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ENCAD CADJET 2 Service Manual

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®
CADJET
2
Service Manual
©
Copyright
1995 ENCAD
, Inc. All rights reserved.
®
ENCAD is a registered trademark of ENCAD, Inc.
Trademark application for CADJET 2 is pending.
HP-GL, HP-GL/2, and HP RTL are registered trademarks of Hewlett-
Packard Company.
AutoCAD is a registered trademark of AutoDesk, Inc.
Other trademarks and registered trademarks are the property of their
respective owners.
No part of this manual may be copied or distributed, transmitted,
transcribed, stored in a retrieval system, or translated in any human or
computing language, in any form or by any means, electronic,
mechanical, magnetic or otherwise, or disclosed to a third party without
the express written permission of ENCAD, Inc., 6059 Cornerstone
Court West, San Diego, CA 92121, U.S.A.
CADJET 2
i

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Summary of Contents for ENCAD CADJET 2

  • Page 1 ENCAD, Inc., 6059 Cornerstone Court West, San Diego, CA 92121, U.S.A. CADJET 2...
  • Page 2 Communications Commission (47 CFR 15.105 and 15.27) has specified that the following notice be brought to the attention of the users of the CADJET 2. FEDERAL COMMUNICATIONS COMMISSION RADIO FREQUENCY INTERFERENCE STATEMENT This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules.
  • Page 3 VDE Statement Hiermit wird bescheinigt, daß der CADJET 2 in Übereinstimmung mit den Bestimmungen der BMPT-AmstbIVfg 234/1991 funkentstört ist. Der vorschriftsmäßige Betrieb mancher Geräte (z.B. Meßsender) kann allergings gewissen Einschränkungen unterliegen. Beachten Sie deshalb die Hinweise in der Bedienungsanleitung. Dem Zentralamt für Zulassungen im Femmeldewesen wirde dan Inverkehrbringen dieses Gerätes angezeigt und die Berechtigung zur...
  • Page 4 CADJET 2 ink is nonhazardous, requiring no special disposal handling. It can be harmful if swallowed and should be kept away from children. To obtain a Material Safety Data Sheet, contact ENCAD, Inc. at: 6059 Cornerstone Court West San Diego, CA 92121-3734 (619) 452-4350 International users should contact their local dealer or distributor.
  • Page 5 PRINTING HISTORY 1st Edition September 18, 1995 CADJET 2...
  • Page 6 DISASSEMBLY/ASSEMBLY ............5-1 CHAPTER 6 CALIBRATION .................. 6-1 CHAPTER 7 REPLACEMENT PARTS LIST............7-1 APPENDIX A EMERGENCY FIRMWARE DOWNLOAD PROCEDURE ....A-1 APPENDIX B PRINTER FIRMWARE UPGRADE PROCEDURE ......B-1 APPENDIX C FINAL ASSEMBLY DRAWINGS............C-1 APPENDIX D SCHEMATICS...................D-1 CADJET 2...

  • Page 7: Table Of Contents

    Subject Headings ..............1-3 2.2.2 Figures and Tables .............. 1-3 2.2.3 Manual Conventions ............1-4 ENCAD Technical Support & Service ............... 1-5 Media Sizes and Plotting Areas................. 1-6 General Product Notes ..................1-9 Plotter Features ....................1-10 Plotter Specifications ..................1-13 Line Length Accuracy ..................
  • Page 8 3.12 Servo Motor ..................2-15 3.13 Parallel and Serial Ports ..............2-16 3.14 Keypad/Display.................. 2-17 3.15 Carriage Circuits ................2-18 3.16 LED’s, Beeper, and Fan ..............2-19 3.17 Dot Firing Sequence ................2-19 3.18 Schematic Diagrams................2-19 viii CADJET 2...
  • Page 9 Ink Cartridge Maintenance ................3-7 Initial Installation of Cartridges ............. 3-7 Cleaning Cartridges ................3-9 Other Causes of Misfiring..............3-11 Storage of Cartridges During Extended Periods of Inoperation ..3-12 Refilled Cartridges................3-12 Upper and Lower Rollers................. 3-13 CADJET 2...
  • Page 10 Drying Plot ..................4-20 Insert Media ..................4-20 Memory Full ..................4-20 RAM OK..................... 4-21 Checksum Error................. 4-21 Plotter Error ..................4-21 Ready to Replot ................. 4-21 Initialization Sequence ..................4-22 RS-422/RS-232 Error Messages..............4-23 10.0 RAM Error ....................... 4-24 CADJET 2...
  • Page 11 Interpreting the Cartridge Diagnostic Test ......4-50 11.10.3 Black Cartridge Flex Test........... 4-51 11.11 Memory Full ..................4-55 11.12 Plotter Hesitates During Plotting ............4-56 11.13 Plot Appearance is not as Expected ..........4-56 11.14 Plots are Cut Off................4-57 CADJET 2...
  • Page 12 Plotter is Noisy................... 4-58 11.16 User Parameters Not Saved When Power Is Cycled......4-58 11.17 Plotter Carriage Moves Erratically............4-59 11.18 Media Movement Erratic ..............4-61 11.19 LCD or LED Key(s) Inoperative ............4-62 11.20 Front Keypad Display Inoperative............4-64 CADJET 2...
  • Page 13 Replacing the Servo Motor..............5-24 Display Assembly .................... 5-25 Removing the Display Assembly............5-25 Reinstalling the Display Assembly ............. 5-26 Service Station Assembly................5-27 Removing the Service Station Assembly ........... 5-27 Reinstalling the Service Station Assembly ......... 5-29 CADJET 2 xiii...
  • Page 14 Reinstalling the Stepper Motor .......... 5-63 11.4 Reinstalling the Inner Platen Parts............. 5-64 11.5 Reassembly of Plotter After Reinstalling the Inner Platen Parts..5-67 12.0 Fixed Blade ..................... 5-70 12.1 Removing the Fixed Blade..............5-70 12.2 Reinstalling the Fixed Blade .............. 5-71 CADJET 2...
  • Page 15 13.0 Cutter Wheel ....................5-72 13.1 Removing the Cutter Wheel............... 5-72 13.2 Replacement of Cutter Wheel............5-74 14.0 Upper Roller Supports ..................5-75 14.1 Removing the Upper Roller Supports ..........5-76 14.2 Installing the Upper Roller Supports ..........5-81 CADJET 2...
  • Page 16 Adjustment of Upper Roller Supports ..........6-34 8.4.1 Visual Verification .............. 6-34 8.4.2 Observation of Paper Skew at Rear Media Alignment Mark................... 6-35 8.4.3 Observation of Paper Skew at Front Media Alignment Mark................... 6-37 8.4.4 Adjustment of the Mounting Screws ........6-38 CADJET 2...
  • Page 17 12.0 Cartridge Calibration - Horizontal and Vertical ..........6-53 12.1 Adjusting the Horizontal Head-to-Head Calibration......6-55 12.2 Adjusting the Vertical Head-to-Head Calibration........ 6-56 13.0 Color Deadband Calibration ................6-57 13.1 Adjusting the Color Deadband Value ..........6-58 14.0 Line Quality Plot (Computer) Test ..............6-60 CADJET 2 xvii...
  • Page 18 Table of Contents CHAPTER 7 REPLACEMENT PARTS LIST A complete listing (numerical, alphabetical, and illustrated alphabetical) of all field replaceable parts and assemblies for the CADJET 2 Color Inkjet Plotters. Introduction ....................... 7-1 Numerical Listing....................7-2 Parts Used in both D-Size and E-Size (Numerical)......7-2 D-Size Unique Parts (Numerical) ............
  • Page 19 Flash EPROM. Emergency Firmware Download Procedure..............A-1 APPENDIX B PRINTER FIRMWARE UPGRADE PROCEDURE Procedure for upgrading a CADJET 2 Color Inkjet Plotter to the newest version of firmware (Flash EPROM is not blank or corrupt). Printer Firmware Upgrade Procedure ................B-1 APPENDIX C...
  • Page 20 Parallel and Serial Loop Back Tests ..........4-30 Figure 4.4 Tri-Color Cartridge Flex ..............4-46 Figure 4.5 Sample of Black Cartridge Diagnostics Test........4-50 Figure 4.6 Black Cartridge Failure Test Setups ..........4-51 Figure 4.7 Black Cartridge Flex Dimple Pattern ..........4-53 CADJET 2...
  • Page 21 CHAPTER 5 DISASSEMBLY/ASSEMBLY Number Title Page Figure 5.1 CADJET 2 Hardware Kit Assembly............5-5 Figure 5.2 CADJET 2 Final Assembly Tools............5-6 Figure 5.3 Preparing the Plotter for Shipping ............5-8 Figure 5.4 Preparing the Plotter for Shipping - Alternate Method ....... 5-10 Figure 5.5...
  • Page 22 Motion of Rollers and Adjustment of Mounting Screws ..... 6-38 Figure 6.13 Deadband Alignment ................. 6-47 Figure 6.14 Vertical Lines (All) ................6-51 Figure 6.15 Vertical Lines (One) ................6-52 Figure 6.16 CADJET 2 Calibration Worksheet ............. 6-62 xxii CADJET 2...
  • Page 23 Assy, Exhaust ............P/N 204384 ..7-12 Figure 7.7 Assy, Fan .............P/N 203443 ..7-12 Figure 7.8 Assy, Hardware Kit CADJET 2, Service ....P/N 205188 ..7-12 Figure 7.9 Assy, Idler ............P/N 203345-1 ..7-12 Figure 7.10 Assy, Keypad Top ..........P/N 203488 ..7-13 Figure 7.11...
  • Page 24 Belt, Ribbed ............P/N 203903 ..7-28 Figure 7.50 Cable, Trailing............P/N 203778 ..7-28 Figure 7.51 Platen, Machined ..........P/N 204848 ..7-28 Figure 7.52 Slide Shaft ............P/N 204007-31 ..7-29 Figure 7.53 Angle, Trailing Cable ........... P/N 203800-3 ..7-30 xxiv CADJET 2...
  • Page 25 APPENDIX A EMERGENCY FIRMWARE DOWNLOAD PROCEDURE Number Title Page Figure A.1 Cable, RS422 Mini-DIN8..............A-3 APPENDIX C FINAL ASSEMBLY DRAWINGS Number Title Page Figure C.1 CADJET 2 D-Size Final Assembly............C-6 Figure C.2 CADJET 2 E-Size Final Assembly ............C-7 CADJET 2...
  • Page 26 Table 4.5 Decision Logic Table Five (DLT 5)............. 4-42 Table 4.6 Black Cartridge Flex Test Matrix............4-54 CHAPTER 6 CALIBRATION Number Title Page Table 6.1 Carriage Height Settings Chart ............6-16 Table 6.2 Potentiometer Adjustment Flowchart ..........6-25 xxvi CADJET 2...

  • Page 27: Introduction

    The CADJET 2 supports both pre-cut and roll media, automatically determining the media size and setting the hardclip limits accordingly. The CADJET 2 uses both a serial interface and the Centronics parallel interface. It understands commands sent from the host computer in several forms, including HP-GL*, HP-GL/2*, and HP-RTL.

  • Page 28: Overview

    These characters are part of the plotter's permanent memory. Related Publications The following publications contain additional information which may be useful in servicing the ENCAD, Inc. CADJET 2 Color Inkjet Plotter. ENCAD, Inc. CADJET 2 User's Guide, P/N 205377 ENCAD, Inc. CADJET 2...

  • Page 29: Features Of This Service Manual

    Figures and Tables Figures are used to clarify procedures. They are for illustrative purposes only and may not necessarily be drawn to scale. Figures and Tables are easily located and cross-referenced, and are listed in the Table of Contents. CADJET 2...

  • Page 30: Manual Conventions

    WARNING possible personal injury to the service person. Warnings are indicated by the “Warning” symbol at the left. The warning text is in bold italics type and is enclosed in a box. CADJET 2...

  • Page 31: Encad Technical Support & Service

    General Information ENCAD Technical Support & Service ENCAD offers full technical support and service for its various products. If you are unable to find the answer to your question in either the User’s Guide, Service Manual, or other related publications, contact our Technical Support and Service Department’s Help Desk.

  • Page 32: Media Sizes And Plotting Areas

    The Expanded setting for the Margins option expands the NOTE plot area and decreases the margins. The current maximum plotting area may be viewed in the CADJET 2 keypad display by performing the following steps: 1. Initialize unit and load paper.
  • Page 33 707 x 1000 mm 677 x 970 mm 697 x 990 mm SPECIAL 30.0” x 42.0” 28.8” x 40.8” 29.6” x 41.6” 26.0” x 38.0” 24.8” x 36.8” 25.6” x 37.6” 27.0” x 39.0” 25.8” x 37.8” 26.6” x 38.6” CADJET 2...
  • Page 34 707 x 1000 mm 677 x 950 mm 697 x 960 mm SPECIAL 30.0” x 42.0” 28.8” x 40.0” 29.6” x 40.4” 26.0” x 38.0” 24.8” x 36.0” 25.6” x 36.4” 27.0” x 39.0” 25.8” x 37.0” 26.6” x 37.4” CADJET 2...

  • Page 35: General Product Notes

    SLIDE SHAFT - Dry the Slide Shaft completely after cleaning it with alcohol. Alcohol contact to the Carriage Assembly bushings will cause damage. START UP - If the CADJET 2 doesn’t power-up, it must be turned off immediately to eliminate any damage until the problem can be resolved.

  • Page 36: Plotter Features

    Figure Chapter 1 .2 is changing. Drawings of the new stand and basket were not available at the time of publication. The major features of the CADJET 2 plotter are illustrated and described in Figure Chapter 1 .1, Figure Chapter 1 .2, and Figure Chapter 1 .3.
  • Page 37 General Information Figure Chapter 1 .1: Front View -- Cover Closed CADJET 2 1-11...
  • Page 38 General Information Figure Chapter 1 .2: Front View -- Cover Open 1-12 CADJET 2...
  • Page 39 Figure Chapter 1 .3: Back View 1. Centronics Parallel Port (J2) 2. RS-422/423 Serial Port/Apple Talk (J3) 3. Power Input Plug and ON/OFF Switch 4. ID Label 5. Left Rollguide 6. Right Rollguide 7. Rear Media Alignment Mark CADJET 2 1-13...

  • Page 40: Plotter Specifications

    20 - 80% RH, Non-condensing Cotton based: Inkjet Vellum Storage Environment: Polyester based: Inkjet Transparency Film -40° to 140°F (-40° to 60°C) (4 mil) and Inkjet Drafting 10 - 80% RH, Non-condensing Matte Film (4 mil) Rasterization: Internal rasterizer 1-14 CADJET 2...

  • Page 41: Line Length Accuracy

    General Information Line Length Accuracy The following information for the CADJET 2 clarifies the amount of acceptable variation for plotting accurately. See Figure Chapter 1 .4. Figure Chapter 1 .4: Line Length Accuracy is to be within ± 0.2% of the length 1.

  • Page 42: Skew

    EQUAL TO: 0.2% of L + 0.2% of L 0.4% of (L EXAMPLE: If: = 60cm = 80cm Then: L should = L = 100cm Actual permissible skew ( L ) = .4% x 100cm = .4cm or 0.157 inches. 1-16 CADJET 2...
  • Page 43 Note: 1. This method is the only method used to specify skew. Other NOTE geometrical constructs may yield different results. 2. Actual output is a function of the combined line length and skew errors and typically is a straight polygon whose four sides are not necessarily equal. CADJET 2 1-17...

  • Page 44: Acronyms And Abbreviations

    32 ft/s Output - grams UART - Universal Asynchronous - Ground Receiver/Transmitter HP-GL - Hewlett-Packard Graphics - Volts Language (older standard) - Volts Alternating Current HP-GL/2 - Hewlett-Packard (standard) - Volt Direct Current Graphics Language - Watts 1-18 CADJET 2...

  • Page 45: Glossary

    Computer circuits used to transmit data from one unit to another on a printed circuit board. Computer Aided Drafting. A computer system or software designed to generate drawings on hardcopy media. CALIBRATION The procedures for adjusting the ink cartridge alignment, line length accuracy, and deadband. CADJET 2 1-19...
  • Page 46 A device used to graphically show data. Dots per inch, the number of dots the plotter lays down in an inch. DUTY CYCLE One complete cycle of time to complete a printing command. EMULATE To equal in quality or quantity. 1-20 CADJET 2...
  • Page 47 INTERFACE CABLE The cable used to connect the plotter to the computer. CADJET 2 uses a serial or parallel interface cable. I/O ERROR A data transmission error between the computer and the plotter (for example, mismatched interfacing conditions such as baud rate and parity).
  • Page 48 A scaling point used by the plotter that specifies the location of the plot's lower left corner. On the CADJET 2, this point will either be NORMAL or MAX. A scaling point used by the plotter that specifies the location of the plot's upper right corner.
  • Page 49 An interface type which uses a single data line to transfer all data bits sequentially between devices. Slower than a parallel interface. SERVO A self-correcting closed loop electromechanical system that compares an output signal to an input or feedback signal. CADJET 2 1-23...
  • Page 50 Cartridges on the plotter fire ink on the media during right to left movement only. VECTOR A graphic created by geometric lines. HP-GL and HP-GL/2 files are vector files. VELOCITY The time-rate of linear motion in a given direction. Commonly referred to as speed. 1-24 CADJET 2...
  • Page 51 2.2 Features of this Service Manual..............1-3 2.2.1 Subject Headings ..................1-3 2.2.2 Figures and Tables................... 1-3 2.2.3 Manual Conventions................. 1-4 3.0 ENCAD Technical Support & Service..............1-5 4.0 Media Sizes and Plotting Areas................1-6 5.0 General Product Notes ..................1-9 6.0 Plotter Features ....................1-10 7.0 Plotter Specifications ..................

  • Page 52: Introduction

    This chapter explains the mechanical and electrical theory of the operation of the CADJET 2 Color Inkjet plotter. The CADJET 2 is a 68340 microprocessor-based digital plotter that receives plotting instructions from a host computer through the RS-422/423 serial interface or the Centronics parallel interface.

  • Page 53: Mechanical Operation

    The Stepper and Servo Motors are controlled from the main printed circuit assembly by the microprocessor, which also supplies to the Carriage the signals necessary to cause the ink cartridge nozzles to fire the desired colors of ink onto the media. CADJET 2...

  • Page 54: Electrical Operation

    Theory of Operation Electrical Operation Circuit Assemblies Four circuit assemblies are contained in the CADJET 2 plotter: the Main Printed Circuit Board (in the right cover assembly), the front panel circuits (in the Keypad Assembly), and the Carriage Flex Assembly and the Carriage Rigid Board (in the moveable Carriage Assembly).

  • Page 55: Carriage Printed Circuit Assembly (Carriage Pcb)

    Theory of Operation 3.1.3 Carriage Printed Circuit Assembly (Carriage PCB) The Carriage Printed Circuit Assembly (Carriage PCB) contains five features: 1. Registers 2. Demultiplexers 3. Ink Nozzle Drivers (Inkjet Driver Circuit) 4. Linear Encoder 5. Paper Sensor (separate board) CADJET 2...

  • Page 56: Block Diagram

    Theory of Operation Block Diagram Figure Chapter 2 .1 illustrates the major functional areas of the plotter. Major control and data paths are shown. Figure Chapter 2 .1: Major Functional Areas of the Plotter CADJET 2...

  • Page 57: Power Supply

    Power Supply An internal UL recognized switching power module supplies power for the CADJET 2. It provides a constant 5Vdc and 24Vdc output from input voltage in the range of 100~240 Vac. A power switch mounted on the back left end of the platen turns the power on and off. The 24V...

  • Page 58: Microprocessor

    The phase-locked-loop (PLL) frequency synthesizer generates the 16.777MHz system clock from a 32768Hz crystal reference. The chip select generator is programmed to generate chip selects at the appropriate addresses, with the appropriate data size (byte, word) and with the appropriate number of wait states. CADJET 2...

  • Page 59: Start-Up Sequence

    7. RAM size is determined, and all RAM is tested. Status information is shown on the display during the test. “Memory OK” is displayed at the end of the test. 8. The code in the EPROM is copied to RAM, and the program begins executing out of RAM. CADJET 2...

  • Page 60: Memory

    EEPROM is an Electrically Erasable, Programmable, Read Only Memory which provides storage for calibration constants and user configuration data entered from the front panel keys. Maximum usable memory is as follows: RAM = 68 MB Flash EPROM = 1 MB EEPROM = 1KB CADJET 2...

  • Page 61: Flash Eprom

    Mode only works through the serial port and requires a special host utility. It is a mode that allows some registers and RAM to be written to, based upon commands sent through the serial port. The special host utility provides user instructions as it runs. 2-10 CADJET 2...

  • Page 62: Ram

    Cover Assembly to install additional memory (see Chapter 5, Section 4.5 for installation procedures). Refer to the User’s Guide for specifications and requirements. EEPROM An 8K bit serial non-volatile EEPROM stores calibration and configuration information. It retains data while the unit is off. CADJET 2 2-11...

  • Page 63: Gate Array

    ROM. This type of gate array allows for the flexibility of upgrading the logic by upgrading the system software. signal is held low by the gate array and all its outputs are in XDONE a high impedance state until its programming is complete. 2-12 CADJET 2...

  • Page 64: Stepper Motor

    The other type of circuit is a bipolar chopper drive which is commonly used for driving stepper and servo motors. In both cases, the circuit has the additional feature that the reference varies with time so that a waveform is generated rather than a steady state signal. CADJET 2 2-13...
  • Page 65 4. Power driver An H-bridge allows the supply voltage to be applied across the winding in either polarity to drive the current to the desired value. Figure Chapter 2 .3: Stepper Motor 2-14 CADJET 2...

  • Page 66: Servo Motor

    Instead, it is read during the servo interrupt and its value compared with that from the previous interrupt. This difference is used to update the absolute position value in the software. CADJET 2 2-15...

  • Page 67: Parallel And Serial Ports

    1MHz clock for high speed serial communications with a Macintosh. The serial port is compatible with RS232 devices when an appropriate adapter cable is used. This cable is available from ENCAD. Please refer to Chapter 7 of this Service Manual for the part number. 2-16...

  • Page 68: Keypad/Display

    (up arrow), and backward (down arrow). The data from the four keys and to the display is encoded on the second serial port of the microprocessor. The display provides information to the user on plotter status. CADJET 2 2-17...

  • Page 69: Carriage Circuits

    Theory of Operation 3.15 Carriage Circuits Figure Chapter 2 .7: Carriage Circuits The Carriage contains the optical encoder for horizontal position sensing, a Paper Sensor, and the logic and drive circuitry for firing the ink jets. 2-18 CADJET 2...

  • Page 70: Leds, Beeper, And Fan

    3.18 Schematic Diagrams Engineering schematic diagrams for the Main PCB Assembly, Keypad PCB Assembly, Carriage PCB Assembly, and the Flex Circuit are located in Appendix D. CADJET 2 2-19...
  • Page 71 3.12 Servo Motor ....................2-15 3.13 Parallel and Serial Ports ................2-16 3.14 Keypad/Display................... 2-17 3.15 Carriage Circuits ..................2-18 3.16 LEDs, Beeper, and Fan ................2-19 3.17 Dot Firing Sequence ................... 2-19 3.18 Schematic Diagrams................... 2-19 2-20 CADJET 2...
  • Page 72 FIGURE 2.1: MAJOR FUNCTIONAL AREAS OF THE PLOTTER ......2-5 FIGURE 2.2: GATE ARRAY ..................2-12 FIGURE 2.3: STEPPER MOTOR ................2-14 FIGURE 2.4: SERVO MOTOR.................. 2-15 FIGURE 2.5: PARALLEL AND SERIAL PORTS............2-16 FIGURE 2.6: KEYPAD DISPLAY ................2-17 FIGURE 2.7: CARRIAGE CIRCUITS ................ 2-18 CADJET 2 2-21...

  • Page 73: Introduction

    Chapter 3 MAINTENANCE Introduction This chapter contains general maintenance and cleaning instructions for the CADJET 2 plotter. Refer to Chapter 4 for troubleshooting information. Always disconnect the power cord and the interface cables before cleaning the plotter. An electrical shock hazard may WARNING result if these procedures are not followed.

  • Page 74: External Cleaning

    Clean the exterior surface of the plotter with a soft, damp cloth. For more persistent stains, a small amount of liquid cleaner may be used. Cleaning intervals are determined by the environment in which the plotter is used. CADJET 2...

  • Page 75: Slide Shaft Maintenance

    2. Disconnect the power cord and interface cables from the plotter. 3. Raise the plotter top cover. 4. Moisten a clean cloth or paper wipe with isopropyl alcohol. 5. Wipe the length of the Slide Shaft with the moistened cloth. CADJET 2...
  • Page 76 If the Carriage Assembly does not move freely, or if there is Carriage vibration and/or any noise, clean the Slide Shaft again and repeat the PRIME plot. If the problem is not resolved, refer to Chapter 4, Section 11.17 “Plotter Carriage Moves Erratically” for additional troubleshooting steps. CADJET 2...

  • Page 77: Service Station Maintenance

    Also clean all the excess ink out of the reservoirs and out of the bottom of the Service Station. 5. Remove all moisture from the seals and the wiper with a dry swab. 6. Reconnect the power cord. CADJET 2...

  • Page 78: Encoder Strip Maintenance

    To clean the Encoder Strip, use a Q-Tip which has been slightly dampened with isopropyl alcohol and wipe along the length of the Encoder Strip on both sides of the Encoder Strip. CADJET 2...

  • Page 79: Ink Cartridge Maintenance

    3. Lower the Cartridge straight down into the Cartridge Cover and firmly press down and forward so that the Cartridge moves forward slightly. Push the lever up until it stops. When installing the Tri-Color Cartridge, press firmly on its top as you close the lever. CADJET 2...
  • Page 80 Section 6.2. You may also need to refer to Chapter 4, Section 11.7 “Ink Cartridge Problems.” 5. After a satisfactory PRIME plot is obtained, perform the Cartridge Calibration. See Chapter 6, Section 12.0 of this service manual. CADJET 2...

  • Page 81: Cleaning Cartridges

    Hold the bottom end (nozzle plate end) of the Cartridge in the water. The green end of the Tri-Color Cartridge should never be CAUTION inserted in the ultrasonic cleaner. Do not allow the Cartridge nozzle plate to rest on the bottom of the ultrasonic cleaner. CADJET 2...
  • Page 82 Cartridge Calibration. See Chapter 6, Section 12.0 of this service manual. 4. If priming and the above maintenance procedures fail to unclog a Cartridge, the Cartridge may be out of ink. Note: Also see Chapter 4, Section 11.7 “Ink Cartridge Problems”. NOTE 3-10 CADJET 2...

  • Page 83: Other Causes Of Misfiring

    Cartridge. 3. Buildup of ink in the Service Clean the Service Station. See Section 4.0. Station. 4. Cartridge damage (due If damaged, replace with a new Cartridge. dropping, improper storage, or tapping Cartridge on a hard surface). CADJET 2 3-11...

  • Page 84: Storage Of Cartridges During Extended Periods Of Inoperation

    They can also be stored in a refrigerator. 5. After stored Cartridges are reinstalled, follow the procedures above in Section 6.1 “Initial Installation of Cartridge.” Refilled Cartridges ENCAD does not recommend or support the use of refilled Cartridges. 3-12 CADJET 2...

  • Page 85: Upper And Lower Rollers

    4. Manually turn the 96 Teeth Gear on the Lower Drive Assembly (the gear is near the Service Station) as you hold a lint-free cloth that has been moistened with distilled water against the rollers. Do not allow the cloth to slip between the Upper and Lower Rollers. CADJET 2 3-13...
  • Page 86 6.1 Initial Installation of Cartridges ..............3-7 6.2 Cleaning Cartridges ..................3-9 6.3 Other Causes of Misfiring................3-11 6.4 Storage of Cartridges During Extended Periods of Inoperation ....3-12 6.5 Refilled Cartridges..................3-12 7.0 Upper and Lower Rollers.................. 3-13 3-14 CADJET 2...

  • Page 87: Introduction

    This chapter contains the CADJET 2 Decision Logic Tables (DLT’s), Service Menu information, instructions for using the Front Keypad and Side Panel keys, and the actions to take when the operation of the plotter does not appear to be normal.

  • Page 88: Decision Logic Tables

    Use the following hypothetical condition to familiarize yourself with the DLTs. CONDITION The media does not load. The plotter is a CADJET 2 and is receiving power. PROCEDURE 1. After reviewing all information at the top of Table Chapter 4 .1, DLT 1, it has been determined that DLT 1 is the proper table to use.
  • Page 89 6. If none of the actions corrects the condition, the last action that will be provided is “CALL ENCAD TECHNICAL SUPPORT.” This does not necessarily mean that you have performed an action incorrectly or that you have misdiagnosed the problem;...
  • Page 90 REPLACE MPCB CHECK STEPPER MOTOR CONNECTOR (JP5) REPLACE STEPPER MOTOR REPLACE MPCB RESEAT FAN CONNECTOR (J5) REPLACE FAN ASSEMBLY REPLACE MPCB CALL ENCAD TECHNICAL SUPPORT (see Chapter 1, Section 3.0) GO TO DECISION LOGIC TABLE 2 (DLT 2) CADJET 2...
  • Page 91 CLEAN AND RESEAT ANY EXTRA SIMMS TEST AND REPLACE ANY EXTRA SIMMS REPLACE SERVO MOTOR REPLACE MPCB VERIFY INPUT POWER QUALITY CHECK AND REPLACE INPUT XFORMER AS REQUIRED REPLACE MPCB POWER OFF AND CALL ENCAD TECHNICAL SUPPORT (see Chapter 1, Section 3.0) CADJET 2...
  • Page 92 WARNING: OBSERVE ALL STANDARD STATIC AND SAFETY PRECAUTIONS REFERENCES: CALIBRATION PROCEDURES (USER’S GUIDE & SERVICE MANUAL) BEGIN WITH: DECISION LOGIC TABLE TWO (DLT 2) OR PLOTTING ERRORS ASSUMPTIONS: 1. CADJET 2 SERIES PLOTTER 2. POWER ON SEQUENCE OK COLUMN NUMBERS CONDITIONS...
  • Page 93 TRY LOWER BAUD RATE. CHECK FOR EXCESSIVE CABLE LENGTH. LINE DRIVER/LINE RECEIVER DEFECTIVE. RS422/232 SERIAL XTDA/XRDA FAILURE. (OCCURS ONLY WITH A LOOP BACK CONNECTOR IN TEST.) RS422/232 DTR OR CTS TEST FAILURE. (OCCURS ONLY WITH A LOOP BACK CONNECTOR IN TEST.) CADJET 2...

  • Page 94: Service Menu

    You should have received a copy of the Service Menu chart with this Service Manual. (If you did not receive the chart, please call the ENCAD Help Desk at the number given in Chapter 1, Section 3.0.) It contains all the necessary instructions for navigating the Service Menu.

  • Page 95: Service Menu Description

    Consult your copy of the Service Menu chart for instructions NOTE for navigating the Service Menu. If you did not receive the chart, please call the ENCAD Help Desk at the number given in Chapter 1, Section 3.0. The Service Menu begins at the following display: UTILITIES SERVICE→...

  • Page 96: Service Information

    Shows the number of bytes available. XXXXXXXX BYTES Shows buffer memory bank and raster memory MEMORY CONFIG available. I/O=128K RAS=3M Shows the Emulation Language in use. EMULATE LANGUAGE CADJET 2 is programmed for HP-GL and HP-GL/2. HPGL2 4-10 CADJET 2...
  • Page 97 MONO 300X300, GRAY 300X300, COLOR COLOR 300X300, MONO 600X600, and GRAY 600X600. Shows the current speed at which the ink is fired onto FIRING RATE the media in 100 Hz increments from 3000 Hz to 5000 10,000 kHz. CADJET 2 4-11...
  • Page 98 PWM was reached before the unit shuts down. The third number is usually at zero unless a function is being performed (such as cutting the paper) during which the shutdown criteria are disabled. 4-12 CADJET 2...

  • Page 99: Information Print Settings

    ERROR/CMD/POS command and Encoder position where the error occurred. If you have an unexplained error and need to call ENCAD’s Technical Support department, this display can give the technician more information to enable the error to be diagnosed. ON TIME Displays how long the plotter has been turned on.

  • Page 100: Service Diagnostics

    This option tests the Cartridges by printing a test DIAGNOSTICS pattern (PRIME). CARTRIDGE This option tests the Carriage vibration by printing a DIAGNOSTICS test pattern which consists of five sets of three CARRIAGE VIBRATE parallel lines. 4-14 CADJET 2...
  • Page 101 This option causes the speaker to sound for one DIAGNOSTICS second. SPEAKER This test gives the option of testing the Servo Motor at DIAGNOSTICS either slow or fast speed. You can enter the number SERVO MOTOR cycles for the Servo Motor test (500 is recommended). CADJET 2 4-15...
  • Page 102 This test feeds the paper (media) forward a specific DIAGNOSTICS number of inches (do not exceed 5 inches) in either PAPER MOTOR slow or fast speed. This option will start the Fan. The Fan will run until DIAGNOSTICS the SELECT key is pressed. 4-16 CADJET 2...

  • Page 103: Service Calibration

    16 regions in uni-directional mode. VERT LINES(ONE) This option prints two 1-1/2” vertical lines within each CALIBRATION of the 16 regions in bi-directional mode. VERT LINES(ALL) This option prints 1 line of deadband across all 16 CALIBRATION regions. SLOW DEADBAND CADJET 2 4-17...

  • Page 104: Led Keys

    Fires the Cartridges to help clear the inkjets. Cuts roll media. Feed Media Interacts with display and arrow keys to move media forward or backward. Load Loads and positions the media for printing. Figure Chapter 4 .1: LED Keys 4-18 CADJET 2...

  • Page 105: Lcd Keypad

    ARROW KEYS to scroll through the choices. Press SELECT to save your choice (blinking stops). Submenu items with an arrow ( ) have additional submenus. MENU MAIN MENU PRINT MODE SELECT Figure Chapter 4 .2: LCD Keypad CADJET 2 4-19...

  • Page 106: Keypad Messages

    If this does not resolve the problem, increase the buffer memory by upgrading the SIMMS module to a larger size (maximum of 64MB). Refer to the CADJET 2 User's Guide for the acceptable sizes, manufacturers, and installation procedures. 4-20...

  • Page 107: Ram Ok

    RAM is fully seated. Incompatible SIMMS may also cause this problem. See the CADJET 2 User’s Guide for acceptable SIMMS sizes and the replacement procedure. Checksum Error A Checksum error during the initialization sequence is CHECKSUM ERROR an indication of a probable ROM error.

  • Page 108: Initialization Sequence

    Decision Logic Tables in Section 2.2 of this chapter for corrective action. When the plotter is not used for seven minutes, it will go into “sleep” mode. Pressing any key or sending data to the plotter will wake it up. 4-22 CADJET 2...

  • Page 109: Rs-422/Rs-232 Error Messages

    ERR 18 I/O error indeterminate. ERR 20 RS-422/RS-232 serial xtda/xrda failure. (Occurs only with a loop back connector in test.) ERR 21 RS-422/RS-232 DTR or CTS test failure. (Occurs only with a loop back connector in test.) CADJET 2 4-23...

  • Page 110: Ram Error

    The SIMM type needs to meet parity by 8 or 9 bits and the speed needs to be 70 nanoseconds or faster. See the CADJET 2 User’s Guide for information concerning the acceptable SIMMS sizes and the replacement procedure in Chapter 5, Section 4.5 of this service manual.

  • Page 111: Operation Problems

    11.0 Operation Problems The information in this section will help to solve a variety of operational problems which may occur with the CADJET 2 plotter. Follow the procedures carefully. Establish a logical procedure for troubleshooting by referencing the Troubleshooting Chart in Section 2.0 of this chapter.

  • Page 112: Plotter Slow To Initialize

    2. there may be a defective Flash EPROM on the Main Printed Circuit Board. Because the Flash EPROM is soldered to the MPCB, it is necessary to replace the MPCB. Refer to Chapter 5, Section 4.3 of this manual for the removal and replacement procedures for the MPCB. 4-26 CADJET 2...

  • Page 113: Plotter Will Not Plot

    Assembly or at the Main PCB. See Chapter 5, Section 8.6 for correct installation procedures. 3. Make sure the system is properly initialized. See Section 8.0 in this chapter. You may need to perform the interface test described in Section 11.3.1 of this chapter. CADJET 2 4-27...
  • Page 114 If the plot fails again, have the interface cable and computer’s interface card tested. 5. Run the Demo Plot from MAIN MENU DEMO PLOT on the plotter. If the plot runs correctly, the problem is not in the plotter. 4-28 CADJET 2...

  • Page 115: Parallel Interface And Serial Interface Tests

    DIAGNOSTICS SERIAL PORT display, or press the DOWN ARROW twice to go to the DIAGNOSTICS PARALLEL PORT display. (Refer to the CADJET 2 Service Menu chart if necessary.) 4. At either the DIAGNOSTICS SERIAL PORT display or the DIAGNOSTICS PARALLEL PORT display, press SELECT and...
  • Page 116 Troubleshooting Figure Chapter 4 .3: Parallel and Serial Loop Back Tests 4-30 CADJET 2...

  • Page 117: No Movement In The Carriage Axis

    If YES: Make sure that nothing is blocking the movement of the Carriage Assembly. Turn off the plotter and move the Carriage Assembly from left to right to make sure it moves freely. CADJET 2 4-31...
  • Page 118 6) There may be a loose bushing on the Carriage Assembly. See Chapter 5, Section 8.0 for instructions on removing the Carriage Assembly so this can be checked. 7) The Carriage Height may not be correct. See Chapter 6, Section 6.2. 4-32 CADJET 2...
  • Page 119 See Chapter 5, Section 4.0. 4) If the problem is not solved after both the Servo Motor and the MPCB are replaced, replace the Stabilizer Bracket Assembly, which contains the Encoder Strip. See Chapter 5, Section 10.0. CADJET 2 4-33...

  • Page 120: Media Problems

    Press SELECT to save the change (the equals sign (=) will stop blinking). Align a sheet of media on the Platen and press the LOAD button. The media will be sized and pulled to the back of the plotter until it reaches the starting position on the Platen. 4-34 CADJET 2...
  • Page 121 Carriage Assembly may sense the preprinted border as the edge of the media if the preprinted border is too wide. Use the Manual Load function (see Chapter 2 in the CADJET 2 User’s Guide for instructions). 3. Certain media types may cause difficulty in loading.

  • Page 122: Media Feeds Out Of Plotter When Plot Is Completed

    The Upper Roller Supports which hold the media have become dirty, misaligned or excessively worn. Refer to the alignment procedures in Chapter 6, Sections 7.0 and 8.0 and/or to the removal and replacement procedures in Chapter 5, Section 14.0 of this manual. 4-36 CADJET 2...

  • Page 123: Loaded Media Not Detected, Media Size Not Detected, Or Plotter Has Incorrect Plot Area

    In some cases, the CADJET 2 will not sense or correctly size certain media, whether roll-feed or sheet media. If this happens, use the Manual Media Loading feature in the Advanced menus.

  • Page 124: Keypad Display Shows Load Media Message When Rollfeed Media Is Loaded

    PRINTER SETUP ROLL=ON Press SELECT to save the change (the equals sign (=) will stop blinking). Align the rollfeed media on the Platen and press the LOAD button. 4-38 CADJET 2...

  • Page 125: Loud Grinding Noise When Media Loads

    For the ROM test, a read-out of RESULT=ERROR could indicate: that the Flash EPROM has failed. Replace the MPCB. See Chapter 5, Section 4.3 for the procedure. the socket on the MPCB is defective. Replace the MPCB. See Chapter 5, Section 4.3 for the procedure. CADJET 2 4-39...
  • Page 126 See the User’s Manual for information concerning the acceptable SIMMS sizes. See Chapter 5, Section 4.5 for the replacement procedure. The socket on the MPCB may be defective. Replace the MPCB. See Chapter 5, Section 4.3 for the procedure. 4-40 CADJET 2...

  • Page 127: Media Cutting Problems

    If the cut edges of the media are ragged, or the cut is not complete across the media, you need to replace the Cutter Wheel. This part is available from your local authorized dealer, or directly from ENCAD. CADJET 2...

  • Page 128: Ink Cartridge Problems

    REPLACE CARRIAGE; REPEAT PRIME. REFER TO CHAPTER 5, SECTION 8.0 for removal and installation of Carriage Assembly. REPLACE MPCB; REPEAT PRIME. REFER TO CHAPTER 5, SECTION 4.3 for removal of the MPCB. CALL ENCAD TECHNICAL SUPPORT (see Chapter 1, Section 3.0). 4-42 CADJET 2...

  • Page 129: Dried Up Cartridge

    After the Carriage Height has been adjusted, install a new Cartridge and run the PRIME plot. You may need to repeat the PRIME two or three times before a satisfactory plot is obtained. See Section 11.8 below for information about evaluating the PRIME plot. CADJET 2 4-43...

  • Page 130: Determining Ink Level

    If the Ink Level Estimator option is being used: You can check to see which Cartridge is low by using the Current Ink Level menu. See Chapter 4 of the CADJET 2 User’s Guide for information about this feature. If necessary, replace the Cartridge, load media, and run the PRIME plot.

  • Page 131: Prime Plot

    Cartridges. See Chapter 3, Section 6.2 for cleaning procedures. If you suspect that an ink cartridge has become clogged during printing, press PRIME. The Cartridges will fire into the Service Station, which will purge the jets. Printing will resume after this purging. CADJET 2 4-45...

  • Page 132: Tri-Color Cartridge Failure Test Procedure

    34 thru 37, 42 thru 50 36 OHM If the resistance measured is 0 OHM or OPEN, the Cartridge jet resistor is defective and the Cartridge must be replaced. An incorrect resistance reading will affect print quality. The Cartridge should be replaced. 4-46 CADJET 2...

  • Page 133: Black Cartridge Failure Test Procedure

    (DLT 5) in this chapter for cleaning procedures. If you perform the cleaning procedures listed in the Table Chapter 4 .5 and arrive at Action Number 6 “PERFORM ‘Cartridge Failure Test Procedure,’ ” you will need to perform the procedures given in this section. CADJET 2 4-47...

  • Page 134: Running The Cartridge Diagnostic Test

    3. Press SELECT once. The display will read: UTILITIES CALIBRATION→ 4. Press the DOWN ARROW once. If the display reads: UTILITIES OPTIONS=ADVANCED press the UP ARROW twice. The display will read: UTILITIES SERVICE→ Go to Step 5. 4-48 CADJET 2...
  • Page 135 The unit will now plot the Cartridge Diagnostics Test. Press MENU three times and the DOWN ARROW once to return to the MAIN MENU, PRINT MODE display. Advance the media and press the CUT key. To interpret this plot, see Section 11.10.2 below. CADJET 2 4-49...

  • Page 136: Interpreting The Cartridge Diagnostic Test

    If any jets are not firing, the section of the diagonal line for that jet will be missing. If any jets are not firing (that is, there are gaps in the diagonal line), go on to Section 11.10.3 “Black Cartridge Flex Test” below. 4-50 CADJET 2...

  • Page 137: Black Cartridge Flex Test

    Cartridge Cartridge 510Ω 30Ω 30Ω Ω 10KΩ 10KΩ 9V Battery 9V Battery Setup with LED (no Ohm Meter) Setup with Ohm Meter (no LED) Figure Chapter 4 .6: Black Cartridge Failure Test Setups CADJET 2 4-51...
  • Page 138 6. If the jet(s) tested shows the proper result, you can assume that the flex is OK. In that case, return to Table Chapter 4 .5 in this chapter for further instructions, beginning with “REPLACE CARTRIDGE IF NECESSARY” (in Action Number 6). 4-52 CADJET 2...
  • Page 139 Troubleshooting Figure Chapter 4 .7: Black Cartridge Flex Dimple Pattern CADJET 2 4-53...
  • Page 140 Troubleshooting Table Chapter 4 .6: Black Cartridge Flex Test Matrix 4-54 CADJET 2...

  • Page 141: Memory Full

    Press the UP ARROW 4 times to go to MAIN MENU PRINTER SETUP Press SELECT. Press the UP ARROW twice to go to PRINTER SETUP MEMORY CONFIG→ Press SELECT to go to MEMORY CONFIG I/0 = 128K RAS=1M CADJET 2 4-55...

  • Page 142: Plotter Hesitates During Plotting

    Run the file again. If this does not resolve the MEMORY FULL problem when transferring plots, additional memory must be added to the plotter (refer to Appendix B of the CADJET 2 User's Guide), or purchase ENCAD’s Vector to Raster Conversion Utility. Another solution may be to ask your software vendor for an HP-RTL device driver.

  • Page 143: Plots Are Cut Off

    4. The plotter may not have correctly sized the media. Use the MANUAL LOAD option to load the media. See “Manual media loading” in Chapter 2 of the CADJET 2 User’s Guide. You may also want to refer to Section 11.5.4 in this chapter for further assistance.

  • Page 144: Plotter Is Noisy

    While this value or setting is displayed and the equals sign (=) is flashing, press the SELECT button to save. Save the desired default settings to “USER1.” This User number will be used when the plotter is powered up. 4-58 CADJET 2...

  • Page 145: Plotter Carriage Moves Erratically

    ERROR appears, the Servo Motor or driver circuits may be faulty. Replace the Servo Motor first. See Chapter 5, Section 5.0 for instructions. If ERROR still appears, replace the MPCB. See Chapter 5, Section 4.3 for instructions. CADJET 2 4-59...
  • Page 146 Carriage Assembly. After replacing the Carriage Assembly, see Chapter 6 for calibration instructions (you will not need to perform the Slide Shaft Profile Adjustment procedure in Section 6.1, but all other sections will need to be done). 4-60 CADJET 2...

  • Page 147: Media Movement Erratic

    Chapter 6, Sections 7.0 and 8.0 for the “Paper Skew Adjustment.” Upper Rollers and/or Lower Rollers are dirty. To clean the rollers, see Chapter 3, Section 7.0. Upper Rollers are worn. If the Upper Roller Supports need to be replaced, see Chapter 5, Section 14.0. CADJET 2 4-61...

  • Page 148: Lcd Or Led Key(S) Inoperative

    Each of the keys will beep when pressed to test circuitry. If the key does not beep when pressed, turn the plotter off and then turn it on again so that the plotter resets. Try the DIAGNOSTICS KEYPAD test again. 4-62 CADJET 2...
  • Page 149 3. For LCD keys only. If Steps 1 and 2 above have been performed and the key is still not responding, the Main PCB is defective. Replace the Main PCB. Refer to the procedures in Chapter 5, Section 4.3. CADJET 2 4-63...

  • Page 150: Front Keypad Display Inoperative

    EPROM. 5. EPROM or Flash EPROM failure. Replace the MPCB. Chapter 5, Section 4.3. 6. The Display Cable may have been installed backwards. Check the orientation of the flex fingers. See Chapter 5, Section 6.2. 4-64 CADJET 2...
  • Page 151 11.0 Operation Problems ..................4-25 11.1 Plotter Does Not Turn On ................4-25 11.2 Plotter Slow to Initialize................4-26 11.3 Plotter Will Not Plot..................4-27 11.3.1 Parallel Interface and Serial Interface Tests .........4-29 11.4 No Movement in the Carriage Axis ..............4-31 CADJET 2 4-65...
  • Page 152 11.15 Plotter is Noisy ..................4-58 11.16 User Parameters Not Saved When Power Is Cycled ........4-58 11.17 Plotter Carriage Moves Erratically .............4-59 11.18 Media Movement Erratic ................4-61 11.19 LCD or LED Key(s) Inoperative ..............4-62 11.20 Front Keypad Display Inoperative .............4-64 4-66 CADJET 2...
  • Page 153 Table 4.2: Decision Logic Table Two (DLT 2) .............4-5 Table 4.3: Decision Logic Table Three (DLT 3)............4-6 Table 4.4: Decision Logic Table Four (DLT 4).............4-7 Table 4.5: Decision Logic Table Five (DLT 5) ............4-42 Table 4.6: Black Cartridge Flex Test Matrix...............4-54 CADJET 2 4-67...

  • Page 154: Introduction

    It is recommended that you read through each procedure before beginning the removal or replacement. Replacement parts are listed in Chapter 7 and may be ordered through the ENCAD Technical Support and Service Department (see Chapter 1, Section 3.0). CADJET 2...
  • Page 155 Servo Motor Assembly MPCB Carriage Assembly Carriage Belt Idler Tensioner Assembly Stabilizer Bracket Y-Arm Assembly Slide Shaft Lower Drive Shaft Assembly Stepper Motor Fan Assembly Upper Roller Supports (only the portions listed in Section 14.2) CADJET 2...
  • Page 156 ESD damage. Anti-static bags are highly recommended for storage or shipment of printed circuit boards. Note: It is recommended that the plotter be removed from the stand NOTE and placed on a stable work surface on foam blocks for servicing. CADJET 2...

  • Page 157: Tools And Equipment Required

    Disassembly/Assembly Tools and Equipment Required Figure Chapter 5 .1 illustrates the CADJET 2 Hardware Kit Assembly, which is listed in Chapter 7. Figure Chapter 5 .2 illustrates the following tools which are recommended to disassemble and reassemble the plotter: Torque Screwdriver...
  • Page 158 Disassembly/Assembly Figure Chapter 5 .1: CADJET 2 Hardware Kit Assembly CADJET 2...
  • Page 159 Disassembly/Assembly Figure Chapter 5 .2: CADJET 2 Final Assembly Tools CADJET 2...

  • Page 160: Stand

    Disassembly/Assembly Stand If you need to ship the plotter to ENCAD for servicing, please observe all the instructions given below. You must contact ENCAD’s Technical Support and Service Department prior to shipping the plotter. See Chapter 1, Section 3.0. Note:...
  • Page 161 Disassembly/Assembly Figure Chapter 5 .3: Preparing the Plotter for Shipping CADJET 2...

  • Page 162: Replacing The Plotter On The Stand

    Replacing the Plotter on the Stand See the CADJET 2 User’s Guide for the plotter assembly procedures if you are using the desktop stand. If you are using the floor stand, have someone help you position the plotter on the stand and hold it in place while you insert and tighten the eight screws which hold the plotter on the stand.

  • Page 163: Alternate Method For Securing Carriage Assembly And Fixed Blade

    Loop the rubberband through itself and knot it securely.) Do not use tape to hold the Carriage Assembly in place. Figure Chapter 5 .4: Preparing the Plotter for Shipping - Alternate Method 5-10 CADJET 2...

  • Page 164: Right Cover Assembly, Simms, And Mpcb

    See Figure Chapter 5 .25. Note: If the LED Keypad on the Right Cover Assembly needs to be NOTE replaced, the entire Right Cover Assembly must be replaced. Figure Chapter 5 .5: Inside View of Right Cover Assembly CADJET 2 5-11...
  • Page 165 Be very careful when removing the Right Cover so that the LED’s on the MPCB are not damaged. 5-12 CADJET 2...

  • Page 166: Removing The Mpcb Connectors

    5. Disconnect the Stepper Motor connector at the JP5 location. Grasp the Stepper Motor connector with the thumb and forefinger and pull straight out. 6. Disconnect the Power Supply connector at the JP1 location. Grasp the Power Supply connector with the thumb and forefinger CADJET 2 5-13...
  • Page 167 Disassembly/Assembly and pull straight out. At this point, all 6 connectors should be disconnected. 5-14 CADJET 2...
  • Page 168 Disassembly/Assembly Figure Chapter 5 .6: MPCB Connectors CADJET 2 5-15...

  • Page 169: Mpcb

    Figure Chapter 5 .6. Hold the top of the MPCB while removing the screws. 3. Place the MPCB in an ESD bag (anti-static bag) in preparation for shipment to ENCAD for replacement or repair, or if it is to be stored for repair at your facility. 5-16...

  • Page 170: Reinstalling The Mpcb

    J1, to the left of JP4, and to the right of JP1. See Figure Chapter 5 .6. Use a #2 6” Phillips screwdriver to tighten the screws until firmly tightened. CADJET 2 5-17...

  • Page 171: Reinstalling The Mpcb Connectors

    If the MPCB is replaced, the Flash EPROM must be NOTE programmed because the Flash EPROM will be blank when the MPCB is shipped from ENCAD. See Appendix A at the end of this manual in order to program the Flash EPROM. 5-18...

  • Page 172: Extra Memory (Simm)

    See Figure Chapter 5 .7, Figure Chapter 5 .8, and Figure Chapter 5 .7: Location of SIMM Figure Chapter 5 .9. Figure Chapter 5 .8: Closeup View of Clip CADJET 2 5-19...
  • Page 173 Disassembly/Assembly Figure Chapter 5 .9: Side View of SIMM Removal 5-20 CADJET 2...

  • Page 174: Extra Memory (Simm) Installation

    4.5.2 Extra Memory (SIMM) Installation For proper specifications and dimensions for the SIMM, please refer to the CADJET 2 User’s Guide, Appendix B. The SIMM must WARNING be within ENCAD’s specifications and tolerances. Note: 1. If you are installing two SIMMS, you must install the bottom NOTE one first.

  • Page 175: Reinstalling The Right Cover Assembly

    See Figure Chapter 5 .5. Using a #2 Phillips screwdriver, tighten the bottom back screw and the top and front screws. All three screws should be firmly tightened. Do not overtighten. 4. Put the Top Cover back on. 5-22 CADJET 2...

  • Page 176: Servo Motor

    6. See Figure Chapter 5 .12 and Figure Chapter 5 .11. While you compress the back of the Frame Tensioner with your left index finger, use your right hand or the straight end of the Scriber to gently remove the Carriage Belt from the Servo Motor pulley. CADJET 2 5-23...
  • Page 177 8. Carefully lower the motor part way out of the opening in the bottom of the Platen. 9. Unlock the connector lock on the Servo Motor. Pull the cable out of the connector and finish removing the Servo Motor from the opening. Figure Chapter 5 .11: Servo Motor 5-24 CADJET 2...
  • Page 178 Disassembly/Assembly Figure Chapter 5 .12: Compression of Frame Tensioner CADJET 2 5-25...

  • Page 179: Replacing The Servo Motor

    Make sure that the three guides on the inside of the belt are inserted in the three pulley grooves. 8. Move the Carriage Assembly back and forth to check the Carriage Belt tension. 9. Reinstall the Trailing Cable Cover and the Top Cover. 5-26 CADJET 2...

  • Page 180: Display Assembly

    Assembly and pull it slightly to the left in order to get the Keypad Shim on the right end of the Keypad Top Assembly to clear the overhang from the Right Cover Assembly. 4. Turn the Keypad Top Assembly over. Figure Chapter 5 .13: Display Assembly CADJET 2 5-27...

  • Page 181: Reinstalling The Display Assembly

    When reinserting the Keypad Cable, make sure that the silver fingers on the end of the cable face the Keypad PCB. Also, make sure that the lip on the right side of the Keypad Top Assembly is under the Right Cover Assembly. 5-28 CADJET 2...

  • Page 182: Service Station Assembly

    The screw in the bottom of the Service Station Assembly NOTE must be in place to attract the magnet on the underside of the top of the Service Station Assembly. Figure Chapter 5 .15: Service Station Assembly CADJET 2 5-29...
  • Page 183 6. Pull up with your fingers (or with the Machinist Scriber) on the right end of the Service Station Bottom while lifting up the left front edge of the Service Station Bottom with your 1/4” x 6” Slotted screwdriver until the Service Station Bottom is out of the Platen. 5-30 CADJET 2...

  • Page 184: Reinstalling The Service Station Assembly

    Service Station Assembly and push it to the far left position. 4. Use a #1 Phillips screwdriver to reattach the plastic right Cam Actuator back into place on the front of the Y-Arm. Be careful not to overtighten the screw or the plastic may break. CADJET 2 5-31...

  • Page 185: Left Cover Assembly, Left Side Plate, Carriage Assembly, Trailing Cable, And Carriage Belt

    4. Slide the Left Cover Assembly off the end of the unit and set it aside. 5. Using a #2 8” Phillips screwdriver, remove the 4 screws on the outside of the Left Side Plate and set it aside. 5-32 CADJET 2...
  • Page 186 Disassembly/Assembly Figure Chapter 5 .16: Inside View of Left Side Plate CADJET 2 5-33...

  • Page 187: Removing The Carriage Assembly

    Carriage PCB. Be careful not to cut the Trailing Cable. See Figure Chapter 5 .17. 3. Unlock the Trailing Cable connector (J1) on the Carriage PCB, carefully pull the Trailing Cable away from the double-sided tape, and remove the Trailing Cable. See Figure Chapter 5 .17. 5-34 CADJET 2...
  • Page 188 Idler Pulley Assembly and the Frame Tensioner. (See Figure Chapter 5 .18 for part names, if necessary.) 7. Use a #1 Phillips screwdriver to remove the plastic Cam Actuator from the left front side of the Y-Arm. See Figure Chapter 5 .18. CADJET 2 5-35...
  • Page 189 Slide Shaft. 9. Place the Carriage Assembly in an ESD (anti-static) bag in preparation for shipment to ENCAD for replacement or repair, or if it is to be stored for repair at your facility. Note: 1. If the Trailing Cable needs to be replaced, see Section 8.5.

  • Page 190: Reinstalling The Carriage Assembly

    Carriage Assembly from left to right on the Slide Shaft. 3. Move the Carriage Assembly to the left end of the Slide Shaft and align the left bushing on the Carriage Assembly with the left end of the Slide Shaft. CADJET 2 5-37...
  • Page 191 Cut off the excess length of the tie wrap. 8. Slide the Carriage Assembly to about the middle of the Slide Shaft and stretch out the Carriage Belt. 5-38 CADJET 2...
  • Page 192 Disassembly/Assembly Figure Chapter 5 .19: Reinstalling the Trailing Cable in J1 Connector CADJET 2 5-39...
  • Page 193 13. Fit the Compression Spring over the post at the back of the Y-Arm. 14. Fit the notch in the front end of the Frame Tensioner over the notch in the front of the Y-Bracket. 5-40 CADJET 2...
  • Page 194 Actuator back onto the front of the Y-Arm. Before careful not to overtighten the screw or the plastic may break. Make sure the orientation is correct (see Figure Chapter 5 .18). 18. Reattach the Trailing Cable Cover to the back of the Y-Arm. 19. Proceed to Section 8.4. CADJET 2 5-41...

  • Page 195: Reinstalling The Left Side Plate And Left Cover Assembly

    5. Insert the third screw into the bottom back hole of the inside of the Left Cover Assembly and tighten slightly. See Figure Chapter 5 .16. 6. Tighten the three screws with a #2 12” Phillips screwdriver. 7. Put the Top Cover back on. 8. Reinstall the Cartridges. 5-42 CADJET 2...

  • Page 196: Removing The Trailing Cable

    2. Remove the Trailing Cable Cover from the back of the Y-Arm. Use a 5/16 Hex Nut Driver to remove the three nuts which secure it to the back of the Y-Arm. 3. Remove the Right Cover Assembly. See Section 4.1. CADJET 2 5-43...
  • Page 197 Trailing Cable away from the double-sided tape, and remove the Trailing Cable. See Figure Chapter 5 .17. 7. Pull the Trailing Cable away from the double-sided tape on the Stabilizer Bracket. Remove the Trailing Cable from the plotter unit. 5-44 CADJET 2...

  • Page 198: Reinstalling The Trailing Cable

    4. Connect the Trailing Cable to the J1 connector lock on the Carriage PCB. Make sure the silver fingers on the Trailing Cable face up before inserting it into the lock. See Figure Chapter 5 .19. Slide both sides of the connector lock shut at the same time. CADJET 2 5-45...
  • Page 199 Disassembly/Assembly Figure Chapter 5 .20: Positioning the Trailing Cable on the Stabilizer Bracket 5-46 CADJET 2...
  • Page 200 12. Remove the fixture. Slide the Carriage Assembly back and forth several times to make sure that the Trailing Cable does not catch on anything and to make sure that the Carriage Assembly will travel the full length of the Slide Shaft. CADJET 2 5-47...

  • Page 201: Removing The Carriage Belt From Carriage Assembly

    Belt Clip which goes under the plastic on the Carriage so that it slides out from under the plastic. Figure Chapter 5 .21. 2. Remove the Belt Clip. The Carriage Belt can now be removed. Figure Chapter 5 .21: Removing the Carriage Belt 5-48 CADJET 2...

  • Page 202: Installing The Carriage Belt On Carriage Assembly

    Figure Chapter 5 .21. 3. Once the Carriage Belt has been installed, refer to Sections 8.3 and 8.4 in this chapter for reinstallation of the Carriage Assembly. Figure Chapter 5 .22: Placement of Carriage Belt on Carriage CADJET 2 5-49...

  • Page 203: Power Supply And On/Off Switch

    Platen, pry up on the bottom of the switch with a screwdriver (from inside the Platen), and push the switch out of the Platen. Remove the ground wire from the Platen. 5-50 CADJET 2...

  • Page 204: Installing The Power Supply And On/Off Switch

    Platen and into the Power Supply. Use a #2 Phillips screwdriver to tighten the screws. (Do not overtighten them). 6. Reinstall the Left Side Plate, Left Cover Assembly, and the Top Cover. See Section 8.4. CADJET 2 5-51...

  • Page 205: Stabilizer Bracket And Encoder Strip

    2. If the Encoder Strip is damaged, the entire Stabilizer Bracket must be replaced. Follow the directions under Sections 10.1 and 10.2 in this chapter. Contact ENCAD’s Technical Support and Service department to obtain an RMA number (see Chapter 1, Section 3.0). Be sure to specify whether you have a D-Size or E-Size model.

  • Page 206: Removing The Stabilizer Bracket

    Bracket. See Figure Chapter 5 .23. 5. Use a 7/64 Hex Nut Driver to remove the three screws from the back of the Y-Arm which hold the Stabilizer Bracket on the Y-Arm and remove the Stabilizer Bracket. See Figure Chapter 5 .23. CADJET 2 5-53...

  • Page 207: Reinstalling The Stabilizer Bracket

    (The exact positioning of the screws in the slot will be done later during the Carriage Height Adjustment in Section 6.2 of Chapter 6. 2. Follow all the steps in Section 8.3 for reinstalling the Carriage Assembly through Step 17. (The Trailing Cable Cover will be reattached later.) 5-54 CADJET 2...
  • Page 208 Section 8.6, Steps 8-12 for the procedure for attaching the Trailing Cable to the tapes on the Stabilizer Bracket. 5. Reattach the Trailing Cable Cover. 6. Reattach the Left Side Plate and Left Cover Assembly. Section 8.4. 7. Reinstall the Cartridges and the Top Cover. CADJET 2 5-55...

  • Page 209: Lower Drive Assembly, Fan Assembly, And Stepper Motor Assembly (Inner Platen Parts)

    (Although the Power Supply and ON/OFF Switch are also inside the Platen, for the purposes of this manual they are not included when a reference to the Inner Platen Parts is made.) Figure Chapter 5 .24: Inner Platen Parts 5-56 CADJET 2...

  • Page 210: Disassembly Of Plotter Before Removing The Inner Platen Parts

    10. Remove the Servo Motor. See Section 5.1, Steps 4-9. 11. Clean and remove the entire Service Station. See Chapter 3, Section 4.0 for cleaning procedure and Chapter 5, Section 7.1 for the removal procedure. 12. Go to Section 11.2 below. CADJET 2 5-57...
  • Page 211 Disassembly/Assembly Figure Chapter 5 .25: Disassembly of Plotter Prior to Removing the Inner Platen Parts 5-58 CADJET 2...

  • Page 212: Removing The Inner Platen Parts

    See Figure Chapter 5 .26. Note: Don’t remove the two screws holding the Stepper Motor NOTE Assembly until Step 9. See Figure Chapter 5 .26. CADJET 2 5-59...
  • Page 213 Disassembly/Assembly Figure Chapter 5 .26: Removing the Lower Drive Shaft Screws 5-60 CADJET 2...
  • Page 214 8. Remove the Foam Block which is beside the Stepper Motor Assembly by putting your index finger into the opening in the top of the Foam Block and pulling it towards you. See Figure Chapter 5 .27. Figure Chapter 5 .27: Removing the Foam Block CADJET 2 5-61...
  • Page 215 Stepper Motor Assembly and Lower Drive Shaft Assembly out of the right end of the Platen. 11. Go to Section 11.3 below if the Stepper Motor Assembly needs to be removed. Otherwise, go to Section 11.4. 5-62 CADJET 2...

  • Page 216: Stepper Motor

    Assembly. 5. If you are replacing the Stepper Motor Bracket, you will need to remove the Retaining Ring, Washer, and Bowed Washer which are between the end of the Lower Drive Assembly and the Stepper Motor Bracket. CADJET 2 5-63...
  • Page 217 Disassembly/Assembly Figure Chapter 5 .28: Lower Drive Assembly and Stepper Motor Assembly 5-64 CADJET 2...

  • Page 218: Reinstalling The Stepper Motor

    Stepper Motor Bracket and secure it with the Retainer Spring Post. Torque to 6 IN-LB. 6. Hook the Extension Spring onto the post on the Stepper Motor Bracket. 7. Complete the reinstallation of the Inner Platen Parts by following the procedures listed below in Section 11.4. CADJET 2 5-65...

  • Page 219: Reinstalling The Inner Platen Parts

    5. Insert the middle Lower Drive Shaft Support through the Snap Plug opening (see Figure Chapter 5 .26), align it with the screw holes, and insert the screws. Using a #2 6” or 8” Phillips screwdriver, tighten them slightly. 5-66 CADJET 2...
  • Page 220 11. Hold the Fan in place with your left hand and insert the screws. Make sure that the screws go in straight. Using a #2 6” or 8” Phillips screwdriver, tighten them just until snug. Do not overtighten or the threads on the screw holes will strip. CADJET 2 5-67...
  • Page 221 Using a #2 6” or 8” Phillips screwdriver, tighten the screws until snug. 13. Reinsert the Snap Plug in the bottom of the Platen and turn the Platen onto its bottom side. 14. Go to Section 11.5. 5-68 CADJET 2...

  • Page 222: Reassembly Of Plotter After Reinstalling The Inner Platen Parts

    Make sure the silver fingers are facing up when they are routed through the Right Side Plate. See Figure Chapter 5 .29. 8. Route the Trailing Cable (with the silver fingers facing up) through the top slot in the Right Side Plate. CADJET 2 5-69...
  • Page 223 Disassembly/Assembly Figure Chapter 5 .29: Routing of Wires and Cables on Right Side Plate and MPCB 5-70 CADJET 2...
  • Page 224 Right Side Plate. See Section 4.6. 15. Reinstall the Left Cover Assembly and the Filler Block. Section 8.4, Steps 2-6. 16. Reinstall the Top Cover. The entire plotter is now reassembled. CADJET 2 5-71...

  • Page 225: Fixed Blade

    Platen. 3. If any of the Fixed Blade Spacers come loose when the Fixed Blade is removed, reattach them according to the instructions in Section 12.2 below Figure Chapter 5 .30: Fixed Blade 5-72 CADJET 2...

  • Page 226: Reinstalling The Fixed Blade

    4. Secure the Fixed Blade and the Fixed Blade Spacers (if any came out during the removal of the Fixed Blade) to the Platen, using the Blackmax Loctite at the “B” locations shown in Figure Chapter 5 .30. CADJET 2 5-73...

  • Page 227: Cutter Wheel

    4. Lift the Cutter Assembly away from the Carriage Assembly. 5. Remove the four screws (Item 9 in Figure Chapter 5 .31) from the Cover Cutter (Item 2). 6. Remove the Cutter Wheel (Item 7) from the Lower Link Cutter (Item 4). 5-74 CADJET 2...
  • Page 228 Disassembly/Assembly Figure Chapter 5 .31: Cutter Assembly CADJET 2 5-75...

  • Page 229: Replacement Of Cutter Wheel

    6. Place the Actuator Link Cutter (Item 5) on the back of the Frame Cutter (Item 1). 7. Reinstall the Cutter Assembly on the Carriage Assembly. 8. Use a pair of needle nose pliers to reattach the spring on the left side of the Cutter Assembly to the Carriage Assembly. 5-76 CADJET 2...

  • Page 230: Upper Roller Supports

    Precision Ground Flat Stock and also the piece of Translite media in the list of recommended tools and fixtures in Section 2.0. 4. If you need assistance during this procedure, call ENCAD's Technical Support and Service department. See Chapter 1, Section 3.0.

  • Page 231: Removing The Upper Roller Supports

    YOU MUST NOT DISTURB THE 3 SCREWS ON THE BACK OF THE Y-BRACKET WHICH HOLD ON THE STABILIZER BRACKET (see Figure Chapter If these are in any way disturbed, the Carriage Head Height will be changed, which will affect the line quality. 5-78 CADJET 2...
  • Page 232 Support , the bottom back part of it will also be bending up slightly. It should be bent as shown below in Figure Chapter 5 .32. Figure Chapter 5 .32: Upper Roller Support - Normal and Bent for Removal CADJET 2 5-79...
  • Page 233 See Figure Chapter 5 .33. Make sure the Upper Roller Support does not catch on the front edge of the Trailing Cable and that it does not damage the Slide Shaft. Figure Chapter 5 .33: Removing the Old Upper Roller Support 5-80 CADJET 2...
  • Page 234 Upper Roller Supports. As you do so, be sure to keep the Carriage Belt looped over the front of the Slide Shaft so it is not damaged. ALSO, MAKE SURE YOU ARE LOOSENING THE CORRECT SCREWS AND NOT THE ONES WHICH HOLD ON THE STABILIZER BRACKET! CADJET 2 5-81...
  • Page 235 Be sure to press the tape back down again after the roller is removed. If you have to use a new piece of tape, make sure it is put down in exactly the same place on the Stabilizer Bracket by using the Fixture, Trailing Cable, Tape, Location (P/N 204142). 5-82 CADJET 2...

  • Page 236: Installing The Upper Roller Supports

    Shaft (between the back of the Slide Shaft and the front of the Stabilizer Bracket) and push it forward as far as possible through the Upper Roller Support opening in the front of the Y-Bracket. See Figure Chapter 5 .34. Figure Chapter 5 .34: Inserting New Upper Roller Supports CADJET 2 5-83...
  • Page 237 3. Grasping the roller between your fingers, move the Upper Roller Support into place. Make sure the point on top back of the Upper Roller Support is in its hole in the Y-Bracket. See Figure Chapter 5 .35. Figure Chapter 5 .35: Positioning Upper Roller Supports 5-84 CADJET 2...
  • Page 238 3. Alternate between the two screws as you tighten them evenly so that both sides become snug at about the same time. 5. Repeat Steps 1 through 4 for the rest of the Upper Roller Supports. CADJET 2 5-85...
  • Page 239 Because the Carriage Belt was loosened during this procedure, you will need to verify the Deadband Adjustment by performing the following portions of Chapter 6: Sections 11.0 through 11.2.1, “Deadband Calibration” 10. Replace the Top Cover after you have finished Step 9. 5-86 CADJET 2...
  • Page 240 7.2 Reinstalling the Service Station Assembly ............ 5-31 8.0 Left Cover Assembly, Left Side Plate, Carriage Assembly, Trailing Cable, and Carriage Belt......................5-32 8.1 Removing the Left Cover Assembly and Left Side Plate ......5-32 8.2 Removing the Carriage Assembly..............5-34 CADJET 2 5-87...
  • Page 241 13.0 Cutter Wheel ....................5-74 13.1 Removing the Cutter Wheel................ 5-74 13.2 Replacement of Cutter Wheel ..............5-76 14.0 Upper Roller Supports..................5-77 14.1 Removing the Upper Roller Supports ............5-78 14.2 Installing the Upper Roller Supports ............5-83 5-88 CADJET 2...
  • Page 242 Disassembly/Assembly Figure 5.1: CADJET 2 Hardware Kit Assembly ............5-5 Figure 5.2: CADJET 2 Final Assembly Tools .............. 5-6 Figure 5.3: Preparing the Plotter for Shipping ............. 5-8 Figure 5.4: Preparing the Plotter for Shipping - Alternate Method ......5-10 Figure 5.5: Inside View of Right Cover Assembly .............
  • Page 243 Disassembly/Assembly Figure 5.33: Removing the Old Upper Roller Support ..........5-80 Figure 5.34: Inserting New Upper Roller Supports ........... 5-83 Figure 5.35: Positioning Upper Roller Supports............5-84 5-90 CADJET 2...

  • Page 244: Introduction

    Chapter 6 CALIBRATION Introduction When using the CADJET 2 to plot drawings with both color and black, the “Cartridge Calibration - Horizontal and Vertical” procedure in Section 12.0 of this chapter must be performed each time you remove or change one of the ink Cartridges.

  • Page 245: Required Supplies And Tools

    Torque screwdrivers pre-set at 3 in. lbs., with P0 Phillips bilts Screwdriver, 1.6 mm., flat blade, and GLIPTAL (P/N 200697) IBM Compatible Computer, 386SX - 16 MHz, 2 MEG OF RAM 40 MEG HD MINIMUM Parallel Cable Special firmware download Serial Cable (P/N 203977) CADJET 2...
  • Page 246 Display Unit, code #572-031A (MITUTOYO) (optional) Linear Gauge, code #575-312 (MITUTOYO) (optional) MITUTOYO User’s Manual (optional) Multimeter, BECKMAN IND. #DM15XL or equivalent Calculator, magnifier, and flash light Note: A dial micrometer alignment gauge will be available shortly to NOTE replace the MITUTOYO system. CADJET 2...

  • Page 247: Required Documentation And Files

    Emergency Flash ROM Boot Procedure - refer to Appendix A of this Service Manual. The files for this procedure are available on the CADJET 2 Utilities Disk which is provided with the plotter. The Utilities Disk may also be obtained from ENCAD’s Technical Support and Service BBS (see Chapter 1,...

  • Page 248: Downloading Files From The Bbs

    Calibration Downloading Files From the BBS See Chapter 1, Section 3.0 for the ENCAD Technical Support and Service BBS telephone numbers. 1. At the BBS Main Menu, press “F” for the Files Menu. 2. At the Files Menu, press “D” to download a file.
  • Page 249 To do a Printer Firmware Upgrade, see Appendix B of this service manual. 9. The files CJ2GS.PLT and CJ2GSD.PLT for the Line Quality Acceptance Standards should be saved for use in Section 14.0, “Line Quality Plot (Computer) Test.” CADJET 2...

  • Page 250: Numbering Sequence Of Upper Roller Supports

    Numbering Sequence of Upper Roller Supports Note: When performing the adjustments, be aware of the NOTE numbering sequence of the Upper Roller Supports as shown in Figure Chapter 6 .1. Figure Chapter 6 .1: Upper Roller Supports Numbering Sequence CADJET 2...

  • Page 251: Adjustments Prior To Calibration

    Chapter 3, Section 5.0 this Service Manual maintenance procedures for the Encoder Strip. 3. Wipe clean the Slide Shaft with a lint-free cloth (Scott Rags-In-A- Box or equivalent). See Chapter 3, Section 3.0. 4. Remove the Trailing Cable Support. CADJET 2...

  • Page 252: Slide Shaft Profile Adjustment

    LGB-110E, code #542-232; and MITUTOYO’s Linear Gauge Counter, LGm1E, code #542-330. A copy of the CADJET 2 Calibration Worksheet (see Figure Chapter 6 .16), which will be referred to as “the Calibration Worksheet.” 1. Prior to performing any test, park the Carriage on the Service Station.
  • Page 253 Calibration Figure Chapter 6 .2: Inner Stand Off Screws and Turnbuckle 6-10 CADJET 2...
  • Page 254 (all measurements) fall within 1.4340 +/- .0100”. If the measured numbers do not fall within 1.424-1.444”, stop the procedure and call ENCAD’s Technical Support and Service department. See Chapter 1, Section 3.0. CADJET 2...

  • Page 255: Cartridge Head Height Adjustment

    Note: 1. The Display Unit should have a Display Preset Number on a NOTE label attached above the LCD. This Display Preset Number is determined when the gauge is calibrated by ENCAD and equals the zero point for that gauge. 2. The Linear Gauge should also have a number on a label attached to the gauge.
  • Page 256 Maintain pressure on the Cartridge while you turn the lever up to firmly position the Cartridge head against the Flex Cable and lock it inside the Carriage. See Figure Chapter 6 .4 (which shows the procedure for installing a typical Black Cartridge). CADJET 2 6-13...
  • Page 257 Calibration Figure Chapter 6 .3: Carriage Height Measurement Fixture 6-14 CADJET 2...
  • Page 258 Calibration Figure Chapter 6 .4: Installation of Typical Black Cartridge CADJET 2 6-15...
  • Page 259 Table 6.1 below is to be used to select the Carriage height settings based on the absolute shaft height/profile settings recorded on the Calibration Worksheet during the Slide Shaft Profile Adjustment procedure in Section 6.1 above. Table Chapter 6 .1: Carriage Height Settings Chart 6-16 CADJET 2...

  • Page 260: Cartridge Head Height Adjusting Procedure

    When adjusting, always allow for a change in the height of up to .002". 2. Do not adjust the screws out of sequence. If you find that a screw has to be readjusted, the adjusting procedure must be repeated from Step 1 of Section 6.2.2. CADJET 2 6-17...

  • Page 261: Verify Head Height Values

    4. If the values are not within specification, repeat the adjustment procedure. Remove the gauge if all values are within specification. 5. Install a set of full Cartridges and proceed to Section 6.3, “Encoder Strip Location/Visual Check.” 6-18 CADJET 2...

  • Page 262: Encoder Strip Location/Visual Check

    If contact is visually detected or heard (squeaking noise), then re- adjust the tilt/height of Carriage until clearance is obtained. Repeat all the steps from Section 6.0, “Adjustments Prior to Calibration,” up to and including this Section 6.3, “Encoder Strip Location/Visual Check.” CADJET 2 6-19...

  • Page 263: Idler Pulley And Belt Position Check

    If there should be a problem with the alignment of the Belt, refer to Chapter 5, Figure 5.18 of this CADJET 2 Service Manual for information concerning the proper alignment of the Idler Pulley Assembly in the Frame Tensioner.

  • Page 264: Power Up And Rom Verification Test

    ON/OFF Switch to the “ON” position. The purpose of this test is to verify that the unit powers up. If it does not power up, see the Decision Logic Tables in Chapter 4. CADJET 2 6-21...
  • Page 265 Serial Port and the “Emergency Flash ROM Boot Procedure” on the CADJET 2 Utilities Disk. See Appendix A of this service manual for the procedure. 2. If the plotter is not “brain dead” (i.e., the Flash EPROM is not...

  • Page 266: Adjustment Of The Paper Sensor Potentiometer

    WARNING Test Point Pad on the board. See Figure Chapter 6 .5. For static control, you must be grounded to a static station by a wrist strap. Figure Chapter 6 .5: Top View of Carriage Board CADJET 2 6-23...
  • Page 267 During the download, the Fan will come on. During this time, adjust the Paper Sensor Potentiometer. 2. Adjust the Potentiometer on the Paper Sensor Harness Assembly using the flowchart in Table Chapter 6 .2 below. 6-24 CADJET 2...
  • Page 268 Calibration Table Chapter 6 .2: Potentiometer Adjustment Flowchart CADJET 2 6-25...
  • Page 269 4. The Carriage should move from the right side to the left side and return to the Service Station. The Cutter will be activated at the left side of the Platen and de-activated at the Service Station when the Carriage returns. 5. Proceed to Section 7.0, “Paper Skew Setup.” 6-26 CADJET 2...

  • Page 270: Paper Skew Setup

    6. Press the Down Arrow. The display will read: PRINTER SETUP ROLL FEED=OFF 7. Press SELECT, then MENU, and then the Down Arrow 4 times until the display reads: MAIN MENU PRINT MODE 8. Proceed to Section 8.0, “Paper Skew Adjustment.” CADJET 2 6-27...

  • Page 271: Paper Skew Adjustment

    Note: 1. Use the sequence given in Section 8.1 as you do the steps NOTE given in Section 8.4. 2. Read and follow ALL of the information in Sections 8.1, 8.2, and 8.3 before you begin Section 8.4. 6-28 CADJET 2...

  • Page 272: Paper Skew Adjustment Sequence

    If you are not working with an E-Size unit, Step 3 below will NOTE not be used. 3. Load a sheet of E-Size paper and adjust Rollers #3, #2, and #1, following the directions in Section 8.4. CADJET 2 6-29...

  • Page 273: Mounting Screw Information

    3. Figure Chapter 6 .6 shows the Upper Roller Support and the mounting screws. You must stand behind the plotter in order to adjust the mounting screws on the Upper Roller Supports. Figure Chapter 6 .6: Upper Roller Support and Mounting Screws 6-30 CADJET 2...
  • Page 274 7. Following all of the information in Section 8.2 precisely will ensure that the Upper Roller Support springs are deflected and the lower tail of the springs will always be pressed against the Y-Arm’s vertical wall (without a gap) as shown in Figure Chapter 6 .7. CADJET 2 6-31...
  • Page 275 Calibration Figure Chapter 6 .7: Correct Positioning of the Spring in the Upper Roller Support 6-32 CADJET 2...

  • Page 276: Other Functional Requirements

    See Figure Chapter 6 .8. Avoid adjusting the Upper Roller Supports so that they touch the Y-Arm's cut outs. Figure Chapter 6 .8: Test for Minimum Acceptable Gap CADJET 2 6-33...

  • Page 277: Adjustment Of Upper Roller Supports

    Make sure that the roller is centered in the Y-Arm. The gap between the roller and the Y-Arm should be approximately equal on both sides of the roller. See Figure Chapter 6 .9. Figure Chapter 6 .9: Visual Verification of Gap between Roller and Y-Arm 6-34 CADJET 2...

  • Page 278: Observation Of Paper Skew At Rear Media Alignment Mark

    Front Media Alignment Mark on the Platen. 2. Hold the media and press LOAD. The paper will be pulled in past the Platen's groove. The paper will roll forward (out) and stop. CADJET 2 6-35...
  • Page 279 Rear Media Alignment Mark (on back of the Platen) is within 2 line widths (0.12”). Figure Chapter 6 .10. Figure Chapter 6 .10: Paper Skew Acceptance Range for Rear Media Alignment Mark 6-36 CADJET 2...

  • Page 280: Observation Of Paper Skew At Front Media Alignment Mark

    #5 and #4, beginning with Section 8.4.1. After Rollers #5 and #4 are adjusted (if you have an E-Size model), adjust Rollers #3, #2, and #1, beginning with Section 8.4.1. Once all rollers are adjusted, proceed to Section 9.0. CADJET 2 6-37...

  • Page 281: Adjustment Of The Mounting Screws

    Rollers #5 and #4, beginning with Section 8.4.1. After Rollers #5 and #4 are adjusted (if you have an E-Size model), adjust Rollers #3, #2, and #1, beginning with Section 8.4.1. Once all rollers are adjusted, proceed to Section 9.0. 6-38 CADJET 2...

  • Page 282: Plotting Prime Pattern

    4. Press the DOWN ARROW. The display will read: UTILITIES OPTIONS=EASY 5. Press SELECT and immediately press the UP ARROW. display will read: UTILITIES OPTIONS=ADVANCED 6. Press SELECT and MENU. The display will read: MAIN MENU UTILITIES CADJET 2 6-39...
  • Page 283 10. Install a new Tri-Color Ink Cartridge and a new Black-104 JET Cartridge, following the procedures for Cartridge installation in the CADJET 2 User’s Guide. Do not ever wipe the ink Cartridges with any highly fibrous materials like tissues or paper towels.
  • Page 284 Cartridge and repeat the test. Make sure that there is no misfiring using the new Cartridge. If misfiring is observed, contact ENCAD’s Technical Support and Service department (see Chapter 1, Section 3.0.). 13. The plotter has passed the PRIME test if misfiring is no longer observed using a second set of Cartridges.
  • Page 285 6. check for Servo Motor noises or any visible Carriage vibration. Readjust the plotter if these sounds or conditions are present. If the problem persists and cannot be corrected, call ENCAD's Technical Support and Service department (see Chapter 1, Section 3.0).

  • Page 286: Xy Calibration

    CALIBRATION option is set to ON. 3. When you set the XY Calibration values, all subsequent images are plotted using the new values until you manually reset the calibration. 4. XY calibration should not be used for merged vector/raster images. CADJET 2 6-43...

  • Page 287: Calibrating The Y-Axis (Carriage Axis Or Horizontal Axis Calibration)

    4. Press DOWN ARROW. The display will read: CALIBRATION USE XY CALIB=NO 5. Press SELECT, DOWN ARROW, and SELECT. The display will read: CALIBRATION USE XY CALIB=YES 6. Press DOWN ARROW. The display will read: CALIBRATION XY=ENGLISH 6-44 CADJET 2...
  • Page 288 SAVE MEDIA=ON Press MENU. Press SELECT. Another 21.00” line will be drawn. Press FEED MEDIA and DOWN ARROW to unload the paper. Verify that the line length is correct. Proceed to Section 10.2 and calibrate the X-Axis. CADJET 2 6-45...

  • Page 289: Calibrating The X-Axis (Paper Axis Or Vertical Axis Calibration)

    Reload the paper and press MENU and SELECT. The plotter will redraw the marks. Unload the paper and verify that the distance between the horizontal lines is correct. Then proceed to Section 11.0, “Deadband Calibration”. 6-46 CADJET 2...

  • Page 290: Deadband Calibration

    11.0 Deadband Calibration Deadband Calibration compensates for minute differences created when bi-directional plotting is used. Figure Chapter 6 .13 shows how to correct the differences. The CADJET 2 Service Menu provides for both Slow Deadband and Fast Deadband Calibration. Note: Uni-directional plotting is not affected by deadband.

  • Page 291: Slow Deadband Calibration

    3. Press the UP ARROW once. The display will read: UTILITIES SERVICE→ 4. Press SELECT & the DOWN ARROW twice. The display will read: SERVICE CALIBRATION→ 5. Press SELECT. The display will read: CALIBRATION * = DEFAULT NUMBER DEADBAND=XX * 6-48 CADJET 2...
  • Page 292 Record this value in Part 3 of the Calibration Worksheet. 11. If the alignment is still not satisfactory, return to CALIBRATION SLOW DEADBAND=0 and press SELECT. Do not choose any other values. Record this value in Part 3 of the Calibration Worksheet. CADJET 2 6-49...

  • Page 293: Fast Deadband (Height Calibration)

    Therefore, if the upper row segments are aligned and acceptable, the lower row segments will also be as good or better in the alignment with each other. Record this value in Part 3 of the Calibration Worksheet. 6-50 CADJET 2...

  • Page 294: Adjusting Fast Deadband; Vertical Lines (All) And Vertical Lines (One)

    5. Press SELECT. This causes 16 single 1.5" high vertical lines to be drawn one segment at a time in bi-directional mode. Figure Chapter 6 .14 for a sample. 5 (31,0 4 (31,0 3 (31,0 (31,0 ALL,F,S(31,0 Figure Chapter 6 .14: Vertical Lines (All) CADJET 2 6-51...
  • Page 295 If after 10 minutes and/or a total of 8 trials of various values the minimum standard cannot be met, stop and call ENCAD's Technical Support and Service department. See Chapter 1, Section 3.0. 10. Press MENU 3 times. The display will read:...

  • Page 296: Cartridge Calibration - Horizontal And Vertical

    The Horizontal and Vertical Calibration allows the user to minimize these variables. 1. Begin at the following display: MAIN MENU UTILITIES 2. Press SELECT. The display will read: UTILITIES CALIBRATION→ 3. Press SELECT. The display will read: CALIBRATION CARTRIDGE CADJET 2 6-53...
  • Page 297 4. Press SELECT. The display will read: CALIBRATION HORIZONTAL=0 The plotter will begin printing three sets of color line patterns (see the CADJET 2 User’s Guide, Appendix A for samples of these patterns): CURRENT HEADS The first pattern shows the horizontal/vertical values of the heads.

  • Page 298: Adjusting The Horizontal Head-To-Head Calibration

    The new head-to-head pattern will reflect the latest settings which you have chosen. Make sure that the “CURRENT HEADS” printout is properly aligned. If it is still not satisfactory, repeat the adjustment until satisfactory results are obtained. Then proceed to Section 13.0. CADJET 2 6-55...

  • Page 299: Adjusting The Vertical Head-To-Head Calibration

    Make sure that the “CURRENT HEADS” printout is properly aligned. If it is still not satisfactory, repeat the adjustment until satisfactory results are obtained. Then proceed to Section 13.0. 6-56 CADJET 2...

  • Page 300: Color Deadband Calibration

    If the COLOR DB is acceptable, record the value in Part 3 of the Calibration Worksheet and proceed to Section 14.0. If it is not acceptable, proceed to Section 13.1. CADJET 2 6-57...

  • Page 301: Adjusting The Color Deadband Value

    4. Press the DOWN ARROW. The display will read: COLOR DB X = CURRENT VALUE FOR CYAN DB=X CYAN DB 5. Press SELECT and the UP ARROW or DOWN ARROW to change the value. Press SELECT to save the new value. 6-58 CADJET 2...
  • Page 302 DEADBAND values which achieve the best results. Record the value in Part 3 of the Calibration Worksheet and proceed to Section 14.0. CADJET 2 6-59...

  • Page 303: Line Quality Plot (Computer) Test

    Load a D-Size sheet with the 36 inch side against the upper rollers. 5. Turn the computer on. At the C: prompt, type on the keyboard: GO CJ2GS.PLT (for CADJET 2 E-Size plotters) GO CJ2GSD.PLT (for CADJET 2 D-Size plotters) 6-60...
  • Page 304 Carriage Assembly/Slide Shaft. If a Cutter malfunction is experienced, call ENCAD's Technical Support and Service department (see Chapter 1, Section 3.0). If no further adjustment is needed and the Cutter performs satisfactorily, compare the plot against the “Gold Standard”...
  • Page 305 AFTER CARTRIDGE HEIGHT ADJUSTMENT LEFT CENTER RIGHT BLACK NOTE: ALL VALUES MUST BE BETWEEN .050 AND .070 PART 3: DEADBAND VALUES BLACK SLOW DEADBAND VALUE: DEADBAND (FAST) VALUE: TRI-COLOR SLOW DEADBAND VALUE: Figure Chapter 6 .16: CADJET 2 Calibration Worksheet 6-62 CADJET 2...
  • Page 306 8.4.4 Adjustment of the Mounting Screws ............6-38 9.0 Plotting PRIME Pattern..................6-39 10.0 XY Calibration....................6-43 10.1 Calibrating the Y-Axis (Carriage Axis or Horizontal Axis Calibration)..6-44 10.2 Calibrating the X-Axis (Paper Axis or Vertical Axis Calibration) ....6-46 11.0 Deadband Calibration..................6-47 CADJET 2 6-63...
  • Page 307 12.1 Adjusting the Horizontal Head-to-Head Calibration ........6-55 12.2 Adjusting the Vertical Head-to-Head Calibration ........6-56 13.0 Color Deadband Calibration ................6-57 13.1 Adjusting the Color Deadband Value............6-58 14.0 Line Quality Plot (Computer) Test ..............6-60 6-64 CADJET 2...
  • Page 308 Figure 6.13: Deadband Alignment ................6-47 Figure 6.14: Vertical Lines (All) ................. 6-51 Figure 6.15: Vertical Lines (One) ................6-52 Figure 6.16: CADJET 2 Calibration Worksheet............6-62 Table 6.1: Carriage Height Settings Chart ..............6-16 Table 6.2: Potentiometer Adjustment Flowchart ............6-25...

  • Page 309: Introduction

    REPLACEMENT PARTS LIST Introduction This chapter lists the part names and part numbers for field replaceable parts and assemblies of the CADJET 2 Color Inkjet Plotter. Section 2.0 is the numerical listing, Section 3.0 is the alphabetical listing, and Section 4.0 is an alphabetical listing with drawings.

  • Page 310: Numerical Listing

    203646..............CAM, ACTUATOR (LEFT AND RIGHT) 203788-1..................... FOAM, TOP, LEFT 203789-1...................FOAM, TOP, RIGHT 203868-1....................ROLL SUPPORT 203918-2...................SPRING, ROLL HOLDER 203977......................CABLE, RS422 204973....................SIDEPLATE, RIGHT 204968....................SIDEPLATE, LEFT 204246 ..................STOP, RETRACTING 204384....................ASSY, EXHAUST 205329 ......................ASSY, MPCB 204849....................POWER SUPPLY 204599........... ON/OFF SWITCH (POWER ENTRY MODULE) CADJET 2...
  • Page 311 204854 ....................ASSY, CARRIAGE 205377 ....................MANUAL, USER 204859 ..............ASSY, ADI DRIVER DISK, CADJET 2 204860 ............. ASSY, WINDOWS DRIVER DISK, CADJET 2 204861 ..............ASSY, DOS UTILITY DISK, CADJET 2 204916 ........ASSY, BRACKET, DRIVE SHAFT (left bracket w/bushing) 204967 ....................MANUAL, SERVICE...

  • Page 312: D-Size Unique Parts (Numerical)

    Replacement Parts List D-Size Unique Parts (Numerical) PART # DESCRIPTION 203800-32................ANGLE, TRAILING CABLE 205175..................ASSY, LEGS AND BASKET 203772-2................BOX, PLOTTER, CADJET 2 203778....................CABLE, TRAILING 203903...................... BELT, RIBBED 204007-31....................SLIDE SHAFT 204367-5 ..................ASSY, TOP COVER 204551............ASSY, STABILIZER BRACKET, SERVICE 204848....................PLATEN, MACHINED...

  • Page 313: E-Size Unique Parts (Numerical)

    203800-3 ................ANGLE, TRAILING CABLE 204007-2 ....................SLIDE SHAFT 204367-7..................ASSY, TOP COVER 204550 ............ASSY, STABILIZER BRACKET, SERVICE 204847 ................ PLATEN, MACHINED, CADJET 2 204917-1 ..................ASSY, LOWER DRIVE Note: If you are ordering the Assy, Top Cover, the Stop, Retracting NOTE (P/N 204246) and the Spring, Compression (P/N 202010) are not included.

  • Page 314: Alphabetical Listing

    Replacement Parts List Alphabetical Listing Parts Used in both D-Size and E-Size (Alphabetical) DESCRIPTION PART # ASSY, ADI DRIVER DISK, CADJET 2 ..............204859 ASSY, BRACKET, DRIVE SHAFT (left bracket w/bushing)........204916 ASSY, CARRIAGE....................204854 ASSY, COVER, LEFT....................203533 ASSY, COVER, RIGHT ..................203476 ASSY, CUTTER.....................203614 ASSY, DOS UTILITY DISK, CADJET 2..............204861...
  • Page 315 P/N 203488. The 8 Stand Screws (P/N 203485) are not included in the Assy, CADJET 2 Hardware Kit, (P/N 205188). Also not included in the Hardware Kit are the 4 long Stand Screws (P/N has not yet been determined) which are 1/4 x 20 x 2.5.

  • Page 316: D-Size Unique Parts (Alphabetical)

    ASSY, LEGS AND BASKET ..................205175 ASSY, LOWER DRIVE ..................204917-31 ASSY, STABILIZER BRACKET, SERVICE ............204551 ASSY, TOP COVER..................204367-5 BELT, RIBBED ......................203903 BOX, PLOTTER, CADJET 2 ................203772-2 CABLE, TRAILING....................203778 PLATEN, MACHINED....................204848 SLIDE SHAFT....................204007-31 Note: If you are ordering the Assy, Top Cover, the Stop, Retracting...

  • Page 317: E-Size Unique Parts (Alphabetical)

    ASSY, LEGS AND BASKET ................. 205174 ASSY, LOWER DRIVE ..................204917-1 ASSY, STABILIZER BRACKET, SERVICE ............204550 ASSY, TOP COVER ..................204367-7 BELT, 3 RIB ......................203230 BOX, PLOTTER, CADJET 2................203479-2 CABLE, TRAILING....................203448 PLATEN, MACHINED, CADJET 2................ 204847 SLIDE SHAFT ....................204007-2 Note:...

  • Page 318: Alphabetical Listing With Drawings

    Replacement Parts List Alphabetical Listing with Drawings Drawings - Parts Used in both D-Size and E-Size Figure Chapter 7 .1: Assy, Bracket, Drive Shaft - P/N 204916 (left bracket w/bushing) Figure Chapter 7 .2: Assy, Carriage - P/N 204854 7-10 CADJET 2...
  • Page 319 Replacement Parts List Figure Chapter 7 .3: Assy, Cover, Left - P/N 203533 Figure Chapter 7 .4: Assy, Cover, Right - P/N 203476 Figure Chapter 7 .5: Assy, Cutter - P/N 203614 CADJET 2 7-11...
  • Page 320 Kit. 2. The Hardware Kit does not include the stand screws. See Figure Chapter 7 .36, P/N 203485. Figure Chapter 7 .8: Assy, Hardware Kit CADJET 2, Service - P/N 205188 Figure Chapter 7 .9: Assy, Idler - P/N 203345-1...
  • Page 321 Replacement Parts List Figure Chapter 7 .10: Assy, Keypad Top - P/N 203488 Figure Chapter 7 .11: Assy, MPCB - P/N 205329 CADJET 2 7-13...
  • Page 322 Replacement Parts List Figure Chapter 7 .12: Assy, Pinch Roller - P/N 203637-2 Figure Chapter 7 .13: Assy, Rollguide, Left - P/N 204969 Figure Chapter 7 .14: Assy, Rollguide, Right - P/N 203477-2 7-14 CADJET 2...
  • Page 323 Replacement Parts List Figure Chapter 7 .15: Assy, Service Station - P/N 203233 Figure Chapter 7 .16: Assy, Servo Motor - P/N 203265 Figure Chapter 7 .17: Assy, Stepper Motor Bracket, Service - P/N 205350 (right bracket w/bushing) CADJET 2 7-15...
  • Page 324 Replacement Parts List Figure Chapter 7 .18: Assy, Stepper Motor Service (includes Gear) - P/N 205128 Figure Chapter 7 .19: Cable, Keypad - P/N 205111 7-16 CADJET 2...
  • Page 325 Replacement Parts List Figure Chapter 7 .20: Cable, RS422 Mini-DIN8 - P/N 203977 Figure Chapter 7 .21: Cam, Actuator (Left and Right) - P/N 203646 Figure Chapter 7 .22: Caster, Locking, Twin - P/N 202513 (P/N will be changing) CADJET 2 7-17...
  • Page 326 Replacement Parts List Figure Chapter 7 .23: Caster, Non-Locking, Twin - P/N 202512 (P/N will be changing) Figure Chapter 7 .24: Clip, Belt - P/N 203644-1 7-18 CADJET 2...
  • Page 327 Replacement Parts List Figure Chapter 7 .25: Cutter, Wheel - P/N 203622-1 Figure Chapter 7 .26: Foam, Block - P/N 205079 Figure Chapter 7 .27: Foam, Bottom, Left - P/N 203480-1 CADJET 2 7-19...
  • Page 328 Replacement Parts List Figure Chapter 7 .28: Foam, Bottom, Right - P/N 203481-1 Figure Chapter 7 .29: Foam, Top, Left - P/N 203788-1 Figure Chapter 7 .30: Foam, Top, Right - P/N 203789-1 7-20 CADJET 2...
  • Page 329 Replacement Parts List Figure Chapter 7 .31: Frame, Tensioner - P/N 203343-1 Figure Chapter 7 .32: Keypad, Bottom - P/N 203440-1 Figure Chapter 7 .33: ON/OFF Switch (Power Entry Module) - P/N 204599 CADJET 2 7-21...
  • Page 330 There are also four long Stand Screws which are 1/4 x 20 x NOTE 2.5. The P/N for them has not yet been determined. All of the Stand Screws are included with the Floor Stand when it is ordered. 7-22 CADJET 2...
  • Page 331 Replacement Parts List Figure Chapter 7 .37: Sideplate, Left - P/N 204968 Figure Chapter 7 .38: Sideplate, Right - P/N 204973 CADJET 2 7-23...
  • Page 332 Replacement Parts List Figure Chapter 7 .39: Spring, Compression (Idler) - P/N 203447 Figure Chapter 7 .40: Spring, Compression (Top Cover) - P/N 202010 Figure Chapter 7 .41: Spring, Roll Holder - P/N 203918-2 7-24 CADJET 2...
  • Page 333 Replacement Parts List Figure Chapter 7 .42: Stop, Retracting - P/N 204246 Figure Chapter 7 .43: Support, Drive Shaft (middle support) - P/N 203556-2 CADJET 2 7-25...

  • Page 334: Drawings - D-Size Unique Parts

    Drawings of it were not available at the time of publication. However, the Part Number shown below is the Part Number for the NEW stand and basket assembly. Figure Chapter 7 .45: Assy, Legs and Basket - P/N 205175 7-26 CADJET 2...
  • Page 335 Replacement Parts List Figure Chapter 7 .46: Assy, Lower Drive - P/N 204917-31 Figure Chapter 7 .47: Assy, Stabilizer Bracket, Service - P/N 204551 Figure Chapter 7 .48: Assy, Top Cover - P/N 204367-5 CADJET 2 7-27...
  • Page 336 Replacement Parts List Figure Chapter 7 .49: Belt, Ribbed - P/N 203903 Figure Chapter 7 .50: Cable, Trailing - P/N 203778 Figure Chapter 7 .51: Platen, Machined - P/N 204848 7-28 CADJET 2...
  • Page 337 Replacement Parts List Figure Chapter 7 .52: Slide Shaft - P/N 204007-31 CADJET 2 7-29...

  • Page 338: Drawings - E-Size Unique Parts

    Drawings of it were not available at the time of publication. However, the Part Number shown below is the Part Number for the NEW stand and basket assembly. Figure Chapter 7 .54: Assy, Legs and Basket - P/N 205174 7-30 CADJET 2...
  • Page 339 Replacement Parts List Figure Chapter 7 .55: Assy, Lower Drive - P/N 204917-1 Figure Chapter 7 .56: Assy, Stabilizer Bracket, Service - P/N 204550 Figure Chapter 7 .57: Assy, Top Cover - P/N 204367-7 CADJET 2 7-31...
  • Page 340 Replacement Parts List Figure Chapter 7 .58: Belt, 3 Rib - P/N 203230 Figure Chapter 7 .59: Cable, Trailing - P/N 203448 Figure Chapter 7 .60: Platen, Machined - P/N 204847 7-32 CADJET 2...
  • Page 341 P/N 203488. The 8 Stand Screws (P/N 203485) are not included in the Assy, CADJET 2 Hardware Kit, (P/N 205188). Also not included in the Hardware Kit are the 4 long Stand Screws (P/N has not yet been determined) which are 1/4 x 20 x 2.5.
  • Page 342 3.3 E-Size Unique Parts (Alphabetical)..............7-9 4.0 Alphabetical Listing with Drawings ..............7-10 4.1 Drawings - Parts Used in both D-Size and E-Size ........7-10 4.2 Drawings - D-Size Unique Parts ..............7-26 4.3 Drawings - E-Size Unique Parts..............7-30 7-34 CADJET 2...
  • Page 343 Figure 7.5: Assy, Cutter - P/N 203614 ..............7-11 Figure 7.6: Assy, Exhaust - P/N 204384 ..............7-12 Figure 7.7: Assy, Fan - P/N 203443 ................7-12 Figure 7.8: Assy, Hardware Kit CADJET 2, Service - P/N 205188......7-12 Figure 7.9: Assy, Idler - P/N 203345-1..............7-12 Figure 7.10:...
  • Page 344 Assy, Top Cover - P/N 204367-7............7-31 Figure 7.58: Belt, 3 Rib - P/N 203230 ............... 7-32 Figure 7.59: Cable, Trailing - P/N 203448 ..............7-32 Figure 7.60: Platen, Machined - P/N 204847............7-32 Figure 7.61: Slide Shaft - P/N 204007-2 ..............7-33 7-36 CADJET 2...

  • Page 345: Emergency Firmware Download Procedure

    2. You should use the most current version of the firmware, which is CJDOS15.ZIP (as of the date of publication of this manual). It is available on ENCAD’s BBS. You may also contact our Help Desk to obtain the most recent version if you do not have access to the BBS.
  • Page 346 15. When the process is completed, reset the plotter’s User Settings to the desired selections and start plotting again. 16. If you need assistance with the above procedures, please call ENCAD's Help Desk at the number listed in Chapter 1, Section 3.0 of this manual. CADJET 2...
  • Page 347 Appendix A Figure Appendix A .1: Cable, RS422 Mini-DIN8, P/N 203977 CADJET 2...

  • Page 348: Printer Firmware Upgrade Procedure

    CJDOS15.ZIP (as of the date of publication of this manual). It is also available on ENCAD’s BBS. You may also contact our Help Desk to obtain the most recent version if you do not have access to the BBS.
  • Page 349 NOTE NOT ON LINE,” the parallel download is not going to work. In this case, you need to call ENCAD’s Help Desk (see Chapter 1, Section 3.0) and order ENCAD’s RS422 Serial Cable P/N 203977. (Be sure to tell the Help Desk that you have received this error message.)

  • Page 350: Final Assembly Drawings

    Appendix C FINAL ASSEMBLY DRAWINGS This appendix contains the Final Assembly Drawings for the CADJET 2. Callouts of the part numbers and descriptions for all numbered items are provided on the pages preceding the drawings. When ordering parts, please be aware that not all the parts listed on these pages are available at a component level;...
  • Page 351 Appendix C D-Size Final Assembly Callouts ITEM # PART # DESCRIPTION 400010 H, KEPNUT, 6-32 204848 PLATEN, MACHINED, CADJET 2 - D 204973 SIDEPLATE, RIGHT 200172 H, LOCTITE BLACK MAX 203556-2 SUPPORT, DRIVE SHAFT 201013 H, SCREW, 6-32 X 3/8 PFH BLK...
  • Page 352 204854 ASSY, CARRIAGE 204007-31 SHAFT, SLIDE, CADJET 2 - D 203637-2 ASSY, PINCH ROLLER 204551 ASSY, STABILIZER BRACKET, SERVICE, CADJET 2 - D 203778 CABLE, TRAILING, CADJET 2 - D 203265 ASSY, SERVO MOTOR 203800-32 ANGLE, TRAILING CABLE - D...
  • Page 353 Appendix C E-Size Final Assembly Callouts ITEM # PART # DESCRIPTION 400010 H, KEPNUT, 6-32 204847 PLATEN, MACHINED, CADJET 2 - E 204973 SIDEPLATE, RIGHT 200172 H, LOCTITE BLACK MAX 203556-2 SUPPORT, DRIVE SHAFT 201013 H, SCREW, 6-32 X 3/8 PFH BLK...
  • Page 354 204854 ASSY, CARRIAGE 204007-2 SHAFT, SLIDE, CADJET 2 - E 203637-2 ASSY, PINCH ROLLER 204550 ASSY, STABILIZER BRACKET, SERVICE, CADJET 2 - E 203448 CABLE, TRAILING, CADJET 2 - E 203265 ASSY, SERVO MOTOR 203800-3 ANGLE, TRAILING CABLE - E...
  • Page 355 Appendix C Figure Appendix C .1: CADJET 2 D-Size Final Assembly Drawing CADJET 2...
  • Page 356 Appendix C Figure Appendix C .2: CADJET 2 E-Size Final Assembly Drawing CADJET 2...

  • Page 357: Schematics

    Appendix D SCHEMATICS This section contains the CADJET 2 Schematics for: SCHEMATIC PART DESCRIPTION PART # DOC. # REVISION # OF PAGES Main PCB Assembly 205329 205325 9 pages Keypad PCB Assembly 203455-1 203456 1 page Carriage PCB Assembly 204941...
  • Page 358 Changed R157 to R172 from 75 ohms to 33 ohms. Added square test post holes to DRAMOE* and GACS*. Changed taps on delay line from 10/30 nsec to 15/30 nsec. 16-SEP-97 UPDATED PER ECN 86088. ENCAD, Incorporated 6059 Cornerstone Court West San Diego, CA 92121-3734 Title Enhanced Main Board (205325.sch)
  • Page 359 XTAL BKPT* F R EEZE C LOCK (3C8,5A5) RES ET* B D I N R 13 470K BDOUT C ONN_BDM ENCAD, Incorporated EXTAL 3.6864MHz Title Enhanced Main Board (CPU.sch) C 12 C 13 32.768KHz C 92 22pF 22pF C 15...
  • Page 360 C AS2* T208 T297 R139 BCAS2* C AS3* T209 T298 R140 BCAS3* R W * T299 ENCAD, Incorported R127 B W E* R176 Title Enhanced Ma in Board (GLUE.sch) T307 C 29 Size Document Number R e v 0.1uF 74F244...
  • Page 361 C 80 C 36 C 35 C 34 M A10 0.1uF 10uF 0.1uF 0.1uF 0.1uF M A11 T125 R 151 ENCAD, Incorporated Title Enhanced Main Board (DRAM.sch) Size Document Number R e v 205325 Date: Monday, November 04, 2002 Sheet...
  • Page 362 XCHKCLK XCHKCLK D O NE/PROG* D O NE/PROG* C L OCK T350 C L OCK RES ET* PGACLK RESET* PGACLK ENCAD, Incorporated Title Enhanced Main Board (FLASH.sch) Size Document Number R e v 205325 Date: Monday, November 04, 2002 Sheet...
  • Page 363 MD 13 R 164 D 14 MD 14 MD[0. .15] R 165 MD[0. .15] D 15 R 166 MD 15 ENCAD, Incorporated C 46 74F245 0.1uF Title Enhanced Main Board (SIMM.sch) R W * DRAMOE* Size Document Number R e v...
  • Page 364 SHDN T121 RXEN TXEN C 86 CPEN 1 uF T122 T196 U 29 C 91 1 uF LTC1323CS ENCAD, Incorporated T154 C 73 Title 1 uF T123 Enhanced Main Board (IO.sch) Size Document Number R e v 205325 Date: Monday, November 04, 2002...
  • Page 365 CARIGE15 74HCT244 CARIGE16 C 57 0.1uF R 86 R 87 C O NN16 C O NN20 R 84 R 85 ENCAD, Incorported C 60 0.001uF C 59 CARRSTAT 0.001uF Title Enhanced Main Board (IO2.sch) Size Document Number R e v...
  • Page 366 U 3 8D TOO_LOW_B C 72 R112 U37B R126 LM393 0.001uF R 119 T266 4.99K T263 R 118 T265 ENCAD, Incorporated Title R 117 T264 Enhanced Main Board (STEPPER.sch) Size Document Number R e v 205325 Date: Monday, November 04, 2002 Sheet...
  • Page 367 7406 +12.1V +24V +12.1V (1C7) 220uH 1000uF MUR410 1000uF 4.7K 4.7K 4.7K 4.7K 7406 (1C7) Encad, Inc. CHA0* (1B1) CHA1* (1B1) 6059 Cornerstone Court 7406 CHA2* (1B1) San Diego, CA 92121 1.13K (1C7) CHA3* (1B1) Title SCH, CADJET CARRIAGE BOARD...
  • Page 368 ALL CAPACITORS ARE IN MICROFARADS, 10%, 50V. ADJUST R30 TO PRODUCE 18-20V AT U1 PIN 1 LOOKING AT WHITE BOND AT A DISTANCE OF 0.200". Encad, Inc. D4 AND Q1 ARE ATTACHED THROUGH A CABLE. 6059 Cornerstone Court THE PIN NUMBERS REFER TO THE CONNECTOR PIN NUMBERS.
  • Page 369 SELECT, then DOWN ARROW INSERT MEDIA ROM REVISION PRINT DIRECTION PRESS LOAD KEY DIAGNOSTICS SERVO MOTOR CADJET 2 V1.50 CARRIAGE VIBRATE CYCLES=1 After media is loaded, all 8 User Settings will print. press MENU to return to “SERVICE INFORMATION” press DOWN ARROW...

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