto the slide
shaft.
Step 16. If ink line becomes separated during carriage

removal/replacement the ink line (s) will need to be reprimed using the
Primer tool (VacLok syringe/cartridge).
Service Guide
Carriage Assembly
Step 17. If replacing the Encoder Sensor
disconnect J3 at Carriage PWA; for paper 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 cleaning pad. Apply to sensor surfaces
by gently rubbing towel back and forth until
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
Carriage Assembly
Step 18. Remove the Paper Sensor; needle nose pliers may be necessary
to help remove paper sensor board from guide channel.
Caution: paper sensor flex cable is extremely fragile, only make gentle bends when re-installing.
Step 19. Remove the Encoder Sensor by gently working sensor free
from carriage restraining clip.
NOTE: If removing the carriage flex driver cables please note that two
small clear plastic shims (adhesive) are to be reinstalled at the base
of each cable - see picture at right for proper positioning. Failure 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
Video - Ink Delivery Removal
Step 1. Remove power from printer and lower air plenum to
maintenance postion (if 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 Carriage 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 Carriage PWA.
Caution: ensure locking clip is

depressed prior to removing; do not
twist plug from connector or damage
will result.
Service Guide
Step 4. Remove the Right Rear Cover by removing 2 securing
screws. Remove 2 screws 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 to new cable will
result in permanent damage.
Video - Trailing Cable Removal

Go to Trailing Cable Removal procedure
Service Guide
Step 6. Open cartridge doors and remove cartridges.
Step 7. Remove 6 door assemblies 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
Step 10. Disconnect tubing lines from 6 septum assemblies using
small needle nose pliers. Lift ink delivery cover up for 2 minutes to
allow ink lines to completely drain back to intermediate reservoirs.
Step 11. After removing the left bottom cover, loosen ink tube
restraining clamps at reservoir chassis.
Step 12. Clamp 6 ink tubing lines with 12 hose clamp tools on
both sides of tubing butt-splice. Disconnect tubing lines at butt
splices. Remove the Ink Delivery Assembly.
Step 13. Following ink delivery system replacement re-establish ink line
pressure 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
Videos
Step 1. Remove power from printer; evacuate ink from defective
intermediate reservoir using special service tool only (VacLok
syringe and Pressure Test Cartridge).
Step 2. Gently disconnect the Intermediate Reservoir Sensor Board connector.
Step 3. Clamp vent tube - it is

attached to the underside of the
reservoir chassis. Caution: carefully
disconnect the vent tube or damage
may occur to cover.
Service Guide
Step 4. Clamp off the ink tubing line on both sides of the service
butt-splice with 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 line between hose clamps only).
Service Guide
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 sensor PWA.
* = Reservoir restraining clips
Service Guide
Step 8. Remove Identification Sensor PWA by removing 4 screws (two T7 starhead and 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 sensor
PWA. These items will need to be transferred to the new intermediate reservoir.
Video - Repriming Ink Line

Video - Cleaning Primer Tool
Step 9. Following assembly replacement use the Primer tool (VacLok

syringe/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.
Service Guide
Service Station
Video - Service Station Replacement

securing screws.
NOTE: Refer to Service Bulletin 10 or the video
below to replace an early model station (geared) with
the new station model (non-geared).
Video - Service
Station Upgrade
Service Guide
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 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 Auto Clean Unit disposal bottle.
Note 1: For new service stations - When re-installing the service
station verify shim is properly located and station tabs are seated
flush against platen.
Note 2: The valve vent line should not be pinched or obstructed check positioning.
Service Guide
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.
Install jumper into J13 to bypass sensor
operations. Refer to Service Bulletin 10 for
complete instructions. Perform steps 7
and 8.
Service Guide
Service Station
Step 7. Disconnect plug adjacent to sensor connection.
Note: The new service station design no longer uses the motor or
sensor functions. 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 assembly (including bracket).
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Service Guide
Auto Clean Unit
Video
Step 2. Remove disposal bottle from auto clean unit.
Note: Loosen the securing

screws and lower unit
approximately 15 cm. Removal
of the securing screws are not
required.
Caution: do not
drop unit or
damage to plug
connections/wir
ing may occur.
Service Guide
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 further to gain access to
motor and sensors.
- Suction Pump/Motor Assembly; see
video.
- Bottle Full Sensor
- Bottle Load (present) Sensor Assembly
Video
Service Guide
Video
Step 2. Remove the Right Rear Cover by

removing 2 securing screws.
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Service Guide
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 Carriage PWA. Move the
Carriage Cover out of the way.
Caution: Ensure that the locking clip is released before

removing the Trailing Cable connection (J1).
Service Guide
Step 5. Remove Carriage Assembly - refer to carriage assembly
removal procedures.
Step 6. Disconnect 6 cartridge door assemblies from carriage by removing door restraints and pushing on door
support clips to release each assembly.
Service Guide
Step 7. Move the Carriage Cover to one side.
Step 8. Remove carriage bushings from carriage by

removing the bushing retainers at each side (1 screw
secures each retainer).
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Service Guide
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Step 9. Install the Belt Removal Tool (P/N 216688-00) between frame
tensioner 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 Tool.
Service Guide
Step 11. Remove the Frame Tensioner, Idler Assembly and the
Compression Spring.
Caution: Ensure that the Idler Assembly is

oriented correctly before installation.
Step 12. Remove the Cutter Actuator by removing 2

securing screws.
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Service Guide
screws. Note: left covers 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 Carriage Assembly is positioned
back onto the Slide Shaft. Damage to the Encoder Strip is
possible if care is not observed.
Service Guide
Step 15. Using a pen, draw position marks above the old encoder
stablizer bracket assembly. Remove Stabilizer Bracket/Encoder Strip
Assembly.
Note: following the repair action, a carriage head height

adjustment may be required. Refer to Service Bulletin 3 or
Mechanical Alignments. The printer service tool kit contains the
carriage head height adjustment tools required.
Service Guide
Pinch Roller Replacement
Step 1. Remove the Rear/Back Cover by removing 12 securing screws.
Step 2. Pitch the back cover toward the rear slightly. Pinch roller eclips can be removed and replaced once the back cover is
positioned to provide assembly removal (clearance provided is
approximately 0.5 inch/2.5 cm)
Caution: Do not remove Y-Arm for this

procedure. Only remove on OEM4 printers
when the long media guide requires
replacement. The 8 crescent springs at left
side allow the Y-Arm to float when dryer is on
for proper operation.
Video - Pinch Roller

Replacement
Service Guide
Pinch Roller Replacement
Step 3. While holding the Pinch Roller, remove the EClip and pull the Pinch Roller back through the Y-Arm
Bracket. Remove the Compression Spring using spring
pliers 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
front of the Pinch Roller, away from the Slide Shaft. Carefully remove the
spring that is going into the Slide Shaft.
Step 5. Remove the Pinch Roller.

NOTE: To reinstall pinch roller, place spring into base of pinch roller, maneuver pinch roller at an
angle under the slide shaft and compress spring using fingers - orient spring into spring hole at base
of slide shaft.
Service Guide
Media Drive System
Video
NOTE: Refer to Service Bulletin 17 for complete replacement
instructions.

2 securing screws.
Step 3. Remove the Left Top Cover by removing 4

screws.
Service Guide
Media Drive System
screws; move assembly clear.
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
disassemble intermediate reservoirs from ink reservoir chassis.
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Service Guide
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
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 Station
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/suction may
not exist for normal operations.
Stepper
Motor Ground
Service Guide
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 assistance from the
other.
Note: Four inner tabs secure Platen Plug to the Platen. Plug may
have to be broken for removal if technicians hands are too large for
removal.
Service Guide
Media Drive System
Step 11. Disconnect the Lower Roller Assembly from the Platen by removing 6
securing 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 installation or low
quality output may result. The thick arm faces towards the front of printer.
Service Guide
Media Drive System
Step 13. Remove the Left Base
Plate by removing 9 securing
screws.
Step 14. Remove the top cover by removing 4 securing

screws.
Step 15. Remove the Left Side Plate by removing 5 securing

screws.
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Service Guide
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 printer may
collapse.
Service Guide
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 out 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 onto new lower roller support brackets and center support bracket refer to Service Bulletin 17 for instructions.
Service Guide
Video

2 securing screws.
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Service Guide

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Service Guide
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
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
Step 10. Remove the (rear) screws securing the Nose
Spacers to the Platen.
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Step 11. Remove Nose Heater Assembly.
Note: once the nose heater has been removed the

thermocouple sensors and thermocouple fuse may be
removed.
Service Guide
Air Plenum Assembly
Video

2 securing screws.
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Service Guide
Air Plenum Assembly

xxx
Service Guide
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 fan assembly.
Note: 4 fans are present in the 42 inch printer, 6 fans are present in
the 60 inch printer.
Service Guide
Video
Step 2. Remove Drive Cradle Assembly by removing 4

securing screws. Remove ESD strike plate.
Note: motor is secured to motor

mount via 2 tie-straps, 3 screws
and an e-clip.
Service Guide
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 the Motor from the Motor Mount.
Service Guide
Step 4. Disconnect Sensor. Cut tie-straps and unscrew the
Sensor from the bracket to remove.
Service Guide
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
Trailing Cable
Step 3. Remove ink chain restraint by removing two #8 star-head screws. Use a Torque
#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 every 10-15 cm along
entire chain length.
Service Guide
Trailing Cable
Step 7. Tape trailing cable lock to protect connector lock.
Step 8. Remove trailing 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 move past each
link.
Caution: do not overstress cable (s) during installation or

damage to cable (s) will result.
Service Guide
Trailing Cable
Step 9. Remove 2 screws securing trailing cable grounding plate.
Step 10. Disconnect trailing cable from main

board.
Step 11. Remove double-sided tape from cable

and remove trailing cable from printer.
Note: when reinstalling cable ensure carriage side
of cable extends only 6-7 inches beyond the last
link.
Note: Depress lock

with a small blunt tool
to release trailing
cable.
Service Guide
Service: Mechanical Alignments
Alignment Theory
Tools Required
Special Notes
Slide Shaft Adjustment
Carriage Head Height Adjustment
Service Guide
Alignment Theory
XXX
Head to Platen Height Relationship
The distance between the bottom of the cartridge

(print head) and the platen surface should be equal
to 0.065 inches (65/1000 of an inch).
The carriage head height normally requires
adjustment following an encoder strip replacement or
if print head scraping occurs on multiple media types.
Service Guide
Tools Required
Head Height Adjustment Kit (221955-00):
- Modified test cartridge with dual tension bands
- Micrometer dial gauge
- Shaft mounting block
- Extension tip (for dial 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
Special Notes
Note 1: A special tool kit is required to perform the mechanical
adjustments. Refer to Service Bulletin 3 for complete
procedures/updates.
Note 2: Only perform mechanical adjustments if carriage head scraping is observed on media surface, if
the color deadband adjustment cannot be calibrated, or if the encoder strip/stabilizer 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
Slide Shaft Adjustment
Video
Step 1. Obtain the Head Height Alignment Kit.

Step 2. Assemble the shaft mounting block to the micrometer dial gauge using 1/16 inch hexkey wrench; ensure the elbow is flush to the front. Tighten the set-screw at the rear of the shaft
mounting 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. Move the shaft mounting block and dial gauge to the right end (above slide shaft
supports) and take a measurement.
Step 5. Move to the center position (directly over turnbuckles) and calculate the average
between the left side and the right side.
Step 6. Using a open ended wrench adjust the turn buckle (or turn buckles - 60 inch unit)
for the average computed value.
Service Guide
Video
Step 1. Obtain tools: head height test cartridge, dial gauge, extension tip, 1/16 and 7/64 inch hexkey wrenches.
Step 2. Attach extension tip to dial gauge. Assemble the test cartridge and micrometer dial gauge
using 1/16 hex-key wrench tool.
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 face 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 screws, 1/2 turn CCW.
Activate dryer to heat setting of 5, select access cartridges to activate vacuum fans.
Service Guide
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 the 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 into the access hole (towards right side) and move gauge/cartridge onto
plate surface. Adjust for 65 +/- 3.
Service Guide
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 the carriage is parallel to the platen
surface - by observing the small dial on the gauge for a consistent reading at all
adjustment positions.
3. If a crossbar or stand assembly is adjusted or installed perform all
mechanical adjustments again. Print Deadband (fast) to verify adjustments are
correct - perform Service Bulletins 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
220468-00
208987-1
222038-00
220236-150
221584-04
220131-065
221986-00
220708-00
223682-00
220854-02
219127-00
207659-01
221781-00
Part Name/Description
AUTOLOAD SENSOR
BELT, 42"
BELT, 60"
BRACKET, LOWER DRIVE SUPPORT
BUSHING SET (2), Kodak 1200i-NJ1000i
CARRIAGE ASSY, COMPLETE, Kodak 1200i-NJ1000i
CARRIAGE FLEX, 640J
CARRIAGE 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

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
215643-01
221282-01
210068-06
222563-150
CONTAINER, PARTS STORAGE

CORE, PAPER, 60"
COVER, BOTTOM, LEFT
COVER, CARRIER ELECTRONICS
COVER, DISPLAY MOUNT
COVER, TOP LEFT
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 & SEPTUM ASSY (INCLUDES COMPLETE DOOR ASSEMBLY, DOOR SUPPORT
MOUNT, DOOR SPRING & BLOCKER CLIP)
E-13b
C-2
C-7
F-2
E-5
B-3c
220461-01
220985-03
220441-02
222016-00
209578-101
217236-00
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" (ENCODER STRIP ONLY - NO TAPE OR STABILIZER
BRACKET INCLUDED)
B-2a
B-2b
220959-150
220639-150
ESD BRUSH, 42"-6, ASSY (QUANTITY OF 6)

ESD BRUSH, 60"-6, ASSY (QUANTITY OF 6)

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
204976
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
EXHAUST, GRILL
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 ADJUSTABLE (FEED & TAKE-UP)
HARNESS, DRYER/WINDER (MAIN PWA - LEG)
HARNESS, LEG DRIVE (INNER LEG)
HARNESS, RESERVOIR SENSOR
HARNESS, THERMAL FUSE
HEATED NOSE, ASSY 42"
HEATED NOSE, ASSY 60"
HOUSING, SENSOR
IDLER ONLY
B-1b / F-3b
B-1a / F-3a
A-2a / F-2a
C-3
H-9
220535-150
220249-150
220853-04
209096-3
211170
INK DELIVERY ASSY 42"

INK DELIVERY ASSY 60"
INTERMEDIATE RESERVOIR, ASSY
KEYPAD
KIT, 2 STRIKEPLATES + 2 BRUSHES
K-4a
221984-01
KIT, FLUSH KIT ASSY

K-1
K-2
B-10a
K-6b
K-6a
A-3
A-6a
A-6b
221955-00
222185-00
221555-00
221945-00
221993-00
221338-00
223071-01
222370-00
KIT, HEIGHT ALIGNMENT, Kodak 1200i-NJ1000i

KIT, INK SYSTEM TEST
KIT, MEDIA GUIDES ASSY
KIT, SERVICE SPARES PREMIUM, Kodak 1200i-NJ1000i
KIT, SERVICE SPARES STANDARD, Kodak 1200i-NJ1000i
KNIFE DELATCHER
LINE FILLING CARTRIDGE w/PLUG BAR
LINE FILLING CARTRIDGE ONLY
D-3a
D-3b
B-10d
C-6
C-5
H-7
J-2
221855-610
221857-610
222007-00
220111-165
216391-00
207767
220695-00
LOWER DRIVE ASSY, 42" (INCLUDES STEPPER MOTOR)

LOWER DRIVE ASSY, 60" (INCLUDES STEPPER MOTOR)
MAGNET, MEDIA WEIGHT
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)
K-7a
K-7b
K-7c
K-7d
K-7e
B-10b
B-10b
B-10c
222824-00
222823-00
215631-01
215627-01
215628-02
221498-01
222191-00
221496-01
PACKAGING, 42" PRINTER HEAD (BOX 1)

PACKAGING, 60" PRINTER HEAD (BOX 1)
PACKAGING, SPACER, BASE POSITIONER (P/O BOX 2)
PACKAGING, SPACER, END (P/O BOX 2)
PACKAGING, SPACER, HOLDER (P/O BOX 2)
PAPER GUIDE, LEFT
PAPER GUIDE, LEFT (LONG; OEM 4 PRINTER)
PAPER GUIDE, RIGHT

B-10c
E-10
B-6a
B-6d
222190-00
220391-02
221881-00
222116-00
PAPER GUIDE, RIGHT (LONG; OEM 4 PRINTER)

PAPER SENSOR W/FLEX
PINCH ROLLER ONLY
PINCH ROLLER ONLY (OEM 4 PRINTER)
D-8
C-10
215189-00
220667-03
PLUG, PLATEN
POWER ENTRY MODULE
C-8
J-3
A-2c / F-2c
E-8
E-6
E-9b / F-8b
H-5
E-9a / F-8a
G-2
220647-02
221231-150
221500-01
220550-01
220374-01
220460-00
207727-02
220420-00
220258-260
POWER SUPPLY (275W)

PUMP ASSY, WASTE RESERVOIR
RESERVOIR DATA BOARD, PWA
RETAINER, BUSHING, LEFT
RETAINER, BUSHING, RIGHT
RING, RETAINING, E-TYPE, 5/16 (FOR SEPTUM)
SENSOR ASSY, TAKE-UP & FEED
SEPTUM, ASSY
SERVICE STATION ASSY (UPGRADE KIT/REPLACEMENT)
D-1
H-1a
H-1b
E-7b
E-12b
A-3b
B-11
B-12
D-10a
221825-00
219681-00
219682-00
221981-00
221964-01
222182-00
221991-00
221992-00
212427-00
SERVO MOTOR, CARRIAGE

SHAFT, 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 DELATCHER
SHIM, SHAFT SUPPORT
SHIM, Y-ARM
SHIM, .005 THICK, LOWER DRIVE (AS REQUIRED)

D-10b
D-10c
I-7a
212428-00
212429-00
220768-04

SHROUD, PLENUM, 42-6
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
220758-05
204804
204654
220596-00
220248-02
215348-00
212542-00
220530-150
220216-150
220510-02
220605-00
220603-00
222088-00
220875-02
220269-02
220558-00
220835-05
220265-01
SHROUD, PLENUM, 60-6

SLIDER LOWER (CARRIAGE)
SLIDER UPPER (CARRIAGE)
SOLID-STATE RELAY, 25A
SPRING PAD (CARRIAGE)
SPRING, COMPRESSION (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 CABLE, SHIELDED, 60"
WASTE CONTAINER (ONLY)
WASTE INK RES., ASSY COMPLETE
WIPER, SERVICE STATION
TRAILING
CABLE
MAIN BOARD
CARRIAGE BOARD
+24V, GND
PRINT HEADS
6 INK BOTTLES
WITH DATA CHIPS
LVDS DIFF. PAIRS

A/D
CONVERTER
2 VACUUM FANS
HEAD
DRIVERS
LVDS
INTF.
FIRE
DRYER BOARD
DRYER
INTERFACE
LC
FPGA
LVDS BCKCHL
HEATERS
LM
FIRE
INTF.
PROGRAM
PAPER
SENSOR
CPROGRAM
BLOWERS
ENCODER
POWER
SUPPLY
C
POWER
SUPPLY
FAN
1.8V
FAN DRIVERS
24V
AC 120 / 240
POWER SUPPLY
3.3V
5V
7V - 11V
FIRING VOLTAGE
3.3V @ 10A
24V
2.5V @ 0.9A
POWER SUPPLY
1.5V @ 2A
5V @ 0.1A
CRYSTAL
SERVO MOTOR
FPGA
MOTOR
DRIVERS
STEPPER MOTOR
AUTOLOAD SENSOR
INTERFACE
AUTOLOAD SENSOR
WINDER / UNWINDER
INTERFACE
WINDER / UNWINDER
ETHERNET
CONNECTOR
ETHERNET PHY
2K EEPROM
CLOCK
WASTE BOTTLE
INTERFACE
WASTE BOTTLE
SERVICE STATION
INTERFACE
SERVICE STATION
POWERPC 405GP
JTAG PORT
NJ1000i
Block Diagram
DISPLAY / KEYPAD
INTERFACES
256K X 18 ZBT RAMS
4M
FLASH
SDRAM
32M
MAIN
MEMORY
DISPLAY / KEYPAD
A
SDRAM DIMM 64M

RASTER MEMORY
Title
Size
Custom
Date:
5
Block Diagram, NJ1000i

Document Number
Rev
AA
222052-00
Sheet
Thursday, February 26, 2004

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NJ1000i-1200i Printer Service Manual - 05122006

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NJ1000i-1200i Printer Service Manual - 05122006

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Revised 05-12-2006

Printer Service Manual

1) Ink Refill Bottles

1. Intelligent Mask Technology (IMT)

- Encrypted for ink monitoring (740 ml shutoff)

- Intermediate reservoir at reservoir base

- One set of ink lines; switch over capability (Dye or

- provides consistent ink supply pressure

- Plug and Play ink refill bottle (700 ml) with

- Replace ink on-the-fly

- Robust carriage bushing design; thick bushings with spring

- Increased productivity with 640 nozzle printheads

- Bushings are grooved to minimize the effect of dirt and

- Clean hands shipping and installation

- Improved quality with 30% smaller drop size

- Cartridge doors secure printheads in place

- Foam filled, eliminate tubing and needles

- Ink is regulated to printhead via ink line dampers

- 2100 ml average life; 2800 ml shutoff

- One-step cartridge installation process

Auto Clean Unit

- Clean hands ink line filling through service station

5) Bottle present sensor

- The heated nose quickly warms the media up with 3 electrical

High Speed mode (2 pass)

220 sfph (20.4 smph)

195 sfph (18.1 smph)

Productivity mode (3 pass)

150 sfph (14.0 smph)

140 sfph (13.0 smph)

Fine mode (4 pass)

115 sfph (10.7 smph)

104 sfph (9.6 smph)

Enhanced mode (6 pass)

75 sfph (7.0 smph)

70 sfph (6.5 smph)

High Quality (16 pass)

26 sfph (2.8 smph)

23 sfph (2.5 smph)

Note: Printer ships with 64 MB

Cartridge Average Life

Cartridge End of Life

Verify ink throughput by selecting UTILITY MENU - INK

Ink Kit Configurations

Using two (2) people minimum, lift

Caution: verify printer is stable prior to stand installation.

Remove right lower shipping bracket (4 screws) and

Remove left lower shipping bracket (4 screws) and

Using a four (4) person lift, grasp base of

Caution: For regions which experience intermittent

Step 1. Install Feed Media/Roller

4) Install roll guide

Verify media is sized correctly by

Note: media may also be manually loaded by selecting

Install Media Edge Holders (magnetic) onto Y-Arm side - the

Note: Wait 5 minutes

Step 1. Print Color Test

Select Utility Menu - Prime Menu Prime All

Verify printhead nozzle performance - ensure diagonal lines

Use this print to evaluate

Obtain User CD from Printer packaging and

Select the Typical installation for a

Note: Individual utilities may be