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1. USERS
This Service Note is only for authorized persons with user ID and password issued by Roland DG Corporation.
2. PURPOSE
Authorized persons can use this Service Note only for the purposes of selling and providing to the customers
maintenance service of SJ-745EX/645EX.
3. REUSE
Authorized persons shall not disclose, transfer, rent or distribute this Service Note to, or allow this Service Note to
be used in any manner by, any third party other than authorized persons.
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5. EFFECT OF VIOLATION
Regardless of circumstances, we will vigorously respond to any violation hereof, through legal action.
Confi dential
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1 Structure & Spare Parts1-1 COVERS ....................................................................................................................................................................1-11-2 FRAME .....................................................................................................................................................................1-31-3 CARRIAGE .................................................................................................................................................................1-51-4 DRIVE UNIT ..............................................................................................................................................................1-71-5 CHASSIS ...................................................................................................................................................................1-91-6 PINCH ROLLER ......................................................................................................................................................1-111-7 STAY ROLL ..............................................................................................................................................................1-121-8 WIPER SYSTEM .....................................................................................................................................................1-131-9 PUMP SYSTEM .......................................................................................................................................................1-141-10 INK SYSTEM ...........................................................................................................................................................1-171-11 BASE FRAME ..........................................................................................................................................................1-181-12 ACCESSORIES & STAND .......................................................................................................................................1-191-13 TUC-1 CONTROLLER .............................................................................................................................................1-201-14 TUC-1 OTHERS .......................................................................................................................................................1-211-15 TUC-1 ACCESSORIES ............................................................................................................................................1-221-16 TU-750/650/550 .......................................................................................................................................................1-22
2 Electrical Section2-1 WIRING MAP .............................................................................................................................................................2-12-2 MAIN BOARD ............................................................................................................................................................2-42-3 HEAD / SERVO BOARD .........................................................................................................................................2-122-4 SUB BOARD ............................................................................................................................................................2-242-5 TUC-1 ......................................................................................................................................................................2-302-6 HEATER BOARD ......................................................................................................................................................2-312-6 MAINTENANCE PARTS LIST .................................................................................................................................2-333 Replacement of Main Parts3-1 HEAD REPLACEMENT ............................................................................................................................................3-13-2 WIPER REPLACEMENT ...........................................................................................................................................3-83-3 CAP TOP REPLACEMENT .....................................................................................................................................3-103-4 CARRIAGE MOTOR REPLACEMENT ....................................................................................................................3-153-5 PUMP REPLACEMENT ...........................................................................................................................................3-193-6 INK TUBE REPLACEMENT ....................................................................................................................................3-233-7 BOARDS REPLACEMENT ......................................................................................................................................3-273-8 BATTERY REPLACEMENT .....................................................................................................................................3-393-9 CARRIAGE WIRE REPLACEMENT ........................................................................................................................3-433-10 ENCODER SCALE REPLACEMENT ......................................................................................................................3-48
4 Adjustment4-1 Special Tools ..............................................................................................................................................................4-14-2 SERVICE MODE .......................................................................................................................................................4-24-3 HOW TO UPGRADE FIRMWARE ............................................................................................................................4-164-4 HEAD ALIGNMENT ..................................................................................................................................................4-194-5 CAP HEIGHT ADJUSTMENT ..................................................................................................................................4-294-6 LINEAR ENCODER SETUP ....................................................................................................................................4-314-7 LIMIT POSITION & CUT DOWN POSITION INITIALIZE ........................................................................................4-324-8 PAPER SIDE SENSOR ADJUSTMENT ..................................................................................................................4-344-9 CALIBRATION (FEEDING DIRECTION) .................................................................................................................4-374-10 CARRIAGE WIRE TENSION ADJUSTMENT ..........................................................................................................4-394-11 NETWORK BOARD INITIALIZE .............................................................................................................................. 4-424-12 OPERATION OF THE HEATER CONTROLLER .....................................................................................................4-444-13 SETTING THE PARAMETER OF THE HEATER CONTROLLER ..........................................................................4-45 5 Supplemental Information5-1 SENSOR MAP ............................................................................................................................................................5-1
6 Troubleshooting6-1 WHITE FINE LINES / BANDING / MISSING DOT / SCRATCHY
PRINTING / BLURRED PRINTING ...........................................................................................................................6-16-2 IT DOESN’T PRINT AT ALL .......................................................................................................................................6-26-3 INK DROPS ON MEDIA .............................................................................................................................................6-26-4 SHIFTING IN PRINTING ............................................................................................................................................6-36-5 VERTICAL BANDING .................................................................................................................................................6-36-6 MEDIA SHIFTING .......................................................................................................................................................6-36-7 MOTOR ERROR .......................................................................................................................................................6-46-8 ERROR MESSAGE ....................................................................................................................................................6-5 SERVICE CALL ...............................................................................................................................................................6-56-9 HEATER TEMPERATURE FAILS TO REACH THE PRESET VALUE .......................................................................6-66-10 RESULTS OF PRINTING ARE COARSE ..................................................................................................................6-66-11 ERROR MESSAGE (HEATER CONTROLLER) .........................................................................................................6-7
7 Service Activities7-1 INSTALLATION CHECK LIST ....................................................................................................................................7-17-2 MAINTENANCE CHECK LIST .................................................................................................................................7-207-3 Specifi cation .............................................................................................................................................................7-22
Contents
Revision Record
RevisonNo. Date Description of Changes Approval Issued
0 2005.2.22 First Edition Inagaki Sato
1 2005.2.25 1-2 FRAME, 1-12 ACCESSORIES & STAND_ Part No. has been revised. Inagaki Nakatani
2 2005.6.22 1-11BASE FRAME_ Part No. has been revised.6-7 Motor Error codes have been added. Kato Hioki
3 2005.8.51-4 DRIVE UNIT 1-5 CHASSIS _ Parts have been revised.
2-7 : MAINTENANCE PARTS LIST_Electrical Parts has been revised.4-3 : HOW TO UPGRADE FIRMWARE Step8_The key has been corrected.
Kato Mabuchi
4 2006.1.12 1-8 WIPER SYSTEM, 1-3 HEAD CARRIAGE_Parts have been revised.7-2 MAINTENANCE CHECK LIST_Check Points has been revised. Kato Misako
5 2006.12.19 3-8 BATTERY REPLACEMENT_Procedures have been revised.1-9 PUMP SYSTEM_Parts have been revised. Kato Misako
6 2007.4.26 1-7 : STAY ROLL, 1-9: PUMP SYSTEM, 1-15 : TUC-1 ACCESSORIES, 2-1 :WIRING MAP Parts have been revised. Kato Misako
7 2007.5.21 Sect1 : Parts have been revised. Kato Mabuchi
8 2007.11.221-3 HEAD CARRIAGE, 1-4 DRIVE UNIT, 1-9 PUMP SYSTEM,
1-15 : TUC-1 ACCESSORIES Parts have been revised.Sect3 : "WARNING" has been revised.
Kato Misako
To Ensure Safe Work
To Ensure Safe Work
About and Notices.
Used for instructions intended to alert the operator to the risk of death or severe injury should the unit be used improperly.
Used for instructions intended to alert the operator to the risk of injury or material damage should the unit be used improperly.* material damage refers to damage or other adverse effects caused with respect to the home and all its furnishings, as well to domestic animals or pets.
About the Symbols
The symbol alerts the user to items that must never be carried out (are forbidden). The specifi c thing that must not be done is indicated by the design contained within the circle.The symbol at left means not to touch.
The symbol alerts the user to things that must be carried out. The specifi c thing that must be done is indicated by the design contained within the circle. The symbol at left means the power-cord plug must be unplugged from the outlet.
The symbol alerts the user to important instructions or warnings. The specifi c meaning of the symbol is determined by the design contained within the triangle. The symbol at left means anger of electrocution
In addition to the and symbols, the symbols shown below are also used.
: Tips and advise before the adjustment.
About the Labels Affi xed to the Unit
HIGH VOLTAGE,HANDLING ATTENTION• Do not touch during power on Electric shock, Compornents damage• Do not repair. Replace power unit.• Do not replace fuse. Can not be recovered.
About the Labels Affi xed to the Unit These labels are affi xed to the body of this product. The following fi gure describes the location.
Electric charge.Do not touch when power is on.
Do not recharge, short-circuit, disassemble the lithium battery, nor put it into fi re.It may cause heat, explosion and fi re.
Put tape around the lithium battery for insulation for disposal or preservation.It may cause heat, explosion and fi re.
Turn off the primary power SW before servicing.
1 Structure & Spare Parts1-1 COVERS
1-1
S6
12
9
14
S6
S1
S101
S1
S10
S6
S9
S6
10
11
2
1516
S6
S7
S533
18
17
S3
3233
S5
S7
6
7
S6
13S5
22
23
24
28
25
6
19
31S5
S10
S2
5
S11
S2
S10
S11
5
S10
S2
S10
S2
34
21
208
30
S6S6
3
4
S8
S8
S8
S6
S4
35
S8
S827
26
1
29
1-1 COVERS
PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts-Parts No. Parts Name Parts No. Parts Name
14 23505851 CABLE ASSY HEAD U/D SENS FJ-540 * * *Revised 8: Refer to Service Information SJ745EX-010.15 23505853 CABLE ASS'Y,P-SIDE SENSOR FJ-540 * * *Revised 4: Refer to Service Information SJ745EX-004.16 23475206 CABLE-CARD 21P1 330L BB * *
23475218 CABLE-CARD 36P1 2710L BB HIGH-V * PARTS LIST -Supplemental Parts-23475198 CABLE-CARD 36P1 2940L BB * Parts No. Parts Name
Revised 37811909000 ASSY,FEED MOTOR FJ-540Refer to the Service Information : SJ-745EX-002Revised 67811909010 ASSY,SCAN MOTOR 2 FJ-540Refer to the Service Information : SJ-745EX-005
Revised 6
Revised 8
Revised 8
1-5 CHASSIS
1-9
3
7
613
14
16
18
19
21 22
23
26
29
30
31
31
31
3132
33
35
25
S2
S3S4
S4
S4
S5 S5
S5
S5
S5
S14
S4
S13
S17
S17
S16
CN
2
CN
3
8
11
S12
5
9
10
17
4
1215
34
S5
S12
27
S8
411
37
S5
S5
S12
2428
236
4039
S5
S14
S15
S15
S15
S7
S8S9
S10
S10
S10
S12
S11
S11
S12 S1
1
S11
S12
S15
20
S6
S6
S6
S6
S1
S12
S5
S6
S5
S5
S5
S5
38
Rev
ised
3
1-5 CHASSIS
PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts-Parts No. Parts Name Parts No. Parts Name
34 22175332 SPRING,PLATE BUSH FJ-540 * * *Revised 5: Refer to Service Information SJ745EX-008.35 22175326 SPRING,TABLE FJ-540 * * *Revised 8: Refer to Service Information SJ745EX-011.36 22175324 SPRING,TABLE MOTOR FJ-540 * *
1 23505462 CABLE-ASSY AC NEUTRAL BLUE FJ-50 * *2 23505463 CABLE-ASSY AC LIVE BROWN FJ-50 * *3 23415288 CABLE-ASSY AC GROUND GREEN 5EX * *4 23415277 CABLE-ASSY 5EX POWER AC * *5 23505840 CABLE-ASSY POWER HEAD FJ-540 * *6 23505841 CABLE-ASSY POWER SERVO FJ-540 * *7 23505999 CABLE-ASSY HEAD BOARD FAN FJ-540 * *
2-6 HEATER BOARDArrangement Diagram_Component Side
2-32
2
Heater Board_Circuit Diagram
2-33
2
2-7 MAINTENANCE PARTS LIST _ Electrical Parts
MAIN BOARDIC No. Parts No. Description FunctionIC17 15169124 LM1086IS-ADJ +3.3V VOLTAGE REGULATORIC18 15169124 LM1086IS-ADJ +1.8V VOLTAGE REGULATOR
SERVO BOARDIC No. Parts No. Description Function
IC2 15189105 MTD2005 MOTOR DRIVER for Right PUMPIC3 15189105 MTD2005 MOTOR DRIVER for Left PUMPIC4 15189105 MTD2005 MOTOR DRIVER for Middle PUMPQ4 15119122 2SJ535 MOTOR POWER SUPPLY
HEAD BOARDIC No. Parts No. Description FunctionIC50 15159127 E09A19RA D/A CONVERTER(CYAN)IC51 15159127 E09A19RA D/A CONVERTER(MAGENTA)IC52 15159127 E09A19RA D/A CONVERTER(YELLOW)IC54 15159127 E09A19RA D/A CONVERTER(BLACK)IC55 15159127 E09A19RA D/A CONVERTER(LIGHT MAGENTA/MAGENTA)IC56 15159127 E09A19RA D/A CONVERTER(LIGHT CYAN/CYAN)IC58 15159127 E09A19RA D/A CONVERTER(CYAN)IC59 15159127 E09A19RA D/A CONVERTER(MAGENTA)IC60 15159127 E09A19RA D/A CONVERTER(YELLOW)IC62 15159127 E09A19RA D/A CONVERTER(BLACK)IC63 15159127 E09A19RA D/A CONVERTER(LIGHT MAGENTA/MAGENTA)IC64 15159127 E09A19RA D/A CONVERTER(LIGHT CYAN/CYAN)TR2 15129121 2SA1746 TRANSISTOR for HEAD DRIVER(CYAN)TR3 15129122 2SC4131 TRANSISTOR for HEAD DRIVER(MAGENTA)TR6 15129121 2SA1746 TRANSISTOR for HEAD DRIVER(YELLOW)TR7 15129122 2SC4131 TRANSISTOR for HEAD DRIVER(BLACK)TR10 15129121 2SA1746 TRANSISTOR for HEAD DRIVER(LIGHT MAGENTA/MAGENTA)TR11 15129122 2SC4131 TRANSISTOR for HEAD DRIVER(LIGHT CYAN/CYAN)TR18 15129122 2SC4131 TRANSISTOR for HEAD DRIVER(CYAN)TR19 15129121 2SA1746 TRANSISTOR for HEAD DRIVER(MAGENTA)TR22 15129122 2SC4131 TRANSISTOR for HEAD DRIVER(YELLOW)TR23 15129121 2SA1746 TRANSISTOR for HEAD DRIVER(BLACK)TR26 15129122 2SC4131 TRANSISTOR for HEAD DRIVER(LIGHT MAGENTA/MAGENTA)TR27 15129121 2SA1746 TRANSISTOR for HEAD DRIVER(LIGHT CYAN/CYAN)TR34 15129121 2SA1746 TRANSISTOR for HEAD DRIVER(CYAN)TR35 15129122 2SC4131 TRANSISTOR for HEAD DRIVER(MAGENTA)TR38 15129121 2SA1746 TRANSISTOR for HEAD DRIVER(YELLOW)TR39 15129122 2SC4131 TRANSISTOR for HEAD DRIVER(BLACK)TR42 15129121 2SA1746 TRANSISTOR for HEAD DRIVER(LIGHT MAGENTA/MAGENTA)TR43 15129122 2SC4131 TRANSISTOR for HEAD DRIVER(LIGHT CYAN/CYAN)TR50 15129122 2SC4131 TRANSISTOR for HEAD DRIVER(CYAN)TR51 15129121 2SA1746 TRANSISTOR for HEAD DRIVER(MAGENTA)TR54 15129122 2SC4131 TRANSISTOR for HEAD DRIVER(YELLOW)TR55 15129121 2SA1746 TRANSISTOR for HEAD DRIVER(BLACK)TR58 15129122 2SC4131 TRANSISTOR for HEAD DRIVER(LIGHT MAGENTA/MAGENTA)TR59 15129121 2SA1746 TRANSISTOR for HEAD DRIVER(LIGHT CYAN/CYAN)TR65 15119122 2SJ535 HEAD POWER SUPPLY
F2 12559102 MMCT 3.15A HEAD POWER FUSE(LIGHT CYAN/LIGHT MAGENTA)F3 12559102 MMCT 3.15A HEAD POWER FUSE(YELLOW/BLACK)F4 12559102 MMCT 3.15A HEAD POWER FUSE(CYAN/MAGENTA)
Revised 3
3-1
3 Replacement of Main PartsThe necessary adjustments after the replacement of each part, and the referential time for each work aredescribed as follows.
HEAD REPLACEMENT : 12min.(1 Head)1. THERMISTER CHECK2. HEAD ALIGNMENT3. HEAD INFORMATION CLEAR4. CHECKING THE CAP HEIGHT *7 Adj. Time : 40min.< Total Time : 70min.>
WIPER REPLACEMENT : 5min.< Total Time : 5min. >
CAP TOP REPLACEMENT : 30min.(6 pcs.) 1. CHECKING THE CAP HEIGHT *7 Adj. Time : 2min.
< Total Time : 32min. >
CARRIAGE MOTOR REPLACEMENT : 20min.1. SERVO LOCK CHECK2. AGING3. MOTOR HOURS CLEAR Adj. Time : 5min.< Total Time : 25min. >
PUMP REPLACEMENT : 25min.(3 pcs.)1. PUMP TIMES CLEAR< Total Time : 25min. >
MAIN BOARD REPLACEMENT : 15min.1. DIP SW SETTING2. BATTERY INSTALLATION3. FIRMWARE INSTALLATION4. SYSTEM PARAMETER INITIALIZE5. HEAD RANK SETTING6. SERIAL NUMBER INPUT *17. CAP & WIPER CHECK *28.CHECKING THE CAP HEIGHT *79. SENSOR CHECK10. LIMIT & CUT DOWN POSITION INITIALIZE11. LINEAR ENCODER SETUP12. PAPER SIDE SENSOR ADJUSTMENT13. INK TYPE SETTING14. HEAD ALIGNMENT15. CALIBRATION Adj. Time : 67min.< Total Time : 82min. >
NETWORK BOARD REPLACEMENT : 10min.1. FIRMWARE UPGRADE2. IP ADDRESS SETTING Adj. Time : 7min.< Total Time : 17min. >
HEAD BOARD REPLACEMENT : 10min.1. THERMISTER CHECK2. HEAD UP/DOWN SENSOR CHECK *33. FAN ON THE HEAD BOARD CHECK Adj. Time : 13min.< Total Time : 23min. >
SERVO BOARD REPLACEMENT : 25min.1. AGING Adj. Time : 5min.< Total Time : 30min. >
BATTERY REPLACEMENT : 7min.1. BATTERY FLAG CLEAR *4< Total Time : 7min. >
PANEL BOARD REPLACEMENT : 7min.1. LCD/LED//BUZ CHECK *52. KEY CHECK *6 Adj. Time : 3min.< Total Time : 10min. >
CARRIAGE BOARD REPLACEMENT : 15min.1. HEAD UP/DOWN SENSOR CHECK *32. THERMISTER CHECK3. PAPER SIDE SENSOR ADJUSTMENT Adj. Time : 5min.<Total Time : 20min.>
INK TUBE REPLACEMENT : 75min. (12 pcs.)< Total Time : 75min. >
CARRIAGE WIRE REPLACEMENT : 45min.1. WIRE TENSION ADJUSTMENT2. LIMIT & CUT DOWN POSITION INITIALIZE3. LINEAR ENCODER SETUP Adj. Time : 15min.< Total Time : 60min. >
LINEAR ENCODER REPLACEMENT : 25min.1. LINEAR ENCODER SETUP Adj. Time : 3min.< Total Time : 28min. >
*1 Input the serial number in the [SERVICE MENU] > [SERIAL NO.].*2 It can be performed in the [SERVICE MENU] > [CAP&WIPER CHECK].*3 It can be performed in the [SERVICE MENU] > [SENSOR CHECK].*4 It can be performed in the [SERVICE MENU] > [CLOCK CHECK].*5 It can be performed in the [SERVICE MENU] > [LCD/LED/BUZ CHK].*6 It can be performed in the [SERVICE MENU] > [KEY CHECK].*7 It can be performed in the [SERVICE MENU] > [CAP ADJUST] > [CHECK GAP].
3-2
3-1 HEAD REPLACEMENT
Turn on the SUB POWER SW while pressing the Left,Right and Down keys to enter the SERVICE MODE.
[MENU] key
[ ], [ ], [ ] + POWER ON
MENUSERVICE MENU
To prevent static damage, discharge static electricity from your body before you touch any ofelectronic components. You can do so by touching an unpainted metal surface on the chassis.
You can also take the following steps to prevent damage from electrostatic discharge (ESD):
When unpacking a static-sensitive component from its shipping carton, do not remove thecomponent from the antistatic packing material until you are ready to install the componentto the machine. Just before unwrapping the antistatic packaging, be sure to discharge staticelectricity from your body.
When transporting a sensitive component, first place it in an antistatic container orpackaging.
Handle all sensitive components in a static-safe area. If possible, use antistatic floor padsand workbench pads.
Revised 8
3-3
4 In [HEAD RANK] menu, select the Head No. of thehead that you are going to replace and input the HEADRANK written on the new head.Input the HEAD RANK by selecting the digit with theLeft and Right keys, and changing the parameters withthe Up and Down keys.Press the [ENTER] key to save the settings.
** The Head No. becomes [HEAD 1], [HEAD 2], [HEAD3] from the head at the left end in order.
HEAD RANKHEAD 1
[ ]
[ ]
[ENTER]
SERVICE MENUHEAD RANK
HEAD RANK 15CY2F2F (1/5)
HEAD RANK
3 Input the HEAD RANK of the head which is going to beinstalled.Turn on the SUB POWER SW while pressing the Left,Right and Down keys to enter the SERVICE MODE.
[MENU] key
[ ], [ ], [ ] + POWER ON
MENUSERVICE MENU
Make sure to input the HEAD RANK beforereplacing the head, because the sticker whichthe head rank is written on will be hiddenonce the head is installed.
2 From the menu (NOT from the service menu), select[INK CONTROL] > [PUMP UP], and select the groupwhich you want to remove the INK of.
5CY2F2F
[ ]
MENUINK CONTROL
INK CONTROLPUMP UP
PUMP UPALL
PUMP UPA GROUP
PUMP UPB GROUP
PUMP UPC GROUP
PUMP UPA-B GROUP
PUMP UPB-C GROUP
PUMP UPA-C GROUP
3-4
5
6
7
Be sure to turn off the MAIN POWER SWwhen replacing the head. The head or mainboard could break, otherwise. I t isrecommended to disconnect the AC code.
[ ]
[ ]
[ENTER]
SERVICE MENUCAP&WIPER CTRL
CAP&WIPER CTRLCAP
CAPOPEN
Turn off the SUB POWER SW, and then turn off theMAIN POWER SW.
MAIN POWER SW
< REAR VIEW >
Select [CAP&WIPER CTRL] > [CAP] > [OPEN], andpress the [ENTER] key. The CAPPING UNIT movesdown and allows you to move the HEAD CARRIAGE byhand.
8 Remove the CARRIAGE COVER.CARRIAGE COVER
Remove the RIGHT I/S COVER.
RIGHT I/S COVER
3-5
12 Remove the SPRING, and remove the 3 screws fixingthe HEAD in order as shown in the figure.Then, pull the HEAD towards the front and pull it up toremove it.
SPRING
1
2
3
11 Disconnect the 2 flexible cables from the HEAD.
10 Remove the HEAD BOARD COVER (the transparentcover).
9 Remove the DAMPER PLATE and remove the 2 INKDAMPERs from the HEAD which will be replaced.
Do not hold both sides of the INK DAMPER sohard. It could break.Be sure to remove and fix the INK DAMPERwith the HEAD BOARD COVER fixed. Itprevents the ink from dropping on the HEADBOARD.
DAMPER PLATE
3-6
13
15
14
Remove the HEAD from the ADAPTER and fix the newHEAD to the ADAPTER.
Make sure to fix the HEAD by pressing it to thebottom left corner of the ADAPTER.Use the 2kgf·cm torque driver (ST-056) totighten up the screws.
Install the HEAD to the head carriage and fix the 3screws temporarily. Then, fix the SPRING and tightenup the 3 screws in order as shown in the figure.
Connect the 2 flexible cables to the HEAD BOARD.
Do not connect cable to the wrong connecter.
ADAPTER
HEAD
Use the 2kgf·cm torque driver (ST-056) totighten up the screws.
16 Fix the HEAD BOARD COVER temporarily.
The HEAD BOARD COVER should be fixed toprevent the ink from dropping on the HEADBOARD when fixing the INK DAMPERs. It isnot necessary to fix the cover with the NYLONLIVET, because the cover needs to be removedfor the HEAD ALIGNMENT.
SPRING
1
2
3
3-7
18
19
Turn on the SUB POWER SW while pressing the Left,Right and Down keys to enter the SERVICE MODE.
[MENU] key
[ ], [ ], [ ] + POWER ON
MENUSERVICE MENU
[ ]
MENUINK CONTROL
INK CONTROLHEAD REPLACE
HEAD REPLACEALL
HEAD REPLACEA GROUP
HEAD REPLACEB GROUP
HEAD REPLACEC GROUP
HEAD REPLACEA-B GROUP
HEAD REPLACEB-C GROUP
HEAD REPLACEA-C GROUP
From the menu (NOT from the service menu), select[INK CONTROL] > [HEAD REPLACE], and select thegroup which you want to fill INK of, and press theENTER key.
17 Replace the 2 new INK DAMPERs, and fix to the HEAD.
Do not hold both sides of the INK DAMPER sohard. It could break.You can connect either INK DAMPER to theeither connector on the HEAD, however,basically please connect the INK DAMPERwhich has the Ink Tube with 2 lines to rear sideand connect the INK DAMPER which has theInk Tube with 1 line to front side.
Make sure to replace the DAMPERs when theHEAD is replaced.
3-8
20 Enter the SERVICE MODE and perform the followingadjustments.
1. THERMISTER CHECK2. HEAD ALIGNMENT3. HEAD INFORMATION CLEAR4. CHECKING THE CAP HEIGHT
< NOTE for fixing the DAMPER PLATE >When you fix the DAMPER PLATE after the aboveadjustments, make sure not to press it down to theDAMPERs.
* Fix the screws at the bottom of the long screw hole.
DAMPER PLATE
[ ]
SERVICE MENUHISTORY MENU
HISTORY MENUHEAD GROUP
HEAD GROUPCLEAR H1
HEAD GROUPCLEAR H2
HEAD GROUPCLEAR H3
HEAD GROUPCLEAR H4
HEAD GROUPCLEAR H5
HEAD GROUPCLEAR H6
HEAD GROUPCLEAR ALL
HOW TO CLEAR THE HEAD INFORMATION
After THERMISTER CHECK and HEAD ALIGNMENT,clear the HEAD INFORMATION from the SERVICEMENU > HISTORY MENU > HEAD GROUP. Select theHEAD you replaced and press the ENTER key.
3-9
1
2
3
4
Turn on the SUB POWER SW while pressing the[CLEANING] key to enter the maintenance mode.
Select [WIPER REPLACE] and press the [ENTER] key.The head moves to the left side.
3-2 WIPER REPLACEMENT
Make sure the screen shown in the figure is displayed.Then, remove the RIGHT I/S COVERs.
Using tweezers, grasp the bottom portion of the wiperand take it off the hook.
MAINTENANCEWIPER REPLACE
NOW PROCESSING..
FINISHED WIPER REPLACEMENT?
RIGHT I/S COVER
3-10
5
6
7
Remove the WIPER and install the new one.
Make sure to fix the wiper so that the rubberside faces the front.
Use the tweezers to press the area shown in the figureand engage the WIPER on the hook.
Make sure to engage it on the hook. If theWIPER is not hooked, it may fall off duringuse.
Fix the RIGHT I/S COVER and press the [ENTER] key.The head carriage moves back to the standby positionand the head cleaning starts automatically. When thehead cleaning finishes, the sub power will be turned off.
RIGHT I/S COVER
3-11
2
4
1
3
[MENU] key
[ ], [ ], [ ] + POWER ON
MENUSERVICE MENU
[ ]
[ ]
[ENTER]
SERVICE MENUCAP&WIPER CTRL
CAP&WIPER CTRLCAP
CAPOPEN
3-3 CAP TOP REPLACEMENT
Turn on the SUB POWER SW while pressing the Left,Right and Down keys to enter the SERVICE MODE.
Move the HEAD CARRIAGE slowly leftwards so that itis not above the capping unit.
Be careful that the head does not strike themedia or media clamp.
Select [CAP&WIPER CTRL] > [CAP] > [OPEN], andpress the [ENTER] key. The CAPPING UNIT movesdown and allows you to move the HEAD CARRIAGE byhand.
Remove the RIGHT I/S COVER.
RIGHT I/S COVER
3-12
5
6
7
8
[ ]
[ ] [ ]
[ENTER]
SERVICE MENUCAP&WIPER CTRL
CAP&WIPER CTRLCAP
CAPUP
Remove the INNER I/S COVER.
INNER I/S COVER
Select [CAP&WIPER CTRL] > [CAP] > [UP], and pressthe [ENTER] key. The capping unit moves up. Pressthe [ENTER] key 3 times, because the capping unitmoves up in 3 steps.
Turn off the SUB POWER SW, and then turn off theMAIN POWER SW.
MAIN POWER SW
< REAR VIEW >
Disconnect the tube (Black) of the CAP TOP from thetube (White) of the PUMP.Keep the JOINT TUBE for connecting the tube of thenew CAP TOP.
Make sure to replace the CAP TOP one byone. If you disconnect the plural tubes at thesame time, there is a danger of connecting toa wrong tube.
JOINT TUBE
3-13
10
12
9
11
Unhook the CAP FRAME with holding it by the otherhand, and remove it.
Make sure to hold the CAP FRAME. There isa SPRING under the CAP TOP. The CAPTOP will jump out unless you hold the capframe when removing it.
Remove the CAP TOP together with the tube.
Fix the new CAP TOP. Make sure to fix it so that thetube side faces the front.
Make sure not to touch the sponge.Make sure the SPRING is properly fixedunder the CAP TOP.
Fix the CAP FRAME.
CAP FRAME
CAP TOP
CAP TOP
CAP FRAME
3-14
14
13
[MENU] key
[ ], [ ], [ ] + POWER ON
MENUSERVICE MENU
[ ]
[ ]
[ENTER]
SERVICE MENUCAP&WIPER CTRL
CAP&WIPER CTRLCAP
CAPOPEN
15
Connect the tube of the CAP TOP to the tube of thePUMP using the JOINT TUBE.
Then, replace the other CAP TOPs in the same way.
Turn on the MAIN POWER SW, then turn on the SUBPOWER SW while pressing the Left, Right and Downkeys to enter the SERVICE MODE.
Select [CAP&WIPER CTRL] > [CAP] > [OPEN], andpress the [ENTER] key. The capping unit moves down.
Fix the INNER I/S COVER.
16
INNER I/S COVER
JOINT TUBE
You can connect either tube of the CAP TOPto the either tube of the PUMP.
3-15
18 Select [CAP&WIPER CTRL] > [CAP] > [UP], and pressthe [ENTER] key to move up the capping unit 1 step.Align the GUIDEs at the two ends of the capping unitwith the GUIDEs at the two ends of the head carriageby moving the head carriage by hand. Then press the[ENTER] key twice more to cap the heads withadjusting the position of the head carriage.
GUIDE GUIDE
17 Move the HEAD CARRIAGE by hand to the standbyposition.
19 Fix the RIGHT I/S cover
Enter the SERVICE MODE and perform the followingadjustment.1.CAP HEIGHT CHECK RIGHT I/S COVER
3-16
1
2
3
4
3-4 CARRIAGE MOTOR REPLACEMENT
Turn off the MAIN POWER SW.
Remove the RIGHT I/S COVER.
Remove the PANEL COVER. Be sure to disconnectthe flexible cable connected to the PANEL BOARD.
Remove the SPRING.
PANEL COVER
SPRING
MAIN POWER SW
< REAR VIEW >
RIGHT I/S COVER
3-17
6
8
5
7
Disconnect the connector of the encoder cable.
Remove the screws fixing the FLANGE and removethe MOTOR together with the FLANGE. Disconnectthe 2 cables from the MOTOR then. FLANGE
Remove the MOTOR from the FLANGE.Fix the new MOTOR to the FLANGE.
Be careful with the fixing direction of theFLANGE.
Connect the 2 cables to the MOTOR and fix theFLANGE with the 2 screws temporarily.
Be careful not to connect the cable to thewrong connector. The red cable should beconnected to the red connector.
FLANGE
FLANGE
CONNECTOR
3-18
9
10
11
Fix the SPRING. Then, tighten up the 2 screws to fixthe FLANGE with checking the gears mesh withoutbacklash.
Connect the connector of the encoder cable.
Tie the cables as shown in the figure to preventthe connector from being disconnected. CONNECTOR
Connect the PANEL CABLE to the PANEL BOARD,and fix the PANEL COVER.
SPRING
PANEL COVER
12
[MENU] key
[ ], [ ], [ ] + POWER ON
MENUSERVICE MENU
Perform the SERVO LOCK CHECK.After turning on the main power, turn on the sub powerwhile pressing the Left, Right and Down keys to enterthe SERVICE MODE.
Apply a proper quantity of grease(P/# 21675101 FLOIL GE-676 BLACK)between gears.
3-19
16 Clear the motor working hours.Go back the SERVICE MENU, and select [HISTORYMENU] > [MOTOR GROUP] > [MOTOR HOURS S] >[CLEAR] and press the [ENTER] key. The motorworking hours will be reset to 0.
13
14
15
[ ]
SERVICE MENUSERVO LOCK
SERVO LOCKS: 3
[ENTER]
SERVO LOCKS: 1688
SERVO LOCKS:* 1688
[ ]
SERVICE MENUAGING
AGINGSCAN
In [SERVO LOCK] menu, select [S].Move the head carriage left and right by hand andmake sure the value on the LCD changes depending onthe head position.
Press the [ENTER] key to excite the MOTOR.Make sure the MOTOR is locked and the value on theLCD doesn't change.
Check the AGING.Go back to the SERVICE MENU, and select [AGING] >[SCAN] and press the [ENTER] key. Make sure themachine do the AGING and finish it.
Do the AGING with the head set at the HIGHposition for its safety.
[ ]
[ ]
[ ]
[ ]
SERVICE MENUHISTORY MENU
HISTORY MENUMOTOR GROUP
MOTOR HOURS S 1653 hours
[ENTER]
MOTOR HOURS SCLEAR
3-20
Turn off the SUB POWER SW, and then turn off theMAIN POWER SW.
MAIN POWER SW
< REAR VIEW >
2
4
1
3
[MENU] key
[ ], [ ], [ ] + POWER ON
MENUSERVICE MENU
[ ]
[ ]
[ENTER]
SERVICE MENUCAP&WIPER CTRL
CAP&WIPER CTRLCAP
CAPOPEN
3-5 PUMP REPLACEMENT
Turn on the SUB POWER SW while pressing the Left,Right and Down keys to enter the SERVICE MODE.
Select [CAP&WIPER CTRL] > [CAP] > [OPEN], andpress the [ENTER] key. The CAPPING UNIT movesdown and allows you to move the HEAD CARRIAGE byhand.
Remove the RIGHT I/S COVER.
RIGHT I/S COVER
3-21
5
6
7
8
Remove the INNER I/S COVER.
Make sure to replace the PUMP one by one.If you disconnect the tubes of the pluralPUMPs at the same time, there is a danger ofconnecting to a wrong tube.
Remove the PUMP and replace it to the new one.Then put the 2 longer tubes into the DRAIN TUBE.
Then, replace the other 2 PUMPs in the same way.
Make sure to fix the 2 projection parts of thePUMP to the holes of the FRAME.
Move the HEAD CARRIAGE slowly leftwards.
Be careful that the head does not strike themedia or media clamp.
PUMP
INNER I/S COVER
Disconnect the tube (Black) of the CAP TOP from thetube (White) of the PUMP.Keep the JOINT TUBE for connecting the tube of thenew PUMP.
JOINT TUBE
3-22
9 Connect the tube of the CAP TOP to the tube of thePUMP using the JOINT TUBE.
10 Fix the INNER I/S COVER.
11 Move the HEAD CARRIAGE by hand to the standbyposition.
[MENU] key
[ ], [ ], [ ] + POWER ON
MENUSERVICE MENU
Turn on the MAIN POWER SW. Then, turn on the SUBPOWER SW while pressing the Left, Right and Downkeys to enter the SERVICE MODE.
12
PUMP
JOINT TUBE
You can connect either tube of the CAP TOPto the either tube of the PUMP.
INNER I/S COVER
3-23
13 Select [CAP&WIPER CTRL] > [CAP] > [UP], and pressthe [ENTER] key to move up the capping unit 1 step.Align the GUIDEs at the two ends of the capping unitwith the GUIDEs at the two ends of the head carriageby moving the head carriage by hand. Then press the[ENTER] key twice more to cap the heads withadjusting the position of the head carriage.
GUIDE GUIDE
14 Clear the pump times.Go back to the SERVICE MENU, and select [HISTORYMENU] > [MOTOR GROUP], and select the PUMP youreplaced and clear the time.
[ ]
SERVICE MENUHISTORY MENU
HISTORY MENUMOTOR GROUP
PUMP TIMES A 122 HOURS
PUMP TIMES B 105 HOURS
PUMP TIMES C 111 HOURS
PUMP TIMES ACLEAR
PUMP TIMES BCLEAR
PUMP TIMES CCLEAR
3-24
2
4
1
3
3-6 INK TUBE REPLACEMENT
Turn on the SUB POWER SW and perform the [PUMPUP] from the [INK CONTROL] menu.When i t f in ishes, the SUB POWER wi l l beautomatically turned off.
Turn off the SUB POWER SW, and then turn off theMAIN POWER SW.
MAIN POWER SW
< REAR VIEW >
Remove the CARRIAGE COVER.
INK CONTROLEMPTY MODE
MENUINK CONTROL
INK CONTROLPUMP UP
CARRIAGE COVER
FRONT RAIL COVER
FRONT COVER
RIGHT TOP COVER
RIGHT I/S COVER
REAR RAIL COVER
Remove the following covers.
LEFT and RIGHT I/S COVERsRIGHT TOP COVERFRONT and REAR RAIL COVERsFRONT COVER
LEFT I/S COVER
3-25
5
6
7
8
Remove the clear cover fixed on the CARRIAGEBOARD, and remove the 4 NYLON LIVETs fixing theclear plates. Then, disconnect all the 6 flexible cablesthat are coming from the CABLE BEAR.
Remove the GUIDE PLATEs of the CABLE BEARand the CABLE GUIDEs. Then, take out the flexiblecables from the CABLE BEAR.
Disconnect the INK TUBEs from the INK DAMPERs,and put the scotch tape at the tip of the ink tubes toprevent the ink from coming out.
Disconnect the INK TUBEs from the JOINTs, and putthe scotch tape at the tip of the INK TUBEs to preventthe ink from coming out.
Make sure not to replace the INK TUBEs ofdifferent colors at the same time. There is adanger of connecting wrongly when fixing thenew ones.
REAR VIEW OF MACHINE
It is not necessary to replace the INK TUBEsof the other side of the JOINTs.
JOINT
CABLE GUIDE
GUIDE PLATE
Blank
REAR VIEW OF MACHINE
3-26
9
10
11
12
Pull out the INK TUBEs from the CABLE BEAR.
Put the new INK TUBEs in the CABLE BEAR.
Connect the new INK TUBEs to the JOINTs, and markthe INK TUBEs to indicate the color of the ink.
Cut the INK TUBEs at appropriate length and connectthem to the INK DAMPERs. Then mark the INK TUBEsto indicate the color of the ink.
Then, replace the other INK TUBEs in the same way.
Be careful which hole of the TUBE GUIDEshould be used for each INK TUBE.
REAR VIEW OF MACHINE
JOINT
KCMLcC
LmM
Y
3-27
14 Put back the GUIDE PLATEs and the CABLE GUIDEs.
Make 1 position for the GUIDE PLATE blank at theedge of the CABLE BEAR.Fix the CABLE GUIDE at the position shown in thefigure.
TUBE GUIDE
Make the 3 positions for the GUIDE PLATE blank at theother TUBE GUIDEs.Fix the CABLE GUIDE at the first GUIDE PLATE afterthe blank.
CABLE GUIDE
GUIDE PLATE
Blank
REAR VIEW OF MACHINE
Connect the 6 FLEXIBLE CABLEs to the CARRIAGEBOARD and fix the NYLON LIVETs to fix the CLEARPLATEs.
13
REAR VIEW OF MACHINE
CABLE GUIDE
GUIDE PLATE
Blank
Make the 3 positions for the GUIDE PLATE blank at theTUBE GUIDE.
REAR VIEW OF MACHINE Blank
TUBE GUIDE
Do not fix CABLE GUIDE here.
3-28
3-7 BOARDS REPLACEMENT (Head / Servo / Network / Main Board / SW Power Supply)
BOARD LAYOUT (IN CHASSIS)
Heater Board Stay
1. When the Board Cover is opened
Head Board
Servo Board
SW Power Supply AC Junction Board Network Board Main Board
2. When the Heater Board Stay and the Shild Stay are removed
Shield Stay
3-29
2 Remove the RIGHT TOP COVER, BOARD COVER andRIGHT I/S COVER .
1 Turn off the MAIN POWER SW.
3 Remove the SHIELD STAY.
MAIN POWER SW
REAR VIEW
RIGHT TOP COVER
RIGHT I/S COVER
BOARD COVER
SHIELD STAY
3-30
2 Remove the screws and disconnect the CONNECTOR.
1
HEAD BOARD REPLACEMENT
Disconnect the CABLEs from the HEAD BOARD.
CN-35,36,37,38,39,40
CN-34
CN-31
CN-30
HEAD BOARD CONNECTOR LAYOUT
3-31
4 Connect all the CABLEs to the HEAD BOARD.
3 Replace the HEAD BOARD to the new one.
5 Carry out the following checks.
1. THERMISTER CHECK2. HEAD UP/DOWN SENSOR CHECK3. FAN ON THE HEAD BOARD
3-32
1 Disconnect all the CABLEs from the SERVO BOARD.
SERVO BOARD REPLACEMENT
SERVO BOARD CONNECTOR LAYOUT
CN2
CN1CN4CN7
CN9CN8
CN11
CN16
CN17
CN18
CN15 CN13
2 Replace the SERVO BOARD to new one.
3-33
3 Connect all the CABLEs to the SERVO BOARD.
Carry out the following checking.41. AGING
3-34
1 Remove the 2 SCREWs.NETWORK BOARD REPLACEMENT
2
3
Disconnect the NETWORK BOARD from the MAIN BOARD.Replace it to the new one and connect it.
Fix the NETWORK BOARD with 2 SCREWs.
Carry out the following adjustment.41. FIRMWARE UPGRADE2. IP ADDRESS SETTING
3-35
2 Remove the NETWORK BOARD.
Disconnect all the CABLEs which are connected to theMAIN BOARD, SERVO BOARD and HEAD BOARD.
1
Make sure to print out the SERVICE REPORTor take a note of the HEAD RANK beforereplacing the MAIN BOARD.We recommend to use the Service Tool"Peck.exe" to receive the all settings.
MAIN BOARD REPLACEMENTMAIN BOARD CONNECTOR LAYOUT
CN14
CN3
CN1
CN12
CN7
CN4
3-36
5 Fix the SERVO BOARD and HEAD BOARD.
4
3
Replace the MAIN BOARD to the new one.
Remove the SERVO BOARD and HEAD BOARD.
6 Fix the NETWORK BOARD.
3-37
Carry out the following adjustments and settings.1. DIP SW SETTING2. BATTERY INSTALLATION3. FIRMWARE INSTALLATION4. SYSTEM PARAMETER INITIALIZE5. HEAD RANK SETTING6. SERIAL NUMBER INPUT *17. CAP & WIPER CHECK *28. CHECKING THE CAP HEIGHT *7
8 9. SENSOR CHECK10. LIMIT & CUT DOWN POSITION INITIALIZE11. LINEAR ENCODER SETUP12. PAPER SIDE SENSOR ADJUSTMENT13. INK TYPE SETTING14. HEAD ALIGNMENT15. CALIBRATION
*1 Input the serial number in the [SERVICE MENU] > [SERIAL NO.].*2 It can be performed in the [SERVICE MENU] > [CAP&WIPER CHECK].*7 It can be performed in the [SERVICE MENU] > [CAP ADJUST] > [CHECK GAP].If you use the Peck.exe and receive & sent the data, it is not necessary to carry out the under lined parts.
7 Connect all the CABLEs.
3-38
1 Remove the HEATER BOARD STAY together with the ACJUNCTION BOARD.
SW POWER SUPPLY REPLACEMENTSW POWER SUPPLY CONNECTOR LAYOUT
To the [CN34] on theHEAD BOARD
To the [CN16] on theSERVO BOARD
To the FAN
To the [CN1] on theAC JUNCTION BOARD
2 Disconnect all the CABLEs.
HEATER BOARD STAY
AC JUNCTION BOARD
3-39
3
4
Remove the SW POWER SUPPLY together with the FAN andreplace it to the new one.
Connect all the CABLEs.
3-40
1
3-8 BATTERY REPLACEMENT
Do not recharge, short-circuit, disassembly the lithium battery, nor putit into fire.It may cause heat, explosion and fire.
Put tape around the lithium battery for insulation for disposal orpreservation.It may cause heat, explosion and fire.
2
MAIN POWER SW
REAR VIEW
RIGHT TOP COVER
RIGHT I/S COVER
BOARD COVER
Remove the RIGHT TOP COVER, BOARD COVER andRIGHT I/S COVER .
Turn off the SUB POWER SW, and then turn off theMAIN POWER SW.
Revised 5
3-41
3
4 Remove the BATTERY on the MAIN BOARD by pushingit down and tilting towards right.
1
SOCKET
MAIN BOARD
2
Replace the BATTERY with new one.SOCKET
BATTERY
MAIN BOARD
Be careful with the direction of the BATTERY.
5
6
Remove the SHIELD STAY.
SHIELD STAY
Fix the SHIELD STAY.
3-42
7 Turn on the MAIN POWER SW and turn on the SUB POWERSW while pressing the Left, Right and Down keys to enterthe SERVICE MODE.
8
9
10
Clear the BATTERY FLAG from the [CLOCK CHECK]menu in the SERVICE MODE.
MAIN POWER SW
REAR VIEW
RIGHT TOP COVER
RIGHT I/S COVER
BOARD COVER
[MENU] key
[ ], [ ], [ ] + POWER ON
MENUSERVICE MENU
CLOCK CHECK B 0y00d00h00m00s
CLOCK CHECK CLEAR BAT FLAG
SERVICE MENU CLOCK CHECK
[ENTER]
Fix the RIGHT TOP COVER, BOARD COVER and RIGHT I/SCOVER .
Turn off the SUB POWER SW, and then turn off theMAIN POWER SW.
Revised 5
3-43
11 Dispose the BATTERY.
FOLLOWING MAY CAUSE EXPLOSION OF BATTERY.RECHARGE, SHORT-CIRCUIT, DISASSEMBLY, HEATING,PUTTING INTO FIRE.DON'T PUT BATTERY WITH OTHER METAL OR BATTERY.DISPOSE BATTERY WITHOUT INSULATION.
3-44
2 Remove the following covers.
LEFT and RIGHT I/S COVERsPANEL COVERLEFT and RIGHT TOP COVERsFRONT and REAR RAIL COVERsFRONT COVERLEFT SIDE COVER
1 Turn off the MAIN POWER SW.
3 Loosen the screw fixing the HEAD CARRIAGE to theCARRIAGE WIRE.
3-9 CARRIAGE WIRE REPLACEMENT
MAIN POWER SW
REAR VIEW
Be sure to disconnect the flexible cableconnected to the PANEL BOARD whenremoving the PANEL COVER.
RIGHT I/S COVERLEFT I/S COVER
LEFT SIDECOVER PANEL COVER
RIGHT TOP COVER
FRONT RAIL COVER
LEFT TOP COVER
REAR RAIL COVER
FRONT COVER
TOP VIEW
3-45
6 Loosen the screws fixing the MOTOR FLANGE, then removethe SPRING.
5 Remove the CARRIAGE WIRE as shown in the figure.
7 Remove the SHAFT STAY and the E RING, then remove theDRIVE PULLEY from the shaft.
4 Loosen the 2 screws and then the ADJUSTMENT SCREWin order to loosen the wire tension.
ADJUSTMENT SCREW
SPRING
FLANGE
SHAFT STAY
E RING
3-46
8
9
10
Fix one end of the new WIRE and fix the DRIVE GEAR to theDRIVE PULLEY with the screws.
11
Put the DRIVE PULLEY into the shaft and fix it with the ERING. Then, fix the SHAFT STAY.
Wind the CARRIAGE WIRE around the DRIVE PULLEYfrom bottom to the top, and fix the other end of the WIRE.
Remove the screws fixing the DRIVE GEAR and remove theCARRIAGE WIRE from the PULLEY.
Make sure that the CARRIAGE WIRE doesnot cross over.
SHAFT STAY
E RING
3-47
15 Fix the HEAD CARRIAGE to the CARRIAGE WIRE.
14 Rotate the DRIVE PULLEY until the CARRIAGE WIREcomes to its second wind from the top.
12 Fix the SPRING, then tighten up the 2 screws to fix theFLANGE with checking the gears mesh without backlash.
SPRING
FLANGE
TOP VIEW
13 Tighten the ADJUSTMENT SCREW and remove the slack inthe Wire.Do not tigten it too tightly. ADJUSTMENT SCREW
3-48
17
18
19 Move the HEAD CARRIAGE in a whole width of the GUIDERAIL several times to remove the slack in the CARRIAGEWIRE.Then, carry out the following adjustments.
1. WIRE TENSION ADJUSTMENT2. LIMIT POSITION & CUT DOWN POSITION INITIALIZE3. LINEAR ENCODER SETUP
[MENU] key
[ ], [ ], [ ] + POWER ON
MENUSERVICE MENU
[ ]
[ ]
[ENTER]
SERVICE MENUCAP&WIPER CTRL
CAP&WIPER CTRLCAP
CAPOPEN
Select [CAP&WIPER CTRL] > [CAP] > [OPEN], andpress the [ENTER] key. The CAPPING UNIT movesdown and allows you to move the HEAD CARRIAGE byhand.
Turn on the MAIN POWER SW. Then, turn on the SUBPOWER SW while pressing the Left, Right and Downkeys to enter the SERVICE MODE.
16 Connect the PANEL CABLE to the PANEL BOARD,and fix the PANEL COVER.
PANEL COVER
3-49
Remove the PLATE.
3
2
4
1
3-10 ENCODER SCALE REPLACEMENT
FRONT RAIL COVER
FRONT COVER
RIGHT TOP COVER
RIGHT I/S COVER
REAR RAIL COVER
Remove the following covers.
LEFT and RIGHT I/S COVERsRIGHT TOP COVERFRONT and REAR RAIL COVERsFRONT COVER
LEFT I/S COVER
[MENU] key
[ ], [ ], [ ] + POWER ON
MENUSERVICE MENU
[ ]
[ ]
[ENTER]
SERVICE MENUCAP&WIPER CTRL
CAP&WIPER CTRLCAP
CAPOPEN
Turn on the SUB POWER SW while pressing the Left,Right and Down keys to enter the SERVICE MODE.
Select [CAP&WIPER CTRL] > [CAP] > [OPEN], andpress the [ENTER] key. The CAPPING UNIT movesdown and allows you to move the HEAD CARRIAGE byhand.
PLATE
3-50
5
6
7
Remove the ENCODER SCALE by removing the PLATEfixing the ENCODER SCALE at its right end and theSPRING on its left end.
8
Remove the SPRING PLATE from the ENCODER SCALEand fix it to the ENCODER SCALE where there is no blackdot written on it.
Put the ENCODER SCALE in between the ENCODERPLATE and the GUIDE RAIL.Then, fix the right end with the PLATE and hook up theSPRING on the left end.Make sure that the ENCODER SCALE its in place.
Make sure not make scratches or put greaseon the ENCODER SCALE when fixing it.
Do not loosen or tighten the screws fixing theENCODER PLATE.
ENCODER SCALE
PLATESPRING
ENCODER SCALE
PLATESPRING
SPRING PLATE BLACK DOT
Move the HEAD CARRIAGE slowly leftwards.
Be careful that the head does not strike themedia or media clamp.
3-51
Move the HEAD CARRIAGE in a whole width of themachine.Make sure that the ENCODER SCALE doesn't makecontact with the ENCODER MODULE and alsoENCODER SCALE is between the sl i t of theENCODER MODULE.
9
10 Carry out the LINEAR ENCODER SETUP.
4-1
Tool No. ST-056Tool Name TORQUE DRIVER N6
Purpose HEAD ALIGNMENT
Tool No. ST-011Tool Name TENSION METER
Purpose WIRE TENSION ADJUSTMENT
Tool No. ST-037Tool Name CLEAN STICK TX712A
Purpose HEAD CLEANING
Tool No. 21755107Tool Name CLEANING LIQUID (SL) 500ML
Table shows a list of special tools recommended by Roland DG Corp.
4-2
4-2 SERVICE MODE
SERVICE MENUHEAD RANK
HEAD RANKHEAD 1
SERVICE MENUSERIAL NO.
SERIAL NO.ZT00000
HEAD RANK 11234567 (1/5)
HEAD RANKHEAD 6
HEAD RANK 61234567 (5/5)
SERVICE MENUSENSOR CHECK
FRHCPULWcwh *** M ***
123456789101112 *** *EC**
SERVICE MENUCAP&WIPER CHECK
SERVICE MENUKEY CHECK
KEY CHECKNONE
CAP&WIPER CHECK NOW PROCESSING..
CAP&WIPER CHECK COMPLETED
[ ] , [ ] , [ ] + POWER ON
[ MENU ] key
SERVICE MENULCD/LED/BUZ CHK
As per display
This menu is used for entering the HEAD RANK for each HEAD with 35 digit number and alphabet.The digits can be changed with [ ] and [ ] keys and parameters can be changed with [ ] and [ ] keys.Press the [ ENTER] key to save the settings. Warning sound comes out when the CHECK SUM is not correct.
This menu is used for entering the Serial No. of the machine.The digits can be changed with [ ] and [ ] keys and parameters can be changed with [ ] and [ ] keys.
This menu is used for checking the CAP & Wiper movement.1. Move the Carriage to the position where is on the Platen by hand.2. Press the [ ENTER] key to check the Cap, Wiper, Wiper Up/ Down, Cap Motor, Cap Sensor, Wiper Motor and Wiper Sensor.3. Checking finishes when the COMPLETED message appears.
This menu displays the status of the sensors. When the sensor is ON, * will be displayed. Alphabet in the menu stands for F: Front Paper Sensor, R: Rear Paper Sensor, H: Origin Sensor, C: Front Cover Sensor, P: Maintenance Cover Sensor, U: Head Height Sensor, L: Pinch Roller Sensor, W: Paper Side Sensor, c: Cap Sensor, w: Wiper sensor, h: Wiper Height Sensor.
Head Height Sensor H : HIGH M : MIDDLE L : LOWMaintenance Cover Sensor R : Right I/ S Cover is ON. L : Left I/ S Cover is ON. * : Both I/ S Covers are ON. Blank : Both I/ S Covers are OFF.
Alphabet of the 2nd page stands for Cartridge Sensor of each color and Ink Empty.Blank : No Cartridge, Ink remainingC : Cartridge installed, Ink remainingE : No Cartridge, Ink empty* : Cartridge installed, Ink empty
This menu is used for checking the panel keys. [ NONE] will be displayed at the bottom row of the LCD if no key is pressed. The name of the key being pressed will be displayed This menu finisheswhen the [ ] key is pressed or it is left without pressing any key for 10 seconds. When there is any keythat has not been pressed, the name of the key will be indicated with the beep sound.Secondary power cannot be turned off even pressing the SUB POWER SW while in this mode.
This menu is used for checking the LCD, LED and the Buzzer. While in this mode, the function check of the LCD, LED and the Buzzer can be performed. All turning ON/ OFF test of the LED,Contrast ON/ OFF test of the LCD, back light test of LCD, Buzzer ON/ OFF test, Displaying the Cursorkey of the LCD, all characters of LCD will be displayed.
4-3
SERVICE MENUTHERMISTOR CHK
THERMISTOR CHKHEAD :26 C/77 F
THERMISTOR CHKBOARD:26 C/77 F
SERVICE MENUFAN CHECK
FAN CHECK
SERVICE MENULINEAR ENCODER
NOW PROCESSING..POS: 1361.00mm
LINEAR ENCODERSETUP COMPLETED
LINEAR ENCODERSETUP FAILED
SERVICE MENUPAPERSIDE SENS
PAPERSIDE SENSOUTPUT LEVEL
OUTPUT LEVEL0.7V
PAPERSIDE SENSSENSOR AUTOTEST
SENSOR AUTOTEST 0.5V, NOISE 0
SERVICE MENUHEAD ADJUST
HEAD ADJUSTBIAS
BIASTEST PRINT
BIAS --- VIEW ---
HEAD ADJUSTVERTICAL
VERTICALTEST PRINT
VERTICAL --- VIEW ---
This menu is used for checking the FAN. FAN will be ON ( HIGH) while in this mode.
The temperature read by the thermistor on the Head will be displayed. Temperature will be displayed in Celsius on the left side and in Fahrenheit on the right side. [ HEAD] and [ BOARD] display higher temperaturethan the environment temperature because there is a possibility that the device temp. of the Head Board goes up. Check and make sure that the temperature displayed on the LCD is not extremely low or high. The temperature of [ HEAD] is not always the same as the one of [ BOARD] .
This menu is used for adj usting the Paper Side Sensor. Refer to [ PAPER SIDE SENSOR ADJUSTMENT] .
This menu is for checking the Linear Encoder and also, recording the position of the edge of sheet withClear Sheet ( SHEET TYPE : CLEAR) . Printing won' t be performed if it is not adj usted. Refer to [ LINEAR ENCODER SETUP] .
LINEAR ENCODERSETUP FAILED
error ( beep 2 times)
normal ( beep 1 time)
Use with [ ] and [ ] keys to change the capadj ustment value.The setting range is from -2.00 to + 2.00. It can be adj usted in 0.25 mm unit. The default value is 0.00.The cap can only be moved in the upwarddirection in 0.25 mm unit. When you move in thedownward direction, press [ ] key to move thecap to the lower end once and then move in theupward direction in 0.25 mm unit.
CAP ADJUSTADJUST POS.
ADJUST POS. 0.00 -2.00
CAP ADJUSTCHECK GAP
CHECK GAP0.00
SERVICE MENUCAP ADJUST
To adj ust and check the height of the cap, refer to the instraction of the [ CAP HEIGHT ADJUSTMENT] .
4-4
HEAD ADJUSTHORIZONTAL
HORIZONTALTEST PRINT
H2 H3 H4 2 1 -3
H5 H6 2 1
HORIZONTALDT1,Low
HORIZONTALDT3,Low
H2 H3 H4 2 1 -3
H5 H6 2 1
HEAD ADJUSTBI-DIR.DEFAULT
BI-DIR.DEFAULTTEST PRINT
H1 H2 H3 12 11 -13
H4 H5 H6 5 10 -11
BI-DIR.DEFAULTDT1,Low
BI-DIR.DEFAULTDT3,Low
H1 H2 H3 12 11 -13
H4 H5 H6 5 10 -11
H1 H2 H3 12 11 -13
H4 H5 H6 5 10 -11
BI-DIR.DEFAULTDT1,Middle
BI-DIR.DEFAULTDT3,Middle
H1 H2 H3 12 11 -13
H4 H5 H6 5 10 -11
SERVICE MENUSERVO LOCK
SERVO LOCKS: 100
SERVO LOCKF: 152
SERVO LOCKS:* 0
SERVO LOCKF:* 0
This menu is used for adj usting the Head Alignment. Refer to [ HEAD ALIGNMENT] .
This menu is used for checking whether the Servo Motor can perform the Servo Lock.This menu makes the Servo free.The value on the LCD will change depending on the head position when you move the carriage left and rightby hand. When the [ ENTER] key is pressed, the Servo Motor will be excited.
HORIZONTALDT1,Middle
H2 H3 H4 2 1 -3
H5 H6 2 1
HORIZONTALDT3,Middle
H2 H3 H4 12 11 13
H5 H6 5 10
4-5
SERVICE MENUAGING
AGINGSCAN
SCANNOW AGING
SERVICE MENUCALIB.DEFAULT
CALIB.DEFAULTTEST PRINT
CALIB.DEFAULTSETTING
SETTING +0.05% +0.10%
AGINGFEED
FEEDNOW AGING
AGINGBOTH
BOTHNOW AGING
SERVICE MENUTEST PATTERN
TEST PATTERNHORIZONTAL
TEST PATTERNBI-DIR.
TEST PATTERNFILL
TEST PATTERNBI-DIR.CHECK
When the [ ENTER] key is pressed, the HEAD CARRIAGE moves back to the locking position and stops the Aging.Make sure not to perform Aging for a long time when the machine is filled with ink to prevent the ink from drying up.
This menu is used for Calibration. Refer to [ CALIBRATION] .
100% fill pattern of all heads will be printed.Printing is done by 720 x 720dpi / 8 pass.
It is for checking the shifting with Bidirection printing.It will be printed in a whole width of the media.
It is for checking the Head Alignment in Bidirection.
It is for checking the Head Alignment in Horizontal.
SERVICE MENUCLOCK CHECK
CLOCK CHECK B 0y000d00h00m00s
CLOCK CHECKCLEAR BAT FLAG
SERVICE MENUDIP SW CHECK
DIP SW CHECK 0000 0000
bit # [ 1234 5678]
This menu is used for checking the REAL TIME CLOCK. Time being passed after the clock has startedto work will be displayed. ( Year / Day / Hour / Minute / Second) When battery is run out, [ B] will be displayedat the upper right corner of the LCD. In this case, battery has to be replaced. However, the flag won' t be cleared even battery is replaced.Make sure to clear the flag by entering the Battery Flag Clear Menu and then pressing the [ ENTER] key.
This menu is used for checking the DIP SW on the MAIN BOARD. Status of bit# 1 ~ # 8 of the DIP SWwill be displayed as 0 for OFF and 1 for ON.
4-6
SERVICE MENUCAP&WIPER CTRL
CAP&WIPER CTRLCAP
CAPOPEN
CAP&WIPER CTRLWIPER
WIPERFRONT
SERVICE MENUCHANGE INKTYPE
CHANGE INKTYPEPIG cm DYE cm
SERVICE MENUPUMP CHECK
PUMP CHECKPUMP SUCTION
PUMP CHECKPUMP RELEASE
NOW PROCESSING..
NOW PROCESSING..
This menu is used for checking the Pump Motor. Rotation for Ink Suction Direction and Ink Drain Direction can be checked. Rotation check will stop after 5 seconds.
It is used for changing the Ink type compulsorily. Head Cleaning or Ink Fill won' t be performed as in theUser' s Mode. It is used for correcting the Ink type in case mistakenly set to the different type.
INK TYPE PIG cm Pigment LcLmPIG OG Pigment OrGrDYE cm Dye Lc LmSOL cm SOL INK LcLmeSOL cm ECO-SOL LcLmeSOL2MC ECO-SOL ( CMYKMC)UNKNOWN Not being selected
It is used for opening / upping the cap.OPEN / UPMake sure not to open the cap for a long time in order to prevent the ink from drying up.
It is used for moving the wiper back and forth.It can be moved at two-level [ FRONT / REAR] .
It is used for moving the wiper up and down.It can be moved at three-level [ HIGH / MIDDLE / LOW] .
* * Please make sure the position of the Cap and Wiper when you move the Carriage by hand.
CAPUP
CAP&WIPER CTRLWIPER HEIGHT
WIPER HEIGHTHIGH
WIPERREAR
WIPER HEIGHTMIDDLE
WIPER HEIGHTLOW
SERVICE MENUPORT CHECK
DETECTING... 00: 0B
NETWORK B3:1073741824B
Waiting for Data Input
Data Input from the Network
This menu is used for checking the Data Input from the Network. The Check Sum and the size of the input data will be displayed on the bottom row.Check Sum will be indicated on the left side and the size of the input data will be indicated on the rightside. The Check Sum and the size of the input data will be cleared when pressing the [ ENTER] key.
4-7
SERVICE MENUSLEEP
SLEEP 15MIN 15MIN
SERVICE MENUMAINTE. MSG.
MAINTE. MSG.NONE 100 hours
This menu is for setting the time of entering in Sleep.Default value : 15min.
This menu is used for setting the Maintenance time.If the printing time reaches the set time, the Maintenance message appears.
SERVICE MENUPERIODIC CL.
PERIODIC CL.INTERVAL
PERIODIC CL.DEGREE
INTERVAL 1.0 1.0
DEGREE LIGHT LIGHT
NONE, 0.1~100.0
WIPE, LIGHT, NORMAL
This menu is for setting the Auto Cleaning during printing.The cleaning interval will be determined automatically depending on the printing mode and the temperature. [ INTERVAL] It changes the magnification of Cleaning Interval Actual Cleaning Interval = Cleaning Interval x [ INTERVAL] [ DEGREE] Cleaning Operation can be cahnged.
[ WIPE] : Wiping & Flushing[ LIGHT] : Least bit of Suction & Wiping[ NORMAL] : Regular Cleaning ( Cleaning Key)
Default value [ INTERVAL] 1.0 [ DEGREE] LIGHT
SERVICE MENUDOUBLED HEADS
DOUBLED HEADSHEAD 5&6 1&2
5&6 1&2 Default : 5&6
SERVICE MENUSET SHEET POS
SET SHEET POSSHEET POS
R: 0mmL: 1361mm
SET SHEET POS DEFAULT POS
This menu is used for setting the additional heads ( 5&6 or 1&2) in CMYKMC Mode.This menu will be displayed only when the Ink Type is CMYKMC.
This menu is for specifying the print range.If the media type is set to Clear, this value becomes effective at the time of the setup.The starting position of the print range in [ R: ] and end position of the print range in [ L: ] can be set in [ SHEET POS] . R and L can be selected by the right key and the setting value becomes effective by the ENTER key. This set-up value is memorized and is held even if a power is turned off.It is set as the same value ( when a sheet type is set clear) by performing DEFAULT POS as the value when the previous setup is performed in a transparent media.
SERVICE MENUSYSTEM SWITCH
SYSTEM SWITCHPAGE1: 00000000
SYSTEM SWITCHPAGE4: 00000000
This menu is for changing the functions of the machine. It is not necessary to change any switches.Each bit can be selected with [ ] and [ ] keys and it can be changed with [ ] and [ ] keys.There are 12 pages of 8 bit System Switch.
bit# [87654321]
Bit Contents Settings DefaultPAGE1: Bit 1 Front Cover Sensor 0 : Standard 1: Always closed status 0PAGE1: Bit 2 I/S Cover Sensor 0 : Standard 1: Always closed status 0PAGE1: Bit 3 Head Height Check 0 : Enable 1: Disable 0PAGE1: Bit 7 Preset for Bidirectional Correction Value 0 : Disable (1 kind) 1: Enable (8 kinds) 1PAGE2: Bit 5 Ink cartridge excahnge during printing 0 : Disable 1: Enable 0PAGE3: Bit 1 Heater Support 0 : Disable 1: Enable 1
PAGE3: Bit 2Heater-related setting for printing testpatterns 0 : Disable 1: Enable 0
PAGE3: Bit 3 Wiper 1mm up 0 : Disable 1: Enable 0
PAGE3: Bit 6Head vibraton outside ofthe printing area
0 : Enable 1: Disable 1
PAGE3: Bit 7Head driving pulseagainst the ink dropping problem
0 : Disable 1: Enable 1
PAGE10: Bit 3Displaying the Amount ofRemaining Media
0 : Disable 1: Enable 1
4-8
SERVICE MENUHISTORY MENU
HISTORY MENUMOTOR GROUP
SERVICE MENUREPORT
REPORTSERVICE REPORT
REPORTHISTORY REPORT
SHOT COUNT 1 26103 KShot
SHOT COUNT 1CLEAR
SERVICE REPORTHEAD H1
SERVICE REPORTHEAD H1
REPORTSERIAL
All the records regarding the usage of the machine will be displayed. When [ ] and [ ] keys arepressed, each title will be displayed on the top row and the parameters will be displayed on the bottomrow. Refer to the table on the next pages. Each title can be cleared when the [ ENTER] key is pressedwhile the CLEAR is displayed in the menu.
- Service Report will be printed. Information necessary for service activity will be printed together with the system report. It will be printed on a A4 size with only one head. - History Report will be printed.- Serial Report Menu will be printed throught the RS-232C Serial with the special tool. ( 9600bps N81 XON/ XOFF)
4-9
Contents of History Report
MOTOR GROUPItem Contents Unit Reference
MOTOR HOURS F Total time that the Feed Motor has been rotated. hourMOTOR HOURS S Total time that the Scan Motor has been rotated. hour Life : 1500 hoursPUMP TIMES A Total time that the Pump Motor A has been rotated. times Life : 50000 hoursPUMP TIMES B Total time that the Pump Motor B has been rotated. times Life : 50000 hoursPUMP TIMES C Total time that the Pump Motor C has been rotated. times Life : 50000 hoursCLEAR ALL Clear all the value in the Motor Group.
HEAD GROUPItem Contents Unit Reference
SHOT COUNT 1 Number of shots fired from the nozzle (H1 left). Shots/1000Life : 6 billion Shots / nozzleInk from SLOT2
SHOT COUNT 2 Number of shots fired from the nozzle (H1 right). Shots/1000Life : 6 billion Shots / nozzleInk from SLOT8
SHOT COUNT 3 Number of shots fired from the nozzle (H2 left). Shots/1000Life : 6 billion Shots / nozzleInk from SLOT3
SHOT COUNT 4 Number of shots fired from the nozzle (H2 right). Shots/1000Life : 6 billion Shots / nozzleInk from SLOT9
SHOT COUNT 5 Number of shots fired from the nozzle (H3 left). Shots/1000Life : 6 billion Shots / nozzleInk from SLOT6
SHOT COUNT 6 Number of shots fired from the nozzle (H3 right). Shots/1000Life : 6 billion Shots / nozzleInk from SLOT12
SHOT COUNT 7 Number of shots fired from the nozzle (H4 left). Shots/1000Life : 6 billion Shots / nozzleInk from SLOT1
SHOT COUNT 8 Number of shots fired from the nozzle (H4 right). Shots/1000Life : 6 billion Shots / nozzleInk from SLOT7
SHOT COUNT 9 Number of shots fired from the nozzle (H5 left). Shots/1000Life : 6 billion Shots / nozzleInk from SLOT5
SHOT COUNT 10 Number of shots fired from the nozzle (H5 right). Shots/1000Life : 6 billion Shots / nozzleInk from SLOT11
SHOT COUNT 11 Number of shots fired from the nozzle (H6 left). Shots/1000Life : 6 billion Shots / nozzleInk from SLOT4
SHOT COUNT 12 Number of shots fired from the nozzle (H6 right). Shots/1000Life : 6 billion Shots / nozzleInk from SLOT10
WIPE H1 Number of times the Wiping has been performed (H1). timesWIPE H2 Number of times the Wiping has been performed (H2). timesWIPE H3 Number of times the Wiping has been performed (H3). timesWIPE H4 Number of times the Wiping has been performed (H4). timesWIPE H5 Number of times the Wiping has been performed (H5). timesWIPE H6 Number of times the Wiping has been performed (H6). timesRUB H1 Number of times the Rubbing has been performed (H1). timesRUB H2 Number of times the Rubbing has been performed (H2). timesRUB H3 Number of times the Rubbing has been performed (H3). timesRUB H4 Number of times the Rubbing has been performed (H4). timesRUB H5 Number of times the Rubbing has been performed (H5). timesRUB H6 Number of times the Rubbing has been performed (H6). timesCLEAN AUTO H1 Number of times the Auto Head Cleaning has been performed (H1). timesCLEAN AUTO H2 Number of times the Auto Head Cleaning has been performed (H2). timesCLEAN AUTO H3 Number of times the Auto Head Cleaning has been performed (H3). timesCLEAN AUTO H4 Number of times the Auto Head Cleaning has been performed (H4). timesCLEAN AUTO H5 Number of times the Auto Head Cleaning has been performed (H5). timesCLEAN AUTO H6 Number of times the Auto Head Cleaning has been performed (H6). timesCLEAN N, H1 Number of times the Normal Head Cleaning has been performed (H1). timesCLEAN N, H2 Number of times the Normal Head Cleaning has been performed (H2). timesCLEAN N, H3 Number of times the Normal Head Cleaning has been performed (H3). timesCLEAN N, H4 Number of times the Normal Head Cleaning has been performed (H4). timesCLEAN N, H5 Number of times the Normal Head Cleaning has been performed (H5). timesCLEAN N, H6 Number of times the Normal Head Cleaning has been performed (H6). timesCLEAN M, H1 Number of times the Medium Head Cleaning has been performed (H1). timesCLEAN M, H2 Number of times the Medium Head Cleaning has been performed (H2). timesCLEAN M, H3 Number of times the Medium Head Cleaning has been performed (H3). timesCLEAN M, H4 Number of times the Medium Head Cleaning has been performed (H4). timesCLEAN M, H5 Number of times the Medium Head Cleaning has been performed (H5). timesCLEAN M, H6 Number of times the Medium Head Cleaning has been performed (H6). timesCLEAN POW, H1 Number of times the Powerful Head Cleaning has been performed (H1). timesCLEAN POW, H2 Number of times the Powerful Head Cleaning has been performed (H2). timesCLEAN POW, H3 Number of times the Powerful Head Cleaning has been performed (H3). timesCLEAN POW, H4 Number of times the Powerful Head Cleaning has been performed (H4). timesCLEAN POW, H5 Number of times the Powerful Head Cleaning has been performed (H5). timesCLEAN POW, H6 Number of times the Powerful Head Cleaning has been performed (H6). times
4-10
Item Contents Unit ReferenceFILL INK H1 Number of times the Fill Ink has been performed (H1). timesFILL INK H2 Number of times the Fill Ink has been performed (H2). timesFILL INK H3 Number of times the Fill Ink has been performed (H3). timesFILL INK H4 Number of times the Fill Ink has been performed (H4). timesFILL INK H5 Number of times the Fill Ink has been performed (H5). timesFILL INK H6 Number of times the Fill Ink has been performed (H6). timesHEAD WASH H1 Number of times the Head Wash has been performed (H1). timesHEAD WASH H2 Number of times the Head Wash has been performed (H2). timesHEAD WASH H3 Number of times the Head Wash has been performed (H3). timesHEAD WASH H4 Number of times the Head Wash has been performed (H4). timesHEAD WASH H5 Number of times the Head Wash has been performed (H5). timesHEAD WASH H6 Number of times the Head Wash has been performed (H6). timesPUMP UP H1 Number of times the Pump Up has been performed (H1). timesPUMP UP H2 Number of times the Pump Up has been performed (H2). timesPUMP UP H3 Number of times the Pump Up has been performed (H3). timesPUMP UP H4 Number of times the Pump Up has been performed (H4). timesPUMP UP H5 Number of times the Pump Up has been performed (H5). timesPUMP UP H6 Number of times the Pump Up has been performed (H6). timesCLEAR H1 Clear all the value of the H1.CLEAR H2 Clear all the value of the H2.CLEAR H3 Clear all the value of the H3.CLEAR H4 Clear all the value of the H4.CLEAR H5 Clear all the value of the H5.CLEAR H6 Clear all the value of the H6.CLEAR ALL Clear all the value of all the Head.
MAINTENANCE GROUPItem Contents Unit Reference
COUNT Number of times the Head Maintenance has been performed. times
TOTAL TIME Lapsed time from the last Head Maintenance. hours
This value is clearedautomaticallyafter carrying out theHead Maintenance.
PRINTING TIME Printing time from the last Head Maintenance. hours
This value is clearedautomaticallyafter carrying out theHead Maintenance.
CLEAR ALL Clear all the value in the MAINTENANCE GROUP.
WIPE GROUPItem Contents Unit Reference
WIPING COUNT Number of times the Wiping has been performed. timesThis value is clearedautomatically afterreplacing it.
RUBBING COUNT Number of times the Rubbing has been performed. timesThis value is clearedautomatically afterreplacing it.
WIPE REPLACE Number of times the Wipe has been replaced. timesCLEAR ALL Clear all the value in the WIPE GROUP.
PRINT GROUPItem Contents Unit Reference
PRINTING TIME Total time of printing performed. hoursTime of the Test printis not included.
PIGMENT PAGES Number of pages printed with Pigment Ink. pagesDYE PAGES Number of pages printed with Dye Based Ink. pagesSOL PAGES Number of pages printed with Sol Ink. pagesHEAD LOW Number of pages printed when the Head height is Low. pagesHEAD MIDDLE Number of pages printed when the Head height is Middle. pagesHEAD HIGH Number of pages printed when the Head height is High. pagesCLEAR ALL Clear all the value in the PRINT GROUP.
INK GROUPItem Contents Unit Reference
CARTRIDGE 1 Number of times the Ink Cartridge 1 has been changed. timesCARTRIDGE 2 Number of times the Ink Cartridge 2 has been changed. timesCARTRIDGE 3 Number of times the Ink Cartridge 3 has been changed. timesCARTRIDGE 4 Number of times the Ink Cartridge 4 has been changed. timesCARTRIDGE 5 Number of times the Ink Cartridge 5 has been changed. timesCARTRIDGE 6 Number of times the Ink Cartridge 6 has been changed. timesCARTRIDGE 7 Number of times the Ink Cartridge 7 has been changed. timesCARTRIDGE 8 Number of times the Ink Cartridge 8 has been changed. timesCARTRIDGE 9 Number of times the Ink Cartridge 9 has been changed. timesCARTRIDGE 10 Number of times the Ink Cartridge 10 has been changed. timesCARTRIDGE 11 Number of times the Ink Cartridge 11 has been changed. timesCARTRIDGE 12 Number of times the Ink Cartridge 12 has been changed. timesCHANGE INK Number of times the Ink Type has been changed. timesCLEAR ALL Clear all the value in the INK GROUP.
4-11
ERROR GROUPItem Contents Unit Reference
SERVICE CALL Number of times the Service Call has occurred. timesS-CALL HISTORY Service Call Number in the last 5 times. No.SERVO ERROR F Number of times the Servo Error (Feed Motor) has occurred. timesSERVO ERROR S Number of times the Servo Error (Scan Motor) has occurred. timesLOW TEMP.ERR. Number of times the Low Temperature Error has occurred. timesHIGH TEMP.ERR. Number of times the High Temperature Error has occurred. timesPROTECT PUMP Number of times the Protect Pump Error has occurred. times
EMERG. CAPPING Number of times the Emergency Capping Error has occurred. times
Number of times it iscapped compulsorily toprotect the head fromdrying up when the head isout of the cap more than 10min..
START UNCAPPED Number of times the machine starts with the uncapped. timesCLEAR ALL Clear all the value in the ERROR GROUP.
SYSTEM GROUPItem Contents Unit Reference
POWER ON COUNT Number of times being powered on. timesPOWER ON TIME Total times that the machine has been on. hours Sleep time is not included.SLEEP TIME Total times that the machine has been in sleep mode. hours
SHEETCUT COUNT Number of times the Sheet Cut has been performed, timesIt counts Auto Sheet Cutperformed both bycommand and panel.
CLEAR ALL Clear all the value in the SYSTEM GROUP.
4-12
Service Report
Roland SOL JET PRO II V series
Model : SJ-745EX Menu unit : mm
Version : 6.00 Menu language : EnglishSerial No. : ZS80101 Head Temperature : 26 C / 78.8 FSheet type : Opaque On Board Temperature : 30 C / 86.0 FEmpty mode : Stop Ink remain (1-6) : 99 / 98 / 99 / 99 / 99 / 98Ink type : ECO-SOL CMYKMC Ink remain (7-12) : 99 / 98 / 99 / 99 / 99 / 98Calibration : +0.60% Head height : MIDDLEFull width scanning : OFF Periodic cleaning : ENABLEScan Interval : 0.0 sec Vacuum power : AutoSheet remain : 0.0 m Set remain at loading : DISABLEAltenate Head : Enable
: H1 H2 H3 H4 H5 H6 Wiping count for head : 18 18 18 18 18 18 times Rubbing count for head : 0 0 0 0 0 0 times Auto cleaning count : 5 5 5 5 5 5 times Normal cleaning count : 2 2 2 2 2 2 times Medium cleaning count : 0 0 0 0 0 0 times Powerful cleaning count : 0 0 0 0 0 0 times Fill ink count : 2 2 2 2 2 2 times Head wash count : 2 2 2 2 2 2 times Pump up count : 0 0 0 0 0 0 times Ink renewal (normal) : 0 0 0 0 0 0 times Ink renewal (full) : 0 0 0 0 0 0 times Ink group Cartridge change (1-6) : 0 0 0 0 0 0 times Cartridge change (7-12) : 0 0 0 0 0 0 times Change ink type : 2 times Renewal messages (N/F) : 0 0 times Renewal canceling (N/F) : 0 0 times Error group Service call count : 0 times Service call history : * * * * * * * * * * * * * * * * * * * * Motor error (feed) : 0 times Motor error (scan) : 1 times Low temperature error : 0 times High temperature error : 0 times Protecting pump error : 0 times Emergency capping : 0 times Start uncapped : 6 times Maintenance group Count : 0 times Total time : 94 hours Printing time : 1 hours Wiper group System group Wiping count : 54 times Power on count : 59 times Rubbing count : 0 times Power on time : 12 hours Wiper replace count : 0 times Sleep time : 16 hours Print group Sheet cut count : 8 times Printing time : 0 hours Print pages by Pigment : 0 pages by Dye ink : 0 pages by SOL ink : 0 pages by ECO-SOL : 18 pages by Head height low : 1 pages by Head height middle : 17 pages by Head height high : 0 pages
4-14
Other Factory Mode
SYSTEM PARAMETER INITIALIZE
[ ] , [ ] , [ ENTER ] + POWER ON
INITIALIZE ALLSYS.PARAMETER
INITIALIZE COMPLETED
DISPLAYED LANGUAGE
[ MENU ] + POWER ON
Roland SJ-745EX Ver.6.00
MENU LANGUAGEENGLISH
MENU LANGUAGEJAPANESE
SERVICE REPORT_PRINTING
[ ] + POWER ON
SERVICE REPORT
SETUP SHEET
Turn on the sub power switch while pressing [ ] key.Service Report can be printed on the A4 size media. The printing will be performed in Cyan.
* Please print the [History Report] from the Service Mode.
All parameters will be initialized. Turn on the sub power switch while pressing [ ], [ ] and [ENTER] keys.Initialize can be performed by pressing the [ENTER] key. It can also be cancelled by pressing the [POWER]key. The power will be off automatically when initialize is completed.It is necessary to setup the LIMIT POSITION after the initialization. The error message [SERVICE CALL 0101] will appear if you don't setup the LIMIT POSITION.
4-15
Key Combination
Service Menu
Service Menu Item Comments
Service Mode Sub PowerPress [ Menu] and [ ] to enterService Menu.
Upgrade F/ W Sub Power[ Are you sure? ] will be displayed.Press [ ENTER] to upgrade F/ W.
System ParameterInitialize
ENTER Sub PowerAll parameters will be initialized.Press [ ENTER] to start Initialize.
Limit/ Cut Down Sub Power
History Report( REPORT)
Service Report Sub PowerService Report ( Adj ustment value)will be printed.
Users Menu
Users Menu Item Comments
Language Menu Sub PowerPress [ ] / [ ] to selectLanguage.
Manual Cleaning Cleaning Sub Power
Select [ CLEANING] and press[ ENTER] .Carriage moves to the maintenanceposition on the left hand side.
Wiper Replace Cleaning Sub PowerPress [ ] one time andpress [ ENTER] .
Combination Key Selection
Combination Key Selection
Press [ ] while aligning Carriage to cap Heads. Press [ ENTER] and set up CutDown Pos. Press [ ENTER] .
Select [ HISTORY REPORT] and press [ ] . Then, select Head and press [ ENTER] to print History Report.
Installing F/ W[ SUM-ERROR] will be displayed.Press [ ENTER] to upgrade F/ W.
Use this when the main board isreplaced.Main Power
ENTERMain Power
REPORT Select [ HISTORY REPORT]ServiceMenu
4-16
1
2
3
4
4-3 HOW TO UPGRADE FIRMWARE (Referential Time : 5min.)
It is necessary to prepare the followings to upgrade the FIRMWARE.
1. Firmware
2. Windows PC (Network port is required.)
3. Peck.exe
4. Network cable
(A cross cable is required when you connect SJ to PC directly.)
Check the SJ's IP address.
Confirm that main power is turned "on" and sub power
is turned "off".
Double-click Peck.exe to start the Peck.
[Peck] screen is displayed. Click [Select Port] button.
[Select Port] screen is displayed.
Check on the [via Network] and input the SJ's IP
address.
Click [OK].
[SUM ERROR] is displayed when the Main
Power SW is turned on if the new Main board
is replaced.
In case of that, press [ENTER] to excute the
installation.
Or refer to step 8 [F/W installation when the
Main Board is replaced].
4-17
5
6
[Peck] screen is displayed again.
Click [Firmware Upgrade] button.
[Open] screen is displayed.
Select the firmware file and click [Open].
Peck starts to send the firmware to the SJ.
7 Machine goes into Firmware Upgrade mode
automatically.
When upgrade is completed, sub power sw will be
turned off automatically.
DATA ERRORFORMAT ERROR
DEVICE ERRORWRITE ERROR
DEVICE ERRORWRITE ERROR
DEVICE ERRORWRITE ERROR
*JET PRO II V6.00 >
ERASING>
WRITING<
VERIFYING<
COMPLETE
NG
NG
NG
NG
4-18
[F/W installation when the Main Board is replaced]Make sure the Main power SW is OFF and then turn on
the Main power SW again while pressing [ ], [ ] and
[ ] keys.
Press [ENTER] to excute the in stallation.
Send the firmware using the Peck.
[ ], [ ], [ ] + MAIN POWER ON
VERSION UP SURE?
WAITING
8
9
Revised 3
4-19
4-4 HEAD ALIGNMENT (Referential Time : 30 min._1 Head Alignment)
[About HEAD ALIGNMENT]
HEAD ALIGNMENT is necessary to obtain the good printing quality.
Be sure to operate the HEAD ALIGNMENT when the HEAD is replaced.
If the heads are not aligned, printing problems such as banding, fine lines and gap between bands could
occur.
1
2
3
Remove the Right I/S COVER.
Remove the DAMPER PLATE.
Remove the CARRIAGE COVER.
DAMPER PLATE
I/S COVER
CARRIAGE COVER
4-20
TEST PATTERN shown in the right figure will be
printed.
[BIAS ADJUSTMENT]
4
5
Remove the HEAD BOARD COVER.
6
7
Select the [BIAS] > [TEST PRINT] menu under the
[HEAD ADJUST] menu and press the [ENTER] key.
Turn on the SUB POWER SW while pressing [ ], [ ]
and [ ] keys to enter the SERVICE MODE.
Setup the PET film on the machine.
[ ]
SERVICE MENUHEAD ADJUST
HEAD ADJUSTBIAS
BIASTEST PRINT
[ ]
[ ]
MENUSERVICE MENU
[ ] , [ ] , [ ] + POWER ON
[MENU] key
HEAD BOARD COVER
C M Y K Lm Lc(M) (C)
4-21
8
9
Loosen the 3 screws fixing the Head in order as shown
in the figure.
Adjustment
Screw
Hole for inserting
the Hexagonal
Wrench
Loosen the screws fixing the Head for 1/2 turn.
If the screws are loosened too much,
adjustments could not be performed correctly.
Insert the 1.5 mm Hexagonal Wrench to the hole of the
HEAD CARRIAGE, then, turn the screw so that the lines
of each color in the test pattern will be straight.
*Reference*
Position of the printing moves 1 line by turning
the screw 3/4 turn.
- When the upper lines are the left side of the lower
lines, turn the screw CW.
- When the upper lines are the right side of the lower
lines, turn the screw CCW.
1
2
3
4-22
11
10 Tighten the screws fixing the Head in the reverse order
when fixing with using the TORQUE DRIVER (ST-056).
Print the test pattern again.
If the result is NG, repeat 6 ~ 10 .
The shifting of lines should be within 1/2 dot.
Torque for tightening is 2kgf • cm (20cNm).
Make sure not to tighten the screws firmly.
3
2
1
4-23
12
13
14
ADJUSTMENT SCREW
15
Select the [VERTICAL] > [TEST PRINT] under the
[HEAD ADJUST] menu and press the [ENTER] key.
[VERTICAL ADJUSTMENT]
TEST PATTERN shown in the right figure will be
printed.
[ ]
SERVICE MENUHEAD ADJUST
HEAD ADJUSTVERTICAL
VERTICALTEST PRINT
[ ]
[ ]
Loosen the 3 screws fixing the Head in order as shown
in the figure.
Loosen the screws fixing the Head for 1/2 turn.
If the screws are loosened too much,
adjustments could not be performed correctly.
Turn the ADJUSTMENT SCREW so that the lines of each
color in the test pattern will be straight.
*Reference*
Position of the printing moves 1/2 line by turning
the screw 30 degrees.
1
2
3
C M C Y C K C Lm C Lc C(M) (C)
4-24
16
- When the lines excepting the C lines are above the C
lines, turn the Adjustment Screw CW.
- When the lines excepting the C lines are below the C
lines, turn the Adjustment Screw CCW.
Adjust the other Heads on the basis of the left
C Head. It is not necessary to adjust the left C
Head.
17 Print the test pattern again.
If the result is NG, repeat 12 ~ 16 .
The shifting of lines should be within 1/2 dot.
Tighten the screws fixing the Head in the reverse order
when fixing with using the TORQUE DRIVER (ST-056).
Torque for tightening is 2kgf • cm (20cNm).
Make sure not to tighten the screws firmly.
3
2
1
4-25
18
19
[ HORIZONTAL ADJUSTMENT ]Select the [HORIZONTAL] > [TEST PRINT] in the
[HEAD ADJUST] menu and press the [ENTER] key.
Following TEST PATTERN will be printed.
Find the position where the block of each color matches the C block and check the number.
In case of having problem deciding the number, the number between the 2 numbers can be selected.
The number with is the current setting.
[ ]
SERVICE MENUHEAD ADJUST
HEAD ADJUSTHORIZONTAL
HORIZONTALTEST PRINT
[ ]
[ ]
Head Position :Middle
Head Position :Low
+ 2+ 10-1-2-3-4-5-6-20 + 3 + 4 + 5 + 6 + 20
H6
H5
H4
H3
H2
DT1.Middle
+ 2+ 10-1-2-3-4-5-6-20 + 3 + 4 + 5 + 6 + 20
H6
H5
H4
H3
H2
DT3.Middle
+ 2+ 10-1-2-3-4-5-6-20 + 3 + 4 + 5 + 6 + 20
H6
H5
H4
H3
H2
DT1.Low
+ 2+ 10-1-2-3-4-5-6-20 + 3 + 4 + 5 + 6 + 20
H6
H5
H4
H3
H2
DT3.Low
4-26
Select [DT1, Low] , [DT3, Low], [DT1, Middle] and
[DT3,Middle] in the [HORIZONTAL] menu and enter
the parameters checked at 19 with [ ] and [ ]
keys.
Press the [ENTER] key to save the settings.
21
[BIDIRECTION ADJUSTMENT]Select [BI-DIR.DEFAULT] > [TEST PRINT] in the
[HEAD ADJUST] menu and press the [ENTER] key.
[ ]
SERVICE MENUHEAD ADJUST
HEAD ADJUSTBI-DIR.DEFAULT
BI-DIR.DEFAULTTEST PRINT
[ ]
[ ]
20
HORIZONTALTEST PRINT
H2 H3 H4 2 1 -3
H5 H6 2 1
HORIZONTALDT1,Low
HORIZONTALDT1,Middle
H2 H3 H4 2 1 -3
H5 H6 2 1
HORIZONTALDT3,Low
H2 H3 H4 12 11 -13
H5 H6 5 10
HORIZONTALDT3,Middle
H2 H3 H4 12 11 -13
H5 H6 5 10
Parameters can be entered
with an increment of 0.5.
4-27
Head Position :Middle
Head Position :Low
22 Following TEST PATTERN will be printed.
Find the position where the upper block matches the lower block and check the number.
In case of having problem deciding the number, the number between the 2 numbers can be selected.
23 Select [DT1, Low], [DT3, Low], [DT1, MIDDLE] and [DT3,
MIDDLE] in the [BI-DIR.DEFAULT] menu and enter the
parameters checked at 22 with [ ] and [ ] keys.
Press the [ENTER] key to save the settings.
BI-DIR.DEFAULTTEST PRINT
H1 H2 H3 12 11 -13
H4 H5 H6 5 10 -11
BI-DIR.DEFAULTDT1,Low
BI-DIR.DEFAULTDT3,Low
H1 H2 H3 12 11 -13
H4 H5 H6 5 10 -11
H1 H2 H3 12 11 -13
H4 H5 H6 5 10 -11
BI-DIR.DEFAULTDT1,Middle
BI-DIR.DEFAULTDT3,Middle
H1 H2 H3 12 11 -13
H4 H5 H6 5 10 -11
25 Fix the DAMPER PLATE.
24 Fix the HEAD BOARD COVER.
Make sure to press the Damper Plate
downward lightly when fixing it.
* Fix the screws at the bottom of the long hole.
If you press the Damper Plate strongly, the
Damper will be broken.
Parameters can be entered
with an increment of 0.5.
HEAD BOARD COVER
DAMPER PLATE
4-29
[About CAP HEIGHT ADJUSTMENT]
CAP HEIGHT ADJUSTMENT is to adjust the height of the cap.
It must be done when you remove or replace the cap unit.
If this adjustment has not been done there is a possibility that a CAP OPEN SUCTION is not performed correctly.
CAP OPEN SUCTION is an operation to suck ink without the heads capped. This can remove the ink
accumulated on the Cap surfaces by the flushing done above the Caps.
1
2
4-5 CAP HEIGHT ADJUSTMENT (Referential Time : 5min.)
Lower the Pinch Rollers.
Make sure to unload the media when it is set on the
machine.
Then, turn on the SUB POWER SW while pressing [ ]
[ ] and [ ] keys to enter the SERVICE MODE.
Select the [CAP ADJUST] menu in the SERVICE
MENU and select [ADJUST POS.].
When the carriage is not in the capping position,
press [ ] key to move the cap lower and then move the
carriage to the capping position.
-Note that the caps do not contact the head.
-When you press the [ ] key, the cap moves to
the position in the setting value -2.00mm.
-It is only possible to move the cap stepwise
to the upward direction in the [ADJUST POS.]
menu. When you move the cap in the
downward direction, press [ ] key to move
the cap lower end once and then move
upward direction in 0.25mm unit.
Head
Cap
MENUSERVICE MENU
[ ] , [ ] , [ ] + POWER ON
[MENU] key
4-30
4 Enter the [CHECK GAP.] menu in the [SERVICE
MODE] to check the cap adjustment value.
3 Move the cap upward to the position that the capcontacts exactly to the head, then press [ENTER] to
update the adjustment value.-When you press [ ] key, the cap moves to the upward
direction in 0.25mm unit.
-When you press [ ] key, the cap moves to the position
in the setting value -2.00mm.
-When you press[ ] key, the adjustment value is not
updated and the capping is carried out and then exiting
the menu.
The cap moves to the same position as the CAP OPEN
SUCTION is performed. Check if there is the gap
between the cap and head.
[CHECK GAP.] is the menu to check the gap
between the caps and head. For adjustment, use
the [ADJUST POS.] menu.
Head
Cap
Gap
4-31
1
2
3
4-6 LINEAR ENCODER SETUP (Referential Time : 3min.)
[About LINEAR ENCODER SETUP]
LINEAR ENCODER SETUP is necessary for the machine to recongnize the width by the software coordinates.
It is also necessary for checking whether the encoder module can read the scale correctly in the whole
width.
Lower the Pinch Rollers.
Make sure to unload the media when it is set on the
machine.
Then, turn on the SUB POWER SW while pressing [ ],
[ ] and [ ] keys to enter the SERVICE MODE.
Select the [LINEAR ENCODER] menu in the SERVICE
MENU and press the [ENTER] key.
One of the messages will appear at the completion of
the set up.
In case of SETUP error, check the followings.1. Dirt/Scratch on the ENCODER SCALE.
2. Dirt/Scratch on the ENCODER MODULE.
3. ENCODER SCALE is not between the
ENCODER MODULE.
4. Backlash of the CARRIAGE MOTOR GEAR and
the DRIVE GEAR.
5.Fixation between the CARRIAGE and the CARRIAGE WIRE.
6. Bad Contact in the cables.
In case of HEADBOARD error, Head Board could bedefective.
MENUSERVICE MENU
[ ] , [ ] , [ ] + POWER ON
[MENU] key
LINEAR ENCODERSETUP COMPLETED
LINEAR ENCODERSETUP FAILED
LINEAR ENCODERHEADBOARD FAILED
SERVICE MENULINEAR ENCODER
NOW PROCESSING..POS: 1361.00mm
4-32
1
2
3
4-7 LIMIT POSITION & CUT DOWN POSITION INITIALIZE (Referential Time : 3min.)
[About LIMIT POSITION & CUT DOWN POSITION INITIALIZE]
This is used to detect the distance between the Limit Sensor and the Capping Position. After completing the
detection, the distance from the Cut Down Position to the Limit Sensor will be detected and setup the model
automatically at the same time. When the Limit Position is not correctly set, locking problem could occur.
Please make sure that the value of the Limit Posiiton in the Service Report is 7.8 +/- 2.5mm.
When the Cut Down Position is not correct, the problem related to Auto Sheet Cutter could occur.
Remove the Right I/S COVER.
Turn on the SUB POWER SW while pressing [ ], [ ]
and [ ] keys.
Align the CARRIAGE by hand to the Capping position
while moving the Capping Unit with [ ] and [ ] keys.
[ ] , [ ] , [ ] + POWER ON
LIMIT INITIALIZE MENU
MOVE TO CAP POS
Align the guides at the both ends of the
CAPPING UNIT with the guides at the both
ends of the CARRIAGE.
Make sure not to move the CARRIAGE when
the CAPPING UNIT is up because the
HEADs could be broken by touching the
CAPPING UNIT.
I/S COVER
4-33
4
5
Press [ENTER] key to cap the HEADs.
Carry out the LIMIT POSITION INITIALIZE by pressing
the [ENTER] key.
After the LIMIT POSITION INITIALIZE is completed,
the message appears as show in the figure.
6
7
Move the HEAD CARRIAGE with your hand until it
makes full contact with the LEFT FRAME with CUT
DOWN status.
Carry out the CUT DOWN POSITION INITIALIZE by
pressing [ENTER] key.
After the completion of the INITIALIZE, print the
SERVICE REPORT. Then, check the value of the
Limit Position is 7.8 +/- 2.5mm.
If not, please adjust again.
DETECTING..
SETTING UPCUTTER DOWN POS
DETECTING..
INITIALIZE COMPLETED
4-34
1
2
3
MENUSERVICE MENU
[ ] , [ ] , [ ] + POWER ON
[MENU] key
4-8 PAPER SIDE SENSOR ADJUSTMENT (Referential Time : 5min.)
[About PAPER SIDE SENSOR ADJUSTMENT]
This is for adjusting the sensitivity of the PAPER SIDE SENSOR, which is for detecting the width of the
media. If it is not adjusted, media width could not be detected correctly.
Remove the Right I/S COVER.
Turn on the SUB POWER SW while pressing [ ], [ ]
and [ ] keys to enter the SERVICE MODE.
Remove the TOP INNER COVER and CARRIAGE
COVER.
I/S COVER
TOP INNER COVER
CARRIAGE COVER
4-35
4
5
6Adjust the VR on the CARRIAGE BOARD so that the
[OUTPUT LEVEL] will be 0.5-0.7V.
Select the [SENSOR AUTO TEST] menu under the
[PAPER SIDE SENSOR] menu.
Press the [ENTER] key to carry out the test and make
sure the voltage is 0.5-1.0V and the NOISE is 0.
7
Select the [OUTPUT LEVEL] under the [PAPER SIDE
SENSOR] menu and press the [ ] key.
Lower the SHEET LOADING LEVER.
SERVICE MENUPAPERSIDE SENS
PAPERSIDE SENSOUTPUT LEVEL
OUTPUT LEVEL 0.7V
[ ]
[ ]
SERVICE MENUPAPERSIDE SENS
PAPERSIDE SENSSENSOR AUTOTEST
SENSOR AUTOTEST 0.5V, NOISE 0
[ ]
[ ]
VR
4-36
8 If the voltage is less than 0.5V, increase the voltage for
0.1V in the [OUTPUT LEVEL] menu and carry out the
[SENSOR AUTOTEST] for checking.
If the voltage is more than 1.0V, decrease the voltage
for 0.1V in the [OUTPUT LEVEL] menu and carry out
the [SENSOR AUTOTEST] for checking.
If the NOISE is more than 0, try the followings.
1. Clean the REFLECTION TAPE.
2. Replace the REFLECTION TAPE in case of
scratch.
4-37
1
2
3
4-9 CALIBRATION (FEEDING DIRECTION) (Referential Time : 20min.)
[About CALIBRATION]
CALIBRATION is for adjusting the feeding amount of the GRIT ROLLER.
Carry out this adjustment in case of having problem to print in the correct length in the media feeding
direction.
Calibration is done by using the PET-G in the Factory. Calibrate the feeding direction with customer's
media if necessary.
Turn on the SUB POWER SW while pressing [ ], [ ]
and [ ] keys to enter the SERVICE MODE.
Set the PET-G film on the machine.
MENUSERVICE MENU
[ ] , [ ] , [ ] + POWER ON
[MENU] key
Select the [TEST PRINT] menu under the [CALIB.
DEFAULT] menu and press the [ENTER] key.
CALIB.DEFAULTTEST PRINT
SERVICE MENUCALIB.DEFAULT
4-38
4
5
6
FORMULA
CA = CL - MLML
x 100
TEST PATTERN will be printed.
Calibrating amount can be calculated with the formula
shown at 5 based on the printing result.
Calculate the amount to be calibrated with the formula
shown at the right figure.
1. CA = Calibrating Amount
2. CL = Commanded Length (=400mm)
3. ML = Measured Length
Select the [SETTING] menu under the [CALIB.
DEFAULT] menu and change the amount to be
calibrated with [ ] and [ ] keys.
Press the [ENTER] key to save the setting.
Parameters can be entered with an increment
of 0.05%.
(MAX. +2.00% ~ MIN. -2.00%)
Scan
Feed
500mm
400mm
CALIB.DEFAULTSETTING
SETTING +0.00% +0.15%
SERVICE MENUCALIB.DEFAULT
TEST PATTERN is always printed with Offset
0.00%. Therefore, TEST PATTERN is not
changed even if you change the amount in the
[SETTING] menu.
4-39
1
2
4
4-10 CARRIAGE WIRE TENSION ADJUSTMENT (Referential Time : 10min.)
Remove the Left COVER, Right & Left I/S COVERs and
COVER PLATE.
3
I/S COVER
COVER PLATE
L E F T
COVER
Adjust the tension with the ADJUSTMENT SCREW so
that it will be as 13lb ~ 15lb when replacing the wire, or
9lb ~ 11lb in other cases.
9lb ~ 11lb is the optimal wire tension. The value for the
wire tension when replacing the wire is set on the
assumption that the tension will get settled in the
optimal wire tension 9lb ~ 11lb, due to the stretch of the
wire.
Measure the wire tension with the TENSION METER
(ST-011) at the center of the LM GUIDE.
Loosen the screws shown in the figure.
4-40
6
7
8
After moving the HEAD CARRIAGE back and forth 20
times, press the [ENTER] key to finish the AGING.
Then, check the tension again.
If the tension changes, re-adjust it.
5
Tighten the screws shown in the figure after completing
the adjustment.
Turn on the SUB POWER SW while pressing [ ], [ ]
and [ ] keys to enter the SERVICE MODE.
Select the [SCAN] menu under the [AGING] menu and
press the [ENTER] key to start AGING.
MENUSERVICE MENU
[ ] , [ ] , [ ] + POWER ON
[MENU] key
SERVICE MENUAGING
AGINGSCAN
[ ]
4-41
9 Check and make sure that the tension is within the
range.
If not, adjust it again.
4-42
4-11 NETWORK BOARD INITIALIZE (Referential Time : 2min.)
[About NETWORK BOARD INITIALIZE]
NETWORK BOARD INITIALIZE is necessary when the network board has stopped responding. When
there is no respnse even if sending "PING" command or connecting from a browser, there is a possibility
that the setting of the network board has become incorrect. In such case, the setting can be returned to the
default by carrying out the INITIALIZE.
After the INITIALIZE is completed, it is necessary to set the IP address again. For details, please refer to
Roland PrintServer Network Setting Guide.
1
2
3
Turn off the MAIN POWER SW.
Turn on the MAIN POWER SW while pressing the
button of the network board.
Release the button after green and yellow LEDs of the
network board start flashing, and press the button
again to carry out the INITIALIZE.
When the INITIALIZE is completed, the yellow LED
flashes regularly after LEDs flash threee times.
MAIN POWER SW
MAIN POWER SW
POWER
POWER
4-43
4 Turn off the MAIN POWER SW and then turn it on
again.
The network board will not work properly if the
MAIN POWER SW is not turned on again.
Such symptom could occur as that the network
board does not accept any data although it
returns the IP address.
MAIN POWER SW
POWER
4-44
How to set values : key : One press increases the value by 1.
Press and hold this key to increase the value fast.
key : One press decreases the value by 1.
Press and hold this key to decrease the value fast.
How to register the set data :Press the key to register displayed values.
Note that the displayed values will be registered in 3 seconds without any operation.
After registration of the set data, press key for 3 seconds to return to the one just
after power-on (PV/SV displayed).
4-12 OPERATION OF THE HEATER CONTROLLER
How to switch parameters :The figure below shows the basic operations for the Controller.
If it has not been used for 30 seconds, the display returns to the one just after power-on (PV/SV displayed).
4-45
4-13 Setting the Parameter of the Heater Controller
<Parameter Display Symbol and Set Value>
ParameterDisplay Symbol
First block Key lock Specifies whether or not to allow the change of parameter 2
Second block Control algorithm Selects the control algorithm. FUZZY
Proportional band 3
Integral time 100
Derivative time 20
Input signal codeSets this parameter when changing the types of thetemperature sensors.
1
Lower limit ofmeasuring range
0
Upper limit ofmeasuring range
150
Setting the decimalpoint position
Sets the decimal point position of PV, SV part. 0
Third blockSV (Set Value) lowerlimiter
Sets the lower limit of the SV. 30
SV (Set Value) upperlimiter
Sets the upper limit of the SV. 50
DI1(Digital input 1)operation
Sets the Heater operations.0 : Always ON 2 : Control RUN/Sleep
2
Standby /Operation
SV Set Value at shipment 40
* You can set the value on SV-L and SV-H freely within the range of P-SL and P-SU. However, even if you change the value of SV-L and SV-H, the Heater cannot reach more than 65 degrees C because of the THERMOSTAT.
** When you change any of the above parameters from the Default Set Value, we cannot guarantee the controller operation.
Blocks Parameter DescriptionDefault Set
Value
5-1
5 Supplemental Information
5
5 Supplemental Information5-1 SENSOR MAP
(Left side of the machine)
GRIT ENCODERIt detects rotation position of the Grit Roller.
MAINTENANCE COVER SENSORIt detects whether the Maintenance Cover is opened or closed.
REAR PAPER SENSORIt detects the rear edge of the media and also whether
the media is set or not.
(Right side of the machine)
FRONT PAPER SENSORIt detects the front edge of the
media.
FRONT COVER SENSORIt detects whether the Front Cover
is opened or closed.
LIMIT SENSORIt detects the origin of the Carriage
Moving Direction and the limit.
5-2
5
5 Supplemental Information
WIPER SENSORIt detects the limit position of the Wiper
moving in back and forth.
(Front side ofthe machine)
WIPER HEIGHT SENSORIt detects the limit position of the Wiper height.
HEAD UP/DOWN SENSORIt detects the position of the Head Height Lever.
ENCODER MODULEIt detects coordinates for Carriage
Moving Direction.
THERMISTOR (HEAD)It takes the temperature around the Head.
The black Head is used for the measurement.
(Rear side of the machine)
CAPPING SENSORIt detects the limit position of the Capping Unit.
PAPER SIDE SENSORIt detects the left and right edges of
the media.
5-3
5 Supplemental Information
5
THERMISTOR (HEAD BOARD)It takes the temperature around the Head Board.
INK CARTRIDGE SENSORIt detects whether the Ink Cartridge is installed or not.
INK EMPTY SENSORIt detects whether the Ink Cartridge is empty or not.
SHEET LOAD SENSORIt detects whether the Pinch Rollers are in UP or DOWN position.
5-4
5
5 Supplemental Information
THERMISTOR(HEATER)It takes the temperature of the Heater.
THERMOSTAT(BED HEATER)If the Heater exceeds the limit temperature, it stops
the power supply.
THERMOSTAT(PLATEN HEATER)If the Heater exceeds the limit temperature, it stops
the power supply.
6 Troubleshooting
6-1 WHITE FINE LINE / BANDING / MISSING DOT / SCRATCHY PRINTING / BLURRED PRINTING
NO CHECKING POINT ACTION REFERENCE OUTLINE
1Temporary clogging
in nozzlesManual Head cleaning Users Manual
Nozzle condition becomes poor due to the foreign substanceattached to the surface of the head or very slight drying of theink.
2Wrong setting for
the mediaApply correct setting
The amount of the ink which can be accepted is differentbetween the each media. If the ink amount is not proper, theprinting image becomes blotted or banding appears in theprinting image because of too much ink. It is necessary to dothe Calibration when printing on the media which has a differentthickness. If the Calibration is not adjusted properly, white linesor banding appear because of the bad feeding amount.
3 Transformation of Cap Cap Top Replacement[3-3 CAP TOP
REPLACEMENT]Cleaning is not performed efficiently and the white or dark linesappear in the printing image.
4 Wiper wears out Wiper Replacement[3-2 WIPER
REPLACEMENT]
Wiper cannot remove the foreign substances stuck on thesurface of the head. In that condition, ink is not fired properlyand the white or dark fine lines appear in the printing image.
5 Foreign substances Manual Cleaning Users Manual
When foreign substances are stuck on the surface of the head,ink is not fired properly resulting in the white or dark fine lines inthe printing image. The same thing happens when foreignsubstances are stuck on the cleaning wiper or cap, because thehead cleaning cannot be performed efficiently in that condition.
6 Pump tube is clogged Pump Replacement [3-5 PUMP
REPLACEMENT]
Cleaning is not performed efficiently because ink is not suckedwell. As a result, white or dark lines appear in the printingimage.
7 Ink Damper is clogged Replace Ink DamperInk is not supplied to the head properly. As a result, the white ordark lines appear in the printing image, or printing becomesscratchy.
8Ink cartridge isalmost empty
Replace Ink Cartridge
When the ink cartridge is approaching to its empty, the negativepressure of the ink increases resulting in the scratchy printing ormissing dot due to lack in ink supply. When the [INKCONTROL] in the menu is set to [LATER], the machine doesn'tstop the job when the ink cartridge becomes almost empty.
9 Head is out of adjustment Head Alignment[4-4 HEAD
ALIGNMENT]
When the Bias or Vertical adjustment is not adjusted properly,white or dark fine lines appear in the printing image. When theHorizontal or Bi-direction adjustment is not performed properly,banding appears in the printing image.
10 Head Rank is incorrect Set Head Rank[3-1 HEAD
REPLACEMENT]Head rank setting affects the amount of the fired ink. If it is notset properly, the printing image becomes light or dark or blurred.
11Broken head
orLife of head
Head Replacement[3-1 HEAD
REPLACEMENT]
Ink cannot be fired correctly and results in missing dot when thehead is broken or reaches its life. When the head is electricallybroken, it sometimes prints unnecessary lines.
12Broken Mainboard or
Head Board
Mainboard or HeadBoard
Replacement
[3-7 BOARDSREPLACEMENT]
If the signal sent to the Head is not normal, the Head doesn'twork properly.
6-1
6-2 DOES NOT PRINT AT ALL
NO CHECKING POINT ACTION REFERENCE OUTLINE
1Ink Cartridge isalmost empty
Confirm remaining ink /Replace the Ink
CartridgeUsers Manual
When the ink cartridge is approaching to its empty, the negativepressure of the ink increases and ink is not fired properly due tolack in ink supply. When the [INK CONTROL] in the menu is setto [LATER] the machine doesn't stop the job when the inkcartridge becomes almost empty.
2 Foreign substances Manual Cleaning Users ManualWhen foreign substances are stuck on the surface of the head,ink is not fired properly.
3 Wiper wears out Wiper Replacement[3-2 WIPER
REPLACEMENT]It cannot remove the foreign substances stuck on the surface ofthe head.
4 Air bubbles in Ink line Powerful Cleaning Users Manual
If there are air bubbles in the link line, ink is sometimes not fired.Air bubbles tend to go into the ink line by installing anduninstalling the ink cartridge so many times. All the air bubblesinside the lines can be removed by the powerful cleaning.
5 Pump Tube is clogged Pump Replacement[3-5 PUMP
REPLACEMENT]Cleaning is not performed properly because ink is not suckedefficiently.
6Ink Damper is clogged
or brokenInk Damper
ReplacementInk is not supplied to the head properly.
REPLACEMENT]Ink is not supplied to the head properly.
8
Bad contact with FlexibleCable
or Cut line in FlexibleCable
Re-fix / Replace FlexibleCable
When there is a bad contact with the Flexible cable connected tothe head, or there is a cut line in the Flexible cable, the headdoesn't work properly.
9Broken Head
orLife of Head
Head Replacement[3-1 HEAD
REPLACEMENT]When the head is mechanically or electrically broken, the headdoesn't work properly.
10Broken Mainboard or
Head BoardMainboard or HeadBoard Replacement
[3-7 BOARDSREPLACEMENT]
If the signal sent to the Head is not normal, the Head doesn'twork properly.
6-3 INK DROPS ON MEDIA
NO CHECKING POINT ACTION REFERENCE OUTLINE
1 Foreign substances Manual Cleaning Users ManualWhen foreign substances such as fiber dust is stuck on thesurface of the head, ink sometimes leaks from it.
2 Media strikes Head Change Media
If the media tends to curl or become bumpy due to ink, the headsometimes strikes the media and it causes the ink droppingproblem. It can be avoided by using the Media Clamps orchanging the head height.
3 Broken Ink DamperInk Damper
ReplacementWhen there is a hole in the Ink Damper, ink flows through thehead nozzles and results in ink dropping.
REPLACEMENT]When the Ink Tube is broken, ink flows through the head nozzlesand results in ink dropping.
5 Broken Head Head Replacement[3-1 HEAD
REPLACEMENT]When the head is broken mechanically, ink flows through thehead nozzles and results in the ink dropping.
6Broken Mainboard or
Head BoardMainboard or HeadBoard Replacement
[3-7 BOARDSREPLACEMENT]
Ink firing could not be controlled correctly and sometimes resultsin the ink dropping.
6-2
6-4 SHIFTING IN PRINTING
NO CHECKING POINT ACTION REFERENCE OUTLINE
1Media is not set
correctlySet Media correctly Users Manual
Media is not set straight. Make sure to set the Media straightreferring to the Users Manual.
2Media width is not read
correctly
Paper SensorAdjustment,
Clean or ReplaceReflection Tape
When the Media edge is not detected correctly, it is possiblethat the printing area does not fit with the media and the printingposition could be shifted.
3Encoder Scale is dirty /
brokenClean or Replace
Encoder Scale[3-10 Encoder Scale
Replacement]
When Encoder Scale is dirty or broken, the printing image canbe shifted in a staircase pattern because the printing position inthe scanning direction cannot be detected correctly.
4Encoder Module is dirty /
brokenClean or ReplaceEncoder Module
When Encoder Module is dirty or broken, the printing image canbe shifted in a staircase pattern because the printing position inthe scanning direction cannot be detected correctly.
5 Head is out of position Head Alignment[4-4 HEAD
ALIGNMENT]
When the heads are not aligned, the color shifting occurs andwhen the bidirectional and horizontal adjustment is not correct,the shifting occurs in every band.
6ABSORPTION FAN
is not workingFAN Replacement
When the ABSORPTION FAN is not working, Media floats onthe BED and this results in the Shifting in Printing.
6-5 VERTICAL BANDING
NO CHECKING POINT ACTION REFERENCE OUTLINE
1 Encoder Scale is dirtyClean / ReplaceEncoder Scale
[3-10 Encoder ScaleReplacement]
When there is scratch or dirt on the Encoder Scale, the printingimage could be affected and the vertical bandings could beappeared at the position where there is scratch or dirt. UseKIMWIPE for cleaning or replace it. Never use chemicals, suchas alcohol, for cleaning.
2 LM Guide is dirty Clean LM Guide
When there is dirt on the LM Guide, the Head carriage has thebig moving resistance and the printing image becomes to bechanged from the other part at the position where there is a dirt .And it results in the vertical banding.
3There is a dirt in teeth of
Drive GearClean Drive Gear
When there is a dirt in the teeth of the Drive Gear, themovement of the Head Carriage is changed at the positionwhere there is a dirt. And it results in the periodical verticalbandings.
4There is a dirt in teeth of
Motor GearClean Motor Gear
When there is a dirt in the teeth of the Motor Gear, themovement of the Head Carriage is changed at the positionwhere there is a dirt. And it results in the periodical verticalbandings.
6-6 MEDIA SHIFTING
NO CHECKING POINT ACTION REFERENCE OUTLINE
1Flanges are not set
correctly to the MediaSetup Media again User's Manual
When the flanges are not fully inserted to the media tube, mediawill be fed eccentric and results in media shifting.
2Media is not set straight to
the machineSetup Media again User's Manual
The most effective measure against media shifting is to set themedia straight to the machine. Small tilting of the media whensetting it up could result in big shifting especially doing longprint. It is recommended to setup the media by adding tensiontowards front and check the shifting by prefeed function beforeactually start printing.
3 Grit Roller is dirty Clean the Grit RollerWhen dust such as pieces of vinyl is stick to the grit roller,power to hold the media will be weakened and results in mediashifting. Use brush to clean the Grit Roller.
4 Grit Roller is loose Fix the Grit RollerWhen Grit Roller becomes loose, feeding amount between leftand right edges will be different and results in media shifting.
6-3
6-7 MOTOR ERROR
NO CHECKING POINT ACTION REFERENCE OUTLINE
1 Media JamRemove cause of
Media Jam
When the edges of the media curls or the media absorbs theInk and becomes to be irregular surface of the media, theHead Carriage catches on the media during printing and resultsin the Motor Error.
2 Broken / life of the Motor Motor Replacement[3-4 Carriage Motor
Replacement]When the Motor is broken or reaches its life, the Motor cannotobey the order from the CPU and it results in the Motor Error.
3Power Supply voltage for
Motor is not suppliedReplace Switching Power
Supply[3-7 BOARDS
REPLACEMENT]When the Power Supply voltage for the Motor is not supplied,the Motor cannot move and it results in the Motor Error.
When the Servo Board is broken, the Power Supply voltage forthe Motor is not supplied and the Motor cannot move. It resultsin the Motor Error.
5There is a dirt in teeth of
Drive GearClean Drive Gear
When there is a dirt in the teeth of the Drive Gear and it cannotrotate, the Motor Error occurs.
6Weight of Media exceeds
usable MediaUse usable Media
When the weight of Media is too heavy, the Motor Error occursdue to the too much load for feeding Media.
MOTOR ERROR
BitNo.
0001
0004
0008
0005
0009
0010
0040
0080
0050
0090
Feed Motor Overcurrent Error 2(A little load is put on the motor movement for a
long time.)
0001 and 0004 occurred at the same time.
0001 and 0008 occurred at the same time.
Scan Motor Deviation Error
< ERROR DESCRIPTION
SCAN MOTOR ERRORCODE : 0000 0000
CURRENT ERROR< ERROR LIST >
MEANING CAUSE
Feed Motor Deviation Error
< User side >1. Media Jam2. Pull or Move the Carriage by hands.3. Carriage runs into a thing/hands.4. Media is stuck because the media end is not separated from thepaper tube.5. Heavy media is used.
< Mechanical Side >1. There is a bad contact/cut-line in the cable.2. Screw fixing the tool carriage to wire is shifted.3. Motor is broken./Life4. Head/Servo Board is broken.
Scan Motor Overcurrent Error 1(Big load is put on the motor movement
instantaneously.)Scan Motor Overcurrent Error 2
(A little load is put on the motor movement for along time.)
0010 and 0040 occurred at the same time.
0010 and 0080 occurred at the same time.
Feed Motor Overcurrent Error 1(Big load is put on the motor movement
instantaneously.)
6-4
LAST ERROR
Display the axis which the Error happens.
Revised 2
Revised2
6-8 ERROR MESSAGE
NO REFERENCE
1 Refer to Service Call
2
SERVICE CALL
MEANING ACTION
Sub CPUCommunicationError
1) Check Cable Connection between MainBoard and Servo Board2) Servo Board Replacement3) Main Board Replacement
DIPSW modelsetting error
1) Check the DIPSW setup2) Replacement the Main Board
Limit PositionError
1) Carry out Limit Position Initialize.
Limit SensorError
1) Limit Sensor Replacement2) Check the mechanical Backlash or loosewith the scanning axes.
Cap UnitProtection Error
1) Cap Motor Replacement2) Cap Unit Replacement3) Cap Sensor Replacement4) Cable and Flexible Cable Replacement
Unset up of theLinear Encoder
1) Carry out Linear Encoder Setup.
Wiper UnitProtection Error
1) Wiper Height Motor Replacement2) Wiper Unit Replacement3) Wiper Height Sensor Replacement4) Cable and Flexible Cable Replacement
Wiper ProtectionError
1) Wiper Motor Replacement2) Wiper Unit Replacement3) Wiper Sensor Replacement4) Cable and Flexible Cable Replacement
Linear EncoderError
1) Confirm whether Encoder Scale is betweenthe slit of Encoder Module in a whole width ofthe machine.2) Linear Encoder Replacement3) Scan Motor Replacement4) Confirm Cable Connection between LinearEncoder Board and Print Carriage Board.5) Confirm Connection between Wire andHead Carriage.6) Main Board Replacement
CODENo.
ACTIONCHECKING
POINT
Restart machineInternal Error
Refer to Service CallService Call
OUTLINE
This message is displayed when an unexpected error happens.In the most case, the error can be fixed by restarting themachine.If the error still happens in spite of restarting the machine, itsometimes could be solved by carrying out the Limit Initializationor changing some setting values.
Disorder of Wiper Height SensorFault of Wiper UnitFault of Wiper Height SensorCut-line or short-circuit of Cable and FlexibleCable
Linear Encoder Setup has not been done.
DIPSW setup errorDIPSW defectMain Board defect
Disorder of Wiper SensorFault of Wiper UnitFault of Wiper SensorCut-line or short-circuit of Cable and FlexibleCable
Read error of Linear EncoderRead error of Encoder on Scan Motor sideWire is not fixed to Head Carriage firmly.
CAUSE
Sub Board does not work correctly.Sub CPU does not work correctly.There is a bad connection between MainBoard and Sub Board.
Limit Position Initialize has not been done.
Limit Sensor does not work correctly or isbroken.
Disorder of Cap MotorFault of Cap UnitFault of Cap SensorCut-line or short-circuit of Cable and FlexibleCable
CONTENTS
Disorder of communication with SubCPU
Limit Position Initialize has not beendone.
Even though the machine carries outthe regular movement, the output of theLimit Sensor does not reach theexpected value.
A setup about the model of DIPSW isset up in an unsuitable combination.
Even though the machine carries outthe regular movement, the output ofCap Sensor does not reach theexpected value.
Even though the machine carries outthe regular movement, the output of theWiper Height Sensor does not reachthe expected value.
0109
0110
Linear Encoder Setup has not beendone.
Even though the machine carries outthe regular movement, the output of theWiper Sensor does not reach theexpected value.
Input value from Linear Encoder is notchanged when Linear Encoder is set upthe Origin.When Motor stops during printing,Motor does not complete the movementwhich is supposed to be done.
0108
0107
0002
0101
0102
0104
0003
6-5
6-9 Heater temperature fails to reach the preset value
NO CHECKING POINT ACTION REFERENCE OUTLINE
1 Operation environment Explain to User Users Manual
In an cold environment, warm up may take a long time or thetemperature may fail to reach the preset value. Explain to usersto use the Heater where the temperature is 20 deg C (68 deg F)or more.
2 Media WidthUse the media having a
width of about 1m ormore
Users ManualMedia of a narrower width may take a long time to heat or fail toreach the preset temperature. Recommend the user use themedia having a width of about 1m or more.
3 Power Supply VoltageCheck the Power Supply
Voltage
Low or unstable voltage may result in inadequate heaterperformance. If the temperature of the Heater fails to riseadequately even if it is used correctly, check the voltage of thepower supply.
4Parameter setting of the
Heater Controller
Check the Parametersetting of the Controller /
parameter resetting
[4-13 Setting theParameter of theHeater Controller]
When the parameter setting is not correct, the temperature mayfail to reach the preset value. Check each parameter is setcorrectly referring to the Service Note [4-13].
5Sub Power of the printer
is not ONTurn ON the Sub Power
for the printer
The Heater is connected to the sub power for the printer. Even ifyou turn on the POWER of the controller, the Heater does notoperate until the sub power for the printer is turned ON.
6The printer becomes
sleep modeRecover from sleep
mode
The Heater is connected to the sub power for the printer. Even ifyou turn on the POWER of the controller, the Heater does notoperate if the printer is in the sleep mode.
7The Cables between theController and the ProII
machine
Replace the Cablesbetween the Controllerand the ProII machine
When there is a cut-line in the Cables between the Controllerand the Heater, the temperature fails to reach the preset value.Check Cables between the Controller and the Heater andreplace broken cables.
6-10 Results of printing are coarse
NO CHECKING POINT ACTION REFERENCE OUTLINE
1The Heater has not
warmed upCheck whether each
setting is correctCheck whether each setting is correct referring to the above [6-9].
2 Media is not warm enough
Increase the presettemperature / Wait for awhile until media warms
up
When media is not heated sufficiently, ink drips andunevenness could happen. Wait for about five minutes after thetemperature of [PV] reaches the set temperature or increase thetemperature to heat the media sufficiently. If the media is stillnot warm enough, surrounding temperature may be low.Recommend the user use the heater and printer within therecommended environmental temperature range.
3 Ink drying timeSet the [SCAN
INTERVAL] value to alonger time
Users manualSetting [SCAN INTERVAL] value to a longer time may improveprinting quality.
4Movement width of the
printing carriageSet the [FULL WIDTH
S] to [FULL]Users manual
This function may improve printing quality by maintaining theuniform speed for media feed by selecting [FULL] in this menu.
5Recommended Media is
not usedUse the recommended
media
Some media cannot dry up the ECO-SOL INK even if you usethe Heater. Recommend the user to use the recommendedmedia.
6-6
6-11 Error message (Heater Controller)
OUTLINE
Parameter setting of [P-n2] is not correct. Set the parameter of [P-n2] to 1.
The Thermistor is broken. Replace the Thermistor Cable.
Set the parameter of [P-SL] to 0, [P-SU] to 150 and [P-n2]to 1.
Set the parameter of [P-SL] to 0, [P-SU] to 150 and [P-n2]to 1.
1 or 4 is set in the parameter of [LoC]. Set the parameter of [LoC] to 2.
Set each parameter in the range of the [SV-L] to [SV-H].(Refer to the section [4-13]. )
Replace the Cable between the Controller andthe Servo Board.
Turn ON the Sub Power for the printer. / Recover themachine from sleep mode.
* When the above displays appear, please check whether each parameter is set correctly referring to [4-13] at first.
Errors are caused by a factor other than the above Replace the Controller
Check the Cable Connection.
Set the parameter of [P-SL] to 0, [P-SU] to 150 and [P-n2]to 1.
Set [P-DP] to 0 and return [P-SU] to 150.
The Cable of the Thermistor which is fixed to theController is broken or short-circuit.
The Cable of the Thermistor which is fixed to theController is loose.
Parameter settings of [P-SL], [P-SU] and [P-n2] arenot correct.
Parameter settings of [P-SL], [P-SU] and [P-n2] arenot correct.
Replace the Thermistor Cable.
DISPLAY CAUSE
Parameter settings of [P-SL], [P-SU] and [P-n2] arenot correct.
When the set value of [P-SU] is larger than 1000, "1"will be registered for [P-DP].
You are trying to set the values of [SV-L] and [SV-H]to out of the range. (Parameters of [SV-L] and [SV-H]).
The SV cannot bechanged.
Sub Power of the printer is not ON. / The printerbecomes sleep mode.
The SV or the set valuesof some parameters havebeen changed without anyoperation.
The Cable between the Controller and the ServoBoard is broken.
6-7
7-1
7-1 INSTALLATION CHECK LIST
7 Service Activities
SJ-745EX/645EX INSTALLATION CHECK LIST
Date :
Serial Number User Date Minimum Space Required
Classification
Purchase Loan Unit Demo Unit Replacement
Unpacking
Accessory Box
Accessory Box
< SJ-745EX >4.2m (W) X 2.0m (L) X1.8m (H)< SJ-645EX >4.0m (W) X 2.0m (L) X1.8m (H)
Reinforcing pipe :1 SOL INK Cleaningcartridges : 4
Transport bars : 2
7-5
Bolts (Large)
Hexagonal wrench
Invert the Stand legs and attach the Casters with 8 Bolts (Large).
A t t a c h i n g t h e
Transport bars 1. Attach the Transport bars at the bottom of the main unit.
Make sure the rubber foot faces down.
Front viewShort
Transport bar
Rear viewLong
Assembling the Stand
Cut in the Bottom box as
shown in the figure.
7-6
2. Secure the Transport bars with 8 Bolts (Small).
3. Grip these position in the figure and move it.
Bolts (Small)
7-7
2. Secure the machine and the Stand with 6 Bolts (Large).
Washer
Fit the position of theFrame at the rear ofthe machine in thefixtures on the Stand.
1. Set the Stand up and place the machine on the stand.
Assembling the Main unit
Bolts (Large)
7-8
Remove the 8 Bolts (Small).
Bolts (Small)
Removing the
Transport bars
7-9
1.Place the 2 Pads on the Bottom box.Note the width of the 2 Pads are different.And also, partitioned space is different.
2.Reverse the 2 Boxes as shown in the figure and place them between the Pads placed at [ 1] and the Partition.
4.Make the 2 Accessories boxes flat.
3.Put the other Small pads or boxes inside the Boxes placed at [ 2] .
5.Put the flattened Accessories boxes.
6.Reverse the Pad as shown in the figure and put it on the flattened accessories boxes.
7.Fold the 2 Side pads as shown in the figure and put them on the Pad [ 6] .
8.Put the Top pad on the Pads [ 7] .
9.Bind up the boxes with PP Band.
Short
Long
Partition
Making the Packaging
smaller
7-10
1. Attach the Stays at the position in the figure.
Stay (Right)
Left side of the rear view
2. Place the Media guide on the Stays and secure it with 4 Bolts (Small).
Media guide
Front
ShortLong
Rear
Bolts (Small)
Direction of the Media guide
Media guide
Right side of the rear view
Stay (Left)
Bolts (Small)
Installing the
Accessories
7-11
3. Attach the Media flanges to the Retainers and secure them with the Flangeretaining pins.
Fit the ridges andgrooves.
Media flanges
Flange retaining pins
Left side of the rear view Right side of the rear view
7-12
Installing the Drain Bottle
1. Secure the Bottle stand with 2 Bolts (Large).
Bolts (Large)
Bottle stand
2. Remove the Stopper from the Drain tube.
Peel off the tapes.Drain tube
3. Insert the Drain tube into the Bottle stand securely.
Drain tube
Bottle stand
Stopper* Explain to keep it, because it willbe necessary when the machine istransferred.
7-13
4. Remove the Cap and the Inner cap of the Drain bottle and attach the Drain bottle to the Bottlestand.Make sure the Drain tube is inserted into the Drain bottle.
7-14
Removing the
protective stuffs
2) Peel off the tape.
6) Peel off the tape. 5) Remove the Retainer B.
3) Pull straightthe pad.
1) Remove the Pads.
Pad
Rear view
Retainer A
1)
2)
The other screw of theRetainer B
4) Remove the Retainer Ausing a screwdriver.
Retainer B
8) Attach the Retainer you removed.Firstly, attach the Retainer B.After that, attach the Retainer A.
Pad
7) Peel off the tape andremove the Pads.
7-15
Connecting the Power Cord
Connecting to the Computer
Setting of Computer
Enter the IP Address (Ex.; 192.168.0.100) and the Subnet Mask (Ex.; 255.255.255.0).
Installation of Ink Cartridges
Before printingSwitching on the Power
Filling Ink
4 pcs. of the SOL INK cleaning cartridges are required in this work.
!! IMPORTANT !!
* Explain to insert the same type and color of Ink Cartridge into 1 ~ 6 and
7 ~ 12.
* Gently shake the cartridge when the Ink Cartridge is installed.
* Explain not to remove an Ink Cartridge until it runs out.
If an Ink Cartridge is removed and inserted often, air may go into the Ink tube
and it may cause the ink dropping problem.
Setting of Roland-PrintServer
Enter the IP Address (Ex.; 192.168.0.101) and the Subnet Mask (Ex.; 255.255.255.0).
ECO-SOL CMYKMC / ECO-SOL LcLm
Connection
Network Setting
Installation of the Roland VersaWorks
!! IMPORTANT !!
<Supported Operation Systems>
Windows XP Service Pack 1 or later / Windows 2000 Service Pack 4
* Windows ME / 98 and MAC OS are available as the client PC.
<Recommended System Requirements on Windows>
CPU: Pentium 4 2.0GHz or faster Memory: 512 MB (1GB or more recommended)
HDD: 10 GB or more for Storage Monitor: High-resolution SXGA (1,280 x 1,024 pixels)
or better display recommended.
Making the Setting for Roland@NET
Select a check box [Download Updates Automatically and Notify] if the customer allows it.
Changing the setting for the language
7-16
Setting Media
TEST PRINTPrinting
Send the printing data via Roland VersaWorks.
!! IMPORTANT !!
* Explain to refix the Media flanges depending on the diameter of roll media.
* Explain to adjust [Head Height], [Feed Correction] and [Bidirectional
Correction] when using another type of media.
* Explain about the thickness of usable media.
Refer to the User's Manual 8-1 Media Conditions].
* Explain to use the Media clamps when using the media which curls easily.
In case the Media clamps are used, make sure the Head Height is set at
2(Middle) or 3 (High).
If the Head Height is set at 1 (Low), the Head may strike the Media clamps and
it may breake the Head.
* Explain to remove the roll media from the machine after use.
If the roll media is installed on the machine for a long time, the roll media may
bend by the weight and it may influence the printing result.
* Explain to install the Reinforcing pipe into the roll sheet in order to prevent the
bend of the roll media when 74/64 inch of roll sheet is used.
And also, explain to remove the Reinforcing pipe from the roll media after use.
Before printing
7-17
Setting the Margins
Setting of [SHEET TYPE]
Replacing the Ink Cartridge
Operation
Checking the remaining Ink
Setting the printing start position
!! IMPORTANT !!
* Explain not to replace the Ink cartridges while the machine is working.
Air may go inside the Ink cartridge and it may influence the printing quality.
* Explain about [CONT.] mode which is for printing continuously.
!! IMPORTANT !!
Explain not to feed back the media using the Up key.
The Pinch rollers may pass over the printed surface and it may smudge the
printed image.
Making corrections for printing with user's media
* Feed Correction
* Bidirectional Correction
Operate the following contents based on the User's manual.
Make the Temperature Setting for the Heaters
!! IMPORTANT !!
* Do not touch the platen when the heater is operating.
You can set the temperature either to "OFF" or to a value from 30 to 50
degrees C (in steps of 1 degrees C) from the Control Panel.
* You can also set the temperature by Roland VersaWorks.
!! IMPORTANT !!
* The display of the remaining ink is reset when the Ink Cartridge is installed
regardless of the real quantity. The displayed information may differ from the
actual amount if you insert a partly used Ink Cartridge or change cartridges
while the power is off.
Save and call Bidirectional correction value
!! IMPORTANT !!
Recommend users to note the memory number which is set the adjustment
value on each media.
7-18
Maintenance
Cleaning the Printing Head using Cleaning Kit
Replacing the Wiper
Cleaning other parts
* Platen
* Grit rollers
* Pinch rollers
(Raise the Pich rollers when not in use.)
* Reflective tape
* Front cover
* Sheet sensor
* Media Clamps
!! IMPORTANT !!
* Explain it is necessary to clean these parts as daily maintenance.
* Explain how to wash off the ink as follows.
1. Water down the cleaner.
2. Soak a cloth in the water and wring it.
3. Wipe gently with the cloth.
Discarding the discharged ink in the Drain bottle
!! IMPORTANT !!
* Explain about the time to discard the discharged ink in the Drain bottle.
* Explain to switch off the machine before performing to discard the
discharged ink.
* Explain to discard carefully the discharged ink from the Drain bottle so
that the ink does not spatter.
!! IMPORTANT !!
Instruct users how to perform the cleaning using the Maintenance Video
so that they can do it rightly by themselves.
Cleaning the Printing Head
* [CLEANING] key
* Normal Cleaning
* Medium Cleaning
* Powerful Cleaning
!! IMPORTANT !!
Explain that the machine will display [PRESS THE POWER KEY TO CLEAN]
message if the machine is left without using for 1 month.
This feature operates when the main power is on.
Please use sub power switch to turn on/off the power of the machine keeping
the main power on all the time.
7-19
Explain to switch off and on the machine and check the result before calling an engineer
when Service Call error occurs. There is a possibility to solve the problem just by doing
so.
Others
Instruct users how to cap the Head.
!! IMPORTANT !!
It is necessary to cap the Head by users if the Head does not return to the
stand by position.
Exchange Time of
the Consumable
Parts
Life TimePARTS NAME
Printing Head
Wiper
Carriage Motor
Cap Top
Ink Tube
Pump Unit
Sponge for Flushing
Sponge for Wiper
Battery
6 billion shots / nozzle (6000000 kshots)
* When the cleaning has been done for the 500 times, the message for
replacement of the Wiper will be shown on the LCD.
1,500 hours
6 months
2,000 hours
6 months
12 months
24 months
50,000 times
Explain to close the cover before switching off the machine if the [Cover Open Error] is
shown.
!! IMPORTANT !!
When the error is shown, the Head will not be capped.
If the power of the machine is switched off before closing the cover and
the Head is left, the Head will be dry and break.
* When the Head is replaced, the Dampers should be replaced at the same time.
6 months or
Wiping 3000 times or
Ribbing 100 times
7-20
ReferenceGet/Output Report OKUpgrade the firmware to the latest version OKConsumables Head OK Perform Cleaning Replacement 6 billion shots
Carriage Motor OK Replacement 1,500 hoursOK Perform Cleaning Replacement 6 months or
Wipping : 3,000 times orRubbing : 100 times
Cap Top OK Perform Cleaning Replacement 6 months
Ink Tube OK Perform Cleaning Replacement 2,000 hoursPump Unit OK Perform Cleaning Replacement 50,000 timesSponge for Frushing OK Perform Cleaning Replacement 6 monthsSponge for Wiper OK Perform Cleaning Replacement 12 monthsLithium Battery OK Perform Cleaning Replacement 24 months
Mechanical Carriage Drive Gear OK Correct Backlash Lubrication Replacement Grease : FLOIL GE-676 P/# 21675101Grit Drive Gear OK Correct Backlash Lubrication Replacement Grease : FLOIL GE-676 P/# 21675101Wire OK Adjust Tension ReplacementPlaten OK Perform CleaningGrit Roller OK Perform CleaningPinch Roller OK Perform CleaningReflective Tape OK Perform CleaningSheet Sensor OK Perform CleaningFront Cover OK Perform CleaningMedia Clamp OK Perform CleaningBed OK Perform Cleaning
Printing OK NG (Reason)
Get/Output Report ** In case of any changes.
ContentsCheck Points
Cleaning Wiper
Model Serial Numer User Date
PC OS Application
7-2 Maintenance Check List
AFTER 6 MONTH MAINTENANCE CHECK LIST
MAINTENANCE
OPERATION CHECK
NOTE
Media Loading OthersPrinting Printing position
Printing CalibrationMaintenance Cleaning using the
Cleaning KitReference Media Type
Head HeightPrinting Area
Roland VersaWorks Printing ModeColor Profiles
Roland@NET
Revised 4
7-21
ReferenceGet/Output Report OKUpgrade the firmware to the latest version OKConsumables Head OK Perform Cleaning Replacement 6 billion shots
Carriage Motor OK Replacement 1,500 hoursOK Perform Cleaning Replacement 6 months or
Wipping : 3,000 times orRubbing : 100 times
Cap Top OK Perform Cleaning Replacement 6 months
Ink Tube OK Perform Cleaning Replacement 2,000 hoursPump Unit OK Perform Cleaning Replacement 50,000 timesSponge for Frushing OK Perform Cleaning Replacement 6 monthsSponge for Wiper OK Perform Cleaning Replacement 12 monthsLithium Battery OK Perform Cleaning Replacement 24 months
Mechanical Carriage Drive Gear OK Correct Backlash Lubrication Replacement Grease : FLOIL GE-676 P/# 21675101Grit Drive Gear OK Correct Backlash Lubrication Replacement Grease : FLOIL GE-676 P/# 21675101Wire OK Adjust Tension ReplacementPlaten OK Perform CleaningGrit Roller OK Perform CleaningPinch Roller OK Perform CleaningReflective Tape OK Perform CleaningSheet Sensor OK Perform CleaningFront Cover OK Perform CleaningMedia Clamp OK Perform CleaningBed OK Perform Cleaning
Printing OK NG (Reason)
Get/Output Report ** In case of any changes.
ContentsCheck Points
Cleaning Wiper
NOTE
MAINTENANCE
AFTER 12 MONTH MAINTENANCE CHECK LISTModel Serial Numer User Date
PC OS Application
Revised 4
7-22
7-3 Specification
Main unit Specification
SJ-745EX
500 to 1879 mm (19-11/16 to 74 in.)
210 to 1879 mm (8-5/16 to 74 in.)
Maximum 1869 mm (73-9/16 in.)
6.5 A (117 V) or 3.3 A (220 to 240 V)
Approx. 770 W
Approx. 55 W
3134 (W) x 742 (D) x 1300 (H) mm (123-7/16 (W) x 29-1/4 (D) x 51-3/16 (H) in.)
174 kg (384 lb.)
3270 (W) x 850 (D) x 1005 (H) mm (128-3/4 (W) x 33-1/2 (D) x 39-5/8 (H) in.)
252 kg (556 lb.)
Piezo ink-jet method
Exclusive ECO-SOL INK cartridge
220 cc ±5 cc
Six colors (cyan, magenta, yellow, black, light cyan and light magenta), orfour colors (cyan, magenta, yellow and black)
Maximum 1440 dpi
Error of less than ±0.3% of distance traveled, or ±0.3 mm, whichever is greater
Error of less than ±0.3% of distance traveled, or ±0.3 mm, whichever is greater
Print heater, Setting range for the preset temperature: 35 to 50C (96 to 122F)
2953 (W) x 742 (D) x 1300 (H) mm (116-5/16 (W) x 29-1/4 (D) x 51-3/16 (H) in.)
170 kg (375 lb.)
3090 (W) x 850 (D) x 1005 (H) mm (121-11/16 (W) x 33-1/2 (D) x 39-5/8 (H) in.)
236 kg (520 lb.)
Printing method
Acceptable media While the print heater iswidths running
While the print heater isnot running
Printing width
Ink cartridges Type
Capacity
Color
Printing resolution (Printing dot resolution)
Distance accuracy While the print heater isrunning (*1)
While the print heater isnot running (*2)
Ink -fixing device (*3)
Interface
Power-saving function
Power supply Voltage and frequency
Required power capacity
Power consumption During operation
Sleep mode
Acoustic noise level During operation
During standby
Dimensions (With stand)
Weight (With stand)
Packed dimensions
Packed weight
Environment Power on (*4)
Power off
Included items
7-23
*1 • Media type: Roland SV-G-1270G, print travel: 1 m • Preset temperature for the print heater: 40˚C • Temperature: 20C, humidity: 50%
*2 • Media type: Roland PET-G-1050, print travel: 1 m
*3The print heater temperature may not reach the preset temperature depending on ambient conditions or the width of the media.Unevenness in temperature may be larger depending on ambient conditions or the width of the media.