OMM 00023 Maintenance Guide J

Basic Maintenance Guide
_____________
GS2000 Pro, GS2000LX, GS2000LX Pro,
GS3250, GS3200 Pro, GS3250 Pro, GS3250LX,
GS3250LX Pro
Copyright 2002-2012 Electronics for Imaging, Inc. All rights reserved.

All trademarks, registered trademarks, and product names used in this document are the
property of their respective owners.
The information contained in this document is confidential and proprietary to Electronics for
Imaging, Inc. (EFI). This information is provided only to authorized representatives of EFI
and EFI customers solely for the purpose of facilitating the use of EFIs products. No
information contained herein may be disclosed to any unauthorized person for any purpose
whatsoever without the prior written consent of EFI.
EFI makes no representations or warranties with respect to the contents of this document.
Further, EFI reserves the right to revise or change this publication and the products it
describes without notice.
English is the original language of this document.
This product may be covered by one or more of the following U.S. Patents5,109,241,
5,150,454, 5,170,182, 5,212,546, 5,260,878, 5,276,490, 5,278,599, 5,335,040, 5,343,311,
5,398,107, 5,424,754, 5,442,429, 5,459,560, 5,467,446, 5,506,946, 5,517,334, 5,537,516,
5,543,940, 5,553,200, 5,563,689, 5,565,960, 5,583,623, 5,596,416, 5,615,314, 5,619,624,
5,625,712, 5,640,228, 5,666,436, 5,682,421, 5,729,665, 5,745,657, 5,760,913, 5,799,232,
5,818,645, 5,835,788, 5,859,711, 5,867,179, 5,937,153, 5,940,186, 5,959,867, 5,970,174,
5,982,937, 5,995,724, 6,002,795, 6,025,922, 6,035,103, 6,041,200, 6,065,041, 6,081,281,
6,112,665, 6,116,707, 6,122,407, 6,134,018, 6,141,120, 6,166,821, 6,173,286, 6,185,335,
6,201,614, 6,209,010, 6,215,562, 6,219,155, 6,219,659, 6,222,641, 6,224,048, 6,225,974,
6,226,419, 6,238,105, 6,239,895, 6,256,108, 6,269,190, 6,271,937, 6,278,901, 6,279,009,
6,289,122, 6,292,270, 6,299,063, 6,310,697, 6,321,133, 6,327,047, 6,327,050, 6,327,052,
6,330,071, 6,330,363, 6,331,899, 6,337,746, 6,340,975, 6,341,017, 6,341,018, 6,341,307,
6,347,256, 6,348,978, 6,356,359, 6,366,918, 6,369,895, 6,381,036, 6,400,443, 6,429,949,
6,449,393, 6,457,823, 6,476,927, 6,487,568, 6,490,696, 6,501,565, 6,519,053, 6,539,323,
6,543,871, 6,546,364, 6,549,294, 6,549,300, 6,550,991, 6,552,815, 6,559,958, 6,572,293,
6,590,676, 6,599,325, 6,606,165, 6,616,355, 6,618,157, 6,633,396, 6,636,326, 6,637,958,
6,643,317, 6,647,149, 6,657,741, 6,660,103, 6,662,199, 6,678,068, 6,679,640, 6,687,016,
6,707,563, 6,741,262, 6,748,471, 6,753,845, 6,757,436, 6,757,440, 6,778,700, 6,781,596,
6,786,578, 6,816,276, 6,825,943, 6,832,865, 6,836,342, 6,850,335, 6,856,428, 6,857,803,
6,859,832, 6,866,434, 6,874,860, 6,879,409, 6,885,477, 6,888,644, 6,905,189, 6,930,795,
6,950,110, 6,956,966, 6,962,449, 6,967,728, 6,974,269, 6,977,752, 6,978,299, 6,992,792,
7,002,700, 7,023,570, 7,027,187, 7,027,655, 7,031,015, 7,046,391, 7,054,015, 7,058,231,
7,064,153, 7,073,901, 7,081,969, 7,090,327, 7,093,046, 7,095,518, 7,095,528, 7,097,369,
7,099,027, 7,105,585, 7,116,444, 7,177,045, 7,177,049, 7,177,472, 7,204,484, 7,206,082,
7,212,312, 7,229,225, 7,233,397, 7,233,409, 7,239,403, 7,245,400, 7,248,752, 7,259,768,
7,259,893, 7,280,090, 7,296,157, 7,301,665, 7,301,667, 7,301,671, 7,302,095, 7,302,103,
7,304,753, 7,307,761, 7,342,686, 7,343,438, 7,349,124, 7,365,105, 7,367,060, 7,367,559,
7,389,452, 7,396,119, 7,396,864, 7,397,583, 7,397,961, 7,426,033, 7,431,436, 7,433,078,
7,453,596, 7,460,265, 7,460,721, 7,461,377, 7,463,374, 7,466,441, RE36,947, RE38,732,
D341,131, D406,117, D416,550, D417,864, D419,185, D426,206, D426,206, D439,851,
D444,793.
EFI Inkjet Solutions

United States
One VUTEk Place
Meredith, New Hampshire 03253 USA
Tel
603-279-4635
Fax
603-279-6411
Technical Support, 24 Hours 603-677-3111

http://w3.efi.com/Vutek/Products
http://w3.efi.com/WideFormat/Products
Europe/Middle East
Ikaros Business Park
Ikaroslaan 9
B-1930
Zaventem, Belgium 1930
Tel
32.2.749.9420
Fax
32.2.749.9465
Internet Support
http://www.vuteksupport.com
This document is published online at http://www.vuteksupport.com
Applications Support
http://www.SuperwideFormatResource.com
Application tips, material database, white papers, industry contacts, and more.
Document ID: OMM-00023-J
OMM-00023
Table of Contents
Table of Contents
Basic Maintenance Guide .................................................................. i
EFI Inkjet Solutions ........................................................................ iii
Table of Contents ...........................................................................iv
Periodic Maintenance Procedures ...................................................... 5
Maintenance Procedures ......................................................... 5

Before Starting ...................................................................... 5
Maintenance Log ................................................................... 5
Every 4 Hours of Operation ..................................................... 6
Daily Maintenance ................................................................. 6
Weekly Maintenance .............................................................11
Replacing Arc Lamp Filter ................................................ 12
Replacing LED Lamp Filter ............................................... 13
Monthly Maintenance ............................................................19

Replacing nitrogen filters ...................................................... 25
Quarterly Maintenance ..........................................................28

Semi Annual Maintenance ......................................................32
Annual Maintenance ..............................................................35
Replacing the Arc Lamp UV Bulbs ............................................36
Grease Gun .........................................................................41
Installing or Replacing the Grease Tube ................................. 41
Grease Tubes ..................................................................... 45
Printer Maintenance Log ........................................................46
Index ..........................................................................................48
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Periodic Maintenance Procedures
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This guide contains a list of maintenance tasks and procedures for completing each
task.
Maintenance Procedures
The Maintenance Log contains maintenance procedures that are performed Every 4 Hours
of Operation, or are Daily Maintenance, Weekly Maintenance, Monthly Maintenance,
Quarterly Maintenance, Semi Annual Maintenance, and Annual Maintenance items.
Caution! You must read and understand the following documents prior to
operating or servicing this printer:
Printer Safety Guide: http://www.vuteksupport.com/doc.php?doc=683
Before Starting
Follow these guidelines for the most efficient maintenance routine.
Verify that you have all the materials required to complete each maintenance procedure.
Perform all maintenance tasks on a routine schedule.
When filling out the Maintenance Log, record the current date and time (if applicable), and write your initials in the space provided.
Perform maintenance activities either before or after printing.
The guidelines for maintenance are based on a production schedule of eight hours of
printing, five days per week. Adjust your maintenance intervals if your operating
shifts are longer than eight hours, five days per week.
Please keep your Printer Maintenance Log current. During service visits, a Field Service
Engineer often reviews your maintenance records.
Maintenance Log
The Printer Maintenance Log provides you with a list of preventive maintenance tasks, as
well as the means for tracking the completion of each task. The log has sections for
hourly, daily, weekly, monthly, quarterly, semi-annual, and annual maintenance
procedures.
Note: Use the Maintenance Log to record your completed maintenance
tasks.
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Every 4 Hours of Operation

Perform the following task every four hours of printer operation.
1. Clean jet pack surfaces

A. Follow the instructions in the Basic Operators Guide for proper jet pack wiping
procedures.
Daily Maintenance
Perform every eight hours of operation.
1. Clean top and bottom carriage rails

A. Power the printer OFF and perform a lockout/tagout.
B. With a clean, dry, lint-free wipe, wipe down entire length of top and bottom carriage rails to remove all debris.
Figure 3-1: Carriage rails
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Upper carriage rail
Lower carriage rail
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2. Wipe down purge tray rails and lubricate with 3-In-ONE oil
A. From the Service menu, select Service Aids. The Service Aids dialog box
opens.
B. In the Carriage Maintenance section, click the Maintenance button. This moves
carriage to center of printer.
C. Click the Capper button. The capper moves out to front of carriage compartment.
D. Power the printer OFF.
E. Wipe down purge tray rails with a clean wipe.
F. Lubricate tray rails and rollers with a clean wipe saturated in 3-IN-ONE Oil.
G. Proceed to 3.
Figure 3-2: Vacuum purge tray
Vacuum purge blocks, one for each jet pack
Tray rollers, both sides
Tray rails, both sides
3. Clean vacuum purge tray and purge blocks

A. Move the carriage to the center of the printer.
B. Manually pull out the vacuum purge tray.
C. Wipe down the entire vacuum purge tray and purge block orifices using a wipe
with the appropriate maintenance fluid to remove debris and ink.
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D. Click the Home button to return carriage Home.
4. Check ink box levels

A. From the Diagnostics menu, select Ink Maintenance. The Ink Details window
opens, Figure 3-4.
B. Replace empty ink boxes as outlined in the Basic Operators Guide.
Note: Check ink box levels more often during times of increased printing
production.
Figure 3-3: Ink Cabinet
Note: GS Series printers contain white ink, located in the waste cabinet.
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Figure 3-4: Ink Details
Ink colors enabled if checked
Percentage of ink remaining
Set Ink Warning Level to 5%
Ink Enable (Ink Color Control) enable/disable colors
5. Check waste tank level

A. Open waste cabinet.
B. Check waste tank level. If tank is greater than 3/4 full, proceed to the next step. If
it is less than 3/4 full, no action is necessary.
C. Unscrew waste tank cover.
D. Remove waste tank and empty into an approved waste container.
E. Re-install waste tank and cover.
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Figure 3-5: Waste container cabinet
Maintenance fluid container (labeled Solvent Bottle)
Vacuum purge container (See Annual Maintenance.)
Waste container (Waste Bottle)
Do not fill maintenance fluid container above (approximately) the

3/4 mark
6. Check head conditioning fluid level

A. Slowly unscrew maintenance fluid container cover to release air pressure inside
bottle. See Figure 3-5.
B. Add fluid to container until it is approximately 3/4 full.
C. Replace cover.
Note: Do not fill this container more than 3/4 full. When purging, the
maintenance fluid is pressurized; never attempt to fill maintenance
fluid container when purge tray is out.
7. Check air compressor water trap

Caution! Water in the air system is a major cause of print defects.
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A. Power printer OFF and perform a lockout/tagout.

B. Contact your facilities manager and the companion documentation for information
on checking and emptying compressors water trap.
8. Wipe nitrogen applicators

B. Wipe down the undersides of both nitrogen applicators on each lamp assembly
(two per lamp) using a lint -free wipe. Location of nitrogen applicators is shown in
Figure 3-6.
Figure 3-6: Nitrogen applicators
Nitrogen applicator
Weekly Maintenance
Perform the following tasks every week of printer operation.
1. Clean static bars and pins

B. Brush Static Bars and pins on both sides of carriage with a brass wire brush to
remove debris.
Note: A brass wire brush is located in the Consumables kit or by ordering
P/N P4340-A.
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C. Static bars are located on printer carriage between lamp enclosures and printer
carriage. See Figure 3-7.
Figure 3-7: Bottom view of static bar
Lamp enclosure
Static bar pins
Static bar
Carriage jet plate
2. Replace Lamp filters

A. Ensure printer is powered OFF and a lockout tagout has been performed prior to
removing or installing a filter.
B. New filters should be cut from bulk roll stock, P/N 45098331. Consider making a
template to ensure consistent sizing when cutting filters.
Replacing Arc Lamp Filter

A. Gently grasp old filter and pull filter out of lamp housing. There are two filters per
lamp.
B. Discard old filters.
C. Cut four replacement filters from bulk roll, P/N 45098331, 2.3 W x 10.5 L, and
remove any stray fibers.
Note: Use one continuous piece. Never assemble scrap pieces to meet the
dimensions.
D. Install replacement filters.

E. Repeat process for opposite lamp.
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Figure 3-8: Arc Lamp filters
Lamp filters, 2 per lamp
Replacing LED Lamp Filter

A. Loosen filter housing set screws and open filter baskets.
B. Remove old filters and discard.
C. Cut four replacement filters from bulk roll, P/N 45098331, 4.75" W x 10" L, and
remove any stray fibers.
Note: Use one continuous piece. Never assemble scrap pieces to meet the
dimensions.
D. Install replacement filters.

E. Repeat the process for the opposite lamp.
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Figure 3-9: LED Lamp filter
LED Lamp housing
Lamp filter and filter basket, 2 per lamp
Filter set screw, 2 per lamp
3. Wipe outside of lamp lenses

Danger! Ensure printer lamps are off and lenses cooled before wiping.
Power the printer OFF and perform a lockout/tagout.
A. Wipe down lamp lenses with a clean wipe and isopropyl alcohol.
Caution! Avoid scratching Lamp lens surfaces.
Figure 3-10: Bottom view of Arc Lamp assembly
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Lamp lens
UV bulb
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Figure 3-11: Bottom of LED Lamp Assembly
Bottom of LED lamp assembly
Lamp lens
Nitrogen applicators
4. Clean Media Roller Encoder strip

A. Wipe down media roller encoder strip using a clean wipe saturated in isopropyl
alcohol.
B. Change the pinch roller position to clean the strip area behind the read head.
Figure 3-12: Media Roller encoder
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Infeed roller
Media roller encoder height strip
Linear encoder read head

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5. Clean optical encoder strip and read head

B. Wipe entire length of optical encoder strip with a clean wipe and isopropyl alcohol
to remove ink and debris, moving carriage as necessary.
C. Dampen a 9 x 9 (23cm x 23cm) knitted polyester wipe with isopropyl alcohol and
slide wipe between optical encoder read head and encoder strip. See Figure 313.
D. Hold ends of wipe and move wipe back and forth across surface of read head.
Figure 3-13: Top left side of carriage
Carriage linear encoder read head
Carriage linear encoder strip
6. Clean Media Infeed/Outfeed Rollers

A. Using a clean wipe saturated with isopropyl alcohol, wipe down metal media
infeed and outfeed rollers to remove any ink, debris, and contaminants.
7. Clean media edge detector

B. Locate media edge detector at left bottom rear of carriage.
C. Clean media edge detector lens using a wipe saturated with isopropyl alcohol.
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Figure 3-14: Media edge detector, bottom of carriage
Media edge detector
Media edge detector lens
8. Check Arc bulb life

Note: LED bulb usage should be checked every six months.
A. In printer VUI, from the Diagnostics menu click Lamp Control. The Lamp Control dialog opens.
B. In the Lamp Life pane, the percentage of lamp life consumed displays.
C. If the consumed life is 100%, or curing problems exist, the arc lamp bulbs need
replacement. Refer to Replacing the Arc Lamp UV Bulbs.
Figure 3-15: Lamp Control dialog
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9. Clean UV light deflectors

A. Move carriage to center maintenance position.
B. Power the printer OFF and perform a lockout/tagout.
C. On each side of media belt, wipe down UV light deflectors with a clean wipe and
isopropyl alcohol to remove debris and ink.
Figure 3-16: UV light deflectors, (L) and (R) of media belt
10. Verify carriage head height

A. Verify the carriage head height as outlined in the GS3250 Basic Operators
Guide: http://www.vuteksupport.com/doc.php?doc=1649.
11. Inspect exhaust fans

There are two large exhaust fans located over the print area.
A. Inspect the exhaust fans for cleanliness and damage. Clean if needed. See
Monthly Maintenance, step 7.
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Monthly Maintenance
Perform the following tasks every month of printer operation.
1. Vacuum the umbilical assembly and shelf

A.
B.
C.
D.

Move carriage to operator end of printer.
Vacuum umbilical assembly and carrier shelf, Figure 3-17.
Return carriage to home.
Figure 3-17: Cable and ink bundle carrier shelf
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Cable and ink bundle carrier shelf
Cable and ink bundle carrier
Front of printer
Back of printer
Upper carriage rail
Lower carriage rail

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2. Clean door flaps and rollers

A. Wipe down rear door flaps and front door rollers with a clean wipe and isopropyl
alcohol to remove ink and debris. See Figure 3-18.
Figure 3-18: Door flaps
Door flaps, rear
Door rollers, front
3. Grease four Carriage Bearings

A. Position carriage at Home position and remove top left red end panel.
B. Using a grease gun with Microlube GL-261 grease, insert grease gun tip into fitting shown in Figure 3-19. There is a fitting on the top and bottom of carriage on
both sides. See Grease Gun for additional information.
C. Pump grease into grease fittings slowly and repeat until grease starts to overflow
from grease fitting or bearing.
Note: Wipe off any external grease on carriage bearing or carriage rail.
Ensure there is no grease on carriage drive belt.
D. Repeat process for lower carriage rail bearing.

E. Move carriage to right most side of printer and remove top right red end panel.
F. Grease top and bottom bearings as outlined in step C.
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Figure 3-19: Carriage bearing grease fitting
Carriage bearing grease fitting; bearings

at each corner of carriage
Upper carriage rail
4. Grease Carriage Lead Screw

A. Move carriage to far right side of printer.
B. Remove top right red end panel. Removing panel activates the E-stop circuit, disabling carriage movement and allows access to the three nuts securing access
panel, Figure 3-20, item 1 and 2.
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Figure 3-20: Lead screw access panel
Access panel
Nuts on inside secure access panel to rear panel
Lead screw access port, rail beam rear, see Figure 3-21, item 1
Main AC disconnect switch
C. Remove three nuts securing access panel.

D. Position carriage so Lead screw is accessible through access panel and access
port in rail beam.
Note: The red end cap must be installed to move carriage using the printer
VUI.
E. Raise carriage manually using adjustment knob on top of carriage so that the bottom of carriage mounting block is above access port in carriage rail beam. Apply a
small quantity of grease to Lead Screw.
F. Remove grease needle.
G. Lower carriage manually using adjustment knob on top of carriage so top of the
carriage mounting block is below access port in carriage rail beam. Apply a small
quantity of grease to Lead Screw.
H. Remove grease needle.
Note: Ensure there is no grease on carriage drive belt.
I. Replace access panel and top right red end panel.

J. With the printer power off, this is a good time to Check nitrogen system filter status and perform Replacing nitrogen filters, if required.
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Figure 3-21: Carriage lift Lead screw, rear of printer
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Access port right rear of rail beam behind monitor and

access hole in carriage mounting plate
Lead screw
Carriage rail beam, right side of printer
Carriage drive motor
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Figure 3-22: Front view of Lead screw assembly with carriage removed
Lead screw
Lead screw carriage mounting block
Access port in carriage mounting plate
Carriage mounting plate
5. Check nitrogen system filter status

A. For printer with LED lamps only, remove lower end cap at printer carriage home.
B. Check nitrogen filter window. Green indicates Clean, red indicates Change.
C. If the filter requires changing, refer to Replacing nitrogen filters.
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Figure 3-23: Nitrogen system filters
Replacing nitrogen filters

Follow these instructions if the filters require replacement.
A. Powerthe printer OFF and perform a lockout/tagout.
B. Remove left filter cover.
C. Unscrew blue filter base and remove filter.
Figure 3-24: Filter with cover removed
D. Install new filter, tighten blue filter base, and replace cover.
E. Repeat process for right hand filter and restart printer as required.
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6. Clean the exhaust fans

There are two large exhaust fans located over the print area.
B. Unscrew the four screws that attach the bottom finger guard.
C. Clean the upper finger guard using a vacuum cleaner wand. Insert the wand
between the fan blades to reach the finger guard.
D. Wipe fan blades or finger guards with a cloth as needed.
E. Clean the bottom finger guard with a vacuum cleaner and/or cloth as needed, and
reinstall.
Figure 3-25: Exhaust fan
7. Grease Arc Lamp Shutters

Note: LED lamp assemblies do not contain lamp shutters.
A. Power the printer OFF and perform a lockout/tagout..

B. Remove four screws holding left UV lamp cover and remove cover.
Caution! Never touch Arc lamp UV bulb unless you are wearing cotton
gloves.
C. Wipe down shutter slide rail with a clean room wipe.

D. Ensure shutter piston is fully closed and apply a small drop of hi-temp grease, P/N
45098081, underneath slide block and to each side of slide rail. See Figure 3-26
and Figure 3-27.
Note: Do not apply grease to shutter piston.
E. Manually open and close shutter five times, or more, to apply grease all along rail.
F. WIpe off any stray or excess grease.
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G. Replace Arc UV lamp cover and screws.

H. Repeat process for right side lamp.
Figure 3-26: Grease in locations indicated by red arrows
Figure 3-27: Greasing the slide rail
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Grease dispenser
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Quarterly Maintenance
Perform the following task every three months of printer operation.
1. Clean printer cabinets and components

B. In power distribution, computer, ink and waste cabinets, remove used/soiled
gloves, wipes, and other large debris.
C. Using a brush attachment, vacuum up dust and debris from components, fans,
boards, and any other locations where dust and debris collects, such as cabinet
corners. See Figure 3-28 and Figure 3-29 where arrows indicate.
D. Vacuum dust off of smoke detector, located inside printer above media table.
Note: Check that all cable connections are secure after cleaning.
Figure 3-28: Power distribution cabinet
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Figure 3-29: Computer/Electronics Cabinet
Note: Some printer configurations contain only a single motherboard.

Figure 3-30: Smoke detector
Smoke detector
Inside front of printer
Front door
2. Clean Arc Lamp assembly

Note: LED lamp assemblies do not require internal cleaning. Only clean LED
lamp lens exterior as described in Clean media edge detector.
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B. Remove lamp assembly and clean inside of lens and lamp bulb with isopropyl
alcohol and a polyester wipe.
C. Refer to Replacing the Arc Lamp UV Bulbs for instructions on disassembling Arc
lamps.
Warning: Never handle an Arc lamp bulb with bare hands. Wear cotton
gloves to prevent residue from hands being deposited on bulb.
D. Before re-installing Arc UV lamps, Replace carriage fan filters.
3. Replace carriage fan filters

A.
B.
C.
D.

Unscrew carriage fan filter housing. See Figure 3-31.
Remove old carriage fan filter and replace with a new one.
Repeat process for opposite side of carriage.
Figure 3-31: Carriage Fan Filter, Left side of Carriage
4. Clean or replace cabinet air intake filters

A. Power the printer OFF perform a lockout/tagout.
B. Locate filters behind rollers on outside panel of each compartment facing center of
printer and two filters on the computer compartment doors There are a total of
eight filters: one each for the ink and waste compartments, two for the electronics
compartment and four on the computer compartment.
C. Vacuum the filters.
D. Inspect filters for wear and tear. If filters are worn or damaged, replace filter by
removing cabinet fan cover and filter.
E. Install new filter and cover.
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Figure 3-32: Cabinet air filters - ink cabinet (L) and computer cabinet (R)
5. Replace transformer enclosure air intake filters

Note: Transformer filters are installed only on GS LED lamp printers.
A. Power the printer OFF and perform a Lockout/Tagout.

B. Remove the inner-facing air intake filter and filter housing on the transformer
enclosure, Figure 3-33.
Figure 3-33: Front of printer showing transformer enclosure location
Air filter
Transformer
C. Insert new filter in filter housing, part number P7442-A, and replace assembly. Filter location is shown in Figure 3-34.
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Figure 3-34: Transformer Enclosure end showing location of air intake filter.
Air Filter
Semi Annual Maintenance

1. Replace all primary ink filters
A. Locate primary ink filter for each color. See Figure 3-35.
Note: Also replace white primary ink filter located in Waste cabinet.
Figure 3-35: Primary Ink filters - (1)
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Primary Ink Filter

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B. Remove primary ink filter from filter clamp by inserting a flat bladed screwdriver at
point shown in Figure 3-36. Twist screwdriver to open clamp.
Figure 3-36: Primary ink filter clamp
Insert flat bladed screwdriver at this point
C. With filter removed from bracket, remove one ink line at a time and install onto
replacement filter.
Note: Place a cloth under each fitting, as ink will flow from ink filter and tubes.
D. Hand-tighten ink line to new primary ink filter.

E. Place Primary Filter Compression Fitting gauge, P/N 45094233, between filter
and ink line.
Figure 3-37: Proper positioning of gauge, P/N 45094233, on filter
F. Hold tube while tightening fitting to prevent tube from twisting.
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Figure 3-38: .130 is the optimal specification within a range of +/- .010
G. Do not over-tighten fitting as tube could compress and restrict ink flow to carriage;
see Figure 3-39.
H. Do not under-tighten as air can transfer into ink system. Under and over-tightening can cause jet dropout and ink starvation.
Figure 3-39: Tubing damaged due to over-tightening fittings
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2. Replace 20 micron Luer Simriz filter

A. Release the quick disconnect at bottom of filter.
B. Unscrew filter at top and remove old filter.
C. Screw new filter to the top of the bleeder line and attach quick connector.
Figure 3-40: Simriz filter
Simriz filter
3. Check nitrogen system filter status

Reference 5.Check nitrogen system filter status section under Monthly Maintenance.
Annual Maintenance
Perform the following task every year of printer operation.
1. Replace the vacuum purge container

A.
B.
C.
D.
Open waste cabinet.

Unscrew vacuum purge container cover.
Discard old container according to site disposal policy.
Remove each of the lines, one at a time, and replace lines into the new cover in
the same configuration.
E. Place new vacuum purge container in cabinet.
F. Replace container cover.
EFI-VUTEk
35
EFI-VUTEk
Figure 3-41: Vacuum Purge Container
Vacuum Purge Container
Replacing the Arc Lamp UV Bulbs

Perform the following task every 1000 hours of printer operation, or as needed.
A. Power the printer OFF and perform a Lockout/Tagout .
B. Remove two top red printer end panels. This allows access to lamp assemblies.
Note: Push carriage to right-most maintenance position to access right
carriage lamp.
C. Remove 4 air filter plate bolts shown in Figure 3-42 item 1.
EFI-VUTEk
36
EFI-VUTEk
Figure 3-42: Side view of lamp assembly
Air filter plate bolts
Air filter plate
Air filter
Cooling fans
D. After removing 4 air filter plate bolts, push plate upwards, pull out on bottom of
plate, then pull air filter plate down.
E. To remove UV bulb enclosure, remove four bolts shown in Figure 3-42 item 2.
There are two bolts at either end.
F. Unplug two UV bulb voltage connectors by pulling gently on each connector, Figure 3-43, item 3.
Note: Do not pull on wires or damage may occur.
G. Slide UV bulb enclosure out of lamp assembly by grasping both sides of lamp
assembly.
Note: Do not allow UV bulb enclosure to touch or drop onto lens.
EFI-VUTEk
37
EFI-VUTEk
Figure 3-43: Lamp assembly with air filter plate removed
UV bulb enclosure and reflector
Bolts to remove UV bulb enclosure, two at either side
Voltage connectors for UV bulb
Grasp lamp assembly at this point to slide assembly out

of lamp housing
H. To remove lens, remove two bolts shown in Figure 3-44. Remove lamp lens
clamp and carefully lift quartz lens out of lamp assembly.
Warning: Wear cotton gloves before touching lens or UV bulb. Failure to
wear cotton gloves will deposit oil from your skin onto lens and
bulb causing premature failure.
EFI-VUTEk
38
EFI-VUTEk
Figure 3-44: Lamp lens clamp
Lamp lens clamp
Quartz lamp lens
Front edge of quartz lamp lens
Figure 3-45: End view of UV bulb enclosure
Bulb clamp
End plate
UV bulb
End of UV bulb
EFI-VUTEk
39
I.
EFI-VUTEk
Remove end plates at both ends of UV bulb enclosure, Figure 3-45, item 2.
Figure 3-46: End view of UV bulb enclosure, end plate removed
End plate
End of UV bulb
Bulb clamp bolt
UV bulb
J. Remove bulb clamp bolt at both ends of UV bulb and lift clamp off bulb. Do not
remove the pin and clips at the bulb clamp pivot point, Figure 3-47, item 3.
EFI-VUTEk
40
EFI-VUTEk
Figure 3-47: Lamp bulb clamp
Bulb clamp
Bulb clamp bolt
Bulb clamp pivot point
UV Bulb
K. Install replacement UV bulb.

L. Reverse above procedure to reinstall lamp assembly.
Grease Gun
Included with your printer are two grease guns. Each grease gun box will contain a 12
(30.5 cm) flexible hose. Packed separately will be the 18 (45.7 cm) flexible hose used for
greasing the lead screw.
Note: When installing grease tubes into grease gun, label each grease gun
with the grease type installed.
Installing or Replacing the Grease Tube

1. Remove grease gun head assembly.
EFI-VUTEk
41
EFI-VUTEk
Figure 3-48: Grease gun, needle installed for carriage bearings
Grease gun metal tube
Grease gun head assembly
Flexible hose
Note: The flexible hose to grease carriage bearings is 12 (30.5
cm) and flexible hose to grease Lead Screw is 18 (45.7 cm).
Plunger rod handle
Needle shown is for Lead screw
2. Pull plunger rod out and slide it to side locking plunger rod in place.
EFI-VUTEk
42
EFI-VUTEk
Figure 3-49: Grease gun tube, head removed and plunger rod out and locked
3. Remove plastic cap from end of grease tube, Figure 3-55, item 1, and insert this end
into grease gun metal tube.
Figure 3-50: Grease tube inserted into grease gun metal tube
4. Remove metal end cap on grease tube.

Figure 3-51: Grease tube inserted into grease gun with cap partially removed
5. Reinstall head assembly and connect flexible hose.

6. Unlock plunger rod and push rod into metal grease tube.
7. Install correct length flexible tube to outlet fitting on grease gun, Figure 3-52.
EFI-VUTEk
43
EFI-VUTEk
Figure 3-52: Grease gun with head assembly installed
8. Pump grease gun until grease exits nozzle. This indicates that any air within grease
gun has been removed.
If grease does not exit needle, carefully unscrew air bleeder screw on head of
grease gun, Figure 3-53.
Caution: Do not remove air bleeder screw completely.
9. Slowly pump grease gun until grease exits air bleeder screw or needle. When grease
exits, retighten air bleeder screw and pump grease gun until grease exits needle in a
smooth flow.
Figure 3-53: Air bleeder screw
EFI-VUTEk
Air bleeder screw
44
EFI-VUTEk
Figure 3-54: Grease gun needle and adapter for greasing carriage bearings
Grease Tubes
Figure 3-55: Grease tubes, Carriage bearings (Left &Center), Lead Screw (Right)
Plastic cap at end of grease tube
Note: Part number 45086492 greases are specifically formulated for

greasing carriage bearings; do not use a substitute. Any high quality
wheel bearing grease is acceptable for greasing lead screw.
EFI-VUTEk
45
Instructions: Print the first page of the Printer Maintenance Log each week to maintain a record of daily and weekly maintenance activities.
Print the second page once per year to maintain a record of monthly, quarterly, semi-annual, and annual maintenance activities. When a task is complete, enter your initials.
Page 46
Printer Maintenance Log

Weekly Maintenance Chart: ___ /___ /___ to ___ /___ /___
Day 1
Every 4 Hours
Day 2
3
Day 3
3
Day 4
3
Day 5
3
Day 6
3
Day 7
3
1. Clean jet pack surfaces using a Polyurethane Foam Wipe (part# 45090057) saturated with appropriate maintenance fluid.
Daily Tasks (Perform prior to Printing and every eight hours
Day 1
Day 2
Day 3
Day 4
Day 5
Day 6
1. Clean top and bottom carriage rails with a clean Knitted Polyester Wipe (part# 45077321).
2. Wipe down purge tray rails and lubricate with a clean Knitted Polyester Wipe (part# 45077321) saturated
with 3-In-ONE Oil (part# P2191-A).
3. Clean vacuum purge tray and purge blocks with a clean Knitted Polyester Wipe (part# 45077321) and the
appropriate cleaning/maintenance fluid.
4. Check ink box levels and replace as needed.
5. Check waste tank level and empty if more than 3/4 full.
6. Fill maintenance fluid container 3/4 full with the appropriate maintenance fluid.
7. Check water trap on facility air compressor and empty as needed.
8. Wipe nitrogen applicators.
Weekly
Date
Initials
1. Clean static bars and pins with Brass Wire Brush (part#P4340-A).
2. Replace lamp filters with Bulk Lamp Filter (part# 45098331).
3. Wipe outside of lamp lenses with a clean Knitted Polyester Wipe (part# 45077321) and isopropyl alcohol.
4. Clean media roller encoder strip with a Knitted Polyester Wipe (part# 45077321) and isopropyl alcohol.
5. Clean optical encoder strip and read head with a Knitted Polyester Wipe (part# 45077321) and isopropyl alcohol.
6. Clean front and rear metal media rollers with a Knitted Polyester Wipe (part# 45077321) and isopropyl alcohol.
7. Clean media edge detector lens with a clean Knitted Polyester Wipe (part# 45077321) and isopropyl alcohol.
8. For arc lamps only: Check remaining bulb life in printer VUI.
9. Clean UV light deflectors with a clean Knitted Polyester Wipe (part# 45077321) and isopropyl alcohol.
10. Verify carriage head height as outlined in the Basic Operators Guide.
11. Inspect exhaust fans.
Technical Support
United States
Europe and Middle East
Other
+1 603 677 3111, ext. 4
+32 2 749 94 50
+1 650-357-4790
Part Orders
+1 603 677 3111, ext. 1
+31 20 658 8070
internationalorders@efi.com
Online Support
http://www.vuteksupport.com/support.php
The maintenance guidelines are based on a production schedule of eight hours of printing, five days/week.
Adjust your maintenance intervals if your operating shifts are longer than eight hours of printing.
2013 Electronics For Imaging, Inc. All Rights Reserved. The EFI logo, Electronics For Imaging, and VUTEk are registered trademarks of Electronics for Imaging, Inc. in the U.S. Patent and Trademark Office and/or certain other foreign jurisdictions.
Day7
Instructions: Print the first page of the Printer Maintenance Log each week to maintain a record of daily and weekly maintenance activities.
Print the second page once per year to maintain a record of monthly, quarterly, semi-annual, and annual maintenance activities. When a task is complete, enter your initials.
Page 47
Maintenance Chart for 20___

Monthly
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sept
Oct
Nov
Dec
1. Vacuum umbilical assembly and shelf.

2. Clean light blocking flaps on the front and rear doors with a clean Knitted Polyester Wipe (part#
45084568) and isopropyl alcohol.
3. Grease four carriage bearings using Microlube GL-281 grease (part# 45086492).
4. Grease carriage lead screw using AeroShell 7 Grease (part# P8166-A) only.
5. LED lamps only: Check the nitrogen system filter status. Replace nitrogen filters as needed.
6. Clean both exhaust fans.
7. Arc lamps only: Apply Hi-Temp Lamp Grease (part# 45098081) to the lamp shutter mechanism components.
Quarterly
Quarter 1
Quarter 2
Quarter 3
Quarter 4
1. Clean/vacuum printer, including cabinet components, intake and exhaust fans, and smoke detector.
2. Arc lamps only: Wearing Cotton Gloves (part# P3775-A) clean inside of the lamp lens, reflector, and bulb with a Knitted
Polyester Wipe (part# 45084568) and isopropyl alcohol.*
3. Replace carriage fan filters on left and right carriage sides with Fan Filter 2.36" (part# P4970-A).
4. Clean or replace cabinet air intake filters with Fan Filter 4" (part# P7442-A).
5. Replace transformer enclosure air intake filter with Fan Filter 4" (part# P7442-A).
Semi Annually
January
July
1. Replace all primary ink filters with Primary Ink Filters (part# P0029-A).
2. Replace 20 micron Luer Simriz Filters (part# 45072843) on bleeder hoses.
3. Check nitrogen filter status.
Annually
One Year Anniversary of Installation
1. Replace Vacuum Purge Container (part# AA90647).
*Warning: Arc lamp bulbs contain mercury powder. If an arc lamp bulb breaks, treat the accident as a hazardous spill and immediately contact a Material Safety expert and follow your companys
protocol for hazardous material handling.
Common Maintenance Items

Description
AeroShell 7, Grease
Hi Temp Lamp Grease (Arc lamps only)
EFI Part Numbers

P8166-A
Description
Brass Wire Brush
EFI Part Numbers

P4340-A
Description
Polyurethane Foam Wipes
EFI Part Numbers

45090057
45098081
Vacuum Purge Container
AA90647-FS
Filter 2.36 fan
P4970-A
45086492
Primary Ink Filter
P0029-A
Filter Fan 4 in 5-Pack
P7442-A
3-In-ONE Oil, 3 oz
P2191-A
Knitted Polyester Wipes
45077321
Bulk Lamp Filter stock, LED and Arc
45098331
Head Cleaning/Maintenance Fluid
45099546
Head Conditioning Fluid GS Series
45084854
Filter set elements Nitrogen System, LED only 45096220
20 Micron Luer Simriz filter
45072843
Microlube
GL-261
The maintenance guidelines are based on a production schedule of eight hours of printing, five days/week.
Adjust your maintenance intervals if your operating shifts are longer than eight hours of printing.
2013 Electronics For Imaging, Inc. All Rights Reserved. The EFI logo, Electronics For Imaging, and VUTEk are registered trademarks of Electronics for Imaging, Inc. in the U.S. Patent and Trademark Office and/or certain other foreign jurisdictions.
Index
A
Annual Maintenance 34
B
Before Starting 5
D
Daily Maintenance 6
E
Every 4 Hours of Operation 6
G
Grease Gun 39
M
Maintenance Log 5
Maintenance Procedures 5
Monthly Maintenance 19
P
Periodic Maintenance Procedures 5
Q
Quarterly Maintenance 26
R
Replacing the Arc Lamp UV Bulbs 34
S
Semi Annual Maintenance 31
W
Weekly Maintenance 11
OMM-00023
48
Auto-Count, BioVu, ColorWise, Command WorkStation, Digital StoreFront, DocBuilder, DocBuilder Pro, DocStream,
EDOX, the EFI logo, Electronics For Imaging, Fabrivu, Fiery, the Fiery logo, Fiery Driven, the Fiery Driven logo, Inkware, Jetrion, MicroPress, OneFlow, PressVu, Printellect, PrinterSite, PrintFlow, PrintMe, PrintSmith Site, Prograph,
RIP-While-Print, Ultravu and VUTEk are registered trademarks of Electronics for Imaging, Inc. in the U.S. Patent and
Trademark Office and/or certain other foreign jurisdictions. BestColor is a registered trademark of Electronics For
Imaging GmbH in the U.S. Patent and Trademark Office.
AutoCal, Balance, BioWare, ColorPASS, EFI, Estimate, Fast-4, Fiery Link, Fiery Prints, Fiery Spark, the Fiery Prints
logo, FreeForm, Hagen, Logic, Pace, Printcafe, PrintSmith, Print to Win, PSI, PSI Flexo, Rastek, RIPChips, Screenproof, SendMe, Splash, Spot-On, UltraTex, UV Series 50, VisualCal and WebTools are trademarks of Electronics for
Imaging, Inc. Best, the Best logo, Colorproof, PhotoXposure, Remoteproof, and Screenproof are trademarks of Electronics For Imaging GmbH.
All other terms and product names may be trademarks or registered trademarks of their respective owners, and are
hereby acknowledged.
2012 Electronics for Imaging.

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Basic Maintenance Guide

Copyright 2002-2012 Electronics for Imaging, Inc. All rights reserved.

EFI Inkjet Solutions

Technical Support, 24 Hours 603-677-3111

Document ID: OMM-00023-J

Maintenance Procedures ......................................................... 5

Monthly Maintenance ............................................................19

Quarterly Maintenance ..........................................................28

Printer Maintenance Log ........................................................46

Periodic Maintenance Procedures

Periodic Maintenance Procedures

Periodic Maintenance Procedures

Every 4 Hours of Operation

1. Clean jet pack surfaces

1. Clean top and bottom carriage rails

Upper carriage rail

Lower carriage rail

Periodic Maintenance Procedures

Vacuum purge blocks, one for each jet pack

Tray rollers, both sides

Tray rails, both sides

3. Clean vacuum purge tray and purge blocks

Periodic Maintenance Procedures

D. Click the Home button to return carriage Home.

4. Check ink box levels

Periodic Maintenance Procedures

Ink colors enabled if checked

Percentage of ink remaining

Set Ink Warning Level to 5%

Ink Enable (Ink Color Control) enable/disable colors

5. Check waste tank level

Periodic Maintenance Procedures

Figure 3-5: Waste container cabinet

Maintenance fluid container (labeled Solvent Bottle)

Vacuum purge container (See Annual Maintenance.)

Waste container (Waste Bottle)

Do not fill maintenance fluid container above (approximately) the

6. Check head conditioning fluid level

7. Check air compressor water trap

Periodic Maintenance Procedures

A. Power printer OFF and perform a lockout/tagout.

8. Wipe nitrogen applicators

1. Clean static bars and pins

Periodic Maintenance Procedures

Static bar pins

Carriage jet plate

2. Replace Lamp filters

Replacing Arc Lamp Filter

D. Install replacement filters.

Periodic Maintenance Procedures

Figure 3-8: Arc Lamp filters

Lamp filters, 2 per lamp

Replacing LED Lamp Filter

D. Install replacement filters.

Periodic Maintenance Procedures

Figure 3-9: LED Lamp filter

LED Lamp housing

Lamp filter and filter basket, 2 per lamp

Filter set screw, 2 per lamp

3. Wipe outside of lamp lenses

Periodic Maintenance Procedures

Figure 3-11: Bottom of LED Lamp Assembly

Bottom of LED lamp assembly