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Roland Advanced Jet AJ-1000 Service Notes

Roland Advanced Jet AJ-1000 Service Notes

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User manual (128 pages)

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SERVICE NOTES

Contents

1 Structure & Spare Parts

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1-1

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1-2

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1-3

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1-4

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1-5

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1-6

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1-7

1-8

MAINTENANCE LIQUID CARTRIDGE

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1-9

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1-10 INK SYSTEM

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1-11 SUB TANK SYSTEM

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1-16 ACCESSORIES

2 Electrical Section

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2-1

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2-2

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2-3

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2-4

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2-5

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2-6

PUMP DRIVE BOARD

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2-7

2-8

MAINTENANCE PARTS LIST

3 Replacement of Main Parts

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3-1

HEAD REPLACEMENT

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3-2

WIPER REPLACEMENT

3-3

CAP TOP REPLACEMENT

3-4

CARRIAGE MOTOR REPLACEMENT

3-5

SUPPLY PUMP REPLACEMENT

3-6

INK TUBE REPLACEMENT

3-7

BOARDS REPLACEMENT

(Main Board / SW Power Supply)

3-8

BATTERY REPLACEMENT

3-9

CARRIAGE BELT REPLACEMENT

3-10 ENCODER SCALE REPLACEMENT

3-11 TU BOARD REPLACEMENT

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1-11

1-13

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1-14

1-15

1-17

1-19

1-20

1-21

1-23

1-25

1-27

2-19

2-26

2-34

2-42

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2-54

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3-13

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3-18

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3-23

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3-30

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3-40

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3-50

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3-53

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3-59

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3-62

1-1

4-1

1-3

4-2

1-5

4-3

HOW TO UPGRADE FIRMWARE

1-7

4-4

1-9

4-5

CAPPING POSITION ADJUSTMENT

4-6

LINEAR ENCODER SETUP

4-7

PAPER SIDE SENSOR ADJUSTMENT

4-8

CALIBRATION (FEEDING DIRECTION)

4-9

BELT TENSION ADJUSTMENT

4-10 BELT POSITION ADJUSTMENT

4-11 NETWORK BOARD INITIALIZE

4-12 LIMIT POSITION & MAX SCAN WIDTH INITIALIZE

5 Supplemental Information

5-1

5-2

HOW TO REMOVE THE AIR IN THE INK LINE

2-1

6 Troubleshooting

2-3

6-1

WHITE FINE LINE / BANDING / MISSING DOT /

2-11

SCRATCHY PRINTING / BLURRED PRINTING

6-2

PARTICULAR COLOR DOES NOT PRINT AT ALL

6-3

SHIFTING IN PRINTING/COLOR SHIFTING

6-4

INK DROPS ON THE MEDIA

6-5

VERTICAL BANDING

6-6

MISSING DOT OR DEFLECTED-FIRED DOT APPEARS

WHEN PERFORMING PRINTING WITH LONG DELAY

6-7

INK EMPTY MESSAGE APPEARS

EVEN IF THE INK HAS NOT RUN OUT

3-3

6-8

THE INK OR MAINTENANCE LIQUID NEVER COMES

3-11

BY PERFORMING FILL INK

6-9

6-10 HEATER TEMPERATURE DOES NOT GO UP

6-11 DRYER TEMPERATURE DOES NOT GO UP

6-12 THE BLOWER FAN DOES NOT MOVE

6-13 THE TAKE-UP/FEED OUT UNIT DOES NOT MOVE

6-14 ERROR MESSAGE

6-15 SERVICE CALL

7 Service Activities

7-1

INSTALLATION CHECK LIST

7-2

MAINTENANCE CHECK LIST

7-3

PREPARATION FOR TRANSPORTATION 1

7-4

PREPARATION FOR TRANSPORTATION 2

7-5

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First Edition

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4-35

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4-43

4-55

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4-57

5-1

5-5

6-1

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6-3

6-3

6-4

6-4

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6-4

6-5

6-6

6-7

6-8

6-9

6-10

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6-10

6-11

6-11

7-1

7-15

7-16

7-24

7-35

70010-00

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Summary of Contents for Roland Advanced Jet AJ-1000

Page 1: Table Of Contents
SERVICE NOTES Contents 1 Structure & Spare Parts 4 Adjustment ...................... COVERS SPECIAL TOOLS ......................FRAME SERVICE MODE ................CARRIADGE HOW TO UPGRADE FIRMWARE 4-17 ....................DRIVE UNIT HEAD ALIGNMENT 4-20 ..................CAPPING POSITION ADJUSTMENT 4-29 ............
Page 2 Revision Date Description of Changes Approval Issued 2006.7.4 First Edition Kato Mabuchi...
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 Do not recharge, short-circuit, Turn off the primary power SWs for disassemble the lithium battery, nor the Printer and Dryer before put it into fire. servicing. It may cause heat, explosion and fire. Put tape around the lithium battery for insulation for disposal or preservation.
Page 5: Structure & Spare Parts
1 Structure & Spare Parts 1-1 COVERS...
Page 6 KEY TOP,D14 WH AJ-1000 33 22535287 LABEL,CAUTION CARRIAGE #LA266 34 22535286 LABEL,CAUTION COVER #LA265 35 22535498 LABEL,CLAMP MEDIA SJ-1000#LA716 36 1000000953 LABEL,EMBLEM LOGO ROLAND 37 22535390 LABEL,EMERGENCY STOP #LA496 38 22535460 LABEL,ENERGY STAR COLOR #LA668 39 1000001099 LABEL,HARMFUL FIRE #LA915 40 1000000952...
Page 7: Frame
1-2 FRAME...
Page 8 1-2 FRAME PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 12359113 ABSORBER TK-2320 12139657 GUIDE,INK FUNNEL PE 6-316-03 6700109040 ASSY,FEED MOTOR AJ-1000 1000000838 HOLDER,DRYER BOARD COVER AJ-1000 W700105210 ASSY,HEATER JUNCTION BOARD AJ-1000 1000000938 HOLDER,DRYER MID AJ-1000 W7001057A1 ASSY,MOTSENS JUNCTION BOARD AJ-1000 1000000741 HOLDER,FUNNEL AJ-1000...
Page 9: Carriadge
1-3 CARRIAGE...
Page 10 1-3 CARRIAGE PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1000000857 ADAPTER,HEAD BIAS AJ-1000 1000000863 SPRING,Z NUT AJ-1000 1000000521 ADAPTER,SCREW FLEX AJ-1000 1000000854 STAY,ALIGN HEAD AJ-1000 1000000522 ADAPTER,TUBE JOINT AJ-1000 1000000869 STAY,CARRIAGE BOARD AJ-1000 W700105630 ASSY,HEAD FLEX BOARD AJ-1000 1000000873 STAY,ENCODER SENS AJ-1000 1000001354...
Page 11: Drive Unit
1-4 DRIVE UNIT...
Page 12 1-4 DRIVE UNIT PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 12359113 ABSORBER TK-2320 1000000896 STAY,RAIL GUIDE AJ-1000 22805542 ASSY,PULLEY T79P2S16 SJ-1000 1000000850 STAY,SUPPORT DRIVE SHAFT AJ-1000 W700105330 ASSY,PUMP FLEX A BOARD AJ-1000 1000000767 STAY,TUBE AJ-1000 W700105340 ASSY,PUMP FLEX B BOARD AJ-1000 22135441 STOPPER,LINEAR SCALE FJ-540...
Page 13: Bed
1-5 BED...
Page 14 1-5 BED PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1000000760 APRON,B AL AJ-1000 31289111AS CUPSCREW SET, M4*6 NI 100 PCS. 1000000763 APRON,B UNDER AJ-1000 31289112AS CUPSCREW SET,M3*10 NI 100 PCS. W700105770 ASSY,FAN JUNCTION BOARD AJ-1000 31289102AS CUPSCREW SET,M3*6 NI 50 PCS.
Page 15: Chassis
1-6 CHASSIS 1-11...
Page 16 1-6 CHASSIS PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 13429701 AC INLET SUP-J15G-E 1000000922 LABEL,SW DRYER AJ-1000#LA883 W700105130 ASSY,AC JUNCTION BOARD AJ-1000 1000000923 LABEL,SW PRINTER AJ-1000#LA882 6700105020 ASSY,HEAD BOARD AJ-1000 31279191 LABEL,WARNING FUSE REPLACE #347 W700105110 ASSY,HEATER CONTROL BOARD AJ-1000 22055565 PLATE,NET CARD FJ-540...
Page 17: Pinch Roller
1-7 PINCH ROLLER PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 21775105 CAM,PINCH ROLLER SHAFT SJ-1000 31289102 CUPSCREW SET,M3*6 NI 50 PCS. 22195133 FRAME,PINCH SJ-1000 22145216 LEVER,PINCH ROLLER FJ-540 22055549 PLATE,PINCH ROLL LEVER FJ-540 21565105 P-ROLLER FD8S3(B15L30) 1000000900...
Page 18: Maintenance Liquid Cartridge
MAINTENANCE LIQUID CARTRIDGE PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1000000521 ADAPTER,SCREW FLEX AJ-1000 31289102AS CUPSCREW SET,M3*6 NI 50 PCS. 1000000522 ADAPTER,TUBE JOINT AJ-1000 31409811 SADDLE,LOCKING WIRE LWS-1211Z W700105530 ASSY,CARTRIDGE IC BOARD AJ-1000 31049170AS SCREW SET,CAP M3*8 NI 50 PCS.
Page 19: Wiper System
1-9 WIPER SYSTEM 1-15...
Page 20 1-9 WIPER SYSTEM PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1000000521 ADAPTER,SCREW FLEX AJ-1000 1000000780 SHAFT,SLIDE CAPTABEL AJ-1000 1000000522 ADAPTER,TUBE JOINT AJ-1000 1000001056 SHEET,HEAD PROTECTION AJ-1000 1000000519 ADAPTER,TUBE PLUG AJ-1000 22165185 SPACER,ROLLER PIX-30 1000000985 ASSY, CAP-TOP AJ-1000 22175308 SPRING,BELT TENSION EGX-20 1000002081...
Page 21 1-10 INK SYSTEM 1-17...
Page 22 1-10 INK SYSTEM PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1000000521 ADAPTER,SCREW FLEX AJ-1000 1000000702 SHAFT,I/C COVER AJ-1000 1000000522 ADAPTER,TUBE JOINT AJ-1000 1000000690 SPRING,PLATE CARTRIDGE AJ-1000 W700105530 ASSY,CARTRIDGE IC BOARD AJ-1000 1000001039 STAY,I/C COVER MAGNET AJ-1000 W700105520 ASSY,INK JUNCTION BOARD AJ-1000 1000000704 STAY,I/C COVER SENSOR AJ-1000...
Page 23: Sub Tank System
1-11 SUB TANK SYSTEM PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name W700105510 ASSY,PUMP DRIVE BOARD AJ-1000 1000000623 CABLE-CARD 40P1 300L BB HIGH-V 1000000521 ADAPTER,SCREW FLEX AJ-1000 1000000622 CABLE-CARD 40P1 3750L BB HIGH-V 1000000522 ADAPTER,TUBE JOINT AJ-1000 1000000916 COVER,PUMP DRIVE BOARD AJ-1000 6700109000...
Page 24: Dryer
1-12 DRYER PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name W700105240 ASSY,BLOWER BOARD AJ-1000 31289109AS CUPSCREW SET,M3*4 NI 100 PCS. W700105120 ASSY,DRYER BOARD AJ-1000 31289102AS CUPSCREW SET,M3*6 NI 50 PCS. 1000000954 ASSY,DRYER MODULE AJ-1000 31409702 SADDLE,LOCKING EDGE LES-1010 W700105230 ASSY,DRYER THERMISTOR BOARD AJ-1000...
Page 25: Stand
1-13 STAND 1-21...
Page 26 1-13 STAND PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 12359113 ABSORBER TK-2320 31289105AS CUPSCREW SET, M3*6 BC 100 PCS. 11879126 ABSORBER,C-30-RK-3225 31289111AS CUPSCREW SET, M4*6 NI 100 PCS. 1000000682 ARM,DANCER L AJ-1000 31289102AS CUPSCREW SET,M3*6 NI 50 PCS.
Page 27: Tu Unit
1-14 TU UNIT 1-23...
Page 28 1-14 TU UNIT PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 22805522 ASSY,TU COVER B SJ-1000 BIND,P-TIGHT 3.5*8 C 22805526 ASSY,TU DC JACK SJ-1000 CLAMP,INSULOK YJ-80 22805524 ASSY,TU JACK BOARD SJ-1000 S3 31149706AS RING SET,E-RING ETW-10 SUS 20 PCS 1000002054 ASSY,TU MAIN BOARD AJ-1000...
Page 29: Tu Roll
1-15 TU ROLL 1-25...
Page 30 1-15 TU ROLL PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 22805530 ASSY,TU HOLDER SJ-1000 31409801AS SADDLE,LOCKING WIRE LWS-0711Z 20 22805523 ASSY,TU L BEARING SJ-1000 31049105AS SCREW SET,CAP M3*6 3CBC 20 PCS 22805529 ASSY,TU L FRAME SJ-1000 31049173AS...
Page 31: Accessories
1-16 ACCESSORIES 240V 230V 240VE 200V(US) 200V(JPN) PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 22805481 ASSY,STOPPER RAIL SJ-740 1000001058 PAD,TU GEAR AJ-1000 23495124 AC CORD 3ASL/100 240VA 10A SAA 1000001057 PAD,TU SHAFT AJ-1000 23495125 AC CORD H05VV 230V 10A S 1000001059 PAD,TU UPPER AJ-1000 13499111...
Page 32: Electrical Section
2 Electrical Section 2-1 WIRING MAP...
Page 33 PARTS NO PARTS NAME PARTS NO PARTS NAME 1 1000000572 CABLE-ASSY LIVE AJ-1000 61 1000000649 CABLE-ASSY WIPE ORG AJ-1000 2 1000000573 CABLE-ASSY NEUTRAL AJ-1000 62 1000000650 CABLE-ASSY WIPE MOTOR AJ-1000 3 1000000574 CABLE-ASSY GND AJ-1000 63 1000000651 CABLE-ASSY C-LIQ P-SENS AJ-1000 4 1000000575 CABLE-ASSY DRYER-AC AJ-1000 64 1000000652...
Page 34: Main Board
2-2 MAIN BOARD Arrangement Diagram_ Component Side DIP SW Bit1 Bit2 Bit3 Bit4 Bit5 Bit6 Bit7 Bit8 AJ1000 OFF OFF OFF OFF OFF OFF OFF OFF It indicates the version of the Main Board.
Page 35 Main Board _ 1/7 Circuit Diagram...
Page 36 Main Board _ 2/7 Circuit Diagram...
Page 37 Main Board _ 3/7 Circuit Diagram 270 1% 100u/25V SML-210MTT86 B2P -VH DD[0. 63] IC19 1SS355 VCC3 TP17 T1086CM 100u/25V CE0.1u 120 1% VCC3 74LVC245 VCC3 120 1% CE0.1u 1.25(1+390/240)+240(120E-6)=3. 1 V 10u/16V(NON) /WR2_1 /WR2_1 120 1% VCC3 270 1% 1SS355 VCC1.
Page 38 Main Board _ 4/7 Circuit Diagram...
Page 39 Main Board _ 5/7 Circuit Diagram...
Page 40 Main Board _ 6/7 Circuit Diagram...
Page 41 Main Board _ 7/7 Circuit Diagram 2-10...
Page 42: Head Board
2-3 HEAD BOARD Arrangement Diagram_ Component Side It indicates the version of the Head Board. 2-11...
Page 43 Arrangement Diagram_ Soldering Side 2-12...
Page 44 Head Board _ 1/6 Circuit Diagram 2-13...
Page 45 Head Board _ 2/6 Circuit Diagram 2-14...
Page 46 Head Board _ 3/6 Circuit Diagram 2-15...
Page 47 Head Board _ 4/6 Circuit Diagram 2-16...
Page 48 Head Board _ 5/6 Circuit Diagram 2-17...
Page 49 Head Board _ 6/6 Circuit Diagram 2-18...
Page 50: Servo Board
2-4 SERVO BOARD Arrangement Diagram_ Component Side It indicates the version of the Servo Board. 2-19...
Page 51 Arrangement Diagram_ Soldering Side 2-20...
Page 52 Servo Board _ 1/5 Circuit Diagram 2-21...
Page 53 Servo Board _ 2/5 Circuit Diagram EXBA10E103J EXBA10E103J 2-22...
Page 54 Servo Board _ 3/5 Circuit Diagram R185 R186 R187 2-23...
Page 55 Servo Board _ 4/5 Circuit Diagram 2-24...
Page 56 Servo Board _ 5/5 Circuit Diagram 2-25...
Page 57: Heater Board
2-5 HEATER BOARD Arrangement Diagram_Component Side It indicates the version of the Heater Board. 2-26...
Page 58 It indicates the version of the Heater Board. 2-27...
Page 59 Heater Board_1/6 Circuit Diagram R53 10K R52 10K EXBA10E103J 2-28...
Page 60 Heater Board_2/6 Circuit Diagram R_non 2-29...
Page 61 Heater Board_3/6 Circuit Diagram 2-30...
Page 62 Heater Board_4/6 Circuit Diagram 2-31...
Page 63 Heater Board_5/6 Circuit Diagram CN307 CN306 to Heater Cont rol Board to DRYER BOARD B5P9-VH B5P9-VH CN305 CN301 PLATEN HEATER to Heater Control Board B2P3-VH CN304 B4P7-VH B2P(4-2.3)-VH BED-F HEATER HEATER JUNCTION BOARD CN303 B2P(4-2.3)-VH CN300 B2P(4-2.3)-VH BED-R HEATER CN302 B2P(4-2.3)-VH CN103 BASE-AL Thermistor...
Page 64 Heater Board_6/6 Circuit Diagram BLOWER BOARD CN21 CN22 B2P-VH B2P-VH B2P-VH B2P-VH CN16 5267-02A 5267-02A CN23 CN24 B2P-VH B2P-VH B2P-VH B2P-VH CN17 5267-02A 5267-02A CN25 CN26 CN10 CN11 B2P-VH B2P-VH B2P-VH B2P-VH CN18 5267-02A 5267-02A CN12 CN13 CN27 CN28 B2P-VH B2P-VH B2P-VH B2P-VH...
Page 65: Pump Drive Board
2-6 PUMP DRIVE BOARD Arrangement Diagram_Component Side I t i n d i c a t e s t h e version of the Pump Drive Board. 2-34...
Page 66 It indicates the version of the Pump Drive Board. 2-35...
Page 67 Pump Drive Board_1/6 Circuit Diagram 2-36...
Page 68 Pump Drive Board_2/6 Circuit Diagram 2-37...
Page 69 Pump Drive Board_3/6 Circuit Diagram 2-38...
Page 70 Pump Drive Board_4/6 Circuit Diagram 2-39...
Page 71 Pump Drive Board_5/6 Circuit Diagram IJVCC CN900 @INK_Exist_LM @INK_Exist_LC @INK_Exist_Y @INK_Exist_M @INK_Exist_C @INK_Exist_K @VCC_out CARTRIDGE_COVER_SW PC900 @sCLK_ out C900 CE0.1u 10u/16V(NON) @D_out @D_in @eeprom_CS_LM CN910 @eeprom_CS_LC @eeprom_CS_Y @eeprom_CS_M eeprom - LM @eeprom_CS_C @eeprom_CS_K @s-pump_sens _LM @s-pump_sens _LC @s-pump_sens _Y 53014-07 @s-pump_sens _M CN911 @s-pump_sens _C...
Page 72 Pump Drive Board_6/6 Circuit Diagram 2-41...
Page 73: Sub Board
2-7 SUB BOARD Arrangement Diagram_ Component Side It indicates the version of the Sub Board. 2-42...
Page 74 It indicates the version of the Sub Board. 2-43...
Page 75 Arrangement Diagram_ Soldering Side CN302 2-44...
Page 76 2-45...
Page 77 Sub Board _ 1/8 Circuit Diagram 2-46...
Page 78 Sub Board _ 2/8 Circuit Diagram 2-47...
Page 79 Sub Board _ 3/8 Circuit Diagram 2-48...
Page 80 Sub Board _ 4/8 Circuit Diagram 2-49...
Page 81 Sub Board _ 5/8 Circuit Diagram 2-50...
Page 82 Sub Board _ 6/8 Circuit Diagram 2-51...
Page 83 Sub Board _ 7/8 Circuit Diagram 2-52...
Page 84 Sub Board _ 8/8 Circuit Diagram LEVCC LEVCC LEVCC C600 R600 CE0.1u CN600 U600 LENCB_PHA CN403 CN402 Vout(A) LENCB_PHB Vout(B) to FAN 1 KE-207 CABLE-ASSY LINEAR-ENC AJ-1000 5267-02A 53014-03 CN401 to FAN 2 LINEAR ENCODER BOARD 5267-02A CN400 Reserve POVCC POVCC 5267-02A(NON) R751...
Page 85: Maintenance Parts List
2-8 MAINTENANCE PARTS LIST _ Electrical Parts SERVO BOARD IC No. Parts No. Description Function 15189105 MTD2005-7101 MOTOR DRIVER for CLEANING MOTOR 15189105 MTD2005-7101 MOTOR DRIVER for HEAD U/D MOTOR 15189105 MTD2005-7101 MOTOR DRIVER for SLIDE MOTOR 15189105 MTD2005-7101 MOTOR DRIVER for WIPE MOTOR 15119122 2SJ535 MOTOR POWER SUPPLY...
Page 86: Replacement Of Main Parts
3 Replacement of Main Parts To Ensure Safe Work - Rear View - Unplug both power cables from the machine before servicing. It is not possible to cut power of completely only by turning off the primary power SWs. UNPLUG AC INLET for AC INLET for the Dryer Unit.
Page 87 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) BATTERY REPLACEMENT : 20min. 1. HEAD RANK SETTING 1. BATTERY FLAG CLEAR *3 Adj. Time : 3min. 2.
Page 88: Head Replacement
3-1 HEAD REPLACEMET To prevent the heads from drying out, finish the procedure 5 to 22 within 20 minutes. Otherwise, Head may break because of dried ink which causes nozzle clogging. When replacing the plural number of Head, replace them one by one. Remove the following parts.
Page 89 When the Head Carriage moves up and the LCD shows <Rear View> [REPLACE HEAD PREPARE], turn off the Sub Power SW and then, turn off the Printer Main Power SW. When replacing the Head, it is necessary to turn off the Printer Main Power SW. If not, the Head or the Main Board could be broken.
Page 90 Remove the Cap from the new Head and fix it to the Ink Damper of current Head. If you don't do it, the ink in the Dumper spills out. Remove the screw shown in the figure and remove the Head Spring. If the Head Spring is fixed too tight, use flat- Head Spring blade screwdriver to remove it.
Page 91 Remove the 2 screws fixing Head and remove the Head <Top View> from the Head Carriage. Screw <Near side> When replacing the Black Head, it is necessary to remove the Head Heater Plate together with the Head Heater and refix it to a new Head.
Page 92 Tighten up only the rear screw temporarily. <Top View> Screw <Near side> Fix the Spring, Head Guide and Head Stay. Hold down the Head Stay and tighten up the Adjustment Screw to Head Stay the point where the Head Stay is not raised up. Head Guide Fix the Spring fitting with the dent of Spring...
Page 93 Tighten up the 2 screws in order as shown in the figure. <Top view> <Near Side> Flexible Cable Connect the Tube to the Ink Damper. Then, fix the flexible cable to the Head. Tube Turn on the Sub Power SW while pressing the Left, Right and Down keys to enter the Service Mode.
Page 94 S e l e c t [ P R I N T M E N U ] > [ R E P L A C E H E A D ] SERVICE MENU PRINT MENU PRINT MENU >[FINALIZE]. Then, select the number of the Head you REPLACE HEAD replaced and press the [ENTER] key.
Page 95 <HOW TO CHECK THE THERMISTOR> SERVICE MENU THERMISTOR CHK THERMISTOR CHK BOARD: 25 C/77 F Select the Head you replaced in [THERMISTOR CHK] menu and check if the temperature displayed on the LCD THERMISTOR CHK is not too low (0 degrees) or too high (100 degrees). BOT.
Page 96: Wiper Replacement
3-2 WIPER REPLACEMENT Select [SUB MENU]>[MAINTENANCE]>[REPLACE WIPER] from the User menu. Then, press [ENTER] key. MENU SUB MENU SUB MENU MAINTENANCE MAINTENANCE REPLACE WIPER [ENTER] Remove the Right I/S cover, when [FINISHED?] shows FINISHED? Right I/S Cover Grasp the lower part of Wiper with tweezers and unhook it.
Page 97 Press the bottom of the wiper by tweezers. Then, attach Hook the hook. Confirm if the hook is attached firmly by push- ing both ends of wiper by tweezers. When replacing wiper, be sure to attach the hook. Otherwise, wiper may come off while using it. Attach the Right I/S cover and press [ENTER].
Page 98: Cap Top Replacement
3-3 CAP TOP REPLACEMENT To prevent the heads from drying out, finish this procedure within 20 minutes. Otherwise, Head may break because of dried ink which causes nozzle clogging. Remove the Right I/S Cover. Right I/S Cover Turn on the Sub Power SW while pressing the Left, Right and Down keys to enter Service Mode.
Page 99 Move the Head Carriage slowly leftwards. Be careful that the head does not strike the media or the media clamp. Remove the screws in the figure and remove the Plate. Plate Remove the screw fixing the Cap in the figure and remove Screw Cap with the Cap Frame.
Page 100 Fix Springs on "+" Mark on the rear side of the new Cap Top. Spring Cap Top Do not touch the sponge part on the top side of Cap Top. "+" Mark When setting the Cap Top to the Cap Frame, be careful about the fixing direction.
Page 101 Make sure to put the Tube in the Hole. Cap Top Assy Hole Check that Cap Top snaps back by pressing the resin part of the Cap Top lightly at its front and rear. Do not touch the sponge part. If the Cap Top doesn't snaps, check that the springs are fixed correctly and the tube is put in the Hole.
Page 102 Select [I/S MENU] > [I/S CONTROL] > [HEAD UP/ SERVICE MENU DOWN] > [OPEN] and press [ENTER] key. I/S MENU Then, Head Carriage will be capped automatically. I/S MENU I/S CONTROL I/S CONTROL HEAD UP/DOWN HEAD UP/DOWN CLOSE [ENTER] 3-17...
Page 103: Carriage Motor Replacement
3-4 CARRIAGE MOTOR REPLACEMENT Turn off the Printer Main Power SW. <Rear view> Dryer Main Power SW Printer Main Power SW Remove the Right I/S Cover. Right I/S Cover Remove the Panel Cover. Panel Cover Flexible cable is connected to the Panel Board. Remove the spring.
Page 104 Disconnect the connector of the Motor cable. Connecto Remove the screws fixing the Flange and remove the Motor together with the Flange. Flange Screw Remove the Motor from the Flange. Fix the Motor Cable of a new motor using a cable tie Screw without bending the cable root, and then fix the new Motor to the Flange.
Page 105 Fix the spring. Then, check the Motor Gear meshes with the Drive Gear and tighten up the screws to fix the Flange. Motor Gear Apply a proper quantity of grease (FLOIL GE- Drive Gear 676) between Drive gear and Motor gear. Spring Connect the connector of the Motor Cable.
Page 106 Select [I/S MENU] > [I/S CONTROL] > [HEAD UP/ SERVICE MENU DOWN] > [OPEN], and press the [ENTER] key. The I/S MENU Head Carriage moves up and you can move it by hand. I/S MENU I/S CONTROL I/S CONTROL HEAD UP/DOWN HEAD UP/DOWN OPEN [ENTER]...
Page 107 Clear the motor working hours. SERVICE MENU Go back the SERVICE MENU, and select [HISTORY HISTORY MENU MENU] > [MOTOR GROUP] > [MOTOR HOURS S] > [CLEAR] and press the [ENTER] key. The motor working HISTORY MENU MOTOR GROUP hours will be reset to 0. MOTOR HOURS S 1653 hours MOTOR HOURS S...
Page 108: Supply Pump Replacement
3-5 SUPPLY PUMP REPLACEMENT Turn on the Sub Power SW for initializing the Pump. As a result, the Supply Pump is set to Open state and the Pressure Pump is set to Closed state. Sub Power SW Turn off the Sub Power SW. Then, turn off the Printer <Rear view>...
Page 109 Disconnect the tube from the Dumper and then, evacuate all ink from the Sub Tank using the syringe Tube according to the following procedures. Special Tool Connect the syringe to the tube and pull the piston. Use the following special tool. Tool NO.: 1000001400 Tool Name: TOOL, SYRINGE 20ML ST-064 Disconnect the syringe from the tube and drain the...
Page 110 To prevent the air from going into the Ink Cartridges, Cartridge Slot remove the Ink Cartridges and insert the Dummy Cover Cartridges. Ink Cartridge Do not remove the Ink Cartridge more than necessary. Do not place the Ink Cartridge with the hole faced up.
Page 111 Disconnect the tube which is connected to the Sub Tank from the Pump. Tube Joint of Sub Tank side When you remove the tube, the ink drips a little. Pull the Pump together with the motor forward, and then pull them out to downward. Pump Remove the screw in the figure, and then remove the Board from the Pump.
Page 112 Fix the Pump with 2 screws in the figure. Screw Connect the 2 tubes to the new Pump. Tube Joint Connect the connector of the Pump Motor and the connector of the Sensor Board. Connector Cable Clip Connector Sensor Board Remove the Dummy Cartridges, and then insert the Ink Cartridges.
Page 113 Disconnect the syringe and connect the tube to the Ink Tube Dumper. Dumper Turn on the Sub Power SW while pressing the Left, Right and Down keys to enter Service Mode. ], [ ], [ ] + POWER ON [MENU] key MENU SERVICE MENU Select the corresponding Supply Pump from [I/S MENU]...
Page 114 Perform the following operations. 1. Clear the Pump working time. 2. Clear the Drain bottle count. <HOW TO CLEAR THE PUMP WORKING TIME> Go back to the SERVICE MENU, and select [HISTORY SERVICE MENU MENU] > [MOTOR GROUP]. Then, select the Pump you HISTORY MENU replaced and clear the time.
Page 115: Ink Tube Replacement
3-6 INK TUBE REPLACEMENT It is neccesary to move the head from the capping position in procedure 10 to 26 . Therefore, finish this procedure as quickly as possible to prevent the heads from drying out. Otherwise, the heads may break because of dried ink which causes nozzle clogging. Turn off the Main Power SW for dryer and the Printer <Rear view>...
Page 116 Remove the Carriage Cover and the Plate shown in the Plate Carriage Cover figure. Remove the Carriage Board Cover. Carriage Board Cover Remove seven Nylon Rivets shown in the figure and then, remove the Head Flexible Board. Rivet Head Flexible Board To detach the Tube easily, remove the Flexible Cables which connect the Heads and the Carriage Board.
Page 117 Turn on the MainPower and then turn on the Sub Power while pressing the Left, Right and Down keys to enter the ], [ ], [ ] + POWER ON Service Mode. [MENU] key MENU SERVICE MENU Select [SERVICE MENU] > [SUB MENU] > [REPLACE TUBE] >...
Page 118 Turn off the Sub Power SW. Then, turn off the Dryer Main <Rear view> Power SW and the Printer Main Power SW. Dryer Main Power Switch Printer Main Power Switch Remove the O Ring, the Tube Joint and the Adapter Screw from the Ink Tube.
Page 119 Hook the Flexible Cable to the Flame as shown in the <Rear view> figure. Flame Flexible Cable Disconnect the all Tubes which are to be iserted into the <Upper view> Pressure Pump Cable Veyor from the Pressure Pumps and pull out the tubes from the Cable Veyor.
Page 120 Insert the Ink Tube straight to the joint part of Pressure Pump . Tighten up the Adapter Screw. Adapter Screw Fix the tubes by Clamp. Make sure that the tubes in the circled part in the figure do not have slack. Remove 6 screws that fix the Carriage Board.
Page 121 Lift up the Carriage Board, then put the each Ink Tube through the Wire Saddle at 2 places. Carriage Board Wire Saddle <Rear view> Fix the Carriage Board by 6 screws. Connect the Flexible Cables to the Carriage Board and Nylon Rivet Protective Plate fix the Protective Plate with the Nylon Rivets.
Page 122 Plug the Tube Joint to the Ink tube. Make sure Tube Joint set in firmly. Tube Joint Attach the O Ring to the Tube Joint. Be careful not to strech the O Ring. Tube Joint O ring By using Plug Tube, push O-Ring until it reaches Plug Tube Tube Joint the end of Adapter Screw.
Page 123 Turn on the Printer Main Power SW and then turn on the sub power while pressing the Left, Right and Down keys ], [ ], [ ] + POWER ON to enter the Service Mode. [MENU] key MENU SERVICE MENU Select [SERVICE MENU] >...
Page 124 Turn off the Sub Power SW. Then, turn off the Sub Power <Rear view> SW. Then, turn off the Dryer Main Power SW and the Printer Main Power SW. Dryer Main Power SW Printer Main Power SW Connect the Head and the Carriage Board with the Flexible Cable.
Page 125: Boards Replacement
3-7 BOARDS REPLACEMENT ( Main Board / SW Power Supply) BOARD LAYOUT (IN CHASSIS) Network Board Signal Junction Board Main Board Servo Board Main Board Stay Signal Board Stay Head Board AC Junction Board When removing the Network / Main / Head Board and Main Board Stay) Heater Control Board 3-40...
Page 126 When removing the Signal Junction Board and Signal Board Stay) SW Power Supply SW Power Supply (41V) (5V, 24V) Turn off the Printer and Dryer Main Power SW. <Rear view> Dryer Main Power SW Printer Main Power SW Remove the Chassis Cover. Chassis Cover 3-41...
Page 127 SW POWER SUPPLY REPLACEMENT (41V) SW POWER SUPPLY CONNECTOR LAYOUT Connected to the [CN102] on the [AC Junction Board] Connected to the [CN23] on the [Signal Junction Board] Disconnect all cables from the Signal Junction Board. And unlock all Wire Saddles to remove cables. Remove 4 screws in the figure with Signal Board Stay.
Page 128 Remove 4 screws in the figure and replace with the new SW Power Supply(41V). Fix it with 4 screws and connect all cables. Fix the Signal Board Stay with 4 screws in the figure with Signal Junction Board. Put all cables through Wire CN24 Saddles and connect all cables.
Page 129 2) Insert the black probe to CN51-1pin(GND) and the red probe to CN51-8pin(Vout) on the SW Power Signal Junction Board Supply. CN51-8pin CN51-1pin Probe 3) Rotate the volume in clockwise direction using the screwdriver to adjust the output voltage value to Volume +41V+ 0.1.
Page 130 SW POWER SUPPLY REPLACEMENT (5V, 24V) SW POWER SUPPLY CONNECTOR LAYOUT Connect to the [CN24] on the [Signal Junction Board] Connect to the [CN103] on the [AC Junction Board] Disconnect all cables from the Signal Junction Board. And unlock all Wire Saddles to remove cables. Remove 4 screws in the figure with Signal Board Stay.
Page 131 Remove 4 screws in the figure and replace with the new SW Power Supply(5V, 24V). Fix it with 4 screws and connect all cables. Fix the Signal Board Stay with 4 screws in the figure with Signal Junction Board. Put all cables through Wire Saddles and connect all cables.
Page 132 MAIN BOARD REPLACEMENT MAIN BOARD CONNECTOR LAYOUT CN12 CN16 Start the Peck3. Perform [Get Report] and [Get Parameters] and get the parameter and report, and save them. 3-47...
Page 133 Remove 2 screws in the figure. Screw Disconnect all cables connecting with the Main Board. Remove screws in the figure and then, remove the Main Network Board Board with Network Board. Remove the Network Board and fix it with the new Main Board.
Page 134 Remove the Network Board and fix with the new Main Board. Head Board Connection Carry out the following operations after replacement. 1. DIP SW Setting 2. Firmware Installation 3. System Parameter Initialize 4. Cap & Wiper Check *2 5. Sensor Check 6.
Page 135: Battery Replacement
3-8 BATTERY REPLACEMENT CAUTION Lithium battery will explode if it is incorrectly replaced. Replace only with the same or equivalent type of battery recommended by the manufacturer. Dispose of used batteries according to the manufacturer's instructions. Do not recharge, short-circuit, disassemble a lithium battery or put it into fire.
Page 136 While pressing the battery on the Main Board downward, Socket incline the battery to remove it. Main Boatd Replace the battery with a new one. Socket Make sure to fix the battery correctly. Main Boatd Turn on the Printer Main Power SW. ], [ ], [ ] + POWER ON...
Page 137 Turn off the Printer Main Power SW and the Dryer Main <Rear view> Power SW. Dryer Main Power SW Printer Main Power SW Fix the Chassis Cover. Chassis Cover Dispose of the battery. CAUTION Never charge, short-circuit, disassemble, heat, or put into fire.
Page 138: Carriage Belt Replacement
3-9 CARRIAGE BELT REPLACEMENT It is neccesary to move the head from the capping position in procedure 5 to 17 . Therefore, finish this procedure as quickly as possible to prevent the heads from drying out. Otherwise, the heads may break because of the dried ink which causes the nozzle clogging. Turn off the Printer Main Power SW and the Dryer Main <Rear view>...
Page 139 Turn on the Sub Power SW while pressing the Left, Right and Down keys to enter the Service Mode. ], [ ], [ ] + POWER ON [MENU] key MENU SERVICE MENU Select [SERVICE MENU] > [I/S MENU] > [I/S SERVICE MENU CONTROL] >...
Page 140 Remove the Flexible Cable from the HEAD 2 and HEAD Flexible Cable Remove the 2 screws fixing the Belt Holder to the Head Carriage. And, move the Head Carriage to the left so as to see the connected part of the belt. Screw Belt Holder Loosen the 2 screws shown in the figure and then loosen...
Page 141 Replace with a new Carriage Belt. When fixing a new Carriage Belt, see from the hole on the rear of the machine to check the Belt is not twisted. Put adequate quantity of grease ( FLOIL G-902) between Pulleys. Tighten the screws shown in the figure to fix both edges Belt Holder of the Carriage Belt to the Belt Holder.
Page 142 Move the Belt Holder by hand to the position of the screw hole for fixing the carriage. Screw Fix the Belt Holder with the Head Carriage with the screws. Belt Holder Tighten the Adjustment Screw to have tension on the Belt.
Page 143 Move the Head Carriage manually to the position where the left Frame of the Head Carriage is aligned to the left Frame of the Cap Unit when seen from the front view. Left Frame of Head Carriage Left Frame of Cap Unit Select [I/S MENU] >...
Page 144: Encoder Scale Replacement
3-10 ENCODER SCALE REPLACEMENT Remove the following covers. Right I/S Cover Right Top Cover Knob Left/Right I/S Cover Right Top Cover Front Rail Cover Rear Rail Cover Front Cover Panel Cover Panel Cover Left I/S Cover Front Rail Cover Rear Rail Cover Front Cover Turn on the Sub Power SW while pressing the Left, Right and Down keys to enter the Service Mode.
Page 145 Move the Head Carriage slowly to the left. Remove the Encoder Scale. 1. Remove the Plate at the right edge. 2. Remove the Spring at the left edge. Encoder Scale Spring Plate Remove the Spring Plate from the Encoder Scale and fix it to the new Encoder Scale at the side which does not have black dot.
Page 146 Move the Head Carriage from left to right. Make sure that the Encoder Scale does not touch the Encoder Module and also Encoder Scale is covered with the Encoder Module. Carry out the Liner Encoder Setup. 3-61...
Page 147: Tu Board Replacement
3-11 TU BOARD REPLACEMENT Remove the Cap Screw fixing the Take-up unit and stand with a hexagonal wrench. Remove the Cable Cover while removing the Cable. Cable Cover To TU To TU Disconnect the Cable from the Take-up unit. Disconnect the Take-up unit from the Stand. 3-62...
Page 148: 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 FIXING PARTS TO PRINT HEAD Tool No. ST-060 Tool Name BIT PHILLIPS 　 NO.1 　 L200MM...
Page 149: Service Mode
4-2 Service Mode ], [ ], [ ] + POWER ON [ MENU ] key HEAD RANK HEAD 1 SERVICE MENU PRINT MENU This menu is used for entering HEAD RANK for each head. The setting range is from 12 to 31. HEAD 1 21.5 >...
Page 150 NOW PROCESSING.. PRINT MENU LINEAR ENCODER normal (beeps 1 time) LINEAR ENCODER POS: 1361.00mm SETUP COMPLETED LINEAR ENCODER LOWER PINCHROLL SETUP FAILED error (beeps 2 times) LINEAR ENCODER PINCHROLL is UP HEADBOARD FAILED This menu is for checking Linear Encoder and recording the position of the sheet edge with Clear Sheet (SHEET TYPE : CLEAR).
Page 151 I/S CONTROL I/S MENU HEAD UP/DOWN HEAD UP/DOWN I/S CONTROL OPEN HEAD UP/DOWN CLOSE I/S CONTROL WIPER WIPER WIPER WIPER DOWN WIPER SLOPE SLIDER I/S CONTROL FRONT SLIDER SLIDER REAR Pressure Pump can be rotated in [PRESSURE] or [REVERSE] I/S CONTROL PRESS PUMP1 direction.
Page 152 Use with [ ] and [ ] keys to change Cap Adjustment value. The setting range is from -2.00 to +2.00. It can be adjusted in increments of 0.25. I/S MENU CAP ADJUST Head can be moved in the downward direction in increments of 0.25. When you move in the upward direction, press [ ] key to move Head to the upper end.
Page 153 RHCPLWSUswpmf M123456 C123456 SERVICE MENU P123456 S123456 SENSOR CHECK *** * **** This menu displays the real-time status of all sensors. When a sensor is ON, * will be displayed. The first page shows all sensors ON/OFF. The second page shows status for each sensor. Each alphabet stands for as follows.
Page 154 SUB MENU MAINTE. LIQUID NOW PROCESSING.. FILL M-LIQUID : Fill maintenance liquid SUPPLY1 : Pump makes one revolution MAINTE. LIQUID FILL M-LIQUID SUPPLY2 : Pump makes two revolutions Filling finished (Beeps once) MAINTE. LIQUID NOW PROCESSING.. SUPPLY1 Finished (Beeps once) MAINTE.
Page 155 DETECTING... SUB MENU Waiting data to be input PORT CHECK NETWORK Showing the data coming via network B3:1073741824B This menu is to check the incoming data via network. At the bottom row in LCD, Sum Check and the data size in bytes will be displayed. Sum Check in 2 digits at left in hex system and data bytes in 10 digits at right in decimal system will be displayed.
Page 156 SERVICE MENU PREHEAT TEMP. OFF,20~40 C 35 C 35 C PREHEAT TEMP. Default : 35 C This menu is to set heater temperature in unsetup status. Temperature of [PREHEAT] under the [PREHEATING] in the USER MENU can be set. HEAT TIMEOUT SERVICE MENU OFF,20~40mins (every 10mins)
Page 157 Contents of History Report MOTOR GROUP Contents Reference Item Unit MOTOR HOURS F Total time that the Feed Motor has been rotated. hours MOTOR HOURS S Total time that the Scan Motor has been rotated. hours Life : 1500 hours Total time that the Press Pump 1 has been rotated.
Page 158 HEAD GROUP Contents Reference Item Unit Number of times the Auto Flush has been performed (H1). AUTO FLUSH H1 times AUTO FLUSH H2 Number of times the Auto Flush has been performed (H2). times AUTO FLUSH H3 Number of times the Auto Flush has been performed (H3). times AUTO FLUSH H4 Number of times the Auto Flush has been performed (H4).
Page 159 ERROR GROUP Contents Reference Item Unit Number of times the Service Call has occurred. SERVICE CALL times Service Call Number in the last 5 times. S-CALL HISTORY MOTOR ERROR F Number of times the Feed Motor Error has occurred. times Number of times the Scan Motor Error has occurred.
Page 160 (DT1. Low) Head bi System SW page(13-16) : 00000000 00000000 00000000 00000000 (DT1. Middle) Roland Advanced Jet series = = = = Information = = = = Model : AJ-1000 Ink type : EcoXtreme INK LcLm Enviromantal temp. : 22...
Page 161 History Report Model : AJ-1000 Serial No. : ZQ00000 Version : 1.00 Date 2006/06/01 16:24 = = = = Motor group = = = = = = = = Maintenance group = = = = Motor feed (trip / total [clear]) : 1 hours [0] Maintenance Count 0 times...
Page 162 ] and [ENTER] SYS.PARAMETER keys. Initialize can be performed by pressing the [ENTER] key after selecting model name. It can also be Roland DG Corp. cancelled by pressing the [POWER] AJ-1000 key. The power will be off automatically when initialize is completed.
Page 163 Key Combination Service Menu Combination Key Selection Comments Service Menu Item Press [Menu] and [ ] to enter Service Mode Sub Power Service Menu. [Are you sure?] will be displayed. Upgrade F/W Sub Power Press [ENTER] to upgrade F/W. Use this when the main board is Main Power replaced.
Page 164: How To Upgrade Firmware
4-3 HOW TO UPGRADE FIRMWARE (Referential Time : 5min.) Check the AJ-1000 IP address. It is necessary to prepare the followings to upgrade the FIRMWARE. 1. Firmware file 2. Windows PC (OS Windows2000/XP) * Network port is required. 3. Peck3.exe 4.
Page 165 [Peck] screen is displayed. Click [Select Port] button. Check on [Type2] from [Product]. Check on [via Network] from [Select], and Input the AJ- 1000 IP address. Click [OK]. Click [Firmware Upgrade] button. Select the firmware file, and click [Open]. Peck starts to send the firmware to the AJ-1000. aj-1000firmware AJ1K120.rfw AJ1K120.rfw...
Page 166 M a c h i n e g o e s i n t o F i r m w a r e U p g r a d e m o d e automatically. When upgrade is completed, sub power sw will be turned off automatically.
Page 167: Head Alignment
4-4 HEAD ALIGNMENT HEAD ALIGNMENT is necessary to obtain the good printing quality. Be sure to operate HEAD ALIGNMENT when HEAD is replaced. If the heads are not aligned, printing problems such as banding, fine lines and gap between bands could occur.
Page 168 [BIAS ADJUSTMENT] Select [PRINT MENU] > [HEAD ADJUST] > [BIAS] > [TEST SERVICE MENU PRINT] and press [ENTER] key. PRINT MENU PRINT MENU HEAD ADJUST HEAD ADJUST BIAS BIAS TEST PRINT Test Pattern shown in the right figure will be printed. By pressing Down key, the media is fed out so that you can see the Test Pattern.
Page 169 - When the upper lines are the left side of the lower lines, turn the screw CW. - When the upper lines are the right side of the lower lines, turn the screw CCW. Tighten up the 2 screws fixing Head in the reverse order shown in the figure.
Page 170 [VERTICAL ADJUSTMENT] Select [PRINT MENU] > [HEAD ADJUST] > [VERTICAL] > SERVICE MENU [TEST PRINT] and press [ENTER] key. PRINT MENU PRINT MENU HEAD ADJUST HEAD ADJUST VERTICAL VERTICAL TEST PRINT Test Pattern shown in the right figure will be printed. By pressing Down key, the media is fed out so that you can see the Test Pattern.
Page 171 - When the lines of the replaced Head are shifted to the rear compared to M lines, turn the Adjustment Screw CW. - When the lines of the replaced Head areshifted to the front compared to M lines, turn the Adjustment Screw CCW.
Page 172 [ HORIZONTAL ADJUSTMENT ] Select [PRINT MENU] > [HEAD ADJUST] > [HORIZONTAL] > [TEST PRINT] and press [ENTER] key. SERVICE MENU PRINT MENU You can print Test Pattern by selected Heads in this menu. You can enable/disable each Head by using Down key. PRINT MENU HEAD ADJUST The number of Standard Head is not displayed in this...
Page 173 Enter the parameters checked at 18 with [ ] and [ ] keys. Press [ENTER] key to save the settings. Parameters can be entered with an increment of 1/2. HORIZONTAL TEST PRINT HORIZONTAL HORIZONTAL MIDDLE 11 -13 10 -11 4-26...
Page 174 [BIDIRECTION ADJUSTMENT] Select [PRINT MENU] > [HEAD ADJUST] > [BI- SERVICE MENU DIR.DEFAULT] > [TEST PRINT] and press [ENTER] key. PRINT MENU You can print Test Pattern by selected Heads in this menu. You can enable/disable each Head by using Down key. PRINT MENU HEAD ADJUST The number of Standard Head is not displayed in this...
Page 175 Enter the parameters checked at 21 with [ ] and [ ] keys. Press [ENTER] key to save the settings. Parameters can be entered with an increment of 1/2. BI-DIR,DEFAULT TEST PRINT BI-DIR,DEFAULT BI-DIR,DEFAULT MIDDLE 11 -13 10 -11 4-28...
Page 176: Capping Position Adjustment
4-5 CAPPING POSITION ADJUSTMENT CAPPING POSITION ADJUSTMENT is to adjust the height of Heads when they are capped. It must be done when you remove or replace a cap or Head Carriage. If this adjustment has not been done there is a possibility that the surface of Head is dries up. Remove Right I/S Cover Right I/S Cover Lower Pinch Rollers.
Page 177 Head moves to the position where the value is +2.00mm. It is only possible to move Head stepwise downward. When you move Head upward, press [ ] key to move Head upper end once and then move downward. Move Head downward to the position where the surface of Head contacts the cap when being seen crossly, then press [ENTER] to update the adjustment value.
Page 178: Linear Encoder Setup
4-6 LINEAR ENCODER SETUP First, this checks if the linear encoder can be read correctly in the whole width. Next, this calibrates the length of the linear encoder which stretches and shrink due to the environmental temperature and humidity. It is necessary to do this operatio if any of the followings has been performed. -The position of Limit Sensor is adjusted.
Page 179: Paper Side Sensor Adjustment
4-7 PAPER SIDE SENSOR ADJUSTMENT This is for adjusting the sensitivity of PAPER SIDE SENSOR which is for detecting the width of the media. If it is not adjusted, media width can not be detected correctly. Remove Right I/S Cover. Right I/S Cover Turn on SUB POWER SW while pressing [ ], [...
Page 180 Remove Top Inner Cover and Head Board Cover. Top Inner Cover Carriage Cover Lower Sheet Loading Lever. Select [PAPERSIDE SENS] > [OUTPUT LEVEL] and press ] key. SUB MENU PAPERSEIDE SENS PAPERSEIDE SENS OUTPUT LEVEL OUTPUT LEVEL 0.7V Head Carriage moves to the position where Paper Side Sensor is over Reflection Tape automatically.
Page 181 Adjust VR on the CARRIAGE BOARD so that [OUTPUT LEVEL] will be 0.5-0.7V. Select [PAPERSIDE SENS] > [SENSOR AUTOTEST] and SUB MENU ress [ENTER] key. PAPERSIDE SENS Carry out the test and make sure the voltage is 0.5-1.0V and the NOISE is 0. PAPERSIDE SENS OUTPUT LEVEL PAPERSIDE SENS...
Page 182: Calibration (Feeding Direction)
4-8 CALIBRATION (FEEDING DIRECTION) Turn on SUB POWER SW while pressing [ ], [ ] and [ keys to enter SERVICE MODE. ], [ ], [ ] + POWER ON [MENU] key MENU SERVICE MENU Set PET-G media to the machine. There is the reference line on Platen Plate for setting short rolled medias.
Page 183 Calculate the amount to be calibrated with the formula shown at the right figure. 1. CA = Calibrating Amount 2. CL = Commanded Length (=400mm) 3. ML = Measured Length FORMULA CA = CL - ML x 100 Select [PRINT MENU] > [CALIB. DEFAULT] > [SETTING] in SERVICE MENU SERVICE MENU and change the value with [ ] and [...
Page 184: Belt Tension Adjustment
4-9 BELT TENSION ADJUSTMENT To the Serial Number ZU50220 Remove Right I/S Cover. Right I/S Cover Turn on SUB POWER SW while pressing [ ], [ ] and [ keys to enter SERVICE MODE. ], [ ], [ ] + POWER ON [MENU] key MENU SERVICE MENU...
Page 185 Remove the following covers. Panel Cover Right Top Cover Right I/S Cover Left I/S Cover Left I/S Cover Panel Cover Right Top Cover Left Cover Right I/S Cover Left Cover <Front View> At the left side of the machine, loosen the 2 screws shown in the figure on Pulley Stand.
Page 186 Tighten up the 2 screws shown in the figure. <Front View> Measure the belt tension again and make sure the tension <Top View> is between 0.97kgf and 1.18kgf. Carry out the procedure 6 - 9 again if the tension is not in the range between 0.97kgf and 1.18kgf.
Page 187 Serial Number ZU50221 and above Remove Right I/S Cover. Right I/S Cover Turn on SUB POWER SW while pressing [ ], [ ] and [ keys to enter SERVICE MODE. ], [ ], [ ] + POWER ON [MENU] key MENU SERVICE MENU Select [I/S MENU] >...
Page 188 Remove the following covers. Panel Cover Left Top Cover Right Top Cover Right I/S Cover Left I/S Cover Left I/S Cover Panel Cover Right Top Cover Left Top Cover Left Cover Right I/S Cover Left Cover Check that Idle Pulley Holder is aligned parallel to Guide <Front View>...
Page 189 Make sure the tension is between 0.97kgf and 1.189kgf <Top View> when Belt makes contact with the the dent part which is hooked the spring. Plate Attach SOLENOID CUSHION (P/N.22265241) 70mm onto the top of ST-001 to make a measurement easier.
Page 190: Belt Position Adjustment
4-10 BELT POSITION ADJUSTMENT Make sure to perform BELT TENSION ADJUSTMENT before doing this adjustment. Serial Number ZU50220 and below Turn on Printer Main Power SW. <Rear View> Printer Main Power SW Turn on SUB POWER SW while pressing [ ], [ ] and [ keys to enter SERVICE MODE.
Page 191 Loosen the screw shown in the figure to have a gap about 1.0mm between Drive Shaft Support and the head of the screw. There is another screw for fixing Drive Shaft Support on the machine with the Servial Number from ZU50190 to ZU50220. In this case, loosen this another screw in the same way as loosening other screws.
Page 192 Rotate Adjustment Screw clockwise (to the direction to tighten) when Belt is in the upper position from the center of Drive Pulley shown in the figure. There is another screw for fixing Drive Shaft Support on the machine with the Servial Number from ZU50190 to ZU50220.
Page 193 Tighten up the 2 screws shown in the figure with pressing Drive Shaft Support downward. Move Head Carriage over a few times in a whole width and check the position of the belt on Drive Pulley again. There is another screw for fixing Drive Shaft Support on the machine with the Servial Number from ZU50190 to ZU50220.
Page 194 No gap in the part A No gap in the part B Next, adjust the belt position at the left side using the 2 <Left Side View> Adjustment Screws. <Front View> Adjustment Screw Loosen the 2 screws shown in the figure on Pulley Stand. <Front View>...
Page 195 Select [MOTOR MENU] > [AGING] > [SCAN] and press SERVICE MENU [ENTER] key. MOTOR MENU MOTOR MENU AGING AGING SCAN [ENTER] By tightening Upper Adjustment Screw, the pully is tiltes <Front View> leftward. And, belt moves down. Adjustment Screw By tightening Lower Adjustment Screw, the pully is tiltes <Front View>...
Page 196 Serial Number from ZU50221 Turn on Printer Main Power SW. <Rear View> Printer Main Power SW Turn on SUB POWER SW while pressing [ ], [ ] and [ keys to enter SERVICE MODE. ], [ ], [ ] + POWER ON [MENU] key MENU SERVICE MENU...
Page 197 <Front View> 1.0mm Screw 3 Screw1, 2 D r i v e S h a f t Support Move Head Carriage over several times in a whole width and check the position of the belt on Drive Pulley. The proper position is that Belt is located in the center of Drive Pulley shown in the figure.
Page 198 Rotate Adjustment Screw CCW (to the direction to loosen) when Belt is in the lower position from the center of Drive Pulley shown in the figure. Adjustment Screw Tighten up Screw1 and 2 shown in the figure with pressing Screw 3 Drive Shaft Support downward with 2kgf (0.2Nm).
Page 199 To start the aging, select [MOTOR MENU] > [AGING] > SERVICE MENU [SCAN] and press [ENTER] key. MOTOR MENU MOTOR MENU AGING AGING SCAN [ENTER] Check the belt position while aging. Check there is a gap at A and B shown in the figure. Go to the procedure 5 again if there is no gap at A and B.
Page 200 Next, adjust the belt position at the left side using Upper <Left Side View> Adjustment Screw. <Front View> At this moment, do not use Lower Adjustment Upper Adjustment Screw Screw when adjusting the blet position at ledt side of the machine. Lower Adjustment Screw Loosen the 2 screws shown in the figure on Rail Guide.
Page 201 By tightening Upper Adjustment Screw, the pully is tiltes <Front View> leftward. And, belt moves down. Upper Adjustment Screw By loosening upper Adjustment Screw, the pully is tiltes <Front View> rightward. And the belt movesd up. By this way, adjust the belt position on the left side of the machine.
Page 202: Network Board Initialize
Network Board has become incorrect. In such case, the setting can be returned to the default by carrying out INITIALIZE. After INITIALIZE is completed, it is necessary to set the IP address again. For details, please refer to Roland PrintServer Network Setting Guide.
Page 203 and then turn it on again. Turn off Printer Main Power SW <Rear View> Network Board will not work properly if Printer Main Power SW is not turned on again. Such symptom could occur as that Network Board does not accept any data although it returns IP address.
Page 204: Limit Position & Max Scan Width Initialize
4-12 LIMIT POSITION & MAX SCAN WIDTH INITIALIZE Remove Right I/S Cover. Right I/S Cover Turn on SUB POWER SW while pressing [ ], [ ] and [ keys. ] , [ ] , [ ] + POWER ON LIMIT INITIALIZE MENU When [SETTING UP HEAD HEIGHT] is displayed, press [ENTER] key to skip this menu.
Page 205 Carry out the LIMIT POSITION INITIALIZE by pressing the [ENTER] key. SETTING UP THE LIMIT [ENTER] NOW PROCESSING... DETECTING... After the LIMIT POSITION INITIALIZE is completed, SETTING UP [SETTING UP MAX.SCAN WIDTH] message appears. MAX. SCAN WIDTH Move the Head Carriage with your hand until it stops at the left end.
Page 206 Put the top surface of the Take-up unit on the floor and then remove the black plate by removing the screw. Disconnect all the Cables from the Board and replace the Board. Fix the black Plate. Put the Take-up unit on the Stand then connect the Cable.
Page 207 Fix the Take-up unit on the Stand. When fixing the Cable Cover on the cable side, hook the Cable as shown on the right. Cable Cover To TU To TU 3-64...
Page 208: Supplemental Information
5 Supplemental Information 5-1 SENSOR MAP THERMOSTAT (PLATEN HEATER) If the Heater exceeds the limit temperature, it stops the power supply. THERMISTOR THERMOSTAT (BED FRONT HEATER) (BED FRONT HEATER L) THERMISTOR (PLATEN HEATER) It measures the temperature of the If the Heater exceeds the limit It measures the temperature of the Heater.
Page 209 THERMOSTAT THERMOSTAT (BED REAR HEATER R (BED REAR HEATER L If the Heater exceeds the limit If the Heater exceeds the limit temperature, it stops the power temperature, it stops the power supply. supply. REAR PAPER SENSOR It detects the rear edge of the media and also whether the media is set or not.
Page 210 SLIDER SENSOR It detects the back and force origin of the capping unit. WIPER SENSOR It detects the Wiper position. INK CARTRIDGE IC It detects whether the Ink Cartridge is installed or not and communicates the ink type and the remaining amount of the ink. MAINTENANCE LIQUID EMPTY SENSOR MAINTENANCE LIQUID CARTRIDGE IC...
Page 211 THERMISTOR (HEAD BOARD) It measures the temperature around the Head Board. ENCODER MODULE It detects the scanning coordinate. PAPER SIDE SENSOR HEAD UP/DOWN SENSOR It detects the left and right edges of It detects the origin of the Head Height direction the media.
Page 212: How To Remove The Air In The Ink Line
5-2 HOW TO REMOVE THE AIR IN THE INK LINE Perform Normal, Powerful, Manual Cleaning but air still remains in the ink line. Check if Adapter Screw is tightened up firmly by hand. There are 30 checking points. 12 are Adapter Screws for Supply Pumps. 12 are Adapter Screws for Pressure Pumps.
Page 213 1. HOW TO CHECK THE BREAK OF O RING AND FIXING OF ADAPTER SCREWS Remove Right I/S Cover. Right I/S Cover Remove Carriage Cover, Front Cover and Front Rail Cover. Carriage Cover Front Rail Cover Front Cover Remove Rail Cover, Subtank Cover and Rear I/C Case Cover.
Page 214 Turn on Sub Power SW while pressing the Left, Right and Down keys to enter Service Mode. ], [ ], [ ] + POWER ON [MENU] key MENU SERVICE MENU Check if Adapter Screws are tightened up firmly by hand. <Head Carrige Part>...
Page 215 <Supply Pump Part> Prepare the tissue or the waste cloth. Patch the tissue or the waste cloth with the joint parts fixed by Adapter Screws. There are also 30 checking points totally. 12 Adapter Screws for Supply Pumps. 12 Adapter Screws for Pressure Pumps. 6 Adapter Screws for Heads.
Page 216 If the ink is put on the tissue or the waste cloth, O Ring in <Head Carrige Part> Tube Joint Adapter could be broken. Go to the procedure [2. HOW TO REPLACE O RING (HEAD PART)]. If the ink is put on the tissue or the waste cloth, O Ring in <Pressure Pump Part>...
Page 217 If the ink is put on the tissue or the waste cloth, O Ring in <Supply Pump Part> Tube Joint Adapter could be broken. Go to the procedure [4. HOW TO REPLACE O RING (SUPPLY PUMP PART)]. If the ink is not put on the tissue or the strip of cloth, this is the end of this checking.
Page 218 2. HOW TO REPLACE O RING (HEAD PART) Remove Right I/S Cover. Right I/S Cover Remove Carriage Cover. Carriage Cover Turn on Printer Main Power SW. <Rear View> Printer Main Power SW Turn on Sub Power SW while pressing the Left, Right and Down keys to enter Service Mode.
Page 219 Select [I/S MENU] > [I/S CONTROL] > [PRESS PUMP 1- 6] > [CLOSE] and press [ENTER] key. SERVICE MENU I/S MENU I/S MENU I/S CONTROL I/S CONTROL PRESS PUMP1 This prodcedure is to prevent the ink from flowing back to Sub Tank when disconnecting PRESS PUMP1 CLOSE the tube from Head.
Page 220 Push O Ring into Tube Joint Adapter by pressing slowly with Tube Joint Adapter Tube Plug Adapter. Tube Plug Adapter O Ring It is necessary to push O Ring to the end of Tube Joint Adapter. PRESS Fix Ink Tube to the damper straight at first. Straight Then, tighten up Adapter Screw.
Page 221 3. HOW TO REPLACE O RING (PRESSURE PUMP PART) Remove Subtank Cover. Subtank Cover Turn on Printer Main Power SW. <Rear View> Printer Main Power SW Turn on Sub Power SW while pressing the Left, Right and Down keys to enter Service Mode. ], [ ], [ ] + POWER ON...
Page 222 Loosen Adapter Screw and disconnect the tube from Pressure Pump. Do not remove Tube Joint Adapter from Ink Tube. Adapter Screw Remove O Ring from Tube Joint Adapter. Tube Joint Adapter O Ring Prepare new O Ring and put it to the top of Tube Joint Adapter.
Page 223 Fix Ink Tube to Pressure Pump straight at first. Straight Screw Adapter Then, tighten up Adapter Screw. Adapter Screw 5-16...
Page 224 4. HOW TO REPLACE O RING (SUPPLY PUMP PART) Remove Right I/S Cover, Subtank Cover, Rear I/C Case Subtank Cover Cover and Carriage Cover. Rear I/C Case Cover Right I/S Cover Carriage Cover Turn on Printer Main Power SW. <Rear View> Printer Main Power SW Turn on Sub Power SW while pressing the Left, Right and Down keys to enter Service Mode.
Page 225 Select [I/S MENU] > [I/S CONTROL] > [PRESS PUMP 1- 6] > [CLOSE] and press [ENTER] key. SERVICE MENU I/S MENU I/S MENU I/S CONTROL I/S CONTROL PRESS PUMP1 This prodcedure is to prevent the ink from flowing back to Sub Tank when disconnecting PRESS PUMP1 CLOSE the tube from Head.
Page 226 When the injector becomes filled with the ink, select [I/S MENU] > [I/S CONTROL] > [PRESS PUMP 1- 6] > [CLOSE] and press [ENTER] key. SERVICE MENU I/S MENU I/S MENU I/S CONTROL I/S CONTROL PRESS PUMP1 PRESS PUMP1 CLOSE [ENTER] to the Remove the syringe from Ink Tube and drain the ink...
Page 227 Select [I/S MENU] > [I/S CONTROL] > [PRESS PUMP 1- 6] > [CLOSE] and press [ENTER] key. SERVICE MENU I/S MENU I/S MENU I/S CONTROL I/S CONTROL PRESS PUMP1 PRESS PUMP1 CLOSE [ENTER] Put the cloth under Adapter Screw. Tube Adapter Screw Then, loosen Adapter Screw and disconnect the ink from Supply Pump.
Page 228 Prepare new O Ring and put it to the top of Tube Joint Adapter. Tube Joint Adapter Do not strech O Ring when putting it to Tube Joint Adapter. O Ring Push O Ring into Tube Joint Adapter by pressing with Tube Tube Joint Adapter Plug Adapter.
Page 229 5. HOW TO REMOVE AIR IN PRESSURE PUMP OR IN INK TUBE BETWEEN HEAD AND PRESSURE PUMP Sub Tank Ink Cartridge Head Pressure Pump Supply Pump When there is the air in Pressure Pump or Ink Tube between Pressure Pump and Head, perform this procedure.
Page 230 Turn on Printer Main Power SW. <Rear View> Printer Main Power SW Turn on Sub Power SW while pressing the Left, Right and Down keys to enter Service Mode. ], [ ], [ ] + POWER ON [MENU] key MENU SERVICE MENU Select [I/S MENU] >...
Page 231 Connect the syringe to Ink Tube. Then, tighten up Adapter Screw. Adapter Screw Be careful not to have the ink spilled on Heads. If the ink is spilled on Head, it causes the short circuit on Main Board, Head Board and Print Carriage Board.
Page 232 to the Remove the syringe from Ink Tube and drain the ink drain bottle through the Funnel. Repeat the step from 6 to 10 4 or 5 times to remove air between Head and Pressure Pump. When the ink in Sub Tank reaches to empty duing pulling the ink, select [I/S MENU] >...
Page 233 Then, tighten up Adapter Screw. Adapter Screw Select [I/S MENU] > [I/S CONTROL] > [PRESS PUMP 1- 6] > [OPEN] and press [ENTER] key. SERVICE MENU I/S MENU I/S MENU I/S CONTROL I/S CONTROL PRESS PUMP1 PRESS PUMP1 OPEN [ENTER] Select [I/S MENU] >...
Page 234 6. HOW TO REMOVE AIR IN SUPPLY PUMP OR INK TUBE BETWEEN SUPPLY PUMP AND SUB TANK Sub Tank Ink Cartridge Head Pressure Pump Supply Pump When there is air in Supply Pump or Ink Tube between Supply Pump and Sub Tank, perform this procedure.
Page 235 Turn on Printer Main Power SW. <Rear View> Printer Main Power SW Turn on Sub Power SW while pressing the Left, Right and Down keys to enter Service Mode. ], [ ], [ ] + POWER ON [MENU] key MENU SERVICE MENU Select [I/S MENU] >...
Page 236 Loosen Adapter Screw and remove Ink Tube with Tube Joint Adapter from the damper. Do not remove Tube Joint Adapter from Ink Tube. Adapter Screw Connect the syringe to Ink Tube. Tehn, tighten up Adapter Screw. Adapter Screw Be careful not to have the ink spilled on Heads. If the ink is spilled on Head, it causes the short circuit on Main Board, Head Board and Print Carriage Board.
Page 237 When the syringe becomes filled with the ink, select [I/S MENU] > [I/S CONTROL] > [PRESS PUMP 1- 6] > [CLOSE] and press [ENTER] key. SERVICE MENU I/S MENU I/S MENU I/S CONTROL I/S CONTROL PRESS PUMP1 PRESS PUMP1 CLOSE [ENTER] to the Remove the syringe from Ink Tube and drain the ink...
Page 238 Disconnect the syringe and connect Ink Tube to the damper straight at first. Straight Then, tighten up Adapter Screw. Adapter Screw When [SUPPLY] is finished, [CANCELED BY INK FILL] is shown on LCD. After this message is shown, press [CLEANING] key and select [NORMAL CL.] >...
Page 239: 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 240 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. Run out of Maintenance Maintenance Liquid Cleaning the head with wiper is not performed efficiently and it cannot User's Manual liquid Cartridge Replacement...
Page 241: Particular Color Does Not Print At All
6-2 PARTICULAR COLOR DOES NOT PRINT AT ALL CHECKING POINT ACTION REFERENCE OUTLINE Air bubbles tend to go into the ink line by installing and uninstalling the Perform Powerful [5-2 HOW TO ink cartridge so many times. All the air bubbles inside the lines can be Cleaning Air bubbles in Ink line REMOVE THE AIR...
Page 242: Ink Drops On The Media
6-4 INK DROPS ON THE MEDIA CHECKING POINT ACTION REFERENCE OUTLINE When foreign substances such as fiber dust is stuck on the surface of Foreign substances Manual Cleaning User's Manual the head, ink sometimes leaks from it. Wipe the surface of head with a cleaning stick.
Page 243: Even If The Ink Has Not Run Out
6-7 INK EMPTY MESSAGE APPEARS EVEN IF THE INK HAS NOT RUN OUT CHECKING POINT ACTION REFERENCE OUTLINE If the Sub Tank doesn't get full after rotating the Supply Pump a certain times, the machine recognizes the ink cartridge is empty, resulting in an ink empty detection.
Page 244: By Performing Fill Ink
6-8 THE INK OR MAINTENANCE LIQUID NEVER COMES BY PERFORMING FILL INK CHECKING POINT ACTION REFERENCE OUTLINE If there is air inside the Supply Pump or Pressure Pump or the tube between the Pressure Pump and the head, air can't be pushed out of the ink line by rotating the Pump and it causes [5-2-5 HOW TO the FILL INK to be failed.
Page 245: Motor Error
6-9 MOTOR ERROR CHECKING POINT ACTION REFERENCE OUTLINE When the edges of the media curls or the media absorbs the Ink and Remove cause of Media Jam becomes to be irregular surface of the media, the head carriage Media Jam catches on the media during printing and results in the Motor Error.
Page 246: Heater Temperature Does Not Go Up
6-10 HEATER TEMPERATURE DOES NOT GO UP CHECKING POINT ACTION REFERENCE OUTLINE The heater temperature does not rise to the set temperature when the Set the media. Press Check the media setting User's Manual [SETUP] lump is OFF on the machine. Set the media and press the the [SETUP] button [SETUP] button, then wait until the media warms up.
Page 247: Dryer Temperature Does Not Go Up
6-11 DRYER TEMPERATURE DOES NOT GO UP CHECKING POINT ACTION REFERENCE OUTLINE Check if the main power Turn on the main power The dryer does not work unless turn the main power switch on. switch on the dryer is ON switch on the dryer Check the power supply Check the cable wiring, connection and contact between the power...
Page 248: The Blower Fan Does Not Move
6-12 THE BLOWER FAN DOES NOT MOVE CHECKING POINT ACTION REFERENCE OUTLINE Check the setting of the Turn on the setting of The blower fan does not work unless turn on the setting of [BLOWER User's Manual blower fan the blower fan FAN] in the heater menu.
Page 249: Error Message
6-14 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. In the most case, the error can be fixed by restarting the machine. If the error Restart the machine still occurs in spite of restarting the machine, it sometimes could be internal error...
Page 250 Input value from Linear Confirm whether Encoder Scale is between the slit of Encoder Module Encoder is not changed in a whole width of the machine when Linear Encoder is Check Cable connection between Linear Encoder Board and Print Read error of Linear Encoder. setup the origin.
Page 251 Check Cable connection of Servo Board Pressure Pump 1 Motor has a problem. Even though the machine Check Cable connection of Junction Board Pressure Pump 1 Sensor has a problem. carries out the regular Check Pressure Pump 1 Magnet Pressure Pump 1 Magnet has dropped out. movement, the output of Pressure Pump 1 Motor replacement Wiring or Flexible Cable has short circuitted...
Page 252 Check Cable connection of Servo Board Supply Pump 3 Motor has a problem. Even though the machine Check Cable connection of Junction Board Supply Pump 3 Sensor has a problem. carries out the regular Check Supply Pump 3 Magnet Supply Pump 3 Magnet has dropped out. movement, the output of Supply Pump 3 Motor replacement 0172...
Page 253: Service Activities
7 Service Activities 7-1 INSTALLATION CHECK LIST AJ-1000 INSTALLATION CHECK LIST Date : User Name : Serial Number : Checking for Installing Place There is a necessary space for installing the machine. 8 m (26 ft.) 5 m (16.25 ft.) Unit space Work space There are two seperate 200-240V power outlets (10A or more) at the position which the included power code can...
Page 254 Disassembling the Steel Package Make sure to work with at least 2 persons. Following tools are required for this operation. - Knife - 12mm Spanner - 17mm Spanner 1. Cut off the nylon belts. 2. Open the zipper and remove the cover. Zipper is located here.
Page 255 4. Remove the bolts fixing the Top Frame, and remove the Top Frame. Then, remove the rest of the Stays. (size of bolts : 12mm) - If you remove the bolts, the Top Frame will fall down. The Top Frame must be supported by one person while another is removing the bolts.
Page 256 Checking for Carrying-in Route There is a space that allows you to operate using a heavy equipment like a forklift or a crane. There is a carrying-in route that the machine can go through without being lifted. In case that there is a step, the machine can be lifted up by a power lifter or the like. The width of the route should be more than 2000mm.
Page 257 Maintenance liquid cartridge : 1 Media clamps : 2 Drain bottle : 1 Power cords : 2 * It is installed on the machine. Roland-PrintServer Hexagonal wrenches Head-unit tool : 1 Software RIP set : 1 CD-ROM : 1 (large, small) (*2)
Page 258 Removing the Packing Materials Remove the bands and the packing materials. Left Front Right Front Band Buffer Band materials Right Rear Left Rear Band Take out the hose from the drain bottle. (The hose will not be necessary.) Hose Buffer material Band Buffer...
Page 259 Remove the bar for the crane. Keep the bars for future use. Remove the packing materials. Packing material A Packing material B Peel off the tape. Packing material D Packing material C...
Page 260 Keep the removed packing materials at the location shown in the figure for future use. Packing material D Packing material C Media gauge This can be attached when not in use. Packing Packing material A material B...
Page 261 Setting up the Network Setting up the network in reference to the "Roland-PrintServer Network Setup Guide". Setting up the PC Enter the IP Address (e.g. 192.168.0.100) and the Subnet Mask (e.g. 255.255.255.0). IP address of the PC Setting up the printer Enter the IP Address (e.g.
Page 262 Loading and Cutting Off Media Explain following items in reference to "2-2 Loading and Cutting Off Media" and "6-1 Usable Media". !! IMPORTANT !! - When loading or moving roll media, use lifting equipment, and exercise care to prevent falls. - Never load media that weighs more than 100 kg (220 lb).
Page 263 Operation Explain following items in reference to the User's Manual. Switching the power on and off Back side of the machine Main power switch Main power switch for the dryer for the printer This machine has five power switches. When you finish printing, you turn off switches 3 and 4 as required.
Page 264 Handlig of the ink cartridge !! IMPORTANT !! - Once a cartridge is inserted, never remove or re-insert the cartridge until it runs out. It may cause air to go inside the ink cartridge, then air enters the ink line, resulting in the breakdown of the machine. - Be sure to replace with an cartridge of identical type.
Page 265 Maintenance Explain following items in reference to the User's Manual. Cleaning function of the head (Normal cleaning / Powerful cleaning) - Selected Head(s) - All Heads Do not perform the powerful cleaning more than necessary. It consumes lots of ink. Cleaning the printing heads using the cleaning kit Replacing the wipers Replacing the Maintenance Liquid Cartridge...
Page 266 When not in use for a prolonged period When moving the machine When moving the machine to another location, consult your authrized Roland DG Corp. dealer. Others Explain the action to take when the head carriage stops over the platen in reference to the User's Manual [5-6 The Print Heads Stopped Moving].
Page 267 7-2 Maintenance Check List AJ-1000 Maintenance Check List Date : User : Serial Number : Check Points Operation Points Check Ask the customer if there is something that he/she is concerned Done Interview the customer about. Get report with [Get Report] of the Peck, or print both Service Report Done Output / Get report before maintenance and History Report.
Page 268: Preparation For Transportation
7-3 Preparation for Transportation 1 This is the procedure of the preparation when transporting the machine without removing the ink. If the preparation is done in this way, the power needs to be turned on again within 48 hours. Make sure to keep the ambient temperature during the transportation between 5 and 40 °C.
Page 269 3) Select [I/S MENU] > [I/S CONTROL] > [WIPER] > SERVICE MENU , and press the [ENTER] key. The WIPERs [UP] I/S MENU move up. I/S MENU I/S CONTROL I/S CONTROL WIPER WIPER [ENTER] Select [I/S MENU] > [I/S CONTROL] > [SLIDER] > SERVICE MENU , and press the [ENTER] key.
Page 270 7) Take up any remaining maintenance liquid with the syringe. Immediately discard the taken-up maintenance liquid Syringe into the drain bottle, leaving none inside the syringe. Otherwise the rubber parts of the syringe may swell and make the syringe unusable. Tube 8) Return the tray to its original location and tighten the screws.
Page 271 Move Head Carriage manually by fitting [ ] Mark on Head Carriage Cover with the left Frame of Cap Unit in the figure. ] Mark Left Frame of Cap Unit 12) Select [I/S MENU] > [I/S CONTROL] > [HEAD UP/DOWN] SERVICE MENU >...
Page 272 3) Attach the emptied bottle and press the [ENTER] key. Press the [ENTER] key again to reset the drained liquid count. RESET DRAIN COUNTER [ ENTER ] MAINTENANCE DRAIN BOTTLE Switch the position of the roll shaft of the Take-up unit and the one of the Feed unit.
Page 273 Insert the 6 dummy cartridges to the ink cartridge holder. Dummy cartridge Remove the packing materials at the location shown in the figure. Packing material D Packing material C Media gauge Packing material A Packing material B 7-21...
Page 274 Fix the removed packing materials at the location shown in the figure. Packing material A Packing material B Packing material D Packing material C Fix the bands as shown in the figure. Band Left Front Right Front Band Band Right Rear Left Rear Band Band...
Page 275 Before moving the machine, raise the Adjuster to the very top. Do not use the Adjusters for the crane. Adjuster Fix the bar for the crane. After the transportation, perform the following operations. 1. Remove the packing materials from the machine. 2.
Page 276: Preparation For Transportation
7-4 Preparation for Transportation 2 This is the procedure of the preparation when transporting the machine with the cleaning liquid filled in If the power can not be turned on again within 48 hours, take this procedure for the preparation. Make sure to keep the ambient temperature during the transportation between 5 and 40 If the ambient temperature can be kept 30 C or below, the machine can be kept safe up to about 72...
Page 277 When the message shown in the figure is displayed, REMOVE CARTRIDGE open the Cartridge-Slot Cover and remove the ink cartridges. Clean the surrounding of the hole of the cartridge, and tape the holes. C a r t r i d g e - S l o t Cover Do not store or transport the cartridge vertically.
Page 278 When finishing the HEAD WASH, [STORAGE STORAGE CANCEL] is displayed. CANCEL Select [STORAGE SET] and press the [ENTER] key. STORAGE The Head Carriage moves to the left automatically. [ENTER] NOW PROCESSING.. When the message shown in the figure is displayed, COVER CAP cover the Cap Unit with the film, and press the WITH FILM...
Page 279 Close the Cartridge-Slot cover, and press the [ENTER] key. The Supply Pumps will be set to Open state automatically. Fill the tube between the maintenance liquid cartridge SERVICE MENU and the tray with the maintenance liquid. I/S MENU Select [SERVICE MENU] > [I/S MENU] > [I/S CONTROL] >...
Page 280 Discard any maintenance liquid that has collected in the SERVICE MENU tray. I/S MENU Turn on the SUB POWER SW while pressing the Left, Right and Down keys to enter the SERVICE I/S MENU MODE. I/S CONTROL Select [SERVICE MENU] > [I/S MENU] > [I/S I/S CONTROL CONTROL] >...
Page 281 Remove the screws shown in the figure and pull out the tray. Tray Screw Tilt the tray to pour out the maintenance liquid to the location shown in the figure. Take up any remaining maintenance liquid with the syringe. Immediately discard the taken-up maintenance Syringe liquid into the drain bottle, leaving none inside the syringe.
Page 282 Select [I/S MENU] > [I/S CONTROL] > [WIPER] > SERVICE MENU [DOWN], and press the [ENTER] key. The Wipers I/S MENU move down. I/S MENU I/S CONTROL I/S CONTROL WIPER WIPER DOWN [ENTER] Select [I/S MENU] > [I/S CONTROL] > [SLIDER] > SERVICE MENU [FRONT], and press the [ENTER] key.
Page 283 Dispose of the drained ink. MENU SUB MENU Press the [MENU] key. [ ] [ ] Select [SUB MENU] > [MAINTENANCE] > [DRAIN BOTTLE]. SUB MENU MAINTENANCE And press the [ENTER] key. MAINTENANCE DRAIN BOTTLE [ ENTER ] Empty the DRAIN BOTTLE after "EMPTY DRAIN BOTTLE"...
Page 284 Remove the packing materials at the location shown in the figure. Packing material D Packing material C Media gauge Packing material A Packing material B 7-32...
Page 285 Fix the removed packing materials at the location shown in the figure. Packing Packing material A material B Packing Packing material D material C Fix the bands as shown in the figure. Band Left Front Right Front Band Band Right Rear Left Rear Band Band...
Page 286 Before moving the machine, raise the Adjuster to the very top. Do not use the Adjusters for the crane. Adjuster Fix the bar for the crane. After the transportation, perform the following operations. 1. Set the drain bottle, and set the drain tube into the drain bottle. 2.
Page 287: Specifications
Power cord, roll shafts, end caps, spacers, media reinforcement pipe, paper pipe, drain bottle, media gauge, media clamps, hexagonal wrenches, Head-unit tool, cleaning kit, syringe, tube, maintenance liq- uid cartridges, software RIP, Roland-PrintServer CD-ROM, User's Manual, Setup Guide, Roland-PrintServer Network Settings Guide At Roland PET film, print travel: 1m Temperature: 20C (68 F), humidity: 50% Not assured when the media heating system is used.