Page 3 - Printing history
iii NovaJet 800 Series Service Manual Copyright Eastman Kodak Company, 2002KODAK, ENCAD ® , VinylJet ® , VinylJet ® , CADJET ® , Extreme Color Printing™, and Graphic Outdoor MatchedSystem™ (GO) are trademarks of Eastman KodakCompany.Other trademarks and registered trademarks are theproperty of their...
Page 6 - VDE Statement
vi NovaJet 800 Series Service Manual VDE Statement Hiermit wird bescheinigt, daß die NOVAJET 800 Serie von Drucker in Übereinstimmung mit den Bestimmungender BMPT-AmstbIVfg 234/1991 funkentstört ist. Dervorschriftsmäßige Betrieb mancher Geräte (z.B.Meßsender) kann allerdings gewissen Einschränkungen...
Page 7 - Material Safety Data Sheet
vii NovaJet 800 Series Service Manual Material Safety Data Sheet ENCAD QIS (Quality Imaging Supplies) ink is nonhazard- ous, requiring no special disposal handling. It can beharmful if swallowed and should be kept away fromchildren. To obtain a Material Safety Data Sheet, contact ENCAD, Inc. at: 605...
Page 8 - Warranty or Damage Claims; United States
viii NovaJet 800 Series Service Manual Warranty or Damage Claims United States ENCAD ® , Inc., warrants its printers ("P RODUCT ") to be free from defects in workmanship and materials for a period of one year from the date ofpurchase. In order to submit a Warranty claim, please contact theEN...
Page 9 - Table of Contents
ix NovaJet 800 Series Service Manual Table of Contents Chapter 1 General Description ....................................... 1-1 Introduction .................................................................................. 1-1Overview ..................................................................
Page 17 - List of Illustrations; Chapter 1 General Description
xvii NovaJet 800 Series Service Manual List of Illustrations Figure Page Chapter 1 General Description 1-1. NovaJet 800 Series Inkjet Printer ................................................. 1-1 Chapter 2 Theory of Operation 2-1. General Block Diagram. .................................................
Page 18 - Chapter 4 Troubleshooting
xviii NovaJet 800 Series Service Manual List of Illustrations (cont) Figure Page Chapter 3 Maintenance (cont.) 3-20. Color Calib Menu. .................................................................... 3-333-21. Vertical Options Menu. ............................................................ 3-...
Page 21 - Chapter 5 Assembly/Disassembly
xxi NovaJet 800 Series Service Manual List of Illustrations (cont) Figure Page Chapter 4 Troubleshooting (cont) 4-98. Probable Defective Carriage PWA. .......................................... 4-92 4-99. Defective Main PWA. ............................................................. 4-92 4-100. C...
Page 22 - Chapter 6 Parts List
xxii NovaJet 800 Series Service Manual List of Illustrations (cont) Figure Page Chapter 5 Assembly/Disassembly (cont.) 5-18. Carriage Coupler Installation. ................................................... 5-285-19. Left Carriage Installation. .........................................................
Page 23 - List of Tables; Chapter 3 Maintenance
xxiii NovaJet 800 Series Service Manual List of Tables Table Page Chapter 3 Maintenance 3-1. Main PWA Connections. ............................................................ 3-103-2. Carriage PWA Connections. ....................................................... 3-11 Chapter 4 Troubleshooting 4-...
Page 24 - General Description 1; Introduction; This manual provides service information for the; NovaJet; Color Inkjet Printers. The
General Description 1-1 NovaJet 800 Series Service Manual General Description 1 Figure 1-1. NovaJet 800 Series Inkjet Printer. Introduction This manual provides service information for the ENCAD ® , Inc. NovaJet ® 800 Series Color Inkjet Printers. The NovaJet 850 printer is available in two sizes: a...
Page 25 - Encad RTL
General Description 1-2 NovaJet 800 Series Service Manual A Centronics parallel connection is provided to interface with the host computer.Commands sent from the host computer can be in several forms including HP-GL/2, HP-RTL and Encad RTL formats. Drivers are supplied to support Windows ® -based PC...
Page 26 - Overview; ENCAD’s; Electrostatic Discharge (ESD) Sensitivity
General Description 1-3 NovaJet 800 Series Service Manual Overview Printers draw according to instructions issued from a “host” computer.Every printer is engineered to understand a specific set of instructionsand to execute each instruction in a precise manner. In addition, mostprinters are designed...
Page 27 - Warnings, Cautions and Notes; NOTE
General Description 1-4 NovaJet 800 Series Service Manual Warnings, Cautions and Notes Warnings, cautions and notes are used when additional information,instructions or care should be observed. In this manual warnings,cautions and notes precede the text to which each applies. Thedefinition of each i...
Page 28 - Printer Specifications
General Description 1-5 NovaJet 800 Series Service Manual Printer Specifications The specifications and performance characteristics of the NovaJet 800 Series Color Inkjet Printers are as follows: Max Printing Area: 42 inch 60 inch Norm 40.8” 58.8” 1.04m 1.49m Extend 41.61” 59.61” 1.06m 1.51m Languag...
Page 29 - Contents of this Service Manual; This manual is divided into six chapters as follows:; Height
General Description 1-6 NovaJet 800 Series Service Manual Contents of this Service Manual Figures are used in this manual to clarify procedures. They are forillustrative purposes only and may not necessarily be drawn to scale. Material in this manual may be repeated in various chapters so thateach c...
Page 30 - AutoCADTM; absolute coordinates: up and down for X, left to right for Y.
General Description 1-7 NovaJet 800 Series Service Manual Chapter 3 MAINTENANCE - This chapter covers the scheduled maintenance, cleaning procedures and alignment/adjustments recommended to perform onthe printers. Diagnostics and a signal flow diagram are also listed. Chapter 4 TROUBLESHOOTING - A t...
Page 31 - Technical Support; offers full technical support and service for its various prod-
General Description 1-8 NovaJet 800 Series Service Manual Technical Support ENCAD offers full technical support and service for its various prod- ucts. If you are unable to find the answer to your question in either theUser’s Guide, Service Manual, or other related publications, check out ENCAD’s Kn...
Page 32 - Series; is a PowerPC 48MHz microprocessor-; Theory of Operation
2 2-1 Introduction This chapter explains the mechanical and electrical theory of operationof the ENCAD NovaJet 800 Series Color Inkjet printers. The NovaJet 800 Series V-8 print engine has eight ink cartridges, eight 500-milliliter ink reservoirs and 12 independent ink lines. Thecartridges are house...
Page 33 - NovaJet 800 Series Printers General Block Diagram
Theory of Operation 2-2 NovaJet 800 Series Service Manual NovaJet 800 Series Printers General Block Diagram Figure 2-1 illustrates the major functional areas of the printers. The NovaJet 800 Series printers consist of three mechanical assem- blies: 1. Paper (Media) Axis Drive 2. Carriage Axis Drive ...
Page 35 - was designed with self aligning
Theory of Operation 2-4 NovaJet 800 Series Service Manual Paper (Media) Axis Drive Figure 2-2. Paper (Media) Axis Drive. The Paper (Media) Axis Drive moves the plotting media in a directionperpendicular to the length of the printer. This friction drive utilizes amicro-step drive technology and consi...
Page 36 - The Carriage Axis Drive
Theory of Operation 2-5 NovaJet 800 Series Service Manual The Carriage Axis Drive CARTRIDGE 1 CARTRIDGE 2 CARTRIDGE 3 CARTRIDGE 4 OPTICAL ENCODER OPTICAL SENSOR PAPER SENSOR CARRIAGE PWA TRAILING CABLE CONNECTION FROM MAIN PWA TRAILING CABLE INKJET DRIVERS LEFT AND RIGHT CARRIAGE ASSEMBLY RIGHT CARR...
Page 37 - Media Feed and Take-Up System
Theory of Operation 2-6 NovaJet 800 Series Service Manual Media Feed and Take-Up System REFLECTOR REFLECTOR SENSORS Figure 2-4. Power Feed and Take-Up System. The media feed and take-up system comprises of two optical sensors,two dc motors and a dryer assembly. See Figure 2-4. Motors are used to adv...
Page 38 - Gate Array
Theory of Operation 2-7 NovaJet 800 Series Service Manual Main PWA (Printed Wiring Assembly) Figure 2-5. Main PWA (Printed Wiring Assembly). The Main PWA (Printed Wiring Assembly) consists of seven functionalareas: 1. Microprocessor (CPU) 2. Gate Array 3. Memory Circuits 4. Stepper Motor Controller ...
Page 39 - Main PWA LED Status Indicators
Theory of Operation 2-8 NovaJet 800 Series Service Manual Main PWA LED Status Indicators D1 - Normally flashes when the DSP is idle. Steady during print opera-tions. D8 - +24V available. D9 - Normally flashes when the Power PC processor is idle. Stopsflashing when processor is busy (i.e. during pape...
Page 41 - Memory Circuits; Maximum installable memory is as follows:; Flash EEPROM
Theory of Operation 2-10 NovaJet 800 Series Service Manual Memory Circuits Memory is used to retain large amounts of information. This informationis stored in the device memory in the form of binary bits. Printer memory consists of Flash EEPROM, SDRAM, and EEPROM. Maximum installable memory is as fo...
Page 42 - SDRAM
Theory of Operation 2-11 NovaJet 800 Series Service Manual SDRAM SDRAM is Synchronous Dynamic Random Access Memory, whichprovides temporary storage of the microprocessor calculation and input/output data. It is also a faster type of memory then the FlashEEPROM. That’s why the printer control program...
Page 43 - Reference waveform generator; - the voltage across a series current sense resistor is mea-; Comparator; - an H-bridge allows the supply voltage to be applied across the
Theory of Operation 2-12 NovaJet 800 Series Service Manual commands which the Stepper Motor receives from the microprocessor. The Stepper Motor Controller contains two identical circuits, one for each winding of thestepper motor. The circuit is a combination of two simpler types of circuits and can ...
Page 44 - Servo Motor Controller
Theory of Operation 2-13 NovaJet 800 Series Service Manual Servo Motor Controller GATE ARRAY MOTOR DRIVER SERVO CONNECTOR CARRIAGE CONNECTOR SERVO MOTOR CARRIAGE ENCODER MAIN PWA Figure 2-8. Servo Motor Controller. The Carriage Assembly is driven by the Servo Motor. The speed of theCarriage Assembly...
Page 45 - ENCODER STRIP
Theory of Operation 2-14 NovaJet 800 Series Service Manual ENCODER STRIP OUTPUT OF DETECTOR 2 COMPOSITE TRANSITION-TRIGGERED OUTPUT OF BOTH DETECTORS OUTPUT OF DETECTOR 1 4 OUTPUT PULSESPER OPTICAL LINE DETECTOR 2DETECTOR 1 Figure 2-9. Quadrature Signal Generation. The direction that the Carriage As...
Page 46 - The serial port is not used.
Theory of Operation 2-15 NovaJet 800 Series Service Manual A hardware counter in the gate array increments as the Carriage Assem-bly moves left and decrements as the Carriage Assembly moves right.The hardware counter is only eight bits wide, so it cannot store a valuelarge enough to represent an abs...
Page 47 - Carriage Assembly Circuits; The Right Carriage Assembly contains:
Theory of Operation 2-16 NovaJet 800 Series Service Manual Carriage Assembly Circuits CARTRIDGE 1 CARTRIDGE 2 CARTRIDGE 3 CARTRIDGE 4 OPTICAL ENCODER OPTICAL SENSOR PAPER SENSOR CARRIAGE PWA TRAILING CABLE CONNECTION FROM MAIN PWA TRAILING CABLE INKJET DRIVERS LEFT AND RIGHT CARRIAGE ASSEMBLY RIGHT ...
Page 49 - Control Panel
Theory of Operation 2-18 NovaJet 800 Series Service Manual Control Panel The Control Panel is located on the right side of the printer and consistsof 8 variable-action control buttons and an LCD graphics display. Thecontrol buttons are assigned to different functions and are dependantupon the select...
Page 50 - The power supply is fused using a 6.3A 250V fast blow type fuse.; Thermal Dryer Assembly
Theory of Operation 2-19 NovaJet 800 Series Service Manual The power supply is fused using a 6.3A 250V fast blow type fuse. The outputs share a common ground which is isolated from earth groundwith in the supply itself. Earth ground and DC ground are connectedexternal of the power supply. The power ...
Page 51 - Sensor Status Menu
Theory of Operation 2-20 NovaJet 800 Series Service Manual The Main PWA has a humidity sensor and a temperature sensor mounted to theback side. The sensors monitor ambient room temperature and humidity. Prior toprint operations the printer should be allowed to acclimate to the environment forat leas...
Page 52 - Beeper and Fans; There exists three types of fans that can be on these printers.
Theory of Operation 2-21 NovaJet 800 Series Service Manual Beeper and Fans The beeper contains built-in driver circuitry so that it beeps under firm-ware control. The beeper alerts the user to error conditions. There exists three types of fans that can be on these printers. A single fan, located bel...
Page 53 - Maintenance
3 3-1 Maintenance Introduction This chapter contains general maintenance and cleaning instructions forthe NovaJet 800 series printers. Scheduled Maintenance Scheduled maintenance consists of a list of checks that are planned tobe performed on a regular basis or when conditions warrant it. Scheduled ...
Page 54 - Cleaning Procedures
Maintenance 3-2 NovaJet 800 Series Service Manual Cleaning Procedures Always turn the printer OFF, remove the power cord and the inter-face cable before cleaning the printer. An electrical shock hazardmay be present if these procedures are not followed. External Cleaning Do not use abrasive cleanser...
Page 55 - Service Station Cleaning
Maintenance 3-3 NovaJet 800 Series Service Manual Printer problems can be caused by an accumulation of dirt or other contamination onthe slide shaft. This contamination may lead to drag on the carriage. Extreme dragresults in a “carriage axis failure” fault and will stop the carriage motion. Thesepr...
Page 56 - Linear Encoder Strip Cleaning; To clean the Encoder Strip:
Maintenance 3-4 NovaJet 800 Series Service Manual 7. If the service station is filling with ink or very dirty it can be removed and rinsedunder warm water. To remove, pull the tab on the right side of the service stationand lift out. Wash, dry thoroughly and replace by placing the left side in first...
Page 57 - MAINTENANCE; Trailing Cables Cleaning; To clean the Trailing Cables:; Platen/Vacuum Hole Cleaning
Maintenance 3-5 NovaJet 800 Series Service Manual MAINTENANCE Trailing Cables Cleaning Clean the trailing cables bi- weekly or as necessary to remove any buildup of debris.Distilled water should be used. Do not pull too hard on the trailing cables or damagemay occur. To clean the Trailing Cables: 1....
Page 58 - Cartridge Dimples Cleaning
Maintenance 3-6 NovaJet 800 Series Service Manual Cartridge Dimples Cleaning CARTRIDGE DIMPLE AREA Figure 3-2. Cartridge Dimple Region. The cartridge dimple area can easily be contaminated by oils and dirt onfingers and hands or ink spilled onto them. This causes the cartridges tonot receive some of...
Page 59 - Flex Cable Contact Cleaning; Flex Cable Contacts
Maintenance 3-7 NovaJet 800 Series Service Manual MAINTENANCE Be sure to clean the yellow cartridge because it is not readily apparent that it isdirty. The yellow ink is hard to see and could be overlooked. Flex Cable Contact Cleaning Flex Cable Contacts Figure 3-3. Flex Cable Contacts. Cleaning the...
Page 60 - Clean and Inspect Stepper Motor Gears
Maintenance 3-8 NovaJet 800 Series Service Manual Clean and Inspect Stepper Motor Gears The stepper motor gears can become dirty after time (typically after 4-5 years ofoperation) if not cleaned. Dirty gears can cause microbanding in the print. This willreduce the quality of the output. Clean the mo...
Page 61 - Dryer Cleaning
Maintenance 3-9 NovaJet 800 Series Service Manual MAINTENANCE Dryer Cleaning To clean ink and debris from the dryer, use a lint-free cloth dampened with water.Clean all external surfaces with the exception of the underside of the dryer. Reseat Connectors on Main PWA and Carriage Boards Integrated ci...
Page 63 - Trailing Cable
Maintenance 3-11 NovaJet 800 Series Service Manual MAINTENANCE J 7 J 6 J 4 J 5 J 3 J 2 J 1 Figure 3-5. Carriage PWA Connection Locations. Table 3-2. Carriage PWA Connections. J1 Trailing Cable J5 Cyan/Slot 2 Drivers J2 Paper Sensor J6 Magenta/Slot 3 Drivers J3 Encoder Sensor J7 Yellow/Slot 4 Drivers...
Page 64 - Replace Trailing Cables
Maintenance 3-12 NovaJet 800 Series Service Manual LOCKING MECHANISM CONNECTOR ASSEMBLY RIBBON UNLOCKED LOCKED Figure 3-6. Ribbon Connector Locking Mechanism. Replace Trailing Cables Before replacing the trailing cables from the printer always remove powerfrom the printer. The trailing cables (2 tot...
Page 65 - Replace Carriage Cover/Carriage Bushings
Maintenance 3-13 NovaJet 800 Series Service Manual MAINTENANCE Replace Carriage Cover/Carriage Bushings The carriage cover bushings (2 total) are rated for approximately2000 hours of operational usage while the carriage assemblybushings (4 total) are rated for approximately 4000 hours of opera-tiona...
Page 66 - Servo Motor Winding Resistance Check
Maintenance 3-14 NovaJet 800 Series Service Manual Servo Motor Winding Resistance Check Figure 3-7. Servo Motor. 1. Disconnect the servo motor connection from J12 on the MainPWA. 2. Using a standard ohmmeter or multimeter, connect the meterleads to the two wires going to the motor. 3. While manually...
Page 67 - Stepper Motor Winding Resistance Check
Maintenance 3-15 NovaJet 800 Series Service Manual MAINTENANCE Stepper Motor Winding Resistance Check * B A Figure 3-8. Stepper Motor. 1. Disconnect the stepper motor connection from J7 on the MainPWA. 2. Using a standard ohmmeter or multimeter, measure betweenpins 1 (red wire) and 3. Point A in Fig...
Page 68 - Power Feed and Take-Up Motor Winding Resistance Check; Banding: Hardware vs Software
Maintenance 3-16 NovaJet 800 Series Service Manual Power Feed and Take-Up Motor Winding Resistance Check Figure 3-9. Power Feed and Take-Up Motor. 1. Remove the feed and/or take-up roll from the printer. 2. Using Phillips screwdriver, remove the four screws that secure thecradle idler from the right...
Page 69 - Banding Differences; HARDWARE
Maintenance 3-17 NovaJet 800 Series Service Manual MAINTENANCE Banding Differences Consistent horizontal banding is usually hardware related. Normallyhorizontal microbanding is caused by improper color deadband or colorcalibrations, dirty cartridges or service station. Inconsistent banding isusually...
Page 71 - Banding Causes & Quick Analysis
Maintenance 3-19 NovaJet 800 Series Service Manual MAINTENANCE Banding Causes & Quick Analysis Horizontal Banding Problems 1. Check the print mode for the type of image being printed. Refer toPrinter Calibrations - 'Checking Print Mode'. Is the high pass mode(5 pass for 2x4 configuration, 10 pas...
Page 74 - Vertical Banding Problems
Maintenance 3-22 NovaJet 800 Series Service Manual 18. Clean or replace encoder strip for image skewing (image walking or skipping). Whether the image skews slights or off the page the encoder strip is at fault.Typically characterized as horizontal banding, often a walking image can alsocreate verti...
Page 76 - Alignments/Adjustments; Slide Shaft Profile Adjustment
Maintenance 3-24 NovaJet 800 Series Service Manual Images CD and refer to 'Demonstration Print' for properprocedures. Alignments/Adjustments The ENCAD NovaJet 850 printers are designed with a minimum of maintenance requirements in mind. Calibrations include: color calibration,deadband alignment, and...
Page 77 - Zero the gauge
Maintenance 3-25 NovaJet 800 Series Service Manual MAINTENANCE Calibration Jo Block (1.434”) - Not used Plastic Gauge Card (0.011”) - Not used There are two basic measurements that are to be made using this kit (ensure poweris off prior to performing these proceures): 1. Slide Shaft Profile Adjustme...
Page 78 - The
Maintenance 3-26 NovaJet 800 Series Service Manual MEASURESECOND MEASURE FIRST MEASURE LAST ADJUST IF NECESSARY Figure 3-12. Measurement Positions for Slide Shaft. 3. Measure the right side (next to media alignment mark) and notethe difference. Divide this amount by two. 4. Measure just off the cent...
Page 79 - Head Height Alignment Procedure
Maintenance 3-27 NovaJet 800 Series Service Manual MAINTENANCE THIS IS THE INNER SCREW. POSITION GAUGE DIRECTLY IN FRONT OF IT. THESE ARE THE TURNBUCKLE SCREWS. POSITION GAUGE IN BETWEEN THE SCREWS AND AS CLOSE TO CENTER AS POSSIBLE. Figure 3-13. Slide Shaft Profile Adjustment. For example: If the L...
Page 80 - HEAD HEIGHT
Maintenance 3-28 NovaJet 800 Series Service Manual HEAD HEIGHT CARTRIDGEJET PLATE PLATEN Figure 3-14. Carriage Head Height Tolerance. 1. Remove the lid and the right cover of the printer. See Chapter 5 forprocedures. 2. Obtain the 3 tools (Micrometer Dial Gauge, Test Cartridge, andMeasuring Tip Exte...
Page 82 - RED
Maintenance 3-30 NovaJet 800 Series Service Manual Damage may occur to the micrometer gauge if theCarriage is moved without lifting up on the mea-suring tip. This action could also take the microme-ter out of alignment and foul the results of the align-ment. 6. While lifting up the measuring tip of ...
Page 83 - Color Calibration
Maintenance 3-31 NovaJet 800 Series Service Manual MAINTENANCE 12. To adjust the far right screw obtain the head height plate and install into the service station access hole (service station must beremoved). Move the carriage assembly over the service stationaccess hole so the Micrometer measuring ...
Page 84 - To perform the Color Calibration:
Maintenance 3-32 NovaJet 800 Series Service Manual -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 COLOR VERTICAL HEAD-TO-HEAD CALIBRATION Y M C COLOR HORIZONTAL HEAD-TO-HEAD CALIBRATION C M Y Current Heads (Y, M, C) Figure 3-18. Vert. and Horiz. Color Calibration. The “Current Heads (Y, M, C, 1, 2, 3, 4)” view rep...
Page 86 - Deadband Alignments
Maintenance 3-34 NovaJet 800 Series Service Manual 4 Vertical Next Option < > Prev Option selected Cancel Ok * Figure 3-21. 4 Vertical Options Menu. 5. Observe the plot and using either “Prev Option” or “Next Option”, rotate through theselections until the one that best aligns the cartridge in...
Page 87 - The deadband test on a; To perform the Slow Deadband Alignment:
Maintenance 3-35 NovaJet 800 Series Service Manual MAINTENANCE Figure 3-22. Slow Deadband. Figure 3-22 shows what the display will look like when printing the slow deadbandtest if it is out of alignment. A correctly aligned printer will appear as if there isonly a series of vertical lines printed. N...
Page 89 - Color Deadband Alignment; To perform the Color Deadband Alignments:
Maintenance 3-37 NovaJet 800 Series Service Manual MAINTENANCE 7. Continue performing steps 4 through 6 until the slow deadband adjustment iscorrect. Color Deadband Alignment The color deadband alignments are necessary to ensure that the output images are beingproduced with the highest quality stand...
Page 91 - Paper Axis Calibration; To perform the paper axis procedure:
Maintenance 3-39 NovaJet 800 Series Service Manual MAINTENANCE 6. Observe the plot and using either “Prev Option” or “Next Option”, rotatethrough the selections until one that seems closer to the correct value isselected. Press “Ok” to accept the selection and return to the LeftCarriage Cartridge Sl...
Page 92 - Diagnostics Menu
Maintenance 3-40 NovaJet 800 Series Service Manual 33" or 83.82 cm Figure 3-27. Paper Axis Test. 5. With a precision drafters measuring stick, measure the exactdistance from each of the “T” intersections. 6. Select “Paper Axis” at the Calibration Menu. This brings up theoptions menu for the pape...
Page 95 - Firmware Download/Upgrading for the PC; To download new firmware to your printer.; Add
Maintenance 3-43 NovaJet 800 Series Service Manual MAINTENANCE Fan #1 and Fan #2 Tests - Tests the operation of the fans on theprinter. Fan #1 Test (while depressed) turns on the power supplycooling fan and the suction fan inside the platen on the right sideof the printer. Fan #2 Test (while depress...
Page 96 - Print; Firmware Download/Upgrading for the MAC
Maintenance 3-44 NovaJet 800 Series Service Manual 4. Select the firmware file in the Files section of the dialog box andpress the Print button. The firmware file is sent to the printer as a normal print job. Approxi-mately 20 - 40 seconds later a single beep should be heard indicating theupdate was...
Page 97 - Internal Cabling and Signal Flow Diagrams
Maintenance 3-45 NovaJet 800 Series Service Manual MAINTENANCE Wait approximately 20 to 40 seconds later until you hear aSINGLE beep, indicating the download was successful. Youmay encounter a set of double beeps shortly after sendingthe firmware file, but you must wait until you hear theSINGLE beep...
Page 100 - Troubleshooting; No Power; Symptoms
Troubleshooting 4-1 NovaJet 800 Series Service Manual Troubleshooting 4 No Power • printer not ON depress powerswitch • faulty power replace power cord cord • AC input not replace AC entry Introduction Chapter 4, Troubleshooting consists of a table that is intended to aide thetechnician in troublesh...
Page 107 - Does Not Print
Troubleshooting 4-8 NovaJet 800 Series Service Manual Symptoms Possible cause Solution Table 4-1. Troubleshooting Table (cont). Media Sen Ref. PtsNot Initialized(NJ880 only) • reference points reset all eleven refer- were accidentally ence p9oints by per- cleared forming the MediaRef Pts. Alignment ...
Page 109 - Ink Cartridge
Troubleshooting 4-10 NovaJet 800 Series Service Manual Symptoms Possible cause Solution Table 4-1. Troubleshooting Table (cont). Ink Cartridge • service station 1) perform Service Misfiring (cont) dirty or not Station Cleaning properly sealing procedures cartridge jet area 2) replace seal onservice ...
Page 110 - Printer Output is
Troubleshooting 4-11 NovaJet 800 Series Service Manual Symptoms Possible cause Solution Table 4-1. Troubleshooting Table (cont). Printer Output is 2) inspect and/or Banding (Horz.) replace stepper (cont) motor gears and/orlower rollerassembly 3) replace MPWA • insufficient replace or refill ink in c...
Page 112 - Noisy Operation
Troubleshooting 4-13 NovaJet 800 Series Service Manual Symptoms Possible cause Solution Table 4-1. Troubleshooting Table (cont). • defective encoder clean encoder strip strip • bad MPWA replace MPWA Keypad Locked-Upor Not FunctioningProperly • firmware 1) reset printer problem 2) refresh or up-grade...
Page 118 - Print Quality Issues
Troubleshooting 4-19 NovaJet 800 Series Service Manual Print Quality Issues Cartridge Misfires (Intermittent Banding) Cartridge or print head misfires (clogged jets or misfiring jets) lead tomicrobanding in prints and can cause operational downtime. ThePrime pattern tests all cartridge jets. Activat...
Page 119 - Failure Analysis - Print Misfires
Troubleshooting 4-20 NovaJet 800 Series Service Manual Failure Analysis - Print Misfires 1. Ensure ink is in supply to cartridge jets? Are the ink lines full of ink at the reservoir tubing needles (connected to reservoir)and at the cartridge tubing/septum needles (connected tocartridges)? 2. Are the...
Page 124 - Common Misfire Problems
Troubleshooting 4-25 NovaJet 800 Series Service Manual Figure 4-11. Stall Configuration. Ensure the left or right Carriage PWA is tested properly. 15. Replace the Main PWA only if a specific test pattern, calibration, or jet sequence fails to print. Magnetic tippedscrewdrivers are known to have caus...
Page 125 - Clearing Cartridge Misfires; running the color test in the single pass mode severely reduces; Multiple Cartridge Failures
Troubleshooting 4-26 NovaJet 800 Series Service Manual Clearing Cartridge Misfires - Press lightly against jets with a water/alcohol moistened lint-freecloth. Blot gold jet plate area, do not wipe. - Insert cartridge and initiate a Color Test @ 100% in the 2-pass mode. Note: running the color test i...
Page 127 - Some types of address line and power line failures are below:; Microbanding
Troubleshooting 4-28 NovaJet 800 Series Service Manual Some types of address line and power line failures are below: Figure 4-16. Catastrophic Jet Failure. Figure 4-17. Power Line Failure. Figure 4-18. Address Line Failure. Figure 4-19. Multiple Address Line Failure. Microbanding Minimal microbandin...
Page 128 - pass, speed 10 is the true photo mode in 1x4 operations.
Troubleshooting 4-29 NovaJet 800 Series Service Manual Figure 4-20. Microbanding. Refer to the following table for the differences between qualitymodes in the 1x4 and 2x4 configurations. Note: 6 pass, speed 10 is the true photo mode in 1x4 operations. Figure 4-21. Quality Print Modes.
Page 129 - Vertical banding is always hardware related.
Troubleshooting 4-30 NovaJet 800 Series Service Manual Banding Differences Consistent horizontal banding is usually hardware related. Normally,horizontal microbanding is caused by improper color deadband or colorcalibrations, dirty cartridges or service station. Inconsistent banding isusually softwa...
Page 130 - Horizontal Banding
Troubleshooting 4-31 NovaJet 800 Series Service Manual Horizontal Banding 1. Check the print mode for the type of image being printed. Isthe enhanced print pass mode printing OK? Note: photopass mode may microband in some of the 2 tone colorranges including blue, gray, orange, and purple hues.Enhanc...
Page 142 - Vertical Banding
Troubleshooting 4-43 NovaJet 800 Series Service Manual 23. Diagonal banding is often RIP related. Lines protruding from text on vertical bands in text are typically errors within theapplications text field. Vertical Banding Figure 4-44. Dirty or Worn Carriage Bushings. Figure 4-45. Worn Bushings or ...
Page 146 - Cartridge Warranty
Troubleshooting 4-47 NovaJet 800 Series Service Manual Figure 4-50. ESD Problem. 7. Change media to see if electrostatic discharge from media iscausing the banding or ink over-spray to occur. Add 3rd partyESD protection if required (static eliminator strip). 8. Perform the carriage vibration test un...
Page 147 - Cartridge Maintenance & Testing
Troubleshooting 4-48 NovaJet 800 Series Service Manual Perform ‘Cartridge Maintenance & Testing’ before calling technicalsupport or your service representative. These steps must be performedbefore cartridges will be replaced in any event. Cartridge Maintenance & Testing ENCAD cartridges are ...
Page 148 - General Print Misfire Analysis
Troubleshooting 4-49 NovaJet 800 Series Service Manual than 2 weeks apply hot water towel to jet plate area for 15 to 30seconds. If cleaning the jet plate thoroughly and re-priming thecartridge does not improve print quality, go to Step 4. 4. Run a prime and inspect the printed lines. If the photo m...
Page 149 - Cartridge Misfires
Troubleshooting 4-50 NovaJet 800 Series Service Manual Figure 4-52. Cartridge Cleaning. Cartridge Misfires - Press lightly against jets with a water/alcohol moistened lint-free cloth.Blot. Do not wipe.- Insert cartridge and initiate a Color Test @ 100% density in a 2-passprint mode. For severe jet c...
Page 150 - Ink Starvation
Troubleshooting 4-51 NovaJet 800 Series Service Manual Figure 4-53. Service Station Cleaning. - If failures are occurring within 40ml ink throughput, improper cleaningof electrical contacts on carriage or a connectivity problem probablyexists. - Initially cartridges should be replaced, but further i...
Page 151 - Inkjet Nozzle Problems
Troubleshooting 4-52 NovaJet 800 Series Service Manual Inkjet Nozzle Problems - Resistor burnout - no firing (175 million firings average per resistor).Severe clogging may be cleared using ultrasonic cleaner (30-40 sec) orhot water (10-15 sec). Ink Starvation Ink starvation of one or more colors can...
Page 152 - Ink System Pressure Theory
Troubleshooting 4-53 NovaJet 800 Series Service Manual Ink System Pressure Theory The ink system works on less than 1/10 psi pressure. The reservoir capsshould remain loose to allow for atmospheric pressure to push down onthe ink to provide adequate pressure on the ink. The purpose of thecartridge p...
Page 156 - overfilling the cartridges with ink (greater than 35 ml) can; Ink Dropout; : The horizontal bands do not extend beyond the page layout or
Troubleshooting 4-57 NovaJet 800 Series Service Manual Figure 4-60. Excessive Ink Pressure. Caution: overfilling the cartridges with ink (greater than 35 ml) can cause pressure regulating problems in the ink delivery system where largeink droplets can fall from cartridges, thus damaging the prints. ...
Page 158 - When performing a firmware download it is important to
Troubleshooting 4-59 NovaJet 800 Series Service Manual As mentioned above the ambient or surrounding temperature does havean effect on the heating of the ink. ENCAD has established that thesesettings will be adequate for most installations. However, if the printer isin an environment that is hot or ...
Page 159 - The symptoms of this problem could be easily confused with; Color Test Problems
Troubleshooting 4-60 NovaJet 800 Series Service Manual is downloaded and can only be corrected with a reinitialization of theprinter. The reinitialization can be performed prior to or immediately aftera firmware download. Figure 4-62. Dirty Service Station Problem. NOTE 2: The symptoms of this probl...
Page 160 - Some microbanding or banding will be seen in the
Troubleshooting 4-61 NovaJet 800 Series Service Manual Figure 4-63. Normal Color Test (3 Pass). Normal Color Test. Some microbanding or banding will be seen in the bar patterns – the purpose of the test is to check for ink pressure and notthe quality of the printed pattern. Verify all bars print at ...
Page 162 - “Unrecognized Cartridge” Error Message; Unrecognized Cartridge Failure Analysis Steps:
Troubleshooting 4-63 NovaJet 800 Series Service Manual Figure 4-66. Ink Starvation. 8. Refer to ‘Ink Starvation’ procedures for any printed output whichresembles the following image where one color stops printingcompletely. “Unrecognized Cartridge” Error Message For an ‘Unrecognized Cartridge error’...
Page 164 - Paper Sensor Error
Troubleshooting 4-65 NovaJet 800 Series Service Manual Figure 4-68. Flex Driver Cable. 6. Test dc voltage across the 2 IC (integrated circuit) identificationdimples on carriage flex driver cable using a DVM (digitalmultimeter). In the DC scale verify that the voltage is jumping from0 to +5Vdc. If th...
Page 165 - Initialization Failure; – Normally flashes DSP is not active. Steady when printing.
Troubleshooting 4-66 NovaJet 800 Series Service Manual Figure 4-69. Paper Sensor. Initialization Failure One symptom of a defective paper sensor is when the carriage assemblysuddenly stops at left end of unit during initialization - initialization doesnot complete (dim or blank control panel display...
Page 166 - Loading Media Failure
Troubleshooting 4-67 NovaJet 800 Series Service Manual Loading Media Failure The carriage paper sensor (infrared sensor) will first obtain a referenceat right side of media surface after load media is selected (or duringautoload), then measure for media front edge detection (roll 1, roll 2, andsheet...
Page 167 - Encoder Sensor Error
Troubleshooting 4-68 NovaJet 800 Series Service Manual Figure 4-70. Paper Sensor Location. 5. Ink on Paper Sensor (most common failure). 6. Trailing cable connections (reseat/replace cable – outer cable). Encoder Sensor Error The encoder sensor error typically happens when a break in continuityoccur...
Page 168 - AutoLoad Paper Sensor Error
Troubleshooting 4-69 NovaJet 800 Series Service Manual Initialization Failure One symptom of a defective encoder sensor is when the carriage headsfail to move during printer initialization - initialization does not completeand a ‘Carriage Axis Error’ results. Replace paper sensor PWA oncarriage in t...
Page 169 - Carriage Axis Error; Carriage Axis Failure; The carriage
Troubleshooting 4-70 NovaJet 800 Series Service Manual Figure 4-72. AutoLoad Paper Sensor. A symptom of failure includes when media is loaded and the printerrejects the media and spits it out the rear of the printer. First ensure theentire platen surface has been thoroughly cleaned using distilled w...
Page 170 - Carriage Test
Troubleshooting 4-71 NovaJet 800 Series Service Manual Figure 4-73. Carriage Head Assembly. Carriage Test Perform a Servo Cycle Test (10 cycles is sufficient) to verify carriagebushings are defective. Ensure Halt time does not exceed 90. Left toRight resistances are normally higher than Right to Lef...
Page 171 - Failure Analysis
Troubleshooting 4-72 NovaJet 800 Series Service Manual Failure Analysis 1. Is the Encoder Strip clean? Has any image skewing occurredprior to the carriage axis error? If skewing resumes following acleaning within a day or two then the encoder strip is damagedand must be replaced. Normally the encode...
Page 175 - – Normally flashes Power PC processor is idle. Stops flashing when
Troubleshooting 4-76 NovaJet 800 Series Service Manual Figure 4-78. Main PWA LED Operation. Ensure Main PWA LEDs (light emitting diodes) are properly functioning: D1 – Normally flashes; DSP is not active. Steady during print operations. D9 – Normally flashes; Power PC processor is idle. Stops flashi...
Page 178 - Media Sensor Reference Points Not Initialized; Quick Troubleshooting List
Troubleshooting 4-79 NovaJet 800 Series Service Manual Media Sensor Reference Points Not Initialized Hardware Failures/Diagnostic Tests Quick Troubleshooting List 1. Send a test image (PRT or RTL) directly to printer to verify ahardware failure. 2. If the carriage stops during normal travel clean en...
Page 179 - Inconsistent Operations
Troubleshooting 4-80 NovaJet 800 Series Service Manual 7. Replace failed subassemblies. Inconsistent Operations ¨ Reinitialize unit. Select Init Settings to re-initialize printer, 1 beep shouldsound. Functional Problems Figure 4-82. Functional Problem. Verify proper grounds from power source exist; ...
Page 180 - ESD Problems; Dryer Failure/Sensor Error; From the top-level menu of the printer, check the sensor status.
Troubleshooting 4-81 NovaJet 800 Series Service Manual ESD Problems Figure 4-84. ESD Problem. 1. Intermittent Banding - jet failures.2. OverSpray3. Severe color loss in either 1x4 right or the 1x4 left print mode. Verify media is not causing the problem. Change to a different mediatype. Dryer Failur...
Page 181 - Plenum T
Troubleshooting 4-82 NovaJet 800 Series Service Manual Figure 4-85. Main PWA Humidity Sensor. The Dryer Mode: (cccccccc) indicates the current dryer setting. Opera- tional modes are “OFF”, “ON”, “AUTO”, or “DISABLED”. Plenum T . and MBoard T. (main-board T.) indicate temperature and are displayed in...
Page 183 - reading that was sampled when the detected error occurred.; There is a particular sequence of events that could result in a
Troubleshooting 4-84 NovaJet 800 Series Service Manual reading that was sampled when the detected error occurred. Failure Analysis 1. Ensure all logic cable and power cable connections are intact. 2. Check lower leg harness cable plug connections between rightstand leg and platen plug, and connectio...
Page 185 - Intermittent Problems/Continuity
Troubleshooting 4-86 NovaJet 800 Series Service Manual Intermittent Problems/Continuity If the printer experiences intermittent print problems or reboots thenensure all connections at Main PWA are good, platen is thoroughlycleaned of ink, verify the DIMM module is seated correctly and checkfor forei...
Page 193 - right
Troubleshooting 4-94 NovaJet 800 Series Service Manual Figure 4-102. Apparent Ink Overspray. Figure 4-103. True Type Font Problem. 18. For ink overspray or rough appearance of text edges ensure Adobe fonts are being used and that embedded text is not scaled via acompression plug-in. Figure 4-104. Pr...
Page 194 - Reinitializing the Printer
Troubleshooting 4-95 NovaJet 800 Series Service Manual Figure 4-105. Text Field Problem. 20. Diagonal banding within text or lines adjacent to text indicates a text field problem. Figure 4-106. Dirty or Defective Encoder Strip. 21. If color deadband appears correct on both edges of the printer but i...
Page 195 - Printer Hesitation/Networking Problems; Data Starvation
Troubleshooting 4-96 NovaJet 800 Series Service Manual Figure 4-107. Initialization Menu Location. Printer Hesitation/Networking Problems Hesitation of the printer carriage is normally caused by the parallel portdata rate not being optimized. Ensure the ECP parallel port mode isutilized, or better, ...
Page 197 - Miscellaneous Notes
Troubleshooting 4-98 NovaJet 800 Series Service Manual Suggest increasing memory to 256 MB for low pass print mode opera-tions. Typically this only affects CAD (computer aided design) users thatsend HP-GL/2 files (vector) to the printer. File format examples include.plt and hp2. Miscellaneous Notes ...
Page 199 - Parallel Port Test; Connecting a parallel printer cable to a printer that is turned on; Other port testing procedures
Troubleshooting 4-100 NovaJet 800 Series Service Manual Parallel Port Test Attach the service loopback test cable to the printer’s parallel port(contact ENCAD Technical Support to obtain). Activate the ‘ContinuousTest’ by selecting the Utility Menu, Service Menu, Diagnostics Menu,Continuous Test. Th...
Page 200 - Firmware Downloading Procedures
Troubleshooting 4-101 NovaJet 800 Series Service Manual Figure 4-112. Demo Print. 2. Refresh printer firmware. Refer to the ‘Firmware Download’ proce-dure. Firmware Downloading Procedures NJ850 Printer 1. Power on the printer. Verify current firmware version on printer to see if a firmware upgrade i...
Page 201 - Note; : the parallel cable should not exceed 6 feet or 2 meters. NT
Troubleshooting 4-102 NovaJet 800 Series Service Manual of the dialog box. Give the new folder a name and press OK . 7. Now press the Add button in the Files section of the dialog box. Find the firmware file that you downloaded from Encad’s websiteand press the Open button. This will add the firmwar...
Page 202 - Expanded Instructions for Firmware Download/Upgrade
Troubleshooting 4-103 NovaJet 800 Series Service Manual Figure 4-113. Firmware Download Procedures. NJ880 Printer 1. Place printer into continuous run mode (two-beep sequence) by holding down the top-left and the bottom-left keys on the keypadand powering on the printer until the two-beep sequence i...
Page 204 - Media Handling System Failure
Troubleshooting 4-105 NovaJet 800 Series Service Manual Media Handling System Failure If the takeup or feed system fails first ensure the printer is in the propermedia supply mode. Four modes are available. Sheet, Roll 1, Roll 2, andTakeUp. Roll 1 activates only the top roller to feed media while Ro...
Page 206 - WARNING; To remove the Top Cover:
Assembly\Disassembly 5-2 NovaJet 800 Series Service Manual A Hardware Kit is available for the printers. See Chapter 6 of thismanual for the part number. WARNING Always turn the printer OFF, remove the power cord andthe interface cable before beginning any disassembly pro-cedures. An electrical shoc...
Page 207 - To remove the Right Cover Assembly:
NovaJet 800 Series Service Manual Assembly\Disassembly 5-3 3. Lift up on the left side of the Top Cover until it clears the Left Coverwhile still depressing the retracting stop assembly, then slide the coverto the left to disengage it from the Right Cover. To remove the Right Cover Assembly: Figure ...
Page 208 - To remove the Left Cover Assembly:
Assembly\Disassembly 5-4 NovaJet 800 Series Service Manual 8. Disconnect the Display data ribbon cable connector at the J10 locationon the Main PWA. To remove the Left Cover Assembly: 1. Disconnect and remove all ink reservoirs. Figure 5-2. Left Cover Removal/Installation. 2. Remove the two screws s...
Page 209 - To install the Left Cover:; CAUTION; To install the Right Cover Assembly:
NovaJet 800 Series Service Manual Assembly\Disassembly 5-5 Install the Left, Top, and Right Covers To install the Left Cover: 1. Position the Left Cover over the Left Frame and while depressing theretracting stop assembly on the Support Bracket, lower the Left Coverinto position onto the Left Frame....
Page 210 - To install the Top Cover:; Remove the E-Connect Network Assembly
Assembly\Disassembly 5-6 NovaJet 800 Series Service Manual CAUTION Applying too much torque to the lower screws can causethe mounts for the standoffs on the cover to break, requir-ing a replacement of the cover. 4. Secure the Right Cover with two screws located on the left side (torqueto 15 in-lbs) ...
Page 211 - Install the E-Connect Network Assembly
NovaJet 800 Series Service Manual Assembly\Disassembly 5-7 Figure 5-3. E-Connect Assembly Installation/Removal. 3. Put on an ESD wrist strap. 4. Slowly lower the E-Connector Assembly until you can disconnect thepower cable from the connection located near the center of the circuitboard. Install the ...
Page 212 - Remove the Keypad and Display
Assembly\Disassembly 5-8 NovaJet 800 Series Service Manual Remove the Keypad and Display 1. Remove the Top and Right Covers following procedures outlinedearlier in this chapter. 2. Turn the Right Cover Assembly over and with a 1/4” socket orwrench, remove the four kepnuts securing the ESD Shield and...
Page 213 - Install the Keypad and Display
NovaJet 800 Series Service Manual Assembly\Disassembly 5-9 4. Disconnect the grounding flex cable from the large standoff beforeremoving the Keypad Assembly. See Figure 5-5 for location. Removethe Keypad Assembly. Figure 5-5. Keypad and Display Grounding Connections. Install the Keypad and Display 1...
Page 214 - Remove Memory Module
Assembly\Disassembly 5-10 NovaJet 800 Series Service Manual 4. Place the ESD Shield onto the Display standoffs using four kepnutswith a 1/4” socket or wrench. Torque to 2.5 in-lbs. 5. Attach ground connections to the Cover Standoffs as shown in Figure5-5. Apply a small drop of loctite into the Cover...
Page 215 - Install Memory Module
NovaJet 800 Series Service Manual Assembly\Disassembly 5-11 Install Memory Module 1. Slowly push the Memory Module into place. Make sure the module isfully seated. 2. Push the side clips towards the Memory Module until they hold themodule securely in place. 3. Install the Top and Right Covers follow...
Page 218 - Install the Main Printed Wiring Assembly (PWA)
Assembly\Disassembly 5-14 NovaJet 800 Series Service Manual CAUTION Failure to use an approved antistatic bag for storage orshipment may cause damage to the Main PWA and affectthe Warranty. 17. Place the Main PWA in an ESD bag (antistatic bag) in preparation for shipment to ENCAD for replacement or ...
Page 219 - Remove Power Supply, Cooling Fan, and AC Entry Module
NovaJet 800 Series Service Manual Assembly\Disassembly 5-15 8. Connect the Vacuum Fan 1 connector to J15 on the Main PWA. 9. Connect the AutoLoad Sensor connector to J13 on the Main PWA. 10. Connect and lock the Trailing Cable A connector to J1 on the Main PWA. 11. Connect and lock the Trailing Cabl...
Page 220 - To remove the Cooling Fan and AC Entry Module:
Assembly\Disassembly 5-16 NovaJet 800 Series Service Manual Figure 5-8. Power Supply Removal. To remove the Cooling Fan and AC Entry Module: 1. Remove the four screws located below the Right Baseplate securingthe Power Supply Bracket to the Right Baseplate. Remove the PowerSupply Bracket. See Figure...
Page 221 - Install the Power Supply, Cooling Fan, and AC Entry Module; To install the Cooling Fan and AC Entry Module:
NovaJet 800 Series Service Manual Assembly\Disassembly 5-17 Figure 5-9. Cooling Fan/AC Entry Module Removal. Install the Power Supply, Cooling Fan, and AC Entry Module To install the Cooling Fan and AC Entry Module: 1. Insert the AC Entry Module into the AC Entry Module hole on the RightBaseplate. P...
Page 222 - Remove Servo Motor
Assembly\Disassembly 5-18 NovaJet 800 Series Service Manual 5. Insert and hold the Power Supply into place while securing it with fourscrews. Torque to 15 in-lbs. 6. Reconnect the Power Supply to the AC Entry Module by reattachingthe quick disconnect connection. Push the quick disconnectassembly beh...
Page 224 - Install Servo Motor
Assembly\Disassembly 5-20 NovaJet 800 Series Service Manual 11. Lower the Trailing Cable back into place. 12. While holding the Servo Motor, remove the front screw on the Servo Motor. 13. Lower the motor to clear the platen and carefully bring the motor out of the printer. Install Servo Motor 1. Rei...
Page 225 - Remove the Ink Delivery System
NovaJet 800 Series Service Manual Assembly\Disassembly 5-21 10. Route the E-Connect power cable through the grommet on the E- Connect Plate. Reinstall the E-Connect Plate under the Platen. Torqueto 15 in-lbs. 11. Connect the Servo Motor connector to J12 on the Main PWA. 12. Install the E-Connect Net...
Page 227 - Install the Ink Delivery System; Remove the Carriage Assembly, Carriage Belt, and the Frame
NovaJet 800 Series Service Manual Assembly\Disassembly 5-23 7. Remove the Floating Carriage Cover from the Left and Right SupportBrackets. The Floating Carriage Cover is part of the Ink DeliverySystem. See Figure 5-13. 8. Carefully slide the Ink Delivery System out of the left side of the printer. I...
Page 235 - Remove the Carriage PWA
NovaJet 800 Series Service Manual Assembly\Disassembly 5-31 22. Turn the Belt Removal Tool to tighten the belt around the Servo Motor pulley. 23. Move the Carriage Assembly back and forth to check the Carriage Belt tension. Remove the Belt Removal Tool. 24. Gently move the Carriage Assembly from end...
Page 237 - Install the Carriage PWA
NovaJet 800 Series Service Manual Assembly\Disassembly 5-33 5. Unlock the latch on the right end of the Carriage and lift up the rightend of the Carriage PWA. See Figure 5-20. 6. Slide the Carriage PWA to the right to remove the tab on the left endof the Carriage PWA from the slot in the Carriage. C...
Page 238 - Remove the Paper Sensor or the Encoder Sensor
Assembly\Disassembly 5-34 NovaJet 800 Series Service Manual Remove the Paper Sensor or the Encoder Sensor 1. Remove the Top, Left and Right Covers following procedures outlinedearlier in this chapter. 2. Remove the Ink Delivery System and the Carriage Assembly followingprocedures outlined earlier in...
Page 240 - Install the Paper Sensor or the Encoder Sensor; To install the Paper Sensor:
Assembly\Disassembly 5-36 NovaJet 800 Series Service Manual Install the Paper Sensor or the Encoder Sensor ROUTE FLEX THROUGH SLOT INSIDE THE CARRIAGE ASSEMBLY 1 2 GROOVES 1 PUSH DOWN ON CLIP. PUSH ENCODER IN OVER CLIP. ENCODER MUST SLIDE PAST THE RIDGES AND SNAP INTO PLACE ALIGN SIDES OF PAPER SENS...
Page 241 - To install the Encoder Sensor:; Replacing the Floating Carriage Cover Bushings
NovaJet 800 Series Service Manual Assembly\Disassembly 5-37 e. Turn the Carriage over and insert the Paper Sensor flex cable into the connector at J3. f. Push both sides of the connector lock shut at the same time. 2. To install the Encoder Sensor: a. Turn the Carriage so that the bottom side of it ...
Page 243 - Replacing the Carriage Bushings
NovaJet 800 Series Service Manual Assembly\Disassembly 5-39 9. Perform the same procedure to replace the Right Support Bracketbushing. Replacing the Carriage Bushings 1. Remove the Top, Left and Right Covers following procedures outlinedearlier in this chapter. 2. Remove the Ink Delivery System and ...
Page 244 - Remove the Service Station
Assembly\Disassembly 5-40 NovaJet 800 Series Service Manual TABS Figure 5-25. Carriage Bushing Installation. 6. Orient the new bushing as shown in Figure 5-25 so that the metal tabon top of the bushing goes into the Carriage Assembly first. 7. Push the bushings in until they snap into place. 8. Inst...
Page 245 - Install the Service Station
NovaJet 800 Series Service Manual Assembly\Disassembly 5-41 5. Lift out the left side of the Service Station from the Platen and removethe Service Station. Moving the Service Station farther to the rightmight be required to release the left side of the Service Station. Install the Service Station 1....
Page 246 - Install the Trailing Cable Assembly
Assembly\Disassembly 5-42 NovaJet 800 Series Service Manual 7. The Trailing Cable Assembly is secured to the Stabilizer Bracket bytwo pieces of double sided tape. Remove the Trailing Cable Assemblyfrom the Stabilizer Bracket. 8. Mark the position of the double sided tape on the Stabilizer Bracketbef...
Page 247 - Remove the Stabilizer Bracket and Encoder Strip
NovaJet 800 Series Service Manual Assembly\Disassembly 5-43 6. Reposition the Floating Carriage Cover/Right Support BracketAssembly and the Left Support Bracket around the CarriageAssembly. Secure the Left Support Bracket to the Floating CarriageAssembly. Torque to 15 in-lbs. 7. Install the Top and ...
Page 248 - Install the Stabilizer Bracket and Encoder Strip
Assembly\Disassembly 5-44 NovaJet 800 Series Service Manual 4. Remove the Stabilizer Bracket from the Y-Arm Assembly by removingthe four alignment Allen screws and washers located on the back ofthe Y-Arm Assembly. CAUTION The Encoder Strip is not a field removable item. The en-tire Stabilizer Bracke...
Page 251 - Sensor
Assembly\Disassembly 5-47 NovaJet 800 Series Service Manual Install the Y-Arm Assembly, Pinch Rollers, Slide Shaft, and AutoLoad Sensor 1. Install the AutoLoad Sensor Assembly into the back part of the Y-Arm Bracket. Torque to 6 in-lbs. 2. Route the AutoLoad Sensor wires through the four wire clamps...
Page 252 - To remove the print gap sensor:; Remove the Lower Roller Assembly, Stepper Motor and Vacuum Fan
Assembly\Disassembly 5-48 NovaJet 800 Series Service Manual Remove the Gap Sensor (NovaJet 880 only) To remove the print gap sensor: 1. Remove the top cover by pulling on the retracting stop at the left end,remove by pulling cover to the left slightly to dislodge tab at the rightend. 2. Locate and r...
Page 255 - Install the Lower Roller Assembly, Stepper Motor and Vacuum Fan
NovaJet 800 Series Service Manual Assembly\Disassembly 5-51 13. Remove the Stepper Motor Extension Spring from the Stepper Motor and the post on the Left Lower Drive Shaft Bracket. See Figure 5-30. ATTACH SPRING TO POST ON BRACKET Figure 5-30. Stepper Motor Removal/Installation. 14. Remove the hardw...
Page 259 - Avoid damaging the encoder strip!
NovaJet 800 Series Service Manual Assembly\Disassembly 5-55 Remove the ink delivery system. 15. Ensure the ink delivery system carriage cover brackets are clear of the rear cover. Remove rear cover by lifting up and pulling away from theY-Arm. Note: do not lose the 2 retracting stop springs. 16. Dis...
Page 261 - Lower Roller Installation Tip (NovaJet 880); To install the lower roller/stepper motor assembly:
NovaJet 800 Series Service Manual Assembly\Disassembly 5-57 NOTE The right side fixed nylon helical wedge and pin assembly/flange shouldnot have to be removed unless the screw length prohibits lower rollerremoval. Three 1/8” and 5/32” allen head screws are used to securethese assemblies). To remove ...
Page 262 - Remove the Media Take-Up and Feed Sensor Brackets and Sensors
Assembly\Disassembly 5-58 NovaJet 800 Series Service Manual Remove the Media Take-Up and Feed Sensor Brackets and Sensors NOTE The sensors for the media Take-Up and Feed Assemblyare identical, but the brackets that they mount to have dis-tinct differences. The top bracket has an additional ex-tended...
Page 263 - Install the Media Take-Up and Feed Sensor Brackets and Sensors
NovaJet 800 Series Service Manual Assembly\Disassembly 5-59 assembly. WIRE TIE WRAPS Figure 5-32. Media Take-Up and Feed Sensor Removal. Install the Media Take-Up and Feed Sensor Brackets and Sensors 1. Install the two screws securing the bracket to the leg assembly. 2. Insert the sensor into the ho...
Page 265 - Remove the Thermal Dryer Assembly
NovaJet 800 Series Service Manual Assembly\Disassembly 5-61 CRADLE IDLER MOTOR MOUNT MOTOR MOTOR GEAR C CLAMP Figure 5-33. Media Take-Up and Feed Motor Removal. Remove the Thermal Dryer Assembly WARNING Once the dryer is plugged in, there is continuous powerbeing applied to the dryer, even when the ...
Page 266 - Install the Thermal Dryer Assembly
NovaJet 800 Series Service Manual Assembly\Disassembly 5-62 Install the Thermal Dryer Assembly 1. Carefully place the Thermal Dryer Assembly onto the supportbrackets. See Figure 5-34. Secure and torque to 15 in-lbs. 2. Attach the data cable to the right side of the Thermal Dryer Assembly. 3. Attach ...
Page 267 - This assembly emits heat by radiation.
Assembly\Disassembly 5-63 NovaJet 800 Series Service Manual WARNING This assembly emits heat by radiation. 1. Disconnect the Thermal Dryer Assembly power cord from the back ofthe printer. 2. Disconnect the data cable from the right side of the Thermal DryerAssembly. 3. Locate and remove the four scr...
Page 268 - Install the Thermal Dryer Right Endcap Assembly
NovaJet 800 Series Service Manual Assembly\Disassembly 5-64 NOTE Some units may have very small servicing loops in the wir-ing of the Dryer Assembly. When removing the RightEndcap, the possibility exists that a connection may havebeen pulled loose elsewhere within the body of the dryer ifextreme for...
Page 270 - Parts List; FIGURE ITEM; RESERVOIR ASSEMBLY, WITH
6 6-1 Parts List This chapter lists the items and their associated numbers for the parts andassemblies of the NovaJet 800 Series printers that are field replace-able. The list is in order of part name as identified in the assembly/disassembly chapter. This list is to be used in conjunction with the ...
Page 271 - FIGURE ITEM
Parts List 6-2 NovaJet 800 Series Service Manual 6-1 7 FITTING, FEMALE, BLUE ...................... 214244-00 FITTING, FEMALE, GRAY .................. 214245-00 6-1 8 C-RING 7/16 .............................................. 207789 HARDWARE KIT .................................... 208810 EASYPRIME ...
Page 273 - CHAIN SUPPORT ASSEMBLY
Parts List 6-4 NovaJet 800 Series Service Manual FIGURE ITEM PART NAME PART # 6-2 1 SPRING, COMPESSION .......................... 209052 6-2 2 RETRACTING STOP, ASSEMBLY ......... 208838-01 6-2 3 COVER ASSY, TOP, 60” .......................... 215571-00 COVER ASSY, TOP, 42” ....................... 21...
Page 275 - COVER ASSEMBLY, WITH KEYPAD
Parts List 6-6 NovaJet 800 Series Service Manual FIGURE ITEM PART NAME PART # 6-3 1 COVER ASSEMBLY, WITH KEYPAD AND DISPLAY, RIGHT ....................... 215350-00 6-3 2 KEYPAD ASSEMBLY ............................. 209096-3 6-3 3 REFLECTIVE DISPLAY ASSY .............. 210068-04 6-3 4 MAIN PRINTED ...
Page 277 - LOWER ROLLER ASSY, COMPLETE
Parts List 6-8 NovaJet 800 Series Service Manual FIGURE ITEM PART NAME PART # 6-4 1 HARNESS, DRYER/WINDER NOVAJET 850 ....................................... 215188-00 NOVAJET 880 ....................................... 217886-01 6-4 2 MOTOR ASSY, SERVO ........................... 215704-01 6-4 3 BL...
Page 279 - ENCODER SENSOR W/FLEX
Parts List 6-10 NovaJet 800 Series Service Manual FIGURE ITEM PART NAME PART # 6-5 1 COVER, CARRIER ELECTRONICS ..... 215111-02 6-5 2 CARRIAGE PWA ..................................... 214751-04 6-5 3 ENCODER SENSOR W/FLEX RIGHT SIDE CARRIAGE ONLY ........ 209578-101 6-5 4 STRAIN RELIEF ...............
Page 285 - LEG DRIVE, WIRING ASSY
Parts List 6-16 NovaJet 800 Series Service Manual FIGURE ITEM PART NAME PART # 6-8 1 SHAFT ASSY, W/FIXED RT SIDE, GUIDE, ADJ (2) AND CLAMP (3) 60” ................................................. 207657-1 42” ................................................. 207657-2 6-8 2 GUIDE, PAPER ADJUSTABLE ....
Page 287 - Index
Index-1 NovaJet 800 Series Service Manual Index A alignments slide shaft . . 3-24 axis drive carrier . . 2-5 paper (media) . . 2-4 B banding . . 3-16 C cabling . . 3-45 calibration color . . 3-31 deadband . . 3-34 X-axis . . 3-39 carrier . . 5-23cartridges . . 3-6 , 3-31 cautions . . 1-4 control pan...