Replacing Maintenance Station Assembly

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Replacing the Maintenance

Station Assembly on a Falcon Outdoor PrinterParts needed for this procedure are as follows:

Maintenance Station Assembly

PrismJet Junior Outdoor 38 Part # P-M-MY-24114PrismJet Outdoor 48 & 62 Part # P-M-MY-24474

Tools needed for this procedure:

Good #2 Phillips head screwdriverSet of Metric Allen Wrenches

1. Turn off and unplug the printer

2. Remove the 4 screws and right side End Cap

3. Remove the control panel cover from the printer


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4. Loosen the 2 screws holding the Front Door at the right of the machine

5. Slide the bar out to the right allowing you to remove the Front Door

6. Remove the Ink Cartridges from the machine and remove the 5 screws from

the ink cartridge carriage tray.


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7. Remove the top cover from the printer. There is 7 screws total


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8. Remove the new Maintenance Assy from the box and inspect for any damage.Occasionally during shipping the hose routing can be altered which can cause a kinkon the hose. Any kink hose must be corrected at this time. (See diagram below)


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9. If you identify a kinked hose as shown above simply re-route it thru the Cable Tieuntil it appears to flow smoothly. (See diagram below) Usually the stainless steel

Coupling should be directly under the Cable Tie

10. Slide the Print Head Carriage Assy out to the middle of the printer.

11. Remove the Heater Control Panel Cover. 4 screws


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12. Release the white retainer by pushing the clip down and remove the datacable being very careful not to damage or crease the cable.

13. Remove the control panel. 2 screws at the base Slide the control panelupwards over the data cable.


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14. You will now see the Maintenance Assembly

15. Remove the clear tubing from the bracket.


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16. Remove the waste lines from the clear tubing.

17. Remove the 4 screws holding the maintenance assembly.


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18. Remove the 3 Allen screws on the black electrical box

19. Remove the 3 Phillips head screws attaching the black electrical box to theprinter.


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20. Let the black box swing down gently. (Make sure the electrical plug isREMOVED from the back of the electrical box)

21. Remove the brass like cover from the box, exposing the main board.


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22. Locate the small white flat cable that is plugged into the main board.


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23. Unplug the white flat cable from the main board by gently pulling up on thewhite retainer and pull upwards on the white cable.

24. Notice the blue marking on the cable, when you replace the cable from thenew maintenance assembly that blue marking will be facing forward in the plug.


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25. The white data cable is fed through the machine and will need to be removedfrom all of the holders before you can remove the maintenance station out of

the machine. Please note the routing of the cable so you can re-route it

correctly upon replacing the new maintenance assembly.

26. Once you have the white cable out of the holders, simply remove themaintenance assembly from the machine.


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27. You are now ready to install the new maintenance assembly. Remove any

tape from the assembly, and unwind the new white data cable making it

straight so you can re-route it through the machine.

28. Do not remove the white covering at the end of the white cable until you havefinished the routing of the white cable through the machine.


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29. Install the new maintenance assembly back into the machine attaching it with

the 4 screws. Make sure to feed the clear tubing out the right side of theframe of the machine.

30. Re-route the new white cabling through the machine being very careful not toBEND or CREASE this cable. Make sure you have it routed the same way itwas removed.


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31. Remove the white cover from the end of the white cable. Plug the white cableinto the main board making sure that the blue stripe is facing forward in the

plug. Once you have inserted the white cable, push down on the white

retainer locking the cable into place on the board.

32. Install the brass cover back onto the black electrical box. Attaching the coverto box with the 3 Allen screws. NOTE: NOTICE BEFORE PUTTING THE BRASS

COVER BACK ON, THAT ALL OF THE FLAT CABLES AND WIRES ARE LINED UP

AND OUT OF THE WAY OF BEING CAUGHT BETWEEN THE COVER. THERE ARE

SLOTS IN THE BACK OF THE BLACK BOX FOR THESE CABLES TO SIT.FAILURE TO DO THIS WILL RESULT IN THE CABLES OR WIRES BEING

CREASED OR EVEN BROKEN, AND WILL CAUSE MACHINE FAILURE.

33. Attach the black electrical box back up into place on the printer, using the 3

small Phillips head screws.


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34. Once this is complete, you are ready to start the re-assembly portion of themachine.

35. On the right side of the machine hook the clear tubing from the newmaintenance assembly to the existing waste lines.

36. Once the clear tubing and waste lines are attached, route the tubing throughthe bracket.


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37. Install the control panel back into the machine, making sure to route the

white flat data cable through the black holder. Once the cable is fed throughthe holder and the control panel is attached back to the machine using the 2

screws, plug the white cable into the white plug on the control panel and lockthe retainer.


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38. Install the heater control panel cover back into place. Using the 4 screwsremoved.


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39. Install the top cover back onto the machine using the 7 screws that were

removed. Make sure to start all of the screws before tightening them alldown. Once you have all of the screws started, slide the printhead back andfourth the make sure the cables are clear and not being bound. Once you

have checked the clearance then go ahead and tighten all of the screws intoplace.


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40. Install the ink cartridge carriage using the 5 screws removed.

41. Install the Front Door


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42. Install the control panel cover.


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43. Install the Right Side End Cap.

This concludes the installation of the maintenance assembly. You have

successfully installed the Maintenance Station Assembly.Please follow the next steps to adjust the Print Head to the new Maintenance

Assembly.

RESET HOME POSITION

1. With machine OFF2. Hold down the CLEANING + MENU + SHIFT all at the same time, turn the

machine ON3. You will hear a series of beeps from the machine, when you hear these beeps

let off the buttons, and the control panel will say DIAG:EXAM4. Press the MENU button ONCE to DIAG:ADJUSTMENT

5. Press the MEDIA button Once


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6. The Print Head will move around a little bit and then re-park itself7. The Control Panel will read ADJ:HOME

8. Press the MEDIA button once, the Print Head will move around again and give

you a negative number such as but not exactly -63.xxx to -64.xxx for the 48& 62 PrismJet Outdoor Printers--- If you have a PrismJet Junior 38 it willread a number such as but not exactly -72.xxx to -75.xxx.

9. Press the media button once again and do not worry about the reading on thecontrol panel, just simply power the machine OFF

After RESETING HOME POSITION perform 2 Powerful Cleanings

Follow the procedure below:Open the front door, slide the Print Head out and pour about a a capful ofcleaning solution into each of the white rectangle pads on the Maintenance

Assembly. Slide the Print Head back into the home position and close the door.Turn the machine on

Wait to initialize (Plot OK)

Press the Menu button until you come to Menu: Utility

Press the Media button OncePress the Menu Button to Clean: NORMAL

Press the Resolution Button once to change NORMAL to POWERFULPress the Media Button Once

The machine will start the powerful cleaning processDuring the Powerful Cleanings watch the waste lines into the waste bottle to

make sure that there is flow of fluids/inks through the lines.

Revision 2/ Version 106/17/2010

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Replacing Maintenance Station Assembly