WELCOME to Neopost USA Addressing Group Digital Color Printer (Mach 5, AS-950C, HJ950C) SERVICE TRAINING Instructor: Keith Wisham Start Time: 8:30 AM Morning Break: ~9:45 AM (15 minutes) Lunch: 11:30 AM – 12:00 noon Afternoon Break: ~3:00 PM (15 minutes) End Time: 5:00 PM Please find a seat, and fill out your name/place card. Please help yourself to refreshments in the cafeteria. Plug in your laptop computer and boot-up.

AS/HJ-950C (Mach 5) Digital Color Printer SERVICE TRAINING Schedule: 1st Day - HJ/AS-950C (Mach 5) Setup & Operation Loading Driver/Toolbox & Testing Operator Maintenance/Troubleshooting 2nd Day - Printing from Adobe, MS-Word, Bulk Mailer. mColor Software Training & Hands on Time 3rd Day- HJ/AS-950C (Mach 5) Service Updating Firmware Troubleshooting and Repair

AS/HJ-950C (Mach 5) Digital Color Printer Hasler HJ950C Neopost AS-950C Rena Systems Mach 5 3

All Specifications are Subject to Change Without Notice

AS/HJ-950C (Mach 5) Digital Color Printer Minimum Computer System Requirements Windows XP, Windows Vista, Windows 7. Supports 32 and 64 bit systems. You must have administrative privileges on the system. Pentium II, 2 GHz minimum (Pentium Dual Core, 2.5 GHz or better, is optimal) System memory – 2 GB minimum; or as recommended for your operating system. At least 10 GB free hard-disk space. Microsoft Internet Explorer 6.0 or higher. Java version 6 or higher CD/DVD drive USB 2.0 port Microsoft ".Net Framework" Version 3.5 must be installed Note: Even if you have a higher .NET Framework version installed (example 4.0); version 3.5 must also be installed, or the toolbox will not open. How to check your system for the minimum system requirements: Right click on "My Computer" and select Properties. The system information, including Operating System, Processor Info and Memory info will be displayed under the "General" tab. How to check your system for the versions of "Microsoft .NET Framework” installed. From the Control Panel; open "Add or Remove Programs" and look for "Microsoft .NET Framework 3.5..." in the list. You can obtain "Microsoft .Net Framework 3.5" via the Microsoft website. http://www.microsoft.com/net/download How to check your system for the version of "Java" installed. From the Control Panel; open "Add or Remove Programs". Look for "Java(TM) 6 .." in the list. You can obtain Java from the following website: www.java.com There are also tools on the Java site to help you detect if you have java installed and what version is installed.

AS/HJ-950C (Mach 5) Digital Color Printer Getting Acquainted

AS/HJ-950C (Mach 5) Digital Color Printer Getting Acquainted NOTICE: Leave the printer powered-up at all times, to allow for proper ink system and printhead maintenance.

AS/HJ-950C (Mach 5) Digital Color Printer Getting Acquainted

AS/HJ-950C (Mach 5) Digital Color Printer Getting Acquainted

AS/HJ-950C (Mach 5) Digital Color Printer INITIAL SETUP Unpacking (Save Packing Material) Note: Service Station (D) is now pre-installed in printer.

AS/HJ-950C (Mach 5) Digital Color Printer INITIAL SETUP Instructors Note: This process assumes you are starting with a new printer (no printhead, ink tanks or service station installed). Tools Needed Knife and scissors to open packaging #2 Philips head Screwdriver Carpenters Level (recommend using 18” or longer level) Protective gloves should be worn to avoid getting ink on hands when removing protective packaging materials from the ink coupling areas, the Ink Tank areas, and when installing/removing Printhead Cartridge and Ink Tanks. Choosing the Location The RENA Mach 5 should be placed on a sturdy, level, worktable or cabinet at least 9 inches from any walls. Protect the Mach 5 from excessive heat, dust, and moisture – avoid placing it in direct sunlight. Work-Table Surface Must be Level IMPORTANT! Level the Table, NOT the Printer! The surface that the printer is placed upon must be level, front to back and side to side. Use a carpenter’s level (bubble level) to verify that the surface is level. If the surface is not level the printer will not perform properly; which can lead to damage not covered under warranty. Why is this Important? The printer’s ink delivery systems, and waste ink drainage system, depend on the table surface being level to perform properly. If this rule is not followed you will experience print quality issues and ink waste draining issues that could cause damage to the printer and void the warranty. Level the Table surface, NOT the Printer. Do NOT use the Toolbox utilities “Tilt” readings to level the printer or table. Use an accurate level (i.e. bubble level that is at least 18” long), to check that the table surface is level (front to back and left to right). It is not acceptable to use your “cell phone app” to check level. Do NOT shim, raise or otherwise modify the printer, or feet of the printer, in any way. If the table surface can not be leveled then the printer should not be placed on it. If the table is not sturdy then the printer should not be placed on it. Do NOT move the printer while the power is on.

AS/HJ-950C (Mach 5) Digital Color Printer INITIAL SETUP

INITIAL SETUP WARNING! Remove Shipping Materials

AS/HJ-950C (Mach 5) Digital Color Printer Installing/Removing the Envelope Printing Attachment Kit (42-900-55)

AS/HJ-950C (Mach 5) Digital Color Printer Installing/Removing the Envelope Printing Attachment Kit (42-900-55) Installing Spacers Tips on Use: If you are going to primarily run flat sheets of media, you may find that the image quality may be enhanced by removing the “PPS Spacers”. Doing so provides a smaller distance between the printhead surface and the media; which may improve dot accuracy. If you find that the media catches on the transition between the height of the platen and the table top; you may need to remove the “PPS Spacers” to avoid this issue. This issue will usually present as a “click” noise, as the piece hits this transition edge. This issue will also cause a heavy line of image distortion, about 1” from the leading edge of the media. Unlike the original version of the Envelope Printing Attachment, this version of the Attachment (metal guide) can be installed or removed without the need to release the printhead cartridge; making it easier to manually clean the attachment and the printhead. If the Service Station is ever replaced; please be sure that you DO NOT discard the two “PPS Spacers”. Please be sure to remove them from the old Service Station, so they can be installed in the new Service Station.

AS/HJ-950C (Mach 5) Digital Color Printer SETUP

AS/HJ-950C (Mach 5) Digital Color Printer Installing the Service Station

AS/HJ-950C (Mach 5) Digital Color Printer Installing the Service Station NOTE: Make sure the wick hanging below the Service Station is inside the plastic trough inside the Ink Tank Station to prevent ink seepage. Make sure Service Station operates smoothly. If it binds or makes irregular noise, reinstall the Service Station. Lubricate Side Tracks and Guide if necessary.

AS/HJ-950C (Mach 5) Digital Color Printer Install the Printer Software (Printer Driver and Toolbox) NOTE: With driver version R9.1 the Toolbox connection is routed to the choice (USB or Network) that was selected during the most recent driver installation. IMPORTANT: Before installing the printer software (Toolbox and Driver); you should temporarily disable all Antivirus programs and Firewalls. In addition; you must be logged onto the system with full administrative privileges (admin rights).

AS/HJ-950C (Mach 5) Digital Color Printer Connecting via Ethernet Network NOTE: With driver version R9.1 the Toolbox connection is routed to the choice (USB or Network) that was selected during the most recent driver installation. IMPORTANT: Before installing the printer software (Toolbox and Driver); you should temporarily disable all Antivirus programs and Firewalls. In addition; you must be logged onto the system with full administrative privileges (admin rights).

AS/HJ-950C (Mach 5) Digital Color Printer Install the Ink Tanks

AS/HJ-950C (Mach 5) Digital Color Printer Install the Ink Tanks WARNING! To avoid damaging the chip on the Ink Tanks. Power-down the printer before inserting or removing Ink Tanks.

AS/HJ-950C (Mach 5) Digital Color Printer Install the Printhead Cartridge

AS/HJ-950C (Mach 5) Digital Color Printer Install the Printhead Cartridge WARNING: Do Not force the latch open or severe damage will result. Use the “Printhead Latch Release” button or the “Release Printhead” feature in the Toolbox.

AS/HJ-950C (Mach 5) Digital Color Printer Install the Printhead Cartridge

AS/HJ-950C (Mach 5) Digital Color Printer Install the Printhead Cartridge Before you begin this process, you will need to obtain some deionized or distilled water and some lint free cloths. These items will be used to wet the printhead nozzles. NOTE: Do NOT use tap water or paper towels to wet or clean the printhead nozzles. Doing so may cause damage to the printhead cartridge and possible contamination to the ink system. Why is it necessary to wet the printhead nozzles? During the priming process a vacuum is created at the non-operator side of the printhead cartridge. If the printhead nozzles are dry (open); air is pulled in through the printhead nozzles causing the priming process to fail (printer is unable to create a vacuum to pull ink into the cartridge). By wetting the printhead nozzles this creates a temporary “water seal”, which prevents air from getting sucked into the printhead during the priming process.

AS/HJ-950C (Mach 5) Digital Color Printer Install the Printhead Cartridge WHAT TO EXPECT: After closing the Printhead Latch there will be a ~15 second pause (no noise or motion). Then you will hear the Service Station move to the capping position. Then you will hear the ink pump start to run. At this time, ink should start flowing through all the tubes, in and out of the printhead. If you see this occurring, then the priming process is working and you can skip to Step 12. NOTE: If any Ink Tank is less than 30% full, the Printhead Cartridge priming process may fail (not enough ink to completely fill the system). In this case you will need to replace the tank(s) containing low ink and repeat the printhead priming process. After the Printhead is primed, you can re-install the original Ink Tank(s) to use up any remaining ink. Please refer to the section titled “Replacing the Ink Tanks”. IMPORTANT! Whenever a printhead cartridge is installed or re-installed, it must be conditioned to perform properly. Before printing a live print-job; please refer to the section titled “Printhead Cartridge Conditioning”. CAUTION DO NOT REPEAT THIS PRIMING PROCEDURE MORE THAN TWICE IN A ROW. DAMAGE TO THE INK SYSTEM MAY RESULT. AFTER TWO ATTEMPTS, LET THE PRINTER SIT FOR AT LEAST 1 - 2 HOURS BEFORE YOU ATTEMPT TO PRIME THE PRINTER AGAIN. CONTACT TECHNICAL SUPPORT FOR ASSISTANCE IF PROBLEMS PERSIST.

AS/HJ-950C (Mach 5) Digital Color Printer Install the Printhead Cartridge

AS/HJ-950C (Mach 5) Digital Color Printer Install the Printhead Cartridge

AS/HJ-950C (Mach 5) Digital Color Printer Install the Printhead Cartridge

AS/HJ-950C (Mach 5) Digital Color Printer Install the Printhead Cartridge

AS/HJ-950C (Mach 5) Digital Color Printer Install the Printhead Cartridge

AS/HJ-950C (Mach 5) Digital Color Printer Operating the Printer

AS/HJ-950C (Mach 5) Digital Color Printer Operating the Printer Status Light Indicators Valid with firmware 110928_u

AS/HJ-950C (Mach 5) Digital Color Printer Operating the Printer

AS/HJ-950C (Mach 5) Digital Color Printer Operating the Printer

AS/HJ-950C (Mach 5) Digital Color Printer Operating the Printer

AS/HJ-950C (Mach 5) Digital Color Printer New Features & Corrections with Firmware 110928_u

AS/HJ-950C (Mach 5) Digital Color Printer New Features & Corrections with Firmware 110928_u

AS/HJ-950C (Mach 5) Digital Color Printer New Features & Corrections with Firmware 110928_u

AS/HJ-950C (Mach 5) Digital Color Printer New Features & Corrections with Firmware 110928_u

AS/HJ-950C (Mach 5) Digital Color Printer Setting up the Feed

AS/HJ-950C (Mach 5) Digital Color Printer Setting up the Feed

AS/HJ-950C (Mach 5) Digital Color Printer Hands On Have students: Install printer driver (don’t connect USB until prompted to do so) Print Test Page from driver Open Toolbox “Print Ink Channels” from Diagnostics screen. TIP: After loading the driver; if you connect a different 950C (Mach 5) printer, a copy of the driver will be loaded. Make sure you are selecting the appropriate driver before you try to print.

AS/HJ-950C (Mach 5) Digital Color Printer Printer Driver Properties

AS/HJ-950C (Mach 5) Digital Color Printer Toolbox Features

AS/HJ-950C (Mach 5) Digital Color Printer Toolbox Features

AS/HJ-950C (Mach 5) Digital Color Printer Toolbox Features

AS/HJ-950C (Mach 5) Digital Color Printer Operator Maintenance Ink Waste Tray Inspection/ Replacement Removing the Antistatic Brush Assy to Clear Jams or Clean Sheet Separator Replacement

AS/HJ-950C (Mach 5) Digital Color Printer Operator Maintenance Feed Rollers and Forwarding Rollers The Feed and Forwarding Rollers can become glazed with paper lint and ink from the media. They should be regularly cleaned with a mild abrasive household cleaner on a damp lint-free cloth. NOTE: Avoid using solvents on the Rubber Rollers. Encoder Wheel If your machine has this type of Encoder Wheel in the Print Engine Area (see picture at right), excess ink spray or splashes may accumulate on the disk. This may disable the Printer and issue a "DATA_PATH_UNDERRUN" error in the Toolbox. It is necessary to wipe off any excess ink spray or splashes to continue optimum performance. Clean with distilled water on a damp, lint-free cloth by grasping the wheel lightly with the cloth and turning the shaft. Take care not to damage the Encoder Wheel.

AS/HJ-950C (Mach 5) Digital Color Printer Operator Maintenance Print Engine Areas in the Print Engine can become glazed with a buildup of dust, paper lint and accumulated ink and have to be cleaned regularly. Open the Top Cover. Open the Clamshell Assembly by releasing the two latches. Use a vacuum to pick up any loose debris. NOTE: Be careful around ink tray and capping station in the Print Engine area as accumulated ink may splash onto other parts of the printer. Take care not to damage the PC Boards or electrical wiring.   [A] Grit Rollers: Clean as needed by moistening a small hard-bristled brush or toothbrush with distilled water. DO NOT use anything other than distilled water to clean the Rollers. [B] Media Sensors: Paper lint and dust may build up on the Media Sensors. Use a can of compressed air or a damp (not wet) foam or lint-free cotton swab to gently swab the Sensors. Take care not to drip water into the circuit boards. Use a clean, dry swab to dab surfaces dry. Remember to wipe the clear panel over the Sensor Receiver in the upper Printhead Assembly (see inset). [C] Capping Station Seal and Squeegee. Clean as needed with distilled water on a damp, lint-free cloth. Be careful not to splash or drip ink on other parts of the Printer. [D] Printing Platen. Wipe with distilled water on a damp, lint-free cloth. Pat dry with a lint-free cloth. CAUTION USE ONLY DEIONIZED/DISTILLED WATER TO CLEAN PRINT ENGINE COMPONENTS. AVOID CONTAMINATING THE PRINTHEAD WITH CLEANERS, LUBRICANTS OR OTHER CHEMICALS.

AS/HJ-950C (Mach 5) Digital Color Printer Troubleshooting Print Quality Issues: Many things can contribute to print quality issues. Here is a list of things to check: To reduce print quality issues, the print engine should remain powered-on. Even in its standby state, the printer will run routine maintenance cycles to help keep the printhead nozzles hydrated and clean. Verify that the media you are printing on is an “inkjet suitable” media. See Paper Types below. Verify that the “graphic” you are printing is of a high quality. See Graphic Types below. Check to be sure the printer has an adequate supply of ink (30% or more) in all five Ink Tanks. Check to be sure all five color tubes, at both sides of the printhead cartridge, have ink filling them. If not, the cartridge will need to be removed, the printhead nozzle surface re-wetted using deionized or distilled water, and the cartridge reinstalled. Please refer to the appropriate sections in this manual for removing and installing the printhead cartridge. Try removing air bubbles from printhead and system using the “Printhead Cartridge Conditioning” routine or Toolbox utility feature “Circulate Ink”. Note: Do not run the Circulate Ink feature more than twice in a row. Replace the Printhead Cartridge. Generally when the ink supply is adequate and the print quality remains poor, even after cleaning; the printhead cartridge should be replaced. Please refer to “Replacing the Printhead Cartridge”. Compatible Paper Types: (look for inkjet suitable stocks) Inkjet Paper - all types (recommended for best color output). Copier Paper Card Stock Kromekote Coated Paper - Gloss finish Coated Paper - Satin finish Coated Paper - Matte finish

AS/HJ-950C (Mach 5) Digital Color Printer Troubleshooting Incompatible Paper Types: Color Laser Gloss Digital Printer Gloss Any Post Print Coated Substrate (aqueous, gravure or UV) Compatible Graphic Types: In general; scalable, vectorized art will produce the best images and color. Note: Graphic types are not really printer dependent. They are dependent on the software program being used to print the graphic, and what types of graphics that program can handle. Incompatible Graphic Types: Low resolution and web images will not produce quality output and should not be used.

AS/HJ-950C (Mach 5) Digital Color Printer Troubleshooting Examples of Print Quality Issues (including possible causes and solutions) The Memjet printhead cartridge contains over 70,000 inkjet nozzles. These nozzles are divided into ten rows; two rows of nozzles for each color channel. Due to the high number of nozzles; it is not uncommon for some nozzles to become contaminated or clogged. The following examples were produced using a Five Band Color Purge YKCKM. A similar purge pattern can be performed using the Services tab within the M Series Driver properties. Click on the “Print Demo Page” button.

AS/HJ-950C (Mach 5) Digital Color Printer Troubleshooting Air in Printhead Nozzle Area: Air in the printhead nozzles will show as jagged, irregular shaped lines of missing color. Lines are normally wider than one nozzle. Possible Solutions: Run “User Level Maintenance 3” from the M Series Driver’s Services tab. Release the Printhead, using the “Release Printhead” button. Then close printhead latch to re-prime the system. Instead of powering the printer off, when not in use, leave the print engine powered-up; so it can perform automatic maintenance routines. Don’t lift the print engine to an angle greater than 60º.

AS/HJ-950C (Mach 5) Digital Color Printer Troubleshooting Clogged Nozzles: Clogged/dehydrated nozzles will normally show as thin, crisp, vertical lines of missing color. Multiple adjacent clogged nozzles will show as wider, crisp, vertical lines of missing color. Clogged nozzles are normally due to Printhead nozzle dehydration or partial contamination. Possible Solutions: Run “User Level Maintenance 3” from the M Series Driver’s Services tab. Manually clean the printhead nozzles using distilled water and a lint free cloth. Replace the printhead cartridge. Instead of powering the printer off, when not in use, leave the print engine powered-up; so it can perform automatic maintenance routines.

AS/HJ-950C (Mach 5) Digital Color Printer Troubleshooting Color Mixing Issues: Color mixing will show as muddy, mottled or distorted (grainy) colors. Color mixing occurs when the ink from one color channel crosses over into another color channel. Since the inkjet nozzle rows are located very close to one another (ten rows of ~7,000 nozzles, located within a 0.8 mm space), it is easy for partials or fibers to create bridges across color channels. These bridges allow ink to flow (wick) from one color channel to another; resulting in a “localized” color mixing event; as shown in the examples below. Color mixing can occur for a number of reasons (here are some common ones) Ink wicking due to fibers bridging (crossing) inkjet nozzles. Wiper roller saturation (too much ink on wiper roller). Ink flooding on the nozzle plate; due to printer not being level or excessive back-pressure in the ink system. Tip: Muddy, mottled, distorted (grainy) colors can also be caused by the media you are printing onto. Test the printer, using a compatible “inkjet suitable” media, to determine if this could be the cause. Possible Solutions: Make sure printer is on a sturdy, level table. Perform a “Printhead Cartridge Conditioning” routine. Instead of powering the printer off, when not in use, leave the print engine powered-up; so it can perform automatic maintenance routines. Don’t lift the print engine to an angle greater than 60º. Contact Service person to have them clean/replace the Service Station.

AS/HJ-950C (Mach 5) Digital Color Printer Troubleshooting MESSAGE SOLUTION …. Ink Low Example: Black Ink Low Reorder Ink Multiple Inks Low …. Out of Ink Example: Cyan Ink Out Replace empty Ink Tank Multiple Ink Tanks Out Replace empty Ink Tanks Paper Jam Clear media from system and close print engine. Cleaning in Progress Wait until the message disappears. The printer will not respond until the cleaning has completed. Incorrect … Ink Tank Clean electrical contacts and re-seat Ink Tank. Unauthorized … Ink Tank Installed Ink Tanks must be purchased from authorized supplier for this printer model. Multiple Unauthorized Ink Tanks The … Ink Tank is missing Insert missing Ink Tank. Multiple Ink Tanks are missing Insert missing Ink Tanks. Clean electrical contacts and re-seat Ink Tanks. Printhead Latch Open Ensure printhead cartridge has been inserted properly then closer the printhead latch so it locks. Excessive Tilt Error See details under “Toolbox System Status Messages” section. Load Paper Load paper into printer and press the PAPER/RESUME button. Incompatible Printhead Remove and re-insert your printhead cartridge. Printhead cartridges must be purchased from authorized supplier for this printer model. Missing Printhead Unauthorized Printhead Remove jammed media. Check for and remove obstruction. Check for proper feed setup. Mechanical Jam Check for and remove obstruction. Reboot your printer. If problem persists contact technical support. Alert Window Messages

AS/HJ-950C (Mach 5) Digital Color Printer Troubleshooting SYSTEM STATUS PROBLEM SOLUTION PAPERPATH_FEED_TIMEOUT Out of Paper No media is reaching the print engine. Load media into printer and press the PAPER/RESUME button. If media is present; check/adjust the guides and separators. PAPERPATH_PRINTZONE_ BLOCKED Paperpath: Entry:Yes Exit:Yes or Paperpath: Entry: No Exit:Yes or Paperpath: Entry:Yes Exit:No No = not blocked Yes = blocked (interrupted) Paper Jam Media jam detected. Printer has detected that one of the media sensors is blocked (interrupted). Carefully remove jammed Media from printer and close the print engine. The System Status message in red should go away. The toolbox “Paperpath” line should change to: Paperpath: Entry: No Exit: No After you clear the jam you can; Press RESUME button to continue printing. Press the CANCEL button to cancel the job, and then manually clear the job from the computer’s print queue. DOOROPEN_FRONT Printer has detected that the “Clamshell” is open. Verify that the print engine is closed and securely latched at both sides. DATA_PATH_UNDERRUN Printer was paused by the user pressing the PAUSE button. Press the RESUME button to continue printing. Press the CANCEL button to cancel the job, and then manually clear the job from the computer’s print queue. X_INK_LOW Example: CYAN_ INK_LOW X = Color. One or more Ink Tanks are low on ink. Ink Tank replacement will be necessary soon. Reorder Ink INK_OUT_X Example: INK_OUT_MAGENTA One or more Ink Tanks are out of ink Replace empty Ink Tank(s) Verify that Ink Tanks are seated firmly and latches are fully closed. Clear error by cycling print engine power, using ON/OFF button. CARTRIDGE_MISSING_X or INK_TANK_MISSING_X Missing Ink Tank, or Ink Tank not being recognized X = Color (CYMKK) Insert missing Ink Tank or pop tank in and out to improve connection. Clear error by cycling print engine power, using ON/OFF button. Toolbox System Status Messages

AS/HJ-950C (Mach 5) Digital Color Printer Troubleshooting SYSTEM STATUS PROBLEM SOLUTION PRINTHEAD_MISSING No printhead installed or printhead not making proper connections. If just powered on, wait a minute; error may clear by itself. Install Printhead Cartridge. Remove and reinstall printhead. Replace printhead. Refer the appropriate sections in this manual for removing and installing the printhead cartridge. PRINTHEAD_UNPRIMED Printhead priming process has failed. Remove Printhead Cartridge, wet print nozzles using deionized or distilled water and re-install printhead cartridge. Refer the appropriate sections in this manual for removing and installing the printhead cartridge. If you continue to have trouble priming printhead; check for kinked or pinched color tubes. TILT_ERROR or EXCESSIVE_TILT_ERROR The printer’s electronics have detected that the print engine is too far out of level. Tilt sensor needs to be re-calibrated. If just powered on, wait a few minutes; error may clear by itself. Once Tilt level drops to 0.5 or less you can clear the error using the “Clear Error” feature in the Toolbox. Make sure printer is placed on sturdy, level, worktable. Do NOT move the printer while the power is on. If the Tilt level is 0.5 or less you can clear this error using the Clear Error feature in the M Series Toolbox. Contact technical support person to have them, check level and possibly use Toolbox “Printer Maint Config” feature (located under Service Menu) to Zero Tilt Sensor. If problem persists they can temporarily disable tilt sensor using “Printing Control Config” features in Service Menus. MECH_CANCELPAGE Job was canceled by user pressing the CANCEL button. Wait until print job has cleared from printer. Then manually clear job from computer’s print queue. Then send new print job. Toolbox System Status Messages

AS/HJ-950C (Mach 5) Digital Color Printer Troubleshooting SYSTEM STATUS PROBLEM SOLUTION PAPERPATH_FEED_TIMEOUT Out of Paper No media is reaching the print engine. Load media into printer and press the PAPER/RESUME button. If media is present; check/adjust the guides and separators. PAPERPATH_PRINTZONE_ BLOCKED Paperpath: Entry:Yes Exit:Yes or Paperpath: Entry: No Exit:Yes or Paperpath: Entry:Yes Exit:No No = not blocked Yes = blocked (interrupted) Paper Jam Media jam detected. Printer has detected that one of the media sensors is blocked (interrupted). Carefully remove jammed Media from printer and close the print engine. The System Status message in red should go away. The toolbox “Paperpath” line should change to: Paperpath: Entry: No Exit: No After you clear the jam you can; Press RESUME button to continue printing. Press the CANCEL button to cancel the job, and then manually clear the job from the computer’s print queue. DOOROPEN_FRONT Printer has detected that the “Clamshell” is open. Verify that the print engine is closed and securely latched at both sides. DATA_PATH_UNDERRUN Printer was paused by the user pressing the PAUSE button. Press the RESUME button to continue printing. Press the CANCEL button to cancel the job, and then manually clear the job from the computer’s print queue. X_INK_LOW Example: CYAN_ INK_LOW X = Color. One or more Ink Tanks are low on ink. Ink Tank replacement will be necessary soon. Reorder Ink INK_OUT_X Example: INK_OUT_MAGENTA One or more Ink Tanks are out of ink Replace empty Ink Tank(s) Verify that Ink Tanks are seated firmly and latches are fully closed. Clear error by cycling print engine power, using ON/OFF button. CARTRIDGE_MISSING_X or INK_TANK_MISSING_X Missing Ink Tank, or Ink Tank not being recognized X = Color (CYMKK) Insert missing Ink Tank or pop tank in and out to improve connection. Clear error by cycling print engine power, using ON/OFF button. Toolbox System Status Messages

AS/HJ-950C (Mach 5) Digital Color Printer Supplies & Optional Hardware Supplies Description Part # Printhead Cartridge M5 PRINT Cyan Ink Tank (250 ml) M5 C250 Magenta Ink Tank (250 ml) M5 M250 Yellow Ink Tank (250 ml) M5 Y250 Black Ink Tank (250 ml) - printer requires two M5 K250 Cartridge Wipes (100/pack) - use with deionized or distilled water 2023 Waste Ink Tray (Tray with Absorbent material) 123-2487 Optional Hardware When ordering the printhead or Ink Tanks; for Neopost add -N, for Hasler add -H

AS/HJ-950C (Mach 5) Digital Color Printer Preparing the Printer for Transport

AS/HJ-950C (Mach 5) Digital Color Printer Preparing the Printer for Transport

AS/HJ-950C (Mach 5) Digital Color Printer Technician Install Check List Instructors Note: Have students locate and open this document.

AS/HJ-950C (Mach 5) Digital Color Printer Customer Training Check List Instructors Note: Have students locate and open this document.

AS/HJ-950C (Mach 5) Digital Color Printer Homework: Review the following mColor Software videos Introducing mColor RIP & Workflow Software  http://youtu.be/KSATDEC1GOk RENA mColor RIP & Workflow Software Color Adjustment  http://youtu.be/BMDuJ70YkIU

AS/HJ-950C (Mach 5) Digital Color Printer SOFTWARE SETUP & HANDS ON DAY 2 SOFTWARE SETUP & HANDS ON

AS/HJ-950C (Mach 5) Digital Color Printer EXAMPLES & APPLICATION TESTING Show students how to design layout in Bulk Mailer with address and barcode & print. Hands On (have students): Setup printer for media feed (sheets of paper) Do Paper Feed Test. Print address, barcode and return address, from Bulk Mailer, in an the appropriate areas. Repeat the above steps (2-4) using #10 envelope. 69

AS/HJ-950C (Mach 5) Digital Color Printer mColor open mColor training presentation Once mColor training is complete, return to this presentation to start the Service process.

AS/HJ-950C (Mach 5) Digital Color Printer Homework: Locate and review the following on the Knowledgebase or Rena Dealer Net site. Mach 5 (950C) “Common Issues & Solutions” Document Locate Mach 5 (950C) Firmware files Browse around and learn where to find things on these sites. Neopost Knowledgbase: http://techsupport.msi-east.com/ Rena USA: www.renausa.com. Click on Dealer Net button. User: neotech PW: fixit

AS/HJ-950C (Mach 5) Digital Color Printer SERVICE Installing Firmware, Measurements, Adjustments, Replacing Common Items DAY 3

AS/HJ-950C (Mach 5) Digital Color Printer How to Zero the Tilt Sensor

AS/HJ-950C (Mach 5) Digital Color Printer Service Bulletins Make sure students know where to find on knowledgebase and in the service school files they were provided.

AS/HJ-950C (Mach 5) Digital Color Printer Installing Firmware Cover firmware update request process for 110928_u firmware. Describe how to update using Toolbox Describe how to update using Firmware Migration Tool NOTE: If you have time you can show this process, but it takes about 30 minutes.

AS/HJ-950C (Mach 5) Digital Color Printer Preparing the Printer for Service Whenever the printer needs to be tilted, for servicing, you must follow the procedure, as outlined below, before performing these tasks. NOTE: We suggest the use of protective gloves during this process. Please complete the following to prepare the printer for service. Plug in the printer. Turn the printer’s Main Power Switch ON; then press the control panel’s ON/OFF button. Wait about 45 seconds for the print engine to power-up (ON/OFF button will illuminate). Open the Toolbox utility. Deprime system using the “System Deprime” feature located in Toolbox utility. NOTE: Use the System Deprime feature, NOT the Release Printhead feature. Remove the Service Station from the printer, using the “Eject Service Station” feature in the Toolbox utility. Refer to “Installing the Service Station”, located in the Operator’s Guide, for help with this process. Follow the sequence in reverse. Wrap the Service Station in paper towels and place into resealable bag. Power-down the system using the ON/OFF button and wait until all lights are off. Turn off the Main Power Switch. Then disconnect the power cable from the printer and wall outlet. IMPORTANT! Do NOT switch off the power at the power outlet or remove the power cable until all lights are off. Failure to do so may damage your printer. Disconnect the USB or Ethernet cable from your printer Remove the Printhead Cartridge and install protective covers on printhead. Store Printhead Cartridge in a sealed plastic bag with a damp cloth. Be careful to avoid spills or stains during this process. CAUTION: Make sure contacts are dry before re-installing printhead. Continued on next page NOTE: If the printer is not working you will not be able to deprime the system. In this case, it is best to keep the head and tanks installed; unless you need to work in a specific area where the head or Tanks will be in your way.

AS/HJ-950C (Mach 5) Digital Color Printer Remove all five Ink Tanks. Be careful to avoid spills or stains during this process. Wrap each ink tank in a clean, lint-free, absorbent material and place them in a sealed plastic bag as a precaution against any spillages during transport. Place paper towels into each Ink Tank slot, making sure the towels make contact with the back of the slots. This is done to absorb any ink that may leak from septum needles. NOTE: Even though the system is deprimed, some ink will remain in the lower areas of the tubing. In transit, this residual ink may drain out. Keep the printer as level as possible during service. CAUTION! During the service process the printer should remain semi-level at all times. Failure to do so may cause the printer to leak ink. When you have finished servicing the printer; please refer to Section 2 of the Operator’s Guide for details on how to properly install the Service Station, Printhead Cartridge, Ink Tanks, etc. Remember the printhead cartridge “nozzle surface” needs to be wetted using distilled water and a lint free cloth or the priming process may fail. Installation and Service Videos (where to find) Installation and Service Videos are also available for this product. Neopost/Hasler Technicians: Please see the Knowledgebase or NeoU for Installation and Service Videos. Rena Systems Technicians: Please see the Rena Dealer Net area for Installation and Service Videos. NOTE: If the printer is not working you will not be able to deprime the system. In this case, it is best to keep the head and tanks installed; unless you need to work in a specific area where the head or Tanks will be in your way.

AS/HJ-950C (Mach 5) Digital Color Printer Recommended Troubleshooting Supplies Items that a Technician should have available to them, when they visit a “Digital Color Printer” customer (in addition to standard tools): A box or ream of “inkjet suitable” media. Known good set of Ink Tanks (Cyan M5C250-N, Magenta M5M250-N, Yellow M5Y250-N, Black M5K250-N, Black M5K250-N); Known good Printhead Cartridge (M5PRINT-N) Known good Service Station (123-2483) Lint-free cloths Distilled or Deionized water Computer (Win XP, Vista, Win 7, with USB 2.0 port) and USB cable. It would be best if the computer system has been previously interfaced and tested with AS-950C. That way they should have documents or jobs already setup to test with printer, drivers loaded, toolbox loaded. Operations CD (contains printer software, drivers, operators guide, etc...) Service Manual Parts Manual; when available. Access to internet. Note: Part numbers, shown above (with “-N”), are for Neopost. Remove “-N” for Rena Systems. Add “-H” for Hasler.

AS/HJ-950C (Mach 5) Digital Color Printer Common Service Tools Needed: This list is in addition to standard tools. Spring Hook Needle Nosed Pliers Side Cutters Voltage Meter SAE set of alan wrenches #1 and #2 Philips Screwdriver T-10 Torx driver Carpenters Level (18” or longer)

AS/HJ-950C (Mach 5) Digital Color Printer Z3/Z4 Wiring Diagram

AS/HJ-950C (Mach 5) Digital Color Printer Instructors Note: Have students locate this tool (script and instructions). Demonstrate how to use Sensor Test Scripts & Service Station (SS) positioning Scripts TIP: If you are having an issue with SS movement or Lift Arm movement, you should not use the SS positioning scripts to test movement or sensor functions. In this case you will need to remove SS and manually interrupt sensors to test.

AS/HJ-950C (Mach 5) Digital Color Printer Items to cover using Service Guide (manual) Cleaning the Service Station (section 6) Removing covers, identifying components (section 5) Accessing and Cleaning media sensors (section 6, see cleaning) Feed Sensor, Paperpath sensors, Old Encoder Power Supply and Sensor Test Points (section 4) Replacing clutch, motor drive belt, feeder encoder sensor (section 5) Replacing feed rollers (section 5) Describe board removal process (show steps using service guide, section 5) Removing/replacing Print-engine (section 5) Tip: When replacing a Z2i engine with newer version you will need to replace large rubber feet and cutout frame Replacing Service Station Sled sensors (section 5) Replacing Paperpath Sensors (section 5) Replacing SS Drive components. Stepper motor & gears (section 5) Replacing Lift Arms (section 6). Motor, Lift Arms & gears (section 5) Replacing Clamshell Latch Pins (section 6) Installing SS Guide & Lubricating (Appendix C) Re-assemble and Test for proper operation.

AS/HJ-950C (Mach 5) Digital Color Printer Present students with problem scenarios and ask them how they would resolve them. Cause and solution. Give Final Exam Give Certificates 83

THE END Thanks for attending.