Roland SOLJET Pro III XC-540 Service Notes
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Roland SOLJET Pro III XC-540 Service Notes

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SERVICE NOTES
Contents
1-1 COVERS ................................................................................... 1-1
1-2 FRAME ...................................................................................... 1-2
1-3 HEAD CARRIAGE .................................................................... 1-4
1-4 DRIVE UNIT ............................................................................. 1-6
1-5 CHASSIS .................................................................................. 1-8
1-6 PINCH ROLLER ....................................................................... 1-9
1-7 TOOL CARRIAGE ................................................................... 1-10
1-8 WIPE SYATEM ........................................................................ 1-11
1-9 CAP SYSTEM .......................................................................... 1-12
1-10 INK SYSTEM ........................................................................... 1-13
1-11 STAND & TU .......................................................................... 1-14
1-12 TU CONTROLLER .................................................................. 1-15
1-13 ACCESSORIES ...................................................................... 1-16
2-1 WIRING MAP ............................................................................ 2-1
2-2 MAIN BOARD ............................................................................ 2-3
2-3 HEAD BOARD ........................................................................ 2-14
2-4 SURVO BOARD ...................................................................... 2-22
2-5 HEATER BOARD .................................................................... 2-28
2-6 INK SYSTEM BOARD ............................................................. 2-31
2-7 SUB BOARD ........................................................................... 2-33
2-8 TAKEUP BOARD ..................................................................... 2-38
2-9 MAINTENANCE PARTS LIST ................................................. 2-40
3-1 HEAD REPLACEMENT ............................................................. 3-3
3-2 WIPER REPLACEMENT ........................................................... 3-9
3-3 CAP TOP REPLACEMENT ...................................................... 3-11
3-4 TOOL CARRIAGE REPLACEMENT ........................................ 3-16
3-5 CARRIAGE MOTOR REPLACEMENT .................................... 3-20
3-6 PUMP REPLACEMENT ........................................................... 3-25
3-7 INK TUBE REPLACEMENT .................................................... 3-30
3-8 BOARDS REPLACEMENT ...................................................... 3-35
3-9 BATTERY REPLACEMENT ..................................................... 3-47
3-10 CARRIAGE WIRE REPLACEMENT ....................................... 3-50
3-11 ENCODER SCALE REPLACEMENT ...................................... 3-54
3-12 CUTTING FLEXIBLE CABLE REPLACEMENT ....................... 3-56
3-13 PINCH ROLLER REPLACEMENT .......................................... 3-62
3-14 TAKE-UP BOARD REPLACEMENT ........................................ 3-63
4-1 Special Tools ............................................................................. 4-1
4-2 SERVICE MODE ....................................................................... 4-2
THE NETWORK CONTROLLER ............................................. 4-21
Windows and MS-DOS are registered trademark or trademark of Microsoft Corporation in the United States and/or other countries.
Unauthorized coplying or transferral, in whole or in part, of this manual is prohibited.
Printed in Japan
4-5 HEAD ALIGNMENT ................................................................. 4-23
4-7 LINEAR ENCODER SETUP ................................................... 4-38
4-8 CAP HEIGHT ADJUSTMENT .................................................. 4-40
4-9 CROP MARK SENSOR ADJUSTMENT .................................. 4-42
4-10 CROP CUT ADJUSTMENT ..................................................... 4-45
4-11 PRINT/CUT POSITION ADJUSTMENT .................................. 4-48
4-12 CALIBRATION (FEEDING DIRECTION) ................................ 4-51
4-13 TOOL HEIGHT ADJUSTMENT ................................................ 4-53
4-14 TOOL PRESSURE ADJUSTMENT .......................................... 4-55
4-15 BELT TENSION ADJUSTMENT .............................................. 4-58
4-16 BELT POSITION ADJUSTMENT ............................................. 4-61
4-17 TAKE-UP UNIT OPERATION CHECK .................................... 4-67
5-1 SENSOR MAP ........................................................................... 5-1
6-3 SHIFTING IN PRINTING / COLOR SHIFTING ........................ 6-3
6-4 INK DROPS ON THE MEDIA ................................................... 6-3
6-5 VERTICAL BANDING ............................................................... 6-3
(WHEN USING THE CROP-MARK FUNCTION) ..................... 6-5
6-9 STITCH CUT ............................................................................. 6-5
6-10 START AND END POINTS DO NOT MATCH ........................... 6-6
6-11 DISTORTED CUTTING FIGURE .............................................. 6-7
6-12 MEDIA SKEW ............................................................................ 6-7
6-13 MOTOR ERROR ....................................................................... 6-8
6-15 THE BLOWER FAN DOES NOT OPERATE ............................. 6-9
6-16 THE TAKE-UP UNIT DOES NOT OPERATE ............................ 6-9
6-17 ERROR MESSAGE ................................................................. 6-10
6-18 SERVICE CALL ...................................................................... 6-10
7-1 INSTALLATION CHECK LIST ................................................... 7-1
7-2 MAINTENANCE CHECK LIST ................................................ 7-15
7-3 Specification ........................................................................... 7-16
Fourth Edition
XC-540 '06.Dec.
Copyright © 2006 ROLAND DG CORPORATION
70031-03

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  • Page 1: Table Of Contents

    Windows and MS-DOS are registered trademark or trademark of Microsoft Corporation in the United States and/or other countries. XC-540 '06.Dec. Unauthorized coplying or transferral, in whole or in part, of this manual is prohibited. Copyright © 2006 ROLAND DG CORPORATION Printed in Japan 70031-03...
  • Page 2 Revision Record Revision Date Description of Changes Approval Issued 2006.9.13 First Edition Kato Sato 3-8 : BOARD REPLACEMENT_MAIN BOARD REPLACEMENT, SW POWER SUPPLY REPLACEMENT Procedures have been revised. 3-10 : CARRIAGE BELT REPLACEMENT Procedures have been revised. 2006.10.3 Kato Mabuchi 4-3 : HOW TO UPGRADE/INSTALL FIRMWARE Procedures have been revised and added.
  • Page 3 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 4 About the Labels Affixed to the Unit These labels are affixed to the body of this product. The following figure 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 6: Structure & Spare Parts

    CUPSCREW SET,M3*6 NI 50 PCS. 21 1000000111 KEY TOP,D14 WH AJ-1000 S6 31289109 CUPSCREW SET,M3*4 NI 100 PCS. 22 1000000953 LABEL,EMBLEM LOGO ROLAND S7 31289111 CUPSCREW SET, M4*6 NI 100 PCS. 23 1000001565 PLATE,COVER PANEL XC-540 S8 31409811 SADDLE,LOCKING WIRE LWS-1211Z 20PCS...

  • Page 7: Frame

    1-2 FRAME...
  • Page 8 1-2 FRAME PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 11909133 ADAPTER,SCREW 2FAI FJ-50 51 21625103 SHUTTER,HEATER CORD SP-300 11909167 ADAPTER,SCREW 3FAI FJ-540 52 22185101 SLIDER,LOCK CJ-70 1000001589 ADAPTER,TUBE 2-3FAI XC-540 53 1000001516 SPACER,BED LOWER XC-540 1000001521 APRON,B XC-540...
  • Page 9 1-3 HEAD CARRIADGE CARRIAGE BOARD PART...
  • Page 10 1-3 HEAD CARRIADGE PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1000001461 ADAPTER,BASE CARRIAGE XC-540 S1 31289109 CUPSCREW SET,M3*4 NI 100 PCS. 1000001478 ADAPTER,CARRIAGE L XC-540 S2 31149703 RING SET,E-RING ETW-4 100 PCS. 1000001453 ADAPTER,CARRIAGE R XC-540 S3 31299102...

  • Page 11: Drive Unit

    1-4 DRIVE UNIT...
  • Page 12 1-4 DRIVE UNIT PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 6700319020 ASSY,FEED MOTOR XC-540 S1 31029101 BUSH,NB-19 W700311391 ASSY,GRIT ENCODER BOARD XC-540 S2 31289111 CUPSCREW SET, M4*6 NI 100 PCS. W7003113A1 ASSY,MOTSENS JUNCTION BOARD XC-540 S3 31289109 CUPSCREW SET,M3*4 NI 100 PCS.

  • Page 13: Chassis

    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 W700311360 ASSY,DC JUNCTION BOARD XC-540 S3 31329601 CLAMP SET,INSULOK T-18S 100 PCS.

  • Page 14: Pinchroller

    1-6 PINCHROLLER PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1 22805483 ASS'Y,P-ROLLER L/R CJ-540 S1 31149702AS RING SET,E-RING ETW-3 100 PCS. 2 22805482 ASS'Y,P-ROLLER M CJ-540 S2 31239102AS SCREW SET,W-SEMS M3*8 BC 100 PCS. 3 22115765 FRAME,P-ROLLER CJ-500 S3 31249211AS...
  • Page 15 1-7 TOOL CARRIADGE Revised 2 Revised 2 PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 22805292 ASSY,CLAMP BLADE CM-500 S1 31029801 BUSH SET,ROLL 2*4 100PCS W700311330 ASSY,CROP SENS BOARD XC-540 S2 31029803 BUSH SET,ROLL 3*5 20 PCS.
  • Page 16 1-8 WIPE SYSTEM PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1000001487 BASE,WIPER MOTOR XC-540 15229506 SENSOR INTERRUPTER,GP1A05A5 11929138 BELT,408P2M4-530 22295132 SHAFT,IDLE PULLEY STX-7 12159536 BUSH,B-S6-17 22155961 SHAFT,WIPER FJ-540 1000001595 COVER,SCRAPER XC-540 1000001489 SHUTTER,WIPE F XC-540 1000001609 COVER,SERGE MIST XC-540...

  • Page 17: Cap System

    1-9 CAP SYSTEM PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 12809448 ASSY,CAP-TOP FJ-540 28 11889107 R-BEARING,D10S6(B3FL) 6700319010 ASSY,PUMP SUB XC-540 29 15229506 SENSOR INTERRUPTER,GP1A05A5 22805572 ASSY,TUBING 2*80MM SP-540V 30 1000001591 SHAFT,GUIDE TABLE XC-540 1000001437 BASE,BOTTOM CAP XC-540 31 22155957 SHAFT,SCREW M8 FJ-540 1000001587 BASE,NEW PUMP XC-540...

  • Page 18: Ink System

    1-10 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 S2 31289112 CUPSCREW SET,M3*10 NI 100 PCS. 2 W700311520 ASSY,CARTRIDGE IC BOARD XC-540 S3 31289109 CUPSCREW SET,M3*4 NI 100 PCS. 3 W700311511 ASSY,INK TANK BOARD XC-540 S4 31409801...

  • Page 19: Stand & Tu

    1-11 STAND & TU PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 11879108 ABSORBER TK-3225 27 1000002515 CASTER,STAND XC-540 2 7498804000 ASSY BRAKE PNS-501 28 1000002462 DANCER BAR XC-540 3 1000001610 ASSY,DANCER BAR XC-540 29 1000002511 STAND,BASE L XC-540...

  • Page 20: Tu Controller

    1-12 TU CONTROLLER S11 9 PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1 6700311200 ASSY,TAKEUP BOARD XC-540 S1 31329501 CLAMP SET,PUSH MOUNT RT30SSF5 20P 2 1000001446 BASE,TU MOTOR XC-540 S2 31289105 CUPSCREW SET, M3*6 3CBC 100 PCS 3 12159563 BUSH,80F-1006...

  • Page 21: Accessories

    1-13 ACCESSORIES 117V 230V 230VC 240VA 240VE Revised 2 Revised 2 1-16...
  • Page 22 1-13 ACCESSORIES PARTS LIST -Main Parts- Parts No. Parts Name 52 1000001626 TRAY,SKID XC-540 23495124 AC CORD 3ASL100 240VA 10A SAA 53 12569656 TWEEZERS PTS-01 13499111 AC CORD H05VV-F 240VE 10A S 54 1000001604 PAD,INK TRASH XC-540 23495125 AC-CORD H05VV 230V 10A S 55 1000001603 COVER,INK TRASH XC-540 13499209...

  • Page 23: Electrical Section

    2 Electrical Section 2-1 WIRING MAP CN100 CN101 CN102 CN604 CN600 CN403 CN402 CN411 CN412 CN413 CN300 CN202 CN203 CN1103 CN500 CN802 CN800 CN804 CN801 CN300 CN404 CN403 CN12 CN12...
  • Page 24 XC-540 WIRING MAP CABLE LIST 1 1000001668 CABLE-ASSY,POWER-AC-L XC-540 50 23475196 CABLE-CARD,24P1 850L BB 2 1000001669 CABLE-ASSY,POWER-AC-N XC-540 51 1000001897 CABLE-CARD,12P1 2610L BB HIGH-V 3 1000000574 CABLE-ASSY,GND AJ-1000 52 1000001898 CABLE-CARD,26P1 880L BB HIGH-V 4 1000001670 CABLE-ASSY,POWER-AC-JUNC XC-540 53 23475232 CABLE-CARD,21P1 385L BB HIGH-V 5 1000001671 CABLE-ASSY,POWER-AC-DC XC-540...

  • Page 25: Main Board

    2-2 MAIN BOARD MAIN BOARD_Arrangement Diagram (Component Side) It indicates the version of the Main Board. DIP SW Bit1 Bit2 Bit3 Bit4 Bit5 Bit6 Bit7 Bit8 XC-540 OFF OFF OFF OFF OFF OFF OFF OFF...
  • Page 26 MAIN BOARD_Arrangement Diagram (Soldering Side)
  • Page 27 MAIN BOARD_Circuit Diagram 1/9...
  • Page 28 MAIN BOARD_Circuit Diagram 2/9...
  • Page 29 MAIN BOARD_Circuit Diagram 3/9...
  • Page 30 MAIN BOARD_Circuit Diagram 4/9...
  • Page 31 MAIN BOARD_Circuit Diagram 5/9...
  • Page 32 MAIN BOARD_Circuit Diagram 6/9 2-10...
  • Page 33 MAIN BOARD_Circuit Diagram 7/9 2-11...
  • Page 34 MAIN BOARD_Circuit Diagram 8/9 2-12...
  • Page 35 MAIN BOARD_Circuit Diagram 9/9 2-13...

  • Page 36: Head Board

    2-3 HEAD BOARD HEAD BOARD_Arrangement Diagram (Component Side) It indicates the version of the Head Board. 2-14...
  • Page 37 HEAD BOARD_Arrangement Diagram (Soldering Side) 2-15...
  • Page 38 HEAD BOARD_Circuit Diagram 1/6 2-16...
  • Page 39 HEAD BOARD_Circuit Diagram 2/6 VHV0 VHV0 CE0.1u FF0_DAC_B[0..9] FF0_DAC_B[0..9] FF0_DAC_B0 VCC45 FF0_DAC_B1 + C3 FF0_DAC_B2 VHV0 FF0_DAC_B3 2SC2873 C106 22u/50V VHV0 NPNB CE0.1u FF0_DAC_B4 FF0_DAC_B5 PNPB R167 FF0_DAC_B6 COM0_A FF0_DAC_B7 2SC4131 VCC3 R168 FF0_DAC_B8 COM0_A FF0_DAC_B9 COM0_A VCC3 FF0_DAC_LAT0 COM0_B COM0_B /FF0_DAC_RESET COM0_B...
  • Page 40 HEAD BOARD_Circuit Diagram 3/6 CN11 VCC3 TP35 TP31 R198 TO Cooling FAN SSI1_B 5267-02A SSI1_B SI1_YB 53398-0490 CN12 TP36 TP32 103HT R199 CE220p SSI1_A SSI1_A SI1_ZB TP33 TP29 R196 SI1_YA SSCK1 SSCK1 TP34 TP30 R197 CE220p SI1_ZA TP19 TP26 R184 SCK1_YB +41V TP20...
  • Page 41 HEAD BOARD_Circuit Diagram 4/6 VHV3 FF0_DAC_B[0..9] VHV3 FF0_DAC_B[0..9] IC13 FF0_DAC_B0 VCC45 FF0_DAC_B1 TR49 + C70 FF0_DAC_B2 VHV3 FF0_DAC_B3 C156 VHV3 NPNB FF0_DAC_B4 FF0_DAC_B5 PNPB R295 R125 TR53 FF0_DAC_B6 COM3_A FF0_DAC_B7 VCC3 FF0_DAC_B8 R296 COM3_A FF0_DAC_B9 COM3_A VCC3 FF0_DAC_LAT3 COM3_B COM3_B /FF0_DAC_RESET COM3_B /F0_POWER_SAVE...
  • Page 42 HEAD BOARD_Circuit Diagram 5/6 VHV2 FF1_DAC_B[0..9] VHV2 FF1_DAC_B[0..9] CE0.1u IC21 FF1_DAC_B0 VCC45 FF1_DAC_B1 TR33 + C48 FF1_DAC_B2 VHV2 FF1_DAC_B3 2SC2873 C144 VHV2 NPNB FF1_DAC_B4 CE0.1u FF1_DAC_B5 PNPB R251 FF1_DAC_B6 TR37 COM5_A 2SC4131 FF1_DAC_B7 VCC3 FF1_DAC_B8 R258 COM5_A FF1_DAC_B9 COM5_A VCC3 FF1_DAC_LAT1 COM5_B COM5_B...
  • Page 43 HEAD BOARD_Circuit Diagram 6/6 VHV3 VHV3 FF1_DAC_B[0..9] IC27 FF1_DAC_B0 VCC45 FF1_DAC_B1 FF1_DAC_B2 TR64 + C88 CN10 C161 FF1_DAC_B3 VHV3 NPNB FF1_DAC_B4 VHV3 FF1_DAC_B5 PNPB R329 R150 FF1_DAC_B6 TR60 COM7_A FF1_DAC_B7 VCC3 R324 FF1_DAC_B8 COM7_A FF1_DAC_B9 COM7_A VCC3 FF1_DAC_LAT3 COM7_B COM7_B /FF1_DAC_RESET COM7_B /F1_POWER_SAVE...
  • Page 44 2-4 SERVO BOARD SERVO BOARD_Arrangement Diagram (Component Side) It indicates the version of the Servo Board. 2-22...
  • Page 45 SERVO BOARD_Arrangement Diagram (Soldering Side) 2-23...
  • Page 46 SERVO BOARD_Circuit Diagram 1/4 2-24...
  • Page 47 SERVO BOARD_Circuit Diagram 2/4 R185 R186 R187 2-25...
  • Page 48 SERVO BOARD_Circuit Diagram 3/4 2-26...
  • Page 49 SERVO BOARD_Circuit Diagram 4/4 EXBA10E103J EXBA10E103J 2-27...

  • Page 50: Heater Board

    2-5 HEATER BOARD HEATER BOARD_Arrangement Diagram (Component Side) It indicates the version of the Board. 2-28...
  • Page 51 HEATER BOARD_Circuit Diagram 1/2 EXBA10E103J EXBA10E103J 2-29...
  • Page 52 HEATER BOARD_Circuit Diagram 2/2 2-30...

  • Page 53: Ink System Board

    2-6 INK SYSTEM BOARD INK SYSTEM BOARD_Arrangement Diagram (Component Side) It indicates the version of the Board. 2-31...
  • Page 54 INK SYSTEM BOARD_Circuit Diagram 2-32...

  • Page 55: Sub Board

    2-7 SUB BOARD SUB BOARD_Arrangement Diagram (Component Side) It indicates the version of the Board. 2-33...
  • Page 56 SUB BOARD_Circuit Diagram 1/4 2-34...
  • Page 57 SUB BOARD_Circuit Diagram 2/4 2-35...
  • Page 58 SUB BOARD_Circuit Diagram 3/4 2-36...
  • Page 59 SUB BOARD_Circuit Diagram 4/4 2-37...

  • Page 60: Takeup Board

    2-8 TAKEUP BOARD TAKEUP BOARD_Arrangement Diagram (Component Side) It indicates the version of the Board. 2-38...
  • Page 61 TAKEUP BOARD_Circuit Diagram 2-39...

  • Page 62: 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,MTD2005-7101 MOTOR DRIVER(Right PUMP) 15189105 IC-LINEAR,MTD2005-7101 MOTOR DRIVER(Left PUMP) 15189105 IC-LINEAR,MTD2005-7101 MOTOR DRIVER(Middle PUMP) HEAD BOARD Reference No. Parts No Description Function...

  • Page 63: 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-540 (Option Dryer) is installed, unplug the power cables of both printer and DU-540 (Option Dryer) before performing parts replacement.
  • Page 64 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) CUTTING CARRIAGE BOARD REPLACEMENT : 7min. 1. THERMISTOR CHECK 1. TOOL UP/DOWN CHECK 2. HEAD ALIGNMENT 2.

  • Page 65: 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. [ ], [ ], [ ] + SUB POWER ON [MENU] key MENU SERVICE MENU Select [SUB MENU] > [HEAD REPLACE], and select the group of the target Head.
  • Page 66 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 67 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 68 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 69 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. After turning on the Main Power SW, turn on the Sub Power SW while pressing the Left, Right and Down keys [ ], [ ], [ ] + SUB POWER ON to enter the Service Mode.
  • Page 70 If you dispose of the drained ink when performing [PUMP U P ] , s e l e c t [ S U B M E N U ] > SUB MENU [MAINTENANCE] >[DRAIN BOTTLE] >[EMPTY DRAIN BOTTLE] > [RESET DRAIN COUNTER] in the User's SUB MENU MAINTENANCE menu, and press the [ENTER] key to reset the drain...

  • Page 71: 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 72 Remove the Wiper and install the new one. Make sure to fix the wiper so that 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 73: Cap Top Replacement

    3-3 CAP TOP REPLACEMENT Remove the Front Cover and Right I/S Cover. Front Cover Right I/S Cover Turn on the Sub Power SW while pressing the Left, Right and Down keys to enter the Service Mode. [ ], [ ], [ ] + SUB POWER ON [MENU] key MENU SERVICE MENU...
  • Page 74 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 75 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 76 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 either tube to the either joint part. 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 enter the Service Mode.
  • Page 77 Select [I/S MENU] > [I/S CONTROL] > [CAP] > [CLOSE], and press the [ENTER] key to move up the Capping Unit 1 step. Then press the [ENTER] key twice more to Cap the Heads with adjusting the position of the Head Carriage.

  • Page 78: Tool Carriage Replacement

    3-4 TOOL CARRIAGE REPLACEMENT Remove the following covers. Revised 3 Front Rail Cover Right I/S Cover Right Top Cover Top Cover Right Top Cover Front Rail Cover Front Cover Top Cover Right I/S Cover Front Cover Separate the Tool Carriage from the Head Carriage. Tool Carriage Head Carriage Remove the Tool Carriage Cover.
  • Page 79 Disconnect the Crop Mark Sensor, Pinch Roller Sensor and Solenoid Wirings. Crop Mark Sensor Pinch Roller Sensor Solenoid Remove the Tool Carriage Board. Tool Carriage Board Screw Remove the Tool Carriage Stay from the Tool Carriage Tool Carriage Stay ASSY. Screw Tool Carriage ASSY Revised 3...
  • Page 80 Remove the Tool Carriage. Screw Tool Carriage Fix the new Tool Carriage by pushing it upwards. Screw Tool Carriage Fix the Tool Carriage by pushing it toward the step of the Cut Carriage Stay when fixing it. Step Cut Carriage Stay Revised 3 Fix the Tool Carriage and the Cut Carriage Stay with the Cut Carriage Stay...
  • Page 81 Fix the Tool Carriage ASSY to the Tool Carriage Stay. Tool Carriage Stay Screw Tool Carriage ASSY Fix the Tool Carriage Board. Tool Carriage Board Fix the Tool Carriage Board so that it is parallel to the Rail. Screw Rail Connect the Crop Mark Sensor, Pinch Roller Sensor and Crop Mark Sensor Pinch Roller Sensor...
  • Page 82 Fix the Tool Carriage Cover. Tool Carriage Cover Be careful not to have a nip at the cable when fixing the Tool Carriage Cover. Carry out the following adjustments and settings. 1. [4-6 LIMIT POSITION & CUT DOWN POSITION INITIALIZE] 2.

  • Page 83: Carriage Motor Replacement

    3-5 CARRIAGE MOTOR REPLACEMENT Turn off the Main Power SW. Main Power SW < REAR VIEW > Remove the Right Inner Plate and Panel Cover. Panel Cover Right Inner Plate Revised 3 Remove the Panel and put it on the Top Cover. Top Cover Flexible Cable is connected to the Panel Panel...
  • Page 84 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 85 Fix the Flange temporarily. And Fix the Spring. Flange Screw Spring Then, tighten up the 4 screws to fix the Flange firmly in Revised 3 Drive Gear order as shown in the figure with checking the gears Motor Gear mesh without backlash. Apply a proper quantity of grease (P/# 21675101 FLOIL GE-676 BLACK 10ML) between gears.
  • Page 86 Fix the Panel Cover and Right Inner Plate. Panel Cover Right Inner Plate Perform the SERVO LOCK CHECK. After turning on the Main Power SW, turn on the Sub [ ], [ ], [ ] + SUB POWER ON Power SW while pressing the Left, Right and Down keys to enter the Service Mode.
  • Page 87 Press the [ENTER] key to excite the Motor. Revised 3 Check the Head Carriage can not be moved easily by hand. SERVO LOCK 1688 [ ENTER ] SERVO LOCK 1688 Check the AGING. Go back to the MOTOR MENU, and select [AGING] > SERVICE MENU [SCAN] >...

  • Page 88: Pump Replacement

    3-6 PUMP REPLACEMENT Remove the Front Cover and Right I/S Cover. Front Cover Right I/S Cover Turn on the Sub Power SW while pressing the Left, Right and Down keys to enter the Service Mode. [ ], [ ], [ ] + SUB POWER ON [MENU] key MENU SERVICE MENU...
  • Page 89 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 90 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 91 Connect the connector of the Pump Motor. Connector Pump Move the Head Carriage to lock it by hand to the lock position. After turning on the Main power SW, turn on the Sub Power SW while pressing the Left, Right and Down keys [ ], [ ], [ ] + SUB POWER ON to enter the Service Mode.
  • Page 92 Clear the pump times. Go back to the Service Menu, and select [HISTORY SERVICE MENU HITORY MENU MENU] > [MOTOR GROUP] > [PUMP TIMES A] > [CLEAR], and press the [ENTER] key. HITORY MENU MOTOR GROUP MOTOR HOURS F 3 hours PUMP TIMES A PUMP TIMES A 9134 times...

  • Page 93: Ink Tube Replacement

    3-7 INK TUBE REPLACEMENT Turn on the Sub power SW while pressing the Left, Right and Down keys to enter the Service Mode. [ ], [ ], [ ] + SUB POWER ON [MENU] key MENU SERVICE MENU Select [SUB MENU] > [PUMP UP], and select the group of the target tube.
  • Page 94 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 95 Disconnect the Ink Tubes from the Ink Dampers, and put the scotch tape at 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 danger of connecting wrongly when fixing the new ones.
  • Page 96 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 97 Cable Guides are fixed next to the Tube Guides. Cable Guide Tube Guide < Rear view of the machine > Turn on the Sub power SW while pressing the Left, Right and Down keys to enter the Service Mode. [ ], [ ], [ ] + SUB POWER ON [MENU] key MENU SERVICE MENU...

  • Page 98: Boards Replacement

    3-8 BOARDS REPLACEMENT (Head / Servo / Main / SW Power Supply) BOARD LAYOUT (IN CHASSIS) 1. When the Board Cover is opened TU Junction Board Heater Servo Board Head Board Main Board Board Board Stay 2. When the Board Stay is removed SW Power Supply (5V, 24V) AC Junction...
  • Page 99 Turn off the Main Power SW and pull out the AC cord. Main Power SW < Rear view > Remove the Board Cover. Board Cover 3-37...
  • Page 100 HEAD BOARD REPLACEMENT HEAD BOARD CONNECTOR LAYOUT CN11 CN11 CN13 CN1~7 Disconnect all the Cables from the Head Board. Remove the screws as shown in the figure to replace to the new Head Board. 3-38...
  • Page 101 Connect all the Cables to the Head Board. Carry out the following checks. 1. THERMISTOR CHECK 2. FAN ON THE HEAD BOARD 3-39...
  • Page 102 SERVO BOARD REPLACEMENT SERVO BOARD CONNECTOR LAYOUT CN16 CN17 CN18 CN15 CN14 CN13 CN12 CN11 CN1,2 Disconnect all the Cables from the Servo Board. Remove the screws as shown in the figure to replace to the new Servo Board. 3-40...
  • Page 103 Connect all the cables to the Servo Board. Carry out the following adjustments and settings. 1. PINCH ROLLER SENSOR CHECK 2. AGING 3. TOOL PRESSURE ADJUSTMENT 4. [4-9 CROP MARK SENSOR ADJUSTMENT] 5. [4-10 CROP-CUT ADJUSTMENT] 6. [4-11 PRINT/CUT POSITION ADJUSTMENT] 3-41...
  • Page 104 MAIN BOARD REPLACEMENT MAIN BOARD CONNECTOR LAYOUT CN12 CN11 CN10 Turn on the Main Power SW. Main Power SW < Rear view > Start the Peck. 3-42...
  • Page 105 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. Remove the screws as shown in the figure fixing the head Revised 1 Board and Main Board, and replace with the new Main...
  • Page 106 Connect all the cables to the Head Board. Perform the following operations after replacement. 1. DIP SW SETTING 2. BATTERY INSTALLATION 3. FIRMWARE INSTALLATION 4. SYSTEM PARAMETER INITIALIZE 5. IP ADDRESS SETTING ( Turn on the power with the Service Mode and set IP Address in the User Menu.) 6.
  • Page 107 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 Revised 1 Disconnect the Cables from the following boards and remove them with the Stays. HEATER BOARD SERVO BOARD Main Board...
  • Page 108 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 109 Revised 1 Fix the following boards. Connect all the Cables. HEATER BOARD SERVO BOARD Main Board Servo Board MAIN BOARD Head Board HEAD BOARD Heater Board 3-47...
  • Page 110 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 111 Connect all the Cables. Revised 1 Fix the following boards. Connect all the Cables. HEATER BOARD SERVO BOARD Main Board Servo Board Head Board MAIN BOARD HEAD BOARD Heater Board 3-49...

  • Page 112: Battery Replacement

    3-9 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. Revised 3 Turn off the Sub Power SW, and then turn off the Main Power SW.
  • Page 113 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 114 Select [SUB MENU] > [CLOCK] > [DATE], and set the SERVICE MENU SUB MENU date and press the [ENTER] key. SUB MENU CLOCK CLOCK DATE DATE 00/00/00 DATE 06/08/08 Edit screen Revised 3 Turn off the Sub Power SW, and then turn off the Main Power SW.
  • Page 115 3-10 CARRIAGE BELT REPLACEMENT Turn off the Main Power SW. Main Power SW < Rear view > Remove the following covers. Right Top Cover Front Rail Cover Right I/S Cover Top Cover Panel Cover Top Cover Right Top Cover Front Rail Cover Front Cover Panel Cover Flexible Cable is connected to the Panel...
  • Page 116 Turn off the Sub Power SW and Main Power SW. Main Power SW < Rear view > Separate the Tool Carriage from the Head Carriage. Tool Carriage Head Carriage Loosen the 2 Fixingscrews as shown in the figure < Top view - Leftside of the Belt > located leftside of the Belt.
  • Page 117 Replace to the new Carriage Belt. Check that the Belt is not twisted. Put adequate quantity of grease (P/# : 39008297•FLOIL G902 14KG) between pulleys. Tighten the Screws shown in the figure to fix both edges < Cross-section diagram > of the Carriage Belt to the Belt Holder.
  • Page 118 Loosen the Screw half around to make a gap between the Stay and Shaft. Screw Tighten the Adjustment Screw to have tension on the < Top view - Leftside of the Belt > Belt. And tighten the 2 Fixingscrews as shown in the figure.
  • Page 119 Carry out the following adjustments and setting. 1. [4-15 Belt Tension Adjustment] 2. [4-16 Belt Position Adjustment] 3. [4-6 Limit Position & Max Scan Width Initialize] 4. Cutting quality check 3-57...

  • Page 120: Encoder Scale Replacement

    3-11 ENCODER SCALE REPLACEMENT Remove the following covers. Front Cover Front Rail Cover Right I/S Cover Right I/S Cover Front Rail Cover Front Cover Turn on the Sub Power while pressing the Left, Right and Down keys to enter the Service Mode. [ ], [ ], [ ] + SUB POWER ON [MENU] key MENU...
  • Page 121 Remove the Encoder Scale by removing the Plate fixing the Encoder Scale at 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 where there is no black dot written on it.

  • Page 122: Cutting Flexible Cable Replacement

    3-12 CUTTING FLEXIBLE CABLE REPLACEMENT This is a procedure to replace the Cutting Flexible Cable between the Servo Board and Tool Carriage. Front Rail Cover Top Cover Remove the following covers. Right I/S Cover Top Cover Front Cover Right I/S Cover Front Rail Cover Front Cover Turn on the Sub Power while pressing the Left, Right and...
  • Page 123 Remove the Encoder Scale by removing the Plate fixing the Encoder Scale at its right end and the Spring on its Spring Encoder Scale left end. Remove the Encoder Scale to protect. Because there is a possibility to scratch or put grease on the Encoder Scale when replacing the Flexible Cable.
  • Page 124 Remove the Tool Carriage Cover. Tool Carriage Cover Remove the Tool Carriage Board Cover. Tool Carriage Board Cover Disconnect the Crop Mark sensor, Pinch Roller Sensor Pinch Roller Sensor Tool Carriage and Solenoid Wirings. Board Crop Mark Sensor And remove the Tool Carriage Board. Solenoid Remove the Flexible cable and the Protection Plate from the Tool Carriage Board.
  • Page 125 Connect the new Flexible Cable to the Tool Carriage Board. Then, fix the 2 new Protection Plate with putting the Flexible Cable between them. Protection Plate Be careful with the fixing direction of the Flexible Cable. Turn over the board and fix the Protection Plate with the rivets.
  • Page 126 Move the Tool Carriage Board to the far left. Pull the Flexible Cable rightward with holding the Inner Protection Plate at the left side so that the Flexible Cable fits to the Inner Protection Plate. If the Flexible Cable is not pulled enough or pulled too much, there will be the slack in the Protection Plate. Tool Carriage Board Inner Protection Plate Flexible Cable...
  • Page 127 Fix the Flexible Cable with the Clamp. Clamp Fix the Tool Carriage Board, and connect the Crop Mark Pinch Roller Sensor Tool Carriage Sensor, Pinch Roller Sensor and Solenoid Wirings. Board Crop Mark Sensor Solenoid Put the Encoder Scale in between the Encoder Plate and the Guide Rail.
  • Page 128 Fix the Tool Carriage Board Cover. Tool Carriage Board Cover Fix the Tool Carriage Cover. Be careful not to have a nip at the cable when fixing the Tool Carriage Cover. Tool Carriage Cover Carry out the following setup. 1. [4-7 Linear Encoder Setup]. 3-66...

  • Page 129: Pinch Roller Replacement

    3-13 PINCH ROLLER REPLACEMENT Conical Type is used on both Left & Right Pinch Rollers Left Pinch Roller Right Pinch Roller and flat type is used for the Middle Pinch Rollers. Red marking is done on the outer side of Left &...

  • Page 130: Take-Up Board Replacement

    3-14 TAKE-UP BOARD REPLACEMENT Remove the TU Cover. TU Cover Remove the 2 screws as shown in the figure to remove the Plate fixing the Board. Board Plate Shaft Remove all the cables that are connected to the Board. Remove the 4 screws to remove the Board from the Plate.
  • Page 131 Connect all the cables to the Board. Fix the Plate. Board Plate Shaft Fix the TU Cover. TU Cover Check the following. 1. [4-17 TAKE-UP UNIT OPERATION CHECK] 3-69...

  • Page 132: Adjustment

    4 Adjustment 4-1 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-002 Tool Name TENSION GAUGE 300g (3N) Purpose TOOL PRESSURE ADJUSTMENT Tool No.

  • Page 133: Service Mode

    4-2 SERVICE MODE MENU ], [ ], [ ] + POWER ON [ MENU ] key SERVICE MENU HEAD RANK 1 SERVICE MENU PRINT MENU HEAD RANK This menu is used for entering the HEAD RANK for each HEAD PRINT MENU HEAD RANK 1234567 (1/5) with 35 digit number and alphabet.
  • Page 134 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 Error is found on LINEAR ENCODER Head Board. HEADBOARD FAILED This menu is for checking the installation and operation of Encoder Module and Encoder Scale.
  • Page 135 Normal NOW PROCESSING.. I/S CHECK SERVICE MENU I/S MENU 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 136 Remove all cartridges Set cartridge to SLOT1 before pressing ENTER All cartridges must be removed before entering IC CARTRIDGE IC CHECK I/S MENU CHECK menu. It detects Ink Cartridge IC, writes and loads information, SLOT1 INSERT CARTRIDGE IC CHECK and checks the communication. First of all, it confirms if there is the driver for IC detection.
  • Page 137 MIN 2.5V MAX2.7 SERVICE MENU CUTTING MENU CROPMARK SENSE PERFORMING OUTLEVEL CHECK TEST PRINT [2.5V ] CUTTING MENU CROPMARK SENSE This menu is used for adjusting the Crop Mark Sensor. Refer to [4-9 CROP MARK SENSOR ADJUSTMENT]. The result of this adjustment can be checked in the SENSOR CHECK menu. However, it must be aware that without adjusting the sensor here, the result of [S: CROP MARK SENSOR] in the SENSOR CHECK menu is not referable.
  • Page 138 THERMISTOR CHK SERVICE MENU This menu is used for checking Thermistor. It displays the temperatures read from the thermistor placed on the K head, HEAD4, and HEAD:25 C/ 77 F THERMISTOR CHK the thermistor placed on the Head Board (TH1). The temperature on the left is in Celsius ans the right is in Fahrenheit. Since the temperature of the device on the Head Board may rise, [HEAD] and [BOARD] shows higher temperature than the room temperature.
  • Page 139 PERIODIC CL. SUB MENU This menu is to select the type of periodic cleaning which is automatically performed during printing. Options: WIPE / LIGHT / NORMAL / MEDIUM Default: NORMAL LIGHT LIGHT PERIODIC CL. WIPE: Wiping and flushing only LIGHT: Wiping and light evacuation (lighter than regular cleaning) only NORMAL/MEDIUM: The regular cleanings that can be executed from the control panel Cleaning period can be set up in PERIODIC CL.
  • Page 140 SCAN : Aging for Scan Motor. AGING SCAN SERVICE MENU MOTOR MENU The Head Carriage runs max. printing width in Scan direction. SCAN NOW AGING MOTOR MENU AGING FEED : Aging for Feed Motor. Grit Roller runs 100mm back and forth. AGING FEED BOTH : The Head Carriage runs max.
  • Page 141 HISTORY MENU SERVICE MENU MOTOR HOURS F MOTOR HOURS F HISTORY MENU MOTOR GROUP 3 hours CLEAR In History Menu, the parameters are separated in groups CATEGORIES : MOTOR GROUP / HEAD GROUP / The menu shown on the upper LCD can be changed with [up] and by categories.
  • Page 142 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 143 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...
  • Page 144 Roland SOL JET PRO III series Ink type Model XC-540 IP Address E-SOL Max LcLm 133, 111, 128, 060 74/ 86/ 64/ 100/ 71/ 100 255, 255, 252, 000 Ink remain (1-6) Version 1.02 Subnet Mask Ink remain(7-12) 100/ 100/ 97/ 72/ 100/ 100 Serial No.
  • Page 145 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 146 Ink Cartridge Report Model XC-540 Serial No. : XX00001 Version 1.02 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 147 ] + SUB POWER ON [MENU] + SUB POWER ON machine in the SERVICE REPORT PRINTING mode. SERVICE REPORT [SERVICE REPORT] is displayed Roland DG Corp. XC-540 and it turns to be the normal mode after printing. SETUP SHEET It starts printing automatically when...
  • Page 148 Key Combinations Function for Service Combination Key Selection Comments Press [MENU] and [ ] to enter Service Service Mode 　 　　　　　　　　+　　Sub Power Menu. [UPDATE FIRMWARE?] will be displayed. Upgrade F/W 　 　　　　　　　　+　　Sub Power Press [ENTER] to upgrade F/W. Use this when the main board is 　...

  • Page 149: How To Upgrade Firmware/Install Firmware

    REVISED 1 4-3 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.Peck4.exe 4.Network cable (A cross cable is required when you connect XC-540 to PC directly.) HOW TO UPGRADE FIRMWARE (Referential Time : 5 min) Check the IP address of XC-540.
  • Page 150 Start the Peck4 on PC. [Peck4] screen is displayed, and click [Select Port] button. Select [Type 3] ProIII etc. from [Product]. Also, select [Via Network] and input IP address of XC-540 specified ealier. Click [OK] button. [Peck4] screen is displayed again. Click [Firmware Upgrade] button.
  • Page 151 The machine goes into the Firmware Upgrade mode automatically. FIRMWARE V1.0 DATA ERROR When upgrade is completed, the Sub Power switch 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 152 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 ENTER key to go next address setting. When [GATEWAY ADDR.] is set, it returns to the waiting mode for receiving the firmware by pressing ENTER key.
  • Page 153 [Peck4] 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 XC-540. It starts loading the firmware. The firmware installation is done when [COMPLETE] FIRMWARE V1.0 DATA ERROR...
  • Page 154 Turn on the Sub Power switch while pressing [ ],and [ENTER] keys to enter [INITIALIZE ALL ] , [ ] , [ENTER] + SUB POWER ON SYS.PARAMETER] menu. Press [ENTER] key to start initialization. The Sub Power turns off automatically when it is completed. INITIALIZE ALL SYS,PARAMETER INITIALIZE...
  • Page 155 Start the Peck4 on PC. [Peck4] 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]. Peck4 starts to send the System Parameter to XC-540.

  • Page 156: How To Upgrade Firmware Of The Network Controller

    4-4 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 157 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. 4-26...

  • Page 158: Head Alignment

    REVISED 3 4-5 HEAD ALIGNMENT (Referential Time : 30 min._1 Head Alignment) [About HEAD ALIGNMENT] HEAD ALIGNMENT is necessary to obtain the good printing quality. Be sure to operate the HEAD ALIGNMENT when the HEAD is replaced. If the heads are not aligned, printing problems such as banding, fine lines and gap between bands could occur. Please DO NOT use Take-Up devise for this alignment.
  • Page 159 Turn on the SUB POWER SW while pressing [ ], [ and [ ] keys to enter the SERVICE MODE. ] , [ ] , [ ] + SUB POWER ON Setup the PET film on the machine. [MENU] key MENU SERVICE MENU [BIAS ADJUSTMENT]...
  • Page 160 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 3/4 turn.
  • Page 161 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. 4-30...
  • Page 162 [VERTICAL ADJUSTMENT] Select the [VERTICAL] > [TEST PRINT] under the SERVICE MENU [HEAD ADJUST] menu and press the [ENTER] key. PRINT MENU [ ] [ ] PRINT MENU HEAD ADJUST HEAD ADJUST VERTICAL VERTICAL TEST PRINT TEST PATTERN shown on the right will be printed. The test pattern changes if the Base Head is changed.
  • Page 163 - 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 refering to the left- end K head as the base position.
  • Page 164 If the VERTICAL test print reult is satisfactory, select the [BIAS] > [TEST PRINT] menu under the [HEAD ADJUST] menu and print the BIAS test pattern again. If the BIAS test print result is not satisfactory, repeat BIAS ADJUSTMENT. 4-33...
  • Page 165 [ HORIZONTAL ADJUSTMENT ] Select the [HORIZONTAL] > [TEST PRINT] in the [HEAD SERVICE MENU ADJUST] menu and press the [ENTER] key. PRINT MENU [ ] [ ] PRINT MENU HEAD ADJUST HEAD ADJUST HORIZONTAL HORIZONTAL TEST PRINT Following TEST PATTERN will be printed. Find the position where the line of each color matches the K line and check the number.
  • Page 166 Select [DT1, Low], [DT3, Low], [DT1, HIGH] and [DT3, HIGH] in the [HEAD ADJUST] 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 167 [ BIDIRECTION ADJUSTMENT ] Select [BI-DIR.DEFAULT] > [TEST PRINT] in the [HEAD ADJUST] menu and press the [ENTER] key. SERVICE MENU PRINT MENU [ ] [ ] 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 168 Select [DT1, Low], [DT3, Low], [DT1, HIGH] and [DT3, HIGH] in the [HEAD ADJUST] menu and enter the Parameters can be entered with an parameters checked at 22 with [ ] and [ ] keys. Press the [ENTER] key to save the settings. increment of 1/2.

  • Page 169: Limit Position & Cut Down Position Initialize

    4-6 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, and also cause a cutter-down error when separating the sheet.
  • Page 170 Confirm that HEAD CARRIAGE is connected to TOOL CARRIAGE. Also, lock the connected carriages if they are not locked. After locking the carriages, push them lightly towards left to confirm it is locked and also to eliminate looseness. Confirm the relative positions of Head and Cap, moving the capping unit up and down with [ ] and [ ] keys.
  • Page 171 Loosen the 4 screws fixing the capping unit. Return the carriages to the lock position. After the carriages are locked, push them to the left lightly to eliminate the looseness. Adjust the position of the capping unit right and left to be located at the proper position under the Head, with your hands.
  • Page 172 Confirm that the Head is certainly capped, and press the [ENTER] key again. The Tool Carriage automatically SETTING UP THE LIMIT leaves the Head Carriage and it starts LIMIT POSITION INITIALIZE. After the completion of the INITIALIZE, the message is indicated as shown on the right.

  • Page 173: Linear Encoder Setup

    4-7 LINEAR ENCODER SETUP (Referential Time : 10min.) LINEAR ENCODER SETUP is performed to confirm that the installation of Linear Encoder is proper, and also to confirm that it properly reads and corrects the width of the scale, which is stretched or shrunk due to the operation environment, by the software coordinates.
  • Page 174 One of the messages appears at the completion of the set up. In case of SETUP error, check the followings. 1. Dirt/Scratch on the ENCODER SCALE. LINEAR ENCODER 2. Dirt/Scratch on the ENCODER MODULE. SETUP COMPLETED 3. ENCODER SCALE is not between the ENCODER MODULE.
  • Page 175 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 176 Move the cap upward to the position that the cap contacts exactly to the head, then press [ENTER] to CAP ADJUST ADJUST POS. update the adjustment value. HEAD ADJUST POS. 0.00 -2.00 -When you press [ ] key, the cap moves upward in 0.25mm unit.
  • Page 177 The result of the crop mark recognition on Roland media is not assured, when any media other than SV-G-1270G is used for this adjustment.
  • Page 178 Turn on the sub power switch while pressing [ ], [ and [ ] keys to enter the SERVICE MODE. ] , [ ] , [ ] + SUB POWER ON Setup the SV-G-1270G film on the machine. [MENU] key MENU SERVICE MENU Select [OUTLEVEL CHECK] under the [CROPMARK...
  • Page 179 Perform [OUTLEVEL CHECK] again and confirm that the MAX voltage is proper. If it is out of range, repeat the adjustment. Min2.5V Max2.7V [2.5V] 4-48...

  • Page 180: Crop Cut Adjustment

    4-10 CROP-CUT ADJUSTMENT (Referential Time : 10min.) This adjustment is for calibrating the relative positions of Tool and Crop Mark Sensor. If it is not adjusted, the cutting position based on the detected Crop Marks becomes wrong, and that results in the mis-alignment of the Print and Cut when performing the auto crop mark detection.
  • Page 181 From the Test Pattern, find the value where the print line <TEST PATTERN> matches the cut line. +2.0 -2.0 In this case, the correction value for the scan direction is Correction-value scale +1.5 -1.5 "-0.3". +1.0 -1.0 -0.5 +0.5 -0.5 When it is difficult to see the cut line visually, use a magnifier.
  • Page 182 A mark is printed, and detected by the crop mark sensor, Broken line is indicating the cut line and its contour is cut. Confirm the cut line position on the print visually. When it is difficult to see the cut line visually, use a magnifier.

  • Page 183: Print/Cut Position Adjustment

    4-11 PRINT / CUT POSITION ADJUSTMENT (Referential Time : 10min.) This adjustment is for calibrating the relative positions of printing and cutting. If it is not adjusted, it may result in the mis-alignment of the printing and cutting. This adjustment is required when Crop Mark Sensor, Tool Carriage or Print Head is replaced or adjusted, and also when the relative distance between Tool and Print Head is changed.
  • Page 184 From the Test Pattern, find the value where the print line <TEST PATTERN> matches the cut line. +2.0 -2.0 In this case, the correction value for the scan direction is Correction-value scale "-0.3". +1.5 -1.5 +1.0 -1.0 -0.5 +0.5 -0.5 When it is difficult to see the cut line visually, use a magnifier.
  • Page 185 Three marks are printed at the left-end , right-end and the center of the media, and each mark is cut. Confirm the cut line positions on the marks visually. When it is difficult to see the cut line visually, use a magnifier. Broken line is indicating the cut line Adjustment is completed if the position error of cut line is within the range below.

  • Page 186: Calibration (Feeding Direction)

    4-12 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 is made based on the value in feeding media [PET-G].
  • Page 187 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] menu, the Test Pattern is not changed.

  • Page 188: Tool Height Adjustment

    4-13 TOOL HEIGHT ADJUSTMENT (Referential Time : 20min.) Remove the Front Rail Cover. FRONT RAIL COVER Turn on the sub power switch while pressing [ ] , [ ] , [ ] + SUB POWER ON ] and [ ] keys to enter the SERVICE MODE. Select [FORCE ADJUST] menu.
  • Page 189 Move the Pinch Rollers at the positions shown in the figure, and lower them. PINCH ROLLER GRIT ROLLER Move the Tool Carriage to the position under the H mark TOP COVER which is written on the rail. RAIL BELT The rail has an H mark at the point where Tool H e i g h t A d j u s t m e n t i s m a d e d u r i n g t h e production of the machine.

  • Page 190: Tool Pressure Adjustment

    4-14 TOOL PRESSURE ADJUSTMENT (Referential Time : 15min) This adjustment is to specify the tool pressure during Cutting. Before this adjustment, it is necessary to carry out [4-13 TOOL HEIGHT ADJUSTMENT]. Turn on the sub power switch while pressing [ ] , [ ] , [ ] + SUB POWER ON...
  • Page 191 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 H e i g h t A d j u s t m e n t i s m a d e d u r i n g t h e production of the machine.
  • Page 192 Pull up the handle part of the Tool Holder with the TENSION GAUGE(ST-002) and measure the pressure ST-002 when the pen tip leaves the Bed. Adjust the parameter in the [200gf] menu with [ and [ ] keys for the pressure to be 195 to 205gf (1.9N to 2.0N).

  • Page 193: Belt Tension Adjustment

    4-15 BELT TENSION ADJUSTMENT (Referential Time : 20min.) Turn on the sub power switch while pressing [ ] and [ ] keys to enter the SERVICE MODE. ] , [ ] , [ ] + SUB POWER ON [MENU] key MENU SERVICE MENU Select [I/S MENU]>[I/S CONTROL]>[CAP]>[OPEN],...
  • Page 194 Remove the Front Rail Cover and Top Cover. TOP COVER FRONT RAIL COVER Measure the tension of the belt at the position above <Front side> Upper Belt the center of the 4th grit roller from the left using TENSION GAUGE(ST-001). Hold down the belt with Tension Gauge Press the upper belt downward with the gauge to make...
  • Page 195 Insert a wrench through the holes on the side frame SCREW prepared for the adjustment, and loosen the two screws to make a gap of 3mm between the tip of the screw and Idle Pulley Holder. (The belt tension cannot be adjusted higher when the screw contacts with Idle Pulley Holder.) The gap between the screws and Idle Pulley can be seen from both front side and rear...

  • Page 196: Belt Position Adjustment

    REVISED 1 4-16 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 197 Turn on the Sub Power switch while pressing [ ] and [ ] keys to enter the SERVICE MODE. ] , [ ] , [ ] + SUB POWER ON [MENU] key MENU SERVICE MENU [ADJUSTMENT ON THE DRIVE PULLEY SIDE] Carry out the AGING test for the belt.
  • Page 198 Loosen the two fixing screws located on the right end of STAY the belt. FIXING SCREW Loosen the screws about 3 rounds for the SCREW bottom of the screw head not to contact with the Stay. STAY Press [ENTER] key to restart AGING. AGING SCAN Adjust the belt position turning the Adjustment Screw...
  • Page 199 Belt leans to the rear side of the machine ADJUSTMENT SCREW -Turn the screw carefully in CW (tightening). Touching the frange on the REAR side of machine 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.
  • Page 200 Press [ENTER] key to cancel AGING. SCAN NOW AGING 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.
  • Page 201 Insert a wrench through the holes on the side frame and IDLE PULLEY adjust the belt position turning the screw 1 and 2 as follows. SCREW Not touching the flanges 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 202 Tighten the two fixing screws shown in the figure. Be cautious with the moving Carriages and Cablebeyor during the work, and also with the sharp edges of the mechanical parts around it. FIXING SCREW Confirm that the belt is not touching the pulley flanges PULLEY FLANGE excessively while the carriages are in the printing area.

  • Page 203: Take-Up Unit Operation Check

    4-17 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 switch.
  • Page 204 Confirm that [START] is selected, and press [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 diplayed on the right. Set the AUTO switch of the Take-up Unit to either FORWARD or BACKWARD.
  • Page 205 Move the Dancer Roller up and down by hand, and confirm that the drive part does not rotate. Drive Part DANCER ROLLER 4-74...

  • Page 206: Supplemental Information

    5 Supplemental Information 5 Supplemental Information 5-1 SENSOR MAP REAR PAPER SENSOR It detects the rear edge of the media and also whether the THERMOSTAT media is loaded or not. If the Heater exceeds the limit temperature, it stops LIMIT SENSOR the power supply.
  • Page 207 5 Supplemental Information THERMISTOR(PRE-HEATER) It takes the temperature of the Pre-Heater. THERMOSTAT If the Pre-Heater exceeds the limit temperature, it stops the power supply. (Rear side of the machine) THERMISTOR(DRYER ) It takes the temperature of the Dryer. THERMOSTAT If the Dryer exceeds the limit temperature, it stops the power supply.
  • Page 208 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. THERMISTOR (HEAD) It takes the temperature around the Head. The black Head is used for the measurement.
  • Page 209 5 Supplemental Information PINCH ROLLER SENSOR It detects the positions of Pinch Roller. It detects whether the Media Clamp is set or not. CROP MARK SENSOR It detects the Crop Mark. THERMISTOR (HEAD BOARD) It takes the temperature around the Head Board. INK CARTRIDGE SENSOR It detects whether the Ink Cartridge is installed or not.
  • Page 210 5 Supplemental Information DANCER ROLLER SENSOR It measure the Dancer angle, carries out the weight control, and then adjusts media tension.

  • Page 211: 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 212: Particular Color Is Not Printed At All

    CHECKING POINT ACTION REFERENCE OUTLINE Nozzle condition becomes poor due to the foreign substances stuck on 14 Foreign substances Manual Cleaning User's Manual the surface of the Head. [3-2 WIPER Cleaning the head with Wiper is not performed efficiently and it cannot 15 Wiper wears out Wiper Replacement REPLACEMENT]...

  • Page 213: Shifting In Printing/Color Shifting

    6-3 SHIFTING IN PRINTING/COLOR SHIFTING CHECKING POINT ACTION REFERENCE OUTLINE Misalignment occurs when the media becomes wrinkled and comes The media is set tilted Set the media correctly User's Manual loose from the Platen if the media is not set straight. Make sure to set the media straight referring to the User's Manual.

  • Page 214: Print Does Not Match With Cut (When Not Using The Crop-Mark Function)

    6-7 PRINT DOES NOT MATCH WITH CUT (WHEN NOT USING THE CROP-MARK FUNCTION) CHECKING POINT ACTION REFERENCE OUTLINE Shifting of Printing and Cutting Position within +/-0.5% of distance traveled, or +/-3mm whichever is greater in tolerance. Repetition between printing and cutting is +/-0.5mm or less. When the heater is used, the media may experience subtle deformation due to thermal Shifting of Printing and expansion or contraction.

  • Page 215: Print Does Not Match With Cut (When Using The Crop-Mark Function)

    6-8 PRINT DOES NOT MATCH WITH CUT (WHEN USING THE CROP-MARK FUNCTION) CHECKING POINT ACTION REFERENCE OUTLINE User's Manual Crop-Cut Adjustment is to calibrate the error in the relative positions of Crop-Cut Adjustment is Tool and Crop Mark Sensor. Therefore, printing and cutting positions Crop-Cut Adjustment not correct [4-10 CROP-CUT...

  • Page 216: Start And End Points Do Not Match

    6-10 START AND END POINTS DO NOT MATCH CHECKING POINT ACTION REFERENCE OUTLINE Blade used on the machine has offset and therefore, tip is shifted from Blade Offset doesn't its center. When the offset setting done on the machine doesn't match match with the offset on Match Offset User's Manual...

  • Page 217: Distorted Cutting Figure

    6-11 DISTORTED CUTTING FIGURE CHECKING POINT ACTION REFERENCE OUTLINE Blade Holder is set loose Secure the Blade When Blade Holder is set loose on Tool Carriage, the blade tip User's Manual on Tool Carriage Holder becomes very shaky when cutting and results in distorted figure. Since the blade used on the machine has offset, tip is shifted from its Blade Offset is not set Match Offset...

  • Page 218: Motor Error

    When Grit Roller becomes loose, feeding amount between left and Grit Roller is loose Fix the Grit Roller right edges will be different and results in media shifting. 6-13 MOTOR ERROR CHECKING POINT ACTION REFERENCE OUTLINE When the edge of the media curls or the media absorbs the Ink and Remove cause of Media Jamming becomes irregular surface of the media, the Print Carriage catches on...

  • Page 219: Heater / Dryer Temperature Does Not Go Up

    6-14 HEATER / DRYER TEMPERATURE DOES NOT GO UP CHECKING POINT ACTION REFERENCE OUTLINE Even if [SETUP] LED is OFF, when the [HEATER MENU] > The media is not loaded [PREHEATING] was set to ''MENU'', the Heater can reach the set Set up the media User's Manual and set up correctly...

  • Page 220: Error Message

    6-17 ERROR MESSAGE CHECKING POINT ACTION REFERENCE OUTLINE service call Refer to service call Refer to service call This message is displayed when an unexpected error occurs. Restart Restart the machine 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 221 Even though the machine Revised 3 carries out the regular Limit Sensor does not work correctly or is Limit Sensor replacement 0103 movement, the output of broken. Check the backlash or loose with the driving parts of the carriage. Limit Sensor does not reach the expected value.

  • Page 222: Service Activities

    7 Service Activities 7-1 INSTALLATION CHECK LIST XC-540 INSTALLATION CHECK LIST Date Serial Number User Unpacking The following space is reserved for installing the machine. 3700 mm (145.7 in.) 2700 mm (106.3 in.) Unit space Work space Install the machine in a location that is level, stable, and able to bear the weight of the machine. Total weight of the machine is 200kg (Body + Stand) or more.
  • Page 223 Unpacking...
  • Page 224 Unpacking the Stand Shafts Stay Stand Legs Unpacking the Accessory Box Ink-cartridge tray Manual, CD-ROM, etc.
  • Page 225 Checking the Accessories Stay : 1 Dancer roller : 1 Stand leg (Left) : 1 Stand leg (Right) : 1 Paper pipe : 1 Shaft : 2 Power cord : 1 Rail slider : 1 Arm/Arm retaining Stopper : 4 Media flanges : 2 ink-cartriddge try :1 screw : 1 set...
  • Page 226 Assembling Set up following items in reference to the Setup Guide [3.Assembling and Installing]. In case of setting up DU-540, refer to the DU-540 Uer's Manual [1-4 Installing on the Printer]. Assemble the Stand Attach the Included Items Mount the Machine Install the Drain Bottle Attach the Ink-cartridge Tray Removing the Packing Materials...
  • Page 227 Free hard-disk space required for installation : 100MB or more Free hard-disk space required for operation : 1GB or more recommended Make the setting for Roland@NET Select the check box [Download Updates Automatically and Notify] if the customer accepts it.
  • Page 228 Loading and Cutting Off Media Explain following items in reference to the User's Manual [2-2 Loading and Cutting Off Media] and [8-1 Usable Media]. Load the Roll Media !! IMPORTANT !! - Never load media that weights more than 30 kg (67 lb.). - Attach the media flanges to the roll media by matching to the inner diameter of the roll media core.
  • Page 229 Operation Explain following items in reference to the User's Manual. Switching the Power On and Off This machine has two power switches (three power switches when with DU-540). Whenever outputting is finished, switch off 2 and 3. Leave the main power switch 1 on at all times, never switching either one off. *This machine switches to a low-power ''sleep mode'' when a fixed interval passes with no operation.
  • Page 230 - Blade Force - Cutting Speed - Blade Offset - Tool-up Speed !! IMPORTANT !! Explain about [CUTTING PRIOR] as below. [MENU]... Cuts with the cutting conditions set on the machine. [COMMAND]... Cuts with the cutting conditions set on the Roland VersaWorks.
  • Page 231 Starting Cutting Print / Cut Position Adjustment Starting Print & Cut !! IMPORTANT !! - Make sure the [AUTO ENV. MATCH] menu is set to ''ENABLE.'' - Before you start cutting, allow the media to dry thoroughly. - Never use the Media Clamps when performing cutting. - Set the value of [CALIBRATION] in [CUTTING MENU] to [0] when using the machine for printing &...
  • Page 232 Maintenance Explain following items in reference to the User's Manual. Disposing of Discharged Ink [CHECK DRAIN BOTTLE] message appears when a certain amount of discharged fluid collects in the bottle. !! IMPORTANT !! - When you dispose of Discharged Ink, make sure to reset the discharged-fluid count from [MENU] > [SUB MENU] >...
  • Page 233 When Moving the Unit !! IMPORTANT !! - Before moving the machine, you must perform [HEAD WASH] in [INK CONTROL] menu. This operation requires eight UNUSED SOL INK cleaning cartridges. - You must fill ink within 1 week after performing the HEAD WASH. The nozzles of the Heads are clogged if the machine is left for a prolonged period after removing the ink.
  • Page 234 Correcting Misalignment for Printing or Cutting Perform following corrections / adjustments to correct misalignment for the media you're using. 1. <Bidirectional Adjustment> Bidirectional adjustment corrects subtle misalignment occurs in the Bi-Direction printing. This misalignment varies according to the head height and thickness of the media, so perform this adjustment to match the media you're using.
  • Page 235 Others Explain to switch off and on the machine and check what happens before calling for inquiry, when [SERVICE CALL] is displayed. It may solve the problem. Explain the action to take when the head carriage stops over the platen in reference to the User's Manual [7-6 The Print Heads Stopped Moving].

  • Page 236: Maintenance Check List

    7-2 Maintenance Check List XC-540 MAINTENANCE CHECK LIST Date : Serial Number User !! IMPORTANT !! If the DU-540 (Drying-heater unit) is installed in the printer, disconnect both power cord of the Printer and Drying-heater unit before performing the maintenance activity. Check Items Operation Points Check...

  • Page 237: Specification

    7-3 Specifications Main Unit Specification XC-540 Printing/Cutting method Piezo ink-jet method/media-moving method Acceptable media widths 260 to 1371 mm (10-1/14 to 54 in.) Printing/Cutting width (*1) Maximum 1346 mm (53 in.) Ink cartridges Types ECO SOL MAX 220cc cartridge / 440cc cartridge Six colors (cyan, magenta, yellow, black, light cyan, light magenta) or Color Four colors (cyan, magenta, yellow, and black)
  • Page 238 The length of printing or cutting is subject to the limitations of the program or driver. At 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 239 Conditions for Usable Media Use genuine media from Roland DG Corp. Media width 10-1/4 to 54 inches (260 to 1371 mm) A) Cuttable media thickness 0.08 to 0.22 mm (3.2 to 8.6 mil) (depending on media composition) B) Maximum media thickness (including backing paper) Printing only : 1.0 mm (39 mil)

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