Neopost RENA MACH 5 User manual

MACH 5, AS-950C, HJ950C
DIGITAL COLOR PRINTER
SERVICE GUIDE
Rev 7-8-11

TABLE OF CONTENTS
Table of Contents
SECTION 1 – GETTING ACQUAINTED ................................................................................................ 6
SAFETY PRECAUTIONS......................................................................................................................... 6
FRONT VIEW ............................................................................................................................................... 7
REAR VIEW ................................................................................................................................................. 8
PRINT ENGINE AREA ................................................................................................................................... 9
BEHIND THE INK TANK DOOR ................................................................................................................... 10
ACCESSORY BOX CONTENTS..................................................................................................................... 11
CONTROL PANEL FUNCTIONS.................................................................................................................... 12
Printer Status Light Indicators............................................................................................................. 13
RECOMMENDED TROUBLESHOOTING SUPPLIES......................................................................................... 16
COMMON SERVICE TOOLS NEEDED:.......................................................................................................... 16
MINIMUM COMPUTER SYSTEM REQUIREMENTS........................................................................................ 16
PREPARING THE PRINTER FOR SERVICE..................................................................................................... 17
INSTALLATION AND SERVICE VIDEOS (WHERE TO FIND) ........................................................................... 17
SECTION 2 – INSTALLING THE SERVICE STATION, INK TANKS AND PRINTHEAD........... 18
TOOLS NEEDED FOR INSTALLATION.......................................................................................................... 18
CHOOSING THE LOCATION ........................................................................................................................ 18
Work-Table Surface Must be Level....................................................................................................... 18
INSTALLING THE SERVICE STATION .......................................................................................................... 19
INSTALL THE INK TANKS........................................................................................................................... 23
Ink Tank Anatomy................................................................................................................................. 23
Procedure (Installing the Ink Tanks):................................................................................................... 24
INSTALLING THE PRINTHEAD CARTRIDGE................................................................................................. 26
Printhead Cartridge Protective Packaging.......................................................................................... 26
Procedure (Installing the Printhead): .................................................................................................. 27
SECTION 3 – TROUBLESHOOTING...................................................................................................... 31
PRINT QUALITY ISSUES:............................................................................................................................ 31
Examples of Print Quality Issues (including possible causes and solutions)....................................... 32
THE PRINTHEAD CARTRIDGE .................................................................................................................... 35
THE PRINTER............................................................................................................................................. 36
Dots or Lines Printed on Media........................................................................................................... 36
Power Problems ................................................................................................................................... 37
Service Station Problems...................................................................................................................... 37
Interface Communication Problems..................................................................................................... 38
Feeding Problems................................................................................................................................. 39
ERROR’S AND WARNINGS ......................................................................................................................... 41
Alert Window Messages........................................................................................................................ 41
Toolbox System Status Messages.......................................................................................................... 42
CLEARING MEDIA JAMS ............................................................................................................................ 44
HOW TO CLEAR A TILT ERROR.................................................................................................................. 45
SECTION 4 – PRINTER DRIVER AND TOOLBOX FEATURES......................................................... 46
PRINTER DRIVER PROPERTIES................................................................................................................... 46
General Tab.......................................................................................................................................... 46
Layout Tab............................................................................................................................................ 47
Media Tab............................................................................................................................................. 48
Services Tab ......................................................................................................................................... 49
TOOLBOX UTILITY (M SERIES TOOLBOX)................................................................................................. 50
2

TABLE OF CONTENTS
To open the Toolbox:............................................................................................................................ 50
User Interface Screen........................................................................................................................... 51
Ink Usage Screen.................................................................................................................................. 52
Diagnostics Screen............................................................................................................................... 52
Service Menus....................................................................................................................................... 53
SECTION 5 – MEASUREMENTS AND ADJUSTMENTS..................................................................... 57
DRIVE BELT TENSION ............................................................................................................................... 57
POWER SUPPLY ......................................................................................................................................... 58
MEDIA SENSORS........................................................................................................................................ 59
Feed Sensor.......................................................................................................................................... 59
Print Engine Sensors............................................................................................................................ 60
FEED ENCODER SENSOR AND ENCODER WHEEL ....................................................................................... 61
PRINT ENGINE OPEN SWITCH .................................................................................................................... 62
DUST EXHAUST FANS................................................................................................................................62
CLUTCH (FEED ROLLER DRIVE)................................................................................................................ 63
INTERFACE BOARD TEST POINTS .............................................................................................................. 64
SECTION 6 – DISASSEMBLY/ASSEMBLY PROCEDURES............................................................. 65
REPLACING THE SHEET SEPARATORS (SEPARATION TIPS) ........................................................................ 65
REMOVING THE ANTISTATIC BRUSH ASSEMBLY....................................................................................... 66
Conductive Brush Replacement: On the bottom of the Antistatic Brush Assembly you will find a
conductive brush (42-103-49). When this brush becomes worn (bristles shortened or lost) it can be
replaced. It is held in place using three screws.................................................................................... 66
REMOVING COVERS AND IDENTIFYING COMPONENTS BEHIND COVERS ................................................... 67
Operator Side Covers (removal) .......................................................................................................... 67
Identifying Components behind the Operator Side Covers .................................................................. 67
Non-operator Side Cover (removal)..................................................................................................... 68
Identifying Components behind the Non-Operator Side Cover............................................................ 68
Ink Tank Door (removal)...................................................................................................................... 69
Entrance Side Panel (removal)............................................................................................................. 69
Identifying Components behind the Entrance Side Panel..................................................................... 69
Exit Roller Cover (removal)................................................................................................................. 70
Top Cover (removal) ............................................................................................................................ 70
REPLACING MOTOR DRIVE BELT OR MOTOR ............................................................................................ 71
REPLACING THE CLUTCH........................................................................................................................... 71
REPLACING FEED ROLLERS AND FORWARDING ROLLERS......................................................................... 73
REPLACING DELIVERY ROLLERS............................................................................................................... 76
REPLACING THE PRINT ENGINE................................................................................................................. 78
REPLACING THE INTERFACE BOARD.......................................................................................................... 81
REPLACING THE PRINTHEAD LATCH ......................................................................................................... 81
REPLACING THE SERVICE STATION LIFTING ARMS ................................................................................... 82
SECTION 7 - MAINTENANCE ................................................................................................................ 84
REPLACING THE INK TANKS...................................................................................................................... 84
PRINTHEAD CARTRIDGE STORAGE AND HANDLING .................................................................................. 86
CLEANING THE PRINTHEAD CARTRIDGE ................................................................................................... 86
From the M Series Driver: ................................................................................................................... 86
From the Toolbox:................................................................................................................................ 86
Using the Clean Printhead Button: ...................................................................................................... 87
Manually Cleaning the Printhead (customer procedure)..................................................................... 87
Manually Cleaning the Printhead (technician’s procedure)................................................................ 88
Printhead Cartridge Conditioning ....................................................................................................... 88
Still Experiencing Print Quality Issues?............................................................................................... 89
REPLACING THE PRINTHEAD CARTRIDGE.................................................................................................. 89
CLEANING/REPLACING THE SERVICE STATION ......................................................................................... 91
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TABLE OF CONTENTS
Removing the Service Station ............................................................................................................... 91
Cleaning the Service Station................................................................................................................. 92
Replacing damaged/worn items in the Service Station......................................................................... 93
Reinstalling or Replacing the Service Station ...................................................................................... 93
INSPECTING/REPLACING THE INK WASTE TRAY........................................................................................ 94
CLEANING PRINTER BODY ........................................................................................................................ 95
CLEANING FEED ROLLERS AND FORWARDING ROLLERS........................................................................... 95
FIRMWARE DOWNLOAD PROCEDURE ........................................................................................................ 96
APPENDIX A – SPECIFICATIONS........................................................................................................ 97
APPENDIX B – SUPPLIES AND OPTIONAL HARDWARE................................................................. 98
APPENDIX C – PREPARING PRINTER FOR TRANSPORT............................................................ 99
LOCAL RELOCATION.................................................................................................................................. 99
REMOTE RELOCATION OR SHIPPING........................................................................................................... 99
APPENDIX D – WIRING DIAGRAM..................................................................................................... 101
4

TABLE OF CONTENTS
NOTES
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5

SECTION 1
GETTING ACQUAINTED
Section 1 – Getting Acquainted
SAFETY PRECAUTIONS
THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY. HOWEVER,
CERTAIN SAFETY RULES SHOULD BE OBSERVED WHEN OPERATING THE DIGITAL
COLOR PRINTER.
BEFORE USING THE PRINTER, YOU SHOULD READ THIS MANUAL CAREFULLY
AND FOLLOW THE RECOMMENDED PROCEDURES, SAFETY WARNINGS, AND
INSTRUCTIONS:
9Keep hands, hair, and clothing clear of rollers and other moving parts.
9Avoid touching moving parts or materials while the machine is in use. Before clearing a jam, be sure
machine mechanisms come to a stop.
9Always turn off the machine before making adjustments, cleaning the machine, or performing any
maintenance covered in this manual.
9The power cord, supplied with the machine, should be plugged into a properly grounded wall outlet
located near the machine and easily accessible. Failure to properly ground the machine can result in
severe personal injury and/or fire.
9The power cord and wall plug is the primary means of disconnecting the machine from the power
supply.
9DO NOT use an adapter plug on the line cord or wall outlet.
9DO NOT remove the ground pin from the line cord.
9DO NOT route the power cord over sharp edges or trap between furniture.
9Avoid using wall outlets that are controlled by wall switches or shared with other equipment.
9Make sure there is no strain on the power cord caused by jamming between the equipment, walls or
furniture.
9DO NOT remove covers. Covers enclose hazardous parts that should only be accessed by a qualified
service representative. Report any damage of covers to your service representative.
9This machine requires periodic maintenance. Contact your authorized service representative for
required service schedules.
9To prevent overheating, do not cover the vent openings.
9Use this equipment only for its intended purpose.
In addition, follow any specific occupational safety and health standards for your workplace or area.
This manual is intended solely for the use and information of Neopost USA, its designated agents, and their
employees. The information in this guide was obtained from several different sources that are deemed
reliable by all industry standards. To the best of our knowledge, that information is accurate in all respects.
However, neither Neopost USA nor any of its agents or employees shall be responsible for any inaccuracies
contained herein.
MemjetTM is a registered trademark of Memjet Labels, Inc.
All other trademarks are the property of their respective holders.
All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical,
including photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher
6

SECTION 1
GETTING ACQUAINTED
Front View
1. Exit Roller Cover – This cover plate must be removed to install the Service Station.
2. Control Panel – Provides printer controls. See “Control Panel Functions” section.
3. Side Guide Locking Knob – Used to secure the position of the side guide.
4. Rear Media Support Guide – Provides the proper angle to enhance paper feeding and
separation.
5. Media Support Wedge – Allows for adjustments in stack angle, based on media type and
length. Helps to force the media against the separation area. Narrow and wide wedges are
provided with the printer, to accommodate different media widths.
6. Adjustable Media Side Guide – Adjusts to hold the media against the Media Registration Side
Guide.
7. Media Registration Side Guide– All media is registered against this guide. It has two positions.
Inner position for media measuring 3” to 8.5” in width.
Outer position for media measuring 8.6” to 9.5” in width.
8. Sheet Separator Locking Screws – These thumb screws (four total) are used to secure the
positions of the four sheet separators.
9. Top Cover – Provides access to the Print Engine.
10. Ink Tank Door – Hinged door provides access to the Ink Tanks and Ink Waste Tray.
7

SECTION 1
GETTING ACQUAINTED
Rear View
1.
Main Power Switch, Receptacle and Fuse – Plug in AC power cord here. Switch turns main
power on or off. Fuse provides over-current protection. Fuse rating: 2.5A, 250V, slow blow.
CAUTION: Make sure power cord is disconnected from printer before checking/replacing fuse.
WARNING: Press the ON/OFF Button, located on control panel, to properly shut-down the print
engine. Wait until all control panel lights turn off, before you turn off the main power switch.
Tip: Starting with S/N 100027598; to power-up the print engine you must press the control
panel’s ON/OFF button after turning ON the Main Power Switch. In earlier units, the print
engine would automatically power-up after turning on the main power switch.
2. USB Port Connection – (USB 2.0) The USB cable attaches to the printer here.
3. Network Connection – (Ethernet) The network cable plugs in here.
4. Sheet Separators – Used to separate a single piece of media from the stack. There are four sheet
separators on this printer.
5. Feed Rollers – Delivers the bottom piece of media, from the stack, through the separation area
and under the forwarding rollers. There are eight feed rollers on this printer.
6. Media Support Wedge Thumb Screw – Used to secure the Media Support Wedge to the Rear
Media Support Guide.
7. Counter – LCD displays number of pieces run for a given job. Reset button zeros counter.
8. Rear Media Support Guide Knob – Attaches the Rear Media Support Guide to the printer body.
8

SECTION 1
GETTING ACQUAINTED
Print Engine Area 2
1
5
3
46
7
Print Engine with printhead cartridge
installed and printhead latch closed.
1. Antistatic Brush Assembly – This assembly contains a conductive brush that is used to help
reduce static energy and remove paper dust from the media. This assembly also contains upper
pressure rollers and fingers that help guide the paper into the print engine.
2.
Printhead Latch – When lowered and locked this device connects the Ink Couplings with the
Printhead Cartridge. Note: The printhead latch on your printer may be blue or black.
WARNING! Never attempt to open the printhead latch manually, when in the closed/locked
position. Sever damage will result. Use the Printhead Release function from the Toolbox utility on
your PC or press the Printhead Latch Release button if a computer is not available.
3. Clean Printhead Button – The button located below this opening can be used to enable a “Level 1
Cleaning” cycle. Insert a non-conductive tool (i.e. plastic pen) into the opening provided, and
lightly press the button.
Additional levels of cleaning can be enabled from the M Series Driver services.
4. Ink Couplings – These devices connect the ink tubes to the printhead cartridge. The printhead
latch is used to engage or disengage these devices from the printhead cartridge.
5. Printhead Latch Release Button – The button, located below this opening, can be used to initiate
the printhead latch release cycle. Insert a non-conductive tool (i.e. plastic pen) and lightly press the
button. If the system is primed it will run a deprime cycle before releasing the latch. This feature
can also be initiated from the Toolbox utility and M Series Driver services.
6.
Print Engine Latches – Lift up on both latches, at the same time, to release and swing open the
top section of the Print Engine.
CAUTION! Do NOT open the Print Engine while the printer is operating.
Make sure the Print Engine is closed and locked before operating.
Do NOT open the Print Engine to an angle greater than 60º.
7. Printhead Cartridge – Memjet® printhead; produces an 8.5” wide, full color, print area.
9

SECTION 1
GETTING ACQUAINTED
Behind the Ink Tank Door
1
23
1. Ink Tank Securing Latches – Used to hold the Ink Tanks in the slots.
NOTE: Please be sure that both sides, at the bottom part of the latch, are engaged.
2. Ink Tanks – Five Ink Tanks are used in the printer.
Cyan (C), Yellow (Y), Magenta (M), Black (K), Black (K)
3. Ink Waste Tray –The purpose of this tray is to catch any waste ink produced by the system. This
tray is filled with absorbent material.
The tabs located at the left and right sides of the tray; secure the tray to the print engine frame.
Please be sure the tabs “click” into the frame to secure the tray’s position.
10

SECTION 1
GETTING ACQUAINTED
Accessory Box ContentsAccessory Box Contents
AB C
DE
F
GH
IJ KK
The following items are included with your printer:The following items are included with your printer:
Items contained in the Accessories Box
QtyQty [Image Reference] Description
5 [A] Ink Tanks
- Cyan, Magenta, Yellow, Black, Black
1 [B] Printhead Cartridge and packaging
1 [C] Rear Media Support Guide
- thumb screw attached to printer
1 [D] Service Station
1 [E] Wide Media Support Wedge
- mounting hardware attached to item C
1 [F] Narrow Media Support Wedge
- mounting hardware attached to item C
1 [G] Media Registration Side Guide
- mounting screws attached to printer
1 [H] Adjustable Media Side Guide
- mounting screws attached to printer
1 [I] USB Cable
1 [J] Power Cord
1 [K] Operation CD
- contains printer software and pdf manual
Note: Ink Tanks and Printhead Cartridges can be purchased through your local Dealer.
11

SECTION 1
GETTING ACQUAINTED
Control Panel Functions
BUTTON FUNCTION(s)
ON/OFF
Press to power-up or power-down the print engine.
Note: The Main Power Switch must be ON, to power-up the print engine.
Powering-up: It takes approximately 45 seconds for the print engine to power-up;
after pressing this button. The ON/OFF button will illuminate when the print
engine is powered-up.
Tip: Starting with S/N 100027598; to power-up the print engine you must press the
control panel’s ON/OFF button after turning ON the Main Power Switch. In earlier
units, the print engine would automatically power-up after turning on the main
power switch.
Powering-down: Before turning off the printer, using the Main Power Switch;
please be sure to power-down the print engine using this button. When the print
engine has completed its power-down cycle, all lights in the control panel will turn
off. It is now safe to turn off the Main Power Switch.
Tip: To reduce print quality issues; the print engine should remain powered-on.
Even in its standby state, the printer will run routine maintenance cycles to help
keep the printhead nozzles hydrated and clean.
WARNING! If this power-down process is not followed; ink color mixing and
printhead nozzle clogging may result.
PAPER/RESUME
PAPER (Paper Feed Test): Before sending data to the printer; you can perform a
paper feed test by pressing and holding this button for 4 seconds. The printer will
feed a single page.
RESUME: If an “out of paper” condition is detected; reload media and press this
button to resume printing.
If the printer was paused using the PAUSE/CANCEL button, press this button to
resume printing.
PAUSE/CANCEL
PAUSE: If you are in the process of printing and you want to pause the print job,
press this button once.
If the printer was paused, using the PAUSE/CANCEL button, press the RESUME
button to resume printing.
CANCEL: If you want to cancel a paused print job, press this button again. The
print job will be cleared from the printer. You must manually clear job from
computer’s print queue.
Please see “Printer Status Light Indicators”, for additional information.
12

SECTION 1
GETTING ACQUAINTED
13
Please see the “Status Light Indicator Chart” on the following pages.
Printer Status Light Indicators
The lights on the three buttons, shown below, indicate the status of the printer.
LEGEND (For the Status Light Indicator chart on the next page.):
Description POWER PAPER
RESUME PAUSE CANCEL
Simultaneous Flash (once per second) /{/{
Simultaneous Fast Flash (twice per second) /{fast /{fast
Alternating Flash (once per second) /{{/
Alternating Fast Flash (twice per second) /{fast {/fast
Power Down Cycle /{{/{/
Sequential Flash, Right to Left (R2L) {//{R2L {//R2L
Power-down Sequence {//{{//{//
Description
ON steady or 
OFF steady {or {
Flashing (once per second) /{or /{
Fast Flash (twice per second) /{fast or /{fast

SECTION 1
GETTING ACQUAINTED
Printer Status Light Indicator Chart (see legend on previous page)
ON/OFF PAPER
RESUME PAUSE CANCEL Feeding Printer Status
corresponding Toolbox message Possible Solution
{{{No Print engine is powered-OFF In this condition, it is safe to turn the Main Power Switch OFF or ON.
{{No Print engine is powered-ON and ready Printer is Ready
{//{{//{//No Print engine powering-down Wait until all lights go out before turning OFF the Main Power Switch.
{/{No Job loading, processing Wait
/{/{No Busy: Cleaning, circulating ink, etc.. Wait
Yes Printing Press PAUSE, to pause printing.
/{{/No Paper time-out (out of paper), other Errors
Toolbox =
PAPERPATH_FEED_TIMEOUT
Press RESUME, to resume printing.
Press the CANCEL button to clear the error or cancel a paused job. If
job was canceled; manually clear job from the computer’s print queue.
Errors can also be cleared using Toolbox Interface.
/{fast {No Tilt Error
Toolbox = TILT_ERROR
Verify that table is level (front to back and left to right).
If just powered on, wait a few minutes; tilt readings may settle
into normal range. Then error can be cleared using CANCEL
button or by using the “Clear Error” feature in the Toolbox.
Check table to be sure it is level and possibly use Toolbox
“Printer Maint Config” feature (located under Service Menu) to
Zero Tilt Sensor.
If problem persists tech can temporarily disable tilt sensor
using “Printing Control Config” features in Service Menus.
{No Ink Tank(s) Empty
Toolbox = INK_OUT_... Replaced empty Ink Tank(s).
Verify that Ink Tanks are seated firmly and latches are fully closed.
Clear error by cycling print engine power, using ON/OFF button.
Please see the “Toolbox System Status Messages” section for more details on Toolbox messages.
14

SECTION 1
GETTING ACQUAINTED
15
Printer Status Light Indicator Chart (continued)
ON/OFF PAPER
RESUME PAUSE CANCEL Feeding Printer Status
corresponding Toolbox message Possible Solution
Printhead Missing
Toolbox = PRINTHEAD_MISSING
Printhead Not Primed
Toolbox = PRINTHEAD_UNPRIMED
Replace missing Printhead.
Remove Printhead Cartridge, wet print nozzles using deionized or
distilled water and re-install printhead cartridge. If you continue to
have trouble; check for kinked or pinched ink color tubes.
Ink Tank(s) Missing
Toolbox = CARTRIDGE_MISSING_...
or INK_TANK_MISSING_...
Insert missing Ink Tank.
Verify that Ink Tanks are seated firmly.
Clear error by cycling print engine power, using ON/OFF button.
/{fast /{fast No
Printing Paused (PAUSE button pressed)
Toolbox = DATA_PATH_UNDERRUN Press the RESUME button to continue printing.
Press the CANCEL button to cancel the job, and then manually clear
the job from the computer’s print queue.
Paper Jam
Printer has detected that one of the media
sensors is blocked (interrupted).
Toolbox =
PAPERPATH_PRINTZONE_BLOCKED
or
PAPERPATH_PAPERJAM
Paperpath: Entry : Yes Exit: Yes
or
Paperpath: Entry : No Exit: Yes
or
Paperpath: Entry : Yes Exit: No
Clear the paper path of media and close the print engine.
The System Status message in red should go away.
The toolbox “Paperpath” line should change to
Paperpath: Entry: No Exit: No
No = not blocked (not interrupted), Yes = blocked (interrupted)
After you clear the jam you can;
Press the RESUME button to continue printing.
Press the CANCEL button to cancel the job, and then manually clear
job from the computer’s print queue.
/{fast {/fast No
Clearing Error or Canceling Job This sequence will occur momentarily; after pressing the CANCEL
button on the printer, or Clear Error button in the Toolbox.
{//{R2L {//R2L No Error – Open Toolbox to View Open Toolbox to view error.
Press CANCEL to clear error or clear error using Toolbox Interface.
Please see the “Toolbox System Status Messages” section for more details on Toolbox messages.

SECTION 1
GETTING ACQUAINTED
Recommended Troubleshooting Supplies
Items that a Technician should have available to them, when they visit a “Digital Color Printer” customer
(in addition to standard tools):
•A box or ream of “inkjet suitable” media.
•Known good set of Ink Tanks (Cyan M5C250-N, Magenta M5M250-N, Yellow M5Y250-N, Black
M5K250-N, Black M5K250-N);
•Known good Printhead Cartridge (M5PRINT-N)
•Lint-free cloths
•Distilled or Deionized water
•Computer (Win XP, Vista, Win 7, with USB 2.0 port) and USB cable. It would be best if the computer
system has been previously interfaced and tested with AS-950C. That way they should have
documents or jobs already setup to test with printer, drivers loaded, toolbox loaded.
•Operations CD (contains printer software, drivers, operators guide, etc...)
•Service Manual
•Parts Manual; when available.
•Access to internet.
Note: Part numbers, shown above (with “-N”), are for Neopost.
Remove “-N” for Rena Systems. Add “-H” for Hasler.
Common Service Tools Needed:
This list is in addition to standard tools.
•Spring Hook
•Needle Nosed Pliers
•Side Cutters
•Voltage Meter
•SAE set of alan wrenches
•#1 and #2 Philips Screwdriver
•T-10 Torx driver
•Carpenters Level (18” or longer)
Minimum Computer System Requirements
•Windows XP, Windows Vista, Windows 7. Supports 32 and 64 bit systems.
You must have administrative privileges on the system.
•Pentium II, 2 GHz minimum (Pentium Dual Core, 2.5 GHz or better, is optimal)
•System memory – 2 GB minimum; or as recommended for your operating system.
•At least 10 GB free hard-disk space.
•Microsoft Internet Explorer 6.0 or higher.
•Java version 6 or higher
•CD/DVD drive
•USB 2.0 port
16

SECTION 1
GETTING ACQUAINTED
Preparing the Printer for Service
Whenever the printer needs to be tilted, for servicing, you must follow the procedure, as outlined below,
before performing these tasks.
NOTE:. We suggest the use of protective gloves during this process.
Please complete the following to prepare the printer for service.
1. Plug in the printer. Turn the printer’s Main Power Switch ON; then press the control panel’s ON/OFF
button. Wait about 45 seconds for the print engine to power-up (ON/OFF button will illuminate).
2. Open the Toolbox utility.
3. Deprime system using the “System Deprime” feature located in Toolbox utility.
NOTE: Use the System Deprime feature, NOT the Release Printhead feature.
4. Remove the Service Station from the printer, using the “Eject Service Station” feature in the Toolbox
utility. Refer to “Installing the Service Station”, located in the Operator’s Guide, for help with this
process. Follow the sequence in reverse.
5. Wrap the Service Station in paper towels and place into resealable bag.
6. Power-down the system using the ON/OFF button and wait until all lights are off.
7. Turn off the Main Power Switch. Then disconnect the power cable from the printer and wall outlet.
IMPORTANT! Do NOT switch off the power at the power outlet or remove the power cable until all
lights are off. Failure to do so may damage your printer.
8. Disconnect the USB or Ethernet cable from your printer
9. Remove the Printhead Cartridge and install protective covers on printhead. Store Printhead Cartridge
in a sealed plastic bag with a damp cloth. Be careful to avoid spills or stains during this process.
CAUTION: Make sure contacts are dry before re-installing printhead.
10. Remove all five Ink Tanks. Be careful to avoid spills or stains during this process. Wrap each ink tank
in a clean, lint-free, absorbent material and place them in a sealed plastic bag as a precaution against
any spillages during transport.
11. Place paper towels into each Ink Tank slot, making sure the towels make contact with the back of the
slots. This is done to absorb any ink that may leak from septum needles.
NOTE: Even though the system is deprimed, some ink will remain in the lower areas of the tubing. In
transit, this residual ink may drain out.
12. Keep the printer as level as possible during service.
CAUTION! During the service process the printer should remain semi-level at all times. Failure to do
so may cause the printer to leak ink.
13. When you have finished servicing the printer; please refer to Section 2 of the Operator’s Guide for
details on how to properly install the Service Station, Printhead Cartridge, Ink Tanks, etc. Remember
the printhead cartridge “nozzle surface” needs to be wetted using distilled water and a lint free cloth or
the priming process may fail.
Installation and Service Videos (where to find)
Installation and Service Videos are also available for this product.
Neopost/Hasler Technicians: Please see the Knowledgebase or NeoU for Installation and Service Videos.
Rena Systems Technicians: Please see the Rena Dealer Net area for Installation and Service Videos.
17

SECTION 2
INSTALLING THE SERVICE STATION, INK TANKS AND PRINTHEAD
Section 2 – Installing the Service Station, Ink
Tanks and Printhead
Please refer to the “Operator’s Guide” for complete Installation and Operation instructions.
Tools Needed for Installation
•Knife and scissors to open packaging
•#2 Philips head Screwdriver
•Carpenters Level (recommend using 18” or longer level)
•Protective gloves should be worn to avoid getting ink on hands when removing protective packaging
materials from the ink coupling areas, the Ink Tank areas, and when installing/removing Printhead
Cartridge and Ink Tanks.
Choosing the Location
The Digital Color Printer should be placed on a sturdy, level, worktable or cabinet at least 9 inches
from any walls. Protect the Digital Color Printer from excessive heat, dust, and moisture – avoid
placing it in direct sunlight.
Work-Table Surface Must be Level
The surface that the printer is placed upon must be level, front to back and side to side. Use a
carpenter’s level to verify that the surface is level. If the surface is not level the printer will not perform
properly. Do NOT move the printer while the power is on.
Operation should take place under the following conditions:
- At temperatures between +15°C and +35°C (59 °F to 95 °F).
- At a relative air humidity between 20% and 80%, non-condensing.
- At an atmospheric pressure between 70 kPa and 105 kPa.
Exposure to conditions that are not permissible may lead to damage which is not externally visible.
Allow the printer, printhead and ink tanks to acclimate to ambient temperature before using the printer
18

SECTION 1
GETTING ACQUAINTED
Installing the Service Station
Due to the technical nature of this procedure; this process should only be performed by a qualified technical
support person. This process is normally performed when the printer is first installed or when technical
maintenance is needed on the printer.
CAUTION
THIS PROCESS MUST BE PERFORMED BY A
QUALIFIED TECHNICAL SUPPORT PERSON.
The Service Station fits in the slot immediately above the Ink Tank slots.
The Service Station contains three separate areas/devices that are used to perform the following tasks.
•Cleaning. The wiper roller cleans the Printhead nozzles of excess ink and debris.
•Printing/Purging. This area acts as a base to support media during printing. It also contains a purging
area; which captures and absorbs ink that is purged, to help keep nozzles clear.
•Capping. This area seals and protects the printhead nozzles when not in use.
PROCEDURE:
1. Make sure the printer is powered OFF.
If the printer is not powered off, press the ON/OFF button once and wait about 45 seconds for the print
engine to power off (all control panel light’s off). Then turn the Main Power Switch OFF.
2. Open the Ink Tank Door (hinged at bottom).
3. Open the Top Cover.
4. Remove the Exit Roller Cover by removing the four (4) screws.
The Service Station Slot and Ribbon Cable will be exposed.
Service Station
Slot
Ink Tank
Door
Ribbon
Cable
19

SECTION 2
INSTALLING THE SERVICE STATION, INK TANKS AND PRINTHEAD
5. Carefully remove the Service Station from its packaging.
NOTE: Loose parts may fall out. Keep wiper roller side facing up, when removing the packaging.
CAUTION!
Make sure latches on the Wiper Roller are fully latched before installing the Service Station.
Check the latch at each end of
the wiper roller.
6. Slide the Cable Securing Latch open on the Service Station Circuit Board; as shown below.
OpenedClosed
7. Insert the Ribbon Cable (blue side up) into the space under the Cable Securing Latch [1].
Make sure the ribbon cable is pushed in all the way and is NOT crooked. Then close the Cable
Securing Latch [2].
21 CloseOpen
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