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Z™406 System SERVICE TRAINING MANUAL

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Table of Contents

Removing Z406 Printer Assembly ................................................................................................... 3 1 Replaceable items on printer assembly ................................................................................... 5 2 Service Station ......................................................................................................................... 9 3 Pump Assembly ..................................................................................................................... 13 4 Electronics Panel.................................................................................................................... 16 5 How to replace parts on Printer Assembly ............................................................................. 20

5.1 Replacing Head Card...................................................................................................... 20 5.2 Replacing 12V Lee Valves.............................................................................................. 22 5.3 Replacing Fast Axis Motor Assembly ............................................................................. 23 5.4 Replacing Pogo Pin Card................................................................................................ 29 5.5 Replacing fluid Septum ................................................................................................... 39 5.6 Replacing Carriage Card................................................................................................. 40

6 How to replace parts on Service Station ................................................................................ 43 6.1 Replacing Parking Cups.................................................................................................. 43 6.2 Replacing Squeegee Blades........................................................................................... 44 6.3 Replacing Squirters......................................................................................................... 46 6.4 Replacing Squirt Pump ................................................................................................... 51 6.5 Replacing Service Station Card ...................................................................................... 54 6.6 Replacing Service Station Motor..................................................................................... 57

7 How to replace parts on Pump Assembly .............................................................................. 61 7.1 Replacing Feed Pump..................................................................................................... 61 7.2 Replacing Switcher Valve ............................................................................................... 65 7.3 Replacing Return Valve .................................................................................................. 67 7.4 Replacing Pressure Sensor ............................................................................................ 69 7.5 Replacing Pump Assembly Card .................................................................................... 71 7.6 Replacing Binder Level Sensor....................................................................................... 74

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Removing Z406 Printer Assembly 1) Remove the 7 screws on the two

piece printer assembly cover.

Screws 2) Disconnect 4 feed lines coming up

from bottom of gantry.

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3) Disconnect gray ribbon cable, power connector & ground wire.

Ribbon cable, power cable

4) Unscrew the 2 screws shown.

Screws

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5) Remove remaining 2 screws and pull printer assembly.

Screws 1 Replaceable items on printer

assembly

Pogo pin cards

5

Replaceable items on printer assembly

Fluid septum’s

Pogo ribbon cables

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Replaceable items on printer assembly

Carriage card

Carriage to head card ribbon cable

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Replaceable items on printer assembly

Head card

Fast axis motor assembly

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Replaceable items on printer assembly

12v Lee Valves

2 Service Station

9

Replaceable items on Service Station

Parking Cups

Squeegees

10

Replaceable items on Service Station

Squirters

Squirt Pump

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Replaceable items on Service Station

Service Station Card

Service Station Motor Assembly

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3 Pump Assembly

Replaceable items on Pump Assembly

Feed Pumps

Switcher Valves (Right)

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Replaceable items on Pump

Assembly

Return Valves (Left)

Pressure Sensor

Pump Assembly Card

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Replaceable items on Pump Assembly

Color binder filter

Color binder level sensor

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4 Electronics Panel

Replaceable items on Electronics Panel

Interface Card

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Replaceable items on Electronics Panel

PCI Card

Video Card

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Replaceable items on Electronics Panel

Mother Board

ATX Power Supply 300W

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Replaceable items on Electronics Panel

24V Power Supply 150W

Hard Drive

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5 How to replace parts on Printer Assembly

5.1 Replacing Head Card

Disconnect Ribbon, Power Cables & Ground Wire.

Disconnect fast axis motor cables.

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How to replace parts on Printer Assembly

Replacing Head Card

Disconnect 24V Lee Valve Cable.

Unscrew 2 nuts & remove Head Card with bracket. Replace with new one.

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How to replace parts on Printer Assembly

5.2 Replacing 12V Lee Valves

Disconnect cable connector Connector pulls off valve stems.

Unscrew Allen Head screws & Replace valve.

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How to replace parts on Printer Assembly

5.3 Replacing Fast Axis Motor Assembly

Disconnect power & encoder cables.

Loosen set screws on fast axis Idler Pulley.

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How to replace parts on Printer Assembly

Replacing Fast Axis Motor Assembly

Remove Fast Axis Belt from motor shaft pulley.

Unscrew 4 Allen Head screws.

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How to replace parts on Printer Assembly

Replacing Fast Axis Motor Assembly

Remove Fast Axis Motor Assembly with Bearing Plate Assembly.

Unscrew 4 Allen Head screws & replace Fast Axis Motor Assembly.

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How to replace parts on Printer Assembly

Installing Fast Axis Motor Assembly

Using the scale included in your Z406 Tool Kit, tension belt to 7lbs & tighten

screws.

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How to replace parts on Printer Assembly

Installing Fast Axis Motor Assembly

Install Fast Axis Motor Assembly to Printer Assembly with 4 Allen Head

screws.

Place Fast Axis Belt on Motor Shaft Pulley.

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How to replace parts on Printer Assembly

Installing Fast Axis Motor Assembly

Using the scale with eyehook included in your Z406 Tool Kit, tension belt to 7lbs & tighten screws on top of idler

pulley.

Unscrew eyehook.

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How to replace parts on Printer Assembly

5.4 Replacing Pogo Pin Card

Remove Printer Assembly as shown on Pages 1 to 5. Unscrew Pogo Cover &

remove.

Undo 2 retainer springs.

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How to replace parts on Printer Assembly

Replacing Pogo Card

Unclip Pogo Ribbon Cables.

Turn Printer Assembly over Remove 2 Philips Head Screws.

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How to replace parts on Printer Assembly

Replacing Pogo Card

Pogo Assembly will slide out.

Using the C clip tool from your Z406 Tool Kit, remove C clips & replace

defective Pogo Card.

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How to replace parts on Printer Assembly

Replacing Pogo Card

Don’t forget there are C clips on both sides of Pogo Card.

Install Pogo Assembly onto Carriage.

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How to replace parts on Printer Assembly

Replacing Pogo Card

Make sure Pogo Ribbon Cables are on backside of cards.

Install 2 Philips Head screws on bottom of carriage.

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How to replace parts on Printer Assembly

Replacing Pogo Card

Insert Pogo Ribbon Cables and flip the retainer clip, to lock in cable.

Clip tension springs back in place.

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How to replace parts on Printer Assembly

Replacing Pogo Card

Install Pogo Cable cover using a single Philips Head screw.

Set Printer Assembly on Gantry Install 2 Allen Head screws. (DO NOT

TIGHTEN)

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How to replace parts on Printer Assembly

Installing Printer Assembly

Install remaining 2 Allen Head screws, making sure printer assembly is flush

with gantry. Now go back and tighten 2 allen head screws from previous step.

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How to replace parts on Printer Assembly

Installing Printer Assembly

Connect Grey Ribbon, Power & Ground Cables.

Connect Fluid Feed Lines.

Before installing Printer Assembly Covers, boot up machine.

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As soon as machine comes Online, install NEW Print Heads. Go to the

service menue and select change print heads, if you do not do it that way then the heads wont get logged. Make sure

you do the head alignment process before you purge the heads. Inspect all

connectors and binder lines, making sure connectors and binder lines are

tight. Once head alignment & inspection are finished, you now can install the Printer Assembly Covers. Make sure covers are installed before the heads

are purged. Now that heads are purged, you can begin a print job.

(ALWAYS INSPECT WORK 2X BEFORE STARTING MACHINE)

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How to replace parts on Printer Assembly

5.5 Replacing fluid Septum

Using septum socket from Z406 Tool Kit, unscrew defective septum & install new one. (DO NOT OVER TORQUE)

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How to replace parts on Printer Assembly

5.6 Replacing Carriage Card

Remove 2 Philips Head screws to Carriage Card Cover.

Pull fluid lines up out of the slot out of the way.

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How to replace parts on Printer Assembly

Replacing Carriage Card

Remove Allen Head screw.

Slide Carriage Card up & disconnect 2 Head Card Ribbon Cables.

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How to replace parts on Printer Assembly

Replacing Carriage Card

Unclip & disconnect Pogo Ribbon Cables.

Replace defective card and follow instructions from pages 79 to 75 to

install new card. Be very careful when reconnecting ribbon cables. Take your

time so cables won’t get damaged. Check all connectors 2x making sure they are correctly connected. Do not

power up until you have checked all the work & connections. It is possible to

damage new cards if connections are incorrect.

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6 How to replace parts on Service Station

6.1 Replacing Parking Cups

Pull off Service Station Cover.

Parking Cup unclips as shown.

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How to replace parts on Service Station

6.2 Replacing Squeegee Blades

Unscrew 2 Allen Head screws & remove squeegee blade.

Undo gray retainer clip & replace blades.

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How to replace parts on Service Station

Replacing Squeegee Blades

Make sure to put blade assembly back in the exact spot it came from.

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How to replace parts on Service Station

6.3 Replacing Squirters

Undo 6 Torx screws.

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How to replace parts on Service Station

Replacing Squirters

Pull Service Station out & set on deck.

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How to replace parts on Service Station

Replacing Squirters

Place Flat Head Screw Driver on retainer screw.

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How to replace parts on Service Station

Replacing Squirters

Using a Crescent Wrench unscrew Squirter while holding flat head screw

driver on other side.

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How to replace parts on Service Station

Replacing Squirters

Make sure rubber O ring is installed on Squirter & Retainer Screw. Failure to do

so will result in Wash Fluid leaking. Make sure when squirter is tightened that the squirter holes are angled to

spray at the Squeegees. Install Service Station, start up machine, plug keyboard

& monitor into the back of machine. When machine comes online press u,

this will unpark carriage. Now press m to get into manufacturers menu. Press s to

make the squirters squirt. Using the crescent wrench, adjust squirters so

they spray wash fluid onto the squeegees. Once they are adjusted,

power machine down, unplug keyboard & monitor. Start machine up & print.

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How to replace parts on Service Station

6.4 Replacing Squirt Pump

Follow steps on pages 86 & 87 to remove Service Station. Unscrew white

compression fittings.

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How to replace parts on Service Station

Replacing Squirt Pump

Unplug Pump power connector.

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How to replace parts on Service Station

Replacing Squirt Pump

Unscrew 2 Allen Head screws & replace pump.

Once defective pump is replaced make sure the white compression fittings have

the black rubber O rings installed. Failure to do so will result in wash fluid

leaking inside machine, which could cause serious damage.

Connect white compression fittings & power cable. Install Service Station into

machine by following instructions on pages 87 & 86.

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How to replace parts on Service Station

6.5 Replacing Service Station Card

Disconnect 3 connectors.

Loosen set screw on sensor wheel & remove.

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How to replace parts on Service Station

Replacing Service Station Card

Remove 4 Phillips screws & replace card

with new one. Install 4 Phillips screws.

Make certain set screw is on flat spot. Push sensor wheel as low as it can go

on the flat spot.

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How to replace parts on Service Station

Replacing Service Station Card

Make certain that sensor wheel is all the way at the bottom of the flat spot on the

shaft. If sensor wheel is installed improperly then the Service Station will

not work properly. Be careful not to damage the sensor wheel sensors on the card. Reconnect connectors and install Service Station into machine.

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How to replace parts on Service Station

6.6 Replacing Service Station Motor

Loosen set screw on sensor wheel & remove.

Disconnect 3 cables.

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How to replace parts on Service Station

Replacing Service Station Motor

Unscrew 4 Allen Head screws & remove Motor Assembly.

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How to replace parts on Service Station

Replacing Service Station Motor

Turn over, unscrew 2 Allen Head screws and replace motor.

Make sure when mounting motor bracket the gears are flush with each

other.

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How to replace parts on Service Station

Replacing Service Station Motor

Install sensor pulley as described on pages 98 & 99.

Check to see that all screws are tight before connecting cables. Connect the 3

cables & install Service Station into machine.

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7 How to replace parts on Pump Assembly

7.1 Replacing Feed Pump

Remove 4 Phillips Head screws on Pump Assembly Cover.

Disconnect power cable to defective pump.

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How to replace parts on Pump Assembly

Replacing Feed Pump

Loosen Allen Head screws on both sides of the defective pump.

Remove defective pump.

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How to replace parts on Pump Assembly

Replacing Feed Pump

Don’t lose duck bill check valves. Pump will not work properly without them.

Install new Feed Pump & tighten Allen Head screws. (DO NOT OVER

TIGHTEN)

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How to replace parts on Pump Assembly

Replacing Feed Pump

Connect power cable.

DO NOT OVER TIGHTEN ANY REPLACMENT PARTS ON PUMP

ASSEMBLY. Over tightening will strip the coils from blocks, rendering the block useless. When replacing any

plumbing parts, always start machine and do a binder flush to be sure there are no leaks, then the Pump Assembly

cover can be installed.

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How to replace parts on Pump Assembly

7.2 Replacing Switcher Valve

Disconnect power cable.

Unscrew 3 Allen Head screws & remove Switcher Valve.

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How to replace parts on Pump Assembly

Replacing Switcher Valve

Install new Switcher Valve & connect power cable.

When installing any replacement parts on Pump Assembly make sure screws

are NOT over tightened. Over tightening screws will render Pump Assembly blocks useless. When replacing any

fluid system parts always start machine and do a binder flush to make certain

there are no leaks.

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How to replace parts on Pump Assembly

7.3 Replacing Return Valve

Disconnect power cable.

Unscrew 3 Allen Head screws & replace Return Valve.

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How to replace parts on Pump Assembly

Replacing Return Valve

When installing any replacement parts on Pump Assembly make sure screws

are NOT over tightened. Over tightening screws will render Pump Assembly blocks useless. When replacing any

fluid system parts always start machine and do a binder flush to make certain

there are no leaks.

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How to replace parts on Pump Assembly

7.4 Replacing Pressure Sensor

Disconnect Pressure Sensor cables.

Unscrew 2 Phillips screws & replace defective Pressure Sensor.

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How to replace parts on Pump Assembly

Replacing Pressure Sensor

When installing any replacement parts on Pump Assembly make sure screws

are NOT over tightened. Over tightening screws will render Pump Assembly blocks useless. When replacing any

fluid system parts always start machine and do a binder flush to make certain

there are no leaks.

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How to replace parts on Pump Assembly

7.5 Replacing Pump Assembly Card

Disconnect all 21 connectors.

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How to replace parts on Pump Assembly

Replacing Pump Assembly Card

Remove card.

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How to replace parts on Pump Assembly

Replacing Pump Assembly Card

Install card and connect the 21 connectors. Recheck that all connectors

are in the right place. Once all connectors are checked, then the

machine can be powered up.

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How to replace parts on Pump Assembly

7.6 Replacing Binder Level Sensor

Disconnect power cable.

Unscrew 2 Allen Head screws & replace defective sensor.

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