Page 1 Users of this Service Note shall be deemed to agree with the following Terms of Use. 1. USERS This Service Note is only for authorized persons with user ID and password issued by Roland DG Corporation. 2. PURPOSE Authorized persons can use this Service Note only for the purposes of selling and providing to the customers maintenance service of VS-640/540/420/300.
Page 2: Table Of Contents
Contents 1 Structure & Spare Parts 3-16 CUTTER PROTECTION REPLACEMENT ....3-81 3-17 CUT RIBBON CABLE REPLACEMENT ......3-82 1-1 COVERS (VS-640/540) 3-18 LINEAR ENCODER BOARD REPLACEMENT ...3-88 ..1-1 (S/N VS-640 : ZAH2971 and below, VS-540 : ZAH1721 and below) 3-19 HOW TO FOLD RIBBON CABLE TO THE HEAD ..3-93 COVERS (VS-640/540) 3-20 INK TUBE REPLACEMENT ........3-96 ..1-3...
Page 3 Revision Record Revision No. Date Description of Changes Approval Issued 2010.5.28 First Edition Kato Misako Following section has been revised for supporting 2010.8.10 VS-540/420/300. Kato Misako Section 3, Section 4 and Section 7 Following section has been revised for supporting VS-540/420/300.
Page 4 To Ensure Safe Work About Notices. Used for instructions intended to alert the operator to the risk of death or severe injury should the unit be used improperly. Used for instructions intended to alert the operator to the risk of injury or material damage should the unit be used improperly.
Page 5 About the Labels Afﬁ xed to the Unit These labels are affi xed to the body of this product. The following fi gure describes the location. Caution : Pinching Hazard Contact during operation may cause the hand or fi ngers to become pinched, rsult- ing in injury.
Page 6 WARNING - FOR CONTINUED PROTECTION AGAINST RISK OF FIRE, REPLACE ONLY WITH FUSE OF THE SPECIFIED TYPE AND CURRENT RATING. F80L HS Electric charge. Do not touch when power is on. The wiring terminal untended for connec- tion of the protective earthing conductor associated with the supply wiring.
Page 7: Structure & Spare Parts
1 Structure & Spare Parts 1-1 COVER ~VS-640/540~ (VS-640 : ZAH2971 and below, VS-540 : ZAH1721 and below)
Page 8 1-1 COVER ~VS-640/540~ (VS-640 : ZAH2971 and below, VS-540 : ZAH1721 and below) PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1000006510 ASSY,COVER FRONT VS-640 S1 31289109AS CUPSCREW SET,M3*4 NI 100 PCS. 1000007209 ASSY,COVER FRONT VS-540 S2 31139103...
Page 9 Revised 3 1-1 COVER ~VS-640/540~ (VS-640 : ZAH2972 and above, VS-540 : ZAH1722 and above)
Page 10 Revised 3 1-1 COVER ~VS-640/540~ (VS-640 : ZAH2972 and above, VS-540 : ZAH1722 and above) PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1000006510 ASSY,COVER FRONT VS-640 S1 31289109AS CUPSCREW SET,M3*4 NI 100 PCS. 1000007209 ASSY,COVER FRONT VS-540 S2 31139103...
Page 11 1-1 COVER ~VS-420/300~ (VS-420 : ZAH0635 and below, VS-300 : ZAH0667 and below)
Page 12 1-1 COVER ~VS-420/300~ (VS-420 : ZAH0635 and below, VS-300 : ZAH0667 and below) PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1000007238 ASSY,COVER FRONT VS-420 S1 31289109AS CUPSCREW SET,M3*4 NI 100 PCS. 1000007254 ASSY,COVER FRONT VS-300 S2 31139103...
Page 13 Revised 3 1-1 COVER ~VS-420/300~ (VS-420 : ZAH0636 and above, VS-300 : ZAH0668 and above)
Page 14: Label,Mark Eco#La1014 Label,Set Ink
1-1 COVER Revised 3 ~VS-420/300~ (VS-420 : ZAH0636 and above, VS-300 : ZAH0668 and above) PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1000007238 ASSY,COVER FRONT VS-420 S1 31289109AS CUPSCREW SET,M3*4 NI 100 PCS. 1000007254 ASSY,COVER FRONT VS-300 S2 31139103...
Page 15: Frame
1-2 FRAME...
Page 16: S10 31289111As Cupscrew Set, M4*6 Ni 100 Pcs
1-2 FRAME PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 21905192 ADAPTER,CLAMP MEDIA SP-540V S1 31029101 BUSH,NB-19 7520501000 ASSY,CAP BOTTLE 2 FJ-52 S2 31029106 BUSH,SQUARE SB-6025 W701406040 ASSY,FAN JUNCTION BOARD VS-640 S3 31329501AS CLAMP SET,PUSH MOUNT RT30SSF5 20P 21985140 BRACKET,INK CATCH TANK SP-540V...
Page 17: Drive Unit (Vs-640)
1-3 DRIVE UNIT ~VS-640~ Revised3 Revised3 73 S6 Revised3 1-11...
Page 18: Drive Unit (Vs-420)
1-3 DRIVE UNIT ~VS-640~ * qt. indicates the number of parts that is described in the figure. PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 6701409040 ASSY,FEED MOTOR VS-640 56 1000001479 SHAFT,IDLE PULLEY XC-540 2 W701406090 ASSY,FLEX 1 VS-640...
Page 19 1-3 DRIVE UNIT ~VS-540~ Revised3 Revised3 73 S6 Revised3 1-13...
Page 20 1-3 DRIVE UNIT ~VS-540~ * qt. indicates the number of parts that is described in the figure. PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 6701409040 ASSY,FEED MOTOR VS-640 56 1000001479 SHAFT,IDLE PULLEY XC-540 2 W701406090 ASSY,FLEX 1 VS-640...
Page 21 1-3 DRIVE UNIT ~VS-420~ Revised3 Revised3 S18 S9 S18 S9 63 57 Revised3 Revised3 73 S6 Revised3 1-15...
Page 22 1-3 DRIVE UNIT ~VS-420~ PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 6701409040 ASSY,FEED MOTOR VS-640 56 1000001479 SHAFT,IDLE PULLEY XC-540 2 W701406090 ASSY,FLEX 1 VS-640 57 22295117 SHAFT,LOCK CJ-70 3 W7014060A0 ASSY,FLEX 2 VS-640 58 1000003089 SHEET,FRAME SUPPORT RAIL VP-540...
Page 23 1-3 DRIVE UNIT ~VS-300~ S18 S9 S18 S9 63 57 Revised3 Revised3 73 S6 Revised3 1-17...
Page 24 1-3 DRIVE UNIT ~VS-300~ PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 6701409040 ASSY,FEED MOTOR VS-640 56 1000001479 SHAFT,IDLE PULLEY XC-540 2 W701406090 ASSY,FLEX 1 VS-640 57 22295117 SHAFT,LOCK CJ-70 3 W7014060A0 ASSY,FLEX 2 VS-640 58 1000003089 SHEET,FRAME SUPPORT RAIL VP-540...
Page 25: Head Carriage
1-4 HEAD CARRIAGE * Cut off 10mm when using the tube. ** Cut off 220mm when using the tube. 1-19...
Page 26 1-4 HEAD CARRIAGE PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name W701407030 ASSY,LINEAR ENCODER BOARD VS-640 S1 31329601AS CLAMP SET,INSULOK T-18S 100 PCS. Revised 3 6700989040 ASSY,LINEAR ENC BOARD SERVICE 1 S2 31289109AS CUPSCREW SET,M3*4 NI 100 PCS.
Page 27: Base Frame(Vs-640/540)
1-5 BASE FRAME ~VS-640/540~ 1-21...
Page 28 1-5 BASE FRAME ~VS-640/540~ PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1000004772 APRON,B RS-640 (VS-640) S1 31029101 BUSH,NB-19 1000004795 APRON,B RS-540 (VS-540) S2 31329601AS CLAMP SET,INSULOK T-18S 100 PCS. 1000006802 APRON,F UNDER VS-640 (VS-640) 31329501AS CLAMP SET,PUSH MOUNT RT30SSF5 20P(VS-640) 12 1000007199...
Page 29 1-5 BASE FRAME ~VS-420/300~ 1-23...
Page 30 1-5 BASE FRAME ~VS-420/300~ PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1000007219 APRON,B VS-420 S1 31029101 BUSH,NB-19 1000005559 APRON,B SP-300i S2 31329601AS CLAMP SET,INSULOK T-18S 100 PCS. 1000007218 APRON,F UNDER VS-420 31329501AS CLAMP SET,PUSH MOUNT RT30SSF5 20P (VS-420) 9 1000007244...
Page 31: Chassis
1-6 CHASSIS PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 6701409020 ASSY,MAIN BOARD VS-640 26 13129170 POWER SW AJ7201B W701406020 ASSY,POWER BOARD VS-640 1000002044 CABLE-ASSY,117V SELECTOR XC-540 1000006708 ASSY,SERVO BOARD VS-640 1000002043 CABLE-ASSY,230V SELECTOR XC-540 15009101 BATTERY CR2032...
Page 32: Pinch Roller
1-7 PINCH ROLLER PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 6700460210 ASSY,PINCHROLL L VP-540 S1 31149702AS RING SET,E-RING ETW-3 100 PCS. 6700460220 ASSY,PINCHROLL R VP-540 S2 31019702AS SCREW SET,BIND P-TIGHT M3*6 3C 100P 6700460300 ASSY,PINCHROLL C VP-540 (VS-640) S3 31249211AS...
Page 33: Stand
1-8 STAND PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 1000006779 ARM,L VS-640 17 1000004721 SHAFT,FEEDER RS-540 2 1000006778 ARM,R VS-640 18 1000005480 SPACER,BASE FEEDER RS-540 3 1000006533 ASSY,BASE STAND VS-640 19 1000006812 STAND,LEG L VS-640 4 1000004718 BASE,FEEDER RS-540 20 1000006811...
Page 34: Tool Carriage
1-9 TOOL CARRIAGE PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 22805571 21 22715168 ASSY,CARRIAGE SP-300 STAY,AUTO CUTTER 2 CM-500 2 22805292 22 22175122 ASSY,CLAMP BLADE CM-500 SPRING,BACK UP PNC-960 3 W701406050 ASSY,CROP SENS BOARD VS-640 23 1000002531 STAY,CUT CARRIAGE BOARD VP-540 W701407020 ASSY,CUT CARRIAGE BOARD VS-640...
Page 35: Wiper And Cap Systems
1-10 WIPE and CAP SYSTEMs PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name 1000006739 ARM,WIPER CAM VS-640 Parts No. Parts Name 1000006747 ARM,LINK UP VS-640 30 1000006825 SPRING,CAP SWING VS-640 6701409070 ASSY,CAP TOP VS-640 1000006523 SPRING,CAP VS-640 Revised 3 1000006521 BASE,BACK-UP CAP VS-640...
Page 36: Ink System
1-11 INK SYSTEM (VS-640 : ZAH2971 and below, VS-540 : ZAH1721 and below, VS-420 : ZAH0635 and below, VS-300 : ZAH0667 and below) S8 S7 1-30...
Page 37: Ink System
1-11 INK SYSTEM (VS-640 : ZAH2971 and below, VS-540 : ZAH1721 and below, VS-420 : ZAH0635 and below, VS-300 : ZAH0667 and below) PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1000004796 ADAPTER,JOINT 2-3FAI RS-540 32 1000002563 SHAFT,PUMP VP-540...
Page 38 1-11 INK SYSTEM Revised 3 (VS-640 : ZAH2972 and above, VS-540 : ZAH1722 and above, VS-420 : ZAH0636 and above, VS-300 : ZAH0668 and above) 1-32...
Page 39 1-11 INK SYSTEM Revised 3 (VS-640 : ZAH2972 and above, VS-540 : ZAH1722 and above, VS-420 : ZAH0636 and above, VS-300 : ZAH0668 and above) PARTS LIST -Main Parts- PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1000004796 ADAPTER,JOINT 2-3FAI RS-540 36 22625103...
Page 40: Ink Tube Wiring (Vs-640 S/N Zz92065 And Below)
INK TUBE WIRING VS-640：S/N ZZ92065 and below * This wiring map is shown as the machine of 8 colors of CMYKLcLmWMT(WMT mode). 1-34...
Page 41 INK TUBE WIRING VS-640：S/N ZZ92066 and above, VS-540/420/300 * This wiring map is shown as the machine of 8 colors of CMYKLcLmWMT(WMT mode). 1-35...
Page 42: Accessory
1-12 ACCESSORY (VS-640 : ZAH2971 and below, VS-540 : ZAH1721 and below, VS-420 : ZAH0635 and below, VS-300 : ZAH0667 and below) 230V BR 117V 230V 240VA 240VE 1-36...
Page 43: Accessory
1-12 ACCESSORY (VS-640 : ZAH2971 and below, VS-540 : ZAH1721 and below, VS-420 : ZAH0635 and below, VS-300 : ZAH0667 and below) PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 23495124 AC CORD 3ASL100 240VA 10A SAA 21545178 PAD,RAIL SPACER SP-300 (VS-640) 2 13499111...
Page 44 1-12 ACCESSORY Revised 3 (VS-640 : ZAH2972 and above, VS-540 : ZAH1722 and above, VS-420 : ZAH0636 and above, VS-300 : ZAH0668 and above) 230V BR 117V 230V 240VA 240VE 1-38...
Page 45 1-12 ACCESSORY Revised 3 (VS-640 : ZAH2972 and above, VS-540 : ZAH1722 and above, VS-420 : ZAH0636 and above, VS-300 : ZAH0668 and above) PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 23495124 AC CORD 3ASL100 240VA 10A SAA 21545178 PAD,RAIL SPACER SP-300 (VS-640) 2 13499111...
Page 46: Electrical Section
2 Electrical Section 2-1 WIRING MAP...
Page 47 CABLE LIST Parts No. Parts Name Parts No. Parts Name 1000002189 CABLE-ASSY,JUNBI A VP-540 1000004962 CABLE-CARD,36P1 2930L BB HIGH-V (VS-640) 1000002190 CABLE-ASSY,JUNBI B VP-540 23475240 CABLE CARD,36P1 2670L BB HIGH-V(VS-540) 23415268 CABLE-ASSY AC GROUND GREEN SP-540 1000007177 CABLE-CARD,36P1 2370L BB HIGH-V (VS-420) 23415116 CABLE ASSY,JUNBI D SP-300 23475213...
Page 48: Main Board
2-2 MAIN BOARD MAIN BOARD_Arrangement Diagram(Component Side) Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7 Bit 8 DIP SW It indicates the version of the Board.
Page 49 MAIN BOARD_Arrangement Diagram (Soldering Side)
Page 50 MAIN BOARD_Circuit Diagram 1/9...
Page 51 MAIN BOARD_Circuit Diagram 2/9...
Page 52 MAIN BOARD_Circuit Diagram 3/9...
Page 53 MAIN BOARD_Circuit Diagram 4/9...
Page 54 MAIN BOARD_Circuit Diagram 5/9...
Page 55 MAIN BOARD_Circuit Diagram 6/9 2-10...
Page 56 MAIN BOARD_Circuit Diagram 7/9 2-11...
Page 57 MAIN BOARD_Circuit Diagram 8/9 NA[0..25] 2-12...
Page 58 MAIN BOARD_Circuit Diagram 9/9 2-13...
Page 59: Servo Board
2-3 SERVO BOARD SERVO BOARD_Arrangement Diagram (Component Side) It indicates the version of the Board. 2-14...
Page 60 SERVO BOARD_Arrangement Diagram (Soldering Side) 2-15...
Page 61 SERVO BOARD_Circuit Diagram 1/4 /SERVO_RES /Serial_Start 2-16...
Page 62 SERVO BOARD_Circuit Diagram 2/4 2-17...
Page 63 SERVO BOARD_Circuit Diagram 3/4 2-18...
Page 64 SERVO BOARD_Circuit Diagram 4/4 2-19...
Page 65 2-4 CARRIAGE BOARD CARRIAGE BOARD_Arrangement Diagram (Component Side) 2-20...
Page 66 CARRIAGE BOARD_Circuit Diagram 1/2 2-21...
Page 67 CARRIAGE BOARD_Circuit Diagram 2/2 CUT CARRIAGE BOARD C104 CE0.1u IC100A BA-10358F CN100 CN101 So1+ To SOLENOID So1- So1+ ILS-2T So1- CN103 To SERVO BOARD PinchPos PinchPos PINCH POS SENSOR /Crop_ON CropSens C106 R101 NoMount R100 IC100B 53398-04 CE0.1u VR100 Q100 DTB123EK 52808-15 BA-10358F...
Page 68: Sub Board
2-5 SUB BOARD SUB BOARD_Arrangement Diagram (Component Side) 2-23...
Page 69 SUB BOARD_Circuit Diagram 1/4 2-24...
Page 70 SUB BOARD_Circuit Diagram 2/4 POWER BOARD to SW Power Supply to Power SW CN1101 CN1102 B2P3-VH B2(4-2 3)P-VH CN1103 to Print Thermostat CLIP PFC-5000-0202 CLIP PFC-5000-0202 FS1100 B2P-VH CN1104 5X20 021706.3MXP 6.3A/250V FS1101 to Print Heater 1 5X20 021706.3MXP 6.3A/250V SSR1100 RELAY,SSR AQ1208 B2P3-VH...
Page 71 SUB BOARD_Circuit Diagram 3/4 2-26...
Page 72 SUB BOARD_Circuit Diagram 4/4 2-27...
Page 73: Maintenance Parts List
2-6 MAINTENANCE PARTS LIST_Electrical Parts MAIN BOARD Parts No Parts Name Description Function IC22 IC21 1000001098 IC,E09A54RA D/A Converter IC26 IC25 TR14 15129122 TR 2SC4131 GB Transistor for Driving HEAD TR11 TR10 15129121 TR 2SA1746 OY Transistor for Driving HEAD TR15 DC Fuse for Head 1000000659...
Page 74: Replacement Of Main Parts
3 Replacement of Main Parts To Ensure safe Work Turn off the Sub Power SW, Main Power SW, and unplug the power cable of the Printer and deodorization equipment before performing parts replacement. Performing the parts replacement while the power is on may result in injury by unintended operation of the machine.
Page 75 The necessary adjustments after the replacement of each part, and the referential time for each work are described as follows. HEAD REPLACEMENT : 20min. 1. THERMISTER CHECK It can be checked in the SERVICE MENU>[THERMISTOR CHK]. 2. HEAD ALIGNMENT 3. HEAD INFORMATION CLEAR 4.
Page 76 MAIN BOARD REPLACEMENT (In case that the parameters can be transferred by Peck.) : 35 min. 1. BATTERY INSTALLATION 2. FIRMWARE INSTALLATION 3. SYSTEM PARAMETER INITIALIZE 4. IP ADDRESS SETTING Start the machine with the Service Mode and set in the User Menu. 5.
Page 77: Head Replacement
3-1 HEAD REPLACEMENT Turn off the Sub Power SW, and then turn off the Main Power Be sure to turn off the main power when replacing the head. The Head or Main Board could break, oth- erwise. It is recommended to disconnect the power cord.
Page 78 Disconnect all Head Ribbon Cables from the Head. Put the disconnected Head Ribbon Cables underneath the Carriage Board. Unhook the Head Cover from the Head. <Left> <Right> Hook Hook Open the Wire Saddles for bundling the ink tubes and pull the ink tubes toward you.
Page 79 Pull up the Damper, the ink tubes and the Head Covers slow- ly with opening the Hook of the Head Cover. Do not touch the valve of the Damper. When you touch the valve, Valve the ink leaks from the Damper.
Page 80 Fix the Damper, the ink tubes and the Head Cover set to the new Head. Tu r n t h e h e a d rank label to the Head rank left and fix the Label Head. D o n o t t o u c h t h e valve of the Damper.
Page 81 Fix the Head with the screws as shown in the ﬁ gure. <Left> You do not have to care about the order for ﬁ xing the screws. <Right> Use the 6kgf·cm torque driver (ST-056) and the Screw hexagonal bit (1000006902 TOOL,BIT HEXAGO- NAL ST-118) to tighten up the screws.
Page 82 Turn on the Main Power SW, and then turn on the Sub Power SW while pressing the left, right and down keys to enter the Service Mode. In [PRINT MENU]>[HEAD RANK] menu, input the Head SERVICE MENU Rank shown in the ﬁ gure printed on the label on the carton PRINT MENU box of the Head.
Page 83 C l e a r t h e H e a d i n f o r m a t i o n . P e r f o r m [ S E RV I C E SERVICE MENU MODE]>[HISTORY MENU]>[HEAD GROUP]>[SHOT HISTORY MENU COUNT 1] to [SHOT COUNT 8]>[CLEAR].
Page 84: Damper Replacement
3-2 DAMPER REPLACEMENT Before replacing the damper, check which ink is ﬁ lled in the damper that you will replace by referring the following im- age. 6 colors 8 colors 4 colors Ink cartridge Ink cartridge Ink cartridge 5 6 7 8 Slot # 5 6 7 8 Slot #...
Page 85 Open the Front Cover and move the Tool Carriage with the Head Carriage leftwards to the position where it is not above the Capping Unit. Then, disconnect the Tool Carriage from the Head Carriage. Remove the Carriage Cover. The positions of ﬁ xing screws for the Carriage Cover are at Carriage Cover the left, right and top of the cover.
Page 86 Unhook the Head Cover from the Head. <Left> <Right> Hook Hook Open the Wire Saddles for bundling the ink tubes and pull the ink tubes toward you. Wire Saddle Pull up the Damper, the ink tubes and the Head Covers slow- ly with opening the Hook of the Head Cover.
Page 87 Pick the both ends of the Damper Joint and remove it from the Damper. Damper Joint Ink leaks from the Damper right after removing the Damper Joint. Pull out the Damper from the Head Cover. Head Cover Damper Insert the new Damper into the Head Cover. Head Cover The Damper has no particular right or left orienta- tion.
Page 88 Fix the Damper, the ink tubes and the Head Cover set to the Head with opening the hook of the Head Cover. When you straighten the Damper, the ink tubes and the Head Cover set, you can ﬁ x them easily. Hook Do not touch the valve of the Damper.
Page 89 Check whether the Head Ribbon Cables are connected to the correct connectors. Open the Chock Valve. Fix the Right Top Cover. Right Top Cover Connect the Tool Carriage to the Head Carriage. Then, move the Head Carriage by hand to the lock position. 3-16...
Page 90 Turn on the Main Power SW, and then turn on the Sub Power SW while pressing the left, right and down keys to enter the Service Mode. Perform [FUNCTION]>[CLEANING]>[POWERFUL CL.] once. FUNCTION CLEANING CLEANING POWERFUL CL. ENTER P e r f o r m [ S E RV I C E M O D E ] > [ S U B M E N U ] > [ C H O C K CL]>[START].
Page 91: Wiper Replacement
3-3 WIPER REPLACEMENT Turn off the Sub Power SW, and then turn off the Main Power Select [SUB MENU]>[MAINTENANCE]>[REPLACE WIPER] in the Users Menu and press the [ENTER] key. MENU SUB MENU SUB MENU MAINTENANCE MAINTENANCE REPLACE WIPER When the message shown in the ﬁ gure appears, remove the Right Cover.
Page 92 Detach the Hook to the hole on the Felt Wiper with the twee- zers. When you press the Wiper Frame, it will rotate and you can return it to the original position. Even if you rotate the Wiper Frame and change its position, there is no problem because the machine always detects the wiper origin position after replacing the Wiper.
Page 93 Fix the Right Cover and press the [ENTER] key. The Head Carriage moves to the lock position and perform the cleaning automatically. Then, the message shown in the ﬁ gure appears after ﬁ nishing the cleaning. CLEANING... >> MAINTENANCE REPLACE WIPER 3-20...
Page 94: Felt Wiper Replacement
3-4 FELT WIPER REPLACEMENT Turn off the Sub Power SW, and then turn off the Main Power Select [SUB MENU]>[MAINTENANCE]>[REPLACE FELT] in the Users Menu and press the [ENTER] key. MENU SUB MENU SUB MENU MAINTENANCE MAINTENANCE REPLACE FELT When the message shown in the ﬁ gure appears, remove the Right Cover.
Page 95 Detach the Hook to the hole on the Felt Wiper with the twee- zers. When you press the Wiper Frame, it will rotate and you can return it to the original position. Even if you rotate the Wiper Frame and change its position, there is no problem because the machine always detects the wiper origin position after replacing the Wiper.
Page 96 Fix the Right Cover and press the [ENTER] key. The Head Carriage moves to the lock position and perform the cleaning automatically. Then, the message shown in the ﬁ gure appears after ﬁ nishing the cleaning. CLEANING... >> MAINTENANCE REPLACE FELT 3-23...
Page 97: Cap Top Replacement
3-5 CAP TOP REPLACEMENT Turn off the Sub Power SW, and then turn off the Main Power Remove the Right Cover. Right Cover Move the Head Carriage leftwards to the position where it is not above the Capping Unit. Remove the Right Under Cover. Right under Cover 3-24...
Page 98 Open the Wire Saddles for bundling the tubes of the Cap Top. Wire Saddle Remove the tubes of the Cap Top from the Pump. Remove the Spring. Do not lose the Spring becasue it is small. Spring Remove the Cap Top with pressing the [T] shape hook down- ward and pull up the Cap Top.
Page 99 Fix the new Cap Top by ﬁ tting the [T] shape hook with the Cap Top Base. Groove When you fix the Cap Top, fit the Spring in the Groove on the bottom of the Cap Top. Fix the Spring. Spring Connect the tubes of the Cap Top to the Pump.
Page 100 Bundle the tubes of the Cap Top with the Wire Saddles. Bundle the tubes as shown in the ﬁ gure. If you do not bundle the tubes, the ink is not drained correctly. Wire Saddle Move the Head Carriage by hand to the lock position. Turn on the Main Power SW, and then turn on the Sub Power SW while pressing the left, right and down keys to enter the Service Mode.
Page 101 Fix the Right Under Cover. Be careful not to pinch the tubes of the Cap Top with the Right Under Cover. Right Under Cover 3-28...
Page 102: Tool Carriage Replacement
3-6 TOOL CARRIAGE REPLACEMENT Remove the following covers in order. 1. Right Cover 2. Front Cover Top Cover 3. Front Rail Cover Left Cover 4. Left Cover 5. Top Cover Front Rail Cover Front Cover Right Cover Separate the Tool Carriage from the Head Carriage. Remove the Tool Carriage Cover.
Page 103 Disconnect the Crop Mark Sensor, Pinch Roller Sensor and Solenoid Solenoid wirings. Crop Mark Sensor Cable Pinch Roller Sensor Cable Remove the two screws ﬁ xing the Tool Carriage Board. Tool Carriage Board Remove the two screws to remove the Tool Carriage Board Tool Carriage Board Stay Stay from the Tool Carriage Assy.
Page 104 Remove the screws shown in the ﬁ gure and remove the Auto Sheet Cutter from the Tool Carriage. Tool Carriage Be careful not to lose the spring. Screw < Rear side > Auto Sheet Cutter Spring Screw Fix the Auto Sheet Cutter to the new Tool Carriage. Tool Carriage Do not forget to ﬁ...
Page 105 Fix the Tool Carriage Assy to the Tool Carriage Board Stay Tool Carriage Board Stay with the two screws as shown in the ﬁ gure. Fix the Tool Carriage Board with the two screws as shown in the ﬁ gure. Tool Carriage Board Connect the Crop Mark Sensor, Pinch Roller Sensor and Solenoid...
Page 106 Remove the Tool Carriage Cover. Tool Carriage Cover Perform the following adjustments and settings. 1. [4-4 LIMIT POSITION & CUT DOWN POSITION INITIALIZE] 2. [4-11 TOOL HEIGHT ADJUSTMENT] 3. [4-12 TOOL PRESSURE ADJUSTMENT] 4. [4-7 CROP MARK SENSOR ADJUSTMENT] 5. [4-8 CROP-CUT ADJUSTMENT] 6.
Page 107: Carriage Motor Replacement
3-7 CARRIAGE MOTOR REPLACEMENT Turn off the Sub Power SW, and then turn off the Main Power Remove the following covers in order. 1. Right Cover 2. Right Top Cover 3. Chassis Cover 4. Panel Cover 5. Right Under Cover ...
Page 108 Remove the spring on the Flange. Spring Remove the three screws ﬁ xing the Flange, and remove the motor together with the Flange. The fixing direction of one screw near the spring is differ- ent from the others. Remove the three screws shown in the ﬁ gure to remove the motor from the Flange.
Page 109 Fix the spring. Spring Unlock the Head Carriage. Turn the Drive Gear by hand to check if the gears mesh to- gether. Tighten up the three screws to fix the Flange in the order shown in the ﬁ gure. 3-36...
Page 110 Turn the Drive Gear by hand for short steps back and forth to check if there is no backlash all the way around. Apply a proper quantity of grease (FLOIL G902) to gears of the motor and Drive Gear. Connect the connector of the Motor Cable. Move the Head Carriage by hand to the lock position.
Page 111 Fix the Right Frame and Panel Cover. When fixing the Panel Cover, ﬁ x the sensor with the sensor cable and the ribbon cable to the Panel Board. Right Frame Panel Board Perform the SERVO LOCK CHECK. After turning on the Main Power SW, turn on the Sub Power SW while pressing the left, right and down keys to enter the Service Mode.
Page 112 Perform the AGING. Go back to the [MOTOR MENU], and select [AGING]>[SCAN] and press the [ENTER] key. Make sure the machine per- SERVICE MENU MOTOR MENU forms AGING and then, ﬁ nish it by pressing [ENTER] key. MOTOR MENU AGING Do not load any media when performing [AGING].
Page 113: Feed Motor Replacement
3-8 FEED MOTOR REPLACEMENT Turn off the Sub Power SW, and then turn off the Main Power Remove the following covers in order. 1. Right Cover 2. Right Top Cover 3. Chassis Cover 4. Panel Cover 5. Right Under Cover ...
Page 114 Remove the Grit Encoder Board. Grit Encoder Board Remove the Grit Encoder Stopper. Grit Encoder Stopper Remove the Grit Encoder. Grit Encoder Make sure not to scratch or leave any ﬁ ngerprints on the Grit Encoder. Move the Head Carriage leftwards by hand. 3-41...
Page 115 Remove the Inner Cover Inner Cover Remove the screw fixing the Cable Support and make it ﬂ oated. Cable Support Remove the Feed Motor Cable with the junction cable from the Junction Board. Junction Board Remove the spring. Spring 3-42...
Page 116 Remove the three screws shown in the ﬁ gure and remove the Feed Motor. The bottom screw shown in the ﬁ gure is removed through the slit on the bottom of the Bed Pull out the Feed Motor leftward and taking out it from the rear side of the Cap Top unit.
Page 117 Remove the three screws as shown in the ﬁ gure to remove the motor from the Flange. And ﬁ x a new motor to the Flange. Be careful with the ﬁ xing direction of the Flange in relation to the motor cables. Connect the Feed Motor Cable to the junction cable.
Page 118 Fix the bottom screw temporarily through the slit on the bot- tom of the Bed Fix the spring. Spring Turn the Drive Gear by hand to check if the gears mesh to- gether. Tighten up the three screws to fix the Flange in the order shown in the ﬁ...
Page 119 Turn the Drive Gear by hand for short steps back and forth to check if there is no backlash all the way around. Apply a proper quantity of grease (FLOIL G902) to gears of the motor and Drive Gear. Connect the Feed Motor Cable to the Junction Board. Junction Board Fix the Cable Support.
Page 120 Move the Head Carriage by hand to the lock position. Fix the Grit Encoder. Grit Encoder The both sides of the Grit Encoder is the same. When fixing the Grit Encoder, make sure not to scratch or leave any ﬁ ngerprints on it. Fix the Grit Encoder Stopper with the three screws while holding the Shaft Grit Encoder Stopper...
Page 121 Rotate the Shaft to check that the Grit Encoder does not touch the sensor Shaft Fix the Right Side Frame Stay. Right Side Frame Stay Fix the Right Frame and the Panel Cover. When fixing the Panel Cover, ﬁ x the sensor with the sensor cable and the ribbon cable to the Panel Board.
Page 122 In [MOTOR MENU]>[SERVO LOCK] menu, select [F]. Move the Head Carriage left and right by hand and make sure the value on the LCD changes depending on the head SERVICE MENU MOTOR MENU position. MOTOR MENU SERVO LOCK SERVO LOCK F: 140 Press the [ENTER] key to excite the motor.
Page 123 Clear the motor working hours. SERVICE MENU G o b a c k t o t h e S e r v i c e M e n u , a n d s e l e c t [ H I S - HISTORY MENU TORY MENU]>[MOTOR GROUP]>[MOTOR HOURS F]>[CLEAR] and press the [ENTER] key.
Page 124: Pump Replacement
3-9 PUMP REPLACEMENT Turn off the Sub Power SW, and then turn off the Main Power Remove the Right Cover. Right Cover Move the Head Carriage leftwards to the position where it is not above the Capping Unit. Remove the Panel Cover and the Right Under Cover. Panel Cover When removing the Panel Cover, remove...
Page 125 Remove the motor cable from the connector. Remove the tubes of the Cap Top and the drain tube. Remove the two screws ﬁ xing the Pump Unit Stay and take out the Pump Unit. Remove the two screws shown in the ﬁ gure and remove the Pump Unit Stay.
Page 126 Remove the three screws shown in the ﬁ gure and remove the motor from the Pump. Then, ﬁ x the new Pump to the motor. Fox the Pump Unit Stay to the Pump with the two screws shown in the ﬁ gure. Pump Unit Stay Fix the Pump Unit with the two screws shown in the ﬁ...
Page 127 Connect the motor cable to the connector. Fix the Right Frame and the Panel Cover. Panel Board When fixing the Panel Cover, ﬁ x the sensor with the sensor cable and the ribbon cable to the Panel Board. Right Frame Move the Head Carriage by hand to the lock position.
Page 128 Select [SERVICE MENU]>[I/S MENU]>[PUMP CHECK], and perform [PUMP SUCTION] and [PUMP RELEASE] to check the pumps work correctly. SERVICE MENU I/S MENU I/S MENU PUMP CHECK PUMP CHECK PUMP SUCTION PUMP CHECK PUMP RELEASE Clear the pump times. Select [SERVICE MENU]>[HISTORY MENU]>[MOTOR SERVICE MENU GROUP]>[PUMP TIMES]>[CLEAR], and press the [ENTER] HISTORY MENU...
Page 129: (Main Board Sw Power Supply)
3-10 BOARDS REPLACEMENT (MAIN BOARD / SW POWER SUPPLY) BOARD LAYOUT (IN CHASSIS) POWER BOARD SERVO BOARD MAIN BOARD SW POWER SUPPLY MAIN BOARD REPLACEMENT MAIN BOARD CONNECTOR LAYOUT CN14 CN15 CN17 CN22 CN19 3-56...
Page 130 Turn on the Main Power SW. < Rear View > Start the Peck. Perform [Get Report] and [Get Parameters], and save the Service Report and the parameters. Turn off the Main Power SW and pull out the Power Cord. < Rear View > 3-57...
Page 131 Remove the Right Cover, the Right Top Cover and the Chas- sis Cover. Chassis Cover Right Cover Right Top Cover Remove the four screws shown in the ﬁ gure. Screw Screw <Top View> Disconnect the cables and release the cables from the clamps.
Page 132 Pull out the Chassis to the front side. Chassis Remove the four screws shown in the ﬁ gure to remove the Servo Board. Disconnect the connector and ﬂ exible cable shown in the ﬁ g- ure and ﬁ x them to the new Main Board. Remove the four screws shown in the ﬁ...
Page 133 Fix the Servo Board with the four screws shown in the ﬁ gure. Put back the Chassis. Chassis Connect all the cables to the Servo Board. CN400 CN207 CN405 CN11 CN401 CN403 CN404 Connect the cables and bundle the cables with the clamps. Do not forget CN1108 CN1107...
Page 134 Fix the Chassis with the four screws shown in the ﬁ gure. Screw Screw < Top View > Perform the following operations after replacement. 1. BATTERY INSTALLATION Refer to [3-11 BATTERY REPLACEMENT]. 2. FIRMWARE INSTALLATION Refer to [4-2 HOW TO UPGRADE/INSTALL FIRMWARE]. 3.
Page 135 Perform the following operations if it is not possible to transfer the parameters by Peck4.exe. 1. BATTERY INSTALLATION Refer to [3-11 BATTERY REPLACEMENT]. 2. FIRMWARE INSTALLATION Refer to [4-2 HOW TO UPGRADE/INSTALL FIRMWARE]. 3. SYSTEM PARAMETER INITIALIZE Refer to [4-2 HOW TO UPGRADE/INSTALL FIRMWARE]. 4.
Page 136 SW POWER SUPPLY REPLACEMENT (41V) SW POWER SUPPLY CONNECTOR LAYOUT Connected to the [CN1] and [CN405] on the SER- VO BOARD, and [CN22] on the Main Board Connected to the [CN302] on the Power Board Turn off the Sub Power SW, and then turn off the Main Power SW and pull out the Power Cord.
Page 137 Remove the four screws shown in the ﬁ gure. Screw Screw < Top View > Disconnect the cables and release the cables from the clamps. Do not forget CN1108 to disconnect CN1107 t h e c a b l e s CN1106 shown in the CN1105...
Page 138 Remove the ﬁ ve screws shown in the ﬁ gure and replace with the new SW Power Supply. Connect all the cables to the SW Power Supply. In case that the volume is accidentally turned around, adjust the output voltage value to +41 +/- 0.1.
Page 139: Battery Replacement
3-11 BATTERY REPLACEMENT Do not recharge, short-circuit, disassembly the lithium battery, nor put it into ﬁ re. It may cause heat, explosion and ﬁ re. Put tape around the lithium battery for insulation for disposal or preservation. It may cause heat, explosion and ﬁ re. Turn off the Sub Power SW, and then turn off the Main Power Remove the Chassis Cover.
Page 140 Replace the battery with new one. Socket Battery Be careful with the direction of the battery. Main Board 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 141 Turn off the Sub Power SW, and then turn off the Main Power Fix the Chassis Cover. Dispose of the battery. 3-68...
Page 142: Carriage Belt Replacement
3-12 CARRIAGE BELT REPLACEMENT !! IMPORTANT !! When replacing the Carriage Belt, make sure to connect the new belt to the current belt, and pass the new belt at the same time as removing the current belt. There is a possibility that the new belt cannot be ﬁ xed without connecting the new belt to the current belt. Turn off the Sub Power SW, and then turn off the Main Power Remove the Covers in order.
Page 143 Remove the Tool Carriage Cover. Tool Carriage Cover Remove the four rivets as shown in the ﬁ gure to remove the Tool Carriage Board Cover. Tool Carriage Board Cover Disconnect the Crop Mark Sensor, Pinch Roller Sensor and Solenoid Cable Solenoid wirings.
Page 144 Remove the two screws to remove the Tool Carriage Board Tool Carriage Board Stay Stay from the Tool Carriage Assy. Loosen the two ﬁ xing screws as shown in the ﬁ gure. < Top View / Left Side of the BELT > And loosen the Adjustment Screw.
Page 145 Slowly pull the belt end which is not connected the new belt Belt Stay until the new one reaches to the Belt Stay. Check that the belt is not twisted. Apply adequate quantity of grease (P/# : 39008297 FLOIL G 902 14KG) to pulleys. <...
Page 146 Fix the Tool Carriage Assy to the Tool Carriage Board Stay. Tool Carriage Board Stay Fix the Tool Carriage Board with the two screws as shown in the ﬁ gure. Tool Carriage Board Connect the Crop Mark Sensor, Pinch Roller Sensor and So- Solenoid Cable lenoid wirings.
Page 147: Encoder Scale Replacement
3-13 ENCODER SCALE REPLACEMENT Remove the Covers in order. Ink Cartridge Cover 1. Right Cover 2. Left Cover Top Cover 3. Front Cover 4. Right Top cover Left Cover 5. Front Rail Cover Right Top Cover 6. Top Cover Front Rail Cover 7.
Page 148 Put the Encoder Scale in between the Encoder Plate and the Encoder Scale Guide Rail. Then, ﬁ x the right end with the plate and hook up the spring on the left end. Make sure that the Encoder Scale is in place. Guide Rail Encoder Plate Do not loosen or tighten the screws fixing the...
Page 149: Grit Encoder Replacement
3-14 GRIT ENCODER REPLACEMENT Turn off the Sub Power SW, and then turn off the Main Power Remove the following covers in order. 1. Right Cover 2. Right Top Cover 3. Chassis Cover 4. Panel Cover 5. Right Under Cover ...
Page 150 Remove the Grit Encoder Board. Grit Encoder Board Remove the Grit Encoder Stopper. Grit Encoder Stopper Remove the Grit Encoder. Grit Encoder Make sure not to scratch or leave any ﬁ ngerprints on the Grit Encoder. Fix the Grit Encoder. Grit Encoder The both sides of the Grit Encoder is the same.
Page 151 Fix the Grit Encoder Stopper with the three screws while holding the Shaft Grit Encoder Stopper Fix the Grit Encoder Board together with the stay so that the Grit Encoder is in between the gap of sensor. Grit Encoder Board Adjust the position of the sensor so that the clearance with...
Page 152 Check the GRIT ENCODER. SERVICE MENU Go back to the [MOTOR MENU], and select [G-ENC. MOTOR MENU CHECK] and press the [ENTER] key. Make sure the Grit Encoder functions correctly by conﬁ rming the display shows [G-ENC. CHECK COMPLETED]. MOTOR MENU G-ENC.
Page 153: Pinch Roller Replacement
3-15 PINCH ROLLER REPLACEMENT Conical type is used on both left & right Pinch Rollers and ﬂ at type is used for the Middle Pinch Rollers. Left Pinch Roller Right Pinch Roller The violet marking is done on the outer side of left and right Pinch Rollers.
Page 154: Cutter Protection Replacement
3-16 CUTTER PROTECTION REPLACEMENT Open the Front Cover and remove the Cutter Protection. Cutter Protection Wipe and remove the adhesion on the Bed with alcohol. Install the Cutter Protection from 1mm from right edge Cutter Protection of the Bed. Make sure that the Cutter Protection is not bumpy. Cutter Protection 3-81...
Page 155: Cut Ribbon Cable Replacement
3-17 CUT RIBBON CABLE REPLACEMENT Remove the following covers in order. Top Cover 1. Right Cover Chassis Cover 2. Right Top Cover Right Top Cover 3. Chassis Cover Left Cover 4. Front Cover 5. Front Rail Cover Front Rail Cover 6.
Page 156 Remove the Cable Holder and disconnect the Cut Ribbon Cable from the Carriage Board. Cut Ribbon Cable Cable Holder Remove the three screws shown in the ﬁ gure and remove the Cable Support. (For VS-640/540) Cable Support Pull the Cut Ribbon Cable to access the screws. Remove the two Cable Holders at the rear side of the ma- chine 3-83...
Page 157 Remove the 12 rivets ﬁ xing the Cut Ribbon Cable and Cable Holder shown in the ﬁ gure. Disconnect the Cut Ribbon Cable from the Servo Board and take out it from the Cable Guides. Cable Guide Cable Guide Cut Ribbon Cable 3-84...
Page 158 Connect the Cut Ribbon Cable to the Servo Board and put it between the Cable Guides. Put the Cut Ribbon Cable rightward with holding the Inner Cable Guide so that the Cut Ribbon Cable ﬁ ts to the Inner Cut Ribbon Cable Cable Guide.
Page 159 Fix the two Cable Holders at the rear side of the machine Fix the Cable Holder and connect the Cut Ribbon Cable to the Carriage Board. Cut Ribbon Cable Cable Holder Connect the Tool Carriage to the Head Carriage by hand. Move the Head Carriage in a whole width of the machine and check whether the Cut Ribbon Cable does not jam.
Page 160 Fix the Cable Support with the three screws shown in the ﬁ g- ure. (For VS-640/540) Cable Support Pull the Cut Ribbon Cable to access the screws. Fix the Tool Carriage Board Cover with the four rivets shown in the ﬁ gure. Tool Carriage Board Cover Fix the Tool Carriage Cover.
Page 161: Linear Encoder Board Replacement
3-18 LINEAR ENCODER BOARD REPLACEMENT Turn off the Sub Power SW, and then turn off the Main Power Remove the Right Cover, the Right Top Cover and the Chas- Right Top Cover sis Cover. Chassis Cover Right Cover Open the Front Cover and move the Tool Carriage and the Head Carriage leftwards to the position where it is not above the Capping Unit.
Page 162 Remove the two rivets ﬁ xing the Print Junction Cover. Print Junction Cover Disconnect all Head Ribbon Cables which are ﬁ x to the Print Carriage Board. Remove four screws ﬁ xing the Print Carriage Board. Disconnect the Linear Encoder Board Cable and the Head Up Down Sensor Cable from the Print Carriage Board.
Page 163 Remove the Linear Encoder Board with the Stay by erecting the Print Carriage Board as shown in the ﬁ gure. Linear Encoder Board with the Stay Remove the Linear Encoder Board from the Stay. Then, ﬁ x the new the Linear Encoder Board to the Stay Linear Encoder Board Stay Fix the Linear Encoder Board with the Stay by erecting the...
Page 164 Fix the Print Carriage Board with the four screws shown in the ﬁ gure. Connect all Head Ribbon Cables to the Print Carriage Board. Fix the Print Junction Cover with the two rivets shown in the ﬁ gure. Print Junction Cover Remove the Carriage Cover.
Page 165 Move the Head Carriage in a whole width of the machine. Make sure that the Encoder Scale doesn't make contact with the Encoder Module and also Encoder Scale is between the slit of the Encoder Module again. Carry out the [4-5 LINEAR ENCODER SETUP]. 3-92...
Page 166: How To Fold Ribbon Cable To The Head
3-19 HOW TO FOLD RIBBON CABLE TO THE HEAD These procedures are for the ribbon cables to the Head. The ribbon cable and the procedure are different from each connector. Refer to the following list and procedures and fold the ribbon cables. Connector A : 1000006702 CABLE-CARD,29P1 256L BB HIGH-V Connector B : 1000006702 CABLE-CARD,29P1 256L BB HIGH-V Connector C : 1000006703 CABLE-CARD,29P1 276L BBR HIGH-V...
Page 167 <Connector B : 1000006702 CABLE-CARD,29P1 256L BB HIGH-V> <Connector B : 1000006702 CABLE-CARD,29P1 256L BB HIGH-V> Place the ribbon cable whose plain side faces up. Plain side There is no difference between left and right direc- tion. Fold the ribbon cable with 90 degree at the 18 +/-5 mm point 18 +/- 5mm from the left end.
Page 168 <Connector C : 1000006703 CABLE-CARD,29P1 276L BBR HIGH-V> <Connector C : 1000006703 CABLE-CARD,29P1 276L BBR HIGH-V> Place the ribbon cable whose plain side faces up. Plain side The black band should be placed at the left side. Black Band Fold the ribbon cable with 90 degree at the 18 +/-5 mm point 18 +/- 5mm from the left end.
Page 169: Ink Tube Replacement
3-20 INK TUBE REPLACEMENT Turn on the Main Power SW, and then turn on the Sub Power SW while pressing the left, right and down keys to enter the Service Mode. MENU MENU SERVICE MENU Select [SERVICE MENU]>[SUB MENU]>[PUMP UP], and SERVICE MENU take out the ink in the Ink Tube by following the messages SUB MENU...
Page 170 Remove the Cut Cable Support by removing the three screws shown in the figure. (For VS-640/540) Cut Cable Support Remove the Left Cover Sensor from the Plate by removing the two screws shown in the figure. Remove the Plate fixed to the Left Cover Sensor Cable by removing the two screws shown in the figure.
Page 171 Remove the Left Support Frame by removing the two screws Left Support Frame shown in the figure. Remove the Cut Cable Guide by removing the three screws shown in the figure. Cut Cable Guide 3-98...
Page 172 Move the Tool Carriage and the Head Carriage leftwards to the position where it is not above the Capping Unit. Then, disconnect the Tool Carriage from the Head Carriage. Remove the Carriage Cover. The positions of screws fixing the Carriage Cover are at the Head Carriage Cover left, right and top of the Carriage Cover.
Page 173 Mark or put the label to the Cartridge side of the Ink Tube to identify which is connected to the Head Carriage side of the Ink Tube. In this procedure, the number labels are put on the Cartridge side of the Ink Tube. The number has been written on the Head Carriage Side of Ink Tubes.
Page 174 Disconnect the Ink Tubes (Head Carriage Side) from the <No.1 to 6> Joint Adapters, the Y Tube Joints and the Circulating Pump. And, put the clear tape at the tip of the Ink Tube to prevent the ink from coming out. It is not necessary to replace the Ink Tubes (Car- tridge Side).
Page 175 When you cut the Ink Tube at the rear of the Head Carriage, it is easy to remove the Ink Tube. Be careful with the ink in the Ink Tubes when you cut the Ink Tube. Remove the Ink Tubes with the Tube Guides from the Holder Holder Cable Plate Cable Plate and the Support Frame.
Page 176 Revised 3 Confirm that No. 1 to No.10 are lined from the top to <Number on the Ink Tube (Head Carriage Side)> the bottom of the Ink Tubes (Head Carriage Side). No.1 to 6 : No.1 1000007188 TUBE,SJ-RDG3*4 LINK6 VS-640_01 No.2 1000007210 TUBE,SJ-RDG3*4 LINK6 VS-540 No.3...
Page 177 Fix the Ink Tubes with the three Wire Saddles shown in the No.1 figure. Check which number of the Ink Tube is fixed to which No.3 Wire Saddles by referring the figure. No.5 Fix the Ink Tubes with the Wire Saddles while pushing them No.7 No.8 backward so as not to locate the front of the Head Carriage.
Page 178 Pass the Ink Tube from No.7 to No.10 through the Support Rail Frame. And, fix them with the Wire Saddle shown in the figure. Wire Saddle Support Rail Frame Connect the Ink Tube (Head Carriage Side) to the Joint <No.1 to 6> Adapters, Y Tube Joints and the Circulating Pump.
Page 179 Damper Joint Check which number of the Ink Tube is connected to which Damper Joint and Y Tube Joint by refer- ring the figure. Head Move the Head Carriage to the position of the right figure. Then, check the clearance between the Ink Tube and the Guide Cable Support is less than 6mm.
Page 180 Pull and move the Ink Tubes to the Print Head side. Revised 3 If the cable tie is extremely loosen, tighten it. Be careful not to make it too tight. Fix the Ink Tubes with the clamps. Perform 27 step [Checking the clearance] again. Revised 3 3-107...
Page 181 Fix the Cut Cable Guide with the three screws shown in the figure. Cut Cable Guide If the Head Carriage is not locked, lock it. Fix the Left Support Frame with the two screws shown in the Left Support Frame figure.
Page 182 Fix the Left Cover Sensor Cable with the two screws shown in the figure. Fix the Cut Cable Support with the three screws shown in the figure. (For VS-640/540) Cut Cable Support Move the Head Carriage in a whole width of the machine manually to check that the Tube Guides make physical con- tact with the Rail.
Page 183 Turn on the Main Power SW, and then turn on the Sub Power SW while pressing the left, right and down keys to enter the Service Mode. MENU MENU SERVICE MENU Select [SERVICE MENU]>[SUB MENU]>[FILL INK], and per- form Ink Filling by following the sequences. It takes about 10 minutes to finish [PUMP UP].
Page 184: Ribbon Cable (Main Board To Carriage Board) Replacement
3-21 RIBBON CABLE (MAIN BOARD TO CARRIAGE BOARD) REPLACEMENT Turn off the Sub power SW and the Main Power SW. You do not need to perform [PUMP UP]. Remove the following covers in order. Ink Cartridge Cover 1. Right Cover Top Cover 2.
Page 185 Remove the Left Cover Sensor from the Plate by removing the two screws shown in the figure. Remove the Plate fixed to the Left Cover Sensor Cable by removing the two screws shown in the figure. Plate Remove the Left Support Frame by removing the two screws Left Support Frame shown in the figure.
Page 186 Remove the Cut Cable Guide by removing the three screws Cut Cable Guide shown in the figure. Open the Front Cover and move the Tool Carriage and the Head Carriage leftwards to the position where it is not above the Capping Unit. Then, disconnect the Tool Carriage from the Head Carriage.
Page 187 Remove the Carriage Cover. The positions of screws for fixing the Carriage Cover are at Head Carriage Cover the left, right and top of the Carriage Cover. The Head Carriage Cover has six screws. Open all Wire Saddles fixing the Ink Tubes shown in the fig- ure.
Page 188 Move the Ink Tubes with the Tube Guides rightward and re- Carriage Board move the Ribbon Cables from the Carriage Board. Remove the Ribbon Cables from the Main Board and remove Cable Clamp the Cable Clamp from the Ribbon Cables. Main Board Remove the Ferrite Core from the Ribbon Cables.
Page 189 Remove the Boards fixed to the Ribbon Cables and remove the Ferrite Core from the Ribbon Cables. Board Ferrite Core Board Remove the Ferrite Core from the Ribbon Cables and take out the Ribbon Cables from the machine. Ribbon Cable Character Side Ferrite Core...
Page 190 Fold the new Ribbon Cable by referring the figure below. The position to fold the Ribbon Cable is different depending on the position to fix the Ribbon Cable to the Carriage Board. There is no difference between left and right direc- tion.
Page 191 Locate the Ribbon Cables among the Cable Holders, the Holder Cable Sheets and the Holder Cable Plate. Ribbon Cable Character Side Connect the Ribbon Cables to the Carriage Board. Carriage Board Fix the Ink Tubes with the Tube Guides to the Holder and the Plate.
Page 192 Confirm the Ribbon Cables, the Cable Holders, the Holder Cable Plate and the Holder Cable Sheets to the Tube Guides by referring the following figures. Cable Holder Ribbon Cable x 1 Holder Cable Sheet x 2 Ribbon Cable x 2 Cable Holder Holder Cable Plate Tube Guide...
Page 193 Pull out the Ribbon Cables from the Bush shown in the figure Ferrite Core and fix them with the Board. Board And, move the Ferrite Core to the position shown in the fig- ure. Bush Pull out the Ribbon Cables to the position near the Scan Mo- Scan Motor tor and fix them with the Board.
Page 194 Close the four Clamps shown in the figure. Clamp Hook the Cable Tie to the Cable Clamp and close the Cable Clamp to cover the Ferrite Core. Cable Clamp Ferrite Core Cable Tie Move the Head Carriage to the position of the right figure. Then, check the clearance between the Ink Tube and the Guide Cable Support is less than 6mm.
Page 195 Move the Head Carridge to the capping position. Then, open the clamps that bundle the Ink Tube. Revised 3 Pull and move the Ink Tubes to the Print Head side. Revised 3 If the cable tie is extremely loosen, tighten it. Be careful not to make it too tight.
Page 196 Fix the Ink Tubes with the clamps. 　 Perform 31 step [Checking the clearance] again. Revised 3 Fix the Cut Cable Guide with the three screws shown in the figure. Cut Cable Guide If the Head Carriage is not locked, lock it. Fix the Left Support Frame with the two screws shown in the Left Support Frame figure.
Page 197 Fix the Plate to the Left Cover Sensor Cable with the two screws shown in the figure. Plate Fix the Left Cover Sensor Cable with the two screws shown in the figure. Fix the Cut Cable Support with the three screws shown in the figure.
Page 198 Move the Head Carriage to the width of the machine manu- ally to check that the Tube Guides make physical contact with the Rail. When the Tube Guides make physical contact with the Rail, remove the Ink Tubes with the Tube Guides from the Cable Holder Plate and the Sup- port Frame.
Page 199: Adjustment
4 Adjustment To Ensure safe Work Turn off the Sub Power SW, Main Power SW, and unplug the power cable of the Printer and deodorization equipment before performing parts replacement. Performing the parts replacement while the power is on may result in injury by unintended operation of the machine.
Page 200: Service Mode
4-1 SERVICE MODE MENU + POWER ON [ MENU ] key SERVICE MENU SERVICE MENU PRINT MENU HEAD RANK This menu is used for entering the Head Rank for each head with 24 digit number and alphabet. The digits can be changed with [ ] and [ ] keys and parameters can be changed with PRINT MENU...
Page 201 MOVE CARRIAGE NOW PROCESSING.. I/S CHECK SERVICE MENU I/S MENU TO AVOID WIPER COMPLETED I/S MENU I/S CHECK Checking Error I/S CHECK ERROR WIPER This is for checking the operation of the wiper motor and sensor. Make sure not to have the Head Carriage and Tool Carriage above the wiper unit during the check. PUMP SUCTION I/S MENU PUMP CHECK...
Page 202 CARTRIDGE SL1 : SERIAL Serial No. of the Ink Cartridge IC is displayed. SLOT 1 1402A30C010000A5 SL1 : INK TYPE Ink type of the Ink Cartridge IC is displayed. Max K SL1 : CAPACITY Ink capacity of the Ink Cartridge IC is displayed. 200cc SL1 : LOT NO.
Page 203 PRINT-CUT ADJ. CUTTING MENU PERFORMING This test pattern is for adjusting the print & cut position. It prints three square Crop Marks along the TEST PRINT TEST PRINT PRINT-CUT ADJ. scan direction and cuts the contours of the marks. When it shows [ ], it means that it has never PRINT-CUT ADJ.
Page 204 EMPTY SUB MENU SET SOLCL-LIQUID SET DUMMY CRT. REMOVE SOL CRT. 　 DRAIN BOTTLE HEAD WASH 12345678 12345678 123456 Goes next, after pressing ENTER REMOVE CARTRIDGE SET CL-LIQUID 12345678 12345678 Goes next, when cartridge is removed Goes next, when cleaning cartridge is set EMPTY REMOVE DUMMY CRT SET SOLCL-LIQUID...
Page 205 CLOCK DATE DATE SUB MENU DATE 09/01/15 09/01/15 CLOCK Display [Year/Month/Day] [Year/Month/Day] Edit TIME CLOCK TIME 01:01:59 TIME 01:01:59 Display Edit TIME TIME It shows [B], when battery is dead. 01:01:59 01:01:59 This is for displaying and editing the date and time. When it detects the battery exhaustion, [B] is indicated on the time display. In this case, battery needs to be replaced.
Page 206 The heater does not operate when the machine is started in Service Mode. SVC.MODE HEAT. SERVICE MENU HEATER MENU Set [START] here when the heater needs to be on. [START] is canceled once the HEATER MENU SVC. MODE HEAT. STOP >...
Page 207 HISTORY MENU MOTOR　GROUP Item Contents Unit Reference MOTOR HOURS F Total time that the Feed Motor has been rotated. hour MOTOR HOURS S Total time that the Scan Motor has been rotated. hour Life: 3000 hours PUMP TIMES Total time that the Pump Motor has been rotated. times Life: 200,000 times PUMP TIMES CIR...
Page 208 CUTTING GROUP Item Contents Unit Reference CUTTING TIME Total time of cutting performed. hour Test print time is excluded. Disconnection of Tool Carriage and Head DISCONNECT Number of times the carriage has been disconnected. times Carriage. CLEAR　ALL Clear all the value in the CUTTING GROUP. INK GROUP　...
Page 209 -0.10/ 0.25 mm Encorder calibration +0.087 % Print-cut adjust (F/S) -0.30/ +0.35 mm Force adjust 30gf Crop sensor adjust Force adjust 200gf Roland Versa CAMM series Model VS-640 IP Address 192.168.000.100 Ink type E-SOL Max 6Color Version 2.10 Subnet Mask 255.255.255.000...
Page 210 HISTORY REPORT History Report Model : VS-640 Serial No. : XXXXXXX Version : 2.10 Date : 2010/03/10 14:24 ==== Motor group ==== Motor feed (trip / total [clear]): hours Motor scan (trip / total [clear]): hours Pump Times (trip / total [clear]): 1,703/ 1,703 times...
Page 211 INK CARTRIDGE REPORT Ink Cartridge Report Model : VS-640 Serial No. : XXXXXXX Version : 2.10 SERIAL/ INK TYPE/ CAP./ LOT No/ CONSUM./ TIME/ INS./ FLAG 14d178b002000071/ Max Lc/ 200cc/ 60907A/ 47.879cc/ 0y015d04h14m08s/ 00000000 14d178b002000071/ Max C/ 200cc/ 61004A/ 75.914cc/ 0y015d04h14m03s/ 00000000 14d178b002000071/...
Page 212 Turn on the Sub Power SW while MENU pressing [ ] key to start the machine in the service report printing mode. Roland DG Corp. The service report will be printed VS-640 automatically when the media is set up. It prints with Black ink. MENU LANGUAGE...
Page 213 Key Combinations Function for Service Combination Key Selection Comments Press [MENU] and [ ] to enter Service Service Mode Menu. "[UPDATE FIRMWARE?] will be displayed. F/W Upgrade Mode Press [ENTER] to upgrade F/W." Use this when the Main Board is replaced. F/W Installation Mode for a brand-new Main Board "[SUM-ERROR] will be displayed.
Page 214 4-2 HOW TO UPGRADE/INSTALL FIRMWARE It is necessary to prepare the followings to upgrade/install the ﬁ rmware. 1.Firmware ﬁ le 2.WindowsPC (Network port is required.) 3.Peck.exe 4.Network cable (A cross cable is required when you connect the printer to PC directly.) HOW TO UPGRADE FIRMWARE (Referential Time : 5 min) Check the IP address of the printer.
Page 215 Start the Peck. [Peck] screen is displayed, and click [Select Port] button. Select [Type4 SPi,VS etc.] from [Product]. Also, select [Via Network] and input IP ad- dress of the printer. Click [OK] button. [Peck] screen is displayed again. Click [Firmware Upgrade] button. [OPEN] screen is displayed.
Page 216: Firmware
The machine goes into the Firmware Upgrade mode automatically. FIRMWARE V3.0 DATA ERROR When upgrade is completed, the Sub Power SW turns off automatically. ERASING DEVICE ERROR WRITING DEVICE ERROR DEVICE ERROR VERIFYING COMPLETED HOW TO INSTALL FIRMWARE (Referential Time : 10 min) This is required when a new Main Board without the ﬁ...
Page 217 Press [MENU] key, and set [IP ADDRESS], [SUBNET MASK] and [GATEWAY ADDR.]. WAITING Press [ ] and [ ] keys for moving between digits, and 000.000.000.000 ] and [ ] keys for selecting value. After setting an ad- dress, press [ENTER] key to go next address setting. MENU When [GATEWAY ADDR.] is set, it returns to the waiting mode for receiving the ﬁ...
Page 218 [Peck] screen is displayed again. Click [Firmware Upgrade] button. [OPEN] screen is displayed. Select the ﬁ rmware le and click [Open]. The ﬁ rmware will be sent to the printer. It starts loading the ﬁ rmware. The firmware installation is completed when FIRMWARE V3.0 DATA ERROR...
Page 219 Turn on the Sub Power SW while pressing [ ], [ ], and [ENTER] keys to enter [INITIALIZE ALL SYS. PARAMETER] menu. ENTER Select the model by pressing [ ] and [ ] keys, and press [ENTER] key to start initialization. The Sub Power turns off automatically when it is completed.
Page 220 Start the Peck on PC. [Peck] screen is displayed, and click [Put Parameters] button. [OPEN] screen is displayed. Select the System Parameter le that is saved before the Main Board replacement. Click [Open]. Peck starts to send the System Parameter to the printer.
Page 221: Head Alignment
4-3 HEAD ALIGNMENT (Referential Time : 15 min.) This is necessary to obtain the good printing quality. Be sure to operate this alignment when the head is replaced. If the heads are not aligned, printing problems such as banding, ﬁ ne lines and gap between bands could occur. The PET-G is required for this alignment.
Page 222 Turn on the Sub Power SW while pressing [ ], [ ] and ] keys to enter the Service Mode. Set up the PET-G on the machine. MENU MENU SERVICE MENU Select [PRINT MENU]>[HEAD ADJUST]>[BIAS]>[TEST SERVICE MENU PRINT] and press [ENTER] key. PRINT MENU [ ] [ ] PRINT MENU...
Page 223 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 straight. Position of the printing moves one line by turning the screw 1/4 turn.
Page 224 [BIDIRECTION ADJUSTMENT] SERVICE MENU Select [PRINT MENU]>[HEAD ADJUST]>[BI-DIR. DEFAULT] PRINT MENU >[TEST PRINT] and press [ENTER] key. [ ] [ ] PRINT MENU HEAD ADJUST HEAD ADJUST Loosen the screws ﬁ xing the head for 1/2 turn. BI-DIR.DEFAULT If the screws are loosened too much, the adjustment cannot be done correctly.
Page 225: Limit Position & Cut Down Position Initialize
4-4 LIMIT POSITION & CUT DOWN POSITION INITIALIZE (Referential Time : 3min.) 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 a head carriage lock error.
Page 226 Conﬁ rm that the head is capped properly, and press [ENTER] SETTING UP key. The Tool Carriage will be separated from the Head Car- THE LIMIT riage and the limit position initialize will start. After initialize is completed, the message is displayed. DETECTING..
Page 227: Linear Encoder Setup
4-5 LINEAR ENCODER SETUP (Referential Time : 5min.) This is for checking the reading of the linear encoder and for calibrating its expansion/contraction caused by the op- eration environment. This operation is required when Limit Sensor, Encoder Scale or Encoder Module is replaced or the position is adjusted.
Page 228 One of the messages appears at the completion of the set up. In case of Setup error, check the followings. LINEAR ENCODER Dirt/Scratch on the Encoder Scale. Dirt/Scratch on the Encoder Module. SETUP COMPLETED Encoder Scale is not between the Encoder Module. Backlash of the Carriage Motor Gear and the Drive Gear.
Page 229: Flushing Position Adjustment
4-6 FLUSHING POSITION ADJUSTMENT (Referential Time : 5min.) This is to adjust the ﬂ ushing position. Without this adjustment, the Flushing may not be performed properly. Turn off the Sub Power SW, and then turn off the Main Power The Head height should be set LOW. High Remove the Right Cover.
Page 230 Remove the Right Under Cover and lock the Head Carriage. Right under Cover Turn on the Sub Power SW while pressing [ ], [ ] and ] keys to enter the Service Mode. MENU MENU SERVICE MENU Select [PRINT MENU]>[FLUSHING ADJ.], and press [EN- TER] key.
Page 231: Crop Mark Sensor Adjustment
The result of the crop mark recognition on Roland media is not assured, when any media other than SV-GG is used for this adjust- ment.
Page 232 Remove the four rivets as shown in the ﬁ gure for removing the Tool Carriage Board Cover. ツールキャリッジボードカバー Turn on the Sub Power SW while pressing [ ], [ ] and ] keys to enter the Service Mode. Setup the SV-GG on the machine. MENU MENU SERVICE MENU...
Page 233 If the MAX voltage is not proper, refer to the voltage dis- played in [ ] on the lower screen. Adjust the VR on the Tool Carriage Board so that the voltage in [ ] to be 2.7 +/-0.2V. Because of the ink dry, the voltage displayed in [ ] decreases in time.
Page 234: Crop-Cut Adjustment
4-8 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 cut- ting position based on the detected Crop Marks becomes wrong, and that results in the mis-alignment of the Print and Cut performed under the auto crop mark detection.
Page 235 From the test pattern, find the value where the print line <TEST PATTERN> matches the cut line. - .0 In this case, the correction value for the scan direction is Correction-value scale "- 0.3". - .0 If it is difﬁ cult to see the cut line visually, use a mag- -0.0 Scan niﬁ...
Page 236 Adjustment is completed if the position error of cut line is within +/-0.1mm. If not, select [SETTING] menu again for fur- CUTTING MENU ther adjustment. CROP-CUT ADJ. key : Moves cut position towards front CROP-CUT ADJ. key : Moves cut position towards rear SETTING key : Moves cut position towards right key : Moves cut position towards left...
Page 237: Print/Cut Position Adjustment
4-9 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 misalignment of the printing and cutting. This adjustment is required when Tool Carriage is replaced, or a head is replaced or adjusted, and also when the relative distance between the Carriage and head is changed.
Page 238 From the test pattern, find the value where the print line <TEST PATTERN> matches the cut line. - .0 In this case, the correction value for the scan direction is "- 0.3". Correction-value scale - .0 If it is difﬁ cult to see the cut line visually, use a mag- -0.0 niﬁ...
Page 239 Adjustment is completed if the position error of cut line is within the range below. If not, select [SETTING] menu again CUTTING MENU for further adjustment. PRINT-CUT ADJ. Mark on the right: Within +/-0.1mm Mark on the left: Within +/-0.3mm (Make an adjustment based on the mark on the right) PRINT-CUT ADJ.
Page 240 4-10 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 calibrat- ing the variation in Grit Roller diameter. Calibration is made based on the value in feeding media [PET-G]. Without proper calibration, it may cause misalignment in the feed amount of media, and it results in the problems such as white banding, banding of overlap or the dimension error of print result compared to the original data.
Page 241: Calibration(Feeding Direction)
Calculate the amount to be calibrated with the formula as shown in the ﬁ gure. Measured 400 - Length Calibration x 100 Value Measured Length Select [PRINT MENU]>[CALIB.DEFAULT]>[SETTING], and SERVICE MENU enter the calibration value with [ ] and [ ] keys.
Page 242: Tool Height Adjustment
4-11 TOOL HEIGHT ADJUSTMENT (Referential Time : 5min.) Install the White Dummy Pen (ST-006) to the Tool Carriage. White Dummy Pen Position the Pinch Rollers as shown in the ﬁ gure, and lower the loading lever. Pinch Roller Grit Roller Remove the Right Cover.
Page 243 Remove the Tool Carriage Cover. Tool Carriage Cover Connect the Tool Carriage to the Head Carriage. Lock the Head Carriage. And move the Tool Carriage to the right side of the bed. Turn the Adjustment Screw to adjust the space between the pen end and bed to be 2.5 mm to 2.6 mm.
Page 244: Tool Pressure Adjustment
4-12 TOOL PRESSURE ADJUSTMENT (Referential Time : 15min) This adjustment is to correct the tool pressure during cutting. Before this adjustment, it is necessary to perform [4-11 TOOL HEIGHT ADJUSTMENT]. Install the White Dummy Pen (ST-006) to the Tool Carriage. White Dummy Pen Move the Pinch Rollers at the positions as shown in the ﬁ...
Page 245 Disconnect the Tool Carriage from the Head Carriage. Remove the Tool Carriage Cover. Tool Carriage Cover Connect the Tool Carriage to the Head Carriage. Lock the Head Carriage. And move the Tool Carriage to the right side of the bed. Turn on the Sub Power SW while pressing [ ], [ ] and...
Page 246 Select [CUTTING MENU]>[FORCE ADJUST]. MENU SERVICE MENU SERVICE MENU CUTTING MENU Only the Tool Carriage can be moved in [FORCE ADJUST] menu. CUTTING MENU FORCE ADJUST Select [FORCE ADJUST]>[30gf], and press [PAUSE] key to move the Tool Carriage down. CUTTING MENU FORCE ADJUST FORCE ADJUST 30gf...
Page 247 Lift up the Tool Holder with the Tension Gauge (ST-002) and 200gf measure the pressure when the pen tip leaves the bed. 56 57 ST-002 Adjust the parameter in [200gf] menu with [ ] and [ [ ] [ ] keys for the pressure to be 195 to 205gf (1.9N to 2.0N).
Page 248: Belt Tension Adjustment
4-13 BELT TENSION ADJUSTMENT (Referential Time : 20min.) Connect the Tool Carriage to the Head Carriage and move them to the right in the lock position. Remove the Covers in order. Ink Cartridge Cover 1. Right Cover 2. Left Cover 3.
Page 249 Loosen the two Fixing Screws which is located on the left <Top view> end of the belt halfway round. Fixing Screw Be careful with the sharp edges around the belt when loosening the screws. It may cause injury. Fixing Screw Insert a wrench through the holes on the Side Frame and loosen the two screws to make a gap of three millimeters between the tip of the screw and Idle Pulley Holder.
Page 250 Tighten the two screws shown in the ﬁ gure to slightly contact with Idle Pulley Holder. Move on to [4-14 BELT POSITION ADJUSTMENT]. Screws Make sure not to tighten the screws too tight. It may move the ﬁ xed Idle Pulley Holder acciden- tally.
Page 251: Belt Position Adjustment
4-14 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 exces- sively. The belt position needs to be conﬁ rmed after the Belt Tension Adjustment and adjusted if it is necessary. Remove the Covers in order.
Page 252 Conﬁ rm the belt position. The position is proper when the belt is not touching the Flanges of the Drive Pulley excessively. When the position is proper, skip this adjustment and go to [ADJUSTMENT ON THE IDLE PULLEY SIDE] described in the later step of this adjustment leaving the belt aging on.
Page 253 Loosen the two Fixing Screws located on the right end of the belt. Loosen the screws about a few rounds for the bottom of the screw head not to contact with the Fixing Screw Stay. Press [ENTER] key to restart Aging. AGING SCAN Adjust the belt position turning the Adjustment Screw as fol-...
Page 254 Tighten the two Fixing Screws for the bottom of the screw head to slightly contact with the Stay. Fixing Screw Conﬁ rm that the belt is not touching the pulley anges exces- sively. When the belt is in improper position, adjust it again. When it is proper, leave the belt aging on, and go to the fol- lowing [ADJUSTMENT ON THE IDLE PULLEY SIDE].
Page 255 Loosen the two Fixing Screws located at the left end of the belt eighth to quarter round. Fixing Screw When the screw is loosen more than necessary, it gives difﬁ culty in adjusting the belt. Also, you need to be careful with the sharp edges around it when turning the screws.
Page 256 Belt leans to the rear side of the machine -Turn the screw 2 carefully in CW to press it to the Idle Pulley Holder. * Make sure to have a gap of three millimeters between the screw 1 and Idle Pulley Holder when turning the screw 2. Screw 1 Screw 2 Tighten one of the screws that has no contact with the Idle...
Page 257 Fix the Right Side Frame by sliding it from behind to hook the tab as shown in the ﬁ g- ure. 4-59...
Page 258: Take-Up Unit Operation Check
4-15 TAKE-UP UNIT OPERATION CHECK (Referential Time : 2min.) This is to check whether Take-up Unit operates properly. Conﬁ rm that the cable of Take-up Unit is connected to the <Rear View> connector and turn on the Main Power SW. Turn on the Sub Power SW while pressing [ ], [ ] and...
Page 259 Conﬁ rm that [START] is selected, and press [ENTER] key to turn on the Take-up Unit. START START [START] or [STOP] can be selected with [ ] and ] keys. The current setting is displayed on the left and the new setting is displayed on the right.
Page 260 Move the Dancer Roller up and down by hand, and conﬁ rm that the drive part does not rotate. Drive Part The setting of [STOP] is canceled when exiting the menu. The initial setting is [START] every time en- tering [TU] menu. Dancer Roller 4-62...
Page 261: Supplemental Information
5 Supplemental Information 5-1 Special Tools Table shows a list of special tools recommended by Roland DG Corp. Parts No. ST-056 Parts Name TORQUE DRIVER N6 Purpose HEAD ALIGNMENT Parts No. 1000005463 Parts Name TOOL,BIT PHILLIPS NO.1 L150MM ST-107 Purpose HEAD ALIGNMENT Parts No.
Page 262: Sensor Map
5-2 SENSOR MAP FRONT COVER SENSOR It detects whether the Front Cover is opened or closed. REAR PAPER SENSOR LIMIT SENSOR HEAD LOCK SENSOR It detects the rear edge of the It detects the limit positon of It detects whether the HEAD media and also whether the the head carriage in the scan CARRIAGE is at the lock position or...
Page 263 WIPER SENSOR It detects the limit position of the Wiper movement. ENCODER MODULE It detects the coordinates in the carriage moving HEAD UP/DOWN SENSOR direction, and also generates the print signal. It detects the position of the Head Height Lever. THERMISTOR It takes the temperature around the Head.
Page 264 PINCH ROLLER SENSOR It detects the positions of Pinch Roller. CROP MARK SENSOR It detects the Crop Mark. INK CARTRIDGE IC SENSOR INK EMPTY SENSOR It communicates with the IC chip of the Ink Cartridge. It detects whether the Ink Cartridge is empty or not.
Page 265: Troubleshooting
6 Troubleshooting 6-1 WHITE FINE LINE / BANDING / MISSING DOT / SCRATCHY PRINTING / BLURRED PRINTING Missing dot or Improved deflected-fired dot Perform Normal Completed appears on the test Cleaning pattern. Not Improved *Several Normal Cleanings and a Powerful Cleaning did not improve the printing result.
Page 266: Poor Printing Quality When Using The Metallic Silver Ink
Check created print image overlap the area specified for metallic silver and CMYK when is not appropriate creating print image, or select the spot color from the Roland color library. 6-3 MIXED COLOR IS PRINTED AT THE METALLIC SILVER SPECIFIED AREA...
Page 267: Particular Color Is Not Printed At All
6-4 PARTICULAR COLOR IS NOT PRINTED AT ALL CHECK ACTION REFERENCE OUTLINE If the Head is not capped correctly, ink suction for one color may [3-5 CAP TOP Defect of Cap Top Replace Cap Top not be done. And, the Head dries and it may cause the nozzle REPLACEMENT] clog.
Page 268: Vertical Banding
If media produces static electricity easily, the ink tends to remain on the head surface while printing and results in ink Static electricity of the Perform [PERIODIC CL] User's Manual dropping. When [PERIODIC CL] is set to [1 min] to [990 min], media automatic cleaning is performed while printing and it may prevent the ink dropping.
Page 269: Print & Cut Misalignment
6-10 Print & Cut Misalignment Ideal Conditions The above illustration shows the ideal print and cut conditions where the red stars signify the printed image and the black lines signify the cut path. Since the actions to be taken are different depending on the conditions of shifting, check how cutting is shifted first and take appropriate actions.
Page 270 Symptom 3 : Cut is OK at Lead Edge but is Getting Shifted as It Goes to the End of Print Possible Causes 1. There is some setting value other than 0 set in [CUTTING MENU]>[CALIBRATION]>[FEED SETTING]. 2. Expansion/Contraction of the media 3.
Page 271 Symptom 5 : Cut is Shifted When Using Crop Marks Possible Causes 1. Crop-cut adjustment is not correctly done. 2. Crop mark sensor adjustment is not correctly done. Actions 1. Perform [ADJUST BI-DIR] in the User menu. 2. Perform [CROP-CUT ADJ.] in the User menu. 3.
Page 272: Poor Cutting Quality (Stitch Cut, Distorted Cut, Mismatched Start And End Points)
6-11 POOR CUTTING QUALITY (STITCH CUT, DISTORTED CUT, MISMATCHED START AND END POINTS) CHECK ACTION REFERENCE OUTLINE Blade Holder is fixed loose Fix the Blade Holder tightly Blade-offset setting is not Set the blade-offset correct correctly [4-12 TOOL PRESSURE Cutting force is not correct Adjust Tool pressure ADJUSTMENT] When using only left and right pinch rollers, middle part of the Middle Pinch Rollers are...
Page 273: Motor Error
6-13 MOTOR ERROR CHECK ACTION REFERENCE OUTLINE Remove cause of Media Jamming Media Jamming Back tension of media is When using hard-to-unroll or too heavy media, Motor Error Use appropriate Media too high occurs due to over load for feeding the media. Perform Limit Position &...
Page 274: Heater / Dryer Temperature Does Not Rise
6-14 HEATER / DRYER TEMPERATURE DOES NOT RISE CHECK ACTION REFERENCE OUTLINE The media is not loaded Set up the media User's Manual Inappropriate temperature Check the temperature When the [PRINT HEATER / DRYER] is [OFF] on the machine, User's Manual is set on the machine setting the Heater does not operate.
Page 275: Problem In Network (Rip Does Not Recognize The Printer)
6-16 PROBLEM IN NETWORK (RIP DOES NOT RECOGNIZE THE PRINTER) CHECK ACTION REFERENCE OUTLINE Turn off the main power It can be solved by restarting the printer with the main power. and restart the printer Try it several times. It can be solved by refixing the network cable. Try it several Refix the cable times.
Page 276: Service Call
6-18 SERVICE CALL CAUSE CODE EXPLANATION ACTION Disorder of communication with Check cable connection between Main Board and Servo Board. Servo Board does not work correctly. Sub CPU Check the other cable connections of Servo Board. Sub CPU does not work correctly. 0002 Servo Board replacement This occurs when the Sub CPU is...
Page 277 CAUSE CODE EXPLANATION ACTION Wiper Unit hits the Tool Carriage Move the Carriages on the bed not to hit the Wiper Unit. Wiper Motor error Wiper Motor Replacement Defect of Wiper Unit Wiper unit does not work 0109 Wiper Unit Replacement Defect of Wiper Sensor correctly.
Page 278: Service Activities
7 Service Activities 7-1 INSTALLATION CHECK LIST VS-640/540/420/300 INSTALLATION CHECK LIST Date : User Name : Serial Number : Checking the place of installation There is a space necessary for installing the machine as below. 3600 mm(141.7 in) VS-640 3400 mm(133.9 in) VS-540 3100 mm(122 in) VS-420 2800 mm(110.2 in) VS-300 Work Space...
Page 279 Unpacking Manual, CD-ROM, DVD- ROM etc.
Page 280 Software RIP : 1 User's Manual : 1 Setup guide : 1 Cleaning Cleaning sticks : 10 Inkjet Printer Maintenance Cartridge-slot label : 1 ﬂ uid : 1 Guide : 1 Roland OnSupport Installation & Setting Guide/Installation disc (one for each)
Page 281 Assembling and Installing Set up the followings in reference to the Setup Guide [3.Assembling and Installing] to [7. Network Settings]. Assembling the Stand – Mounting the Machine Installing the Drain Bottle Removing the Packing Materials Connecting the Cables Revised 3 Apply the cleaning liquid to the rubber gasket of the Cap Top with the cleaning stick.
Page 282 Installing the Ink Cartridges Gently shake the ink cartridges before inserting them to the slots. MAX ink cartridges Dummy cartridges Cleaning cartridges (Cleaning the heads : approx. 60 minutes) (Ink filling : approx.10 minutes ) Using 2 pcs of cleaning cartirdges and dummy cartridges, First, insert the MAX cartridges into slots 7 and 8.
Page 283 � To use Roland@NET and VersaWorks Online: Internet connec- tion and web browser For the latest information, see the Roland DG Corp. website (http://www.rolanddg.com/) Make the setting for Roland@NET Select the check box [Download Updates Automatically and Notify] if the customer accepts it.
Page 284 - Registering the Roland DG Account if the customer accepts it When you register the Roland DG Account (Roland DG ID), you will become able to use OnSupport more effectively. You are to communicate with our OnSupport server in registering your account.
Page 285 Basic Operation Explain following items in reference to the User's Manual. Switch On! !! IMPORTANT !! Always leave the main power on. Maintenance operation is automatically carried out every 12 hours while the machine is not in use. Use the sub power switch for the daily powering on and off. Loading Media For the stable media feeding, place the middle pinch rollers above all the grit rollers that lie between the left and right pinch rollers.
Page 286 Maintenance of Ink Cartridges - Shake the ink cartridge periodically to maintain the good ink condition. - "SHAKE CARTRIDGE" appears periodically. - "SHAKE CARTRIDGE" does not appear when in the sleep mode or the sub power is off. - The message shows up with beeps. After that, no beeps are made. - During the message is displayed, the machine does not do anything unless the message is cleared.
Page 287 When Problems Such As Dot Drop-out are Not Cleared Up - About [INK RENEWAL] Even after performing cleaning using the cleaning function (normal, medium, or powerful) or manual cleaning, perform this operation. Replacing the Wiper (Be careful about the fitting direction.) Replacing the Felt Wiper Replacing the Blade Replacing the Separating Knife...
Page 288 Fully Utilize the Media Heating System !! IMPORTANT !! To obtain stable temperature, use the machine at an ambient temperature of 20 to 32°C (68 to 90°F). The optimal temperature for the media varies according to the type of media and differences in the print mode. If the ink forms lumps or smudges, raise the temperature.
Page 289 - Use Conditions of Take-up System When “TU2” is Selected (This is mainly for Print & Cut operation.) - How to Output by Limiting Length (Roland VersaWorks) (Select ”CustomCUT” from [Size] under “Media Settings.” and Set “H”at 300mm.) - If the length of output at one time is too long, the media may get soiled by touching the work floor. To avoid the media from getting soiled by touching the floor, output the media by about 300 mm.
Page 290 Output Operation Management Determining What Happens When Ink Runs Out - [EMPTY MODE] Returning All Settings to Their Initial Values When you use metallic silver ink and white ink * Only for the ink type 8 colors (WMT mode) Explain following items in reference to the SPECIAL COLOR INK GUIDE. Characteristics of Inks and Important Notes - White ink and metallic silver ink precipitate.
Page 291 In the print mode for Mt ink, the ink may not dry fully depending on the type of the media. Confirm the proper printing result in a trial printing beforehand. Job outputting from Roland VersaWorks Explain each procedure as follows on a job outputting from Roland VersaWorks. Printing Cutting !! IMPORTANT !! Never use the Media clamps during cutting.
Page 292 Others Explain to refer to the User's Manual when an error message is displayed. And also explain to switch off and on the machine and check what happens before calling for inquiry when [SERVICE CALL] is displayed, since it occasionally solves the problem just by restarting.
Page 293: Maintenance Check List
7-2 Maintenance Check List VS-640/540/420/300 Maintenance Check List Date : User Name : Serial Number : Check items Operation points Check Interview the customer Ask the customer if there is something that he/she is concerned about. Done Done Output / Get Report before maintenance [Get Report] by Peck, or print both Service Report and History Report.
Page 294: Specification
Eight colors (cyan, magenta, yellow, black, light cyan, light magenta, metallic silver, white) Maximum 1,440 dpi Printing resolution (dots per inch) 10 to 300 mm/s Cutting speed 30 to 300 gf Blade force Roland CAMM-1 series compatible Cutting Type blade 0 to 1.5 mm(0 to 0.059 in) Blade offset 0.025 mm/step Software resolution (when cutting) Error of less than ±0.3% of distance traveled, or ±0.3 mm, whichever is greater...
Page 295 Note: The media holder of this machine is exclusive use for the media of paper tube (core) inner diameter 3 inches. To use 2 inches media, the optional media flanges are required. The length of printing or cutting is subject to the limitations of the program. Media type: Media specified by Roland DG Corp. (Cutting only) � � Temperature: 25°C (77°F), humidity: 50% �...

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