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Colordyne 1600-S Service Manual

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Colordyne 1600-S
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Summary of Contents for Colordyne 1600-S

  • Page 1 Colordyne 1600-S COLOR PAGE PRINTER SERVICE MANUAL...

  • Page 2: Safety Precautions

    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 Colordyne Technologies, LLC, its designated agents, customers, and their employees. The information in this guide was obtained from several different sources that are deemed reliable by all industry standards.

  • Page 3: Table Of Contents

    Interface Communication Problems Feeding Problems The Memjet Printhead The Service Station Printing Problems Software Problems Jams in the Colordyne 1600-S Printer SECTION 3 – Functional Operation Sequence of Operation Printer Controls Control Panel Button/LED Indicators Printer Driver Properties General Tab...
  • Page 4 Print Engine Grit Rollers Media Sensors Capping Station and Squeegee Error! Bookmark not defined. Printing Platen Error! Bookmark not defined. Appendices Appendix A – Colordyne 1600-S Specifications Appendix B – Supplies and Optional Hardware Appendix C – Z4 Wiring Diagram Index...
  • Page 5 TABLE OF CONTENTS NOTES ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________...

  • Page 7: Section 1 - Installation

    SECTION 1 INSTALLATION SECTION 1 – Installation Contents of Packaging COLORDYNE 1600-S Printer Ink Tanks – Cyan, Magenta, Yellow, Black, Black Printhead Cartridge Media Side Guides: Registration (Fixed) and Adjustable – mounting screws attached to Printer Rear Media Support Guide –...

  • Page 8: Hydrating The Printhead Cartridge

    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. ...

  • Page 9: Removing Service Station Transport Tab

    SECTION 1 INSTALLATION Removing Service Station Transport Tab Open the Top Cover. 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...
  • Page 10 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.

  • Page 11: Connecting The Colordyne 1600-S

    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.

  • Page 12: Install The Printer Driver

    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. ...
  • Page 13 SECTION 1 INSTALLATION After a few moments the “Printer Connections” window opens. Click “Configure to print using USB”. Then click Next>. 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.
  • Page 14 SECTION 1 INSTALLATION 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>. 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.

  • Page 15: Install The Ink Tanks

    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: Open the Toolbox. Go to All Programs, open the Printer Folder and open the Toolbox.

  • Page 16: Install The Printhead Cartridge

    SECTION 1 INSTALLATION 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. Lock the three Latches. Close the Front Cover. WARNING The ink in the Ink Tanks may be harmful if swallowed.
  • Page 17 SECTION 1 INSTALLATION 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.
  • Page 18 SECTION 1 INSTALLATION 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.
  • Page 19 SECTION 1 INSTALLATION 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. When the Printer stops processing and all the fields in System Status are black, the Printer is ready for use.

  • Page 20: Section 2 - Troubleshooting

    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 SOLUTION Power is ON, nothing happens. No power to Printer. Check that the power cord is plugged in.

  • Page 21: Feeding Problems

    SECTION 2 TROUBLESHOOTING Feeding Problems CONDITION PROBLEM SOLUTION Intermittent feeding Feed Ramp not used. The Feed Ramp adds a slope to the stack and helps feeding. Loosen the Side Guides slightly. Side Guides set improperly. Clean the Feed Roller with distilled water Dirty Feed Rollers.

  • Page 22: The Memjet Printhead

    SECTION 2 TROUBLESHOOTING The Memjet Printhead CONDITION PROBLEM SOLUTION Missing parts of letters or Air and bubbles blocking nozzles. Clean the Printhead using text. Printhead is dry. recirculation, priming or cycles of depriming and priming found in the Maintenance section of the Driver.

  • Page 23: The Service Station

    SECTION 2 TROUBLESHOOTING The Service Station CONDITION PROBLEM SOLUTION  Check each of the Motor stalls Jammed gear train due to possible causes and broken post or improperly correct if possible: seated gears.  reseat the gears and/or Squeegee blade wedged, not squeegee, clean debris seated properly.

  • Page 24: Printing Problems

    SECTION 2 TROUBLESHOOTING Printing Problems CONDITION PROBLEM SOLUTION Extra lines; losing data Database problem. Check data in database program. Improper output (address Wrong interface settings. Check software or database information out of order, miss- on PC. feeding, etc.) Close the software and then Static electricity.

  • Page 25: Jams In The Colordyne 1600-S Printer

    Damaged media, such as dog-eared (turned down corners). 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. Envelopes caught under the flap of another envelope or stick to one another.

  • Page 26: Section 3 - Functional Operation

    SECTION 3 FUNCTIONAL OPERATION SECTION 3 – Functional Operation Sequence of Operation The User Prepares the Printer Installs Ink Tanks in proper locations. Uses a single piece of media to set Sheet Separators. Loads media and adjusts the Side guide to within 1/32" of media. Stacks media in Feeder and adjusts Feed Ramp.

  • Page 27: Printer Controls

    SECTION 3 FUNCTIONAL OPERATION Printer Functional Description 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.

  • Page 28: Control Panel Button/Led Indicators

    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. ...
  • Page 29 SECTION 3 FUNCTIONAL OPERATION PRINTER ERROR INDICATORS POWER PAPER CANCEL PROBLEM (ON/OFF) (STOP/RESUME) (CANCEL JOB) Paper Feed LED ON, steady LED ON, flashing about 3 LED OFF Times Out/Out times/second. of Paper ACTION: Press PAPER to pause job. Check/clear paper jams or reload Feeder. If OK, press PAPER to resume printing.

  • Page 30: Printer Driver Properties

    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.

  • Page 31: Layout Tab

    SECTION 3 FUNCTIONAL OPERATION  Media – Choose a type of media or different MEDIA TYPE MEDIA PROFILE size media than the document was originally Plain Paper designed for. Type: Chart at right lists the Bright White Paper Plain Paper media profiles associated with the type of Transparency Film media chosen.

  • Page 32: Services Tab

    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.

  • Page 33: Using The Toolbox

    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.
  • Page 34 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 –...

  • Page 35: Diagnostics

    SECTION 3 FUNCTIONAL OPERATION [C] Firmware Download – Get the latest version of firmware for your Printer. How to download new firmware: 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.

  • Page 36: Network Configuration

    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: The Printer is still connected to the computer via the USB cable. To connect the Printer to a network, open the Toolbox.

  • Page 37: Service Menu

    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,”...
  • Page 38 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”...

  • Page 39: Printer Toolbox Error Messages

    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.
  • Page 40 SECTION 3 FUNCTIONAL OPERATION Look through the open side of the Printer. The Dual Pinch Valve connector (white) is located just behind the Bottom Fan Duct. Use a long-blade flat-tip screwdriver to carefully reach across the Print Engine and push in or reconnect the small white PCA connector.

  • Page 41: Section 4 - Adjustment

    SECTION 4 ADJUSTMENTS SECTION 4 – Adjustment Colordyne 1600-S Drive Belt Tension Adjustment REQUIREMENT: To ensure the Drive Belt has the proper tension. ADJUSTMENT: Unplug the machine and remove the Right-hand Side Cover. (6 screws) Loosen the two screws [1] that mount the Main Drive Motor to the Frame.

  • Page 42: Section 5 - Disassembly/Assembly Procedures

    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 Unplug the Printer before replacing the Separator Tips. Loosen the Separator Locking Knob and raise the Separator to its maximum raised position.

  • Page 43: Left-Hand Side Covers

    SECTION 5 DISASSEMBLY AND ASSEMBLY Left-hand Side Covers Remove (2) screws at the top and bottom of the Left- hand Rear Side Cover. Remove the Cover. Remove (2) screws at the top and bottom of the Left- hand Front Side Cover. Pull Cover away from machine slightly.

  • Page 44: Right-Hand Side Cover

    SECTION 5 DISASSEMBLY AND ASSEMBLY Right-hand Side Cover 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 Interface PC Board Main Power Plug, Switch, Fuse USB Connector Network Connector...

  • Page 45: Replacing Motor Drive Belt Or Motor

    SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Motor Drive Belt or Motor Remove Right-hand Side Cover. NOTE: To remove the Motor, remove the six screws holding the Rear Panel Cover. [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.

  • Page 46: Replacing The Feeder Encoder And/Or Encoder Sensor

    SECTION 5 DISASSEMBLY AND ASSEMBLY Push the Clutch in toward the Pulley to get access to the retaining pin. Remove the retaining pin. Remove the Clutch from the Feed Roller Shaft. Reassemble in reverse order. Replacing the Feeder Encoder and/or Encoder Sensor Remove the Encoder Sensor from the Rear Side Frame.

  • Page 47: Replacing Feed Rollers

    SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Feed Rollers Unplug the Printer from power. Follow the instructions above and remove the Right- hand Side Cover, Drive Belt and Clutch before beginning the replacement of the Feed and Forwarding Rollers. Remove the Left-hand Rear Side Cover and set aside. Remove the Side Paper Guides and the Rear Paper Support.
  • Page 48 SECTION 5 DISASSEMBLY AND ASSEMBLY Lift the Center Plate Assembly from the machine and set aside. 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.
  • Page 49 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.

  • Page 50: Replacing Delivery Rollers

    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. Remove the Left-hand Rear Side Cover by removing the (2) screws at the top and bottom of the Cover. Remove the Cover. Remove (2) screws at the top and bottom of the Left- hand Front Side Cover.
  • Page 51 SECTION 5 DISASSEMBLY AND ASSEMBLY Remove Top Cover. Remove mounting screw on left-hand side (Control Panel Side). Remove Top Cover and set aside. 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.
  • Page 52 SECTION 5 DISASSEMBLY AND ASSEMBLY 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. Remove Left-hand Inner Side Frame (3 screws). )Remove the Ink Tank Door mounting screw.
  • Page 53 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.

  • Page 54: Replacing Interface Pc Board

    SECTION 5 DISASSEMBLY AND ASSEMBLY Replacing Interface PC Board Remove the Right hand Side Cover. Unplug the PC Board power cord [1] from the Power Inlet on the PC Board. Unplug (9) Connectors for Clutch, Sensors, Motor, Encoder and Counter wires. NOTE: Wires are labeled for easy reconnection.

  • Page 55: Removing The Print Engine

    SECTION 5 DISASSEMBLY AND ASSEMBLY Removing the Print Engine 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.
  • Page 56 SECTION 5 DISASSEMBLY AND ASSEMBLY 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. Remove Top Cover. Remove mounting screw from left- hand side (Control Panel Side).
  • Page 57 SECTION 5 DISASSEMBLY AND ASSEMBLY 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.
  • Page 58 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.
  • Page 59 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.

  • Page 60: Print Engine Basic Disassembly

    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.

  • Page 61: Replacing Peristaltic Pump Assembly

    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.

  • Page 62: Replacing Dpca Board

    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.

  • Page 63: Replacing Buffer Boxes (3 Per Machine)

    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.

  • Page 64: Removing The Pen Driver Printed Circuit Assembly (Pca)

    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.

  • Page 65: Replacing The Ink Tank Latches

    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.

  • Page 66: Removing The Main Printed Circuit Assembly (Mpca) Cover

    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. Remove (4) screws to remove the Cover.

  • Page 67: Replacing Encoder Or Encoder Sensor

    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.

  • Page 68: Replacing Belt Drive Gear Pulleys

    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”.

  • Page 69: Replacing Lifter Motor Assembly Or Lifter Gear

    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.

  • Page 70: Replacing Stepper Motor

    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.

  • Page 71: Removing The Clamshell Assembly

    SECTION 5 DISASSEMBLY AND ASSEMBLY Removing the Clamshell Assembly Provides access to parts under the Clamshell Assembly. Removing Clamshell Assembly Remove the (4) screws attaching the Clamshell to the Chassis (1 at each corner). Gently lift the Clamshell from the Chassis – Take care not to pinch or damage any wires or ink hoses.

  • Page 72: Replacing Label Web Sensor

    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.

  • Page 73: Replacing Service Station Sled Printed Circuit Boards

    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.
  • Page 74 SECTION 5 DISASSEMBLY AND ASSEMBLY Reinstall Main Printed Circuit Board Assembly Gently lift up the Wiring Panel. NOTE: DO NOT pinch or cut wires running through Frame. Reinstall the two (2) mounting screws into bottom of MPCA Panel. Reinstall (4) screws to attach the Cover.

  • Page 75: 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. 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.
  • Page 76 SECTION 6 MAINTENANCE 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.

  • Page 77: Cleaning/Replacing The Printhead Cartridge

    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.
  • Page 78 SECTION 6 MAINTENANCE 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.
  • Page 79 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! 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.
  • Page 80 SECTION 6 MAINTENANCE 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.

  • Page 81: Replacing The Ink Revolvers

    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. Remove Cover by squeezing sides to release the tabs. Lift out Cover and set aside. Route the hose leads from the new Revolver through the same frame cutout as the existing hoses.
  • Page 82 SECTION 6 MAINTENANCE 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. Reinstall the Pin and C-clip. Reinstall the Ink Revolver Cover.

  • Page 83: Cleaning/Replacing The Service Station

    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.
  • Page 84 SECTION 6 MAINTENANCE 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.

  • Page 85: Cleaning The Service Station

    SECTION 6 MAINTENANCE Cleaning the Service Station 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.

  • Page 86: Removing The Wiper Motor Assembly

    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.

  • Page 87: Replacing Service Station Lifting Arms

    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 Non- Operator Side installation.) Service Station must be removed prior to servicing the Lifting Arms (see “Removing the Service Station”).

  • Page 88: Lubricating The Service Station

    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.
  • Page 89 SECTION 6 MAINTENANCE Lubricate Lifting Arm Pivot Points Apply lubricant to the Lifting Arm Pivot as shown. (1 on each side).

  • Page 90: Reinstalling Or Replacing The Service Station

    SECTION 6 MAINTENANCE Reinstalling or Replacing the Service Station 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.
  • Page 91 SECTION 6 MAINTENANCE [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.

  • Page 92: Replacing The Ink Waste Tray

    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. Open Ink Tank Door.

  • Page 93: Cleaning

    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.

  • Page 94: Print Engine

    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.

  • Page 95: Appendices

    APPENDICES Appendix A – Colordyne 1600-S Specifications Best: 1600 x 1600 DPI PRINT RESOLUTION Normal: 1600 x 800 DPI Up to 3600 letter size pages or 9000 envelopes per hour SPEED (color or mono) Minimum: 3" x 4.2" (76 mm x 107 mm) MEDIA SIZE Maximum: 9.5"...

  • Page 96: Appendix C - Z4 Wiring Diagram

    APPENDICES Appendix C – Z4 Wiring Diagram...
  • Page 97 APPENDICES...

  • Page 98: Index

    INDEX INDEX Adjustment, Printer Drive Belt Tension Hydrating Printhead Cartridge 2, 11, 72 Antistatic Brush Assembly Assembling Printer Indicators, Control Panel Ink Revolvers Buffer Boxes, Replacing Ink Station Door Ink Tank Latches Ink Tanks Clamshell Assembly Disposal Cleaning Installing Capping Station Seal & Squeegee Remove/Replace Grit Rollers Storage...
  • Page 99 Layout Tab Print Engine Properties Base, Removing Services Tab Basic Disassembly Printer Toolbox Buffer Boxes Diagnostics Clamshell Assembly Error Messages Cleaning Ink Usage DPCA Board Network Configuration Dual Pinch Valve Assembly Service Menu Encoder/Encoder Sensor User Interface Exit Sensor Using Gear Pulleys, Belt Drive Printhead Ink Revolvers...
  • Page 100 INDEX Separator Tips Setup Service Station 77, 84 Network Configuration Service Station Lifting Arms Printer Service Station Sled PC Boards Sheet Separators Service Station Transport Tab Side Fan Sheet Separators Starwheel Assemblies Side Fan Stepper Motor Starwheel Assembly Storage, Ink Tanks Stepper Motor Supplies Top Cover...
  • Page 102 Copyright © 2012 COLORDYNE TECHNOLOGIES LLC 02/15/2012 Part Number: 300-CDT1600-S REV. J...

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