GCC Technologies J5 Series Maintenance Manual
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GCC Technologies J5 Series Maintenance Manual

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Version : 9.0
J5 & J5 LX Series
Maintenance Manual
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Summary of Contents for GCC Technologies J5 Series

  • Page 1 Version : 9.0 J5 & J5 LX Series Maintenance Manual...

  • Page 2: Table Of Contents

    Version : 9.0 Table of Contents Chapter 1：Overview ........................3 1.1 Introduction ......................... 3 Chapter 2：Mechanical System ....................4 2.1 Main Unit Assembly ......................5 2.2 Left End Assembly ......................8 2.3 Right End Assembly ......................10 2.4 Motor Bracket and Belt Assembly ................. 12 2.5 Carriage Assembly ......................

  • Page 3: Chapter 1：Overview

    Trouble shooting & System Diagnostics  Chapter 6 We have the parts list to show the part no. of difference size of J5 series. Manual contents may be subject to change without notice. Please contact GCC Customer Service by calling at 886-2-2694-6687 or e-mailing to tech.support@gccworld.com for services.

  • Page 4: Chapter 2：Mechanical System

    Version : 9.0 Chapter 2：Mechanical System We will have diagrams to show the part number for every part in the following sections. They are:  Main unit  Left End Assembly  Right End Assembly  X Motor Bracket and Belt Assembly ...

  • Page 5: Main Unit Assembly

    Version : 9.0 2.1 Main Unit Assembly...
  • Page 6 Version : 9.0 Main Unit Assembly – Parts List No. Part No. Description 20600051G Y axis carriage belt (2GT-L3366-W14) 22801068G Square bar 22801149G Top Rail 22801466G White Bush 0604 234000410G Control Panel Sticker 23500005G Nut(M4xt3.2xS7) 241006780G Front platen extension 132 241006810G Rear platen extention 132 24100247G Right cover Jaguar.(Black)
  • Page 7 Version : 9.0 No. Part No. Description 290107330G MainBoard with J5-61 Firmware (from S/N S70549) 290107340G Mainboard with J5-101 Firmware (from S/N R88284) 290107350G Mainboard with J5-132 Firmware (from S/N S70664) 290107410G Mainboard with J5-101LX Firmware (from S/N R88289) 290107420G Mainboard with J5-132LX Firmware (from S/N R70069) 290107430G Mainboard with J5-183LX Firmware (from S/N R88374) 29006251G Main Beam Assembly...

  • Page 8: Left End Assembly

    Version : 9.0 2.2 Left End Assembly...
  • Page 9 Version : 9.0 Left End Assembly – Parts List Part No. Description 20600007G Y-axis belt. 2GT-L172-W10 22000149G P.C.B interval pillar (LCA4-10A) 22801359G Y-axis Motor Spacer 23800032G Motor board. (12258) 24400039G Pully bottom bracket 24400041G Y-motor bracket 24400526G Pully top bracket 24400755G Side support left 25200052G Pan head machine screw including spring washer 25200182G Truss head screw including external teech washer...

  • Page 10: Right End Assembly

    Version : 9.0 2.3 Right End Assembly 290106350G Flat cable 9 pin to 8 pin PCB Assembly...
  • Page 11 Version : 9.0 Right End Assembly – Parts List Part No. Description 20600039G X-axis belt (2GT-L240-W10) 22000149G P.C.B interval pillar (LCA4-10A) 24400038G X-motor adjusting bracket 244060930G Cable basket 24400304G Ideal pulley ass y bracket 24400715G Idel pulley Assembly adjusting bracket 24400757G Right Side Plate 24400761G X-motor bracket 25200017G Truss head machine screw(M3*15L).black...

  • Page 12: Motor Bracket And Belt Assembly

    Version : 9.0 2.4 Motor Bracket and Belt Assembly...
  • Page 13 Version : 9.0 Motor Bracket and Belt Assembly – Parts List Part no. Description 29001804G Motor assembly, Jaguar. 6.1.1 23100014G Motor MS090600, Jaguar. 6.1.2 21700009G Motor pulley, 2GT-P18, Jaguar. 6.1.3 25200169G Headless Screw, M4x3.5. 6.1.4 22000107G Cable Tie, YJ-160. 24400761G X-motor bracket, Jaguar.

  • Page 14: Carriage Assembly

    Version : 9.0 2.5 Carriage Assembly...
  • Page 15 Version : 9.0 Carriage Assembly – Parts List Part No. Description 20200071G Blade holder slide bracket assembly 20700029G Bearing 21700034G Y-axis belt bracket 22000036G Cable saddle (YL-1) 22800410G Carrier guide roller(DU type) 22800411G Spacer for carrier guide roller(DU type) 22800769G Right-Slide shaft in tool carriage. 22800767G Carrier guide roller(DU type)shaft 22800769G Right-Slide shaft in tool carriage.

  • Page 16: Lx Carriage Assembly (Aas)

    Version : 9.0 2.6 LX Carriage Assembly (AAS)
  • Page 17 Version : 9.0 LX Carriage Assembly – Parts List Part No. Description 20200071G Blade holder slide bracket assembly 20700029G Bearing 21700034G Y-axis belt bracket 22000036G Cable saddle (YL-1) 22800410G Carrier guide roller(DU type) 22800411G Spacer for carrier guide roller(DU type) 22800769G Right-Slide shaft in tool carriage.
  • Page 18 Version : 9.0 Part No. Description 290108340G Flat cable Assembly for 61 model (1050mm) 290108320G Flat cable assembly for 132 model (1830mm) 290108310G Flat cable assembly J5-183.(2250mm) S13 20901523G AAS II Sensor PCB to carriage PCB S16 20900128G Cable (from VCM Encoder to tool carriage) S17 20900430G VCM Board to Carriage Board Cable (1.5*5pin soft cabe 12cm)

  • Page 19: Pinch Roller Assembly

    Version : 9.0 2.7 Pinch Roller Assembly...
  • Page 20 Version : 9.0 Pinch Roller Assembly – Parts List Part No. Description 20200003G Pinch roller wheel 21700010G Releasing arm 22800028G Pinch roller active arm shaft 22800029G Pinch roller shaft 22800030G Releasing arm shaft 22800031G Blocking arm shaft 24100142G Blocking arm 24100268G Pinch roller base 24100276G...

  • Page 21: Main Beam Assembly

    Version : 9.0 2.8 Main Beam Assembly...
  • Page 22 Version : 9.0 Main Beam Assembly – Parts List Part No. Description 21700003G Bearing supprt 22200040G DC FAN 22802179G Main beam 24000570G SPACE PE styrofoam 24400760G Main beam support fixer 24400879G Platen 24402272G Sensor Bracket 25200084G 90° dish flat head machine screw M2.6*6 25200093G Pan head machine screw(M3*4L black) 25200115G Truss head machine screw(M3*6L SUS) 25200208G Truss head screw including spring &...

  • Page 23: Drum Assembly

    Version : 9.0 2.9 Drum Assembly...
  • Page 24 Version : 9.0 Drum Assembly – Parts List Part No. Description 20700039G Grid Drum Bearing 22800407G Grid Drum shaft 22800564G Bearing Blocker 24100189G X axis actively belt gear 25200169G Socket headness set screw.(M4*3.5L) 26500432G 5cm Japanese grid drum...

  • Page 25: Chapter 3：Circuit System

    Version : 9.0 Chapter 3：Circuit System 3.1 System Diagram...

  • Page 26: J5 Wiring Diagram

    Version : 9.0 3.2 J5 Wiring Diagram 3.2.1 Mainboard Mainboard Port Connected to Pinch Roller switch 20x2 Ribbon Cable connect to Motor Drive Board J10 External Ethernet Port Control Panel External USB Port 20x2 Ribbon Cable connect to Motor Drive Board J19 JDR1 External RS-232C Port...
  • Page 27 Version : 9.0 3.2.2 Motor Driver Board Mainboard Port Connected to X Motor encoder Y Motor encoder Rear paper sensor Front paper sensor X Motor power Y Motor power DC Power input J10 20x2 Ribbon Cable connect to Main Board J8 J19 20x2 Ribbon Cable connect to Main Board J41 J21 Flat cable connect to Flat cable 9 pin to 8 pin PCB Assembly J23 DC FAN...

  • Page 28: Chpater 4 Maintenance

    Version : 9.0 Chpater 4 Maintenance This chapter deals with component replacement and maintenance of the J5 Cutting Plotter. gives detailed step-by-step instruction on how to replace or adjust the components of this machine. 4.1 Components Replacement and Belt Tension Adjustment 4.1.1 Removing the Front, Back, End and Top Covers The following steps are those involved in removal of the front, back, end and top covers.
  • Page 29 Version : 9.0 To Remove the Top Cover: Unscrew the two screws at each end of the Top Cover Remove the panel PCB cover screws and take out the cover. Disconnect the grounding cable. Disconnect control panel on the main board side.

  • Page 30: Replacing The Pinch Roller Sets

    Version : 9.0 4.1.2 Replacing the Pinch Roller Sets The following steps are those involved in replacing pinch roller sets. To Unlatch the Pinch Roller Lever: Pull down the Square Bar Lever to unlatch the Pinch Rollers To Remove the Square Bar Holding Bracket: Remove the bracket and washer.
  • Page 31 Version : 9.0 To Remove the Pinch Roller Sets: Slide the pinch roller to the notch at the right end Remove the pinch roller set through the notch. of the Square Bar. Note: When re-installing the Pinch Roller Set, the Cam Roller must be aligned squarely to the Square Bar.

  • Page 32: Replacing The Tool Carriage

    Version : 9.0 4.1.3 Replacing the Tool Carriage The following are those you must follow to successfully replace the Tool Carriage. To Loosen the Carriage Belt: Retaining Screws Adjustment screw Unscrew the 2 retaining screws, but don’t remove them. Then turn the Adjustment Screw anti-clockwise to loosen the carriage belt.
  • Page 33 Version : 9.0 To Remove the Tool Carriage cover: Depress the two locking clips at the top of the Tool Carriage Cover and pull the Cover away.
  • Page 34 Version : 9.0 To Prepare the Tool Carriage for Removal: Pop up the plastic locking pins using a Disconnect the Flat Sensor Cable. flathead screwdriver. Bolt A Bolt B Unbolt and remove nut A and B, and then unscrew both Bolt A and Bolt B until they are flush with the bracket.
  • Page 35 Version : 9.0 To Remove the Tool Carriage: Separate the Sprung Washer/Rollers as seen in the figure above. Swing the Tool Carriage down and out while keeping the Sprung Washer/Rollers apart. Note 1. To install a new Tool Carriage or replace the original Tool Carriage simply reverse the steps for Tool Carriage removal.

  • Page 36: Replacing The Y-Motor

    Version : 9.0 4.1.4 Replacing the Y-Motor The following steps are those involved in the replacement of the Y-motor. Loosen the all 3 tension-bracket retaining screws as well as the tension adjustment screw, but do not remove them. 2. Depress the jumper clips, and pull to unplug the 2 3.
  • Page 37 Version : 9.0 Note 1: To install or replace the Y-motor, simply reverse the steps to remove it. Note 2: After the Y-motor is in place, you must adjust the Y- motor belt tension as described in the Y-motor belt tension adjustment section of this chapter.

  • Page 38: Replacing The Vcm Pc Board

    Version : 9.0 4.1.5 Replacing the VCM PC Board The following is what is involved in replacement of the VCM PC board. Unplug the two sensor connectors, then loose the two PC board screws to remove the board. Note：If the Pinch Roller Sensor is still not effective after replacement the Tool Carriage or the may need replacement.

  • Page 39: Main Board Connection Or Replacement

    Version : 9.0 4.1.6 Main board Connection or Replacement Main board connection or replacement must follow the following steps to be sure that no damage comes to either service personnel or the components: Note: To ensure absolute safety for service personnel and components, please follow the safety instruction at the beginning of this manual, before installing or replacing any current carrying components 1.

  • Page 40: Adjusting The Tool Carriage Transmission Belt

    Version : 9.0 4.1.8 Adjusting the Tool Carriage Transmission Belt When you replace the tool carriage or belt itself, the belt tension needs to be adjusted to 150g. This is done as follows: Use a tension gauge to 1. Move the tool carriage to the far left end of measure the the guide beam after the tool carriage or belt’s tension by...

  • Page 41: Adjusting The X Motor Tension Belt

    Version : 9.0 4.1.9 Adjusting the X Motor Tension Belt Loosen the 4 retaining screws locking the X-motor bracket in place. Place the push-pull tension gauge’s hook-arm at the hole of X motor bracket and pull the motor toward yourself along the direction parallel to the racket edge, and keep it at...

  • Page 42: Adjusting The Y Motor Tension Belt

    Version : 9.0 4.1.10 Adjusting the Y Motor Tension Belt Loosen the 3 retaining screws locking the tension bracket in place but do not remove them. 2. Place the push-pull tension gauge’s hook-arm at the hole of Y motor bracket and pull the motor toward yourself along the direction parallel to the line that passes through the motor shaft and the drive pulley shaft.
  • Page 43 Version : 9.0 Tighten the tension screw to retain the tension. Note: The belt connecting the drive pulley and Y motor needs to be tightened up with a tension of 4 kg.

  • Page 44: Chapter 5. Troubleshooting

    Version : 9.0 Chapter 5. Troubleshooting 5.1 Maintenance Diagnostics This section provides maintenance diagnostics as troubleshooting aids. This diagnostic feature is to check hardware to find out which components are good or defective. Using this diagnostic test facility enables the diagnosing of the hardware components.
  • Page 45 Version : 9.0 SRAM OK System cannot go on testing, LCM display current message more than 3 seconds X Mb DRAM OK Error occur Exit Diagnostic Test Initial State Cancel Key Please Reset Machine Down Arrow Key Pressed Down Arrow Key Pressed Holder Down? Check Lever Sensor? Up Arrow Key Pressed...

  • Page 46: Diagnostic Test For Sram And Dram

    Version : 9.0 5.1.2 Diagnostic Test for SRAM and DRAM This test provides the ability to diagnose the SRAM and DRAM. If these two components are bad, replace them. Otherwise the cutting plotter will not work properly. 5.1.3 Diagnostic Test for Lever Sensor This feature diagnoses the lever sensor.

  • Page 47: Diagnostic Test For Media Sensors

    Version : 9.0 5.1.4 Diagnostic Test for Media Sensors This test is to diagnose the media sensors. If they are faulty, the cutting plotter cannot detect the media length correctly. You can see the current front and rear sensor condition, you can turn it on or off to see if sensors are out of order or not.

  • Page 48: Diagnostic Test For Width Sensor

    Version : 9.0 5.1.5 Diagnostic Test for Width Sensor If the sensor is faulty, the cutter cannot sense the media width correctly. Refer to the maintenance chapter to replace it. You must first move the tool carriage to the rightmost position; the lever must be down to do this. Once this is done please move the tool carriage to left.

  • Page 49: Diagnostic Test For Motor Encoder And Tool Holder Encoder

    Version : 9.0 5.1.6 Diagnostic Test for Motor Encoder and Tool Holder Encoder This feature provides the ability to diagnose the X and Y motor encoder and tool holder encoder. If the encoder is defective, the cutting plotter cannot work properly. To check if the encoder is bad or good, you can apply a slight force to the tested part (such as a drum, the tool carriage or the tool holder) then examine the readings.

  • Page 50: Y Motor Encoder Test

    Version : 9.0 5.1.7 Y Motor Encoder Test Holder Encoder Up/Down Key Enter Key Move Holder Up/Down Cancel_key W ait for 3 seconds Previous/Next test item Display encoder count Holder Motor Encoder Reading CANCEL 5.1.8 Diagnostic Test for Tool Force (VCM) This test is to diagnose the VCM.
  • Page 51 Version : 9.0 Drum Moves Backward ? Up/Down Key Enter Key Cancel Key X Motor Moving Now Previous/Next test item Backward CANCEL Carriage Goes Left ? Up/Down Key Enter Key Cancel Key Y Motor Moving Now Previous/Next test item Forward CANCEL Carriage Goes Right ? Up/Down Key...

  • Page 52: Diagnostic Test For The Rs-232 Interface

    Version : 9.0 5.1.10 Diagnostic Test for the RS-232 Interface Check RS-232 ? Up/Down Key Enter Key Previous/Initial state Type any characters From Computer CANCEL Cancel Key No => Type any character Error or not? Wait for 3 seconds from the computer The message you typed Error Messages Type any character...

  • Page 53: Problems And Solutions

    Version : 9.0 5.2 Problems and Solutions This section discusses typical problems you may encounter while operating the cutting plotter and offers you possible solutions The line quality is not good enough at the corner or the end point. Causation and recovery: a.
  • Page 54 Version : 9.0 5. The lines quality is wavy. Causation and recovery: a. Forget to fasten the tool fastening screw. (Fasten it.) b. The blade is worn. (Change it.) c. The acceleration is too high. (Set the acceleration to a lower value; please refer to the default value.) d.
  • Page 55 Version : 9.0 11. The machine makes noise when it is on the standby status. Causation and recovery: a. The screws of tool carriage cover are loose. (Fasten the screws.) b. X or Y motor belt is loose. (Adjust the belt tension.) c.

  • Page 56: Firmware Update

    Version : 9.0 16. Media drops sometimes Causation and to recovery: a. Media is loaded askew. (Re-load the media.) b. The position of pinch roller is not on the top of drum. (Move the pinch roller to a right position.) c.
  • Page 57 Version : 9.0 Step3: Plug USB cable to computer, select a desired firmware and port on "Uploader.exe" dialogue box, then press “START” for uploading. Firmware and Uploader can be downloaded from GCC website: http://gccf.gcc.com.tw/distributor/login.aspx Step4: When firmware is updated completely, LCM will show as below, then “factory default” the machine Step 5: Machine off line and press “tool select”, use arrow key to select “Factory Default”...

  • Page 58: Chapter 6 Appendix

    Version : 9.0 Chapter 6 Appendix 6.1 Recommended Parts and Accessory List Following table shows the Part No. of each size of J5 series. Part No. Description J5-61 J5-61LX J5-101 J5-101LX J5-132 J5-132LX J5-183LX 241006740G Front Platen Extension 183 241006750G Back Platen Extension 183...
  • Page 59 Version : 9.0 Part No. Description J5-61 J5-61LX J5-101 J5-101LX J5-132 J5-132LX J5-183LX 241006760G Front platen extension 61 29001804G Motor Assembly Paper Sensor Assembly 29004856G Paper Sensor Assembly 29004854G Jaguar II ~ Jaguar V 29002348G Pinch roller Assembly 241006790G Rear platen extension 101 241006810G Rear platen extension 132 241006990G Rear platen extension 160 241006750G Rear platen extension 183...

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J5 lx series

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