Page 1 The use of this Service Note constitutes agreement with the following Terms of Use. 1. USERS This Service Note is only for authorized persons with user ID and password issued by Roland DG Corporation. 2. PURPOSE Authorized persons can use this Service Note only for the purposes of selling and providing the customers with maintenance services of SG2-640/540/300.
Page 2: Table Of Contents
Table of Contents Table of Contents ........T-1 Crop Mark Sensor Adjustment .
Page 3: Revision History
Revision History Revision Date Description Approver Author July 31, 2019 First edition Nimura Saito September 4, 2019 Chapter 4 Service Activities [Installation Checklist] Nimura Saito Chapter 2 Adjustment [Service Mode] October 2, 2019 Nimura Saito Chapter 4 Service Activities [Installation Checklist] SG2-640/ 540/300...
Page 4: Warning Labels
Warning Labels Service parts For information on service parts required for the replacement of parts or adjustment, refer to Parts Finder Web. https://365rolanddg.sharepoint.com/sites/extranet/Work-SitePages/GSV-PartsFinder.aspx Warning Labels A.warning.label.is. .to.the.machine.to.make.areas.of.danger.immediately.clear..The.meaning.of. this.label.is.indicated.below..Be.sure.to.heed.this.warning..Also,.never.remove.the.label.or.allow.it.to. become.dirty. The.platen.and.dryer.become.hot..Exercise. .to.avoid. .or.burns. Be.careful.not.to.allow.the. .to.become.pinched.when.closing.covers. The.print.heads.inside.the.cover.move.at.high.speed.and.pose.a.hazard.. Never.insert.the.hand.or. .into.the.gap. If.these. .come.into.contact.with.the.eyes.or.skin,.it.may.be.hazardous. to.the.health..When.performing.maintenance.work,.for.example.when.dis- posing.of.discharged.
Page 5: Special Tools
Special Tools Part No. ST-056 Part Name TORQUE DRIVER N6 Print head replacement Purpose Print head alignment Part No. 1000015274 Part Name TOOL, BIT PHILLIPS NO.1 L200MM Print head replacement Purpose Print head alignment Part No. ST-001 Part Name TENSION GAUGE 2000GF/2000CN Purpose Belt tension adjustment Part No.
Page 6: Key Combinations
Key Combinations For service engineers Panel key combination Description In order to enter the service mode, you need to connect Peck2 to the machine. Service mode  Press the [MENU] [ ] keys to enter the service menu. “UPDATE FIRMWARE?” is displayed. Firmware upgrade mode Press the [ENTER] key to upgrade firmware.
Page 7: Chapter 1 Replacement Of Main Parts
Chapter 1 Replacement of Main Parts Workflow ........1-63 Important Points .
Page 8 Encoder Scale Replacement ....1-91 Information .......1-91 Outline Diagram .
Page 9: Important Points
Important Points Turn off the sub power switch and main power switch, and unplug the power cord of the printer before performing parts replacement. Performing the parts replacement while the power is on may result in injury due to the unexpected operation of the printer. Static electricity can harm some electronic devices.
Page 10: Print Head Replacement
Print Head Replacement Information Necessary tools General tools No. 2 Phillips screwdriver Gloves (anti-slip) Waste cloth Special tools ST-056 TORQUE DRIVER N6 1000015274 BIT, PHILLIPS NO.2 L200MM Typical work time Contents of work Time Print head replacement (1 piece) 30 min. Clearing the print head information 1 min.
Page 11: Outline Diagram
Print Head Replacement Outline Diagram 1. Print head 2. Print carriage board 3. Panel board SG2-640/540/300...
Page 12: Cover That Needs To Be Removed
Print Head Replacement Cover That Needs to Be Removed Panel Carriage cover C AUTION Disconnect the cable from the panel board. NOTE • The screws are on the right and left side of the carriage cover. SG2-640/540/300...
Page 13: Workflow
Print Head Replacement • When you attach the carriage cover, place the left side of the cover inside the metal plate. Workflow Disconnect all the ribbon cables from the print carriage board. C AUTION Open the cover in the direction of the arrow marked "1". Then, disconnect the ribbon cable from the print carriage board. SG2-640/540/300...
Page 14 Print Head Replacement Remove the plate that fixes the ribbon cables. Place waste cloth under the tube joints so that ink does not spatter around the print head. Remove the print head that you are going to replace from the L-shaped tubes. C AUTION Remove the ink tubes slowly to prevent ink from dripping or spattering.
Page 15 Print Head Replacement Refer to the following table, remove the tube that corresponds to the print head that you are going to replace. Print head Tube removing to be replaced from pump ② ① Connect all the ribbon cables of the print heads to the print carriage board. C AUTION Be sure to connect each ribbon cable to the correct connector.
Page 16 Print Head Replacement 11. Disconnect the ribbon cables which are connected to the print head you are going to replace from the print carriage board. C AUTION Open the cover in the direction of the arrow marked "1". Then, disconnect the ribbon cable from the print carriage board. 12.
Page 17 Print Head Replacement 13. Detach the filler guard from the print head, and attach it to the new print head. NOTE Pinch the upper part of the filler guard and detach it. C AUTION Be careful not to touch the filler. 14.
Page 18 Print Head Replacement 15. Attach the new print head to the head base. C AUTION Be careful not to touch the filler. 15-1. Hook the spring, which is on the left front side of the print head, to the head base. 1-12 SG2-640/540/300...
Page 19 Print Head Replacement 15-2. Then, press the spring against the head base until the spring bends, and then push the rear side of the print head into the head base. NOTE Make sure that the print head is attached to the base firmly. C AUTION • If the print head is not attached firmly, it may crack when you secure it with screws.
Page 20 Print Head Replacement • Make sure that the print head is level to the head base. 16. Tighten two screws with a torque screwdriver in the order shown below to secure the print head (torque value: 0.2 N ・ m/20 cN ・...
Page 21 Print Head Replacement 18. Connect the tubes to the cleaning pump. 19. Attach the tubes connected to the L-shaped joint to the print heads. C AUTION • Be sure to wear gloves (anti-slip). • Insert the tube straight so that it does not bend. 20.
Page 22 Print Head Replacement 22. Connect all the ribbon cables of the print heads to the print carriage board. C AUTION Be sure to connect each ribbon cable to the correct connector. The cable with head rank is the upper side. 23.
Page 23 Print Head Replacement 25. Go to [SERVICE MENU] > [SUB MENU] > [FILL DAMPER] and select the head group of the print head you replaced. Then, perform [FILL DAMPER]. * Ink filling: about 7 min. SUB MENU FILL DAMPER ENTER EMPTY DRAIN BOTTLE ENTER...
Page 24: Cap Top Replacement
Cap Top Replacement Information Necessary tools General tools No. 2 Phillips screwdriver Special tools None Typical work time Contents of work Time Cap top replacement (1 piece) 10 min. Outline Diagram 1. Cap top 1-18 SG2-640/540/300...
Page 25: Cover That Needs To Be Removed
Cap Top Replacement Cover That Needs to Be Removed NOTE Unlock the print-head carriage, and move it to the left by hand when you remove the covers. 1. Print-head carriage Workflow Slide the cap-base frame to the right, and then lift it up to remove it. 1.
Page 26 Cap Top Replacement Detach the tube from the cap-base frame. Bottom view Remove the screw that secures the rear part of the cap top. Loosen the screw that secures the front side of the cap top. C AUTION Do not remove the screw completely. Just loosen them. If you remove it, the base part of the cap top will fall off. 1-20 SG2-640/540/300...
Page 27 Cap Top Replacement Slide the cap top to the front. Then, lift up the rear side of the cap top, and remove it. C AUTION There are springs under the cap top. Remove the cap top carefully so that these springs will not jump out. Remove the tube from the new cap top.
Page 28 Cap Top Replacement Attach the new cap top. Check that the spring is attached properly. No Good 1-22 SG2-640/540/300...
Page 29 Cap Top Replacement Insert the tubes. Bottom view 10. Attach the spring removed in step 2. 11. Attach the covers, and then lock the print-head carriage. 12. Select [SERVICE MENU]>[I/S MENU]>[CAP CHECK] to perform micro opening ink suction adjustment. 1-23 SG2-640/540/300...
Page 30: Tool Carriage Replacement
Tool Carriage Replacement Information Necessary tools General tools No. 2 Phillips screwdriver 2.5 mm hexagonal wrench Special tools None Typical work time Contents of work Time Tool carriage replacement 20 min. Outline Diagram 1. Tool carriage 2. Tool carriage board 1-24 SG2-640/540/300...
Page 31: Cover That Needs To Be Removed
Tool Carriage Replacement Cover That Needs to Be Removed Workflow Remove the sheet cutter holder. Unplug the solenoid cables and connectors from the tool carriage board. 1-25 SG2-640/540/300...
Page 32 Tool Carriage Replacement Unfasten the clamp to release the cable. Remove the blade holder. Remove the stay. 1-26 SG2-640/540/300...
Page 33 Tool Carriage Replacement Detach the spring from the black stay. C AUTION When unhooking the spring, be careful not to lose it. Remove the plate at the side of the tool carriage. 1-27 SG2-640/540/300...
Page 34 Tool Carriage Replacement Remove the stay. Remove the tool carriage and replace it with a new one. 1-28 SG2-640/540/300...
Page 35 Tool Carriage Replacement 10. Attach the stay. 11. Attach the plate at the side of the tool carriage. 12. Hook the spring and attach it to the black stay. 13. Attach the blade holder. 14. Bundle the cables with the clamp. 1-29 SG2-640/540/300...
Page 36 Tool Carriage Replacement 15. Plug the cables to the tool carriage board. 16. Attach the sheet cutter holder. 17. Attach the covers and perform the following adjustments. 17-1. Chapter 2 "Limit Position & Cut Down Position Initialization" 17-2. Chapter 2 "Tool Height Adjustment" 17-3.
Page 37: Scan Motor Replacement
Scan Motor Replacement Information Necessary tools General tools No. 2 Phillips screwdriver No.2 Phillips screwdriver (80 mm or less) 3.0 mm hexagonal wrench Special tools 6000004129 GREASE,FLOIL G-902 10ML_02 Typical work time Contents of work Time Scan motor replacement 30 min. Servo lock check 1 min.
Page 38: Cover That Needs To Be Removed
Scan Motor Replacement Cover That Needs to Be Removed Panel Side cover Carriage cover C AUTION • Disconnect the cable from the panel board. • Before removing the side cover, remove the cable of the cover sensor. 1-32 SG2-640/540/300...
Page 39 Scan Motor Replacement NOTE • The screws are on the right and left side of the carriage cover. • When you attach the carriage cover, place the left side of the cover inside the metal plate. 1-33 SG2-640/540/300...
Page 40: Workflow
Scan Motor Replacement Workflow C AUTION A Phillips screwdriver with a length of 80 mm or less is necessary. 80 mm or less Scan motor replacement Detach the rivet. Remove the cover shown in the figure. NOTE • The length of a Phillips screwdriver you can use is limited to 80 mm or less because the cleaning liquid pouch tray is just above it.
Page 41 Scan Motor Replacement • Use a Phillips screwdriver with a length of 80 mm or less. Unplug the connectors. Remove the spring. 1-35 SG2-640/540/300...
Page 42 Scan Motor Replacement Remove the motor together with the flange. Attach the new motor to the flange. C AUTION Be careful to correctly orient the flange in relation to the motor cables. 1-36 SG2-640/540/300...
Page 43 Scan Motor Replacement Temporarily fasten the flange with three screws. Attach the spring. Turn the drive gear more than three times by hand and check that the gears mesh together. C AUTION Apply grease to the motor gear and the drive gear. • Grease: FLOIL G-902 10ML_02 • Volume: as needed 1-37...
Page 44 Scan Motor Replacement 10. Fully tighten three screws to secure the flange. NOTE You can tighten the screws in any order. 11. Plug the connector into the motor. 12. Bundle the cables with the clamps to attach the cover. 1-38 SG2-640/540/300...
Page 45 Scan Motor Replacement 13. Attach the rivet to secure the cover. 14. Attach the panel. C AUTION Connect the cable to the panel board. 15. Attach the covers, and turn on the power switch. Then connect Peck2 to the machine, and enter the service mode. 1-39 SG2-640/540/300...
Page 46 Scan Motor Replacement 16. Select [SERVICE MENU] > [SENSOR CHECK]. SERVICE MENU SENSOR CHECK 17. Slide the maintenance cover sensor R to the front until "*" under "D" disappears. Then, tighten two screws to secure the sensor. When the cover is open FRSHODPLWwaCQT When the cover is closed FRSHODPLWwaCQT...
Page 47 Scan Motor Replacement Aging check 20. Go back to [MOTOR MENU]. Select [AGING] > [SCAN], and press the [ENTER] key. Make sure the printer performs aging, and then finish by pressing the [ENTER] key. C AUTION Remove media before performing aging. SERVICE MENU MOTOR MENU MOTOR MENU...
Page 48: Feed Motor Replacement
Feed Motor Replacement Information Necessary tools General tools No. 2 Phillips screwdriver 3.0 mm hexagonal wrench 2.0 mm hexagonal wrench 1.5 mm hexagonal wrench Special tools 6000004129 GREASE,FLOIL G-902 10ML_02 Typical work time Contents of work Time Feed motor replacement 45 min.
Page 49: Cover That Needs To Be Removed
Feed Motor Replacement Cover That Needs to Be Removed Side cover C AUTION • Disconnect the cable from the panel board. • Before removing the side cover, remove the cable of the cover sensor. 1-43 SG2-640/540/300...
Page 50: Workflow
Feed Motor Replacement Workflow Remove the grit encoder board. Remove the grit encoder stopper and the grit encoder. Detach the rivets from the motor cover. 1-44 SG2-640/540/300...
Page 51 Feed Motor Replacement Remove the grit encoder stay and the motor cover. Remove the spring. Remove the motor together with the flange. 1-45 SG2-640/540/300...
Page 52 Feed Motor Replacement Slide the motor as shown in the figure below to remove connector from the motor. Unfasten the clamp to remove the cables of the motor, and then unplug the connector. Slide the cap-base frame to the right, and then lift it up to remove it. Put it in the front side. 1-46 SG2-640/540/300...
Page 53 Feed Motor Replacement 10. Remove the feed motor from the right side of the cap-base frame. 11. Attach the new motor to the flange. C AUTION Be careful to correctly orient the flange in relation to the motor cables. 12. Move the motor back to its original position.
Page 54 Feed Motor Replacement 13. Temporarily fasten the flange with three screws. 14. Attach the springs. 15. Turn the drive gear more than three times by hand and check that the gears mesh together. C AUTION Apply grease to the motor gear and the drive gear. • Grease: FLOIL G-902 10ML_02 • Volume: as needed 16.
Page 55 Feed Motor Replacement 17. Attach the grit encoder stay. Tighten the screws to secure the grit encoder stay. 18. Attach the rivets to secure the motor cover. 19. Tighten three screws to secure the grit encoder stopper and the grit encoder. C AUTION Be careful not to scratch or get grease on the grit encoder when installing it.
Page 56 Feed Motor Replacement 20. Attach the grit encoder board. C AUTION Secure the stay to keep the grit encoder sensor in the center position of the sensor. Make sure to keep the gap is approximately 1 mm to the front and rear to the sensor. 1.
Page 57 Feed Motor Replacement 23. Slide the maintenance cover sensor R to the front until "*" under "D" disappears. Then, tighten two screws to secure the sensor. When the cover is open FRSHODPLWwaCQT When the cover is closed FRSHODPLWwaCQT Servo lock check 24.
Page 58 Feed Motor Replacement Grit encoder check 26. Select [MOTOR MENU] > [G-ENC. CHECK] and press the [ENTER] key. Confirm that [G-ENC. CHECK COMPLETED] is displayed and the grit encoder works properly. When [G-ENC. CHECK FAILED] is displayed, check the following. 1.
Page 59 Feed Motor Replacement Clearing the motor time 28. Go back to [SERVICE MENU]. Select [HISTORY MENU] > [MOTOR GROUP] > [MOTOR HOURS F] > [CLEAR], and press the [ENTER] key. The motor working hours will be reset to 0. SERVICE MENU HISTORY MENU HISTORY MENU MOTOR GROUP...
Page 60: Pressure Pump Replacement
Pressure Pump Replacement Information Necessary tools General tools No. 2 Phillips screwdriver Waste cloth Special tools None Typical work time Contents of work Time Pressure pump replacement (1 piece) 100 min. Outline Diagram 1. Pressure pump 1-54 SG2-640/540/300...
Page 61: Cover That Needs To Be Removed
Pressure Pump Replacement Cover That Needs to Be Removed NOTE If you remove the cover at back of the maintenance space, you can reach the parts from the front side. Workflow Turn on the power switch. Then connect Peck2 to the machine, and enter the service mode. Perform [SERVICE MENU] >...
Page 62 Pressure Pump Replacement Turn off the machine, then unplug the power cord and remove the covers. Unplug the connectors of the cables. Remove the pump drive board stay. Unplug the connector connected to the pump you are going to replace. 1-56 SG2-640/540/300...
Page 63 Pressure Pump Replacement Ink circulation pump Detach the hook below the bottom plate of the machine to remove the pump unit. Push up two hooks in the center, and push the surrounding 3 hooks toward the back. Pull out the tray about 70 mm. C AUTION Do not pull out the tray more than 70 mm.
Page 64 Pressure Pump Replacement Push up the claw under the pump, and raise the back side of the pump to remove it. 1-58 SG2-640/540/300...
Page 65 Pressure Pump Replacement 10. Attach the pump unit to the bottom plate of the machine. 11. Attach the pump to the pump unit. 12. Plug the connector into the pump cable. 1-59 SG2-640/540/300...
Page 66 Pressure Pump Replacement 13. Cut the ink tubes 5 mm from the end before connecting them to the pressure pump. C AUTION Do not cut the tube end more than 5 mm. If the ink tube becomes too short to connect, replace it with a new one. 5 mm 14.
Page 67: Main Board Replacement
Main Board Replacement Information Necessary tools Software Peck2 General tools No. 2 Phillips screwdriver Special tools None Typical work time Contents of work Time Main board replacement (When parameters 40 min. cannot be transferred by Peck2) Main board replacement (When parameters can 20 min.
Page 68: Outline Diagram
Main Board Replacement Outline Diagram 1. Main board Cover That Needs to Be Removed 1-62 SG2-640/540/300...
Page 69: Workflow
Main Board Replacement Workflow Start Peck 2, and connect the machine to the computer by clicking [Connect Printer]. The parameter will be automatically transferred to the specified folder. Turn off the power switch, and remove the cover. Remove the main board. Set DIP SW of the new main board rerring to the following table.
Page 70 Main Board Replacement C AUTION • Make sure to attach the removed battery to the new main board. • There are no connectors to plug into CN 6 and CN 2. (the location shown by the yellow arrow) Attach the covers and perform the following adjustments. 6-1.
Page 71 Main Board Replacement 6-4. Temporary IP address setting * Turn on the main power switch while pressing the [FUNCTION] key. Press and hold the [FUNCTION] key for about 10 seconds until BEEP sound rings one time. If the BEEP sound rings three times, try it again. The temporary IP address [192.168.1.99]. is automatically set.
Page 72 Main Board Replacement 7-6. IP address settings * Start the machine with the service mode and set in the user menu. 7-7. Time and date setting * Set the time and date from [SUB MENU] > [CLOCK] > [DATE] > [TIME]. * Set [DATE] in the order of [Year/Month/Day].
Page 73: Servo Board Replacement
Servo Board Replacement Information Necessary tools General tools No. 2 Phillips screwdriver Special tools None Typical work time Contents of work Time Servo board replacement 20 min. Outline Diagram 1. Servo board 1-67 SG2-640/540/300...
Page 74: Cover That Needs To Be Removed
Servo Board Replacement Cover That Needs to Be Removed Workflow Remove the servo board. 1-68 SG2-640/540/300...
Page 75 Servo Board Replacement Replace the servo board with a new one. C AUTION There are no connectors to plug into the location shown by the yellow arrow. 1-69 SG2-640/540/300...
Page 76: Signal Jc Board Replacement
Signal JC Board Replacement Information Necessary tools General tools No. 2 Phillips screwdriver Special tools None Typical work time Contents of work Time Signal JC board replacement 15 min. Outline Diagram 1. Signal JC board 1-70 SG2-640/540/300...
Page 77: Cover That Needs To Be Removed
Signal JC Board Replacement Cover That Needs to Be Removed Workflow Remove the signal JC board, and replace it with a new one. 1-71 SG2-640/540/300...
Page 78: Sw Power Supply Replacement
SW Power Supply Replacement Information Necessary tools General tools No. 2 Phillips screwdriver Special tools None Typical work time Contents of work Time SW power supply (5V) 18 min. SW power supply (37V) 18 min. Outline Diagram 1. SW power supply (37V) 2.
Page 79: Cover That Needs To Be Removed
SW Power Supply Replacement Cover That Needs to Be Removed Workflow Removing the chassis Remove the carriage retainer. 1-73 SG2-640/540/300...
Page 80 SW Power Supply Replacement Remove screws that secure the chassis tray. Pull out the chassis tray. Unfasten the connector which are on the back part of the chassis tray. Then, pull out the chassis tray further. 1-74 SG2-640/540/300...
Page 81 SW Power Supply Replacement SW Power supply (5V) replacement Remove the SW power supply (5V) and replace it with a new one. C AUTION In case you accidentally turn the potentiometer, adjust the output voltage value to +5 +/- 0.1. Proceed to step 8.
Page 82 SW Power Supply Replacement C AUTION In case you accidentally turn the potentiometer, adjust the output voltage value to +37 +/- 0.1. Insert the chassis tray back to the machine, and fasten the connector on the back. Tighten five clamp to secure the chassis tray. 10.
Page 83: Pump Drive Board Replacement
Pump Drive Board Replacement Information Necessary tools General tools No. 2 Phillips screwdriver Special tools None Typical work time Contents of work Time Pump drive board replacement 10 min. Outline Diagram 1. Pump drive board (EX MTR 9CH BOARD) 1-77 SG2-640/540/300...
Page 84: Cover That Needs To Be Removed
Pump Drive Board Replacement Cover That Needs to Be Removed Workflow Remove the pump drive board, and replace it with a new one. Attach the covers. Perform powerful cleaning and check that the filler sensor works properly. 1-78 SG2-640/540/300...
Page 85: Ink System Rfid Board Replacement
Ink System RFID Board Replacement Information Necessary tools General tools No. 2 Phillips screwdriver Special tools None Typical work time Contents of work Time Ink system RFID board replacement 10 min. Outline Diagram 1. Ink system RFID board 1-79 SG2-640/540/300...
Page 86: Cover That Needs To Be Removed
Ink System RFID Board Replacement Cover That Needs to Be Removed Workflow Remove the ink system RFID board, and replace it with a new one. Attach the covers, and turn on the power switch. Then connect Peck2 to the machine, and enter the service mode. Go to [SERVICE MENU] >...
Page 87: Rfid R/W Board Replacement
RFID R/W Board Replacement Information Necessary tools General tools No. 2 Phillips screwdriver Special tools None Typical work time Contents of work Time RFID R/W board replacement 45 min. Outline Diagram 1. RFID R/W board 1-81 SG2-640/540/300...
Page 88: Cover That Needs To Be Removed
RFID R/W Board Replacement Cover That Needs to Be Removed Workflow Slide and remove the ink cartridge. Unhook the cover to remove it. 1-82 SG2-640/540/300...
Page 89 RFID R/W Board Replacement Unplug the connector from the RFID R/W board, and replace the board with a new one. C AUTION Be careful with the needle. Take care not to drop the connector. Place the RFID R/W board so that two pins can be fitted into the holes of the board, and then close the cover. Slide and set the ink cartridge.
Page 90: Carriage Belt Replacement
Carriage Belt Replacement Information Necessary tools General tools No. 2 Phillips screwdriver 3.0 mm hexagonal wrench Tape Special tools 6000004129 GREASE,FLOIL G-902 10ML_02 Typical work time Contents of work Time Carriage belt replacement 45 min. Outline Diagram 1. Carriage belt 2.
Page 91: Cover That Needs To Be Removed
Carriage Belt Replacement Cover That Needs to Be Removed Tool carriage cover C AUTION Disconnect the cable from the panel board. Workflow Disconnect the tool carriage from the print-head carriage. 1-85 SG2-640/540/300...
Page 92 Carriage Belt Replacement Loosen the fixing screws located at the left end of the belt. Then, loosen the adjustment screw. < Top View > Left end of the belt Adjustment Fixing screw screw Remove the tool carriage cover. Unplug the solenoid cable and connectors. Release the cable from the clamp.
Page 93 Carriage Belt Replacement Slide the tool carriage away from the stay. Remove the carriage belt. C AUTION When removing the carriage belt, make sure the carriage belt does not touch the encoder scale. If the grease applied to the carriage belt gets on the encoder scale, printing problems may occur. Remove the carriage belt from the stay.
Page 94 Carriage Belt Replacement 10. Slowly pull the end of the old belt that is not connected to the new belt until the new belt reaches the belt stay. C AUTION Check that the belt is not twisted. 1. Old carriage belt 2.
Page 95 Carriage Belt Replacement 1. Screw 2. Metal plate 3. Carriage belt 4. Plastic plate 5. Belt holder Cross-section diagram No Good 13. Tighten the adjustment screw to remove the slack in the belt. Then, tighten the fixing screws. C AUTION Do not overtighten the screws.
Page 96 Carriage Belt Replacement 14. Slide the tool carriage back to the original position, and align the screws on the tool carriage and the screw holes of the stay. 15. Attach the stay. 16. Plug the solenoid cable and connectors into the tool carriage board. 17.
Page 97: Encoder Scale Replacement
Encoder Scale Replacement Information Necessary tools General tools No. 2 Phillips screwdriver Special tools None Typical work time Contents of work Time Encoder scale replacement 15 min. Linear encoder setup 5 min. Outline Diagram 1. Encoder scale 1-91 SG2-640/540/300...
Page 98: Workflow
Encoder Scale Replacement Workflow Remove the encoder scale by removing the plate holding the encoder scale at its right end and the spring on its left end. 1. Encoder scale 2. Encoder plate 3. Spring Remove the spring plate from the encoder scale and fasten it to the end of the new encoder scale that does not have a clipped corner.
Page 99 Encoder Scale Replacement Move the print head carriage across the whole width of the machine manually and confirm that the encoder scale does not make contact with the encoder sensor. Also, check that the encoder scale is in between the slit of the encoder sensor. Perform Chapter 2 "Linear Encoder Setup".
Page 100: Linear Encoder Board Replacement
Linear Encoder Board Replacement Information Necessary tools General tools No. 1 Phillips screwdriver No. 2 Phillips screwdriver Special tools None Typical work time Contents of work Time Linear encoder board replacement 25 min. Linear encoder setup 5 min. 1-94 SG2-640/540/300...
Page 101: Outline Diagram
Linear Encoder Board Replacement Outline Diagram Side view 1. Linear encoder board 2. Print-head carriage 3. Print carriage board 1-95 SG2-640/540/300...
Page 102: Cover That Needs To Be Removed
Linear Encoder Board Replacement Cover That Needs to Be Removed Carriage cover C AUTION Disconnect the cable from the panel board. NOTE • The screws are on the right and left side of the carriage cover. 1-96 SG2-640/540/300...
Page 103: Workflow
Linear Encoder Board Replacement • When you attach the carriage cover, place the left side of the cover inside the metal plate. Workflow Disconnect all the ribbon cables of the print heads from the print carriage board. C AUTION Open the cover in the direction of the arrow marked "1". Then, disconnect the ribbon cable from the print carriage board. 1-97 SG2-640/540/300...
Page 104 Linear Encoder Board Replacement Remove the plate that fixes the ribbon cables. Remove the print carriage board. Remove the black sheet under the print carriage board. 1-98 SG2-640/540/300...
Page 105 Linear Encoder Board Replacement Remove the linear encoder board along with the stay. 1. Linear encoder board 2. Stay Unplug the connector from the linear encoder board. Then, plug the connector into the new linear encoder board. Remove the linear encoder board from the stay. Then, attach the new linear encoder board to the stay. 1.
Page 106 Linear Encoder Board Replacement Fasten the linear encoder board along with the stay. C AUTION Make sure that the encoder scale does not make contact with the encoder sensor. Also, check that the encoder scale is in between the slit of the encoder sensor. 1.
Page 107 Linear Encoder Board Replacement 10. Attach the print carriage board, and connect the cables. C AUTION Attach the plate that fixes the ribbon cables. 11. Connect all the ribbon cables of the print heads to the print carriage board. 1-101 SG2-640/540/300...
Page 108: Battery Replacement
Battery Replacement Information Necessary tools General tools No. 2 Phillips screwdriver Typical work time Contents of work Time Battery replacement 7 min. Time and date setting 2 min. Outline Diagram 1. Battery Cover That Needs to Be Removed 1-102 SG2-640/540/300...
Page 109: Workflow
Battery Replacement Workflow C AUTION Danger of explosion if the lithium battery is incorrectly replaced. Replace only with the same or equivalent type. Dispose of used batteries according to the manufacturer's instructions. Lithium battery: CR2032 CAUTION Do not recharge, short-circuit, disassembly the lithium battery, nor put it into fire. It may cause heat, explosion and fire. Disconnect the motor cable from the connector.
Page 110 Battery Replacement Connect Peck2 to the machine, and enter the service mode. Select [SUB MENU] > [CLOCK] > [TIME]. Set the time, and press the [ENTER] key. C AUTION The display of [B] which shows battery exhaustion disappears by this step. SERVICE MENU SUB MENU SUB MENU...
Page 111: Choke Valve Replacement
Choke Valve Replacement Information Necessary tools General tools No. 2 Phillips screwdriver Waste cloth Special tools None Service parts 6000003132* TUBE,CUT PT05-RDG 3X3.8 1500MM Cut the tube into 65 mm for use. Typical work time Contents of work Time Choke valve replacement 100 min.
Page 112: Cover That Needs To Be Removed
Choke Valve Replacement Cover That Needs to Be Removed Workflow C AUTION If you are replacing multiple choke valves at the same time, be sure to reconnect each tube to the correct choke valve (be careful not to connect it to the wrong choke valve). Turn on the power switch.
Page 113 Choke Valve Replacement Unhook the solenoid to remove it. Unhook the choke valve to remove it. Attach new 65 mm tube to both ends of the choke valve. 65 mm C AUTION Do not use the old tube. Ink may leak because the end of the old tube is enlarged. 1-107 SG2-640/540/300...
Page 114 Choke Valve Replacement Attach the choke valve and solenoid. 1. Choke valve 2. Solenoid Connect the new ink tubes to the choke valve. Attach the covers, and turn on the power switch. Then connect Peck2 to the machine, and enter the service mode. 10.
Page 115: Ink Tube Replacement
Ink Tube Replacement Information Necessary tools General tools No. 2 Phillips screwdriver 2.0 mm hexagonal wrench Waste cloth Gloves (anti-slip) Tape Special tools None Typical work time Contents of work Time Ink tube replacement 100 min. 1-109 SG2-640/540/300...
Page 116: Outline Diagram
Ink Tube Replacement Outline Diagram Back view Top view 1. Ink tube 2. Print-head carriage 1-110 SG2-640/540/300...
Page 117: Cover That Needs To Be Removed
Ink Tube Replacement Cover That Needs to Be Removed Carriage cover NOTE • The screws are on the right and left side of the carriage cover. 1-111 SG2-640/540/300...
Page 118: Workflow
Ink Tube Replacement • When you attach the carriage cover, place the left side of the cover inside the metal plate. Workflow C AUTION The figures below show which color connects to which tube. Be sure to observe the figures before replacing the ink tubes. CMYK (4 colors) Pressure pump...
Page 119 Ink Tube Replacement Connect Peck2 to the machine, and enter the service mode. Perform [SERVICE MENU] > [SUB MENU] > [PUMP UP] and discharge ink from the ink lines. C AUTION Be sure to discharge ink in accordance with the message on the panel. Failure to do so will cause ink to spill out of the drain bottle.
Page 120 Ink Tube Replacement Remove the plate that fixes the ribbon cables. Remove the connectors and remove the print carriage board. Remove the sheet under the print carriage board. 1-114 SG2-640/540/300...
Page 121 Ink Tube Replacement Disconnect the cables that are attached to the pump drive board (EX MTR 9CH BOARD) and ink system RFID board. 1. Ink system RFID board 2. Pump drive board (EX MTR 9CH BOARD) NOTE Remove the cables from the metal plate with the clamps in order to make it easier when attaching the cables. Remove the pump drive board stay.
Page 122 Ink Tube Replacement 11. Remove the clamp. 12. Remove plate 1 and 2. Each plate is secured with one screw. Print-head carriage back view 1. Plate 1 2. Plate 2 13. Remove plate 3 and 4. Each plate is secured with two screws. 1.
Page 123 Ink Tube Replacement 14. Unfasten all clamps on the print-head carriage to release the tubes. 15. Remove the tubes from the L-shaped joints. C AUTION Remove the ink tubes slowly so that ink will not drip or spatter. Putting waste cloth under the L-shaped tubes is recommended. NOTE Wipe off any ink from the ribbon cables and print heads with waste cloth.
Page 124 Ink Tube Replacement 17. Remove the screws. C AUTION Unfasten the retaining band from the metal plate. 18. Lift up the print-head carriage plate and detach one tube guide. 1-118 SG2-640/540/300...
Page 125 Ink Tube Replacement 19. Detach the rest of the tube guides from the cable guide plate and frame. The number of tube guides to remove in this step: SG2-640:29 tube guides SG2-540: 26 tube guides SG2-300:20 tube guides 1. Tube guide 2.
Page 126 Ink Tube Replacement 22. Remove the ink tubes along with the tube guides. 23. Insert the new ink tubes through the tube guides. Total number of tube guides: SG2-640:30 tube guides SG2-540: 27 tube guides SG2-300:21 tube guides Pressure pump side Tube number No.
Page 127 Ink Tube Replacement 25. Insert the new ink tubes into the machine. 26. Lift up the print-head carriage plate and attach the tube guide to the print-head carriage. C AUTION If you press the tube guide too hard, the tube guide will break. Be sure to align the tube guide plate with the cutout of the head carriage, and then attach the tube guide.
Page 128 Ink Tube Replacement 28. Tighten two screws. 29. Fasten 6 clamps to secure the tubes. No. 1, 2 No. 1, 2 No. 3, 4 No. 3, 4 No. 1, 2, 3, 4 No. 1, 2, 3, 4 30. Connect the ink tubes to the L-shaped joints. C AUTION • Be sure to wear gloves (anti-slip).
Page 129 Ink Tube Replacement 31. Connect the ink tubes to the pressure pumps, ink circulation pumps, and the choke valve. C AUTION • Be sure to wear gloves (anti-slip). • Hold the tube about 10 mm from the end and insert it straight so that it does not bend. • See the figure below and connect each tube to the correct joint.
Page 130 Ink Tube Replacement 34. Attach plate 3 and 4. 1. Plate 3 2. Plate 4 35. Bundle the cables with the clamps. 36. Attach the pump drive board stay. 1-124 SG2-640/540/300...
Page 131 Ink Tube Replacement 37. Connect all the connectors to the pump drive board (EX MTR 9CH BOARD) and ink system RFID board, and attach the removed clamps. 38. Attach the sheet under the print carriage board. NOTE Insert the sheet below the screw heads. 1-125 SG2-640/540/300...
Page 132 Ink Tube Replacement 39. Attach the print carriage board. C AUTION Do not forget to attach the plate that fixes the ribbon cables. 40. Connect all the cables to the print carriage board. 41. Connect all the ribbon cables of the print heads to the print carriage board. C AUTION Be sure to connect each ribbon cable to the correct connector.
Page 133 Ink Tube Replacement 43. Attach the covers and turn on the power switch. Then connect Peck2 to the machine, and enter the service mode. 44. Perform [SERVICE MENU] > [SUB MENU] > [FILL INK] and fill the ink lines with ink. NOTE Required time for [FILL INK]: approx.
Page 134: Chapter 2 Adjustment
Chapter 2 Adjustment Workflow ........2-46 Service Mode ....... . 2-2 Belt Tension Adjustment .
Page 135: Service Mode
Service Mode MENU + POWER ON [ MENU ] key ＊In order to enter the service mode, you need to connect Peck2 to SERVICE MENU the machine. SERVICE MENU PRINT MENU HEAD RANK HEAD RANK 1 00003E83E8 PRINT MENU HEAD RANK HEAD 1 HEAD RANK HEAD RANK 2...
Page 136 Service Mode PERFORMING CALIB.DEFAULT PRINT MENU TEST PATTERN TEST PRINT CALIB.DEFAULT CALIB.DEFAULT SETTING Calibration (Feed Direction) SETTING +0.00% +0.00% - Range: -2.00% to +2.00% (changeable by 0.01%) PERFORMING PRINT MENU TEST PATTERN - Check if the horizontal head correction value is correctly entered and whether TEST PATTERN TEST PATTERN HORIZONTAL...
Page 137 Service Mode Insert the ink cartridge to SLOT1 IC CHECK I/S MENU CARTRIDGE CARTRIDGE IC CHECK SLOT1 INSERT Remove the ink cartridge from SLOT1 Normal end IC CHECK SLOT1 Error IC CHECK SLOT1 ERROR Insert the ink cartridge to SLOT4 IC CHECK SLOT4 INSERT...
Page 138 Service Mode I/S MENU WIPE ADJUST 0.00mm 0.10mm WIPE ADJUST Wiper Position Adjustment - If you select this menu, the wiper starts rotating and stops at the straight up position. Also, the carriage moves to the left side of H2. - Move the head carriage with [] [] keys so that the edge of the wiper touches the left side of the print head straight.
Page 139 Service Mode CUTTING MENU CROP-CUT ADJ. PERFORMING TEST PATTERN TEST PRINT CROP-CUT ADJ. CROP-CUT ADJ. F:+0.30 +0.30mm S:-0.40 -0.40mm SETTING PERFORMING CROP-CUT ADJ. TEST PATTERN TEST PRINT 2 Adjusting the Position of the Crop Mark Sensor and the Position of the Blade TEST PRINT It prints a test pattern to align the position of the crop mark sensor and the position of the blade.
Page 140 Service Mode FRSHODPLWwaCQT F1234 C1234M SERVICE MENU SENSOR CHECK Sensor Check - This menu is for showing the real-time state of each sensor. If there is a response, a * mark is displayed. - The rst display shows the status of each of the sensors. Symbol Sensor name Description...
Page 141 Service Mode CHANGE TO NEW EMPTY CLEANING... SUB MENU INK CARTRIDGE DRAIN BOTTLE > 11:30 FILL DAMPER * Error EMPTY CLEANING ERROR DRAIN BOTTLE Fill Damper - It starts cleaning when you press the [ENTER] key. - During cleaning, progress and the remaining time are displayed at the bottom of the LCD screen. - “CLEANING ERROR”...
Page 142 Service Mode Date and time setting - This menu is for displaying and editing the date and time. When the machine detects a dead battery, “B” is indicated on the time display. In this case, the batter needs to be replaced. “B” does not disappear automatically when the battery is replaced. “B” is deleted when the time is newly set up with the [ENTER] key on the time edit menu.
Page 143 Service Mode MOTOR MENU AGING NOW AGING SERVICE MENU AGING MOTOR MENU SCAN AGING NOW AGING FEED AGING NOW AGING BOTH AGING NOW AGING CUTTING Motor Aging - To stop aging, press the [ENTER] key. The head carriage automatically returns to the capping position. After the head is capped, it returns to the previous menu.
Page 144 Service Mode HEATER MENU PREHEAT TEMP. PREHEAT TEMP. 30°C 30°C Heater Warm-Up Temperature Setting - Sets the temperature of the PREHEAT (warm-up) in the PREHEATING menu of the user menu. - Setting range: 20°C to 40°C - Default value: 30°C HEATER MENU HEAT TIMEOUT HEAT TIMEOUT...
Page 145: History Menu
History Menu MOTOR GROUP Item Description Unit Remarks MOTOR HOURS F Total time the feed motor rotated hour Brush life time MOTOR HOURS S Total time the scan motor rotated hour Brush life time S PUMP TIMES Number of times the cleaning pump rotated times Pump life P PUMP TIMES 1 to 4...
Page 146 History Menu PRINT GROUP Item Description Unit Remarks PRINTING TIME Total printing time hour Test print time is excluded. PRINT PAGES Number of pages printed pages PRINT AREA Total area of printing performed square meter CLEAR ALL Clear all values under PRINT GROUP CUTTING GROUP Item Description...
Page 147 History Menu SYSTEM GROUP Item Description Unit Remarks POWER ON COUNT Number of times the sub power switch was turned on times POWER ON TIME Hours that the sub power switch is on hour SLEEP TIME Total time the printer was in the sleep mode hour It counts auto sheet cut performed by SHEETCUT COUNT...
Page 148: Firmware Upgrade
Firmware Upgrade Information Necessary tools Software Peck2 Latest firmware Typical work time Contents of work Time Firmware upgrade 5 min. Workflow C AUTION It is necessary to prepare the following to upgrade/install the firmware. • A firmware file • Windows computer (Network port is required.) • Peck2 • Network cable (A cross cable is required when you connect the printer to a computer directly.) Check the IP address of the printer.
Page 149 Firmware Upgrade Start Peck 2 on a computer, and by pressing [Login] button, log in with Imagi-net ID. Logging in can be omitted the second time and after. Press [Connect Printer] button. Set the same IP address as the machine in Peck2, and press [Connect] button. 2-16 SG2-640/540/300...
Page 150 Firmware Upgrade Check [Model] and [Status] on Peck 2 main screen, and confirm that the machine is connected. Press [Update Firmware] button, and select the firmware. Click [Open] and the firmware will be sent to the printer. The printer goes into the firmware upgrade mode automatically. When the upgrade is completed, the sub power switch turns off automatically.
Page 151: Firmware Installation
Firmware Installation Information Necessary tools Software Peck2 Latest firmware Typical work time Contents of work Time Firmware installation 10 min. Workflow C AUTION Perform this procedure when a brand-new main board without firmware is installed. Turn on the main power switch while pressing the[] [] [] keys. UPDATE FIRMWARE? Press the [ENTER] key to prepare the printer for receiving the firmware.
Page 152 Firmware Installation Press the [MENU] key, and set [IP ADDRESS], [SUBNET MASK], and [GATEWAY ADDR.]. Press the [] [] keys for moving between digits, and the [] [] keys for selecting values. After setting an address, press the [ENTER] key to go to the next address setting.
Page 153 Firmware Installation Press [Connect Printer] button. Set the IP address [192.168.1.99] in Peck2, and press [Connect] button. Press [Update Firmware] button, and select the firmware. Click [Open] and the firmware will be sent to the printer. 2-20 SG2-640/540/300...
Page 154 Firmware Installation Firmware loading begins. The firmware installation is completed when the [COMPLETED] message is displayed. Turn off the sub power switch. FIRMWARE V1.10 DATA ERROR ERASING DEVICE ERROR WRITING DEVICE ERROR VERIFYING DEVICE ERROR COMPLETED Turn on the sub power switch while pressing the [] [] [ENTER] keys to enter the [INITIALIZE ALL SYS. PARAMETER] menu.
Page 155 Firmware Installation 11. Set the IP address [192.168.1.99] and press [Connect] button in [Connect Printer] in Peck2. 12. Press [Put Parameters] button. 13. Select the parameter file that was acquired before the main board replacement. Click [Open] and the system parameter will be sent to the printer.
Page 156 Firmware Installation 14. Click [Check Report] to import the system report file. Confirm that system parameters are reloaded properly. NOTE The network settings set at step 11 are replaced with the system parameters when [Put Parameters] is executed. Please do the network settings again if necessary.
Page 157: Limit Position & Cut Down Position Initialization
Limit Position & Cut Down Position Initialization Information Necessary tools General tools None Special tools None Typical work time Contents of work Time Limit position & cut down 3 min. position initialization Workflow C AUTION • This is for adjusting the relative distance between the limit sensor and the capping position, and also detecting the distance from the cut down position to the limit sensor after completing the adjustment.
Page 158 Limit Position & Cut Down Position Initialization Lock the print-head carriage. Confirm that the print-head carriage is locked by pushing it lightly to the left to eliminate looseness. Confirm that the print head is capped properly, and press the [ENTER] key. The tool carriage will be separated from the print-head carriage and limit position initialization will start.
Page 159 Limit Position & Cut Down Position Initialization Move the tool carriage and print-head carriage with your hand until they make full contact with the left frame with the cutter in the down position. NOTE In order to shorten the work time, the tool carriage and the print-head carriage are not separated. Press the [ENTER] key to perform cut down position initialization.
Page 160: Linear Encoder Setup
Linear Encoder Setup Information Necessary tools General tools No. 2 Phillips screwdriver Special tools None Typical work time Contents of work Time Linear encoder setup 5 min. Workflow C AUTION This adjustment is for checking reading by the linear encoder and for calibrating encoder expansion/contraction caused by the operation environment.
Page 161 Linear Encoder Setup One of the messages appears at the completion of setup. LINEAR ENCODER SETUP COMPLETED LINEAR ENCODER SETUP FAILED NOTE In case of [SETUP FAILED] error occurs, check the following. • Dirt/scratches on the encoder scale • Dirt/scratches on the encoder sensor • Limit position &...
Page 162: Flushing Position Adjustment
Flushing Position Adjustment Information Necessary tools General tools None Special tools None Typical work time Contents of work Time Flushing position 3 min. adjustment Cover That Needs to Be Removed 2-29 SG2-640/540/300...
Page 163: Workflow
Flushing Position Adjustment Workflow C AUTION This is to adjust the flushing position. Without this adjustment, the flushing may not be performed properly and that can cause nozzle firing problem. Set the head height to LOW. Unlock the print-head carriage. Slide the cap-base frame to the left by hand until it does not go any further.
Page 164 Flushing Position Adjustment Select [PRINT MENU] > [FLUSHING ADJ], and press the [ENTER] key. The print-head carriage automatically moves to the current flushing position. SERVICE MENU PRINT MENU PRINT MENU FLUSHING ADJ. FLUSHING ADJ. 0.00mm -0.40mm Move the print-head carriage to the position where the head base makes contact with the tip of the cap base by pressing the [] and [] keys.
Page 165 Flushing Position Adjustment Confirm that there is a gap between the head base and the backup cap base. NOTE • Check that there is the gap by shining a flashlight from behind the head carriage. 1. Backup cap base 2. Head base • If you do not see any gap, go back to step 5 and perform the adjustment again.
Page 166: Crop Mark Sensor Adjustment
Crop Mark Sensor Adjustment Information Necessary tools General tools White sticker media Flat head screwdriver (1.0 to 2.0 mm) Special tools None Typical work time Contents of work Time Crop mark sensor adjustment 10 min. Cover That Needs to Be Removed 2-33 SG2-640/540/300...
Page 167: Workflow
Also, in case you perform this adjustment using media other than IJ5331, the sensor may not be able to detect crop marks printed on Roland original media. Connect Peck2 to the machine, and enter the service mode.
Page 168 Crop Mark Sensor Adjustment Perform [OUTLEVEL CHECK]. Confirm that the display is 4.8 V ±0.1 V. Min2.4V Max4.8V [4.8V] NOTE If not, carry out the adjustment again. (End of procedure) 2-35 SG2-640/540/300...
Page 169: Print Head Alignment
Print Head Alignment Information Necessary tools General tools Media No. 2 Phillips screwdriver 1.5 mm hexagonal wrench Special tools ST-056 TORQUE DRIVER N6 1000015274 BIT, PHILLIPS NO.2 L200MM Typical work time Contents of work Time Print head alignment 20 min. Cover That Needs to Be Removed Carriage cover 2-36...
Page 170: Workflow
Print Head Alignment NOTE • The screws are on the right and left side of the carriage cover. • When you attach the carriage cover, place the left side of the cover inside the metal plate. Workflow C AUTION • This adjustment is to obtain the good printing quality. Make sure to perform this alignment after print head replacement. If the print heads are not aligned, printing problems such as banding, fine lines and gaps between bands may occur.
Page 171 Print Head Alignment Unlock the print-head carriage. Remove the carriage cover. Connect Peck2 to the machine, and enter the service mode. Set PET-G on the printer. Select [PRINT MENU] > [HEAD ADJUST] > [BIAS/VERTICAL] > [TEST PRINT], and press the [ENTER] key. SERVICE MENU PRINT MENU [ ] [ ]...
Page 172 Print Head Alignment BIAS Adjustment Loosen four screws that secure the print head base. C AUTION Turn the screws about half a turn. If you loosen them too much, print head alignment cannot be performed properly. Turn the adjustment screw using a 1.5 mm hexagonal wrench and adjust the print head base position so that the lines of the BIAS test pattern will be aligned.
Page 173 Print Head Alignment When the top half of the lines are shifted right side: Turn the adjustment screw counterclockwise. Tighten the fixing screws to secure the print head base using a torque driver (torque value: 0.6 N ・ m//60 cN ・ m). C AUTION Do not overtighten the screws.
Page 174 Print Head Alignment 10. A test pattern is printed. Find the position where the two lines are overlapping and check the number of each color. NOTE • In case of problems selecting one of two numbers, half values are also available for inputting. • The number with [] is the current setting.
Page 175 Print Head Alignment 13. A test pattern shown below is printed. Find the position where the two lines are overlapping and check the number of each color. Horizontal No.1 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 +1 +2 +3 +4 +5 +6 +7 +8 +9 +10 +11 +12 +13 +14 +15 NOTE • In case of problems selecting one of two numbers, half values are also available for inputting.
Page 176: Tool Height Adjustment
Tool Height Adjustment Information Necessary tools General tools No. 2 Phillips screwdriver Thickness gauge 1.5 mm hexagonal wrench Special tools ST-006 WHITE DUMMY PEN Typical work time Contents of work Time Tool height adjustment 10 min. Cover That Needs to Be Removed 2-43 SG2-640/540/300...
Page 177: Workflow
Tool Height Adjustment Workflow Connect Peck2 to the machine, and enter the service mode. Select [CUTTING MENU] > [FORCE ADJUST]. MENU SERVICE MENU [ ] [ ] SERVICE MENU CUTTING MENU [ ] [ ] CUTTING MENU FORCE ADJUST NOTE When you enter the [FORCE ADJUST] menu, the tool carriage automatically moves to the position shown below.
Page 178 Tool Height Adjustment Fasten the white dummy pen to the tool carriage. Remove the tool carriage cover. Turn the adjustment screw with 1.5 mm hexagonal wrench. Turn the adjustment screw so that the space between the pen tip and the bed becomes 2.5 mm to 2.6 mm. Perform the tool pressure adjustment in reference to Chapter 2 "Tool Pressure Adjustment".
Page 179: Tool Pressure Adjustment
Tool Pressure Adjustment Information Necessary tools General tools No. 2 Phillips screwdriver Special tools ST-002 TENSION GAUGE 300g (3N) ST-006 WHITE DUMMY PEN ST-012 DIAL TENSION METER DTB-50 Typical work time Contents of work Time Tool pressure adjustment 15 min. Workflow C AUTION • This adjustment must be performed after tool carriage replacement.
Page 180 Tool Pressure Adjustment NOTE When you enter the [FORCE ADJUST] menu, the tool carriage automatically moves to the position shown below. Place the pinch rollers above the grit areas as shown in the figure below. Then, lower the pinch rollers. Pinch roller Grit rollers Fasten the white dummy pen to the tool carriage.
Page 181 Tool Pressure Adjustment Select [FORCE ADJUST] > [LOW]. Then, press the [PAUSE] key to lower the tool carriage. CUTTING MENU FORCE ADJUST [ ] [ ] FORCE ADJUST [ ] [ ] 30gf 32gf [PAUSE] Lift the tool holder with the dial tension meter and measure the pressure when the pen tip leaves the bed. Then, input the value indicated by the dial tension meter with the [] [] keys.
Page 182 Tool Pressure Adjustment Lift the tool holder with the tension gauge and measure the pressure when the pen tip leaves the bed. Then, input the value indicated by the tension gauge with the [] [] keys, and press the [ENTER] key to save the setting. Then press the [ENTER] key to save the setting.
Page 183: Belt Tension Adjustment
Belt Tension Adjustment Information Necessary tools General tools No. 2 Phillips screwdriver 3.0 mm hexagonal wrench Typical work time Contents of work Time Belt tension adjustment 40 min. Workflow Open the maintenance cover L. Lock the print-head carriage. Confirm that the print-head carriage is locked by pushing it lightly to the left to eliminate looseness. 2-50 SG2-640/540/300...
Page 184 Belt Tension Adjustment Measure the tension of the belt at the position above the center of the 5th grit roller from the left (for SG2-300, the 3rd grit roller from the left) using the tension gauge. If the tension is proper, the adjustment is not necessary. When the tension is not proper, move on to the next step and adjust the belt tension.
Page 185 Belt Tension Adjustment Loosen two fixing screws which are located on the left end of the belt halfway turn. C AUTION Be careful with the sharp edges around the belt when loosening the screws. It may cause injury. Insert a wrench through the holes on the side frame and loosen two adjustment screws to make a gap of three millimeters between the tip of the screw and idle pulley holder.
Page 186 Belt Tension Adjustment Tighten two fixing screws, and again confirm that the tension is within the proper range. Tighten two adjustment screws until they slightly touch the idle pulley holder. C AUTION Do not overtighten the screws. Overtightening could move the idle pulley holder. Idle pulley holder 10.
Page 187: Belt Position Adjustment
Belt Position Adjustment Information Necessary tools General tools No. 2 Phillips screwdriver 3.0 mm hexagonal wrench Typical work time Contents of work Time Carriage belt position 40 min. adjustment Cover That Needs to Be Removed Side cover C AUTION Before removing the side cover, remove the cable of the cover sensor. 2-54 SG2-640/540/300...
Page 188: Workflow
Belt Position Adjustment Workflow C AUTION • This adjustment is to prevent the belt wear which is caused by the belt contacting the pulley flanges excessively. The belt position needs to be checked after the belt tension adjustment and adjusted if necessary. • When adjusting the drive pulley side, the pressure of engagement between the white gear of the drive pulley and the scan motor gear is changed, possibly resulting in teeth breaking on the white gear or failure of the scan motor.
Page 189 Belt Position Adjustment NOTE Belt partly touching the flange is acceptable. Press the [ENTER] key to interrupt aging. SCAN NOW AGING Loosen two fixing screws located on the right end of the belt. C AUTION Loosen the screws a few turns. Loosen the screws a few turns to make a small gap between the bottom of the screw head and stay.
Page 190 Belt Position Adjustment When the belt is shifted toward the front side of the machine: " Turn the screw carefully clockwise (tightening). When the belt is shifted toward the rear side of the machine: " Turn the screw carefully counterclockwise (loosening). Tighten two screws until the bottom of the screw heads slightly touch the stay.
Page 191 Belt Position Adjustment Confirm that the belt is not touching the pulley flanges excessively. When the belt is properly positioned, leave the belt aging on, and proceed to "Adjustment on the ide pulley side". When the belt is improperly positioned, adjust it again. Adjustment on the idle pulley side Check the position of the belt.
Page 192 Belt Position Adjustment 11. Loosen two fixing screws located at the left end of the belt by a quarter turn. C AUTION If you loosen the screws too much, it will make it difficult to adjust the belt position. Be careful with the sharp edges around the belt when loosening the screws.
Page 193 Belt Position Adjustment 14. Insert a wrench through the holes on the side frame and adjust the belt position by turning the screws as follows. When the belt is shifted toward the front side of the machine: " Turn screw 1 carefully clockwise to where it touches to the idle pulley holder. * Make sure that there is a gap of three millimeters between screw 2 and the idle pulley holder when turning screw 1.
Page 194 Belt Position Adjustment 16. Confirm that the belt is not touching the pulley flanges excessively. When positioning is correct, press the [ENTER] key to interrupt aging. When the belt is improperly positioned, adjust it again. SCAN NOW AGING 17. Tighten two fixing screws. 18.
Page 195 Belt Position Adjustment 20. Attach the covers and turn on the power switch. Then connect Peck2 to the machine, and enter the service mode. 21. Select [SERVICE MENU] > [SENSOR CHECK]. SERVICE MENU SENSOR CHECK 22. Slide the maintenance cover sensor R to the front until "*" under "D" disappears. Then, tighten two screws to secure the sensor.
Page 196: Wiper Position Adjustment
Wiper Position Adjustment Information Necessary tools General tools None Special tools None Typical work time Contents of work Time Wiper position adjustment 3 min. Workflow C AUTION This adjustment is to set the reference position for wiping. Connect Peck2 to the machine, and enter the service mode. Select [I/S MENU] >[WIPE ADJUST]. MENU SERVICE MENU [ ] [ ]...
Page 197 Wiper Position Adjustment Move the print-head carriage with [] [] keys so that the edge of the wiper touches the left side of the print head straight. Press the [ENTER] key to set the reference position for the wiper. 1. Wiper 2.
Page 198: Feed Calibration
Feed Calibration Information Necessary tools General tools SP-M (Matte-PET artificial paper) Special tools None Typical work time Contents of work Time Feed calibration 15 min. Workflow C AUTION • This adjustment is for calibrating the feed amount of media. It allows the media to be fed in proper amount by calibrating the variation in grit roller diameter.
Page 199 Feed Calibration Measure the length of the feed direction and use the value to calculate the correction value with the formula shown at step 4. C AUTION Test pattern is always printed with correction value 0.00%. Even if a correction is made in the [SETTING] menu, the test pattern is not affected.
Page 200: Feed Adjuster Adjustment
Feed Adjuster Adjustment Information Necessary tools General tools 6.0 mm hexagonal wrench Masking tape Ruler Special tools Adjustment paper (included) Carriage stopper(included) Paper tube (included) Typical work time Contents of work Time Making a paper ring for 3 min. adjustment Feed adjuster adjustment 10 min.
Page 201 Feed Adjuster Adjustment C AUTION • Before making a paper ring, check that the adjustment papers are not scratched nor distorted. • Be careful not to make a folding line. • Nicely align the edges of the paper ring, and tape it. The upper edge and the lower edge of the paper ring are nicely aligned.
Page 202 Feed Adjuster Adjustment Pass the paper ring through the paper tube and place the paper ring approximately 50 mm from the left edge of the paper tube. Insert the end of adjustment ring to the gap between the grit and the pinch roller. Pull the paper ring in the direction indicated with the arrow, and stabilize it.
Page 203 Feed Adjuster Adjustment Press the carriage stopper against the frame. Lightly pull the paper ring for adjustment to remove slack. Then, draw a line along the carriage stopper with a ballpoint pen. Move the paper ring to the cartridge side with the paper ring passing through the paper tube. (Place it approx. 50 mm from the right edge of the paper tube).
Page 204 Feed Adjuster Adjustment 10. Referring to step 6 through 8, draw a line with a ball point pen at the cartridge side also. 11. Measure the gap between the two lines with a ruler (the line you drew on the panel side and the line you drew on the cartridge side).
Page 205 Feed Adjuster Adjustment 13. Perform adjustment by turning the adjustment screw. NOTE • Size of the gap: 1 turn • Turning direction If the line you drew on the panel side is upper: clockwise If the line you drew on the cartridge side is upper: counterclockwise In the case of figure in step 11, the size of the gap is 3 mm, and the line you drew on the cartridge side is upper.
Page 206: Chapter 3 Supplement
Chapter 3 Supplement Motor Errors ........3-2 Service Call Errors .
Page 207: Motor Errors
Motor Errors Error Description SCAN MOTOR ERROR CODE : 0000 0000 *Current error Initial error * If different errors occur in order, their codes are added up. ex) 0022 is displayed, if 0002 (FEED motor error) and 0020 (SCAN motor error) occur in order. Code Meaning Cause...
Page 208: Service Call Errors
Service Call Errors Action (You do not have to perform everything Code Error name Contents Possible causes listed below. Sometimes performing just one or some of the following can solve the problem.) • The sub board does not work correctly. • Check the cable connection between main board and servo board.
Page 209 Service Call Errors Action (You do not have to perform everything Code Error name Contents Possible causes listed below. Sometimes performing just one or some of the following can solve the problem.) • Wiper motor error • Replace the wiper motor. • Defect of the wiper unit • Replace the wiper unit.
Page 210 Service Call Errors Action (You do not have to perform everything Code Error name Contents Possible causes listed below. Sometimes performing just one or some of the following can solve the problem.) • Replace the pump board. • Sub CPU does not work correctly. • Check the following cable connection.
Page 211: Supplement On Service Call 0400
Supplement on Service Call 0400 When the error "0400" occurs, the message below appears on the operation panel screen. SERVICE CALL 0400 [00C0] SERVICE CALL No. Nozzle line code (It indicates which nozzle the error occurred to.) How to read the nozzle line code In case the error "0400"...
Page 212: Sensor Map
Sensor Map Thermistor (print heater) Maintenance cover sensor R It measures the temperature of the heater. It detects the open/close state of the maintenance cover R. (It prevents scan motor operation when the right maintenance cover is open.) Grit encoder sensor It detects the rotation speed of the grit Front paper sensor roller.
Page 213 Sensor Map Ink slot cover sensor It detects whether the ink slot cover is open or closed. tooltip Thermostat (print heater) Power supply to the heater will be cut off when the temperature exceeds allowable temperature limit. Maintenance cover sensor L It detects the open/close state of the maintenance cover L.
Page 214 Sensor Map Limit sensor Head lock sensor It detects the starting position of the carriage. It detects whether the print-head carriage is at the lock position or not. Auto pinch sensor It detects up/down of auto pinch. Rear paper sensor It detects the rear end of media.
Page 215 Sensor Map Ink empty sensor It detects whether the cleaning liquid pouch is empty or not. Ink cartridge sensor It detects whether the ink cartridge or cleaning liquid pouch is installed or not. Ink cartridge RFID sensor It communicates information such as the remaining ink amount.
Page 216 Sensor Map Thermistor (print carriage board) It measures the temperature around the print carriage board. Head up/down sensor 0 Head up/down sensor 1 It detects the position of the print head. Linear encoder sensor It detects the coordinates of the carriage and sends print signals.
Page 217: Wiring Map
Wiring Map Service Parts For more information on the cables, refer to the Parts Finder Web. https://365rolanddg.sharepoint.com/sites/extranet/Work-SitePages/GSV-PartsFinder.aspx Description of sensor name The name of each sensor is described as written below. GRIT ENCODER BOARD Grit encoder sensor PAPER SENSOR REAR Rear paper sensor PINCH U/D SENSOR Pinch lever sensor...
Page 218: Sg2-640 Wiring Map
Wiring Map SG2-640 Wiring Map 3-13 SG2-640/540/300...
Page 219: Sg2-540 Wiring Map
Wiring Map SG2-540 Wiring Map 3-14 SG2-640/540/300...
Page 220: Sg2-300 Wiring Map
Wiring Map SG2-300 Wiring Map 3-15 SG2-640/540/300...
Page 221: Chapter 4 Service Activities
Chapter 4 Service Activities Installation Checklist ......4-2 Maintenance Checklist ..... .4-21 SG2-640/540/300...
Page 222: Installation Checklist
Installation Checklist SG2-640/SG2-540/SG2-300 Installation Checklist Date: User name: Serial number: Installation space □ The space is secured in order to use this machine. Included item □ Confirm that the included items are all present and accounted for in reference to Setup Guide. Installation and preparation Refer to "Assembly and Ink Filling"...
Page 223 Installation Checklist [Necessary parts] Part No. Part Name ARM,PACKING L SV CG2076 1000020778 ARM,PACKING L SV CG2076 1000020777 11879122 ABSORBER,K-16 x4 31049125 SCREW,CAP M6*30 NI x8 SCREW,CAP M6*20 31049157 3CBC+PW+SW x4 Attach the ABSORBER to both end of ARM, Packing U (2 pieces). ネジ...
Page 224 Installation Checklist Cut the four corners of the cardboard box with a cutter, and open it. Pull out the packing material in the middle, and remove the packing materials of both sides. NOTE If the packing materials are hard to remove, lift the machine slightly. C AUTION Make sure that the bottom plug does not interfere with the packing material.
Page 225 Installation Checklist Temporarily tighten SCREW,CAP M6*20 at the positions shown in the figure. Approx. 10 mm Pass ARM,PACKING U through the bolt hole, and slide it towards the direction indicated with the arrow. NOTE Attach Pass ARM,PACKING U in the orientation shown in the figure. The figure shows the panel side. SG2-640/540/300...
Page 226 Installation Checklist Tighten the screws with a hexagonal wrench. C AUTION Confirm that ARM,PACKING U has no backlash. Insert ARM,PACKING U SV CG2076 by sliding. NOTE Insert ARM,PACKING L so that the positions of its holes match those of ARM,PACKING U. 1.
Page 227 Installation Checklist Tighten the screws (SCREW,CAP M6*30 NI) on both ends. When the machine is fixed on the stand, remove ARM,PACKING. C AUTION Remove a plastic bag when you move the machine so as not to slip. 10. (End of procedure) Assembling using the shoulder strap Prepare the following items: [Necessary tool]...
Page 228 Installation Checklist [Necessary parts] Part No. Part Name STAY,SHOULDER STRAP SV 1000020779 CG2076 SCREW,CAP M6*20 31049157 3CBC+PW+SW x8 Perform step 2 to 3 of the procedure for “Assembling using the lift bar”. Temporarily tighten four SCREW,CAP M6*20 for one side. Pass STAY,SHOULDER STRAP through the bolt hole, and slide it.
Page 229 Installation Checklist Tighten the screws with a hexagonal wrench. C AUTION Confirm that STAY,SHOULDER STRAP has no backlash. Pass the shoulder strap through STAY,SHOULDER STRAP. When the machine is fixed on the stand, remove STAY,SHOULDER STRAP. C AUTION Remove a plastic bag when you move the machine so as not to slip. (End of procedure) SG2-640/540/300...
Page 230 Installation Checklist □ Installing the media holders □ Installing the drain bottle □ Removing the retainers/packing materials □ Connecting the cables □ Feed adjuster adjustment C AUTION Perform feed adjuster adjustment in reference to chapter 2 “Feed adjuster adjustment”. □ Connecting the damper tube Connecting the damper tube This work is not necessary on the machines with the serial numbers below.
Page 231 Installation Checklist NOTE Loosen two screws, and slide the shaft toward the left, and then remove the front cover. Move the print-head over the bed, and remove the tube stopper. Connect the tubes. 4-11 SG2-640/540/300...
Page 232 Installation Checklist NOTE • There are red and blue marks on the tubes. Be sure to connect the tubes with the same colors. • Do not perform this work for multiple print heads simultaneously. Connect the tubes of one print head at a time so as not to connect wrong tubes mistakenly.
Page 233 Turn off the computer's power-saving functions which make the computer go standby or sleep. It may stop a job being output. Installing Roland OnSupport Perform installation referring to" Roland OnSupport" in Manual Library. □ Basic operations • How to display OnSupport Help □...
Page 234 • Register the Roland DG account if the customer accepts it. C AUTIO N When you register the Roland DG account (Roland DG ID), you will become able to use OnSupport more effectively. You are to communicate with our OnSupport server in registering your account. An e-mail address is required.
Page 235 Installation Checklist □ Cutting off the media □ Switch off Lower the sheet loading lever when the machine is not in use. Maintenance □ Checking the remaining ink amount C AUTIO N The remaining ink amount displayed on the operation panel screen is slightly different from the actual remaining amount. □...
Page 236 Installation Checklist □ Care and maintenance of the print head • Normal cleaning • Medium cleaning • Powerful cleaning • Super cleaning C AUTIO N Super cleaning consumes a large amount of ink. Perform super cleaning only when normal, medium, powerful, and manual cleaning cannot solve missing dot problems.
Page 237 Installation Checklist C AUTIO N Cleaning errors occur if ink runs out during damper cleaning. Be sure to install ink pouches that have a large remaining amount of ink. Fully utilizing the machine □ Preset function • Saving various settings as a name assigned preset • Loading a saved preset All menu items listed below can be saved in presets.
Page 238 *1 Perform these procedures for each media individually. Media gap calibration and feed calibration are required after changing the head height. If you are setting feed calibration on your machine, check in advance that [Use Printer Settings] is selected on Roland VersaWorks. □...
Page 239 Setting print head to use • [NOZZLE MASK] Setting print head to use by VersaWorks from the results of test printing. (in the case missing dots etc. occurred) □ Roland Mobile Panel 2 Required System Environment • iOS 10.0 or later Supported operating • Android 6 or later...
Page 240 Installation Checklist □ Returning all settings to their initial values • Explaining [FACTORY DEFAULT] Outputting from RIP software □ Printing Others □ Tell the user to see the User's Manual when error messages are displayed. If a service call occurs, switch off and on the machine and see if the problem is solved before calling for inquiry. Sometimes errors can be recovered just by restarting the machine.
Page 241: Maintenance Checklist
Maintenance Checklist SG2-640/540/300 Maintenance Checklist Date: User name: Serial number: Check items Important Points Check Interview with the customer Ask the customer if there is something that he/she is concerned about. □ Done Output / Get report before maintenance [Get report] by Peck2, or print both service report and history report. □Done If large amount of ink is discharged in the drain bottle, dispose of □Good...

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Roland TrueVIS SG2-640 Service Notes

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Chapter 1 Replacement of Main Parts

Chapter 2 Adjustment

Chapter 3 Supplement

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