Roland SOLJET PRO III XJ-540 Service Notes

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User manual (128 pages)

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Summary of Contents for Roland SOLJET PRO III XJ-540

Page 1 Users of this Service Note shall be deemed to agree with the following Terms of Use. 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 XJ-740/640/540.
Page 2: Table Of Contents
Contents 1 Structure & Spare Parts COVERS ................................1-1 FRAME ................................1-3 HEAD CARRIAGE ............................... 1-5 DRIVE UNIT ............................... 1-7 CHASSIS ................................1-9 PINCH ROLLER ..............................1-11 WIPE SYSTEM ..............................1-12 CAP SYSTEM ..............................1-13 INK SYSTEM ..............................1-14 1-10 STAND ................................1-15 1-11 TU CONTROLLER ............................
Page 3 Revision Record Revision Date Description of Changes Approval Issued 2007.12.13 First Edition Kato Sato 2008.4.11 1-1 COVER, 1-7 WIPE SYSTEM : Parts have been revised. Kato Mabuchi 2008.5.8 1-3 HEAD CARRIAGE : Parts have been revised. Kato Mabuchi 2008.7.29 1-7 WIPER SYSTEM, 4-4 HEAD ALIGNMENT has been revised. Kato Misako 1-1 COVER, 1-5 CHASSIS : Parts have been revised.
Page 4 To Ensure Safe Work About 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.
Page 5 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. HIGH VOLTAGE, HANDLING ATTENTION T h e w i r i n g t e r m i n a l u n t e n d e d f o r •...
Page 7: Structure & Spare Parts
1 Structure & Spare Parts 1-1 COVER...
Page 8 35 1000000111 KEY TOP,D14 WH AJ-1000 * * * 1000001517 APRON,F UNDER XC-540 36 1000004067 LABEL,CAUTION XJ#LA1025 * * * 1000004061 APRON,FRONT XJ-740 37 1000000953 LABEL,EMBLEM LOGO ROLAND * * * 1000004063 APRON,FRONT XJ-640 38 1000003489 LABEL,MARK ECO#LA1014 * * * 1000002465 APRON,FRONT XC-540...
Page 9: Frame
1-2 FRAME...
Page 10 1-2 FRAME PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 11909133 ADAPTER,SCREW 2FAI FJ-50 * * * 1000003606 RAIL,LINEAR SCALE XJ-740 2 11909167 ADAPTER,SCREW 3FAI FJ-540 * * * 1000003687 RAIL,LINEAR SCALE XJ-640 3 1000001589 ADAPTER,TUBE 2-3FAI XC-540 * * *...
Page 11 1-3 HEAD CARRIADGE...
Page 12 1-3 HEAD CARRIADGE PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 1000001461 ADAPTER,BASE CARRIAGE XC-540 * * * 47 21495115 SCREW,BLADE SET CM-500 * * * 2 1000003621 ADAPTER,CARRIAGE L XJ-740 * * * 48 22155960 SHAFT,HEXAGON CARRIAGE FJ-540 * * * 3 1000001453...
Page 13: Drive Unit
1-4 DRIVE UNIT...
Page 14 1-4 DRIVE UNIT PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 6700739010 ASSY,FEED MOTOR XJ-740 * * * 45 1000001536 LEVER,CAM PINCH XC-540 * * * 2 11879108 ABSORBER TK-3225 * * * 46 12399102 MAGNET CATCHER TL-105 * * * 3 1000003656...
Page 15: Chassis
1-5 CHASSIS...
Page 16 1-5 CHASSIS PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1 13429701 AC INLET SUP-J15G-E S1 31029101 BUSH,NB-19 2 W700311440 ASSY,AC JUNCTION BOARD XC-540 S2 31029106 BUSH,SQUARE SB-6025 3 W700731360 ASSY,DC JUNCTION BOARD XJ-740 S3 31329601AS CLAMP SET,INSULOK T-18S 100 PCS.
Page 17: Pinchroller
1-6 PINCHROLLER PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1 21775105 CAM,PINCH ROLLER SHAFT SJ-1000 S1 31119108 PIN,PARALLEL 3*30 SUS H7 2 1000003610 FRAME,PINCH XJ-740 3 1000003615 LEVER,PINCH XJ-740 4 1000003652 PLATE,LEVER PINCH XJ-740 5 1000003616 P-ROLLER,FD8S3(B15B15L60)
Page 18: Wipe System
1-7 WIPE SYSTEM PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 1000001487 BASE,WIPER MOTOR XC-540 27 15229506 SENSOR INTERRUPTER,GP1A05A5 2 11929138 BELT,408P2M4-530 28 1000004034 SHAFT,WIPE PULLEY XC-540 3 12159536 BUSH,B-S6-17 29 22155961 SHAFT,WIPER FJ-540 4 1000001595 COVER,SCRAPER XC-540...
Page 19: Cap System
1-8 CAP SYSTEM 25 22 Revised 8: Refer to the Service Information XJ740-008 PARTS LIST -Main Parts- Parts No. Parts Name 1000002794 ASSY,CAP-TOP XC-540 Parts No. Parts Name Revised 8 1000004546 ASSY,CAP-TOP 2 XC-540 30 22055542 PLATE,NUT FJ-540 2 6700319010 ASSY,PUMP SUB XC-540 31 1000001585 PLATE,P-MOTOR XC-540...
Page 20: Ink System
1-9 INK SYSTEM PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1 11909133 ADAPTER,SCREW 2FAI FJ-50 S1 31289112AS CUPSCREW SET,M3*10 NI 100 PCS. 2 W700311520 ASSY,CARTRIDGE IC BOARD XC-540 S2 31019116AS SCREW SET,BINDING M3*6 3CBC 100 PCS 3 W700311511 ASSY,INK TANK BOARD XC-540 S3 31019801...
Page 21: Stand
1-10 STAND 1-15...
Page 22 1-10 STAND PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 11879108 ABSORBER TK-3225 * * * 41 1000002511 STAND,BASE L XC-540 * * * 2 1000002464 ARM,DANCER L XC-540 * * * 42 1000002507 STAND,BASE R XC-540 * * * 3 1000002463 ARM,DANCER R XC-540...
Page 23: Tu Controller
1-11 TU CONTROLLER PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1 6700311200 ASSY,TAKEUP BOARD XC-540 S1 31329501AS CLAMP SET,PUSH MOUNT RT30SSF5 20P 2 1000001446 BASE,TU MOTOR XC-540 S2 31289105AS CUPSCREW SET, M3*6 3CBC 100 PCS 3 12159563 BUSH,80F-1006 S3 31289111AS...
Page 24: Accessories
1-12 ACCESSORIES 117V 230V 240VA 240VE 10 68 1-18...
Page 25 1-12 ACCESSORIES PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 23495124 AC CORD 3ASL100 240VA 10A SAA * * * 36 1000001631 PAD,L-LEFT XC-540 * * * 2 13499111 AC CORD H05VV-F 240VE 10A S * * * 37 1000001632 PAD,L-RIGHT XC-540...
Page 26: Electrical Section
2 Electrical Section 2-1 WIRING MAP CN100 CN101 CN102 CN604 CN600 CN403 CN402 CN411 CN412 CN413 CN202 CN203 CN1103 CN500 CN802 CN800 CN804 CN801 CN300 CN404 CN403 CN12 CN12...
Page 27: Wiring Map
WIRING MAP CABLE LIST HEAD & CARRIAGE FFC CONNECTION LIST Head Print Carriage Board Parts No. Parts Name CN15 1 1000001668 CABLE-ASSY,POWER-AC-L XC-540 CN18 2 1000001669 CABLE-ASSY,POWER-AC-N XC-540 3 1000000574 CABLE-ASSY GND AJ-1000 CN11 4 1000001670 CABLE-ASSY,POWER-AC-JUNCTION XC-540 CN16 5 1000004054 CABLE-ASSY,POWER-AC-DC XJ-740 CN19 6 1000001672...
Page 28: Main Board
2-2 MAIN BOARD MAIN BOARD_Arrangement Diagram (Component Side) DIP SW Bit1 Bit2 Bit3 Bit4 Bit5 Bit6 Bit7 Bit8 XJ-540/640/740 OFF OFF OFF OFF OFF OFF OFF OFF It indicates the version of the Main Board.
Page 29 MAIN BOARD_Arrangement Diagram (Soldering Side)
Page 30 MAIN BOARD_Circuit Diagram 1/9...
Page 31 MAIN BOARD_Circuit Diagram 2/9...
Page 32 MAIN BOARD_Circuit Diagram 3/9...
Page 33 MAIN BOARD_Circuit Diagram 4/9...
Page 34 MAIN BOARD_Circuit Diagram 5/9...
Page 35 MAIN BOARD_Circuit Diagram 6/9 2-10...
Page 36 MAIN BOARD_Circuit Diagram 7/9 2-11...
Page 37 MAIN BOARD_Circuit Diagram 8/9 2-12...
Page 38 MAIN BOARD_Circuit Diagram 9/9 2-13...
Page 39: Head Board
2-3 HEAD BOARD HEAD BOARD_Arrangement Diagram (Component Side) It indicates the version of the Head Board. 2-14...
Page 40 HEAD BOARD_Arrangement Diagram (Soldering Side) 2-15...
Page 41 HEAD BOARD_Circuit Diagram 1/9 2-16...
Page 42 HEAD BOARD_Circuit Diagram 2/9 2-17...
Page 43 HEAD BOARD_Circuit Diagram 3/9 2-18...
Page 44 HEAD BOARD_Circuit Diagram 4/9 2-19...
Page 45 HEAD BOARD_Circuit Diagram 5/9 2-20...
Page 46 HEAD BOARD_Circuit Diagram 6/9 2-21...
Page 47 HEAD BOARD_Circuit Diagram 7/9 2-22...
Page 48 HEAD BOARD_Circuit Diagram 8/9 2-23...
Page 49 HEAD BOARD_Circuit Diagram 9/9 2-24...
Page 50: Servo Board
2-4 SERVO BOARD SERVO BOARD_Arrangement Diagram (Component Side) It indicates the version of the Board. 2-25...
Page 51 SERVO BOARD_Arrangement Diagram (Soldering Side) 2-26...
Page 52 SERVO BOARD_Circuit Diagram 1/4 2-27...
Page 53 SERVO BOARD_Circuit Diagram 2/4 R185 R186 R187 2-28...
Page 54 SERVO BOARD_Circuit Diagram 3/4 2-29...
Page 55 SERVO BOARD_Circuit Diagram 4/4 EXBA10E103J EXBA10E103J 2-30...
Page 56: Heater Board
2-5 HEATER BOARD HEATER BOARD_Arrangement Diagram (Component Side) It indicates the version of the Board. 2-31...
Page 57 HEATER BOARD_Circuit Diagram 1/2 EXBA10E103J EXBA10E103J 2-32...
Page 58 HEATER BOARD_Circuit Diagram 2/2 2-33...
Page 59: Ink System Board
2-6 INK SYSTEM BOARD INK SYSTEM BOARD_Arrangement Diagram (Component Side) It indicates the version of the Board. 2-34...
Page 60 INK SYSTEM BOARD_Circuit Diagram 2-35...
Page 61: Sub Board
2-7 SUB BOARD SUB BOARD_Arrangement Diagram (Component Side) It indicates the version of the Board. 2-36...
Page 62 SUB BOARD_Circuit Diagram 1/4 2-37...
Page 63 SUB BOARD_Circuit Diagram 2/4 2-38...
Page 64 SUB BOARD_Circuit Diagram 3/4 2-39...
Page 65 SUB BOARD_Circuit Diagram 4/4 2-40...
Page 66: Takeup Board
2-8 TAKEUP BOARD TAKEUP BOARD_Arrangement Diagram (Component Side) It indicates the version of the Board. 2-41...
Page 67 TAKEUP BOARD_Circuit Diagram 2-42...
Page 68: Maintenance Parts List
2-9 MAINTENANCE PARTS LIST _ Electrical Parts SERVO BOARD Reference No. Parts No Description Function 15119122 TR,FET 2SJ535 MOTOR POWER SUPPLY 15189105 IC-LINEAR MTD2005 MOTOR DRIVER(Right PUMP) 15189105 IC-LINEAR MTD2005 MOTOR DRIVER(Left PUMP) 15189105 IC-LINEAR MTD2005 MOTOR DRIVER(Middle PUMP) HEAD BOARD Reference No.
Page 69: Replacement Of Main Parts
3 Replacement of Main Parts To Ensure safe Work Turn off the Main Power SW and unplug the power cable of the Printer before performing parts replacement. In case that the DU-740/640 (Option Dryer) is installed, unplug the power cables of both printer and DU-740/640 (Option Dryer) before performing parts replacement.
Page 70 The necessary adjustments after the replacement of each part, and the referential time for each work are described as follows. HEAD REPLACEMENT : 20min. (1 Head) 1. THERMISTER CHECK 2. HEAD ALIGNMENT 3. HEAD INFORMATION CLEAR 4. CAP HEIGHT CHECK It can be performed in the I/S MENU >...
Page 71 MAIN BOARD REPLACEMENT (In case that the parameters can be transferred by Peck.) : 30 min. 1. DIP SW SETTING 2. BATTERY INSTALLATION 3. FIRMWARE INSTALLATION 4. SYSTEM PARAMETER INITIALIZE 5. IP ADDRESS SETTING Start the machine with the Service Mode and set it in the User Menu. 6.
Page 72: Head Replacement
3-1 HEAD REPLACEMENT Turn on the Sub Power SW while pressing the Left, Right and Down keys to enter the Service Mode. MENU MENU SERVICE MENU Select [SUB MENU] > [HEAD REPLACE], and select the group of the target Head. SERVICE MENU SUB MENU C h e c k t h e i n k...
Page 73 Select [I/S MENU] > [I/S CONTROL] > [CAP] > [OPEN], SERVICE MENU and press the [ENTER] key. The Capping Unit moves I/S MENU down and allows you to move the Head Carriage by hand. I/S MENU I/S CONTROL I/S CONTROL OPEN Turn off the Sub Power SW, and then turn off the Main Power SW.
Page 74 Remove the 2 screws as shown in the figure to remove the Head Board Cover. Head Board Cover Disconnect the 2 flexible cables from the Head. Flexible Cable Make sure that LED on the Carriage Board is off when disconnecting the flexible cables. Remove the Spring, and remove the 3 screws fixing the Head as shown in the figure.
Page 75 Install the Head to the Head Carriage with the 3 screws temporarily. Then, fix the Spring and tighten up the 3 screws as shown in the figure. Use the 2kgf·cm torque driver (ST-056) to tighten up the screws. Spring Connect the 2 flexible cables to the Head Board. Flexible Cable Be careful not to connect the wrong flexible cable.
Page 76 Fix the Damper Plate. Damper Plate Make sure not to press it down to the Dampers. Dampers could break. * Fix the screws at the bottom of the long screw holes. After turning on the Main Power SW, turn on the Sub Power SW while pressing the Left, Right and Down keys to enter the Service Mode.
Page 77 If you dispose of the drained ink when performing [PUMP UP] at 2 , select [SUB MENU] > [MAINTENANCE] > SUB MENU [DRAIN BOTTLE] > [EMPTY DRAIN BOTTLE] > [RESET DRAIN COUNTER] in the User's menu, and press the SUB MENU MAINTENANCE [ENTER] key to reset the drain counter.
Page 78: Wiper Replacement
3-2 WIPER REPLACEMENT Select [SUB MENU] > [MAINTENANCE] > [REPLACE WIPER] in the User's Menu, and press the [ENTER] key. SUB ENU SUB ENU AINTENANCE AINTENANCE REPLACE WIPER The Head Carriage moves to a location permitting wiper OPEN FRONT replacement, and then the screen shown in the figure COVER appears.
Page 79 Remove the Wiper and install the new one. Make sure to fix the wiper to make the rubber side faces the front. Use the tweezers to press the area shown in the figure and engage the Wiper on the hook. Make sure to engage it on the hook.
Page 80: Cap Top Replacement
3-3 CAP TOP REPLACEMENT Remove the Front Cover and Right I/S Cover. Right I/S Cover Front Cover Turn on the Sub Power SW while pressing the Left, Right and Down keys to enter the Service Mode. MENU MENU SERVICE MENU Select [I/S MENU] >...
Page 81 Remove the 5 screws shown in the figure to remove the Pump Cover together with the Right Inner Plate. Pump Cover Right Inner Plate Select [I/S MENU] > [I/S CONTROL] > [CAP] > SERVICE MENU [CLOSE], and press the [ENTER] key. The Capping Unit I/S MENU moves up.
Page 82 Unhook the Cap Frame with holding it by the other hand, Cap Frame and remove it. Make sure to hold the Cap Frame. There is a Spring under the Cap Top. The Cap Top will jump out unless you hold the cap frame when removing it.
Page 83 Connect the tube of the Cap Top to the joint part of the Pump. Then, replace the other Cap Tops in the same way. You can connect the 2 tubes to any one of the joint parts. Fix the tubes firmly. Pump Turn on the Main Power SW, then turn on the Sub Power SW while pressing the Left, Right and Down keys to...
Page 84 Select [I/S MENU] > [I/S CONTROL] > [CAP] > [CLOSE], and press the [ENTER] key to move up the Capping Unit 1 step. Align the guides at the two ends of the capping unit with the guides at the two ends of the Head Carriage by moving the Head Carriage by hand.
Page 85: Carriage Motor Replacement
3-4 CARRIAGE MOTOR REPLACEMENT Turn off the Sub Power SW, and then turn off the Main Power SW. Main Power SW < REAR VIEW > Remove the Right Inner Plate and Panel Cover. Panel Cover Right Inner Plate Remove the Panel and put it on the Top Cover. Top Cover Flexible Cable is connected to the Panel Panel...
Page 86 Remove the Spring. Spring < Front view > Disconnect the connector of the motor cable. Connector Remove the 4 screws as shown in the figure to remove the Motor together with the Flange. Flange Screw Remove the 4 screws to remove the Motor from the Flange.
Page 87 Fix the Flange temporarily. And Fix the Spring. Flange Screw Spring Check the gears mesh without backlash in the following procedures. Insert the head-unit tool into the hole at the bottom of the machine and turn it gently. The Capping Unit moves down.
Page 88 4) Make the guides at the edges of the Head Carriage line up with the guides at the edges of the Capping Unit. When the heads make contact with the Capping Unit, turn the tool one or two turns more. Guide Guide Then, tighten up the 4 screws to fix the Flange firmly in...
Page 89 Fix the Panel Cover and Right Inner Plate. Panel Cover Front Cover Right Inner Plate Perform the SERVO LOCK CHECK. After turning on the Main Power SW, turn on the Sub Power SW while pressing the Left, Right and Down keys to enter the Service Mode.
Page 90 Press the [ENTER] key to excite the Motor. Check the Head Carriage can not be moved easily by hand and the value on the LCD doesn't change. SERVO LOCK 1688 [ ENTER ] SERVO LOCK 1688 Perform the AGING for checking. Go back to the [MOTOR MENU], and select [AGING] >...
Page 91: Pump Replacement
3-5 PUMP REPLACEMENT Remove the Front Cover and Right I/S Cover. Right I/S Cover Front Cover Turn on the Sub Power SW while pressing the Left, Right and Down keys to enter the Service Mode. MENU MENU SERVICE MENU Select [I/S MENU] > [I/S CONTROL] > [CAP] > [OPEN], SERVICE MENU and press the [ENTER] key.
Page 92 Turn off the Sub Power SW, and then turn off the Main Power SW. Main Power SW < Rear view > Remove the 5 screws shown in the figure to remove the Pump Cover together with the Right Inner Plate. Pump Cover Right Inner Plate Disconnect the connector of the Pump Motor.
Page 93 Remove the 2 screws as shown in the figure to remove the Pump Unit. Screw Remove the 3 screws shown in the figure to remove the Motor from the Pump Unit. Fix the new Pump Unit to the Motor. Motor Pump Unit Fix the Pump Unit with the 2 screws as shown in the figure.
Page 94 Connect the connector of the Pump Motor. Connector Pump Move the Head Carriage to lock it by hand to the standby position. After turning on the Main power SW, turn on the Sub Power SW while pressing the Left, Right and Down keys to enter the Service Mode.
Page 95 Clear the pump rotation times. Go back to the Service Menu, and select [HISTORY SERVICE MENU MENU] > [MOTOR GROUP]. Then, select the pump HITORY MENU you replaced. HITORY MENU Select [CLEAR] and press the [ENTER] key. MOTOR GROUP MOTOR HOURS F 3 hours PUMP TIMES A PUMP TIMES A...
Page 96: Ink Tube Replacement
3-6 INK TUBE REPLACEMENT After turning on the Main power SW, turn on the Sub Power SW while pressing the Left, Right and Down keys to enter the Service Mode. MENU MENU SERVICE MENU Select [SUB MENU] > [PUMP UP], and select the group of the target tube.
Page 97 Remove the 4 screws as shown in the figure to remove Carriage Cover the Carriage Cover. Remove the Carriage Board Cover. Carriage Board Cover Remove the Carriage B o a r d C o v e r b y p u s h i n g t h e p a r t indicated by the arrows because the top part of the support is easy to...
Page 98 Disconnect the Ink Tubes from the Ink Dampers, and put the scotch tape on the tip of the Ink Tube to prevent the ink from coming out. Make sure not to replace the Ink Tubes of the different colors at the same time. There is a risk of connecting wrongly when fixing the new ones.
Page 99 Cut the Ink Tubes at appropriate length and connect them to the Ink Dampers. Then, replace the other Ink Tubes in the same way. Connect the 6 Flexible Cables to the Carriage Board and Filters Flexible Cables fix the Nylon Rivets to fix the Clear Plates. Be careful not to forget to fix the Filters.
Page 100 Fix the Cable Guide at the position shown in the figure. Cable Guides are to be fixed next to the Tube Guides. Cable Guide Tube Guide < Rear view of the machine > After turning on the Main power SW, turn on the Sub Power SW while pressing the Left, Right and Down keys to enter the Service Mode.
Page 101: Boards Replacement (Head / Servo / Main / Sw Power Supply)
3-7 BOARDS REPLACEMENT (Head / Servo / Main / SW Power Supply) BOARD LAYOUT (IN CHASSIS) 1. Board Cover opened TU Junction Board Heater Servo Board Head Board Main Board Board Board Stay 2. Board Stay removed SW Power Supply (5V, 24V) AC Junction Board...
Page 102 Turn off the Sub Power SW and then turn off the Main Power SW, and pull out the AC cord. Main Power SW < Rear view > Remove the Chassis Cover. Chassis Cover 3-34...
Page 103 HEAD BOARD REPLACEMENT HEAD BOARD CONNECTOR LAYOUT CN12 CN11 CN13 CN1~7 Disconnect all the Cables from the Head Board. Revised 7 Remove the screws as shown in the ﬁ gure to replace to the new Head Board. Make sure that there is no gap in connected part with the main board when connecting the Main Board Head Board...
Page 104 Connect all the Cables to the Head Board. Carry out the following checks. 1. THERMISTOR CHECK 2. HEAD UP/DOWN SENSOR CHECK It can be performed in the SENSOR CHECK. 3. FAN ON THE HEAD BOARD 3-36...
Page 105 SERVO BOARD REPLACEMENT SERVO BOARD CONNECTOR LAYOUT CN16 CN17 CN18 CN15 CN14 CN12 CN11 CN1,2 Disconnect all the Cables from the Servo Board. Remove the screws shown in the figure to replace with the new Servo Board. 3-37...
Page 106 Connect all the cables to the Servo Board. Carry out the following adjustments and settings. 1. PINCH ROLLER SENSOR CHECK 2. AGING 3-38...
Page 107 MAIN BOARD REPLACEMENT MAIN BOARD CONNECTOR LAYOUT CN11 CN10 Connect the AC cord, and turn on the Main Power SW. Main Power SW < Rear view > Start the Peck. 3-39...
Page 108 Perform [Get Report] and [Get Parameters], and save them. Turn off the Main Power SW and pull out the AC cord. Main Power SW < Rear view > Disconnect all the Cables which are connected to the Main Board. Remove the screws as shown in the ﬁ gure ﬁ xing the Revised 7 head Board, and disconnect from the Main Board.
Page 109 Revised 7 Remove the screws as shown in the ﬁ gure ﬁ xing the Main Board, and replace with the new Main Board. Main Board Revised 7 Connect the Head Board to the Main Board, and ﬁ x it with the screws as shown in the ﬁ gure. Make sure that there is no gap in connected part with the main board when connecting the Main Board...
Page 110 Perform the following operations after replacement. 1. DIP SW SETTING 2. BATTERY INSTALLATION Refer to [3-8 BATTERY REPLACEMENT] 3. FIRMWARE INSTALLATION Refer to [4-2 HOW TO UPGRADE/INSTALL FIRMWARE] 4. SYSTEM PARAMETER INITIALIZE Refer to [4-2 HOW TO UPGRADE/INSTALL FIRMWARE] 5. IP ADDRESS SETTING Start the machine with the Service Mode and set it in the User Menu.
Page 111 SW POWER SUPPLY REPLACEMENT (41V) SW POWER SUPPLY CONNECTOR LAYOUT Connected to the [CN301] on the AC Junction Board Connected to the [CN800] on the DC Junction Board Disconnect the Cables from the following boards and remove them with the Stays. HEATER BOARD SERVO BOARD Main Board...
Page 112 Connect all the Cables. Set the output voltage of SW Power Supply to + 41V. Turn on the Main Power SW. Use the Digital multi-Meter that can measure the direct voltage. Main Power SW < Rear view > Put the black probe into CN51-1pin (GND) and the red probe into CN51-8pin (Vout) on the SW Power CN51-1pin Supply.
Page 113 Fix the following boards removed in the step 1 . Connect all the Cables. HEATER BOARD SERVO BOARD Main Board Servo Board Head Board MAIN BOARD HEAD BOARD Heater Board Revised 7 Make sure that there is no gap in connected part with the main board when connecting the Head Board.
Page 114 SW POWER SUPPLY REPLACEMENT (5V, 24V) SW POWER SUPPLY CONNECTOR LAYOUT Connected to the [CN302] on the AC Junction Board Connected to the [CN801] on the DC Junction Board Disconnect the Cables from the following boards and remove them with the Stays. HEATER BOARD SERVO BOARD Main Board...
Page 115 Connect all the Cables. Fix the following boards removed in the step 1 . Connect all the Cables. HEATER BOARD SERVO BOARD Main Board Servo Board MAIN BOARD Head Board HEAD BOARD Heater Board Revised 7 Make sure that there is no gap in connected part with the main board when connecting the Head Board.
Page 116: Battery Replacement
3-8 BATTERY REPLACEMENT Do not recharge, short-circuit, disassembly the lithium battery, nor 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. Turn off the Sub Power SW, and then turn off the Main Power SW.
Page 117 Remove the Battery on the Main Board by pushing it down and tilting towards right. Socket Main Board Replace the Battery with a new one. Socket Be careful with the direction of the Battery. Battery Main Board Turn on the Main Power SW and turn on the Sub Power SW while pressing the Left, Right and Down keys to enter the Service Mode.
Page 118 Select [SUB MENU] > [CLOCK] > [DATE], and set the date and press the [ENTER] key. SERVICE MENU SUB MENU SUB MENU CLOCK CLOCK DATE DATE 00/00/00 DATE 06/08/08 Edit screen Turn off the Sub Power SW, and then turn off the Main Power SW.
Page 119: Carriage Belt Replacement
3-9 CARRIAGE BELT REPLACEMENT Turn off the Sub Power SW, and then turn off the Main Power SW. Main Power SW < Rear view > Remove the following covers. Front Rail Cover Right I/S Cover Top Cover Top Cover Right Top Cover Right Top Cover Front Rail Cover Right I/S Cover...
Page 120 Turn off the Sub Power SW, and then turn off the Main Power SW. Main Power SW < Rear view > Remove the Carriage Cover. Carriage Cover Remove the Damper Plate. Damper Plate Remove the Ink Dampers from head 2 and 3. Remove the 2 screws fixing the Belt Holder to the Head Carriage.
Page 121 Loosen the 2 Fixingscrews as shown in the figure < Top view - Leftside of the Belt > located leftside of the Belt. And loosen the Adjustment Screw. Fixingscrew Adjustment Screw Move the Belt Holder to the left. Do not scratch the Encoder Scale when removing the Belt from the Carriage or moving the Belt Holder.
Page 122 Tighten the Screws shown in the figure to fix both edges < Cross-section diagram from the front view > of the Carriage Belt to the Belt Holder. Screw Plastic Plate Plastic Plate Metal Plate When fixing the Carriage Belt, make sure the ends of the Belt are not overlapped.
Page 123 Fix the Damper Plate. Damper Plate Make sure not to press it down to the Dampers. Dampers could break. * Fix the screws at the bottom of the long screw hole. Tighten the Adjustment Screw to have tension on the <...
Page 124: Encoder Scale Replacement
3-10 ENCODER SCALE REPLACEMENT Remove the following covers. Left I/S Cover Right I/S Cover Front Rail Cover Front Rail Cover Right I/S Cover Front Cover Left I/S Cover (XJ-740 only) Front Cover After turning on the Main power SW, turn on the Sub Power SW while pressing the Left, Right and Down keys to enter the Service Mode.
Page 125 Remove the Encoder Scale by removing the Plate fixing the Encoder Scale on its right end and the Spring on its left end. Encoder Scale Spring Plate Remove the Spring Plate from the Encoder Scale and fix it to the Encoder Scale on the side without a cutout. Cutout Spring Plate Make sure not to make scratches or put grease...
Page 126: Pinch Roller Replacement
3-11 PINCH ROLLER REPLACEMENT Remove the Pinch Roller from the Pinch Lever. Pinch Lever Pinch Roller Fix the new Pinch Roller to the Pinch Lever. Pinch Lever Make sure that the Pinch Roller is fixed firmly at the 3 points and the hook. Pinch Roller Hook <...
Page 127: Take-Up Board Replacement
3-12 TAKE-UP BOARD REPLACEMENT Turn off the Sub Power SW and Main Power SW of the machine, and turn off the SW of the Take-up unit. Remove the TU Cover. TU Cover Remove the 2 screws as shown in the figure to remove the Plate fixing the Board.
Page 128 Connect all the cables to the Board. Fix the Plate. Board Plate Shaft Fix the TU Cover. TU Cover Check the following. 1. [4-12 TAKE-UP UNIT OPERATION CHECK] 3-60...
Page 129: Adjustment
4 Adjustment 4-1 SERVICE MODE MENU ], [ ], [ ] + POWER ON [ MENU ] key SERVICE MENU SERVICE MENU PRINT MENU HEAD RANK HEAD RANK 1 This menu is used for entering the HEAD RANK for each HEAD 1234567 (1/5) PRINT MENU HEAD RANK...
Page 130 Normal (beeps 1 time) PRINT MENU NOW PROCESSING.. LINEAR ENCODER LINEAR ENCODER POS: 1361.00mm SETUP COMPLETED Error (beeps 2 times) LINEAR ENCODER Error is found on Linear Encoder and Scale. SETUP FAILED LINEAR ENCODER Error is found on Head Board. HEADBOARD FAILED This menu is for checking the installation and operation of Encoder Module and Encoder Scale.
Page 131 Normal SERVICE MENU I/S MENU NOW PROCESSING.. I/S CHECK COMPLETED I/S MENU I/S CHECK Checking Error I/S CHECK ERROR This menu is for checking the motors and sensors of Cap (Up/Down), Wipers and Slider. **Make sure to move the head carriage towards left off the capping unit before performing this check.
Page 132 Remove all cartridges before pressing ENTER Set cartridge to SLOT1 All cartridges must be removed before entering IC IC CHECK I/S MENU CARTRIDGE CHECK menu. IC CHECK SLOT1 INSERT CARTRIDGE It detects Ink Cartridge IC, writes and loads information, and checks the communication. First of all, it confirms if there is the driver for IC detection.
Page 133 SERVICE MENU FRHCPULWcwab 123456789101112 SENSOR CHECK This menu displays the real-time status of each sensor. It shows " " when the sensor is ON. The first page shows the status of each sensor. Each alphabet stands for as follows. The second page shows the status of each Head Up/Down Sensor Cartridge Sensor and Ink Empty Sensor.
Page 134 Washes print heads. A to C shown on the lower LCD are the head groups. Cursor can be moved with [left] and [right] keys. Use [up] and [down] keys for SUB MENU HEAD WASH CHECK ON/OFF. By pressing [ENTER] key, it starts to wash the selected head groups.
Page 135 DIP SW CHECK SUB MENU This menu is to check Dip Switch. It displays the real-time status of the No.1 to 8 from the left. DIP SW CHECK 0110 0000 [0] is OFF and [1] is ON. bit # [1 2 3 4 5 6 7 8] This menu is to check the operation of panel keys.
Page 136 SVC.MODE HEAT. SERVICE MENU HEATER MENU This is to specify ON/OFF of the heater when the machine is started in the Service Mode. HEATER MENU SVC. MODE HEAT. STOP > STOP START : Heater ON Default : STOP STOP : Heater OFF HEATER MENU HEATER ADJUST This menu is to offset the temperature of each heater.
Page 137 HISTORY MENU MOTOR GROUP Item Contents Unit Reference Motor feed Total time that the Feed Motor has been rotated hour Motor scan Total time that the Scan Motor has been rotated hour Life: 1500 hours Pump Times A Total time that the Pump Motor A has been rotated times Life: 200,000 times Pump Times B...
Page 138 MAINTENANCE GROUP Item Contents Unit Reference MAINTE. COUNT Number of times the Head Maintenance has been performed times TOTAL TIME Lapsed time from the last Head maintenance hour This value is cleared automatically after carrying out the Head Maintenance. PRINTING TIME Printing time from the last Head Maintenance hour This value is cleared automatically after carrying out the Head Maintenance.
Page 139 Roland SOL JET PRO III series Ink type Model XJ-740 IP Address E-SOL Max LcLm 133, 111, 128, 060 Ink remain (1-6) 74/ 86/ 64/ 100/ 71/ 100 Version 2.00 Subnet Mask 255, 255, 252, 000 Ink remain(7-12) 100/ 100/ 97/ 72/ 100/ 100 Serial No.
Page 140 Service Report Head rank H1 6CZ343CUYUOVVRT 00B. . D 73V3739TVUXVVSV 00C. . D 6FW3436TVUXWWST 004. . D 6BV3230UTVVWVSU 00D. . D 6DT332FUSWSVVTT 00P. . D 6ET3935TTVUVVTU 00H. . D Head hori. (DT1. Low) (DT3. Low) (DT1. High) (DT3. High) Head bi (DT1.
Page 141 Ink Cartridge Report Model XJ-740 Serial No. : XX00001 Version 2.00 No : SERIAL / INK TYPE / CAP. / LOT No/ CONSUM. / TIME / INS. / FLAG NO IC CHIP / eSOL C / 400 cc / 61002A / 55.526cc / 0y003d00h07m48s / 1 / 00000000...
Page 142 MENU pressing [ ] key to start the machine in the SERVICE REPORT PRINTING mode. [SERVICE REPORT] is displayed Roland DG Corp. XJ-740 and it turns to be the normal mode SERVICE REPORT after printing. It starts printing automatically when...
Page 143 Special Key Combinations Function for Service Combination Key Selection Comments Press [MENU] and [ ] to enter Service Service Mode Menu. [UPDATE FIRMWARE?] will be displayed. Upgrade Firmware Press [ENTER] to upgrade firmware. Use this when the Main Board is replaced. Installing Firmware (At Main Board Change) [SUM-ERROR] will be displayed.
Page 144: How To Upgrade Firmware/Install Firmware
4-2 HOW TO UPGRADE/INSTALL FIRMWARE It is necessary to prepare the followings to upgrade/install the firmware. 1.Firmware file 2.WindowsPC (Network port is required.) 3.Peck.exe 4.Network cable (A cross cable is required when you connect XJ-740/640/540 to PC directly.) HOW TO UPGRADE FIRMWARE (Referential Time : 5 min) Check the IP address of XJ-740/640/540.
Page 145 Start the Peck on PC. [Peck] screen is displayed, and click [Select Port] button. Select [Type 3] ProIII etc. from [Product]. Also, select [Via Network] and input IP address of XJ- 740/640/540 specified earlier. Click [OK] button. [Peck] screen is displayed again. Click [Firmware Upgrade] button.
Page 146 The machine goes into the Firmware Upgrade mode automatically. FIRMWARE V1.0 DATA ERROR When upgrade is completed, the Sub Power SW turns off automatically. ERASING DEVICE ERROR WRITING DEVICE ERROR VERIFYING DEVICE ERROR COMPLETE HOW TO INSTALL FIRMWARE (Referential Time : 5 min) This is required when a new Main Board without the firmware is installed.
Page 147 Press MENU key, and set [IP ADDRESS], [SUBNET MASK] and [GATEWAY ADDR.]. Press [ ] and [ ] keys for moving between digits, and ] and [ ] keys for selecting value. After setting an address, press the [ENTER] key to go to the next address setting.
Page 148 [Peck] screen is displayed again. Click [Firmware Upgrade] button. [OPEN] screen is displayed. Select the firmware file and click [Open]. It starts to send the firmware to XJ-740/640/540. It starts loading the firmware. The firmware installation is done when [COMPLETE] FIRMWARE V1.0 DATA ERROR...
Page 149 Turn on the Sub Power SW while pressing [ ], [ and the [ENTER] keys to enter [INITIALIZE ALL SYS.PARAMETER] menu. ENTER Press the [ENTER] key to start initialization. The Sub Power SW turns off automatically when it is completed. INITIALIZE ALL SYS.PARAMETER SELECT MODEL...
Page 150 Start the Peck on PC. [Peck] screen is displayed, and click [Put Parameters] button. [OPEN] screen is displayed. Select the System Parameter file that is saved before the main board replacement. Click [Open]. Peck starts to send the System Parameter to XJ-740/640/540.
Page 151: How To Upgrade Firmware Of The Network Controller
4-3 HOW TO UPGRADE FIRMWARE OF THE NETWORK CONTROLLER ( Referential Time : 5min.) Turn on the Main Power SW and Sub Power SW. Select MENU [SYSTEM INFO.] > [NETWORK] > [IP ADDRESS] in the User's Menu and set the IP address. MENU SYSTEM INFO.
Page 152 The progress is shown in percentage while upgrading. Do not turn off the power or press any keys during the upgrade. When upgrading is completed, the version of upgraded firmware appears. Turn off the sub power and main power once. 4-24...
Page 153: Head Alignment
4-4 HEAD ALIGNMENT (Referential Time : 30 min._1 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 HEAD ALIGNMENT is not adjusted, printing problems such as banding, fine lines and gap between bands could occur.
Page 154 Turn on the Sub Power SW while pressing [ ], [ and [ ] keys to enter the Service Mode. Setup the sheet media (PET-G) film on the machine. MENU MENU SERVICE MENU [BIAS ADJUSTMENT] Select [PRINT MENU] > [HEAD ADJUST] > [BIAS] > SERVICE MENU [TEST PRINT] menu and press the [ENTER] key.
Page 155 Insert the 1.5 mm Hexagonal Wrench through the hole of the Head Carriage, then, turn the adjustment screw to make the lines of each color in the test pattern to be straight. *Reference* Adjustment Position of the printing moves 1 line by turning Screw the screw for a 3/4 turn.
Page 156 Print the test pattern again. If the result is not satisfactory, repeat 5 to 9 . The shifting of lines should be less than 1/2 dot. 4-28...
Page 157 [VERTICAL ADJUSTMENT] Select [PRINT MENU] > [HEAD ADJUST] > [VERTICAL] SERVICE MENU > [TEST PRINT] and press the [ENTER] key. PRINT MENU [ ] [ ] PRINT MENU HEAD ADJUST HEAD ADJUST VERTICAL VERTICAL TEST PRINT test pattern shown in the figure will be printed. Test pattern can be moved by [ ] and [ ] keys.
Page 158 - When the lines other than K are above the K lines, turn the Adjustment Screw CW. - When the lines other than K are below the K lines, turn the Adjustment Screw CCW. Adjust the Head positions referring to the left- end K head as the base position.
Page 159 Revised 3 If the Vertical test print result is satisfactory, select the [BIAS] > [TEST PRINT] menu uder the [HEAD ADJUST] menu and print the Bias test pattern again. If the Bias test print result is not satisfactory, repeat the Bias Adjustment.
Page 160 [ HORIZONTAL ADJUSTMENT ] S e l e c t [ P R I N T M E N U ] > [ H E A D A D J U S T ] > SERVICE MENU [HORIZONTAL] > [TEST PRINT] and press the [ENTER] PRINT MENU [ ] [ ] key.
Page 161 Select [HORIZONTAL] > [TEST PRINT] > [DT1, Low], [DT3, Low], [DT1, High] and [DT3, High] menu and enter the parameters checked at 19 with [ ] and [ ] keys. Press the [ENTER] key to save the settings. Parameters can be entered with an increment of 1/2.
Page 162 [ BIDIRECTION ADJUSTMENT ] Select [PRINT MENU] > [HEAD ADJUST] > [BI- SERVICE MENU DIR.DEFAULT] > [TEST PRINT] and press the [ENTER] PRINT MENU [ ] [ ] key. PRINT MENU HEAD ADJUST HEAD ADJUST BI-DIR.DEFAULT BI-DIR.DEFAULT TEST PRINT Following test pattern will be printed. Find the position where the two lines are overlapping and check the number of each color.
Page 163 Select [BI-DIR.DEFAULT] > [TEST PRINT] > [DT1, Low], [DT3, Low], [DT1, High] and [DT3, High] in the [HEAD Parameters can be entered with an ADJUST] menu and enter the parameters checked at 22 increment of 1/2. with [ ] and [ ] keys.
Page 164: Limit Position & Cut Down Position Initialize
4-5 LIMIT POSITION & CUT DOWN POSITION INITIALIZE (Referential Time : 10min.) This is for adjusting the relative distance between the Limit Sensor and the Capping Position, and also detecting the distance from the Cut Down Position to the Limit Sensor after completing the adjustment. When the Limit Position is not correctly set, it may cause some problems such as a head capping error.
Page 165 Press the [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 shown in the figure. DETECTING.. SETTING UP CUTTER DOWN POS Move the Head Carriage with your hand until it makes full contact with the Left Frame.
Page 166: Paper Side Sensor Adjustment
4-6 PAPER SIDE SENSOR ADJUSTMENT (Referential Time : 5min.) 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.
Page 167 Adjust the VR on the Carriage Board so that the [OUTPUT LEVEL] will be 0.5 - 0.7V. Carriage Board Select [PAPER SIDE SENSE] > [SENSOR AUTOTEST] SERVICE MENU menu. SUB 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.
Page 168: Linear Encoder Setup
4-7 LINEAR ENCODER SETUP (Referential Time : 10min.) Linear Encoder Setup is necessary for the machine to recognize 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. Be sure to perform this setup when the adjustment or replacement of the Limit Sensor, Encoder Scale and Encoder Module.
Page 169 One of the messages appears at the completion of the set up. In case of Setup error, check the followings. LINEAR ENCODER 1. Dirt/Scratch on the ENCODER SCALE. SETUP COMPLETED 2. Dirt/Scratch on the ENCODER MODULE. 3. ENCODER SCALE is not between the ENCODER MODULE.
Page 170: Cap Height Adjustment
4-8 CAP HEIGHT ADJUSTMENT (Referential Time : 5min.) Cap Height Adjustment is to adjust the height of the cap. This adjustment is required when the cap unit is removed or replaced. Without this adjustment, the Cap Evacuation* may not be performed properly. * Cap Evacuation is an operation of ink evacuation with the Heads uncapped.
Page 171 Move the cap upward to the position that the cap contacts exactly to the head, then press the [ENTER] to update CAP ADJUST ADJUST POS. Head ADJUST POS. 0.00 -2.00 the adjustment value. -When you press [ ] key, the cap moves upward in 0.25mm unit.
Page 172: Calibration
4-9 CALIBRATION (FEEDING DIRECTION) (Referential Time : 20 min.) This adjustment is for calibrating the feed amount of media. It allows the media to be fed proper amount by calibrating the variation in Grit Roller diameter. Calibration of the machine is made based on the value in feeding media [PET-G] (Roll media with a width of 1050mm.) Without proper calibration, it causes misalignment in the feed amount of media, and results in the problems such as white banding, banding of overlap or the dimension error of print result compared...
Page 173 test pattern is printed. Measure the length of the feed direction and use the value to calculate the calibration amount with the formula shown at 5 . test pattern is always printed with offset 0.00%. Even if a correction is made in the [SETTING] 500mm menu, the Test Pattern is not changed.
Page 174: Belt Tension Adjustment
4-10 BELT TENSION ADJUSTMENT (Referential Time : 20min.) Remove the following covers. Left I/S Cover Front Rail Cover Front Rail Cover Top Cover Top Cover Left I/S Cover (XJ-740 only) Turn on the Sub Power SW while pressing [ ], [ and [ ] keys to enter the Service Mode.
Page 175 Measure the tension of the belt at the position above the <Front side> Upper Belt center of the grit roller as below using Tension Gauge (ST-001). Hold down the belt w i t h T e n s i o n Press the upper belt downward with the gauge to make Gauge slight contact with the lower belt.
Page 176 Turn the adjustment screw shown in the figure to adjust Adjustment Screw so that the value of the tension gauge is the following with the procedure of 6 . The value of the tension gauge XJ-740 0.8kgf XJ-640 0.95kgf XJ-540 1.05kgf Turn the screw CW: Tension is increased Turn the screw CCW: Tension is decreased Tighten the two fixing screws shown in the figure, and...
Page 177: Belt Position Adjustment
4-11 BELT POSITION ADJUSTMENT (Referential Time : 30min.) This adjustment is to prevent the belt wear which is caused by the belt contacting with the pulley flanges excessively. The belt position needs to be confirmed after the Belt Tension Adjustment and adjusted if it is necessary.
Page 178 [ADJUSTMENT ON THE DRIVE PULLEY SIDE] Carry out the AGING test for the belt. SERVICE MENU Select [MOTOR MENU] > [AGING] > [SCAN], and press MOTOR MENU the [ENTER] key. MOTOR MENU AGING AGING SCAN Confirm the belt position. <Top view - Right end The position is proper when the belt is not touching the of the belt - >...
Page 179 Press the [ENTER] key to restart Aging. AGING SCAN Adjust the belt position turning the Adjustment Screw as follows. The work space is limited. Be cautious and try not to touch the driving pulley and belt. Also, there are many mechanical parts around it.
Page 180 Tighten the two fixing screws for the bottom of the screw head to slightly contact with the Stay. Fixing Screw Make sure not to tighten the screws too tight. It may move the fixed Drive Pulley Holder Screw accidentally. Stay Confirm that the belt is not touching the pulley flanges excessively while the carriages are in the printing area.
Page 181 Loosen the two fixing screws located at the left end of the belt eighth to quarter round. When the screw is loosen more than necessary, it gives difficulty in adjusting the belt. Also, you need to be cautious with the sharp edges around it when turning the screws.
Page 182 Belt leans to the front side of the machine Screw -Turn the screw 1 carefully in CW to press it to the Idle Pulley Holder. * Make sure to have a gap of 3mm between the screw 2 and Idle Pulley Holder when turning the screw 1 . Touching the flange on the FRONT side of machine Belt leans to the rear side of the machine...
Page 183 Confirm that the belt is not touching the pulley flanges Pulley Flange excessively while the carriages are in the printing area. When the belt is in improper position, adjust it again. When it is proper, press the [ENTER] key to cancel Aing. SCAN NOW AGING 4-55...
Page 184: Take-Up Unit Operation Check
4-12 TAKE-UP UNIT OPERATION CHECK (Referential Time : 2min.) This is required when Take-up unit is installed or TU Junction Board is replaced. This is to check whether Take-up Unit operates properly. Confirm that the cable is connected to the connector Undersurface of the right side of machine named [TAKE UP] and turn on the Main Power SW.
Page 185 Confirm that [START] is selected, and press the [ENTER] key to turn on the Take-up Unit. [START] or [STOP] can be selected with START START ] and [ ] keys. The current setting is displayed on the left and the new setting is displayed on the right. Set the Auto switch of the Take-up Unit to either Forward or Backward.
Page 186 Move the Dancer Roller up and down by hand to confirm that the drive part does not rotate. Drive Part The setting of [STOP] is canceled when exiting the menu. The initial setting is [START] every time entering [TU] menu. Dancer Roller 4-58...
Page 187: Supplemental Information
5 Supplemental Information 5 Supplemental Information 5-1 SPECIAL TOOLS Table shows a list of special tools recommended by Roland DG Corp. Tool No. ST-056 Tool Name TORQUE DRIVER N6 Purpose HEAD ALIGNMENT Tool No. ST-001 Tool Name TENSION GAUGE 2000GF/2000CN...
Page 188: Sensor Map
5-2 SENSOR MAP SHEET LOAD SENSOR It detects whether the Sheet Loading Lever is UP or DOWN. LIMIT SENSOR It detects the limit positon of the Head Carriage. FRONT COVER SENSOR It detects whether the Front Cover is opened or closed. (Right side of the machine) GRIT ENCODER It detects rotation position of the Grit Roller.
Page 189 THERMISTOR (PRE-HEATER) It takes the temperature of the Pre-Heater. THERMOSTAT (PRE-HEATER) If the Pre-Heater exceeds the limit temperature, it cuts the power being supplied. (Rear side of the machine) THERMISTOR (HEAD BOARD) It takes the temperature around the Head Board.
Page 190 5 Supplemental Information WIPER SENSOR It detects the limit position of the Wiper movement. ENCODER MODULE It detects coordinates for carriage moving direction. HEAD UP/DOWN SENSOR It detects the position of the Head Height Lever. PAPER SIDE SENSOR It detects the left and right edges of the media. THERMISTOR (HEAD) It takes the temperature around the Head.
Page 191 INK CARTRIDGE SENSOR It detects whether the Ink Cartridge is installed or not. INK EMPTY SENSOR It detects whether the Ink Cartridge is empty or not. INK CARTRIDGE IC SENSOR It reads the infromation of the IC chip. DANCER ROLLER SENSOR It detects the limit position of the Dancer Roller.
Page 192: Troubleshooting
6 Troubleshooting 6-1 WHITE FINE LINE / BANDING / MISSING DOT / SCRATCHY PRINTING / BLURRED PRINTING Improved Missing dot or Perform Normal deflected-fired dot Completed Cleaning appears on the test pattern. Not Improved *Several Normal Cleanings and a Powerful Cleaning do not improve the printing result.
Page 193: Particular Color Is Not Printed At All
Cleaning does not work effectively and the nozzle condition cannot be [3-3 CAP TOP 13 Defect of Cap Top Cap Top Replacement improved. Also, if the head is not capped correctly, the head dries and it REPLACEMENT] may cause the head nozzle clogging. Generally, we do not recommend to wipe the surface of Head with a Clean the head surface cleaning stick.
Page 194: Shifting In Printing/Color Shifting
6-3 SHIFTING IN PRINTING/COLOR SHIFTING CHECKING POINT ACTION REFERENCE OUTLINE Load the media while the left media holder is positioned close to the left edge. Also, never secure the media holder in place before loading the media. Loading media without following the steps described in the User's Manual may make smooth and straight media feed impossible The media is set tilted Set the media correctly User's Manual...
Page 195: Missing Dot Or Deflected-Fired Dot Appears When Performing Printing After Leaving The Machine Unused For A Long Time
6-6 MISSING DOT OR DEFLECTED-FIRED DOT APPEARS WHEN PERFORMING PRINTING AFTER LEAVING THE MACHINE UNUSED FOR A LONG TIME CHECKING POINT ACTION REFERENCE OUTLINE When the main power is off, the maintenance flushing is not performed Check the main power Do not switch off the User's Manual and it may cause the Head nozzle clogging.
Page 196: Motor Error
6-8 MOTOR ERROR CHECKING POINT ACTION REFERENCE OUTLINE Remove cause of Media Jamming Media Jam When using hard-to-unroll or too heavy media, Motor Error occurs due to the too much load for feeding the media. Back tension of media is Use appropriate Media When [MEDIA RELEASE] is enabled, the setting-media is fed too high...
Page 197: Heater / Dryer Temperature Does Not Go Up
6-9 HEATER / DRYER TEMPERATURE DOES NOT GO UP CHECKING POINT ACTION REFERENCE OUTLINE The media is not loaded Set up the media User's Manual Inappropriate temperature Check the temperature When the [PRE / PRINT / DRYER] is [OFF] on the machine, the Heater User's Manual is set on the machine setting...
Page 198: Error Message
6-13 ERROR MESSAGE CHECKING POINT ACTION REFERENCE OUTLINE Restart the machine Restart the machine and see if the same error occurs again. service call Refer to SERVICE [6-14 SERVICE CALL below CALL] Restart the machine Restart the machine and see if the same error occurs again. Internal Error Upgrade the firmware to Check the revision record of the firmware version and upgrade it if the...
Page 199 Capping Motor does not work correctly or is broken. Even though the machine Capping Unit does not work correctly or is Capping Motor replacement carries out the regular broken. Capping unit replacement 0104 movement, the output of Capping Sensor does not work correctly or is Capping Sensor replacement Capping Sensor does not broken.
Page 200: Service Activities
7 Service Activities 7-1 INSTALLATION CHECK LIST XJ-740/640/540 INSTALLATION CHECK LIST Date User Serial Number Unpacking There is a space necessary for installing the machine as follows. XJ-740: 4.3 m (169 in.) / XJ-640: 4.0 m (157 in.) / XJ-540: 3.7 m (146 in.) XJ-740: 3.3 m (130 in.) / XJ-640: 3.0 m (118 in.) /XJ-540: 2.7 m (106 in.) Unit space Work space...
Page 201 Unpacking...
Page 202 Unpacking the Stand Shafts Jig for setting up Stay, etc. Stand Legs Unpacking the Accessory Box Ink-cartridge tray, etc. Manual, CD-ROM, etc.
Page 203 Checking the Accessories Stand legs Dancer roller : 1 Rail slider : 1 Stay : 1 (left and right) : 1 set Arm/Arm retaining Paper pipe : 1 Shaft : 2 Power cord : 1 screw : 1 set Media holders and Drain bottle stand : 1 ink-cartriddge try :1 Shaft clamps : 2...
Page 204 Installation and Preparation Set up following items in reference to the Setup Guide from [3.Assembling and Installing] to [6. Network Settings]. In case of setting up DU-740/640/540, refer to the DU-740/640/540 Uer's Manual [1-4 Installing on the Printer]. Assemble the Stand Mount the Machine Install the Drain Bottle Install the Media Holders...
Page 205 Installing Roland VersaWorks Install Roland VersaWorks in reference to the Quick Start Guide. System requirements for installing the software Operating system : Windows Vista Ultimate (32-bit edition) or Windows Vista Business (32-bit edition) or Windows XP Professional Service Pack 2...
Page 206 Loading and cutting off media For setting media straight, load the media while the left media holder is positioned close to the left edge. Also, never secure the media holder in place before loading the media. Loading media without performing these steps in the proper order may make smooth media feed impossible or causes poor printing results.
Page 207 - Never store ink at any locations where high temperature may occur or exposed to open flame. Job outputting from Roland VersaWorks Explain the following procedure for a job outputting from Roland VersaWorks. Printing Adding Media Profiles Explain the procedure of adding Media Profiles of third-party media.
Page 208 A feed-correction value set while printing is in progress is saved only as a setting on the machine. If you'd like to use the changed feed-correction value in the next printing, set the [Feed Calibration Control] to [Use Printer Settings] in Roland VersaWorks. Preset function All menu items listed below can be saved in Presets.
Page 209 Explain the following items in reference to the User's Manual [3-2. Using the Take-up System]. Loading Roll Media !! IMPORTANT !! Avoid following operations that pull the media with undue force. - Never operate the MANUAL switch when the loading lever is lowered. - Never use to feed the media in reverse.
Page 210 When not in use for a prolonged period Transporting the unit When transporting the unit, head cleaning is required and you need 8 unused cleaning cartridges for performing it. !! IMPORTANT !! Fill ink within one week after transporting. If the machine is left without ink, the nozzles on the heads may get clogged.
Page 211: Maintenance Check List
Good Sponge under Wipers or the time period from the last replacement. Replacement Done Replacement Cycle : 12 months Clean it manually using the Roland cleaning sticks and cleaning liquid. Cleaning Done Wiper Scraper Replace it if necessary. Replacement Done...
Page 212: Specification
RIP, User’s Manual, etc. The length of printing is subject to the limitations of the program. With Roland PET film, print travel: 1 m Temperature: 25 C (77 F), humidity: 50% Not assured when the print heater or dryer is used.
Page 213 Conditions for Usable Media Use genuine media from Roland DG Corp. Media width XJ-740: 210 to 1,879 mm (8.3 to 74 inches) XJ-640: 210 to 1,625 mm (8.3 to 64 inches) XJ-540: 210 to 1,371 mm (8.3 to 54 inches) Roll outer diameter ( A) Maximum 210 mm (8.3 inches)
Page 214 XJ-740 XJ-640 XJ-540...

This manual is also suitable for:

Soljet pro iii xj-640 Soljet pro iii xj-740

Roland SOLJET PRO III XJ-540 Service Notes

1 Structure & Spare Parts

2 Electrical Section

3 Replacement of Main Parts

4 Adjustment

5 Supplemental Information

6 Troubleshooting

7 Service Activities

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