Colordyne 1600-S COLOR PAGE PRINTER SERVICE MANUAL
SAFETY PRECAUTIONS THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY. HOWEVER, CERTAIN SAFETY RULES SHOULD BE OBSERVED WHEN OPERATING THE COLORDYNE 1600-S PRINTER. BEFORE USING THE PRINTER, YOU SHOULD READ THIS MANUAL CAREFULLY AND FOLLOW THE RECOMMENDED PROCEDURES, SAFETY WARNINGS, AND INSTRUCTIONS: Keep hands, hair, and clothing clear of rollers and other moving parts. Avoid touching moving parts or materials while the machine is in use.
TABLE OF CONTENTS Table of Contents SECTION 1 – Installation 1 Contents of Packaging Tools Required Unpacking and Setup Hydrating the Printhead Cartridge Removing Service Station Transport Tab Assembling the Printer Connecting the Colordyne 1600-S Install the Printer Driver Install the Ink Tanks Install the Printhead Cartridge SECTION 2 – Troubleshooting 1 1 1 2 3 3 5 6 9 10 14 Power Problems Interface Communication Problems Feeding Problems The Memjet Printhead The Service Station Printing Problems
TABLE OF CONTENTS Print Engine Basic Disassembly 54 Removing the Print Engine Base 54 Replacing Peristaltic Pump Assembly 55 Replacing Dual Pinch Valve Assembly 55 Replacing DPCA Board 56 Replacing Buffer Boxes (3 per machine) 57 Replacing QA Chip Assembly (3 per machine) 57 Removing the Pen Driver Printed Circuit Assembly (PCA) 58 Removing the Starwheel Assemblies 58 Replacing the Ink Tank Latches 59 Removing the Main Printed Circuit Assembly (MPCA) Cover 60 Replacing Encoder or Encoder Sensor 61 Replac
TABLE OF CONTENTS NOTES ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ _______________________________________________
SECTION 1 INSTALLATION SECTION 1 – Installation Contents of Packaging 1. COLORDYNE 1600-S Printer 2. Ink Tanks – Cyan, Magenta, Yellow, Black, Black 3. Printhead Cartridge 4. Media Side Guides: Registration (Fixed) and Adjustable – mounting screws attached to Printer 5. Rear Media Support Guide – thumbscrew attached to Printer 6. Media Support Wedges: Narrow and Wide – mounting hardware attached to Rear Media Support Guide 7. Envelope Printing Attachment (Head Media Guide) 8.
SECTION 1 INSTALLATION Hydrating the Printhead Cartridge Before you begin assembling the Printer, it is a good idea to hydrate the Printhead Cartridge. CAUTION Use electro-static discharge (ESD) protection when handling. Hold the Printhead Cartridge by the handles ONLY. DO NOT touch the ink couplings, nozzle surface or electrical contacts. DO NOT unpack the Printhead Cartridge until the Printer is ready for installation.
SECTION 1 INSTALLATION Removing Service Station Transport Tab 1. Open the Top Cover. 2. Release the two latches (one on either side of the Print Engine). Open the top half of the Print Engine by lifting both levers at the same time. CAUTION OPERATE AND HOLD ONTO BOTH LATCHES WHEN OPENING AND CLOSING THE PRINTHEAD ASSEMBLY TO PREVENT DAMAGE. DO NOT ALLOW THE ASSEMBLY TO DROP BY ITSELF WHEN CLOSING. TO PREVENT DAMAGE TO THE INK LINES, A STOP LIMITS RAISING THE ASSEMBLY MORE THAN 60°. 3.
SECTION 1 INSTALLATION Next install the Envelope/Paper Side Guide using the two screws [2] provided. Attach the Rear Paper Support using the knob [3] provided. NOTE: The two outside holes fit over the socket head screws. Install the Back Guide using the thumbscrew and washer [4] provided. The washer goes between the screw and the Rear Paper Support.
SECTION 1 INSTALLATION Connecting the Colordyne 1600-S Plugging in the Printer Connect the power cord to the receptacle [1] at the rear of the Printer. The internal power supply in the Printer is rated 115 to 240VAC, 50/60 Hz. CAUTION DO NOT USE AN ADAPTER PLUG OR EXTENSION CORD TO CONNECT THE PRINTER TO THE WALL RECEPTACLE. DO NOT USE OUTLETS CONTROLLED BY WALL SWITCHES. DO NOT USE AN OUTLET THAT SHARES THE SAME CIRCUIT WITH LARGE ELECTRICAL MACHINES OR APPLIANCES.
SECTION 1 INSTALLATION Install the Printer Driver For the Printer software to operate properly check that the computer system meets these minimum requirements: Windows XP, Windows Vista, Windows 7. (Supports 32 and 64 bit systems) You must have administrative privileges on the system. Microsoft Internet Explorer 6.0 or higher. Java version 6 or higher USB 2.0 port (ports will be identified as “USB2” or “Enhanced” in the Device Manager.) Microsoft .NET Framework 3.
SECTION 1 INSTALLATION 4. After a few moments the “Printer Connections” window opens. Click “Configure to print using USB”. Then click Next>. 5. After a few moments the “M Series Driver” window opens followed by the “Would you like to install this device software?” window. Click Install and the driver software will load from the disk. 6. The software will start to download and a second “Would You Like to Install This Device Software” opens. Click Install. 7. The “Connect Device Now” window opens.
SECTION 1 INSTALLATION 8. The “Finished software installation” window opens. Do not print a test page since printer is not set up yet. Do not check the Print Test Page. Click Next>. 9. The M Series Driver welcome window returns. Note that you can click on the User’s Guide for installation, document set up and printer maintenance, cleaning and troubleshooting information. If you are connected to the Internet you can click Website. Click Exit to close CD. 10.
SECTION 1 INSTALLATION Install the Ink Tanks Printer uses a single Printhead Cartridge and five Ink Tanks (two Black, one Cyan, one Magenta, and one Yellow). Install the Ink Tanks as follows: TURN PRINTER OFF: 1. Open the Toolbox. Go to All Programs, open the Printer Folder and open the Toolbox. On the Opening Screen you will see System Status information in the upper left corner. 2. Open the Front Cover (hinged at bottom). Open the three Latches [A]. 3. Remove the new Tank(s) from packaging. 4.
SECTION 1 INSTALLATION 5. Watch the Toolbox screen on your computer; you will see the ink colors fill in as the Tanks are installed. If the ink color does not fill in after a few seconds, reinstall the Ink Tank. 6. Lock the three Latches. Close the Front Cover. WARNING The ink in the Ink Tanks may be harmful if swallowed. Keep new and used Tanks out of reach of children. Discard empty Ink Tanks immediately. Install the Printhead Cartridge The Printhead Cartridge is a delicate precision device.
SECTION 1 INSTALLATION 2. Take the Printhead Cartridge you hydrated and set aside earlier, remove the orange cover and proceed to Step 3. Otherwise, follow the Steps below: Carefully remove the Printhead Cartridge from the foil packaging. [A] Tear at notch or cut end with scissors. [B] Remove the protective plastic cover. Hold the Printhead by the handle and unclip the cover from the Printhead. [C] Remove protective strip from the Printhead Electrical Contacts.
SECTION 1 INSTALLATION 4. Wet the Printhead Surface. This ensures that the Printhead will prime correctly. Open the Top Cover. Release and lift up the two latches (one on each side of the Printhead Assembly) at the same time to raise the Printhead Assembly. Moisten the Printhead nozzles using distilled water and a wet, lint-free cloth. Close and relatch the Printhead Assembly. CAUTION OPERATE AND HOLD ONTO BOTH LATCHES WHEN OPENING AND CLOSING THE PRINTHEAD ASSEMBLY TO PREVENT DAMAGE.
SECTION 1 INSTALLATION 6. Watch the Toolbox screen on your computer again. Notice that some of the information is in red. As the Printer circulates ink and primes the system these fields should all turn black. 7. When the Printer stops processing and all the fields in System Status are black, the Printer is ready for use. Close the Top Cover. NOTE: The Printer may take up to 12 minutes to set itself up during initial startup. This is normal.
SECTION 2 TROUBLESHOOTING SECTION 2 – Troubleshooting This section is arranged by first the condition that might occur, and then by possible problems, their cause and recommended solutions. Power Problems CONDITION PROBLEM Power is ON, nothing happens. No power to Printer. SOLUTION Check that the power cord is plugged in. Check that the power outlet is live. Replace AC Adapter. Interface Communication Problems CONDITION Printer does not respond to software. PROBLEM Connection problems.
SECTION 2 TROUBLESHOOTING Feeding Problems CONDITION Intermittent feeding PROBLEM SOLUTION Feed Ramp not used. Side Guides set improperly. Dirty Feed Rollers. Paper stuck together. Uneven mail piece. Multiple feeds Failure to feed Jams The Feed Ramp adds a slope to the stack and helps feeding. Loosen the Side Guides slightly. Clean the Feed Roller with distilled water and a cloth. DO NOT use any solvents or detergents as they may damage the Feed Rollers. Fan media before placing it in Printer.
SECTION 2 TROUBLESHOOTING The Memjet Printhead CONDITION PROBLEM Missing parts of letters or text. Air and bubbles blocking nozzles. Printhead is dry. Print shows regularly missing or misdirected nozzles or ink color mixing. Debris on Printhead. Ink mixing – Mixed or muddy colors. Causes: Ink flooding, air in the Printhead or a dirty Printhead. No print or crisp blocks of missing drops. Electrical failure or poor electrical connection.
SECTION 2 TROUBLESHOOTING The Service Station CONDITION Motor stalls PROBLEM Color mixing Service Station cannot be removed from the Print Engine SOLUTION Jammed gear train due to broken post or improperly seated gears. Squeegee blade wedged, not seated properly. Debris build-up on blade and rollers, increasing friction. Bad Motor. 1. Wiper Roller is saturated. Squeegee blade is wedged, not seated properly or bowed. 1.
SECTION 2 TROUBLESHOOTING Printing Problems CONDITION PROBLEM SOLUTION Extra lines; losing data Database problem. Check data in database program. Improper output (address information out of order, missfeeding, etc.) Wrong interface settings. Check software or database on PC. Close the software and then turn Printer OFF and ON. Clean Media Sensor. Static electricity. Dirty Media Sensor. Media jams Double feeding. Media is curled or bent. Media is too thin. Unit not receiving power.
SECTION 2 TROUBLESHOOTING Jams in the Colordyne 1600-S Printer If a jam occurs, STOP the Printer. Some possible causes for jamming are: 1. Feeding more than one piece of media (double-feeding). 2. Damaged media, such as dog-eared (turned down corners). 3. Media that is not stiff enough may not be usable. Media that meets Postal stiffness requirements for automated feeding is acceptable in the Colordyne 1600-S. 4. Envelopes caught under the flap of another envelope or stick to one another.
SECTION 3 FUNCTIONAL OPERATION SECTION 3 – Functional Operation Sequence of Operation The User Prepares the Printer 1. Installs Ink Tanks in proper locations. 2. Uses a single piece of media to set Sheet Separators. 3. Loads media and adjusts the Side guide to within 1/32" of media. 4. Stacks media in Feeder and adjusts Feed Ramp. 5. Turns Printer ON. The User Prepares the Layout and Creates a Job 1. The user selects the database and opens the layout software such as Microsoft Word. 2.
SECTION 3 FUNCTIONAL OPERATION Printer Functional Description 1. A Photosensor located behind the Sheet Separators sees the lead edge of the paper, another Photosensor in the Print Engine sends a signal to the Print Engine on the Main Board that the mailing piece is ready for printing. The Feed Clutch remains disengaged as long as a mailing piece is in view of the Photosensor. 2.
SECTION 3 FUNCTIONAL OPERATION Control Panel Button/LED Indicators The Control Panel has 3 buttons with LED indicators. POWER (ON/OFF) – Turns Printer power ON and OFF. Turn off power for cleaning and maintenance PAPER (STOP JOB/RESUME) – Stops Paper Feed or Resumes Printing. Press to Stop Paper Feed Immediately. Printer will clear media in Printer and stop. Press to Resume Printing. Restart printing after a paper feed error (such as a paper jam or running out of paper).
SECTION 3 FUNCTIONAL OPERATION PRINTER ERROR INDICATORS POWER PROBLEM Paper Feed Times Out/Out of Paper (ON/OFF) LED ON, steady PAPER (STOP/RESUME) LED ON, flashing about 3 times/second. CANCEL (CANCEL JOB) LED OFF ACTION: Press PAPER to pause job. Check/clear paper jams or reload Feeder. If OK, press PAPER to resume printing. If not fixed, press CANCEL to cancel the job. Sensor(s) Covered ACTION: LED ON, steady Tilt Error LED ON, steady ACTION: Press PAPER to stop feed.
SECTION 3 FUNCTIONAL OPERATION Printer Driver Properties The Printer Driver for the Colordyne 1600-S works the same as any other Printer Driver for Windows. It does have some enhancements to help you maximize the ability of the Printer to print variable addressed pieces quickly and efficiently. Windows XP, Vista, Windows 7: Once the job is set up, click File, then Print. The window on the right will open. Make sure the M Series Driver is the selected Printer.
SECTION 3 FUNCTIONAL OPERATION Media – Choose a type of media or different size media than the document was originally designed for. Type: Chart at right lists the media profiles associated with the type of media chosen. Sizes: 21 sizes are available. The document is automatically resized to fit the new media. You can also create and save a Custom Size to suit your needs. NOTE: Do not exceed maximum paper size for the Printer.
SECTION 3 FUNCTIONAL OPERATION Services Tab Services allows you to: Print Configuration Page – Prints out the current configuration of the Printer including current Firmware Version, Network Connection, printer Serial Number and more. Print Sample Page – Prints type and color bands to check print quality. Print Diagnostic Page – Shows basic Printer information, memory, Network Settings, Event Log and RAM partitions.
SECTION 3 FUNCTIONAL OPERATION Using the Toolbox Once the Printer Driver is installed you have access to the Toolbox. The Toolbox lets you monitor ink usage, perform diagnostic checks, print reports and run maintenance tasks on the Printer from your computer. To open the Toolbox: Click Start from the Windows taskbar, go to All Programs, open the printer folder, then click on “Toolbox”.
SECTION 3 FUNCTIONAL OPERATION Cleaning Buttons: Provide 3 levels of cleaning for the Printhead Cartridge. These work the same way as the 3 Maintenance Level Buttons in the Printer Driver: Quick Clean Printhead – Circulates ink, wipes and cleans the Printhead Cartridge. Normal Clean Printhead – Runs cleaning and wiping routine twice for better flushing and cleaning. Full Clean Printhead – Runs the cleaning routine multiple times for the most thorough flushing and cleaning of the Printhead.
SECTION 3 FUNCTIONAL OPERATION [C] Firmware Download – Get the latest version of firmware for your Printer. How to download new firmware: 1. 2. 3. 4. 5. When you are notified that new firmware is available for your Printer, download the *.fbf file and save it to your desktop. Open the Toolbox. On the “User Interface” page, find Firmware Downloads. Click the “Browse” button and find the file you just saved to your desktop. Click “Submit”.
SECTION 3 FUNCTIONAL OPERATION Network Configuration Permits you to view, enter or change settings to connect the Printer to your network. Network Connection Set Up: 1. The Printer is still connected to the computer via the USB cable. To connect the Printer to a network, open the Toolbox. On the “User Interface” page, click Network Config. This will open the “Printer Toolbox Home” page. 2. The “Network Status and Configuration” page opens.
SECTION 3 FUNCTIONAL OPERATION Service Menu For authorized personnel only. Provides access to more advanced Printer Control and Maintenance menus. Enter password to view the Service menus. You will notice that several new menu options are available: “Printer Maint Config,” “Printing Control Config,” “Exit Service Menu, ” and “Commands Help.” Printing Control Configuration Screen: Allows you to make fine adjustments as to how a job is fed into and through the Printer and how it will print.
SECTION 3 FUNCTIONAL OPERATION Printer Maintenance Configuration Screen: Allows you to enable or disable certain maintenance functions. Printer Commands Help Screen: Provides a list and descriptions of available EWS service commands Clicking “Exit Service Menus” closes the Service Menu options and takes you back to the “Printer User Control” screen.
SECTION 3 FUNCTIONAL OPERATION Printer Toolbox Error Messages The following procedures should resolve Printer issues when these error messages appear in the Printer Toolbox. [Fatal 71 02-? offline cancelpage] This message appears in the “System Status” and “Mech Status” lines in the top left corner of the Printer Control Screen in the Printer Toolbox. This may indicate that the Dual Pinch Valve Printed Circuit Assembly connector may be loose or disconnected. 1. Shut off the Printer.
SECTION 3 FUNCTIONAL OPERATION 3. Look through the open side of the Printer. The Dual Pinch Valve connector (white) is located just behind the Bottom Fan Duct. 4. Use a long-blade flat-tip screwdriver to carefully reach across the Print Engine and push in or reconnect the small white PCA connector. 5. Reinstall Right-hand Side Cover.
SECTION 4 ADJUSTMENTS SECTION 4 – Adjustment Colordyne 1600-S Drive Belt Tension Adjustment REQUIREMENT: To ensure the Drive Belt has the proper tension. ADJUSTMENT: 1. Unplug the machine and remove the Right-hand Side Cover. (6 screws) 2. Loosen the two screws [1] that mount the Main Drive Motor to the Frame. 3. Move the Motor up or down to obtain a Belt deflection of between 0.085" and 0.065" when a force of 1 lb. is applied as shown. 4. Tighten the two motor mount screws [1]. 5.
SECTION 5 DISASSEMBLY AND ASSEMBLY SECTION 5 – Disassembly/Assembly Procedures Printer Basic Disassembly Turn Power OFF Disconnect Power Cord Disconnect Interface Cable Replacing the Separator Tips 1. Unplug the Printer before replacing the Separator Tips. 2. Loosen the Separator Locking Knob and raise the Separator to its maximum raised position. 3. Use a Phillips screwdriver to remove the screw holding the metal Cover over the Separator.
SECTION 5 DISASSEMBLY AND ASSEMBLY Left-hand Side Covers 1. Remove (2) screws at the top and bottom of the Lefthand Rear Side Cover. Remove the Cover. 2. Remove (2) screws at the top and bottom of the Lefthand Front Side Cover. Pull Cover away from machine slightly. [A] Disconnect the wires attached to the Power, Paper and Cancel Buttons. Carefully remove the Cover. NOTE: Wires are labeled to simplify reconnection. 3. Reassemble in reverse order.
SECTION 5 DISASSEMBLY AND ASSEMBLY Right-hand Side Cover 1. Remove the (3) screws at the top of the Cover. Then remove the (3) screws from the bottom of the Cover. Major Components under Right-hand Side Cover 1. Interface PC Board 2. Main Power Plug, Switch, Fuse 3. USB Connector 4. Network Connector 5. Feed Clutch and Feed Roller Assembly 6. Encoder 7. Encoder Sensor 8. Drive Belt 9.
SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Motor Drive Belt or Motor 1. Remove Right-hand Side Cover. NOTE: To remove the Motor, remove the six screws holding the Rear Panel Cover. 2. [1] Loosen the (2) Motor mounting screws to relieve tension on the Motor Drive Belt. [2] Then remove the (2) screws and the Encoder Sensor. NOTE: To remove the Motor, disconnect the wires and remove the two mounting screws. CAUTION DO NOT SCRATCH OR OTHERWISE DAMAGE THE ENCODER WHEEL WHEN REMOVING THE MOTOR DRIVE BELT.
SECTION 5 DISASSEMBLY AND ASSEMBLY 3. Push the Clutch in toward the Pulley to get access to the retaining pin. Remove the retaining pin. 4. Remove the Clutch from the Feed Roller Shaft. 5. Reassemble in reverse order. Replacing the Feeder Encoder and/or Encoder Sensor 1. Remove the Encoder Sensor from the Rear Side Frame. [A] Remove the (2) screws holding the Encoder Circuit Board to the two standoffs. [B] Remove the Encoder Sensor by carefully moving the Sensor down and away from the Encoder Wheel.
SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Feed Rollers 1. Unplug the Printer from power. 2. Follow the instructions above and remove the Righthand Side Cover, Drive Belt and Clutch before beginning the replacement of the Feed and Forwarding Rollers. 3. Remove the Left-hand Rear Side Cover and set aside. 4. Remove the Side Paper Guides and the Rear Paper Support. 5. Move the Sheet Separators to the “Up” position.
SECTION 5 DISASSEMBLY AND ASSEMBLY 8. Lift the Center Plate Assembly from the machine and set aside. 9. Remove the screw holding the Clutch Support Bracket and remove the Bracket. 10. Remove the Rear Feed Roller Drive Pulley. NOTE: The spring and washer keep tension on the Clutch so that the pin holding the Clutch remains in place. Reassemble these parts in order shown.
SECTION 5 DISASSEMBLY AND ASSEMBLY 11. Remove the washer and spring from the Feed Roller Shaft. NOTE: The spring and washer keep tension on the Clutch so that the pin holding the Clutch remains in place. Reassemble these parts in order shown. 12. Remove the two screws holding the Bearing Housing to the Side Frame. Push the Rear Feed Roller Assembly toward you to release it from the Bearing on the other side of the machine. Carefully remove the Belt.
SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Delivery Rollers The Delivery Rollers are part of the Front Center Assembly on the feed end of the Print Engine. 1. Remove the Left-hand Rear Side Cover by removing the (2) screws at the top and bottom of the Cover. Remove the Cover. 2. Remove (2) screws at the top and bottom of the Lefthand Front Side Cover. Pull Cover away from machine slightly. [A] Disconnect the wires attached to the Power, Paper and Cancel buttons. Carefully remove the Cover.
SECTION 5 DISASSEMBLY AND ASSEMBLY 4. Remove Top Cover. Remove mounting screw on left-hand side (Control Panel Side). Remove Top Cover and set aside. 5. Remove Antistatic Brush Assembly [A] from mounting studs. Unlatch the two latches (one on either side of the Assembly) and lift the Assembly off the four mounting pins as shown. Do not bend the brushes! CAUTION DO NOT BEND, PINCH OR CUT THE INK LINES LOCATED DIRECTLY IN FRONT OF THE BRUSH ASSEMBLY.
SECTION 5 DISASSEMBLY AND ASSEMBLY 7. Remove Ink Station Door. Carefully unhook the (2) springs (one on each side), then remove the mounting screw from the left-hand side (Control Panel Side). Remove Door and set aside. 8. Remove Left-hand Inner Side Frame (3 screws). )Remove the Ink Tank Door mounting screw. First remove the Door Spring attached to the screw under the Base Plate. Then remove the screw. NOTE: Be careful not to lose the Ink Door Spring. 9.
SECTION 5 DISASSEMBLY AND ASSEMBLY 10. Remove Side Fan (2 screws). [A] Remove Media Bracket Stud #1 (1 screw) and small screw holding the Assembly on left-hand side. [B] Take the Front Center Plate by sliding it off the alignment studs on the Print Engine. 11. Remove Front Center Plate Assembly. Remove the (2) screws holding the Delivery Roller Shaft to the Assembly. NOTE: You will have to remove the Bearing to remove Shaft from the Assembly. The Rollers are attached to the Shafts with Allen screws.
SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Interface PC Board 1. Remove the Right hand Side Cover. 2. Unplug the PC Board power cord [1] from the Power Inlet on the PC Board. 3. Unplug (9) Connectors for Clutch, Sensors, Motor, Encoder and Counter wires. NOTE: Wires are labeled for easy reconnection. CAUTION DO NOT DAMAGE THE WIRES WHEN REMOVING THEM. 4. Remove the (4) screws that attach the PC Board to the Side Frame and remove the PC Board.
SECTION 5 DISASSEMBLY AND ASSEMBLY Removing the Print Engine 1. Open the Top Cover. Open the Toolbox, press the Release Printhead button. Printer will “deprime,” pumping all the ink back to the Ink Tanks, then the Printhead Cover will open. Remove the Printhead Cartridge and carefully put it back in the original packaging. Shut the Printer down by first pressing the Control Panel Power button, then the Main Power switch on the Rear Panel. Unplug the unit. 2.
SECTION 5 DISASSEMBLY AND ASSEMBLY 6. Remove Ink Station Door. Carefully unhook the (2) springs (one each side), then remove the mounting screw from the left-hand side (Control Panel Side). Remove Door and set aside. 7. Remove Top Cover. Remove mounting screw from lefthand side (Control Panel Side). Remove Top Cover and set aside. 8. [A] Remove the (2) screws holding the left-hand side Media Separator Guide.
SECTION 5 DISASSEMBLY AND ASSEMBLY 9. Unplug USB, Network and Main Power connectors from Print Engine Circuit Board. 10. Remove Antistatic Brush Assembly [A] from mounting studs. Unlatch the two latches (one on either side of the Assembly) and lift the Assembly off the four mounting pins as shown. Do not bend the brushes! CAUTION DO NOT BEND, PINCH OR CUT THE INK LINES LOCATED DIRECTLY IN FRONT OF THE BRUSH ASSEMBLY.
SECTION 5 DISASSEMBLY AND ASSEMBLY 11. Disconnect the following wires from the Interface Printed Circuit Board located on the right hand side of the Printer Frame: [A] Clutch Out (J8), [B] S4 (J9) [C] Motor In (J2) [D] Disconnect the Encoder wire from the Encoder Printed Circuit Board. Pull these wires clear from the other wiring so they won't snag when the Print Engine is removed. 12. Remove Left hand Inner Side Frame (3 screws). Remove the Ink Tank Door Spring mounting screw.
SECTION 5 DISASSEMBLY AND ASSEMBLY 13. Lift and support the Printer so you can reach underneath to access and remove the (4) screws holding the bottom of the Print Engine to the Base Plate. 14. Carefully slide Print Engine out of Printer. (Print Engine is entire unit including the Ink Station) 15. Reassemble in reverse order. IMPORTANT! WHEN REINSTALLING THE PRINT ENGINE, MAKE SURE THAT THE ALIGNING PINS ARE FLUSH WITH EACH OTHER WHEN THE PRINT ENGINE IS PUSHED AGAINST THE FRONT CENTER PLATE ASSEMBLY.
SECTION 5 DISASSEMBLY AND ASSEMBLY Print Engine Basic Disassembly The Print Engine must be removed from the Printer for these procedures. See “Removing the Print Engine” in previous pages. It is also assumed that the Ink Tanks, Printhead and Service Station are removed. Removing the Print Engine Base Provides access to parts located underneath the Print Engine. 1. Remove Ink Waste Tray from below Ink Reservoirs and put aside. 2. Remove Engine Base.
SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Peristaltic Pump Assembly Remove old Pump Assembly: [A] Remove (4) screws that hold Bracket to Chassis. [B] Cut cable tie holding wiring harness to Assembly. [C] Unplug connector from Pump Motor Circuit Board. [D] Cut or remove Ink Hoses from barbs IMPORTANT! Make sure you know where each Ink Hose connects. Remove old Pump Assembly. Install new Pump Assembly: Plug wire connector into new Pump Assembly Motor Circuit Board [C].
SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing DPCA Board [A] Remove (2) screws on the outside of the Chassis that attach the Circuit Board Bracket to Chassis. [B] Carefully move the DPCA Assembly out to unplug the wire harness connectors. NOTE: Make sure you know which connectors go with which socket. [C] Remove the (3) screws attaching the DPCA to the Bracket. Remove DPCA Board. Install in reverse order.
SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Buffer Boxes (3 per machine) ) [A] Each Buffer Box is held in place by (2) screws accessed through the Ink Tank Station. Using a long Phillips screwdriver, remove the screws and pull up on the Box to remove it from the Chassis. [B] Push new Buffer Box down onto the ink ports. Attach with (2) screws from inside Ink Tank Station.
SECTION 5 DISASSEMBLY AND ASSEMBLY Removing the Pen Driver Printed Circuit Assembly (PCA) ) Location: Upper Clamshell next to the Printhead Cartridge bay. [A] Remove the Pen Driver PCA Cover (lightly glued in place). [B] Disconnect the (2) Ethernet data cables, then unplug the power connector and Main PCA harness connectors. [C] Remove (3) screws holding the Head Board Mount. [D] Remove the Pen PCA from the unit. [E] Remove (2) screws attaching the PCA to the Head Board Mount. Install in reverse order.
SECTION 5 DISASSEMBLY AND ASSEMBLY Internal: [A] Remove the Pen Driver Printed Circuit Board Cover. [B] Remove (2) screws from bottom of Pen Driver Printed Circuit Board bay. [C] Locate and carefully release the (2) black locking tabs holding the Starwheel Assembly to the metal bracket. NOTE: Locking tabs break easily! Remove the Starwheel Assembly. Install in reverse order. Replacing the Ink Tank Latches Ink Tanks must be removed prior to replacing latches.
SECTION 5 DISASSEMBLY AND ASSEMBLY Main Printed Circuit Assembly (MPCA) Cover Removing the Main Printed Circuit Assembly (MPCA) Cover To get access to parts on the Print Engine clamshell, the MPCA Panel Cover must be removed and the panel folded out of the way. 1. Remove (4) screws to remove the Cover. Set aside. NOTE: End Panel screws intentionally left off to improve accessibility. 2. Remove two (2) mounting screws from bottom of MPCA Panel. 3. Fold Main Printed Circuit Assembly down out of the way.
SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Encoder or Encoder Sensor [A] Remove (3) screws holding the Encoder Cover. [B] Unplug wire harness from the Encoder Sensor. [C] Carefully pivot the Cover away from the Encoder Wheel. Be careful of the spring. [D] Remove the (2) screws holding the Encoder Sensor in place and pull away from Encoder Wheel. NOTE: Be careful not to damage the Wheel. [E] Remove the single screw holding the Encoder Wheel to the Roller Shaft. Remove the Encoder Wheel Assembly.
SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Belt Drive Gear Pulleys There are three. One is mounted on the Exit Grit Roller Shaft, one is located behind the Encoder Assembly on another Grit Roller Shaft and one is mounted on the Entry Grit Roller Shaft. First, you may need to loosen or remove the Drive Belt, see “Replacing the Paper Path Motor or Drive Belt”. Exit Grit Roller Gear Pulley [A] Remove the Paper Path Motor. See “Removing Paper Path Motor”.
SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Lifter Motor Assembly or Lifter Gear Remove Lifter Motor Assembly Only: [A] Unplug the wire harness from the Lifter Motor Assembly. [B] Remove the (2) screws holding the Motor Assembly to the Motor Assembly Bracket. [C] Gently remove the Motor Assembly. Take care that the Worm Gear does not damage the Lifter Gear. Install in reverse order. NOTE: Make sure Worm Gear and Lifter Gear are engaged correctly. Apply a small amount of gear lube to Lifter Gear.
SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Stepper Motor [A] Remove (2) screws. [B] Unplug the wire harness from the Stepper Motor Printed Circuit Board. [C] Note the position of the Motor gears to make sure gears will mesh with the Service Station gear (if Service Station is installed.) Install in reverse order.
SECTION 5 DISASSEMBLY AND ASSEMBLY Removing the Clamshell Assembly Provides access to parts under the Clamshell Assembly. Removing Clamshell Assembly 1. Remove the (4) screws attaching the Clamshell to the Chassis (1 at each corner). 2. Gently lift the Clamshell from the Chassis – Take care not to pinch or damage any wires or ink hoses. NOTE: Remember to reinstall the ground cable when reattaching Clamshell Assembly to Chassis. Check that no wires or hoses are being snagged or pinched.
SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Label Web Sensor The Label Web Sensor consists of a Receiver located in the upper Clamshell and an Emitter located in the lower Clamshell. Receiver (Under Upper Clamshell): [A] Remove (2) screws. [B] Disconnect wiring harness. Install in reverse order. Emitter (Under Lower Clamshell): [A] Remove (1) screw. [B] Carefully pull Emitter off locating pins. [C] Turn Emitter over and unplug wiring harness. Install in reverse order.
SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Service Station Sled Printed Circuit Boards [A] Remove (2) screws. [B]. Carefully disconnect the (2) connectors. [C] Swing Sled away from Clamshell and turn over. Carefully unclip the two Printed Circuit Boards. Install reverse order. NOTE: Make sure wire harnesses are plugged into correct printed circuit board. Replacing Wiper Motor Flex Cable PCA [A] Carefully unclip the Printed Circuit Board from the Holder and turn it over. NOTE: Tabs break easily.
SECTION 5 DISASSEMBLY AND ASSEMBLY Reinstall Main Printed Circuit Board Assembly 1. Gently lift up the Wiring Panel. NOTE: DO NOT pinch or cut wires running through Frame. 2. Reinstall the two (2) mounting screws into bottom of MPCA Panel. 3. Reinstall (4) screws to attach the Cover.
SECTION 6 MAINTENANCE SECTION 6 - Maintenance This section covers how to care for the Ink Tanks, Printhead Cartridge, Service Station, clear paper jams, and replace the Sheet Separators. Replacing the Ink Tanks Replace the Colordyne 1600-S Ink Tanks when the ink runs out. 1. Open the Toolbox. Go to All Programs, open the Printer Folder and open the Toolbox. On the opening screen you will see System Status information in the upper left corner. 2. Open the Front Cover (hinged at bottom).
SECTION 6 MAINTENANCE 5. Turn Printer ON with the Control Panel Power Button. Watch the Toolbox screen on your computer, you will see the ink colors fill in as the Tanks are installed. If the ink color does not fill in after a few seconds, reinstall the Tank. 6. Prime the system by running the Circulate Ink routine from the User Interface window in the Toolbox. 7. Watch the Toolbox screen on your computer again. Notice that some of the information is in red.
SECTION 6 MAINTENANCE Cleaning/Replacing the Printhead Cartridge Cleaning The Printhead Cartridge in the Colordyne 1600-S Printer is cleaned automatically each time the machine is turned on or when the Level 1 Maintenance routine is performed by the operator. This can be found under the Service Tab, Level 1 Maintenance in the Printer Driver. Level 2 and Level 3 Maintenance can be used to more thoroughly clean or clear the Printhead.
SECTION 6 MAINTENANCE 2. Open the Top Cover. Press the Printhead Cover Release Button [1]. The Printer pumps any ink in the system back into the Ink Tanks. Then the Printhead Cover pops open [2]. NOTE: You can perform this same function from your computer by clicking Printhead Release from the Services tab in Print Properties or the User Interface screen in the Toolbox. CAUTION DO NOT PRY OR MANUALLY LIFT THE PRINTHEAD COVER OR THE COVER MAY BREAK.
SECTION 6 MAINTENANCE WARNING To avoid electrical shock or shorting: Before installing the Printhead, make sure the nozzles are hydrated and the contacts are DRY! 4. Carefully insert the Cartridge into the compartment at an angle [4], with the Printhead surface facing down and the Ink Nozzles facing the Ink Hoses. Once it is seated, gently tilt the Cartridge back until it snaps into an upright position [5]. DO NOT FORCE the Printhead Cartridge into position. 5. Wet the Printhead Surface.
SECTION 6 MAINTENANCE 6. Close the Printhead Cover [6]. The Printer will automatically run a start-up routine and prime the ink into the Printhead. This may take a few minutes. Make sure that ink is flowing through the hoses. If air bubbles appear you may have to tap the lines or run the Circulate Ink routine to clear them. 7. Watch the Toolbox screen on your computer again. Notice that some of the information is in red.
SECTION 6 MAINTENANCE Replacing the Ink Revolvers First Deprime the system and remove the Printhead Cartridge. New Ink Revolver includes attached leader hoses and hose connectors. 1. Remove Cover by squeezing sides to release the tabs. Lift out Cover and set aside. 2. Route the hose leads from the new Revolver through the same frame cutout as the existing hoses. 3. Work one hose at a time: Carefully match, cut and connect the existing ink hoses to the hose leads on the new Ink Revolver.
SECTION 6 MAINTENANCE 6. Slide the new Ink Revolver back into its track and align the yoke on rear with the hinge bracket. Make sure the new Revolver is turned correctly. 7. Reinstall the Pin and C-clip. 8. Reinstall the Ink Revolver Cover.
SECTION 6 MAINTENANCE Cleaning/Replacing the Service Station The Maintenance Station cleans the Printhead Cartridge of excess ink and debris, keeps the Printhead hydrated and protected when not in use, captures ink used to keep nozzles clear, and acts as a base to support media during printing. It fits in the port immediately above the Ink Tank Station. Removing the Service Station 1. Open the Front Cover (hinged at bottom). Remove the Exit Roller Cover by removing the four (4) screws.
SECTION 6 MAINTENANCE 3. Slide the Service Station out of the Service Station port. NOTE: Do not pull Station all the way out until you disconnect the Ribbon Cable. NOTE: It is a good idea to place an absorbent towel under the Service Station as you remove it to prevent any drips or leaks. 4. Disconnect the Ribbon Cable. Slide the Latch open on the Service Station Circuit Board to release the Ribbon Cable. Remove the Service Station.
SECTION 6 MAINTENANCE Cleaning the Service Station 1. Wiper Roller. .Lift up the Wiper Roller Assembly. Carefully loosen the two small screws retaining the Wiper Roller Latches. DO NOT remove the screws. Release the two latches holding the Roller. Remove the Roller and wipe with distilled water. Replace the Roller. Make sure the gear on the Roller engages the gear in the Service Station Tray. Carefully close the latches. NOTE: Make sure latches are fully locked and the screws are tightened. 2.
SECTION 6 MAINTENANCE Removing the Wiper Motor Assembly Remove the Service Station (See Maintenance Section if not already removed.) [A] Disconnect the Wiper Module cable from the Service Station Printed Circuit Board. [B] Lift out the Wiper Motor Assembly. [C] Loosen the two small screws retaining the Wiper Roller Latches just enough to release the (2) Latches. DO NOT remove the screws! [D] Remove the Wiper Roller. Install in reverse order.
SECTION 6 MAINTENANCE Replacing Service Station Lifting Arms Replacement Kit includes two Springs, two C-Clips and two Lifting Arms (one each for Operator and NonOperator Side installation.) Service Station must be removed prior to servicing the Lifting Arms (see “Removing the Service Station”). 1. 2. Remove C-Clip. Slide Lifting Arm and Spring from stud. Slip on new Lifting Arm and Spring Assembly. Secure with C-Clip.
SECTION 6 MAINTENANCE Lubricating the Service Station Friction points on the Service Station should be lubricated to ensure optimum performance and reduce wear. This maintenance should be performed when installing a new Service Station, or monthly (after ® printing about 50,000 pieces.) Use a standard silicone or Teflon based grease or lubricant. CAUTION DO NOT USE PETROLEUM-BASED LUBRICANTS OR GREASE.
SECTION 6 MAINTENANCE Lubricate Lifting Arm Pivot Points 1. Apply lubricant to the Lifting Arm Pivot as shown. (1 on each side).
SECTION 6 MAINTENANCE Reinstalling or Replacing the Service Station 1. Carefully unwrap the new Service Station. (Or reuse cleaned Service Station.) NOTE: Loose parts may fall out. Keep Roller side facing up when removing packaging. CAUTION MAKE SURE THE LATCHES ON THE WIPER ROLLER ARE FULLY LOCKED BEFORE INSTALLING THE SERVICE STATION. 2. Slide the Latch open on the Service Station Circuit Board. 3. [1] Plug the Ribbon Connector (blue side up) into the space under the Latch. [2] Close the Latch.
SECTION 6 MAINTENANCE 4. [1] Slide the Service Station into the Service Station port until it touches the bar. [2] Look down through the Top Cover to make sure Service Station is aligned with the bar. IMPORTANT! Service Station must be perfectly aligned with bar to prevent misalignment and operating problems. 5. GENTLY push the Service Station while turning the large Gear on right side of Print Engine clockwise. Gear should engage gear on Service Station Roller and pull it in.
SECTION 6 MAINTENANCE Replacing the Ink Waste Tray The Ink Tray soaks up any excess ink that may drip from the Print Engine during operation. After a period of time it may become saturated and need replacement. 1. Open Ink Tank Door. 2. Push in on the Tabs to release the Ink Waste Tray and remove it from unit. 3. Replace with a new Ink Waste Tray. Replacing the Sheet Separators The Sheet Separators insure separation of the pieces as they are being fed.
SECTION 6 MAINTENANCE Cleaning WARNING THE PRINTER IS A PRECISION MACHINE THAT SHOULD BE CLEANED REGULARLY TO INSURE MANY YEARS OF SERVICE. BEFORE PERFORMING ANY MAINTENANCE, DISCONNECT THE MACHINE FROM ITS POWER SOURCE! DO NOT REMOVE SIDE COVERS! HIGH VOLTAGES PRESENT. Clean the Printer regularly to remove accumulated paper dust and ink. Depending on the types of media that are run, paper dust may accumulate inside the Printer and on the Transport. 1.
SECTION 6 MAINTENANCE Print Engine Areas in the Print Engine can become glazed with a buildup of dust, paper lint and accumulated ink and have to be cleaned regularly. Open the Top Cover and release the two latches on the Printhead Assembly. NOTE: Be careful around Ink Tray and Capping Station in the Print Engine area as accumulated ink may splash onto other parts of the Printer. Take care not to damage the PC Boards or electrical wiring.
APPENDICES Appendix A – Colordyne 1600-S Specifications PRINT RESOLUTION SPEED (color or mono) MEDIA SIZE PRINT AREA Best: 1600 x 1600 DPI Normal: 1600 x 800 DPI Up to 3600 letter size pages or 9000 envelopes per hour Minimum: 3" x 4.2" (76 mm x 107 mm) Maximum: 9.5" x 17" (241 mm x 431 mm) 8.5" x 17" (215 mm x 431 mm) INK Minimum: 0.004" (0.102 mm) Maximum: 0.020" (0.5 mm) Water-based ink.
APPENDICES Appendix C – Z4 Wiring Diagram 90
APPENDICES 91
INDEX INDEX A Adjustment, Printer Drive Belt Tension Antistatic Brush Assembly Assembling Printer H 35 45 3 Hydrating Printhead Cartridge Indicators, Control Panel Ink Revolvers Ink Station Door Ink Tank Latches Ink Tanks Disposal Installing Remove/Replace Storage Ink Usage, Toolbox Ink Waste Tray Inner Side Frame, Left-hand Installing Ink Tanks Printer Driver Printhead Service Station B Buffer Boxes, Replacing 57 C Clamshell Assembly Cleaning Capping Station Seal & Squeegee Grit Rollers Media Sensors
Print Engine Base, Removing Basic Disassembly Buffer Boxes Clamshell Assembly Cleaning DPCA Board Dual Pinch Valve Assembly Encoder/Encoder Sensor Exit Sensor Gear Pulleys, Belt Drive Ink Revolvers Label Web Sensor Lifter Motor/Gear Assembly Main PC Assembly Paper Path Motor/Drive Belt Pen Driver PC Assembly Peristaltic Pump QA Chip Assembly Remove/Replace Starwheel Assembly Stepper Motor Printer Assembly Basic Disassembly Cleaning Clutch Connection Controls Delivery Rollers Disassembly Procedures Drive Bel
INDEX Separator Tips Service Station Service Station Lifting Arms Service Station Sled PC Boards Service Station Transport Tab Sheet Separators Side Fan Starwheel Assembly Stepper Motor Top Cover Wiper Motor Assembly Wiper Motor Flex Cable PCA Wiper Roller 36 77, 84 81 67 3 86 47 58 64 45 80 67 79 Setup Network Configuration Printer Sheet Separators Side Fan Starwheel Assemblies Stepper Motor Storage, Ink Tanks Supplies System Requirements, Minimum T Top Cover Troubleshooting Feeding Problems Interface C
Copyright © 2012 COLORDYNE TECHNOLOGIES LLC 02/15/2012 Part Number: 300-CDT1600-S REV.
