GCC Technologies Jaguar IV Series Maintenance Manual
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GCC Technologies Jaguar IV Series Maintenance Manual

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V3 Sept., 2012
Jaguar IV Series
Maintenance Manual

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Summary of Contents for GCC Technologies Jaguar IV Series

  • Page 1 V3 Sept., 2012 Jaguar IV Series Maintenance Manual...

  • Page 2: Important Safety Information

    Important Safety Information Safety Instructions General and Personal Safety Precautions PERSONAL SAFETY For personal safety, observe the following general precautions : A second person should be available to disable the system in an emergency Wear appropriate protective gear that fits comfortably Do not wear loose-fitting clothes.

  • Page 3: Table Of Contents

    Table of Contents Important Safety Information Introduction and Component Overview Main Unit Assembly Jaguar IV 4 1.1.1 Main Unit Assembly Jaguar IV 4 – Price List Electronic and Electrical Assembly 1.2.1 Electronic and Electrical Assembly – Price List Left End Assembly 1.3.1 Left End Assembly –...

  • Page 4: Main Unit Assembly Jaguar Iv

    4. Troubleshooting Maintenance Diagnostics 4.1.1 How to Begin Maintenance Diagnostics 4.1.2 Diagnostic Test for SRAM and DRAM 4.1.3 Diagnostic Test for Lever Sensor 4.1.4 Diagnostic Test for Media Sensor 4.1.5 Diagnostic Test for Motor Encoder and Tool Holder Encoder 4.1.6 X Motor Encoder Test 4.1.7 Y Motor Encoder Test...

  • Page 5: Introduction And Component Overview

    1. Introduction and Component Overview This Maintenance Guide provides step-by-step instructions for replacing and maintaining the components of the Jaguar Cutting plotter. It also includes a troubleshooting chapter with some handy hints when problems arise or if the plotter does not operate properly. This Maintenance Guide provides system diagrams, wiring diagrams and numerous flow charts detailing the maintenance diagnostics built into the Jaguar Cutting plotter.
  • Page 6 1.1 Jaguar IV Main Unit Assembly...

  • Page 7: Main Unit Assembly Jaguar Iv 4 - Price List

    1.1.1 Jaguar IV Main Unit Assembly – Parts List A Most recommend B Frequently asked C Sometimes needed D Barely asked X Can not order separately Y Screws, Nuts & washer Z Cables ITEM Part no. Description Remark 20600051G Y axis carriage belt (2GT-L3366-W14) 22801068G Square bar 22801149G...
  • Page 8 1.1.1 Jaguar IV Main Unit Assembly – Parts List ITEM Part no. Description Remark 25200181G Truss head machine screw(M4*6L) 25200198G Truss head machine screw(M4*8L) 25200199G Truss head screw including external tooth washer 25200237G Socket head set screw.(M4*16L sus + coating) 25200253G Socket head set screw.(M4*30L) 25500013G...
  • Page 9 1.1.1 Jaguar IV Main Unit Assembly – Parts List (Cables) ITEM Part no. Description QTY Remark 20900035G Static PCB To C/B Cable Converter 2*5Pin 23cm 20900087G M/B to Lever Switch Cable (2.0-2Pin130mm) 20900126G Y Motor Driver cable 3.96-2pin 155cm 20900128G Cable (from VCM Encoder to tool carriage) 20900430G VCM Board to Carriage Board Cable (1.5*3pin soft cable 12cm)

  • Page 10: Electronic And Electrical Assembly

    1.2 Jaguar IV Electronic and Electrical Assembly...

  • Page 11: Electronic And Electrical Assembly - Price List

    1.2.1 Jaguar IV Electronic and Electrical Assembly – Parts List ITEM Part no. Description Remark 21800034G AC PLUG (including EMI Filter ) (K/3C) 22300021G Fuse Holder Type3A/250V(K/3C) 250W Isolated Dual Output with PFC(Power Factor Correction) 24500083G Function(PID-250C) Power board 25700075G ON/OFF Power Switch (K/3C) ROHS Main board for Cutter all series assembly (With new 29005691G...

  • Page 12: Left End Assembly

    1.3 Jaguar IV Left End Assembly...

  • Page 13: Left End Assembly - Price List

    1.3.1 Jaguar IV Left End Assembly – Parts List ITEM Part no. Description Remark 20600007G Y-axis belt. 2GT-L172-W10 22000149G P.C.B interval pillar (LCA4-10A) 22801359G Y-axis Motor Spacer 23800032G Motor board. (12258) 24400039G Pulley bottom bracket 24400041G Y-motor bracket 24400526G Pulley top bracket 24400755G Side support left 25200052G Pan head machine screw including spring washer 25200182G Truss head screw including external tooth washer...

  • Page 14: Tool Carriage Assembly Right End Assembly

    1.4 Jaguar IV Right End Assembly...

  • Page 15: Tool Carriage Assembly Right End Assembly - Price List

    1.4.1 Jaguar IV Right End Assembly – Parts List ITEM Part no. Description QTY Remark 20600009G X-axis belt. 2GT-L220-W10 22000149G P.C.B interval pillar (LCA4-10A) 24400038G X-motor adjusting bracket 24400066G Cable basket 24400304G Ideal pulley ass y bracket 24400715G Ideal pulley Assembly adjusting bracket 24400757G Right Side Plate 24400761G X-motor bracket 25200017G Truss head machine screw(M3*15L).black...

  • Page 16: Motor Bracket And Belt Assembly

    1.5 Jaguar IV X Motor Bracket and Belt Assembly...

  • Page 17: Motor Bracket And Belt Assembly - Price List

    1.5.1 Jaguar IV X Motor Bracket and Belt Assembly – Parts List Number Part no. Description Remark 29001804G Motor assembly, Jaguar. 6.1.1 23100014G Motor MS090600, Jaguar. 6.1.2 21700009G Motor pulley, 2GT-P18, Jaguar. 6.1.3 25200169G Headless Screw, M4x3.5. 6.1.4 22000107G Cable Tie, YJ-160. 24400761G X-motor bracket, Jaguar.

  • Page 18: Carriage Belt Idle-Pulley Assembly

    1.6 Jaguar IV Carriage Assembly...

  • Page 19: Carriage Belt Idle-Pulley Assembly - Price List

    1.6.1 Jaguar IV Carriage Assembly – Parts List ITEM Part no. Description Remark 20200071G Blade holder slide bracket assembly 20700029G Bearing 21700034G Y-axis belt bracket 22000105G Cable saddle 22800410G Carrier guide roller(DU type) X(29005702G) 22800411G Spacer for carrier guide roller(DU type) X(29005702G) 22800765G Slide shaft in tool carriage X(Carriage assy)
  • Page 20 1.6.1 Jaguar IV Carriage Assembly – Parts List ITEM Part no. Description Remark Pan head machine screw including flat 25200065G washer.(2*6) 25200093G Pan head machine screw(M3*4L black) Pan head machine screw including spring 25200107G washer. 25200112G Truss head screw including flat washer 25500041G Spring for carrier guide roller X(29005702G) 25500043G Tool carriage spring...

  • Page 21: Pinch Roller Assembly

    1.7 Jaguar IV Pinch Roller Assembly...

  • Page 22: Pinch Roller Assembly - Price List

    1.7.1 Jaguar IV Pinch Roller Assembly – Price List ITEM Part no. Description Remark 20200003G Pinch roller wheel 21700010G Releasing arm X(29002348G) 22800028G Pinch roller active arm shaft X(29002348G) 22800029G Pinch roller shaft X(29002348G) 22800030G Releasing arm shaft X(29002348G) 22800031G Blocking arm shaft X(29002348G) 24100142G Blocking arm X(29002348G)

  • Page 23: Grid Drum Assembly

    1.8 Jaguar IV Main Beam Assembly...

  • Page 24: Grid Drum Assembly - Price List

    1.8.1 Jaguar IV Main Beam Assembly – Parts List ITEM Part no. Description Remark 21700003G Bearing support 22200040G DC FAN 22802179G Main beam 24000570G SPACE PE Styrofoam 24400760G Main beam support fixer 24400879G Platen 24402272G Sensor Bracket X(Paper sensor assy) 25200084G 90°...

  • Page 25: Grid Roll Housing Assembly

    1.9 Jaguar IV Drum Assembly...

  • Page 26: Grid Roll Housing Assembly - Price List

    1.9.1 Jaguar IV Drum Assembly – Parts List ITEM Part no. Description Remark 20700009G Grid Drum Bearing 22800407G Grid Drum shaft 22800564G Bearing Blocker 24100111G Roll Wheel 25200169G Socket headness set screw.(M4*3.5L) 26500432G 5cm Japanese grid drum...

  • Page 27: Jaguar Iv Parts Used On All Size Models - Price List

    1.10 Jaguar IV parts used on all size models – Parts List Jaguar IV 61 Jaguar IV 132S Jaguar IV 183S Item Part no. Description Remark (Mutoh VC-600) (Mutoh VC-1300) (Mutoh VC-1800) 20200026G Media basket support Jaguar II 132. 20200029G Media basket support Jaguar II 61.
  • Page 28 1.10 Jaguar IV parts used on all size models – Parts List Jaguar IV 61 Jaguar IV 132S Jaguar IV 183S Item Part no. Description Remark (Mutoh VC-600) (Mutoh VC-1300) (Mutoh VC-1800) Y Motor to Interface converter Board 20902023G Encoder cable 2.54-4PIN 1850mm Y Motor to Interface converter Board 20902025G Encoder cable 2.54-4PIN 2180mm...
  • Page 29 1.10 Jaguar IV parts used on all size models – Parts List Jaguar IV 61 Jaguar IV 132S Jaguar IV 183S Item Part no. Description Remark (Mutoh VC-600) (Mutoh VC-1300) (Mutoh VC-1800) 22802197G carriage base finishing(Jaguar IV) 22802347G carriage base finishing - Jaguar IV 22802585G Main beam(183) - Jaguar IV 23300362G...
  • Page 30 1.10 Ja guar IV parts used on all size models – Parts List Jaguar IV 61 Jaguar IV 132S Jaguar IV 183S Item Part no. Description Remark (Mutoh VC-600) (Mutoh VC-1300) (Mutoh VC-1800) 24000357G side carton board-VOGUE 24000366G Outer carton for machine 24000387G Carton for stand 24000389G...
  • Page 31 1.10 Jaguar IV parts used on all size models – Parts List Jaguar IV 61 Jaguar IV 132S Jaguar IV 183S Item Part no. Description Remark (Mutoh VC-600) (Mutoh VC-1300) (Mutoh VC-1800) 24400755G Side support left 24400757G Right Side Plate 24400759G Main beam support fixer.
  • Page 32 1.10 Jaguar IV parts used on all size models – Parts List Jaguar IV 61 Jaguar IV 132S Jaguar IV 183S Item Part no. Description Remark (Mutoh VC-600) (Mutoh VC-1300) (Mutoh VC-1800) 244044230G Top cover Jaguar IV 183.(Mutoh) 25200120G Socket flat head set screw.(M3*8) Truss head machine screw &...
  • Page 33 1.10 Jaguar IV parts used on all size models – Parts List Jaguar IV 61 Jaguar IV 132S Jaguar IV 183S Item Part no. Description Remark (Mutoh VC-600) (Mutoh VC-1300) (Mutoh VC-1800) 26500432G 5cm Japanese grid drum 29000568G A roller Assembly 29000577G Roll holder support Assembly 29001794G...
  • Page 34 1.10 Jaguar IV parts used on all size models – Parts List Jaguar IV 61 Jaguar IV 132S Jaguar IV 183S Item Part no. Description Remark (Mutoh VC-600) (Mutoh VC-1300) (Mutoh VC-1800) 29005316G Carriage assembly 29005445G Main Beam Assembly 29005447G Main Beam Assembly 29005570G Stand Assembly (183cm)

  • Page 35: System Diagram And Components Of Main Board

    2. System Diagram and Components of Main Board 2.1 Jaguar IV System Diagram...

  • Page 36: Jaguar Wiring Diagram

    2.2 Jaguar IV Wiring Diagram...

  • Page 37: Maintenance

    3. Maintenance This chapter deals with component replacement and maintenance of the Jaguar Cutting Plotter. It gives detailed step-by-step instruction on how to replace or adjust the components of this machine. 3.1 Components Replacement and Belt Tension Adjustment 3.1.1 Removing the Front, Back, End and Top Covers The following steps are those involved in removal of the front, back, end and top covers.
  • Page 38 To Remove the Front and Back Covers : 1. Unscrew the 7 Front Cover and 7 Back Cover screws To Remove the Top Cover: Unscrew the two screws at each end of the Top Cover. Unplug the Control Panel Cable before removing the top cover completely.

  • Page 39: Replacing The Pinch Roller Sets

    3.1.2 Replacing the Pinch Roller Sets The following steps are those involved in replacing pinch roller sets. To Unlatch the Pinch Roller Lever: Pull down the Square Bar Lever to unlatch the Pinch Rollers To Remove the Square Bar Holding Bracket: Remove the bracket and washer.
  • Page 40 To Remove the Pinch Roller Sets: Slide the pinch roller to the notch at the right end Remove the pinch roller set through the notch. of the Square Bar. Note: When re-installing the Pinch Roller Set, the Cam Roller must be aligned squarely to the Square Bar.

  • Page 41: Replacing The Tool Carriage

    3.1.3 Replacing the Tool Carriage The following are those you must follow to successfully replace the Tool Carriage. To Loosen the Carriage Belt: Retaining Screws Adjustment Screw Unscrew the 2 retaining screws, but don’t remove them. Then turn the Adjustment Screw anti-clockwise to loosen the carriage belt. To Remove the Tool Carriage cover: Depress the two locking clips at the top of the Tool Carriage Cover and pull the Cover away.
  • Page 42 To Prepare the Tool Carriage for Removal: Pop up the plastic locking pins using a Disconnect the Flat Sensor Cable. flathead screwdriver. Bolt A Bolt B Unbolt and remove nut A and B, and then unscrew both Bolt A and Bolt B until they are flush with the bracket.
  • Page 43 To Remove the Tool Carriage: Separate the Sprung Washer/Rollers as seen in the figure above. Swing the Tool Carriage down and out while keeping the Sprung Washer/Rollers apart. Note 1. To install a new Tool Carriage or replace the original Tool Carriage simply reverse the steps for Tool Carriage removal.

  • Page 44: Replacing The Y-Motor

    3.1.4 Replacing the Y-Motor The following steps are those involved in the replacement of the Y-motor. Loosen the all 3 tension-bracket retaining screws as well as the tension adjustment screw, but do not remove them. 2. Depress the jumper clips, and pull to unplug the 2 3.
  • Page 45 Note 1: To install or replace the Y-motor, simply reverse the steps to remove it. Note 2: After the Y-motor is in place, you must adjust the Y- motor belt tension as described in the Y-motor belt tension adjustment section of this chapter. Note 3: Make the Y-motor jumper reconnection the last step after the Y-motor tension belt adjustment when you have finished installing or replacing the Y-motor.

  • Page 46: Replacing The Vcm Pc Board

    3.1.5 Replacing the VCM PC Board The following is what is involved in replacement of the VCM PC board. Unplug the two sensor connectors, and then unscrew the two PC board screws to remove the board. Note：If the Pinch Roller Sensor is still not effective after replacement the Tool Carriage or the Flat Cable may need replacement.

  • Page 47: Main Board Connection Or Replacement

    3.1.6 Main board Connection or Replacement Main board connection or replacement must follow the following steps to be sure that no damage comes to either service personnel or the components: Note: To ensure absolute safety for service personnel and components, please follow the safety instruction at the beginning of this manual, before installing or replacing any current carrying components 1.

  • Page 48: Replacement Of Fuses

    2. Unscrew and remove the 5 restraining screws, and the pop out support to completely remove the main board. Note: To install or replace the main board simply reverse the steps to remove it. 3.1.7 Replacement of Fuses The Fuse pops out for easy replacement as follows: Holding clip Holding clip With your fingers apply equal pressure to both of the...

  • Page 49: Adjusting The Tool Carriage Transmission Belt

    3.1.8 Adjusting the Tool Carriage Transmission Belt When you replace the tool carriage or belt itself, the belt tension needs to be adjusted to 150g. This is done as follows: Use a tension gauge to measure the belt’s tension 1. Move the tool carriage to the far left end of by placing the the guide beam after the tool carriage or gauge’s push arm...

  • Page 50: Adjusting The X Motor Tension Belt

    3.1.9 Adjusting the X Motor Tension Belt Loosen the 4 retaining screws locking the X-motor bracket in place. Place the push-pull tension gauge’s hook-arm at the hole of X motor bracket and pull the motor toward yourself along the direction parallel to the racket edge, and keep it at the 4kg tension...

  • Page 51: Adjusting The Y Motor Tension Belt

    3.1.10 Adjusting the Y Motor Tension Belt Loosen the 3 retaining screws locking the tension bracket in place but do not remove them. 2. Place the push-pull tension gauge’s hook-arm at the hole of Y motor bracket and pull the motor toward yourself along the direction parallel to the line that passes through the motor shaft and the drive pulley shaft.
  • Page 52 Tighten the tension screw to retain the tension. Note: The belt connecting the drive pulley and Y motor needs to be tightened up with a tension of 4 kg.

  • Page 53: Troubleshooting

    4. Troubleshooting 4.1 Maintenance Diagnostics This section provides maintenance diagnostics as troubleshooting aids. This diagnostic feature is to check hardware to find out which components are good or defective. Using this diagnostic test facility enables the diagnosing of the hardware components. How to Begin Maintenance Diagnostics Diagnostic test for the media sensors Diagnostic test for the width sensor...
  • Page 54 SRAM OK System cannot go on testing, LCM display current message more than 3 seconds X Mb DRAM OK Error occur Exit Diagnostic Test Initial State Cancel Key Please Reset Machine Down Arrow Key Pressed Down Arrow Key Pressed Check Lever Sensor? Holder Down? Up Arrow Key Pressed Down Arrow Key Pressed...

  • Page 55: Diagnostic Test For Sram And Dram

    4.1.2 Diagnostic Test for SRAM and DRAM This test provides the ability to diagnose the SRAM and DRAM. If these two components are bad, replace them. Otherwise the cutting plotter will not work properly. 4.1.3 Diagnostic Test for Lever Sensor This feature diagnoses the lever sensor.

  • Page 56: Diagnostic Test For Media Sensor

    4.1.4 Diagnostic Test for Media Sensors This test is to diagnose the media sensors. If they are faulty, the cutting plotter cannot detect the media length correctly. You can see the current front and rear sensor condition, you can turn it on or off to see if sensors are out of order or not.
  • Page 57 4.1.5 Diagnostic Test for Width Sensor If the sensor is faulty, the cutter cannot sense the media width correctly. Refer to the maintenance chapter to replace it. You must first move the tool carriage to the rightmost position; the lever must be down to do this. Once this is done please move the tool carriage to left.

  • Page 58: Diagnostic Test For Motor Encoder And Tool Holder Encoder

    4.1.6 Diagnostic Test for Motor Encoder and Tool Holder Encoder This feature provides the ability to diagnose the X and Y motor encoder and tool holder encoder. If the encoder is defective, the cutting plotter cannot work properly. To check if the encoder is bad or good, you can apply a slight force to the tested part (such as a drum, the tool carriage or the tool holder) then examine the readings.

  • Page 59: Y Motor Encoder Test

    4.1.7 Y Motor Encoder Test Holder Encoder Up/Down Key Enter Key Move Holder Up/Down Cancel_key W ait for 3 seconds Previous/Next test item Display encoder count Holder Motor Encoder Reading CANCEL 4.1.8 Diagnostic Test for Tool Force (VCM) This test is to diagnose the VCM. If the VCM is bad, the tool carriage cannot perform the up/down action that generates the tools force on the material.
  • Page 60 Drum Moves Backward ? Up/Down Key Enter Key Cancel Key X Motor Moving Now Previous/Next test item Backward CANCEL Carriage Goes Left ? Up/Down Key Enter Key Cancel Key Y Motor Moving Now Previous/Next test item Forward CANCEL Carriage Goes Right ? Up/Down Key Enter Key Cancel Key...

  • Page 61: Diagnostic Test For The Rs-232 Interface

    4.1.10 Diagnostic Test for the RS-232 Interface Check RS-232 ? Up/Down Key Enter Key Previous/Initial state Type any characters From Computer CANCEL Cancel Key No => Type any character Error or not? Wait for 3 seconds from the computer The message you typed Error Messages Type any character from computer...

  • Page 62: Problems And Solutions

    4.2 Problems and Solutions This section discusses typical problems you may encounter while operating the cutting plotter and offers you possible solutions The line quality is not good enough at the corner or the end point. Causation and recovery: a. Forgetting to fasten the tool (Fasten it.) b.
  • Page 63 5. The lines quality is wavy. Causation and recovery: a. Forget to fasten the tool fastening screw. (Fasten it.) b. The blade is worn. (Change it.) c. The acceleration is too high. (Set the acceleration to a lower value; please refer to the default value.) d.
  • Page 64 11. The machine makes noise when it is on the standby status. Causation and recovery: a. The screws of tool carriage cover are loose. (Fasten the screws.) b. X or Y motor belt is loose. (Adjust the belt tension.) c. The carriage belt is loose (Adjust the carriage belt tension) d.
  • Page 65 16. Media drops sometimes Causation and to recovery: a. Media is loaded askew. (Re-load the media.) b. The position of pinch roller is not on the top of drum. (Move the pinch roller to a right position.) c. The edge of media is broken. (Change the media.) d.

  • Page 66: Appendix

    5. Appendix 5.1 Recommended Parts and Accessory List 5.2 Customer Service Request Form...

  • Page 67: Recommended Parts & Accessory List

    Jaguar Parts and Accessory List VC600 € VC1300 VC1800 Part no. Level Description J4-61 J4-132S J4-183S 29001804G Motor Assembly (Jaguar/Ultra ) 29002348G Pinch roller Assembly 29005378G 2 in 1 Cutter main board with Jaguar IV firmware (for Service) - Jaguar IV 290069100G Power Board of JIV-61(for service) 290069130G...

  • Page 68: Customer Service Request Form

    星雲電腦股份有限公司 The Electro-Optical Automation Provider I3-R-S001-01 Customer Service Request Form 2003/6/10 00:00 Company Name： ： ： ： Phone： ： ： ： Contact Person: Fax: Address: Serial Number： ： ： ： Product Name: Model Number: Date of purchase: Part No： ： ： ： Part Name.：...

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