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Roland VersaUV LEJ-640 Service Notes

Roland VersaUV LEJ-640 Service Notes

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SERVICE NOTES

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 LEJ-640.

3. REUSE

Authorized persons shall not disclose, transfer, rent or distribute this Service Note to, or allow this

Service Note to be used in any manner by, any third party other than authorized persons.

4. REPRODUCTION

Authorized persons shall not copy, change or alter this Service Note without permission of Roland

DG Corporation.

5. EFFECT OF VIOLATION

Regardless of circumstances, we will vigorously respond to any violation hereof, through legal action.

TERMS OF USE

Conﬁ dential

Copyright

2013 ROLAND DG CORPORATION

c

70158-14

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Summary of Contents for Roland VersaUV LEJ-640

Page 1 TERMS OF USE 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 LEJ-640.
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 SYATEM............................1-12 CAP SYSTEM ............................1-14 INK SYSTEM............................1-15 1-10 STAND & TU ............................1-17 1-11 TU CONTROLLER..........................
Page 3 Revision Record Revision Date Description of changes Approval Issured 2011.7.8 First Edition Hoshi Misako 4-15 MEDIA THICKNESS CHECKING SENSOR ADJUSTMENT has been 2011.7.25 Hoshi Umemoto revised. 2011.9.15 5-2 SENSOR MAP has been revised. Hoshi Misako 2011.10.6 1-3 HEAD CARRIAGE has been revised. Hoshi Misako 1-3 HEAD CARRIAGE parts...
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: Covers
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. Flammable: Ink and discharged ﬂ uid are ﬂ ammable. Keep away from open ﬂ ame. Ink Is Toxic: Ink and discharged ﬂ...
Page 6 1 Structure & Spare Parts 1-1 COVER 48 41 42 47...
Page 7 LABEL, CAUTION UV#LA1097 29 1000004160 LABEL, REFLECTION XC-540#LA1041 30 1000006358 LABEL,CAUTION LEC-330#LA1149 31 1000007128 LABEL,COVER CLOSE LEC-540#LA-1186 32 1000000953 LABEL,EMBLEM LOGO ROLAND 33 1000003489 LABEL,MARK ECO#LA1014 34 1000004914 LABEL,SET INK LEC-300#LA1071 35 1000004913 LABEL,USE UV LEC-300#LA1070 36 1000005297 LABEL,UV LED LEC-300#LA1099...
Page 8: Frame
1-2 FRAME...
Page 9 1-2 FRAME PARTS LIST -Main Parts- PARTS LIST -Supple77 Parts No. Parts Name Parts No. Parts Name 1000007809 APRON, F UNDER LEJ-640 S1 31329601AS CLAMP SET,INSULOK T-18S 100 PCS. 1000007812 APRON,B LEJ-640 S2 31329501AS CLAMP SET,PUSH MOUNT RT30SSF5 20P 1000006379 APRON,F AL RS-640 S3 31379101 CLAMP,FLAT CABLE FCS-50P...
Page 10 1-3 HEAD CARRIADGE *Cut the Tube to the following length Revised 10 when using. (mm) No.17 Ink Cartridge Circulating Pump 3490 3430 3430 3350 3310 3240 3270 3220 Revised 4 Revised 10 Revised 10 Revised 3 Revised 3 Revised 3 Revised 10 Revised 4 Revised 3...
Page 11 1-3 HEAD CARRIADGE PARTS LIST -Main Parts- Revised 10: Refer to the Service Information LEJ640-010 Parts No. Parts Name Parts No. Parts Name 1 1000007881 ADAPTER,BASE, CARRIAGE LEJ-640 68 1000007864 PLATE,DAMPER LEJ-640 2 1000007836 ADAPTER,CARRIAGE L LEJ-640 69 22055557 PLATE,ENC SENS FJ-540 3 21905166 ADAPTER,HEAD FJ-540 70 22055547...
Page 12: Drive Unit
1-4 DRIVE UNIT...
Page 13 1-4 DRIVE UNIT PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1 11879108 ABSORBER TK-3225 56 1000006377 SHIELD,UV PAD LEC-330 W701588430 ASSY,FAN JUNCTION LEJ-640 57 1000001051 SHUTTER,THERMISTOR AJ-1000 W701568230 ASSY,FAN JUNCTION BOARD LEC-540 58 22175157 SPRING,C P-ROLLER CM-500 W7003113B0...
Page 14: Chassis
1-5 CHASSIS...
Page 15 1-5 CHASSIS PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 13429701 AC INLET SUP-J15G-E 45 12399331 FILTER(E),FPC-31-12 W701588410 ASSY,AC JUNCTION LEJ-640 46 1000004672 FUSE,0154004DR W701568210 ASSY,AC JUNCTION BOARD LEC-540 47 1000002682 LABEL,LAN VP-540#LA964 W701588420 ASSY,DC JUNCTION LEJ-640 48 22535117 LABEL,POWER CM-500 NO.893 W701568220 ASSY,DC JUNCTION BOARD LEC-540...
Page 16: Pinchroller
1-6 PINCHROLLER PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name Revised 5 1 1000009316 ASSY,P-ROLLER LEJ-640_01 S1 31119108 PIN,PARALLEL 3*30 SUS H7 2 1000007819 CAM,PINCH LEJ-640 3 1000007821 FRAME,PINCH LEJ-640 4 1000007818 LEVER,PINCH LEJ-640 5 1000007820 SPRING,PINCH LEJ-640 * qt.
Page 17: Wipe Syatem
1-7 WIPE SYSTEM 1-12...
Page 18 1-7 WIPE SYSTEM PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 1000002870 ASSY,TUBING DRAIN 300MM XC-540 55 1000001024 STOPPER,G-SHAFT FP-740 2 1000007843 BASE,T-MOTOR LEJ-640 56 1000007841 TABLE,MAIN WIPE LEJ-640 3 1000001487 BASE,WIPER MOTOR XC-540 57 1000001484 TRAY,WIPE XC-540...
Page 19: Cap System
1-8 CAP SYSTEM PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 1000004546 ASSY,CAP-TOP 2 XC-540 28 22435106 MOTOR,103-593-1041 2 6700319010 ASSY,PUMP SUB XC-540 29 21575126 NUT,TABLE FJ-540 1000007135 ASSY,TUBING EPDM ID2-OD4 450MM (190 2 30 22055542 PLATE,NUT FJ-540 (3000000053) (TUBE,EPDM ID2-OD4 100M)
Page 20: Ink System
1-9 INK SYSTEM Revised 8 *Cut the Tube to the following length when using No.8 (2 FAI Tube) No.9 (3 FAI Tube) No.10 (3 FAI Tube) Ink Cartridge Y-Joint - 2 FAI Tube -Joint - Circulating Pum 1-15...
Page 21 1-9 INK SYSTEM PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1 1000006316 ADAPTER,JUNCTION VZY430 BK S1 31329601AS CLAMP SET,INSULOK T-18S 100 PCS. 2 11909133 ADAPTER,SCREW 2FAI FJ-50 S2 31289112AS CUPSCREW SET,M3*10 NI 100 PCS. 3 11909167 ADAPTER,SCREW 3FAI FJ-540 S3 31289109AS...
Page 22: Stand & Tu
1-10 STAND & TU 1-17...
Page 23 1-10 STAND & TU PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1 11879108 ABSORBER TK-3225 S1 31379111 CLAMP,CABLE CKS-13-H 2 1000002464 ARM,DANCER L XC-540 S2 31289105AS CUPSCREW SET, M3*6 3CBC 100 PCS 3 1000002463 ARM,DANCER R XC-540 S3 31289111AS...
Page 24: Tu Controller
1-11 TU CONTROLLER PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 6700311200 ASSY,TAKEUP BOARD XC-540 22 22035196 STAND,LEVER SP-300 2 1000001446 BASE,TU MOTOR XC-540 23 1000001467 STAY,DANCER SENS XC-540 3 12159563 BUSH,80F-1006 24 1000001468 STAY,TU BOARD XC-540 4 1000001352 BUSH,80F-1620 25 12399353...
Page 25: Accessories
1-12 ACCESSORIES 100/117V 230V 240VA 230V BR 240VE Service Parts for Rigit Media Skewing Revised 6 Revised 7 The parts are not included in the machine from the factory. 1-20...
Page 26 1-12 ACCESSORIES PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 23495124 AC CORD 3ASL100 240VA 10A SAA 49 1000003556 PAD,SHAFT SHEET XJ-740 2 13499111 AC CORD H05VV-F 240VE 10A S 50 1000008132 PAD,SHIELD UV LEJ-640 3 23495125 AC-CORD H05VV 230V 10A S 51 1000008134...
Page 27: Ru-640
1-13 RU-640 Revised 4 Revised 14 PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 11879127 ABSORBER,TK-2017 12 1000008737 STAY,TOP RU-640 2 1000008736 ASSY,LEG RU-640 13 1000008740 STAY,UNDER RU-640 1000008745 CASTER,BASE RU-640 14 1000008741 STAY,WING L RU-640 1000009342 CASTER,BASE ADJUST RU-640 Revised 6 15 1000008742 STAY,WING S RU-640...
Page 28: Mb-640
1-14 MB-640 Revised 4 Revised 14 PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1000008712 ASSY,CASTER BASE MB-640 22 1000008734 SCREW,CAP M5*16 3CBC Revised 6 1000009343 CASTER,BASE ADJUST MB-640 23 1000008733 SCREW,FLAT M4*6 NI 2 1000008706 ASSY,FRONT PINCH LEVER MB-640 24 1000008732 SCREW,PAN M3*8 NI 3 1000008705 ASSY,SHAFT SHEET LOWER SET MB-640...
Page 29: Electrical Section
2 Electrical Section 2-1 WIRING MAP...
Page 30 CABLE LIST Parts No. Parts Name Parts No. Parts Name 1000001668 CABLE-ASSY,POWER-AC-L XC-540 1000005750 CABLE-ASSY,P-SIDE SENS FB-740 1000001669 CABLE-ASSY,POWER-AC-N XC-540 42 1000007801 CABLE-ASSY,I/S MTR JUNC LEJ-640 1000000574 CABLE-ASSY GND AJ-1000 44 1000007799 CABLE-ASSY,CAR U/D SENS LEJ-640 1000004055 CABLE-ASSY,POWER-OP.DRYER DU-740 45 1000008077 CABLE-ASSY,F-COVER SW LEJ-640 1000001671 CABLE-ASSY,POWER-AC-DC XC-540...
Page 31: Main Board
2-2 MAIN BOARD MAIN BOARD_Arrangement Diagram(Component Side) DIP SW Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7 Bit 8 It indicates the version of the Board. LEJ-640 LEC-300/330/540 XC-540 XJ-540/640/740...
Page 32 MAIN BOARD_Arrangement Diagram (Soldering Side)
Page 33 MAIN BOARD_Circuit Diagram 1/9...
Page 34 MAIN BOARD_Circuit Diagram 2/9...
Page 35 MAIN BOARD_Circuit Diagram 3/9...
Page 36 MAIN BOARD_Circuit Diagram 4/9...
Page 37 MAIN BOARD_Circuit Diagram 5/9...
Page 38 MAIN BOARD_Circuit Diagram 6/9 2-10...
Page 39 MAIN BOARD_Circuit Diagram 7/9 2-11...
Page 40 MAIN BOARD_Circuit Diagram 8/9 2-12...
Page 41 MAIN BOARD_Circuit Diagram 9/9 2-13...
Page 42: Head Board
2-3 HEAD BOARD HEAD BOARD_Arrangement Diagram (Component Side) It indicates the version of the Board. 2-14...
Page 43 HEAD BOARD_Arrangement Diagram (Soldering Side) 2-15...
Page 44 HEAD BOARD_Circuit Diagram 1/9 2-16...
Page 45 HEAD BOARD_Circuit Diagram 2/9 2-17...
Page 46 HEAD BOARD_Circuit Diagram 3/9 2-18...
Page 47 HEAD BOARD_Circuit Diagram 4/9 2-19...
Page 48 HEAD BOARD_Circuit Diagram 5/9 2-20...
Page 49 HEAD BOARD_Circuit Diagram 6/9 2-21...
Page 50 HEAD BOARD_Circuit Diagram 7/9 2-22...
Page 51 HEAD BOARD_Circuit Diagram 8/9 2-23...
Page 52 HEAD BOARD_Circuit Diagram 9/9 2-24...
Page 53: Servo Board
2-4 SERVO BOARD SERVO BOARD_Arrangement Diagram (Component Side) It indicates the version of the Board. 2-25...
Page 54 SERVO BOARD_Arrangement Diagram (Soldering Side) 2-26...
Page 55 SERVO BOARD_Circuit Diagram 1/4 EXBA10E103J EXBA10E103J 2-27...
Page 56 SERVO BOARD_Circuit Diagram 2/4 R185 R186 R187 2-28...
Page 57 SERVO BOARD_Circuit Diagram 3/4 2-29...
Page 58 SERVO BOARD_Circuit Diagram 4/4 2-30...
Page 59: Sub Board
2-5 SUB BOARD SUB BOARD A_Arrangement Diagram (Component Side) It indicates the version of the Board. 2-31...
Page 60 SUB BOARD A_Circuit Diagram 1/3 2-32...
Page 61 SUB BOARD A_Circuit Diagram 2/3 AC JUNCTION BOARD CN13 CAP-SCREW1100 HEATSINK1100 from AC Switch NoMount NoMount (CAP-SCREW,3*6 3CBC) (AQ1801) CAP-SCREW1101 B2(4-2 3)P-VH SSR1000 NoMount RELAY,SSR AQ1208 CN14 (CAP-SCREW,3*6 3CBC) to ZWS30PAF-5/JRDG C1002 NoMount (CE0.1u) B2P3-VH R1000 C1000 C1001 CN1001 10u_16V CE0.1u CN1000 from UV JUNCTION...
Page 62 SUB BOARD A_Circuit Diagram 3/3 2-34...
Page 63 SUB BOARD B_ Arrangement Diagram (Component Side) 2-35...
Page 64 SUB BOARD B_Circuit Diagram 1/6 2-36...
Page 65 SUB BOARD B_Circuit Diagram 2/6 2-37...
Page 66 SUB BOARD B_Circuit Diagram 3/6 to PRINT CARRIAGE BOARD 2-38...
Page 67 SUB BOARD B_Circuit Diagram 4/6 from STEP DRIVE BOARD to PRINT CARRIAGE BOARD to PRINT CARRIAGE BOARD 2-39...
Page 68 SUB BOARD B_Circuit Diagram 5/6 from SERVO BOARD from SSERVO BOARD 2-40...
Page 69 SUB BOARD B_Circuit Diagram 6/6 to UV JUNCTION BOARD to MOTSENS JUNCTION BOARD to UV JUNCTION BOARD from SERVO BOARD 2-41...
Page 70: Ink System Board
2-6 INK SYSTEM BOARD INK SYSTEM_Arrangement Diagram (Component Side) 2-42...
Page 71 INK SYSTEM BOARD_Circuit Diagram 2-43...
Page 72: Takeup Board
2-7 TAKEUP BOARD TAKEUP BOARD_Arrangement Diagram (Component Side) It indicates the version of the Board. 2-44...
Page 73 TAKEUP BOARD _Circuit Diagram 2-45...
Page 74: Maintenance Parts List
2-8 MAINTENANCE PARTS LIST_Electrical Parts SERVO BOARD Parts No Parts Name Description Function 15119122 TR,FET 2SJ535 MOTOR POWER SUPPLY HEAD BOARD Parts No Parts Name Description Function 15129121 TR, 2SA1746 OY TR6,TR8 TRANSISTOR for HEAD DRIVER(CYAN) 15129122 TR, 2SC4131 GB TR5,TR7 15129121 TR, 2SA1746 OY...
Page 75: Replacement Of Main Parts
3 Replacement of Main Parts To Ensure safe Work Turn off the Sub Power SW, Main Power SW, and unplug the power cable of the Printer and deodorization equipment before performing parts replacement. Performing the parts replacement while the power is turned on may result in injury by unintended operation of the machine.
Page 76 The necessary adjustments after the replacement of each part, and the referential time for each work are described as follows. HEAD REPLACEMENT : 25min. ( 1 Head ) 1. THERMISTER CHECK It can be checked in the SERVICE MENU > THERMISTOR CHK. 2.
Page 77 HEAD BOARD REPLACEMENT : 10min. 1. THERMISTOR CHECK It can be checked in the SERVICE MENU > THERMISTOR CHK. 2. HEAD UP/DOWN SENSOR CHECK It can be performed in the SERVICE MENU > SENSOR CHECK. 3. FAN ON THE HEAD BOARD CHECK It can be checked whether the fan connected to the Head Board work correctly when turning on the power sw.
Page 78: Head Replacement
3-1 HEAD REPLACEMENT Finish the replacement within 20 minutes to prevent the CLEANING ink from hardening. When 20 minutes passes, perform the Medium Cleaning for all the heads. CLEANING MEDIUM MEDIUM Always use the UV protection sheet during this replacement, or ink will harden and clog inside the ink line. UV protection sheet Parts NO.: 1000005829 Parts Name : TOOL,VINYL YE UV RESISTANT ST-113...
Page 79 Turn on the Sub Power SW while pressing the Left, Right and Down keys to enter the Service Mode. MENU MENU SERVICE MENU Select [PRINT MENU] > [HEAD RANK], and select the head HEAD RANK SERVICE MENU number of the Head that you are going to replace and input PRINT MENU 5CY2F2F the Head Rank written on the new head.
Page 80 Select [I/S MENU] > [I/S CONTROL] > [CAP] > [OPEN], and SERVICE MENU press the [ENTER] key. The Capping Unit moves down and I/S MENU 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 <...
Page 81 Pull the Head Shield to the front and remove it. Head Shield Fix the Head Board Cover temporarily, and remove the 2 Ink Dampers from the Head that will be replaced. Be sure to remove and ﬁ x the Ink Damper with the Head Board Cover fixed.
Page 82 When you replace the screws ﬁ xing [HEAD 5], use any of a No.1 bit which length from 200mm to 300mm or [TOOL,BIT CROSS NO1 V17 7X207L ST-121] Place the driver to the cutout of the Motor Stay as shown in the ﬁ gure. Remove the Head from the Head Adapter and fix the new Head to the Head Adapter.
Page 83 Connect the 2 ﬂ exible cables to the Head Board. And ﬁ x the Head Board Cover. Head Board Cover Be careful not to connect the wrong ﬂ exible cable. Flexible Cable Fix the Ink Dampers to the Head. Ink Damper Be sure to remove and ﬁ...
Page 84 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 slotted hole. 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.
Page 85 < HOW TO CLEAR THE HEAD INFORMATION > SERVICE MENU HISTORY MENU After THERMISTOR CHECK and HEAD ALIGNMENT, clear the HEAD INFORMATION from [SERVICE MENU] > HEAD GROUP HISTORY MENU [HISTORY MENU] > [HEAD GROUP]. Select the Head that you HEAD GROUP CLEAR ALL replaced and press the [ENTER] key.
Page 86: Wiper Replacement
3-2 WIPER REPLACEMENT Always use the UV protection sheet during this replacement, or ink will harden and clog inside the ink line. UV protection sheet Parts NO.: 1000005829 Parts Name : TOOL,VINYL YE UV RESISTANT ST-113 Select [SUB MENU] > [MAINTENANCE] > [REPLACE WIPER] in the User's Menu, and press the [ENTER] key.
Page 87 Using tweezers, grasp the bottom part of the Wiper and take it off the hook. Clean the Wiper Carriage and Scraper using the Cleaning stick if they need to be cleaned. Scraper Wiper Carriage Remove the Wiper and install the new one. Fix the wiper so that the rubber side faces the front.
Page 88: Cap Top Replacement
3-3 CAP TOP REPLACEMENT Finish the replacement within 20 minutes to prevent the ink from hardening. When 20 minutes passes, CLEANING perform the Medium Cleaning. CLEANING MEDIUM MEDIUM Always use the UV protection sheet during this replacement, or ink will harden and clog inside the ink line. UV protection sheet Parts NO.: 1000005829 Parts Name : TOOL,VINYL YE UV RESISTANT ST-113...
Page 89 Remove the I/S Cover. Screw I/S Cover Screw Hook 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], and SERVICE MENU press the [ENTER] key.
Page 90 Remove the 5 screws as shown in the ﬁ gure to remove the Pump Cover together with the Right Inner Plate. Pump Cover　　　 Inner Plate Select [I/S MENU] > [I/S CONTROL] > [CAP] > [CLOSE], and press the [ENTER] key. The Capping Unit moves up. Press the [ENTER] key 3 times.
Page 91 Unhook the Cap Frame by holding it with the other hand, and Cap Frame 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. Hook Remove the Cap Top together with the tube.
Page 92 Connect the tube of the Cap Top to the joint part of the Pump. And then, replace other Cap Tops in the same way. You can connect either tube to the either joint part. Fix the tubes ﬁ rmly. Turn on the Main Power SW, then turn on the Sub Power SW while pressing the Left, Right and Down keys to enter the Service Mode.
Page 93 Select [I/S MENU] > [I/S CONTROL] > [CAP] > [CLOSE], and press the [ENTER] key to move the Capping Unit up 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 94: Head U/D Motor Replacement
3-4 HEAD U/D MOTOR REPLACEMENT Finish the replacement within 20 minutes to prevent the ink from hardening. When 20 minutes passes, CLEANING perform the Medium Cleaning. CLEANING MEDIUM MEDIUM Always use the UV protection sheet during this replacement, or ink will harden and clog inside the ink line. UV protection sheet Parts NO.: 1000005829 Parts Name : TOOL,VINYL YE UV RESISTANT ST-113...
Page 95 Remove the I/S Cover and Right Top Cover. Right Top Cover Screw I/S Cover Screw Hook 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], and SERVICE MENU press the [ENTER] key.
Page 96 Remove the 2 screws to remove the Carriage Cover. Carriage Cover The screws for ﬁ xing the Carriage Cover are the screw with washer. Loosen the 2 screws ﬁ xing the Motor Stay. Screw Remove the spring. Spring Remove the belt. Belt 3-22...
Page 97 Open the Saddle and disconnect the connector of the motor cable. Connector Saddle Remove the 2 screws loosened in step 6 to remove the motor together with the stay. Be sure that the motor do not hit against Ink Tube and Flexible Cable.
Page 98 Connect the connector of the motor cable and bundle it by the Wire Saddle. Connector Wire Saddle Replace the belt as shown in the ﬁ gure. Belt Hook up the spring. Spring Tighten up the screws as shown in the ﬁ gure to ﬁ x the Motor Stay.
Page 99 Fix the Carriage Cover temporarily with the 2 screws as shown in the ﬁ gure. And tighten them without distorting the Carriage Cover Cover. Hook Be careful not to distort the Carriage Cover. The Carriage can be distorted and it may cause the head position problem.
Page 100 Move the Head Carriage by hand to the capping position. Select [I/S MENU] > [HEAD U/D CHECK] and press the [ENTER] key to check the sensors of HEAD (UP/DOWN). SERVICE MENU I/S MENU I/S MENU HEAD U/D CHECK HEAD U/D CHECK COMPLETED!! Select [I/S MENU] >...
Page 101: Carriage Motor Replacement
3-5 CARRIAGE MOTOR REPLACEMENT Finish the replacement within 20 minutes to prevent the ink from hardening. When 20 minutes passes, CLEANING perform the Medium Cleaning. CLEANING MEDIUM MEDIUM Always use the UV protection sheet during this replacement, or ink will harden and clog inside the ink line. UV protection sheet Parts NO.: 1000005829 Parts Name : TOOL,VINYL YE UV RESISTANT ST-113...
Page 102 Remove the I/S Cover. Screw I/S Cover Screw Hook 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], and SERVICE MENU press the [ENTER] key.
Page 103 Remove the Right Inner Plate and Panel Cover. Panel Cover Right Inner Plate Remove the panel and put it on the Right Top Cover. Flexible Cable is connected to the Panel Board. Do not disconnect the Flexible Cable. Panel Panel Board Right Top Cover Remove the spring.
Page 104 Disconnect the connector of the motor cable. Connector Remove the 4 screws ﬁ xing the Flange to remove the Motor together with the Flange. Flange Remove the 4 screws to remove the Motor from the Flange. Fix the Motor Cable of a new Motor using a cable tie without bending the cable root, and then fix the new Motor to the Flange Flange.
Page 105 Fix the spring. Spring Turn the Drive Gear at least 1 revolution by moving the Head Carriage left and right to check if the gears mesh to- Motor Gear gether. Drive Gear < Top View > Tighten up the screws to ﬁ x the Flange in the order as shown Flange in the ﬁ...
Page 106 Apply a proper quantity of grease (P/# : 21675102 GREASE, Drive Gear FLOIL GE-676 BLACK 10ML) between Drive Gear and Motor Gear. < Top view > Connect the connector of the motor cable. Connector Fix the panel. Panel 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 107 In [MOTOR MENU] > [SERVO LOCK] menu, select [S]. Move the Head Carriage left and right by hand and make SERVICE MENU sure the value on the LCD changes depending on the Head MOTOR MENU position. MOTOR MENU SERVO LOCK SERVO LOCK Press the [ENTER] key to electrify the Motor.
Page 108: Pump Replacement
3-6 PUMP REPLACEMENT Finish the replacement within 20 minutes to prevent the ink from hardening. When 20 minutes passes, per- CLEANING form the Medium Cleaning. CLEANING MEDIUM MEDIUM Always use the UV protection sheet during this replacement, or ink will harden and clog inside the ink line. UV protection sheet Parts NO.: 1000005829 Parts Name : TOOL,VINYL YE UV RESISTANT ST-113...
Page 109 Remove the I/S Cover. Screw I/S Cover Screw Hook 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], and SERVICE MENU press the [ENTER] key.
Page 110 Turn off the Sub Power SW, and then turn off the Main Power < Rear side > Main Power SW Sub Power SW 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 111 Remove the 2 screws as shown in the ﬁ gure to remove the Pump Unit. Remove the 3 screws shown in the ﬁ gure to remove the Mo- tor 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 ﬁ...
Page 112 Connect the connector of the Pump Motor. Connector Move the Head Carriage to the capping position by hand. 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 113 Clear the pump rotation times. Go back to the Service Menu, and select [HISTORY MENU] SERVICE MENU > [MOTOR GROUP]. And then, select the pump you re- HITORY MENU placed. Select [CLEAR] and press the [ENTER] key. HITORY MENU MOTOR GROUP MOTOR HOURS F 3 hours PUMP TIMES A...
Page 114: Circulating Pump Replacement
3-7 CIRCULATING PUMP REPLACEMENT Finish the replacement within 20 minutes. If 20 minutes passes, perform the Medium Cleaning for all heads. CLEANING Because the light that slightly entered can harden ink. CLEANING MEDIUM MEDIUM While in service mode, the menu which involves a motion of Head UP/DOWN holds and keeps the head carriage at the very top position, where the menu does not proceed any further.
Page 115 Remove the Cartridge Cover. Cartridge Cover < Rear side > Disconnect the connector of the Circulating Pump Motor. < Inside the Cartridge Cover > Disconnect the tubes from the Circulating Pumps. < Inside the Cartridge Cover / From front view> Remove the 2 screws as shown in the ﬁ...
Page 116 Remove the 4 screws shown in the figure to remove the Pump Unit Stay. Pump Unit Stay Separate the 2 pumps. Replace with the new pump. Bearing < Procedure for pump with the motor > Remove the setscrew as shown in the ﬁ gure to remove the Setscrew gear and bearing from the Shaft.
Page 117 Set the bearing and gear to the Shaft. Bearing Shaft Gear Be careful with the ﬁ xing direction of the bearing and gear. Fix the setscrew at the D-cut part by pushing the gear against the bearing. Setscrew Setscrew Gear Gear Bearing D-cut part...
Page 118 Fix the Pump Unit Stay with the 4 screws as shown in the ﬁ g- ure. Pump Unit Stay Connect the tubes of the Ink Cartridge and the tubes of the Cableveyor to the pumps. Connect the tubes ﬁ rmly. <...
Page 119 Connect the connector of the Circulating Pump Motor. < Inside the Cartridge 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. MENU MENU SERVICE MENU...
Page 120: Ink Tube Replacement
3-8 INK TUBE REPLACEMENT Finish this replacement in the shortest possible time. Always use the UV protection sheet during this replacement, or ink will harden and clog inside the ink line. UV protection sheet Parts NO.: 1000005829 Parts Name : TOOL,VINYL YE UV RESISTANT ST-113 While in service mode, the menu which involves a motion of Head UP/DOWN holds and keeps the head carriage at the very top position, where the menu does not proceed any further.
Page 121 Turn on the Sub power SW while pressing the Left, Right and Down keys to enter the Service Mode. MENU MENU SERVICE MENU Select [SERVICE MENU] > [SUB MENU] > [HEAD WASH], and select the group of the target tube. SERVICE MENU SUB MENU [ ] [ ]...
Page 122 Remove the 2 screws as shown in the ﬁ gure to remove the Carriage Cover. Carriage Cover Carriage Board Cover Remove the Carriage Board Cover. Remove the Carriage Board Cover by pushing the part indicated by the arrows because the top part of the support is easy to break.
Page 123 Disconnect the Ink Tube from the Y tube joint (Head side), Y Tube Joint and put the scotch tape at the tip of the Ink Tubes to prevent the ink from coming out. It is not necessary to replace between the Y tube joint and the Damper.
Page 124 Pull the Ink Tube for Ink Cartridge from the Y tube joint. You don't need to pull the Ink tube connected to circulating pump. Circulating Pump Y tube joint Ink Cartridge <Rear side> <OK> Secure the tips of the new Ink Tube and the current Ink Tube Secure tubes with tape Current Ink Tube with tape ﬁ...
Page 125 Connect the new Ink Tube to the Ink Cartridge. <Rear side> 1 2 3 Connect the Ink Tube to Tube Adapters for Ink Cartridge as follows. Ink Tube O-ring Ink Cartridge Tube Adapter New Ink Tube Pass nut and O-ring which is removed in step 11 Connect the new Ink Tube to the Tube Adapter.
Page 126 Connect the Ink Tube to the Y tube joint (Head side). Y Tube Joint Connect the Ink Tube to the joint so that they do not bend. Connect the 6 Flexible Cables to the Carriage Board and ﬁ x Filters Flexible Cables Nylon Rivet the Nylon Rivets to ﬁ...
Page 127 Cable Guides are ﬁ xed next to the Tube Guides. Cable Guide Tube Guide < Rear view > 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] >...
Page 128: Boards Replacement
3-9 BOARDS REPLACEMENT (Head / Servo / Main / SW Power Supply) BOARD LAYOUT (IN CHASSIS) 1. When the Board Cover is opened TU Junction Board UV Junction Board Servo Board Main Board Head Board Step Drive Board Board Stay 2.
Page 129 Finish the replacement within 20 minutes. If 20 minutes pass- es, perform the Medium Cleaning for all heads. Because the CLEANING light that slightly entered can harden ink. CLEANING MEDIUM MEDIUM Turn off the Main Power SW and pull out the power cord. <...
Page 130 HEAD BOARD REPLACEMENT HEAD BOARD CONNECTOR LAYOUT CN13 CN11 CN1~7 Disconnect all the Cables from the Head Board. Remove the screws as shown in the ﬁ gure to replace to the new Head Board. 3-56...
Page 131 Connect all the Cables to the Head Board. Perform the following checks. 1. THERMISTOR CHECK It can be performed in the SERVICE MENU > THERMISTOR CHK. 2. FAN ON THE HEAD BOARD It can be checked whether the fan connected to the Head Board work correctly when turning on the power 3-57...
Page 132 SERVO BOARD REPLACEMENT SERVO BOARD CONNECTOR LAYOUT CN16 CN17 CN18 CN15 CN12 CN11 CN10 CN1,2 Disconnect all the Cables from the Servo Board. Remove the screws as shown in the ﬁ gure to replace with the new Servo Board. 3-58...
Page 133 Connect all the cables to the Servo Board. Perform the following adjustments and settings. 1. PINCH ROLLER SENSOR CHECK It can be checked in the SERVICE MENU > SENSOR CHECK. 2. AGING It can be checked in the SERVICE MENU > MOTOR MENU > AGING. 3-59...
Page 134 MAIN BOARD REPLACEMENT MAIN BOARD CONNECTOR LAYOUT CN11 CN10 Turn on the Main Power SW. Main Power SW < Rear view > Start Peck. 3-60...
Page 135 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, Servo Board and Head Board. Switch the DIP SW No.2 to ON on the new Main Board.
Page 136 Remove the screws as shown in the ﬁ gure ﬁ xing the head Board and Main Board, and replace with the new Main Board. Head Board Main Board Connect all the cables to the Main Board. Perform the following operations after replacement. 1.
Page 137 Perform the following operations if it is not possible to transfer the parameters by Peck.exe. 1. BATTERY INSTALLATION Fix the battery in reference to step 3 and 4 in [3-9 BATTERY REPLACEMENT]. 2. FIRMWARE INSTALLATION Refer to [4-2 HOW TO UPGRADE/INSTALL FIRMWARE] 3.
Page 138 SW POWER SUPPLY REPLACEMENT (41V) SW POWER SUPPLY CONNECTOR LAYOUT Connected to [CN1002] on the Energy Board Connected to [CN34] on the DC Junction Board Necessary special tool Be careful not to fix the wrong voltage 1000007423 of the SW board. It can damage the UV CABLE-ASSY,JIG POWER LEC-540 ST-119 Lamp or board.
Page 139 Disconnect all the cables connected to the SW Power Sup- ply. Remove the 4 screws as shown in the ﬁ gure and replace with the new SW Power Supply (41V). Connect all the Cables. Disconnect 4 connectors as shown in the ﬁ gure from the DC Junction Board.
Page 140 Disconnect the connector of the CN1001 on the AC Junction Board and CN2 on the SW supply (5V), and connect them with the special tool cable. Special Tool Cable Special tool cable CN1001 1000007423 CABLE-ASSY,JIGU POWER LEC-540 AC Junction Board SW Power Supply (5V) Turn on the main power SW.
Page 141 Turn off the main power SW. < Rear side > Main power Connect the connector of CN204 on the DC Junction Board. CN204 DC Junction Board Turn on the main power SW. < Rear side > Main Power Put the black probe into CN204-8pin on the DC Junction Board and the red probe into CN204-7pin to conﬁ...
Page 142 Turn off the main power SW. < Rear side > Main power Disconnect the special tool cable. And connect the connector of the CN1001 on the AC Junc- tion Board and CN2 on the SW supply (5V). Special tool cable CN1001 AC Junction Board SW Power supply (5V)
Page 143 SW POWER SUPPLY REPLACEMENT (27V) SW POWER SUPPLY CONNECTOR LAYOUT Connected to the [CN202] on the DC Junction Board Connected to the [CN1101] on the AC Junction Board Connected to the [CN201] on the DC Junction Board Connected to the [CN1100] on the AC Junction Board Necessary special tool Be careful not to fix the wrong voltage...
Page 144 Disconnect the Cables from the following boards and remove the boards together TU Junction Board with the Stays. Step Drive Board Servo Board Step Drive Main Board Board UV Junction Head Board Board UV Junction Board TU Junction Board Main Board Head Board Servo Board Disconnect all the cables which are connected to the SW...
Page 145 Disconnect 4 connectors as shown in the ﬁ gure from the DC Junction Board. CN204 CN42 Do not connect the disconnected cables until setting and checking of the output voltage is completed. UV DC Junction Board lamp or board may be broken. CN36 CN37 Disconnect the connector of the CN1001 on the AC Junction...
Page 146 Rotate the volume clockwise using the screwdriver to adjust the output voltage value to +27V+0.1. When the output voltage exceeds the +27.6V, SW Power Supply does not output the voltage by the protection circuit on it. In this case, SW Power Supply will output the volt- Volume age by rotating the volume counterclockwise.
Page 147 Put the black probe into CN204-8pin on the DC Junction Board and the red probe into CN204-2pin (for SW supply Probe 27V(A)) or CN204-4pin (for SW supply 27V(B)) to confirm that output voltage value is +27V+0.1. 8 pin 2 pin SW supply 27V (A) Probe SW supply 27V (B)
Page 148 Connect 3 connectors on the DC Junction Board. CN42 DC Junction Board CN36 CN37 Fix the following boards. Connect all the cables. TU Junction Board Step Drive Board Servo Board Main Board Step Drive Head Board Board UV Junction Board UV Junction Board TU Junction Board Main Board...
Page 149 SW POWER SUPPLY REPLACEMENT (5V) SW POWER SUPPLY CONNECTOR LAYOUT Connected to the [CN203] on the DC Junction Board Connected to the [CN14] on the AC Junction Board Remove the Right Top Cover. Right Top Cover < Rear side > Disconnect the Cables from the following boards and remove the boards together TU Junction Board...
Page 150 Disconnect all the cables which are connected to the SW Power Supply. Remove the 4 screws as shown in the ﬁ gure and replace the new SW Power Supply (5V). Connect all the Cables. Fix the following boards. Connect all the cables. TU Junction Board Step Drive Board Servo Board...
Page 151: Battery Replacement
3-10 BATTERY REPLACEMENT Do not recharge, short-circuit, disassembly the lithium battery, nor put it into ﬁ re. It may cause heat, explosion and ﬁ re. Put tape around the lithium battery for insulation for disposal or preservation. It may cause heat, explosion and ﬁ re. Turn off the Sub Power SW, and then turn off the Main Power <...
Page 152 Remove the Battery on the Main Board by pushing it down and tilting towards right. Socket Main Board Replace the Battery with 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 153 Select [SUB MENU] > [CLOCK] > [DATE], and set the date SERVICE MENU SUB MENU and press the [ENTER] key. SUB MENU CLOCK CLOCK DATE DATE 00/00/00 DATE 09/01/13 ENTER Turn off the Sub Power SW, and then turn off the Main Power <...
Page 154: Carriage Belt Replacement
3-11 CARRIAGE BELT REPLACEMENT Finish the replacement within 20 minutes to prevent the ink from hardening. When 20 minutes passes, per- CLEANING form the Medium Cleaning. CLEANING MEDIUM MEDIUM Always use the UV protection sheet during this replacement, or ink will harden and clog inside the ink line. UV protection sheet Parts NO.: 1000005829 Parts Name : TOOL,VINYL YE UV RESISTANT ST-113...
Page 155 Turn off the Main Power SW. Main Power SW < Rear view > Remove the following covers. Top Cover I/S Cover Front Cover Front Rail Cover Right Top Cover Panel Cover Right Top Cover Top Cover Left Side Cover Front Rail Cover I/S Cover Left Side Cover Front Cover...
Page 156 Turn off the Sub Power SW, and then turn off the Main Power < Rear side > Main Power SW Sub Power SW Remove the 2 screws to remove the Carriage Cover. Carriage Cover The screws for ﬁ xing the Carriage Cover are the screw with washer.
Page 157 Change the Head U/D Height by moving the Head U/D Belt by hand so that the screws shown in the ﬁ gure can be accessed. Head U/D Belt Screw Remove the 2 screws fixing the Belt Holder to the Head Carriage.
Page 158 Loosen the 4 screws to remove the Carriage Belt. Do not scratch the Encoder Scale when removing the carriage Belt. If the grease of the Belt adheres to the Encoder Scale, it can be a cause of defective printing. Replace with the new Carriage Belt. Check that the Belt is not twisted.
Page 159 Move the Belt Holder by hand to the position of the screw hole which is for ﬁ xing with the carriage. Fix the Belt Holder to the Head Carriage with the screws. Use the new locked screws. Fix the Ink Dampers to the head 3 and 4. Tighten the Adjustment Screw to have tension on the Belt.
Page 160 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 [I/S MENU] > [I/S CONTROL] > [CAP] > [CLOSE], and press the [ENTER] key to move the Capping Unit up 1 step.
Page 161: Encoder Scale Replacement
3-12 ENCODER SCALE REPLACEMENT Finish the replacement within 20 minutes to prevent the ink from hardening. When 20 minutes passes, per- CLEANING form the Medium Cleaning. CLEANING MEDIUM MEDIUM Always use the UV protection sheet during this replacement, or ink will harden and clog inside the ink line. UV protection sheet Parts NO.: 1000005829 Parts Name : TOOL,VINYL YE UV RESISTANT ST-113...
Page 162 Remove the following covers. I/S Cover Front Rail Cover Front Rail Cover Front Cover I/S Cover Front Cover Turn on the Sub Power while pressing the Left, Right and Down keys to enter the Service Mode. MENU MENU SERVICE MENU Select [I/S MENU] >...
Page 163 Remove the Encoder Scale by removing the Plate ﬁ xing the Encoder Scale Spring Plate Encoder Scale at its right end and the Spring on its left end. Remove the Spring Plate from the Encoder Scale and ﬁ x it to Spring Plate the Encoder Scale where there is no black dot written on it.
Page 164: Pinch Roller Replacement
3-13 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 Pinch Roller ﬁ rmly at the 3 points and the hook. 3-90...
Page 165: Uv Lamp Replacement
3-14 UV LAMP REPLACEMENT Finish the replacement within 20 minutes to prevent the ink from hardening. When 20 minutes passes, per- CLEANING form the Medium Cleaning. CLEANING MEDIUM MEDIUM Always use the UV protection sheet during this replacement, or ink will harden and clog inside the ink line. UV protection sheet Parts NO.: 1000005829 Parts Name : TOOL,VINYL YE UV RESISTANT ST-113...
Page 166 Remove the following covers. I/S Cover Front Rail Cover Right Top Cover Right Top Cover Front Rail Cover I/S Cover Turn on the Sub Power while pressing the Left, Right and Down keys to enter the Service mode. MENU MENU SERVICE MENU Select [I/S MENU] >...
Page 167 < Right UV Lamp > Move the Head Carriage slowly leftwards so that it is not above the Capping Unit. Disconnect the cables. Cable Remove the 2 screws for removing the UV Lamp together with the plate from the Head Carriage. Hold the UV Lamp by hand when removing it.
Page 168 Fix the UV Lamp together with the plate to the Head Car- riage. Hook the UV Lamp to the tab of the stay when ﬁ xing it to the Head Carriage. Carriage Cover Connect the cable. Cable Wrap the cable around the Wire Saddle. Move the Head Carriage to the right edge of the bed.
Page 169 < Left UV Lamp > Disconnect the Motor Cable and Sensor Cable from the Car- riage Board. Release the cables from the Wire Saddles. Motor Cable Sensor Cable Carriage Board Remove the Cable Cover. Cable Cover Remove the Push Mount shown in the ﬁ gure with pliers. Push Mount The Push Mount will be reused.
Page 170 Remove the 2 screws for removing the UV Lamp together Slider with the slider from the Head Carriage. Hold the UV Lamp by hand when removing it. Remove the Slider Cover. Slider Cover Loosen the 2 screws as shown in the ﬁ gure. Remove the spring.
Page 171 Remove the Shaft Holder and Shaft. Shaft Shaft Holder Remove the belt from the pulley, and remove the UV lamp together with the plate from the frame. Plate Frame Pulley Belt Remove the plate. And ﬁ x the new UV Lamp to the plate in the order as shown Plate in the ﬁ...
Page 172 Set the Shaft Holder to the frame, and set the shaft to the Frame Shaft Holder Shaft Holder. Shaft Fix the Shaft Holder to the frame. Shaft Holder Fix the spring in the order as shown in the ﬁ gure. Spring Tighten up the screws of the stay.
Page 173 Fix the Slider Cover. Slider Cover Fix the UV lamp together with the slider. Hook the UV Lamp to the tab of the stay and push it the upwards when ﬁ xing it to the Head Carriage. Fix the PushiMount and connect the UV Lamp Cable. Push Mount Cable 3-99...
Page 174 Fix the Push Mount removed at the step 14 . Push Mount Fix the Cable Cover. Cable Cover Connect the Motor Cable and Sensor Cable to the Carriage Board. Slide the UV Lamp to the front and bundle the cables with the Wire Saddles. Motor Cable Sensor Cable Carriage Board...
Page 175 Turn on the Sub Power while pressing the Left, Right and Down keys to enter the Service mode. MENU MENU SERVICE MENU Select [I/S MENU] > [I/S CONTROL] > [HEAD UP/DOWN] SERVICE MENU > [MIDDLE], and press the [ENTER] key. The Capping Unit I/S MENU moves down and the Head Carriage moves to the Middle po- sition.
Page 176: Uv Lamp Motor Replacement
3-15 UV LAMP MOTOR REPLACEMENT Finish the replacement within 20 minutes to prevent the ink from hardening. When 20 minutes passes, per- CLEANING form the Medium Cleaning. CLEANING MEDIUM MEDIUM Always use the UV protection sheet during this replacement, or ink will harden and clog inside the ink line. UV protection sheet Parts NO.: 1000005829 Parts Name : TOOL,VINYL YE UV RESISTANT ST-113...
Page 177 Remove the following covers. I/S Cover Front Rail Cover Right Top Cover Right Top Cover Front Rail Cover I/S Cover Front Cover Shield Front Cover Shield Turn on the Sub Power while pressing the Left, Right and Down keys to enter the Service mode. MENU MENU SERVICE MENU...
Page 178 Disconnect the UV Lamp Cable, Motor Cable and Sensor Cable from the Carriage Board. Release the cables from the Wire Saddles. Motor Cable Sensor Cable UV Lamp Cable Carriage Board Remove the 2 screws for removing the UV Lamp together Slider with the slider from the Head Carriage.
Page 179 Connect the connector of the Motor Cable. Turn the pulley at least 1 revolution by moving the UV lamp left and right to conﬁ rm the gears mesh without the backlash. Motor Gear Pulley Fix the UV lamp together with the slider. Hook the UV Lamp to the tab of the stay and push it the upwards when ﬁ...
Page 180 Connect the UV Lamp Cable, Motor Cable and Sensor Cable to the Carriage Board. Slide the UV Lamp to the front and bundle the cables with the Wire Saddles. Motor Cable Sensor Cable UV Lamp Cable Carriage Board Turn on the Sub Power while pressing the Left, Right and Down keys to enter the Service mode.
Page 181 Move the Head Carriage to the right edge of the bed. And check that the space between the UV Lamp and bed is 7mm to 7.5mm. If the space between the UV Lamp and bed is not 7mm to 7.5mm, go back to the step 12 and ﬁ x the UV Lamp again. Enter the Service Mode and perform the following check.
Page 182: Take-Up Board Replacement
3-16 TAKE-UP BOARD REPLACEMENT Remove the TU Cover. TU Cover Remove the 2 screws as shown in the ﬁ gure to remove the Plate ﬁ xing the Board. Board Screw Plate Remove all the cables that are connected to the Board. Remove the 4 screws to remove the Board from the Plate.
Page 183 Connect all the cables to the Board. Fix the Plate. Board Screw Plate Fix the TU Cover. TU Cover Check the following. 1. [4-11 TAKE-UP UNIT OPERATION CHECK] 3-109...
Page 184: Ink Damper Replacement
3-17 INK DAMPER REPLACEMENT Finish the replacement within 20 minutes to prevent the ink from hardening. When 20 minutes passes, per- CLEANING form the Medium Cleaning. CLEANING MEDIUM MEDIUM Always use the UV protection sheet during this replacement, or ink will harden and clog inside the ink line. UV protection sheet Parts NO.: 1000005829 Parts Name : TOOL,VINYL YE UV RESISTANT ST-113...
Page 185 Remove the 2 screws as shown in the ﬁ gure to remove the Carriage Cover. Carriage Cover The screws for ﬁ xing the Carriage Cover are the screw with washer. Remove the Damper Plate. Damper Plate Pull the Head Shield to the front and remove it. Head Shield Fix the Head Board Cover temporarily, and remove the 2 Ink Dampers from the Head which will be replaced.
Page 186 Pull out the Ink Damper from the Damper Shield and set the new Ink Damper to the Damper Shield. < How to set the Damper Shield > Ink Damper Damper Shield 4 . C l o s e t h e 2 g a p s w i t h 1.
Page 187 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 Slotted hole. Fix the Carriage Cover temporarily with the 2 screws shown in the ﬁ...
Page 188: Paper Side Sensor Replacement
3-18 PAPER SIDE SENSOR REPLACEMENT Finish the replacement within 20 minutes to prevent the ink from hardening. When 20 minutes passes, per- CLEANING form the Medium Cleaning. CLEANING MEDIUM MEDIUM Always use the UV protection sheet during this replacement, or ink will harden and clog inside the ink line. UV protection sheet Parts NO.: 1000005829 Parts Name : TOOL,VINYL YE UV RESISTANT ST-113...
Page 189 Remove the I/S Cover. Screw Hook I/S Cover Screw Turn on the Sub Power 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], and SERVICE MENU press the [ENTER] key.
Page 190 Remove the 2 screws as shown in the ﬁ gure to remove the Carriage Cover. Carriage Cover The screws for ﬁ xing the Carriage Cover are the screw with washer. Cut the Push Mount ﬁ xing the Paper Side Sensor Cable and Media Thickness Checking Sensor Cable.
Page 191 Remove the 2 screws to remove the Paper Side Sensor together with the unit. Support the Unit when you remove it to keep the unit from falling. Remove the screw to remove the Paper Side Sensor from the unit. Fix the new Paper Side Sensor to the unit. Paper Side Sensor Fix the new Paper Side Sensor and Media Thickness Checking Sensor to the unit using a insulock.
Page 192 Connect the Paper Side Sensor Cable and the Media Thickness Checking Sensor Cable fto the Print Carriage Board. CN14 CN21 Fix the Right Top Cover. Right Top Cover Perform the following Adjustments.. 1. [4-14 PAPER SIDE SENSOR ADJUSTMENT] 2. [4-15 MEDIA THICKNESS CHECKING SENSOR ADJUSTMENT] 3.
Page 193: Media Thickness Checking Sensor Replacement
3-19 MEDIA THICKNESS CHECKING SENSOR REPLACEMENT Finish the replacement within 20 minutes to prevent the ink from hardening. When 20 minutes passes, per- CLEANING form the Medium Cleaning. CLEANING MEDIUM MEDIUM Always use the UV protection sheet during this replacement, or ink will harden and clog inside the ink line. UV protection sheet Parts NO.: 1000005829 Parts Name : TOOL,VINYL YE UV RESISTANT ST-113...
Page 194 Remove the following covers. I/S Cover Right Top Cover Right Top Cover I/S Cover Turn on the Sub Power 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], and SERVICE MENU press the [ENTER] key.
Page 195 Remove the 2 screws as shown in the ﬁ gure to remove the Carriage Cover. Carriage Cover The screws for ﬁ xing the Carriage Cover are the screw with washer. Cut the Push Mount ﬁ xing the Paper Side Sensor Cable and Media Thickness Checking Sensor Cable.
Page 196 Remove the 2 screws to remove the Paper Side Sensor together with the unit. Support the Unit when you remove it to keep the unit from falling. Remove the screw to remove the Paper Side Sensor from the unit. Paper Side Sensor Remove the screw to remove the Media Thickness Checking Sensor together with the stay as shown in the ﬁ...
Page 197 Disconnect the Connector of the Media Thickness Checking Sensor. Connector Remove the Media Thickness Checking Sensor from the stay. Fix the new sensor to the stay. Be careful with the fixing direction of the sensor. Fix the connector to the Media Thickness Checking Sensor. Connector Fix the Push Mount as shown in the ﬁ...
Page 198 Fix the Media Thickness Checking Sensor together with the stay to the unit. Screw Fix the Paper Side Sensor to the unit. Paper Side Sensor Fix the new Paper Side Sensor and Media Thickness Checking Sensor to the unit using a insulock. The knot of the insulock sholud be back of the Stay.
Page 199 Connect the Paper Side Sensor Cable and the Media Thickness Checking Sensor Cable fto the Print Carriage Board. CN14 CN21 Fix the Right Top Cover. Right Top Cover Perform the following Adjustments.. 1. [4-14 PAPER SIDE SENSOR ADJUSTMENT] 2. [4-15 MEDIA THICKNESS CHECKING SENSOR ADJUSTMENT] 3.
Page 200: Linear Encoder Board Replacement
3-20 LINEAR ENCODER BOARD REPLACEMENT Finish the replacement within 20 minutes to prevent the ink from hardening. When 20 minutes passes, per- CLEANING form the Medium Cleaning. CLEANING MEDIUM MEDIUM Always use the UV protection sheet during this replacement, or ink will harden and clog inside the ink line. UV protection sheet Parts NO.: 1000005829 Parts Name : TOOL,VINYL YE UV RESISTANT ST-113...
Page 201 Remove the following covers. I/S Cover Right Top Cover Right Top Cover I/S Cover Turn on the Sub Power 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], and SERVICE MENU press the [ENTER] key.
Page 202 Remove the 2 screws as shown in the ﬁ gure to remove the Carriage Cover. Carriage Cover The screws for ﬁ xing the Carriage Cover are the screw with washer. Open the Wire Saddle for bundling the Linear Encoder Board. Wire Saddle Disconnect the Paper Side Sensor Cable from the Print Carriage Board.
Page 203 Remove the 2 screws to remove the Linear Encoder Board from the stay. Fix the new Linear Encoder Board to the stay. Screw Fix the Linear Encoder Board together with the stay. Module Make sure that the Encoder Scale doesn't make contact with the Encoder Module and also Encoder Scale is between the slit of the Encoder Module.
Page 204 Fix the Carriage Cover temporarily with the 2 screws shown in the ﬁ gure. And tighten them without distorting the Cover. Carriage Cover Hook Be careful not to distort the Carriage Cover when tight- ening the 2 screws. The Carriage can be distorted and it may cause the head position problem.
Page 205: Uv Lamp Filter Replacement
Revised 13 3-21 UV LAMP FILTER REPLACEMENT Finish the replacement within 20 minutes to prevent the ink from hardening. When 20 minutes passes, per- CLEANING form the Medium Cleaning. CLEANING MEDIUM MEDIUM Always use the UV protection sheet during this replacement, or ink will harden and clog inside the ink line. UV protection sheet Parts NO.: 1000005829 Parts Name : TOOL,VINYL YE UV RESISTANT ST-113...
Page 206 Remove the following covers. I/S Cover Front Rail Cover Right Top Cover Right Top Cover Front Rail Cover I/S Cover Front Cover Shield Front Cover Shield Turn on the Sub Power while pressing the Left, Right and Down keys to enter the Service mode. MENU MENU SERVICE MENU...
Page 207 Move the Head Carriage slowly leftwards so that it is not above the Capping Unit. This procedure is unnecessary when remov- ing the ﬁ lter of the left UV Lamp. Remove the Filter Cover of the UV Lamp. Filter Cover Remove the UV Lamp Filter and install the new one.
Page 208 Move the Head Carriage to the capping position by hand. 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 [I/S MENU] >...
Page 209: Adjustment
4 Adjustment To Ensure safe Work Turn off the sub power SW, main power SW, and unplug the power cable of the Printer and deodorization equipment before performing parts replacement. Performing the parts replacement while the power is on may result in injury by unintended operation of the machine.
Page 210 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 with 35 digit number and alphabet. The digits can be changed with [left] PRINT MENU HEAD RANK HEAD 1...
Page 211 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 212 PUMP CHECK PUMP SUCTION I/S MENU NOW PROCESSING.. PUMP SUCTION PUMP CHECK PUMP SUCTION NOW PROCESSING.. CIR-PUMP PUMP CHECK PUMP RELEASE NOW PROCESSING.. PUMP RELEASE PUMP RELEASE NOW PROCESSING.. CIR-PUMP This is for checking the pump motor. The rotation for both ink suction and release can be checked. All pump motors rotate for 5 seconds and stop.
Page 213 CAP AGING I/S MENU NOW PROCESSING.. This is to confirm that the capping is COMPLETED CAP AGING done properly within the operation range. The cap move up and down 20 times in Error (beeps 2 times) this menu. CAP AGING FAILED !! WIPER AGING NOW PROCESSING..
Page 214 SL1 : TIME The used time of the Ink Cartridge is displayed. 0y000d00h00m00s SL1 : INSERT The insert count of the Ink Cartridge is displayed 1 times SL1 : FLAG The Flag information of the Ink Cartridge is displayed. 000000000 It reads the information written on the IC of each carriage.
Page 215 Fills Ink to each print head. A to C shown on the lower LCD are the head groups. Cursor can be moved with [left] and SUB MENU FILL INK CHECK [right] keys. Use [up] and [down] keys for ON/OFF. By FILL INK A B C DRAIN BOTTLE...
Page 216 CLOCK DATE SUB MENU DATE DATE 05/09/10 05/09/10 CLOCK [Year/Month/Day] [Year/Month/Day] Display Edit TIME CLOCK TIME TIME 01:01:59 01:01:59 Display Edit TIME It shows [B], when TIME battery is dead. 01:01:59 01:01:59 This menu is to display and edit the date and time. When it detects the battery exhaustion, [B] is indicated on the time display. In this case, battery needs to be replaced.
Page 217 Servo Motor : LOCKED This menu is to check whether Servo Motor can be locked properly. SERVO LOCK MOTOR MENU SERVO LOCK While in this menu, Servo Motor is free. When the Carriages are SERVO LOCK moved by hands, the displayed values change as the feedback is performed normally.
Page 218 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 219 MAINTENANCE GROUP Item Contents Unit Reference MAINTE. COUNT Number of times the Head Maintenance has been performed times This value is cleared automatically after carrying out the Head TOTAL TIME Lapsed time from the last Head Maintenance hour Maintenance. This value is cleared automatically after carrying out the Head PRINTING TIME Printing time from the last Head Maintenance hour...
Page 220 Roland VersaUV series LEJ-640 Ink type ECO-UV CMYKGIW Model LEJ-640 IP Address 133.111.136.090 74/ 86/ 64/ 100/ 71/ 100 255.255.254.000 Ink remain (1-6) Version 1.00 Subnet Mask Serial No . XXXXXXX Gateway Address 000.000.000.000 Date 2010/04/17 16:24 MAC Address 00:40:AB:FF:01:30...
Page 221 Service Report Head rank H1 : 70W3135TYTZUURS .... 10A..E : 70X3533XUWUVVRR .... 00R..E : 71X3231UVVWVVRS .... 105..E : 73Z3535UXVYVVRS .... 10D..E : 78T3935TVTVUURS .... 40B..E : 75V3335VVWVUUSS .... 106..E (DT1. Low) Head hori. (DT3. Low) (DT1. High) (DT3. High) Head bi (DT1.
Page 222: Service Mode
Ink Cartridge Report Model LEJ-640 Serial No. : XXXXXXX Version 1.00 No : SERIAL / INK TYPE / CAP. / LOT No/ CONSUM. / TIME / INS. / FLAG EUV-C 0y009d00h07m48s / 200 cc / 80918 / 56.526cc / 4 / 00000000 1400dfa0020000a6 / EUV-M 200 cc /...
Page 223 Turn on the sub power SW while MENU pressing the Down key to start the machine in the SERVICE REPORT PRINTING mode. [SERVICE REPORT] is displayed Roland DG Corp. SERVICE REPORT LEC-540 and it returns to the normal mode after printing. It starts printing automatically when...
Page 224 Key Combinations Function for Service Combination Key Selection Comments Press [MENU] and [ ] to enter Service Service Mode Menu. [UPDATE FIRMWARE?] will be displayed. Upgrade F/W Press [ENTER] to upgrade F/W. Use this when the main board is replaced. Installing F/W (At Main Board Change) [SUM-ERROR] will be displayed.
Page 225 4-2 HOW TO UPGRADE/INSTALL FIRMWARE It is necessary to prepare the followings to upgrade/install the ﬁ rmware. 1.Firmware ﬁ le 2.WindowsPC (Network port is required.) 3.Peck.exe 4.Network cable (A cross cable is required when you connect LEJ-640 to PC directly.) HOW TO UPGRADE FIRMWARE (Referential Time : 5 min) Check the IP address of the machine.
Page 226 Start the Peck on PC. When [Peck] screen is displayed, click [Select Port]. Select [Type 3] from [Product]. And select [Via Network] from [Select port] and input the printer IP address. Click [OK]. Click [Firmware Upgrade]. [OPEN] screen is displayed. Select the ﬁ...
Page 227 The machine goes into the Firmware Upgrade mode automatically. FIRMWARE V1.00 DATA ERROR When upgrade is completed, the sub power SW turns off automatically. ERASING DEVICE ERROR WRITING DEVICE ERROR DEVICE ERROR VERIFYING COMPLETE HOW TO INSTALL FIRMWARE (Referential Time : 5 min) This is required when a new Main Board without the ﬁ...
Page 228 Press the [MENU] key, and set [IP ADDRESS], [SUB- NET MASK] and [GATEWAY ADDR.]. WAITING Press the Left and Right keys for cursor movement, 000.000.000.000 and the Up and Down keys for selecting value. After MENU setting an address, press the [ENTER] key to go next ,to address setting.
Page 229 Click [Firmware Upgrade]. [OPEN] screen is displayed. Select the ﬁ rmware ﬁ le and click [Open]. It starts to send the ﬁ rmware to the machine. It starts loading the ﬁ rmware. The ﬁ rmware installation is done when [COMPLETE] FIRMWARE V1.00 DATA ERROR...
Page 230 Turn on the sub power SW while pressing the Up, Down, and the [ENTER] keys to enter [INITIALIZE ALL ENTER SYS.PARAMETER] menu. Press the [ENTER] key to start initialization. The sub power turns off automatically when it is completed. INITIALIZE ALL SYS.PARAMETER SELECT MODEL LEJ-640...
Page 231 Start the Peck on PC. When [Peck] screen is displayed, click [Put Param- eters]. [OPEN] screen is displayed. Select the System Parameter ﬁ le that was saved be- fore the main board replacement. Click [Open]. It starts to send the System Parameter to the machine.
Page 232: 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. MENU Select [SYSTEM INFO.] > [NETWORK] > [IP AD- DRESS] in the User's Menu and set the IP address. MENU SYSTEM INFO.
Page 233 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 ﬁ rmware appears. Turn off the sub power SW and main power SW once. 4-25...
Page 234: Head Alignment
4-4 HEAD ALIGNMENT (Referential Time : 30 min._1 Head Alignment) [About HEAD ALIGNMENT] HEAD ALIGNMENT is necessary to obtain the good printing quality. Be sure to perform the HEAD ALIGNMENT when the Head is replaced. If the heads are not aligned, printing problems such as banding, ﬁ ne lines and gap between bands could occur.
Page 235 Remove the 2 screws to remove the Carriage Cover. Carriage Cover The screws for ﬁ xing the Carriage Cover are the screw with washer. Remove the Damper Plate. Damper Plate Put back the I/S Cover temporarily to prevent the ink I/S Cover from hardening.
Page 236 Select [PRINT MENU] > [HEAD ADJUST] > [BIAS/ SERVICE MENU VERTICAL] and press the [ENTER] key. PRINT MENU [ ] [ ] PRINT MENU HEAD ADJUST HEAD ADJUST BIAS/VERTICAL BIAS/VERTICAL TEST PRINT The test pattern shown in the ﬁ gure will be printed. The test pattern can be moved by [ ] and ] keys.
Page 237 [BIAS ADJUSTMENT] Loosen the 3 screws ﬁ xing the Head in order as shown in the ﬁ gure. Loosen the screws ﬁ xing the Head approxi- mately 1/2 turn. If the screws are too loose, it may affect the result of this alignment. When you loosen the screws ﬁ...
Page 238 Tighten the screws ﬁ xing the Head in the reverse order of loosening, using the TORQUE DRIVER (ST-056). Torque for tightening is 2kgf cm (20cNm). • Make sure not to tighten the screws ﬁ rmly. When you tighten the screws ﬁ xing [HEAD 5], use any of a No.1 bit which length from 200mm to 300mm or [TOOL,BIT CROSS NO1 V17 7X207L ST-121] Place the driver to the cutout of the Motor Stay...
Page 239 Turn the Adjustment Screw to make the lines of each color in the test pattern straight. Position of the printing moves 1/2 line by turning the screw 30 degrees. Adjustment Screw - When the lines other than K are above the K lines, turn the Adjustment Screw CW.
Page 240 Put back the I/S Cover temporarily to prevent the ink from hardening. I/S Cover There is no need to ﬁ x the screws. Hook When you adjust [HEAD 5], fix the Right Top Right Top Cover Cover. Print the test pattern again. SERVICE MENU If the result is not satisfactory, repeat 6 to 15 .
Page 241 Following test pattern will be printed in the size of 350mm 200mm. Find the position where the line of each color matches the K line and check the number. If it is difﬁ cult to select just one between two numbers, 1/2 is also available when setting up the value.
Page 242 Select [DT1, Low], [DT3, Low], [DT1, High] and [DT3, High] in the [HEAD ADJUST] menu and enter the pa- rameters checked at 19 with the Up and Down keys. Press the [ENTER] key to save the settings. HORIZONTAL TEST PRINT Parameters can be entered HORIZONTAL with an increment of 1/2.
Page 243 Following test pattern will be printed in the size of 400mm 300mm. Find the position where the 2 lines are overlapping and check the number of each color. If it is difﬁ cult to select just one between two numbers, 1/2 is also available when setting up the value.
Page 244 Select [DT1, Low], [DT3, Low], [DT1, Middle], [DT3, Middle], [DT1, High] and [DT3, High] in the [HEAD AD- JUST] menu and enter the parameters checked at 22 with the Up and Down keys. Press the [ENTER] key to save the settings. BI-DIR.DEFAULT TEST PRINT BI-DIR.DEFAULT...
Page 245 Fix the Carriage Cover with the 2 screws shown in the ﬁ gure temporarily. And tighten them without distorting the Cover. Carriage Cover Be careful not to distort the Carriage Cover when tight- ening the 2 screws. The Carriage can be distorted and it may cause the head position problem.
Page 246: 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 set correctly, it may cause some problems such as a head capping error, and also cause a cutter-down error when separating the sheet.
Page 247 Turn on the Sub Power SW while pressing Left, Up and Right keys for LIMIT INITIALIZE mode. + SUB POWER ON Click [ENTER] key 4 times to skip the [HEAD HEIGH ADJUSTMENT] and [AUTO CUTTER ADJUSTMENT], and display the [MOVE TO CAP POS]. SETTING UP LIMIT INITIALIZE AUTOCUT HEIGHT...
Page 248 Press the [ENTER] key to cap the heads. MOVE TO CAP POS Carry out the Limit Position Initialize by pressing the [ENTER] key again. SETTING UP After the limit Position Initialize is completed, the mes- THE LIMIT sage appears as shown in the ﬁ gure. DETECTING..
Page 249: Linear Encoder Setup
4-6 LINEAR ENCODER SETUP (Referential Time : 10min.) LINEAR ENCODER SETUP is performed to conﬁ rm that the installation of Linear Encoder is proper, and also to conﬁ rm that it properly reads and corrects the width of the scale, which is stretched or com- pressed due to the operation environment, by the software coordinates.
Page 250 Lower the Pinch Rollers. Make sure to unload the media when it is set on the machine. Also, the media clamps must be removed. Select [PRINT MENU] > [LINEAR ENCODER], and SERVICE MENU press the [ENTER] key. PRINT MENU [ ] [ ] PRINT MENU LINEAR ENCODER NOW PROCESSING...
Page 251: Cap Height Adjustment
4-7 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 252 Remove the I/S Cover and Right Inner Plate. Screw Right Inner Plate has a small hook on its Hook I/S Cover right bottom and it is inserted to the lower cover. Be cautious when removing it. Screw Right Inner Plate Make sure to unload the media when it is set on the machine.
Page 253 Move the cap upward to the position that the cap con- CAP ADJUST ADJUST POS. tacts exactly to the head, then press the [ENTER] to ADJUST POS. 0.00 -2.00 update the adjustment value. - When you press the Up key, the cap moves upward in HEAD 0.25mm unit.
Page 254 4-8 CALIBRATION (FEEDING DIRECTION) (Referential Time : 20 min.) This adjustment is for calibrating the feed amount of media. It allows the media to be fed in proper amount by calibrating the variation in Grit Roller diameter. Calibration is made based on the value in feeding media [PET-G].
Page 255 Select [TEST PRINT] under [CALIB.DEFAULT] menu SERVICE MENU and press the [ENTER] key. PRINT MENU The test print requires 510mm or more of the PRINT MENU media Setup width. CALIB.DEFAULT CALIB.DEFAULT TEST PRINT The test pattern is printed. Measure the length of the feed direction and use the value to calculate the calibration amount with the for- mula shown in 5 .
Page 256: Belt Tension Adjustment
4-9 BELT TENSION ADJUSTMENT (Referential Time : 20min.) Finish the replacement within 20 minutes to prevent the ink from hardening. When 20 minutes passes, per- CLEANING form the Medium Cleaning. CLEANING MEDIUM MEDIUM Necessary special tools : ST-001 TENSION GAUGE 2000GF/2000CN While in service mode, the menu which involves a motion of Head UP/DOWN holds and keeps the head carriage at the very top position, where the menu does not proceed any further.
Page 257 Select [I/S MENU] > [I/S CONTROL] > [CAP] > [OPEN], SERVICE MENU and press the [ENTER] key. I/S MENU The Cap Unit moves down and be free to move by hand. I/S MENU I/S CONTROL This adjustment cannot be done correctly I/S CONTROL when the Head Carriage is capped.
Page 258 Loosen the 2 ﬁ xing screws that is located on the left <Top view> Left end of the belt end of the belt halfway round. Be careful with the sharp edges around the belt when loosening the screws. It can cause injury.
Page 259 Tighten the 2 screws shown in the figure to slightly Screw contact with Idle Pulley Holder. Be sure not to tighten the screws too tight. The ﬁ xed Idle Pulley Holder can be moved accidentally. Move on to [4-10 BELT POSITION ADJUSTMENT]. 4-51...
Page 260: Belt Position Adjustment
4-10 BELT POSITION ADJUSTMENT (Referential Time : 30min.) This adjustment is to prevent the belt wear which is caused by the belt contacting with the pulley ﬂ anges excessively. The belt position needs to be conﬁ rmed and adjusted if necessary after the Belt Tension Adjustment.
Page 261 Conﬁ rm that the Belt Tension Adjustment is completed and turn on the main power SW. Turn on the sub power SW while pressing the Left, Down and Right keys to enter the Service Mode. MENU MENU SERVICE MENU [ADJUSTMENT ON THE DRIVE PULLEY SIDE] Carry out the AGING test for the belt.
Page 262 Press the [ENTER] key to cancel AGING. SCAN NOW AGING Loosen the 2 ﬁ xing screws located on the right end of Stay the belt. Fixing Screw Loosen the screws about 3 rounds so that Screw the bottom of the screw head not to contact with the Stay.
Page 263 Belt leans to the front side of the machine Adjustment Screw -Turn the screw carefully in CCW (loosening). Touching the ﬂ ange on the FRONT side of machine Belt leans to the rear side of the machine Adjustment Screw -Turn the screw carefully in CW (tightening). Touching the ﬂ...
Page 264 [ADJUSTMENT ON THE IDLE PULLEY SIDE] Conﬁ rm the position of the belt. [ Left end of the belt ] Idle Pulley The position is proper when the belt is not touching the ﬂ anges excessively. When the position is proper, ﬁ nish this Belt Position Adjustment.
Page 265 Press the [ENTER] key to restart Aging. AGING SCAN Insert a wrench through the holes on the side frame Idle Pulley and adjust the belt position turning screw 1 and 2 as follows. Screw1 Screw1 Not touching the ﬂ anges Belt leans to the front side of the machine -Turn the screw 1 carefully in CW to press it to the Idle Pulley Holder.
Page 266 Tighten one of the screws that has no contact with the Screw Idle Pulley Holder to slightly touch the Idle Pulley Hold- (The one with no contact with Idle Pulley Holder.) Be sure not to tighten the screws too tight. The ﬁ...
Page 267: Take-Up Unit Operation Check
4-11 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. While in service mode, the menu which involves a motion of Head UP/DOWN holds and keeps the head carriage at the very top position, where the menu does not proceed any further.
Page 268 Select [TU] menu under [SUB MENU] > [TU CHECK]. SERVICE MENU SUB MENU [TU] menu supports the connector marked SUB MENU TU CHECK [TAKE UP]. Although [OPTION-TU] menu is for another TU CHECK connector with no name, but it is not in use. START START Conﬁ...
Page 269 Select [STOP] with the Up and Down keys, and press the [ENTER] key. START STOP Move the Dancer Roller up and down by hand, and conﬁ rm that the drive part does not rotate. Drive Part The setting of [STOP] is canceled when ex- iting the menu.
Page 270: Wiper Cover Position Adjustment
4-12 WIPER COVER POSITION ADJUSTMENT (Referential Time : 5min.) WIPER COVER POSITION ADJUSTMENT is to adjust the position of the Wiper Cover to the Heads. It is necessary when the Wiper Cover is removed or replaced. If the Wiper Cover is ﬁ xed at front side from its proper position, the spattered ink accumulates on the bottom of the Head Carriage and results in ink dropping.
Page 271 Remove the I/S Cover. Screw I/S Cover Screw Hook Remove the 5 screws shown in the ﬁ gure to remove the Pump Cover together with the Right Inner Plate. Pump Cover Right Inner Plate Turn on the sub power SW while pressing the Left, Down and Right keys to enter the Service Mode.
Page 272 Loosen the screw shown in the figure and slide the Wiper Cover to the front end by hand. Fully slide Careful handling is required, the Wiper Cover can be deformed easily. Screw Move the Head Carriage to the position where the 2 Heads from the left can be wiped.
Page 273 Move the Wiper Cover 1mm to the front by checking the mark. Then tighten the screw. Move 1mm Move the Head Carriage left and right slowly, and make sure the Wiper Cover never touches the Heads. Move the Head Carriage to lock it by hand to the lock position.
Page 274 Fix the Pump Cover together with the Right Inner Plate. Right Inner Plate Pump Cover Fix the I/S Cover. Screw I/S Cover Screw Hook 4-66...
Page 275: Uv Lamp Check
4-13 UV LAMP CHECK (Referential Time : 5min.) This is required when UV Lamp unit is installed. This is to check whether UV Lamp Unit operates properly. While in service mode, the menu which involves a motion of Head UP/DOWN holds and keeps the head carriage at the very top position, where the menu does not proceed any further.
Page 276 Select [SERVICE MENU] > [UV LAMP MENU] > [CON- SERVICE MENU NECT CHECK] and press the [ENTER] key. UV LAMP MENU Check that the screen shown in the ﬁ gure is displayed. [ ] [ ] UV LAMP MENU CONNECT CHECK CONNECT CHECK CONNECTED Check that the UV Lamps are connected properly if the...
Page 277 Select the right or left UV Lamp with the Up and Down < When the right Lamp is selected > keys. RIGHT : : [ ] Check that the selected UV Lamp can be performed LEFT : : [ ] properly by turning ON/OFF the UV Lamp by pressing the [ENTER] key while the cover is closed.
Page 278 Go back to [UV LAMP MENU] and select [SLIDE] > [SLIDE CHECK], and press the [ENTER] key. UV LAMP MENU SLIDE When the Slide Check is completed properly, [COM- PLETED] is displayed. SLIDE SLIDE CHECK If [FAILED] is displayed, check the following. - Slide Limit Sensor - Cable of the Slide Limit Sensor - Slide Motor...
Page 279 4-14 PAPER SIDE SENSOR ADJUSTMENT (Referential Time : 10min.) 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. Finish the replacement within 20 minutes to pre- vent the ink from hardening.
Page 280 Remove the I/S Cover. Screw Hook I/S Cover Screw Lower the Sheet Loading Lever. Sheet Loading Lever Remove the 2 screws to remove the Carriage Cover. Carriage Cover The screws for ﬁ xing the Carriage Cover are the screw with washer. Select [SUB MENU] >...
Page 281 Adjust the VR on the Carriage Board so that the [OUTPUT LEVEL] will be 0.5 - 0.7V. Carriage Board S e l e c t [ PA P E R S I D E S E N S E ] > [ S E N S O R SERVICE MENU AUTOTEST] menu.
Page 282 Fix the I/S Cover. Screw I/S Cover Screw Hook 4-74...
Page 283 4-15 MEDIA THICKNESS CHECKING SENSOR ADJUSTMENT (Referential Time : 20min.) This is for adjusting the position and height of the MEDIA THICKNESS CHECKING SENSOR, which detects the media ati the thickness you enter. If it is not adjusted, the media could not be detected correctly.
Page 284 Lower the Sheet Loading Lever. Revised 1 Sheet Loading Lever Remove the following covers. Front Rail Cover FRONT RAIL COVER FRONT COVER SHIELD Front Cover Shield Turn on the sub power while pressing the Left, Right and Down keys to enter the Service Mode. MENU MENU SERVICE MENU...
Page 285 Move the Tool Carriage to the position under the H mark Top Cover which is written on the rail. Rail The rail has an H mark at the point where Tool Belt Height Adjustment is made during the production of the machine. H mark indicates the highest position of the bed.
Page 286 Fix the Media Thickness Checking Sensor Unit by using the Media Thickness Checking Sensor Unit Block [1000008363 : TOOL,BLOCK LEJ-640 ST-122] following the below steps. Block Projection Block While holding the Sensor Unit up, slide the Block to put it under the unit.
Page 287 Select [I/S MENU] > [I/S CONTROL] > [HEAD UP/ SERVICE MENU DOWN] > [MIDDLE], and press the [ENTER] key to set I/S MENU the head height to [MIDDLE]. I/S MENU I/S CONTROL I/S CONTROL HEAD UP/DOWN HEAD UP/DOWN MIDDLE Turn off the sub power SW and main power SW. <...
Page 288 Select [I/S MENU] > [I/S CONTROL] > [HEAD UP/ SERVICE MENU DOWN] > [LOW], and press the [ENTER] key to set I/S MENU the head height to [LOW]. I/S MENU I/S CONTROL I/S CONTROL HEAD UP/DOWN HEAD UP/DOWN Fix the Media thickness Checking Sensor Cable and the Paper Side Sensor Cable using a insulock tie.
Page 289: Paper Side Sensor Adjustment
Fix the following covers. Front Rail Cover FRONT RAIL COVER FRONT COVER SHIELD Front Cover Shield Turn on the sub power while pressing the Left, Right and Down keys to enter the Service Mode. MENU MENU SERVICE MENU Remove the I/S Cover. Screw Hook I/S Cover...
Page 290: Supplemental Information
5 Supplemental Information 5-1 SPECIAL TOOLS Table shows a list of special tools recommended by Roland DG Corp. Parts No. ST-056 Parts Name TORQUE DRIVER NS Purpose HEAD ALIGNMENT Parts No. 1000005463 Parts Name TOOL,BIT PHILLIPS NO.1 L150MM ST-107 Purpose HEAD ALIGNMENT Parts No.
Page 291 Parts No. 21755107 Parts Name CLEANING LIQUID(SL) 500ML Purpose HEAD CLEANING (SOL) Parts No. 22085118 Parts Name KIT, CLEANING(SL) HEAD CLEANING (SOL) Purpose *Cleaning Liquid + Cleaning Sticks 10 pcs. Parts No. 1000005467 Parts Name TOOL,GLASSES UV COATING ST-111 Purpose PROTECTIVE GOGGLES Parts No.
Page 292: Sensor Map
5-2 SENSOR MAP REAR PAPER SENSOR SHEET LOAD SENSOR It detects the rear edge of the media and also whether the media is loaded or not. It detects whether the Sheet Loading Lever is UP or DOWN. HEAD LOCK SENSOR It detects wheter the HEAD CARRIAGE is at locking position or not.
Page 293 WIPER SENSOR It detects the limit position of the Wiper movement. ENCODER MODULE It detects the coordinates in the carriage moving direction, and also generates the print signal. (Front side of the machine) Revised 2 MEDIA THICKNESS CHECKING SENSOR It detects the media thickness is not greater than the entered value.
Page 294 CAPPING SENSOR It detects the limit position of the Capping Unit. INK CARTRIDGE IC SENSOR It communicates with the IC chip of the InkCartridge. INK CARTRIDGE SENSOR INK EMPTY SENSOR It detects whether the Ink Cartridge is installed It detects whether the Ink Cartridge is empty or not. or not.
Page 295: Troubleshooting
6 Troubleshooting 6-1 WHITE FINE LINE / BANDING / MISSING DOT / SCRATCHY PRINTING / BLURRED PRINTING Missing dot or Improved Perform Normal deflected-fired dot Completed appears on the test Cleaning pattern. Not Improved *Several Normal Cleanings and a Powerful Cleaning do not improve the printing result.
Page 296 6-1 WHITE FINE LINE / BANDING / MISSING DOT / SCRATCHY PRINTING / BLURRED PRINTING CHECKING POINT ACTION REFERENCE OUTLINE If air-conditioning or heating equipment is near the printer, The printer is near air- Move the printer away it cools or heats the ink inside the printer at small area, conditioning or heating from air-conditioning User's Manual...
Page 297: Particular Color Is Not Printed At All
6-2 PARTICULAR COLOR IS NOT PRINTED AT ALL CHECKING POINT ACTION REFERENCE OUTLINE When the printer keeps printing with Ink Cartridge almost Check remaining Ink / Ink Cartridge is almost empty, the negative pressure delivered in the ink tube Replace the Ink User's Manual empty causes the improper ink supplying and the head cannot...
Page 298: Ink Drops On The Media
6-3 SHIFTING IN PRINTING / COLOR SHIFTING CHECKING POINT ACTION REFERENCE OUTLINE Encoder Module is Clean or replace When Encoder Module is not read correctly, printing dirty/broken Encoder Module position may shift. Head is out of [4-4 HEAD If the Heads are not aligned or Horizontal adjustment is Head Alignment adjustment ALIGNMENT]...
Page 299: Missing Dot Or Deflected-Fired Dot Appears When Performing Printing After Leaving The
6-6 MISSING DOT OR DEFLECTED-FIRED DOT APPEARS WHEN PERFORMING PRINTING AFTER LEAVING THE PRINTER UNUSED FOR A LONG TIME CHECKING POINT ACTION REFERENCE OUTLINE When the main power is off, the maintenance flushing is Check the main power Do not switch off the not performed and it may cause the Head nozzle clogging.
Page 300: Motor Error
6-9 MOTOR ERROR CHECKING POINT ACTION REFERENCE OUTLINE In using the media take-up system to perform output with Remove cause of Media Jamming pullback movement, you have to select the [TU2] of the Media Jam [SETUP SHEET] menu. When using hard-to-unroll or too heavy media, Motor Back tension of media is Use appropriate Media Error occurs due to the too much load for feeding the...
Page 301: Take-Up Unit Does Not Operate
6-10 TAKE-UP UNIT DOES NOT OPERATE CHECKING POINT ACTION REFERENCE OUTLINE The cable for Take-Up Connect the cable to Unit is not connected the printer AUTO switch is not Make the setting for the AUTO switch on Check the connection/bad contact of the cables from AC Check the cable Check the cable [3-16 TAKE-UP...
Page 302: Service Call
6-14 SERVICE CALL CODE CONTENTS CAUSE ACTION Servo Board does not work correctly. Check cable connection between Main Board and Servo Sub CPU does not work correctly. Board. Disorder of communication with Sub CPU There is a bad connection between Main Board and Check the other cable connections of Servo Board.
Page 303 CONTENTS CAUSE ACTION CODE The UV Lamp is not connected / tuned on. There is a bad connection between UV Lamp and Print Check the lighting of [DC OK] LED on the UV device It is not possible to communicate with the Carriage Board.
Page 304 The UV Lamp Unit and UV Lamp Sensor do UV Lamp Motor error UV Lamp Motor replacement not work correctly. Defect of UV Lamp Sensor UV Lamp Sensor replacement Defect of UV Lamp Unit UV Lamp Unit replacement There is a bad connection between UV Lamp Unit and Check cable connection between UV Lamp Unit and Print Print Carriage Board.
Page 305: Service Activities
7 Service Activities 7-1 INSTALLATION CHECK LIST LEJ-640 INSTALLATION CHECK LIST Date User Serial Number Unpacking The following space is necessary for installing the machine. When using the main unit only When using the Table Unit (Table Unit are not used) 4300 mm (169.3 in.) 4300 mm (169.3 in.) 3300 mm (129.9 in.)
Page 306 Unpacking...
Page 307 Head-unit tool : 1 Software RIP : 1 User's Manual : 1 Setup guide : 1 White and Gloss Ink Roland OnSupport Installa- Replacement wipers Guide : 1 tion & Setting Guide/Installa- tion disc (1 of each) Maintenance Kit : 1...
Page 308 Cartridge-slot labels Front cover 2 : 1 Media guide : 1 Alignment guide : 2 (1 of each) : 2 Connection Tweezers : 1 adapter : 1 Installation and Preparation Set up following items in reference to the Setup Guide from [ 3.Assembling and Installing ] to [ 7. Installation of Ventilating Equipment ].
Page 309 To use Roland@NET and VersaWorks Online: Internet connec- tion and web browser For the latest information, see the Roland DG Corp. website (http://www.rolanddg.com/) Make the setting for Roland@NET Select the check box [Download Updates Automatically and Notify] if the customer agrees with it.
Page 310 - Registering the Roland DG Account if the customer accepts it When you register the Roland DG Account (Roland DG ID), you will be able to use OnSupport more effectively. You are to communicate with our OnSupport server in registering your account.
Page 311 Preliminary note (to the user) Explain the following items before operating the unit. Interlock Function !! IMPORTANT !! The safety against the UV light is assured for users having the UV light shielding measures in the apertural area and the interlock feature that cuts off the UV light when the front cover is opened. Never disable the front cover sensor.
Page 312 Protection against the light* during the Service Activity !! IMPORTANT !! Be sure to use the UV-proof sheet when the ink line is exposed to the light during the replacement, or ink will harden and clog in the ink line. And it results in a serious in uence to a machine.
Page 313 Job outputting from Roland VersaWorks (Basic Operation) Explain the printing procedure in reference to Roland VersaWorks Quick Start Guide section 2. Printing !! IMPORTANT !! - Use the media clamps when using media that is less than 0.5 mm (0.02 inches) thick. Otherwise the edges of the media may warp and catch on the print head.
Page 314 Maintenance Explain the following items referring to the User's Manual [Chapter 4 Maintenance]. Each day, before starting the day's operations, be sure to remove the white ink cartridges and shake them gently, then reinsert them. The ingredients in white ink tend to settle. Checking for Remaining Ink and Replacing Cartridges - Checking for Remaining Ink - How to Replace Ink Cartridges...
Page 315 When Normal Cleaning Is Not Effective - Medium/ Powerful Cleaning Considerable amount of ink is consumed for the Powerful cleaning. Maintenance that Should Be Performed More Than Once a Month - When Manual-Cleaning Becomes Necessary - Performing Manual Cleaning !! IMPORTANT !! - It is a very important work to maintain the heads/UV lamps in good condition and must be done periodically.
Page 316 !! IMPORTANT !! - These adjustments are required for each Media. - If you are setting Feed Calibration on your machine, check in advance that [Use Printer Settings] is set on Roland VersaWorks. Output Operation Management - Printing a System Report...
Page 317 Job outputting from Roland VersaWorks (When using White and Gloss ink) Explain the following items referring to the White & Gloss Ink Guide [Chapter 1 Getting Started] to [Chapter 4 Advanced]. White Ink Features and Printing Methods - Features of White Ink...
Page 318 Others Compatibility of ECO-UV ink to the media ECO-UV ink can come off easily of the PET ﬁ lm media. We recommend performing a trial printing to check for the compatibility of media before you carry out actual printing. The dust becomes noticeable on the media if it is attached to the gloss ink due to the characteristics of the gloss ink.
Page 319: Maintenance Check List
Sponge under Wipers or the time period from the last replacement. Replacement Done Replacement Cycle : 12 months Cleaning Done Clean it manually using the Roland cleaning sticks and cleaning liquid. Wiper Scraper Replace it if necessary. Replacement Done Good...
Page 320 Temperature: 5 to 40˚C (41 to 104˚F), Relative humidity: 20 to 80% Power off RH (no condensation) Exclusive stands, power cord, media clamps, replacement blade Accessories for separating knife, software RIP (Roland VersaWorks) , User's Manual, etc. * The "table unit" indicates RU-640 and MB-640. 7-16...
Page 321 (*1) The media holder of this machine is exclusive use for the media of paper tube (core) inner diameter 3 inches. (*2) The length of printing is subject to the limitations of the program. (*3) Temperature: 25°C (77°F), humidity: 50%RH Roll media must be loaded correctly.

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