IS-14-0042 - Rev.1 - DCS Ink Flow Troubleshooting Guide MVP 1800Z 1800SBG 7200Z - 050922

Doc ID.
IS-14-0042
Rev.1
INK FLOW TROUBLESHOOTING GUIDE
SECTION 1 7200Z Pg. 2 - 13

SECTION 2 MVP & 1800Z Pg. 14 - 23
SECTION 3 1800S & 1800BG Pg. 24 - 31
HOW IT WORKS
The ink lines are fed from gravity/syphon and are not pressurized, so the more ink in the tank
the betterthe flow of ink. The tanks need air for the flow to be “continuous”. Without air a
vacuum can be created starving the damper and print head of ink flow.
If followed accurately, these steps can help quickly identify the ink flow restriction or issue.
Do not skip a step or assume that a step isn’t necessary. If this process is followed correctly,
you will identify the ink flow issue.
Ink system components (Bulk Tanks, Level Sensors, Ink Lines, Fittings, Dampers, Capping
Stations, and Print Heads) are classified as consumable items and are not covered under
warranty.
Warning: Failure to use proper personal protective equipment can cause skin and or eye
irritation.
• Gloves must be worn to carry out these instructions. Failure to do so could cause harm
to personnel.
• Eye protection must be worn to carry out these instructions. Failure to do so could
cause harm topersonnel.
SECTION 1: 7200Z PRINTERS
SECTION 1
7200Z
** Special Note**
If you are experiencing white ink flow issues should trouble shoot all 4 white
tanks at the same time. The reason being that lines can become mixed up from
prior maintenance or troubleshooting on the ink system. Also, the ink flow path
crosses inside the damper so don’t just assume that the first White Channel is
the first White Tank. SEE APPENDIX A (PG. 13) FOR THE INK PATH OVERVIEW.
Page 2 of 31
Troubleshooting
Flow Chart
Page 3 of 31
Step 1: Inspect the Ink Lines

The first thing to remember is that ink lines are consumable and therefore wear out. Consider replacing
the ink lines proactively every year or two. Inspect the ink line for kinks and or visual damage such as
leaking. This is straight forward if you see a kink or a line leaking, repair the kink if possible, or replace
the ink line. If you are leaking ink, please disconnect the line from the tank and do whatever you can to
stop the flow of ink. This can be achieved but is not limited to, possibly kinking the line before the leak
to prevent further spillage. Contact technical support immediately.
Step 2: Visually Confirm the Bulk Tanks are Full

The reason for this step is because the Level Sensors inside the Bulk Ink Tanks can sometimes fail which
then gives the operator a false reading on the Pendant. It is always good to visibility inspect that there is
in the tank before doing too much troubleshooting.
2A: Remove the breather from the top of the Tank by unscrewing with your hand or with a socket
wrench.
2B: Place a metal rod or zip tie into the top of the tank through the breather hole. Make sure the Tank is
at least 50% full before continuing. NOTE: SEE NEXT PAGE FOR MEASUREMENTS.
• No Ink: The Tank Level Sensor has most likely failed. Keep the breather off and fill the tank while
visually inspecting through the breather hole so that you do not overfill the tank then proceed
to step 2C.
• Ink: Proceed to Step 3. Keep the Breather(s) off the tank(s).
2C: Run a Power Clean and test print to verify if that has solved the problem.
Page 4 of 31
After you remove the “dip-stick” from the Bulk Tank, measure the portion that has ink. If the
measurement is below 1.38in, fill the Bulk Tank before proceeding.
Page 5 of 31
Step 3: Verify the Capping Station Health/Life. Replace if necessary.

The capping station is responsible for sealing the print head when the printer is idle and drawing ink
through the print head to ensure the nozzles are filled with ink and ready to print. Capping Stations
deteriorate over time regardless of how much the printer has been used. Once the gaskets that seal the
print head are exposed to ink they will start to swell/degrade.
Make sure that the print head is sitting flushon the capping station. Inspect it for damage such as
cracked or swollen seals, kinked hoses, or unusual sounds. Perform Maintenance on the Capping
Station.
3A: Uncap the Print Head from the Capping Station.
3B: Use a swab to clean the five Capping Station Gaskets.
3C: Pull out the Wiper and Ink Discharge Tray.
3D: Use an IPA Wipe to clean the Ink off the Wiper Blade and absorb any excess ink in the discharge
tray.
Page 6 of 31
Step 4.1: Testing the Bulk Tank Fitting

For this step you will need; 1. An empty clear container to catch the ink that will be drained from the
Tank. A clear container is recommended so you can visually inspect for sediment or contamination in the
ink once it is drained. 2. Drain Hose Assembly (PT-1320-A055).
4.1A: Disconnect the Tank Fitting from the Bulk Tank.
NOTE: Breather should still be removed from the Bulk Tank (See Step 2).
4.1 B: Place the hose on the Drain Hose Assembly into the clear container and then plug the drain hose
into the Tank Fitting. Watch the ink as it flows into the container. NOTE: IF THE TANK FITTING ON A
WHITE TANK IS CLOGGED, IT IS MOST LIKELY DUE TO THE CIRCULATION PUMP. SEE STEP 4.2 FOR
CHECKING THE CIRCULATION PUMPS.
• Ink Does Not Flow Smoothly/Trickles out of the tank. Replace the Tank Fitting(s). When
replacing the Tank Fitting, do not overtighten. Use Teflon Tape and hand tighten only. Confirm
the Ink Flows smoothly after replacement and proceed to step 5.
• Ink Flows smoothly out of the Tank. Proceed to Step 5.
Page 7 of 31
STEP 4.2: Checking the White Circulation Pumps

The Pumps on top of the White Bulk Tanks are responsible for circulating the White Ink so it stays in
suspension. The White Ink contains Titanium Dioxide which can separate out if the ink isn’t flowing
through the Tank and Ink Lines. If this happens, fittings, ink lines, dampers and/or print heads can
become clogged. Make sure the Circulation Pumps are running by following the steps below.
4.2 A: Turn the Circulation Pump(s) on from the Pendant and confirm the pump(s) are running by feeling
for vibration.
• Not Running: Check the connection where it plugs into the wire harness. If you don’t notice any
loose wires and everything is connected, you will need to replace the Circulation Pump then
drain all the White Ink from that Ink Flow Path and replenish with fresh White Ink.
• Running: Proceed to Step 4.2B to confirm the ink is circulating.
4.2 B: While the pump is running, pinch the small hose (going from the pump to the top of the tank) with
your fingers. You should be able to feel the ink circulating through the tube.
• Do not feel ink circulating: You will need to replace the White Circulation Pump Assembly. This
includes the pump and the hoses where it connects to the tank.
• Feel Ink Circulating: Proceed to Step 5. Note: If you are doing this step because ink was not
flowing smoothly in Step 4.1, replace the Tank Fitting prior to moving to Step 5.
Circulation Hose from the Pump to

the top of the Bulk Ink Tank.
Page 8 of 31
Step 5: Checking for a clogged Breather

The breather should have been removed for Steps 2, 3, 4.1 and 4.2. If it wasn’t, go back and repeat the
steps with the breather removed from the tank. Now, we will repeat Step 4.1 with the breather
installed.
Typically, if a level sensor has failed in a tank, the operator has no way of knowing how much to fill the
tank and it results in ink overflowing out of the tank through the breather hole. Overtime, this ink will
harden and clog the breather which creates a vacuum in the ink system and ink is not able to flow
through the print head.
5A: Disconnect the Tank Fitting from the Bulk Tank if it isn’t already.
5B: Place the hose on the Drain Hose Assembly into the clear container and then plug the drain hose
into the Tank Fitting. Watch the ink as it flows into the container and compare it to the flow you saw in
Step 4.1.
• Ink Does Not Flow as Smoothly as Step 4: Clean or replace the breather. To Clean the breather,
soak it in Isopropyl Alcohol overnight then blow it out with an Air Hose and re-install. Re-
connect the Tank Fitting then run a Power Clean and Nozzle Test to see if the Ink Flow problem
has been resolved.
• Ink Flows smoothly out of the Tank. Re-connect the Tank Fitting and proceed to Step 6.
Breather
Page 9 of 31
Step 6: Checking the Ink Line/Damper for restriction

Before you begin, confirm that the Tank Fittings have all been re-installed after performing Step 5.
In this step, we will use a syringe to draw ink out of the bottom of the dampers.
6B: Remove the black Front Plate from the Carriage.
6C: Inspect the Brass Fittings on top of the dampers for leaks. If there are leaks, replace the damper(s)
then proceed to Step 6D.
6D: Inspect the bottom of the Print Head for leaks. If ink is leaking out of the bottom of the Print Head,
the applicable damper will need to be replaced. Replace the damper(s) and proceed to step 6E.
6E: Unplug the ink line from the Tank.
6F: Remove the Damper from the Print Head.

• Ink Flowing from Damper: Replace the damper.
• No Ink Flowing from Damper: Proceed to step 6E.
6G: Re-connect the Tank Fitting to the Bulk Tank.
6H: Use a syringe to pull ink through the Damper and verify there is no restriction or air.
• Restriction when Priming: Replace the damper.

• No Restriction when Priming: Determine if there is Air when priming.
• Air when Priming: Continue priming to see if the Air can be removed if it cannot, replace the
damper and perform step 6H again.
• No Air when Priming: Continue to Step 7.
Page 10 of 31
Step 7: Checking Flow through the Capping Station

The Capping Station has five separate caps that each pull ink from two of the channels. Underneath the
Capping Station are five separate hoses that connect to these caps. Once the ink is pulled through the
head and into the caps, it is then pumped out through these five hoses into the Waste Bottle. We want
to confirm that Ink is flowing through the Head and the caps.
7A: Ensure the Damper Assembly is re-installed properly after performing Step 6. Also, ensure the Tank
Fitting(s) are all re-installed onto the tanks.
7B: Re-boot the Printer to ensure the Carriage is capped on the Capping Station in the correct position.
7C: Remove the four screws holding the Lower Front Cover on the printer so you can access the Capping
Station from the front.
7D: Locate the five hoses and remove the corresponding hose for the channel(s) you are diagnosing. If
you are unsure, you can perform step 7E for each.
7E: Using a Syringe with a piece of hose attached to it,

pull through the Capping Station port where the hose
was recently connected.
• No Flow: Replace the Capping Station. Note, the

print head still might be clogged but you will not
know this until a new Capping Station is tested.
• Smooth/Consistent Flow: through the Capping

Station: Proceed to Step 8.
Page 11 of 31
Step 8: Manually Flushing the Print Head

WARNING: Manually Flushing the Print Head could lead to damage if not performed properly.
If you are unsure about this procedure, contact DCS Technical Support.
8A: Uncap the Carriage from the Capping Station. Ensure the Print Head is over the table.
8B: Use Paper Towels to cover the table underneath the Print Head.
8C: Turn the Machine Off.
8D: Remove the Damper Assembly from the Carriage.
8E: Fill the Purge Tool Syringe with Monomer Flush and flush through the channel(s). You should see a
“Solid Curtain” of fluid come out of the bottom of the print head.
• Partial and/or Deflected Curtain of Flush through the Print Head: Replace the Print Head
• Solid & Straight Curtain of Flush through the Print Head: Most likely an electrical failure. The
Print Head Cables will need to be replaced.
NOTE: CHANGING THE PRINT HEAD CABLES IS THE FINAL STEP. IF THIS DOES NOT WORK, ONE OF THE
PREVIOUS STEPS WAS DONE INCORRECTLY. IF YOU HAVE GOTTEN TO THIS POINT, YOU MAY WANT TO
CONFIRM THE PREVIOUS STEPS WERE ALL DONE CORRECTLY.
Step 9: Print Head Cable Replacement

Inspect the cables that connect to the
Print Head from the Carriage Board for
damage or missing contacts. If the
cables have visible damage (see image
to the right) they will need to be
replaced. If the cables are in good
condition, the Print Head will need to
be replaced. Please contact Technical
Support for further instructions.
Page 12 of 31
Appendix A: 7200 Ink Path Overview

These images show the ink setup on the 7200z. It follows the ink system starting with the Bulk Ink Tanks,
through the ink lines to the top of the damper (Figure 1), then through the damper to the Print Head
Manifold (Figure 2) and finally through the Print Head Nozzle Plate. Just remember, sometimes these ink
lines can get switched around if a prior service was done on the machine.
Page 13 of 31
SECTION 2: MVP & 1800Z PRINTERS
SECTION 2
MVP & 1800Z PRINTERS
Page 14 of 31


then gives the operator a false reading on the Control Panel. It is always good to visibility inspect that
there is in the tank before doing too much troubleshooting.
2A: Remove the breather from the top of the Tank by unscrewing with your hand or with a socket
wrench.
at least 50% full before continuing. NOTE: SEE NEXT PAGE FOR MEASUREMENTS.
• No Ink: The Tank Level Sensor has most likely failed. Keep the breather off and fill the tank while
visually inspecting through the breather hole so that you do not overfill the tank then proceed
to step 2C.
• Ink: Proceed to Step 3. Keep the Breather(s) off the tank(s).
2C: Run an Initial Charge and test print to verify if that has solved the problem.
Page 15 of 31
After you remove the “dip-stick” from the Bulk Tank, measure the portion that has ink. If the
measurement is below 1.38in, fill the Bulk Tank before proceeding.
Page 16 of 31

Station.
3B: Inspect the Capping Station Caps for deterioration.
You can visually inspect the Capping Station during a cleaning cycle to confirm it is pulling ink from the
print head. Run an Initial Charge and watch to see if the Capping Station chambers are full of ink when
the Print Head moves away from the Capping Station.
• If the chambers are not filling with ink, replace the Capping Station and determine if that fixes
the problem.
Page 17 of 31

For this step you will need; 1. An empty clear container to catch the ink that will be drained from the
Tank. A clear container is recommended so you can visually inspect for sediment or contamination in the
ink once it is drained. 2. Drain Hose Assembly (PT-1320-A055).
4.1A: Disconnect the Tank Fitting from the Bulk Tank.
NOTE: Breather should still be removed from the Bulk Tank (See Step 2).
4.1 B: Place the hose on the Drain Hose Assembly into the clear container and then plug the drain hose
into the Tank Fitting. Watch the ink as it flows into the container. NOTE: IF THE TANK FITTING ON A
WHITE TANK IS CLOGGED, IT IS MOST LIKELY DUE TO THE CIRCULATION PUMP. SEE STEP 4.2 FOR
CHECKING THE CIRCULATION PUMPS.
• Ink Does Not Flow Smoothly/Trickles out of the tank. Replace the Tank Fitting(s). When
replacing the Tank Fitting, do not overtighten. Use Teflon Tape and hand tighten only. Confirm
the Ink Flows smoothly after replacement and proceed to step 5.
Page 18 of 31

The Pump on top of the White Bulk Tank is responsible for circulating the White Ink so it stays in
suspension. The White Ink contains Titanium Dioxide which can separate out if the ink isn’t flowing
through the Tank and Ink Lines. If this happens, fittings, ink lines, dampers and/or print heads can
become clogged. Make sure the Circulation Pumps are running by following the steps below.
4.2 A: Turn the Circulation Pump on from the Control Panel and confirm the pump is running by feeling
for vibration.
flowing smoothly in Step 4.1, replace the Tank Fitting prior to moving to Step 5.

Page 19 of 31
Step 5: Checking for a clogged Breather

The breather should have been removed for Steps 2, 3, 4.1 and 4.2. If it wasn’t, go back and repeat the
steps with the breather removed from the tank. Now, we will repeat Step 4.1 with the breather
installed.
5A: Disconnect the Tank Fitting from the Bulk Tank if it isn’t already.
5B: Place the hose on the Drain Hose Assembly into the clear container and then plug the drain hose
into the Tank Fitting. Watch the ink as it flows into the container and compare it to the flow you saw in
Step 4.1.
• Ink Does Not Flow as Smoothly as Step 4: Clean or replace the breather. To Clean the breather,
soak it in Isopropyl Alcohol overnight then blow it out with an Air Hose and re-install. Re-
connect the Tank Fitting then run a Power Clean and Nozzle Test to see if the Ink Flow problem
has been resolved.
• Ink Flows smoothly out of the Tank. Re-connect the Tank Fitting and proceed to Step 6.
Breather
Page 20 of 31

Before you begin, confirm that the Tank Fittings have all been re-installed after performing Step 5.
6B: Inspect the Brass Fittings on top of the dampers for leaks. If there are leaks, replace the damper(s)
then proceed to Step 6C.
6C: Inspect the bottom of the Print Head for leaks. If ink is leaking out of the bottom of the Print Head,
the applicable damper will need to be replaced. Replace the damper(s) and proceed to step 6E.
6D: Unplug the ink line from the Tank.
6E: Remove the Damper from the Print Head.

• No Ink Flowing from Damper: Proceed to step 6F.
6F: Re-connect the Tank Fitting to the Bulk Tank.
6G: Use a syringe to pull ink through the Damper and verify there is no restriction or air.

damper and perform step 6G again.
Page 21 of 31
PRIMING A DAMPER
To prime a specific channel or to check for leaks in a line/damper assembly, Remove the damper from
thecarriage, insert the priming tip all the way until it bottoms out as shown below (green arrow).
If you’re checking for air leaks it is sometimes easier to turn the damper and syringe upside down so if
any small air bubbles are pulled out, they are easier to see as they bubble up through the ink in the
syringe.
There will always be a small amount of air/bubbles as you first start pulling the ink into the syringe like
thesyringe in the green circle (notice how they syringe/priming tip is fully seated in the damper), the
bubbles should stop almost immediately. If bubbles are continuously pulled into the syringe (blue circle),
odds are there is an air leak.
Page 22 of 31

8D: Remove the Damper Assembly from the Print Head.

condition, the Print Head will need to be
replaced. Please contact Technical
Page 23 of 31
SECTION 3: 1800S & 1800BG PRINTERS
SECTION 3
1800S & 1800BG PRINTERS
Page 24 of 31


then gives the operator a false reading on the Control Panel. It is always good to visibility inspect that
there is in the tank before doing too much troubleshooting.
2A: Remove the Ink Line from the back cap (Sensor Cap) on the tank and pull the cap and sensor up.
at least 50% full before continuing.
• No Ink: The Tank Level Sensor has most likely failed. fill the tank while visually inspecting so that
you do not overfill the tank then proceed to step 2C.
• Ink: Re-install the Cap and Sensor assy. back onto the Tank and re-connect the Ink Line then
proceed to Step 3.
2C: Run an Initial Charge and test print to verify if that has solved the problem.
Ink Line
Sensor Cap
Zip-Tie
Page 25 of 31

Station.
3B: Inspect the Capping Station Caps for deterioration.
You can visually inspect the Capping Station during a cleaning cycle to confirm it is pulling ink from the
print head. Run an Initial Charge and watch to see if the Capping Station chambers are full of ink when
the Print Head moves away from the Capping Station.
• If the chambers are not filling with ink, replace the Capping Station and determine if that fixes
the problem.
Page 26 of 31
4.1A: Disconnect the Ink Line from the Sensor Cap.
4.1 B: Use a Syringe to draw ink out of the tank where the Ink Line was removed.
• Ink Does Not Flow Smoothly/Trickles out of the tank. Replace the Sensor Cap Assy. If this is the
White Ink Tank, proceed to Step 4.2 before moving on to Step 5.
Connected to fitting on the Cap Assy.
Page 27 of 31

The Pump for the White Bulk Tank is responsible for circulating the White Ink, so it stays in suspension.
The White Ink contains Titanium Dioxide which can separate out if the ink isn’t flowing through the Tank
and Ink Lines. If this happens, fittings, ink lines, dampers and/or print heads can become clogged. Make
sure the Circulation Pumps are running by following the steps below.
4.2 A: Turn the Circulation Pump(s) on from the Control Panel and confirm the pump is running by
feeling for vibration.
flowing smoothly in Step 4.1, replace the Sensor Cap prior to moving to Step 5.

Page 28 of 31
Step 5: Checking for a Clogged Breather Cap

5A: Remove the Breather/Fill Cap from the Bulk Tank.
5B: Remove the Ink Line from the Tank and attempt to draw ink from the Tank (with the Breather/Fill
Cap still removed.
• Ink Flows Smoothly out of the Tank: Replace the Breather/Fill Cap. To Clean the breather, Re-
connect the Ink Line then run a Power Clean and Nozzle Test to see if the Ink Flow problem has
been resolved. Then proceed to Step 6.
Breather/Fill Cap
Page 29 of 31

Before you begin, confirm that the Ink Lines have all been re-installed.
6B: Inspect the Brass Fittings on top of the dampers for leaks. If there are leaks, replace the damper(s)
then proceed to Step 6C.
6C: Inspect the bottom of the Print Head for leaks. If ink is leaking out of the bottom of the Print Head,
the applicable damper will need to be replaced. Replace the damper(s) and proceed to step 6D.
6D: Disconnect the ink line from the Tank.
6E: Remove the Damper from the Print Head.

• No Ink Flowing from Damper: Proceed to step 6F.
6F: Re-connect the Tank Fitting to the Bulk Tank.
6G: Use a syringe to pull ink through the Damper and verify there is no restriction or air.

damper and perform step 6G again.
Page 30 of 31

8D: Remove the Damper Assembly from the Print Head.

condition, the Print Head will need to be
replaced. Please contact Technical
Page 31 of 31

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INK FLOW TROUBLESHOOTING GUIDE

SECTION 1 7200Z Pg. 2 - 13

Step 1: Inspect the Ink Lines

Step 2: Visually Confirm the Bulk Tanks are Full

• Ink: Proceed to Step 3. Keep the Breather(s) off the tank(s).

Step 3: Verify the Capping Station Health/Life. Replace if necessary.

3A: Uncap the Print Head from the Capping Station.

3B: Use a swab to clean the five Capping Station Gaskets.

3C: Pull out the Wiper and Ink Discharge Tray.

Step 4.1: Testing the Bulk Tank Fitting

4.1A: Disconnect the Tank Fitting from the Bulk Tank.

• Ink Flows smoothly out of the Tank. Proceed to Step 5.

STEP 4.2: Checking the White Circulation Pumps

• Running: Proceed to Step 4.2B to confirm the ink is circulating.

Circulation Hose from the Pump to

Step 5: Checking for a clogged Breather

Step 6: Checking the Ink Line/Damper for restriction

6A: Uncap the Print Head from the Capping Station.

6B: Remove the black Front Plate from the Carriage.

6E: Unplug the ink line from the Tank.

6F: Remove the Damper from the Print Head.

• No Ink Flowing from Damper: Proceed to step 6E.

6G: Re-connect the Tank Fitting to the Bulk Tank.

• Restriction when Priming: Replace the damper.

Step 7: Checking Flow through the Capping Station

7E: Using a Syringe with a piece of hose attached to it,

• No Flow: Replace the Capping Station. Note, the

• Smooth/Consistent Flow: through the Capping

Step 8: Manually Flushing the Print Head

8C: Turn the Machine Off.

8D: Remove the Damper Assembly from the Carriage.

Step 9: Print Head Cable Replacement

Appendix A: 7200 Ink Path Overview

Step 1: Inspect the Ink Lines

Step 2: Visually Confirm the Bulk Tanks are Full

• Ink: Proceed to Step 3. Keep the Breather(s) off the tank(s).

Step 3: Verify the Capping Station Health/Life. Replace if necessary.

3A: Uncap the Print Head from the Capping Station.

3B: Inspect the Capping Station Caps for deterioration.

Step 4.1: Testing the Bulk Tank Fitting

4.1A: Disconnect the Tank Fitting from the Bulk Tank.

• Ink Flows smoothly out of the Tank. Proceed to Step 5.

STEP 4.2: Checking the White Circulation Pumps

• Running: Proceed to Step 4.2B to confirm the ink is circulating.

Circulation Hose from the Pump to

Step 5: Checking for a clogged Breather

Step 6: Checking the Ink Line/Damper for restriction

6A: Uncap the Print Head from the Capping Station.

6D: Unplug the ink line from the Tank.

6E: Remove the Damper from the Print Head.

• No Ink Flowing from Damper: Proceed to step 6F.

6F: Re-connect the Tank Fitting to the Bulk Tank.

• Restriction when Priming: Replace the damper.

Step 7: Manually Flushing the Print Head

8C: Turn the Machine Off.

8D: Remove the Damper Assembly from the Print Head.

Step 8: Print Head Cable Replacement

Step 1: Inspect the Ink Lines

Step 2: Visually Confirm the Bulk Tanks are Full

Step 3: Verify the Capping Station Health/Life. Replace if necessary.

3A: Uncap the Print Head from the Capping Station.

3B: Inspect the Capping Station Caps for deterioration.