Roland sect3e

7/21/2019 Roland sect3e

1/66

3-1

3 Replacement of Main Parts

To Ensure safe Work

UNPLUG

- Rear View -

AC INLET for the

Printer Unit.

Turn off the Main Power SW, and unplug the power cable of the Printer

before performing parts replacement.

It is not possibl e to cut power of completely only by tu rning off t he secondary power

SWs.


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3-2

The necessary adjustments after the replacement of each part, and the referential time for each work are

described as follows.

HEAD REPLACEMENT : 30min. (1 Head)1. THERMISTOR CHECK

2. 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 : 40min. (8 pcs.) 1. CHECKING THE CAP HEIGHT *7 Adj. Time : 5min.

< Total Time : 45min. >

CARRIAGE MOTOR REPLACEMENT : 20min.1. SERVO LOCK CHECK2. AGING3. MOTOR HOURS CLEAR Adj. Time : 5min.

< Total Time : 25min. >

PUMP REPLACEMENT : 30min. (4 pcs.)1. PUMP HOURS CLEAR< Total Time : 30min. >

MAIN BOARD REPLACEMENT(Including BATTERY INSTALLATION) : 30min.

1. DIP SW SETTING2. FIRMWARE INSTALLATION3. SYSTEM PARAMETER INITIALIZE4. HEAD RANK SETTING5. SERIAL NUMBER INPUT *16. CAP & WIPER CHECK *27. CAP HEIGHT ADJUSTMENT8. SENSOR CHECK9. LIMIT & CUT DOWN POSITION INITIALIZE10. LINEAR ENCODER SETUP11. PAPER SIDE SENSOR ADJUSTMENT12. INK TYPE SETTING13. HEAD ALIGNMENT (SOFTWARE ONLY)14. CALIBRATION Adj. Time : 70min.< Total Time : 100min. >

HEAD BOARD REPLACEMENT : 25min.1. THERMISTOR CHECK

2. HEAD UP/DOWN SENSOR CHECK *33. HEAD BOARD FAN CHECK Adj. Time :13min.< Total Time : 38min. >

SERVO BOARD REPLACEMENT : 25min. 1. AGING Adj. Time : 5min. < Total Time : 30min. >

BATTERY REPLACEMENT : 20min.1. BATTERY FLAG CLEAR *4 Adj. Time : 3min.< Total Time : 23min. >

AC JUNCTION BOARD REPLACEMENT: 15min< Total Time : 15min. >

SW POWER SUPPLY REPLACEMENT: 25min< Total Time : 25min. >

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. THERMISTOR CHECK3. PAPER SIDE SENSOR ADJUSTMENT Adj. Time : 5min.

INK TUBE REPLACEMENT : 75min. (16 pcs.)< Total Time : 75min. >

CARRIAGE BELT REPLACEMENT : 40min.1. BELT TENSION ADJUSTMENT2. CARRIAGE BELT POSITION ADJUSTMENT3. LIMIT & CUT DOWN POSITION INITIALIZE

Adj. Time : 20min.< 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] > [I/S MENU] > [I/S CHECK].*3 It can be performed in the [SERVICE MENU] > [SENSOR CHECK].

*4 It can be performed in the [SERVICE MENU] > [SUB MENU] > [CLOCK].

*5 It can be performed in the [SERVICE MENU] > [SUB MENU] > [LCD/LED/BUZ CHECK].

*6 It can be performed in the [SERVICE MENU] > [SUB MENU] > [KEY CHECK].

*7 It can be performed in the [SERVICE MENU] > [I/S MENU] >[CAP ADJUST] > [CHECK GAP].

NETWORK BOARD REPLACEMENT : 20min.1. FIRMWARE UPGRADE2. IP ADDRESS SETTING Adj. Time : 10min.< Total Time : 30min. >


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3-3

4

Select [PRINT MENU] > [HEAD RANK], and select the

Head No. of the HEAD that you are going to replace and

input the HEAD RANK written on the new HEAD.

Input the HEAD RANK by selecting the digit with the Left

and Right keys, and changing the parameters with the

Up and Down keys.

* The Head No. becomes [HEAD1], [HEAD2],[HEAD3]

from the HEAD at the left end in order.

Press the [ENTER] key to save the settings.

Make sure to input the HEAD RANK before

replacing the HEAD, because the sticker which

the HEAD RANK is written on will be hidden

after the HEAD is installed.

2

1

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

MENU

SERVICE MENU

[ ]

[ ]

SERVICE MENU

PRINT MENU

PRINT MENU

HEAD RANK

HEAD RANK

HEAD 1

[ENTER]

HEAD RANK 1

701302D(1/5)

[ ]

5CY2F2F

Head Rank

Remove the RIGHT I/S COVER.

RIGHT I/S COVER

3

[ ]

[ ]

SERVICE MENU

I/S MENU

I/S MENU

I/S CONTROL

I/S CONTROL

CAP

[ENTER]

CAP

OPEN

[ ]

Select [I/S MENU] > [I/S CONTROL] > [CAP] > [OPEN]

and press the [ENTER] key. The CAPPING UNIT moves

down and it allows you to move the HEAD CARRIAGE by

hand.


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3-4

Remove the HEAD BOARD COVER and remove the

Flexible Cables from the Head which will be replaced.

Remove the DAMPER PLATE.

DAMPER PLATE

Remove the CARRIAGE COVER.

Move the HEAD CARRIAGE slowly to the left.

CARRIAGE COVER

5

6

7

8

Be sure to turn off the MAIN POWER SW

when replacing the head. Otherwise, the head

or main board can be damaged. It is

recommended to disconnect the AC code.

Turn off the SUB POWER SW and then turn off the

MAIN POWER SW.< REAR VIEW >

MAIN POWER SW

HEAD BOARD COVER

FLEXIBLE CABLEs

Hold the HEAD with fingers when removing

the Flexible Cables.


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3-5

12

11

10

Do not hold the INK DAMPER too hard.

Otherwise, it will be damaged.

Be sure to remove and fix the INK DAMPER

with the HEAD BOARD COVER fixed. It

prevents ink from dropping on the HEAD

BOARD.

9Fix the HEAD BOARD COVER temporarily, and remove

the 2 INK DAMPERs from the HEAD which will be

replaced.

HEAD BOARD COVER

INK

DAMPERs

Remove the SPRING, and remove the 3 Screws fixing the

HEAD.Then, pull the HEAD towards the front and lift it up to

remove it from the CARRIAGE.

SPRING

5CY2F2F

Remove the HEAD from the HEAD ADAPTER and fix a

new HEAD to the ADAPTER.

Make sure to fix the HEAD by pressing it to the

bottom left corner of the ADAPTER.

Use the 2kgfcm torque driver (ST-056) to

tighten up the screws.

Install the HEAD to the CARRIAGE and fix the 3 Screws

temporarily. Then, fix the SPRING and tighten up the 3

Screws.

HEAD ADAPTER

HEAD

Use the 2kgfcm torque driver (ST-056 + ST-060

bit) to tighten up the screws.

SPRING


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3-6

Do not hold the INK DAMPER too hard. Otherwise, it

could be damaged.Either INK DAMPER can be

connected to either connector on the HEAD.

But, the basic way of installing is as the following.

In case of the rear side of the HEAD )

Connect the INK DAMPER which has the Ink Tube with

1 line to the front side, and 2 lines to the rear side.

In case of the front side of the HEAD)

Connect the INK DAMPER which has the Ink Tube with

3 lines to the front side, and 4 lines to the rear side.

Fix the HEAD BOARD COVER.

The cover should be fixed to prevent ink from

dropping on the HEAD BOARD when the INK

DAMPERs are fixed. It is not necessary to fix

the cover with the NYLON LIVET, because the

cover needs to be removed for the HEAD

POSITION ADJUSTMENT.

13

14

15Connect the Flexible Cables to the HEAD.

Be sure to connect the cables correctly.

HEAD BOARD COVER

Install the new INK DAMPERs to the head.

Install the new INK DAMPERs when you replace

the head.

INK

DAMPERs

Front sideRear side

FLEXIBLE CABLEs


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3-7

16

17

After turning on the MAIN POWER SW, press the

[CLEANING] key and select the group which is replaced

to the new HEAD.

Enter the SERVICE MODE and perform the following

adjustments.

1. THERMISTOR CHECK

2. HEAD ALIGNMENT

3. HEAD INFORMATION CLEAR

4. CHECKING CAP HEIGHT

< HOW TO CLEAR THE HEAD INFORMATION >

After THERMISTOR CHECK and HEAD ALIGNMENT,

select [SERVICE MENU] > [HEAD GROUP]. Then, select

the HEAD you replaced and press the ENTER key.

[ ]

SERVICE MENU

HISTORY MENU

HISTORY MENU

HEAD GROUP

HEAD GROUP

CLEAR H1

HEAD GROUP

CLEAR H8

HEAD GROUP

CLEAR ALL

< NOTE for f ixing the DAMPER PLATE >

When you fix the DAMPER PLATE after the above

adjustments, make sure not to press the plate down onto the

DAMPERs with force.

* Fix the screws at the bottom of the long screw hole.

DAMPER PLATE


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3-8

Remove the WIPER and fix a new one.

Make sure to fix the WIPER so that the rubber

side faces the front.

1

2

3

4

[ ]

MENU

SUB MENU

SUB MENU

MAINTENANCE

MAINTENANCE

REPLACE WIPER

[ ]

[ ]

[ ]

[ENTER]

Select [SUB MENU] > [MAINTENANCE] > [REPLACE

WIPER] in the User's Menu, and press the [ENTER] key.

Remove the RIGHT I/S COVER when the screen shown

in the figure.

3-2 WIPER REPLACEMENT

Using a tweezer, pick the bottom portion of the WIPER

and remove it from the hook.

RIGHT I/S COVER

Clean the WIPER CARRIAGE and SCRAPER

using the Cleaning Stick if they need to be

cleaned.

WIPER CARRIAGE

SCRAPER


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3-9

MAINTENANCE

REPLACE WIPER

5

6

Press the area shown in the figure using a tweezer and

hang the WIPER on the hook.

When fixing the WIPER, make sure to hook it.

If it is not hooked, the WIPER may fall off during

use.

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 the

head cleaning finishes, the screen shown in the figure

appears.

RIGHT I/S COVER

Hook


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3-10

2

4

1

3

[MENU] key

[ ], [ ], [ ] + POWER ON

MENU

SERVICE MENU

3-3 CAP TOP REPLACEMENT




Remove the media and Media Clamps if they

are loaded.


RIGHT I/S COVER

[ ]

[ ]

SERVICE MENU

I/S MENU

I/S MENU

I/S CONTROL

I/S CONTROL

CAP

[ENTER]

CAP

OPEN

[ ]




hand.


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3-11

5

6

7

8

[ ]

SERVICE MENU

I/S MENU

I/S MENU

I/S CONTROL

I/S CONTROL

CAP

[ ]

[ ]

CAP

CLOSE

[ ] [ ]

[ ]

Remove the INNER I/S COVER.

Select [I/S MENU] > [I/S CONTROL] > [CAP] >

[CLOSE], and press the [ENTER] key. The capping unitmoves up. Press the [ENTER] key 3 times, because the

capping unit moves up in 3 steps.


MAIN POWER SW.

Disconnect the tube (Black) of the CAP TOP from the

tube (White) of the PUMP.

Keep the JOINT TUBE for connecting the tube of the

new CAP TOP later.

Make sure to replace the CAP TOP one by one

so that the tubes are connected correctly.

JOINT TUBE

INNER I/S COVER

< REAR VIEW >

MAIN POWER SW

The tube (White) of the PUMP may be colored

by ink.


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3-12

10

12

9

11

Unhook the CAP FRAME while holding it, and remove it.

Make sure to hold the CAP FRAME when

removing the CAP FRAME. If the FRAME is

not held, the CAP TOP will jump out when the

FRAME is removed. There is a SPRING under

the CAP TOP.

Pull up the CAP TOP together with the tube.

Fix a new CAP TOP with the tube side facing the front.

Do not touch the sponge.

Make sure the tube side is facing the front

when fixing a new CAP TOP.

Fix the CAP FRAME.

CAP TOP

CAP TOP

CAP FRAME

CAP FRAME

HOOK


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3-13

14

13

[MENU] key

[ ], [ ], [ ] + POWER ON

MENU

SERVICE MENU

15

Connect the tube of the CAP TOP to the tube of the

PUMP using the JOINT TUBE.

Then, replace the other CAP TOPs in the same way.

Turn on the MAIN POWER SW and then turn on the SUB

POWER SW while pressing the Left, Right and Down

keys to enter the SERVICE MODE.

16

Either tube of the CAP TOP can be connected

to either tube of the PUMP.

Fix the INNER I/S COVER.

JOINT TUBE

INNER I/S COVER

[ ]

[ ]

SERVICE MENU

I/S MENU

I/S MENU

I/S CONTROL

I/S CONTROL

CAP

[ENTER]

CAP

OPEN

[ ]



down.


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3-14

18Select [I/S MENU] > [I/S CONTROL] > [CAP] >

[CLOSE], and press the [ENTER] key once.The CAPPING UNIT moves up one step.

Next, moving the Carriage by hand, adjust the HEAD

position by aligning the GUIDEs at both ends of the head

carriage with the GUIDEs at both ends of the capping unit.

Then, press the [ENTER] key twice to cap the HEAD.

* The CAPPING UNIT moves up in 3 steps.GUIDE GUIDE

17Move the HEAD CARRIAGE to the capping position by

hand.

19Check the CAP HEIGHT with [CHECK GAP] in reference

to [4-5 CAP HEIGHT ADJUSTMENT].


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3-15

1

2

3

4

3-4 CARRIAGE MOTOR REPLACEMENT

Turn off the MAIN POWER SW.


Remove the PANEL COVER.

Remove the 2 Screws 1 , and loosen the 2 Screws 2 to

remove the PANEL ASSY.

Disconnect the Flexible Cable from the PANEL BOARD.

PANEL COVER

PANEL ASSY

< REAR VIEW >

MAIN POWER SW

RIGHT I/S COVER

Screw 2

Screw 1


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3-16

7

5

8

Disconnect the connector of the Motor Cable.

Remove the Screws fixing the FLANGE and remove the

MOTOR together with the FLANGE.

FLANGE

Remove the 4 Screws to remove the MOTOR from the

FLANGE.

Fix the cable of a new MOTOR using CABLE TIE without

bending the cable root, and then fix the new MOTOR to

the FLANGE.

Be careful with the fixing direction of the

FLANGE.

FLANGE

CONNECTOR

CABLE TIE

Remove the SPRING.

SPRING

6

SCREW

SCREW


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3-17

9Fix the FLANGE temporarily.

FLANGE

SCREW

10

11

12

Fix the SPRING. Then, check the Motor gear meshes

with the Drive gear and tighten up the 2 screws to fix theFLANGE.

Connect the connector of the Motor Cable.

CONNECTOR

Connect the Flexible Cable to the PANEL BOARD, and

fix the PANEL ASSY.

SPRING

PANEL ASSY

Apply a proper quantity of grease (FLOIL GE-676)

between gears.

MOTOR GEAR

DRIVE GEAR


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3-18

In [MOTOR MENU] > [SERVO LOCK] menu, select [S].

Move the HEAD CARRIAGE from left to right by hand

and check values on the LCD change as the head

moves.

13

14

15

Fix the PANEL COVER. PANEL COVER

16

[MENU] key

[ ], [ ], [ ] + POWER ON

MENU

SERVICE MENU

Perform the SERVO LOCK CHECK.

Turn on the MAIN POWER SW and then turn on theSUB POWER SW while pressing the Left, Right and

Down keys to enter the SERVICE MODE.

[ ]

[ ]

SERVICE MENU

I/S MENU

I/S MENU

I/S CONTROL

I/S CONTROL

CAP

[ENTER]

CAP

OPEN

[ ]




hand.

[ ]

[ ] [ ]

SERVICE MENU

MOTOR MENU

MOTOR MENU

SERVO LOCK

SERVO LOCKS: 3


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3-19

17

18

19

Press the [ENTER] key to excite the MOTOR.

Check the HEAD CARRIAGE can not moved easily by

hand.

Check the AGING.

Go back to the MOTOR MENU, and select [AGING] >[SCAN] and press the [ENTER] key. Check the machine

performs the AGING and finish it.

Set the head to [HIGH] when performing the

AGING for safety.

[ENTER]

SERVO LOCK

S: 1688

SERVO LOCK

S:* 1688

[ ]

SERVICE MENUMOTOR MENU

MOTOR MENU

AGING

AGING

SCAN

[ ]

Clear the motor working hours.

Go back the SERVICE MENU, and select [HISTORY

MENU] > [MOTOR GROUP] > [MOTOR HOURS S] >

[CLEAR] and press the [ENTER] key. The motor working

hours will be reset to 0.

[ ]

[ ]

[ ]

[ ]

SERVICE MENU

HISTORY MENU

HISTORY MENU

MOTOR GROUP

MOTOR HOURS S

1653 hours

[ENTER]

MOTOR HOURS S

CLEAR


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3-20

Turn off the SUB POWER SW and then turn off the MAIN

POWER SW.

2

4

1

3

[MENU] key

[ ], [ ], [ ] + POWER ON

MENU

SERVICE MENU

3-5 PUMP REPLACEMENT




RIGHT I/S COVER

[ ]

[ ]

SERVICE MENU

I/S MENU

I/S MENU

I/S CONTROL

I/S CONTROL

CAP

[ENTER]

CAP

OPEN

[ ]




hand.

< REAR VIEW >

MAIN POWER SW


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3-21

5

6

7

8Remove the PUMP and fix a new one. Then, insert 2

long tubes into the DRAIN TUBE.

Make sure to fix the 2 projections of the PUMP

into the holes of the FRAME.


Remove the media and Media Clamps if they

are loaded.

Remove the INNER I/S COVER.

INNER I/S COVER

Disconnect the tube (Black) of the CAP TOP from the

tube (White) of the PUMP.

Keep the JOINT TUBE for connecting the tube of the

new CAP TOP later.

Make sure to replace the CAP TOP one by one

so that the tubes are connected correctly.

JOINT TUBE

The tube (White) of the PUMP may be colored

by ink.

DRAIN TUBE

PROJECTIONS


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3-22

9Connect the tube of the CAP TOP to the tube of the

PUMP using the JOINT TUBE.

10

11Move the HEAD CARRIAGE by hand to the capping

position.

[MENU] key

[ ], [ ], [ ] + POWER ON

MENUSERVICE MENU

Turn on the MAIN POWER SW. Then, turn on the SUB



12

Either tube of the CAP TOP can be connected

to either tube of the PUMP.

Fix the INNER I/S COVER.

JOINT TUBE

INNER I/S COVER


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3-23

13

14Clear the pump working hours.

Go back to the SERVICE MENU and select [HISTORYMENU] > [MOTOR GROUP]. Then, select the PUMP

you replaced and clear the time.

Select [I/S MENU] > [I/S CONTROL] > [CAP] >

[CLOSE], and press the [ENTER] key once.

The CAPPING UNIT moves up one step.

Next, moving the Carriage by hand, adjust the HEAD

position by aligning the GUIDEs at both ends of the head

carriage with the GUIDEs at both ends of the capping

unit.

Then, press the [ENTER] key twice to cap the HEAD.

* The CAPPING UNIT moves up in 3 steps.

GUIDE GUIDE

[ ]

SERVICE MENU

HISTORY MENU

HISTORY MENU

MOTOR GROUP

PUMP TIMES A

2326times

PUMP TIMES B

2051times

PUMP TIMES A

CLEAR

PUMP TIMES B

CLEAR

[ ] [ ]

PUMP TIMES C 2051times

PUMP TIMES CCLEAR

PUMP TIMES D

2051times

PUMP TIMES D

CLEAR


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3-24

3

4

2

1

3-6 INK TUBE REPLACEMENT

Select [SUB MENU] > [PUMP UP], and select the group

of the target tube.

[ ]

[ ]

SERVICE MENUSUB MENU

SUB MENU

PUMP UP

PUMP UP

A B C

[ENTER]

[ ]


RIGHT I/S COVER

[MENU] key

[ ], [ ], [ ] + POWER ON

MENU

SERVICE MENU




[ ]

[ ]

SERVICE MENU

I/S MENU

I/S MENU

I/S CONTROL

I/S CONTROL

CAP

[ENTER]

CAP

OPEN

[ ]




hand.


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3-25

5

6

8


MAIN POWER SW.

Remove the following covers.

LEFT I/S COVER

RIGHT TOP COVER

FRONT RAIL COVER

REAR RAIL COVER

FRONT COVER

FRONT RAIL COVER

REAR RAIL COVER

RIGHT TOP COVER

FRONT COVER

LEFT I/S COVER

MAIN POWER SW

7 Remove the CARRIAGE COVER.

CARRIAGE COVER

Remove the 3 Screws as shown in the figure to remove

the CARRIAGE BOARD COVER.

There is a transparent Plate in front of the

CARRIAGE BOARD COVER.

PLATE

CARRIAGE BOARD COVER

< TOP VIEW >


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3-26

9

11

12

Remove 2 NYLON LIVETs fixing the Protective Plate.

Then, disconnect all the Flexible Cables connected from

the CABLE VEYOR.

Remove the GUIDE PLATEs of the CABLE VEYOR and

the CABLE GUIDEs. Then, disconnect the flexiblecables from the CABLE VEYOR. GUIDE PLATE

CABLE GUIDE

10

Disconnect the INK TUBEs from the INK DAMPERs and

cover the tips of the ink tubes with tape to prevent ink

leaking.

Replace 2 tubes of the same color at once to

prevent the tubes from being connected

incorrectly.

Disconnect the INK TUBEs from the JOINTs and cover

the tips of the ink tubes with tape to prevent ink leaking.

It is not necessary to replace the tubes

connected at the other side of the JOINTs.

< TOP VIEW >

PROTECTIVE PLATENYLON LIVETs

TUBEs

< REAR VIEW >

JOINT


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3-27

Each mark of the Tube is as the following.

Rear side of the HEAD )

Front side Ink Tube: 1 line

Rear side Ink Tube : 2 lines

Front side of the HEAD)

Front side Ink Tube: 3 line

Rear side Ink Tube : 4 lines

13

14

15

16

Pull out the INK TUBEs from the CABLE VEYOR.

Insert new INK TUBEs through the CABLE VEYOR.

Make sure each INK TUBE is inserted through

the hole of the TUBE GUIDE correctly.

Connect the new INK TUBEs to the JOINTs and mark the

INK TUBEs using a permanent marker etc. to indicate

the color of the ink.

Cut the INK TUBEs at an appropriate length and mark

the INK TUBEs using a permanent marker etc. to

indicate the color of the ink.

Then, replace the other INK TUBEs in the same way.

< REAR VIEW >

< REAR VIEW >

JOINT

Rear side

Front side

K

K

C

C

M

M

Y

Y

Y

Y M

M C

CK

K


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3-28

19Fix the GUIDE PLATEs and the CABLE GUIDEs as

shown in the figure.

CABLE GUIDEs are fixed next to the TUBE GUIDEs. Fix

the rest of the CABLE GUIDEs in the same way.

Connect the FLEXIBLE CABLEs to the CARRIAGE

BOARD and fix the Protective Cover with the NYLON

LIVETs. Then, fix the CARRIAGE BOARD COVER.

17< TOP VIEW >

PROTECTIVE PLATENYLON LIVETs

Fix the CARRIAGE BOARD COVER.

There is a transparent Plate in front of the

CARRIAGE BOARD COVER.

Be careful not to forget to fix it.

PLATE

CARRIAGE BOARD COVER

< TOP VIEW >

18

GUIDE PLATE TUBE GUIDE CABLE GUIDE

< FRONT VIEW >


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3-29

Select [SUB MENU] > [INK CONTROL] > [FILL INK], and

select the group which you want to fill INK of, and pressthe [ENTER] key.

[ ]

[ ]

SERVICE MENU

SUB MENU

SUB MENU

FILL INK

FILL INK

A B C

[ENTER]

[ ]

21

20

[MENU] key

[ ], [ ], [ ] + POWER ON

MENU

SERVICE MENU





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3-30

1. When the Board Cover is opened

2.When the Servo Board Stay and Main Board Stay are removed

3-7 BOARDS REPLACEMENT (Head / Servo / Network / Main Board / SW Power Supply)

BOARD LAYOUT (IN CHASSIS)

Servo Board

Head Board

NetworkBoard

MTD Board

SW Power Supply (5,24V) SW Power Supply (41V)

AC Junction Board

Power Junction Board

Main Board

Main Board Stay

Servo Board Stay


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3-31

2Remove the RIGHT I/S COVER, RIGHT TOP COVER,

and BOARD COVER.

1Turn off the MAIN POWER SW.

RIGHT TOP COVER

RIGHT I/S COVER

BOARD COVER

MAIN POWER SW

CABLE RAIL CABLE VAYOR

3Remove the CABLE RAIL with holding up the CABLE

VAYOR.

< REAR VIEW >


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3-32

1

2

3

Disconnect the Cables from the following boards and

remove them with the Stays.

MTD BOARD

SERVO BOARD

MAIN BOARD

HEAD BOARD

Disconnect all the Cables from the SW POWER

SUPPLY(41V).

Replace with a new SW POWER SUPPLY (41V).

Connect all the Cables.

SW POWER SUPPLY REPLACEMENT (41V)

SW POWER SUPPLY CONNECTOR LAYOUT Connected to the [CN501]on the AC JUNCTION

BOARD

Connected to the [CN803]

on the AC JUNCTION

BOARD

MTD Board

Servo Board Main Board Head Board


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3-33

4 Set the output voltage of SW Power Supply to +41V.

1)

2)

3)

Turn on the Main Power SW.

Put the black probe into CN501-1pin (GND) and the

red probe into CN501-8pin (Vout) on the SW PowerSupply.

Rotate the volume clockwise using the screwdriver to

adjust the output voltage to + 41V+0.1.

Use the Digital multi-Meter that can measure

the direct voltage.

When the output voltage exceeds the +41.4V,

SW Power Supply does not output the voltage

by the protection circuit on it.

In this case, SW Power Supply will not output

the vo l tage by ro ta t ing the vo lume

counterclockwise. When the protection circuit

works, SW Power Supply may not output for a

while. Measure the voltage some time later

again.

MAIN POWER SW

< REAR VIEW >

CN501-8pinCN501-1pin

PROBE

VOLUME

5 Fix the following Boards.

MTD BOARD

SERVO BOARD

MAIN BOARD

HEAD BOARD

MTD Board



34/66

3-34

2

3

SW POWER SUPPLY REPLACEMENT (5V,24V)

SW POWER SUPPLY CONNECTOR LAYOUT

Replace with a new SW POWER SUPPLY (5V,24V).

Connect all the Cables.

Disconnect all the Cables from the SW POWER

SUPPLY(5V,24V).

1Disconnect the Cables from the following boards and

remove them with the Stays.

MTD BOARD

SERVO BOARD

MAIN BOARD

HEAD BOARD


on the AC JUNCTION

BOARD


on the AC JUNCTION

BOARD

MTD Board



35/66

3-35

4 Fix the following Boards.

MTD BOARD

SERVO BOARD

MAIN BOARD

HEAD BOARD

MTD Board



36/66

3-36

MAIN BOARD REPLACEMENT

MAIN BOARD CONNECTOR LAYOUT

2

1

Start the Peck.

CN5

CN4

CN9

CN6

CN7

Turn on the MAIN POWER SW.

MAIN POWER SW

< REAR VIEW >

Upward compatible from Peck3.exe.


37/66

3-37

3

4

Perform [Get Report] and [Get Parameters], and save

them.

MAIN POWER SW

< REAR VIEW >Turn off the MAIN POWER SW and pull out the AC cord.

5

6

Remove the 2 Screws as shown in the figure.

Disconnect all the Cables from the MAIN BOARD.

SCREW

Select [Type2:AJ-1000 etc.] for communication

in [Select Port].


38/66

3-38

7

8

MAIN POWER SW

< REAR VIEW >Remove the NETWORK BOARD, and fix it to the new

MAIN BOARD.

Replace the battery in reference to [3-8 BATTERY

REPLACEMENT].

Remove the Screws as shown in the figure, and remove

the MAIN BOARD with NETWORK BOARD.

NETWORK

BOARD

Remove the Network Board

by push ing t he pa r t

indicated by the arrows.

9

10 Fix the 2 Screws as shown in the figure.

Fix the MAIN BOARD, and connect all the Cables to the

MAIN BOARD.

SCREW


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3-39

Carry out the following adjustments and settings.

1. DIP SW SETTING

2. FIRMWARE INSTALLATION

3. CAP & WIPER CHECK *2

4. SENSOR CHECK

5. PAPER SIDE SENSOR ADJUSTMENT

After performing these operations, perform [Put Parameters] with Peck and write the parameter that was saved

before replacement to the Main Board.

11

Perform the following operations if it is not possible to transfer the parameters by Peck.

1. DIP SW SETTING 8. SENSOR CHECK

2. FIRMWARE INSTALLATION 9. LIMIT & CUT DOWN POSITION INITIALIZE

3. SYSTEM PARAMETER INITIALIZE 10. LINEAR ENCODER SETUP

4. HEAD RANK INPUT 11. PAPER SIDE SENSOR ADJUSTMENT

5. SERIAL NUMBER INPUT *1 12. INK TYPE SETTING

6. CAP & WIPER CHECK *2 13. HEAD ALIGNMENT (SOFTWARE ONLY)

7. CAP HEIGHT ADJUSTMENT 14. CALIBRATION

*1 Input the serial number in the [SERVICE MENU] > [SERIAL NO.].

*2 It can be performed in the [SERVICE MENU] > [I/S MENU] > [I/S CHECK].


40/66

3-40

2

1

HEAD BOARD REPLACEMENT

HEAD BOARD CONNECTOR LAYOUT

Disconnect all the Cables from the HEAD BOARD.

Remove the Screws as shown in the figure, and replace

to the new HEAD BOARD.

CN30

CN34

CN31

CN35~42


41/66

3-41

3

4Carry out the following checks.

1. THERMISTOR CHECK

2. HEAD UP/DOWN SENSOR CHECK

3. HEAD BOARD FAN CHECK

Connect all the CABLEs to the HEAD BOARD.


42/66

3-42

SERVO BOARD REPLACEMENT

1

2

SERVO BOARD CONNECTOR LAYOUT

Disconnect all the Cables from the SERVO BOARD.

Remove the Screws as shown in the figure, and replace

to the new SERVO BOARD.

CN11

CN14CN15

CN1

CN6

CN2

CN4

CN7

CN12

CN16


43/66

3-43

Connect all the CABLEs to the SERVO BOARD.3

Carry out the following.4

1. AGING


44/66

3-44

Remove the 2 Screws as shown in the figure.

NETWORK BOARD REPLACEMENT

1

2

3 Fix the NETWORK BOARD.

4 Carry out the following.

1. FIRMWARE UPGRADE

2. IP ADDRESS SETTING

Remove the NET WORK BOARD, and replace it to the

new NETWORK BOARD.

SCREW

Remove the Network Board

by push ing t he pa r t

indicated by the arrows.

SCREW


45/66

3-45

1Turn off the MAIN POWER SW.

3-8 BATTERY REPLACEMENT

2Remove the BOARD COVER.

CAUTION

Lithium battery will explode if it is incorrectly replaced.

Replace only with the same or equivalent type of battery recommended by the manufacturer.

Dispose of used batteries according to the manufacturer's instructions.

Do not recharge, short-circuit,

disassemble a lithium battery or put

it into fire.

It may cause heat, explosion and fire.

Put tape around the lithium battery

for insulation for disposal or

preservation.

It may cause heat, explosion and fire.

MAIN POWER SW

< REAR VIEW >

BOARD COVER

< REAR VIEW >


46/66

3-46

[MENU] key

[ ], [ ], [ ] + POWER ON

MENU

SERVICE MENU

Turn on the MAIN POWER SW.

While pressing the Right, Left, and Down keys, turn on

the sub power switch to enter the Service mode.

Select [SERVICE MODE] > [CLOCK] > [TIME] and set

the time and press the [ENTER] key to clear the battery

flag.

While pressing the battery on the MAIN BOARD

downward, incline the battery to remove it.

1

2

3

4

5

6

Replace the battery with a new one.

Make sure to fix the battery correctly.

MAIN BOARD

SOCKET

MAIN BOARD

SOCKET

[ ]

SERVICE MENU

SUB MENU

SUB MENU

CLOCK

CLOCK

TIME

TIME

01:01:59 B

[ ] [ ]

[ ]

[ENTER]

TIME01:01:59 B


47/66

3-47

7

8

9

10

Turn off the MAIN POWER SW.

Fix the BOARD COVER.

Select [SERVICE MODE] > [CLOCK] > [DATE] and set

the date and press the [ENTER] key.

[ ]

SERVICE MENU

SUB MENU

SUB MENU

CLOCK

CLOCK

DATE

DATE

00/00/00

[ ] [ ]

[ ]

[ENTER]

DATE

06/09/08

MAIN POWER SW

< REAR VIEW >

BOARD COVER

< REAR VIEW >

Dispose of the battery.

CAUTION

Never charge, short-circuit, disassemble, heat, or

put into fire.

Do not mix with other metal or batteries.

Tape around the lithium battery for insulation for

disposal or preservation.

Otherwise, it may cause heat, explosion and fire.


48/66

3-48

3-9 CARRIAGE BELT REPLACEMENT 1

1

3

2

[MENU] key

[ ], [ ], [ ] + POWER ON

MENU

SERVICE MENU




For the following Serial No.

YU80100 ~ YU80108

YU90109 ~ 119, 123 ~ 127, 142 ~ 145

ZU80100 ~ 101

ZU90102 ~ 126

ZV00127 ~ 135

RIGHT I/S COVER

[ ]

[ ]

SERVICE MENU

I/S MENU

I/S MENU

I/S CONTROL

I/S CONTROL

CAP

[ENTER]

CAP

OPEN

[ ]




hand.


49/66

3-49


LEFT I/S COVER

PANEL COVER

LEFT and RIGHT TOP COVERs

FRONT RAIL COVER

REAR RAIL COVER

FRONT COVER

LEFT COVER

4

6

LEFT I/S COVER

LEFT COVER

PANEL COVER

RIGHT TOP COVER

FRONT RAIL COVER

LEFT TOP COVER

REAR RAIL COVER

FRONT COVER

Remove the CARRIAGE COVER.CARRIAGE COVER

Turn off the SUB POWER SW and MAIN POWER SW.

MAIN POWER SW

< REAR VIEW >

5


DAMPER PLATE

7


50/66

3-50

9 Remove all the Flexible Cables and INK DAMPERs.

10

Disconnect the CARRIAGE U/D SENSOR and PAPER

SIDE SENSOR from the CARRIAGE BOARD.

8Remove the CABLE HOLDER.

FLEXIBLE CABLEs

11

Remove the HEAD BOARD COVER.

CABLE HOLDER

INK DAMPERs

HEAD BOARD COVER

CARRIAGE U/D SENSOR

PAPER SIDE SENSOR




51/66

3-51

14

Remove the 6 Screws to remove the HEAD CARRIAGE.15

Put the HEAD ADJUSTER PLATE under the HEAD

CARRIAGE.

Use the following special tool.

Tool No. : 22055611

Tool Name : PLATE,HEAD ADJUSTER HU-540

13 Set the height of the HEADs to [MIDDLE] by the

HEIGHT-ADJUSTMENTLEVER.

12Move the HEAD CARRIAGE onto the PLATEN.

PLATEN

HIGH

HEIGHT-ADJUSTMENT

LEVER

LOW

MIDDLE

HEAD ADJUSTER PLATE

SCREW

Be careful not to strike it to the HEAD.


52/66

3-52

18

Move the BELT HOLDER 1 , 2 to the left.19

Loosen the 2 Fixingscrews as shown in the figure

located leftside of the Belt.

And loosen the Adjustment Screws.

17

16Remove the 2 Screws as shown in the figure fixing the

BELT HOLDER 1 to the HEAD CARRIAGE.

PLATEN

BELT HOLDER 1

SCREW

Remove the 2 Screws as shown in the figure fixing the


BELT HOLDER 2

SCREW

FIXING SCREWADJUSTMENT

SCREW

Do not scratch the encoder scale when moving

the BELT HOLDER.

It is recommended for working easily and safely

to remove the encoder/encoder scale when it is

difficult to remove and move the BELT HOLDER.

Loosen the 6 Screws to remove the CARRIAGE BELT.

BELT HOLDER 1 BELT HOLDER 2

Do not scratch the encoder scale when removing

the BELT HOLDER from the CARRIAGE.




53/66

3-53

1.

2.

3.

20

21

Replace with a new CARRIAGE BELT.

Apply a proper quantity of grease (FLOIL G-902) between

PULLEYs.

Fix the CARRIAGE BELT to the BELT HOLDER.

When fixing a new CARRIAGE BELT, see fromthe hole on the rear of the machine to check the

BELT is not twisted.

Fix the one end of the CARRIAGE BELT at the right

side of the BELT HOLDER 1 .

BELT HOLDER 1

BELT HOLDER 2

BELT HOLDER 1

Fix the BELT HOLDER 2 .

Fix the BELT at the left side of the BELT HOLDER 2

with the Screws as shown in the figure.

Leave a space of 29 teeth between the BELT

HOLDER 1 and BELT HOLDER 2 .

When fixing the CARRIAGE BELT, make sure

the end of the BELT is at the middle of the BELT

HOLDER.

BELT HOLDER 1 BELT HOLDER 229 teeth


54/66

3-54

22 Move the BELT HOLDER by hand to the position of the

screw hole for fixing with the carriage.

Fix the BELT HOLDER 2 to the HEAD CARRIAGE.

When fixing the CARRIAGE BELT, make sure theend of the BELT does not overlap.

OK

PLASTIC

PLATE

CARRIAGE BELT

SCREW

METALPLATE

BELT HOLDER

CARRIAGE BELT

SCREW

BELT HOLDER

CARRIAGE BELT

SCREW

BELT HOLDER

NG

PLASTIC

PLATE

METAL

PLATE

METALPLATE

PLASTIC

PLATE

PLASTIC

PLATE

PLASTIC

PLATE

PLASTIC

PLATE

PLATEN

BELT HOLDER 1

SCREW

BELT HOLDER 2

SCREW

BELT

HOLDER

2

HEAD CARRIAGE

< REAR VIEW >

Put the bottom of the

BELT HOLDER 2 to

the hole of the HEAD

CARRIAGE, and fix it.

23 Fix the BELT HOLDER 1 to the HEAD CARRIAGE.


55/66

3-55

26

27

Fix the HEAD BOARD COVER.

25

24Fix the screws for the HEAD CARRIAGE in the order as

shown in the figure.

1

3

2

4

5

6

Connect the CARRIAGE U/D SENSOR and PAPER

SIDE SENSOR from the CARRIAGE BOARD. CARRIAGE U/D SENSOR

PAPER SIDE SENSOR

Put the connector of

the PAPER SIDE

SENSOR through the

hole of the FRAME.

< TOP VIEW >

HEAD BOARD COVER

The cover should be fixed to prevent ink from

dropping on the HEAD BOARD when the INK

DAMPERs are fixed. It is not necessary to fix

the cover with the NYLON LIVET.

Fix all the Flexible Cables and INK DAMPERs.

FLEXIBLE CABLEs

INK DAMPERs

The height of the HEADs is [MIDDLE] when fix

the HEAD CARRIAGE.

Fix the Screws at the top of the long screw

hole.


56/66

3-56

30

28

Fix the DAMPER PLATE.29

Tighten the Adjustment Screws to have tension on the

Belt.

In this case, do not tighten the Screw too hard.

Tighten the Fixing Screws.

When you fix the DAMPER PLATE, make

sure not to press the plate down onto the

DAMPERs with force.

Fix the screws at the bottom of the long screw

hole.

Fix the CABLE HOLDER. CABLE HOLDER

DAMPER PLATE


SCREW

31 Set the height of the HEADs to [HIGH] by the HEIGHT-ADJUSTMENT LEVER. HIGH

HEIGHT-ADJUSTMENT

LEVER

LOW

MIDDLE


57/66

3-57

Fix the Encoder Scale and Encoder Module if you have removed them.

Carry out the following adjustments and setting.

1. BELT TENSION ADJUSTMENT

2. BELT POSITION ADJUSTMENT

3. LIMIT & CUT DOWN POSITION INITIALIZE

4. LINER ENCODER SETUP

(only when you remove the Encoder Scale or Encoder Module)

33

32Move the HEAD CARRIAGE to the capping position.

Remove the HEAD ADJUSTER PLATE.

HEAD ADJUSTER PLATE


58/66

3-58

3-10 CARRIAGE BELT REPLACEMENT 2

1

3

2

[MENU] key

[ ], [ ], [ ] + POWER ON

MENU

SERVICE MENU




For EXCEPT the fo llowing Serial No.

YU80100 ~ YU80108

YU90109 ~ 119, 123 ~ 127, 142 ~ 145

ZU80100 ~ 101

ZU90102 ~ 126

ZV00127 ~ 135

RIGHT I/S COVER

[ ]

[ ]

SERVICE MENU

I/S MENU

I/S MENU

I/S CONTROL

I/S CONTROL

CAP

[ENTER]

CAP

OPEN

[ ]




hand.


59/66

3-59


LEFT I/S COVER

PANEL COVER

LEFT and RIGHT TOP COVERs

FRONT RAIL COVER

REAR RAIL COVER

FRONT COVER

LEFT COVER

4

6

LEFT I/S COVER

LEFT COVER

PANEL COVER

RIGHT TOP COVER

FRONT RAIL COVER

LEFT TOP COVER

REAR RAIL COVER

FRONT COVER

Remove the CARRIAGE COVER.CARRIAGE COVER

Turn off the SUB POWER SW and MAIN POWER SW.

MAIN POWER SW

< REAR VIEW >

5


DAMPER PLATE

7


60/66

3-60

10

Move the BELT HOLDER 1 , 2 to the left.11

Loosen the 2 Fixingscrews as shown in the figure

located leftside of the Belt.

And loosen the Adjustment Screws.

9

8Remove the FLEXIBLE CABLEs and INK DAMPERs

from HEAD 3.



SCREW


BELT HOLDER 2 to the HEAD CARRIAGE. CARRIAGE FRAME


SCREW

Loosen the 6 Screws to remove the CARRIAGE BELT.

BELT HOLDER 1 BELT HOLDER 2

There are 2 holes on the CARRIAGE FRAME.

The 2 Screws can be removed from the

CARRIAGE FRAME.



Do not scratch the encoder scale when moving

the BELT HOLDER.

It is recommended for working easily and safely

to remove the encoder/encoder scale when it is

difficult to remove and move the BELT HOLDER.






61/66

3-61

1.

2.

3.

12

13

Replace with a new CARRIAGE BELT.

Apply a proper quantity of grease (FLOIL G-902) between

PULLEYs.

Fix the CARRIAGE BELT to the BELT HOLDER.

When fixing a new CARRIAGE BELT, see fromthe hole on the rear of the machine to check the

BELT is not twisted.

Fix the one end of the CARRIAGE BELT at the right

side of the BELT HOLDER 1 .

BELT HOLDER 1

BELT HOLDER 2

BELT HOLDER 1

Fix the BELT HOLDER 2 .

Fix the BELT at the left side of the BELT HOLDER 1

with the Screws as shown in the figure.

Leave a space of 29 teeth between the BELT

HOLDER 1 and BELT HOLDER 2 .

When fixing the CARRIAGE BELT, make sure

the end of the BELT is middle of the BELT

HOLDER.

BELT HOLDER 1 BELT HOLDER 229 teeth


62/66

3-62

14 Move the BELT HOLDER by hand to the position of the

screw hole for fixing with the carriage.

Fix the BELT HOLDER 2 to the HEAD CARRIAGE.

When fixing the CARRIAGE BELT, make sure theend of the BELT does not overlap.

OK

PLASTIC

PLATE

CARRIAGE BELT

SCREW

METALPLATE

BELT HOLDER

CARRIAGE BELT

SCREW

BELT HOLDER

CARRIAGE BELT

SCREW

BELT HOLDER

NG

PLASTIC

PLATE

METAL

PLATE

METALPLATE

PLASTIC

PLATE

PLASTIC

PLATE

PLASTIC

PLATE

PLASTIC

PLATE

SCREW

BELT

HOLDER

2

HEAD CARRIAGE

< REAR VIEW >

Put the bottom of the

BELT HOLDER 2 to

the hole of the HEAD

CARRIAGE, and fix it.

15 Fix the BELT HOLDER 1 to the HEAD CARRIAGE.

Fix the INK DAMPERs and FLEXIBLE CABLEs to the

HEAD 3.


63/66

3-63

Fix the Encoder Scale and Encoder Module if you have removed them.

Carry out the following adjustments and setting.

1. BELT TENSION ADJUSTMENT

2. BELT POSITION ADJUSTMENT

3. LIMIT & CUT DOWN POSITION INITIALIZE

4. LINER ENCODER SETUP

(only when you remove the Encoder Scale or

Encoder Module)

18

16 Fix the DAMPER PLATE.

17 Tighten the Adjustment Screws to have tension on the

Belt.In this case, do not tighten the Screw too hard.

Tighten the Fixing Screws.

When you fix the DAMPER PLATE, make

sure not to press the plate down onto the

DAMPERs with force.

Fix the screws at the bottom of the long screw

hole.

DAMPER PLATE


SCREW


64/66

3-64

3

2

1

3-11 ENCODER SCALE REPLACEMENT


LEFT and RIGHT I/S COVERs

RIGHT TOP COVER

FRONT RAIL COVER

REAR RAIL COVER

FRONT COVER

[MENU] key

[ ], [ ], [ ] + POWER ON

MENU

SERVICE MENU



REAR RAIL COVER

LEFT I/S COVER

RIGHT TOP COVER

FRONT COVER

FRONT RAIL COVER

RIGHT I/S COVER

[ ]

[ ]

SERVICE MENU

I/S MENU

I/S MENU

I/S CONTROL

I/S CONTROL

CAP

[ENTER]

CAP

OPEN

[ ]




hand.


65/66

3-65

Insert the ENCODER SCALE into the space between the

ENCODER PLATE and the GUIDE RAIL.

Then, fix the right end with the PLATE and hook the

SPRING on the left end.

Make sure that the ENCODER SCALE fits in place.

Do not loosen or tighten the screws fixing the

ENCODER PLATE.

ENCODER SCALE

PLATESPRING

ENCODER PLATE

5

6

7

Remove the ENCODER SCALE by removing the PLATE

fixing the right side of the ENCODER SCALE and theSPRING on its left end.

Remove the SPRING PLATE from the ENCODER

SCALE and fix it to the new ENCODER SCALE where

there is no black dot written on it.

When fixing the PLATE, do not scratch the

ENCODER SCALE.

ENCODER SCALE

PLATESPRING

SPRING PLATEBLACK DOT

Move the HEAD CARRIAGE slowly to the left.4


66/66

Move the HEAD CARRIAGE from left to right.

Make sure that the ENCODER SCALE does not touch

the ENCODER MODULE and also ENCODER SCALE is

covered with the ENCODER MODULE.

9Carry out the LINEAR ENCODER SETUP.

8

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