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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

2

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.

3

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

Ribbon cable, power cable

4) Unscrew the 2 screws shown.

Screws

4

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

6


Carriage card

Carriage to head card ribbon cable

7


Head card

Fast axis motor assembly

8


12v Lee Valves

2 Service Station

9

Replaceable items on Service Station

Parking Cups

Squeegees

10


Squirters

Squirt Pump

11


Service Station Card

Service Station Motor Assembly

12

3 Pump Assembly

Replaceable items on Pump Assembly

Feed Pumps

Switcher Valves (Right)

13

Replaceable items on Pump

Assembly

Return Valves (Left)

Pressure Sensor

Pump Assembly Card

14

Replaceable items on Pump Assembly

Color binder filter

Color binder level sensor

15

4 Electronics Panel

Replaceable items on Electronics Panel

Interface Card

16


PCI Card

Video Card

17


Mother Board

ATX Power Supply 300W

18


24V Power Supply 150W

Hard Drive

19

5 How to replace parts on Printer Assembly

5.1 Replacing Head Card

Disconnect Ribbon, Power Cables & Ground Wire.

Disconnect fast axis motor cables.

20

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.

21


5.2 Replacing 12V Lee Valves

Disconnect cable connector Connector pulls off valve stems.

Unscrew Allen Head screws & Replace valve.

22


5.3 Replacing Fast Axis Motor Assembly

Disconnect power & encoder cables.

Loosen set screws on fast axis Idler Pulley.

23


Replacing Fast Axis Motor Assembly

Remove Fast Axis Belt from motor shaft pulley.

Unscrew 4 Allen Head screws.

24


Replacing Fast Axis Motor Assembly

Remove Fast Axis Motor Assembly with Bearing Plate Assembly.

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

25


Installing Fast Axis Motor Assembly

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

screws.

26



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

screws.

Place Fast Axis Belt on Motor Shaft Pulley.

27



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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5.4 Replacing Pogo Pin Card

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

remove.

Undo 2 retainer springs.

29


Replacing Pogo Card

Unclip Pogo Ribbon Cables.

Turn Printer Assembly over Remove 2 Philips Head Screws.

30


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.

31


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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Replacing Pogo Card

Make sure Pogo Ribbon Cables are on backside of cards.

Install 2 Philips Head screws on bottom of carriage.

33


Replacing Pogo Card

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

Clip tension springs back in place.

34


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)

35


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.

36


Installing Printer Assembly

Connect Grey Ribbon, Power & Ground Cables.

Connect Fluid Feed Lines.

Before installing Printer Assembly Covers, boot up machine.

37

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)

38


5.5 Replacing fluid Septum

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

39


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.

40


Replacing Carriage Card

Remove Allen Head screw.

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

41


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.

42

6 How to replace parts on Service Station

6.1 Replacing Parking Cups

Pull off Service Station Cover.

Parking Cup unclips as shown.

43

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.

44


Replacing Squeegee Blades

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

45


6.3 Replacing Squirters

Undo 6 Torx screws.

46


Replacing Squirters

Pull Service Station out & set on deck.

47


Replacing Squirters

Place Flat Head Screw Driver on retainer screw.

48


Replacing Squirters

Using a Crescent Wrench unscrew Squirter while holding flat head screw

driver on other side.

49


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.

50


6.4 Replacing Squirt Pump

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

compression fittings.

51


Replacing Squirt Pump

Unplug Pump power connector.

52


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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6.5 Replacing Service Station Card

Disconnect 3 connectors.

Loosen set screw on sensor wheel & remove.

54


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.

55


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.

56


6.6 Replacing Service Station Motor

Loosen set screw on sensor wheel & remove.

Disconnect 3 cables.

57


Replacing Service Station Motor

Unscrew 4 Allen Head screws & remove Motor Assembly.

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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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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.

62


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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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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7.2 Replacing Switcher Valve

Disconnect power cable.

Unscrew 3 Allen Head screws & remove Switcher Valve.

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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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7.3 Replacing Return Valve


Unscrew 3 Allen Head screws & replace Return Valve.

67


Replacing Return Valve




there are no leaks.

68


7.4 Replacing Pressure Sensor

Disconnect Pressure Sensor cables.

Unscrew 2 Phillips screws & replace defective Pressure Sensor.

69


Replacing Pressure Sensor




there are no leaks.

70


7.5 Replacing Pump Assembly Card

Disconnect all 21 connectors.

71


Replacing Pump Assembly Card

Remove card.

72


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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7.6 Replacing Binder Level Sensor


Unscrew 2 Allen Head screws & replace defective sensor.

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