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Ioline FlexJet Service Manual

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S er vi c e M a nu a l
Ioline FlexJet™

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  • Page 1 S er vi c e M a nu a l Ioline FlexJet™...
  • Page 2 Ioline Corporation assumes no responsibility for any errors that may be contained herein. Ioline has made every effort to make the FlexJet easy to operate, maintain, and repair. It is the responsi- bility of the operator of the printer to monitor the performance of the printer and maintain it in proper working condition by following the instructions in this manual and in the FlexJet User Guide and to follow all safety precautions and warnings that are described in these publications.
  • Page 3 Ioline FlexJet™ Ser vi c e M a nu a l...
  • Page 5 Figure 33. The Frame Gap window ..................48 Figure 34. Frame gaps on the plot ................... 49 Figure 35. Frame gaps may indicate that the FlexJet platen or stand is not level ..49 Figure 36. The height-adjusting spacer ................... 49...
  • Page 6 Figure 38. Carriage noise may indicate a dirty or faulty wheel ........50 Figure 39. Replacing the fuse ....................51 Figure 40. A good transitor on the left; the one on the right is blown ......52 Figure 41. Testing the Y-Axis motor ..................54 Figure 42.
  • Page 7 Figure 82. Remove the logic board cover ................83 Figure 83. Carefully unplug connections to the board ............84 Figure 84. Carefully remove the logic board ................ 84 Figure 85. Inspect the connections to the logic board ............85 Figure 86. Remove the keypad screws and bracket. Unplug the keypad cable ..... 87 Figure 87.

  • Page 9: Table Of Contents

    Chapter 1 Overview Product overview ........................19 Supported languages ......................19 Specifications ......................... 20 How the FlexJet works ....................... 21 Paper movement ........................21 Carriage movement ......................21 Serial number identification ....................21 Glossary ..........................22 Software setup options ....................... 22 Power on ............................
  • Page 10 Keypad error codes ......................... 36 Legend ............................. 36 Power problems ........................37 Communications ........................37 The FlexJet won’t respond to the computer ..............37 Serial communication ......................37 Common problems ........................ 38 Paper problems ........................42 Regular or intermittent paper tearing ................42 Media tracking ........................
  • Page 11 Keypad replacement ......................87 Y-Axis procedures ........................ 88 Y-Axis belt adjustment ......................88 X-Axis procedures ......................89 Chapter 5 Parts & Drawings FlexJet BOM (Bill of Materials) ..................91 Ioline FlexJet (Exploded view) ................... 94 Ioline FlexJet (Electronics view) ..................95 Index...
  • Page 13 Safety & Cautions The Ioline FlexJet has many fast moving components. To avoid in- jury and prevent electrical shock, please read and follow these safety guidelines before attempting to service the printer: Do not try to repair the machine without factory authoriza- tion.

  • Page 14: Warranty Policy

    Warranty Policy Ioline warranty policy Ioline Corporation provides a 12 month parts and labor warranty on all new equipment and 90 days on repaired units, unless specifically noted otherwise. Every unit is recorded by serial number when it leaves the factory. The warranty period is based on the serial num- ber of the unit and extends from the date of manufacture up to 12 months, plus an extra 3 months for shelf life.

  • Page 15: How To Use This Manual

    FlexPlot Service Manual personnel Specifications, part names, drawings FlexPlot Service Manual What’s in this Service Manual The FlexJet Service Manual provides extensive product specifica- tions, testing and repair procedures. Chapter 1 Introductory information and general specifications. Chapter 2 Descriptive drawings listing part names for the FlexJet.
  • Page 16 A. Left End Cover Feed Roll B. Safety Cover G. Take-up Shaft C. Right End Cover H. Paper Hub (2) D. Take-up Motor Feed Shaft E. Stand Leveling Foot Support Block (2) Figure 2. The Ioline FlexJet Printer front view.

  • Page 17: Visual Reference Guide

    K. Stand Leg (2) O. Power Switch and fuse L. Take-up Motor Cable Platen Leveling Foot M. Take-up Motor Outlet Q. Cross-member (3) N. Serial & USB Ports Figure 3. The Ioline FlexJet Printer rear view (head tilted in maintenance position.) xvii...
  • Page 18 S. Cartridge Stall Latch X. Platen T. Pinchwheel Lever Y. Pinchwheel U. Keypad Z. Drive Shaft Marker V. Service Station aa. Traverse ab. Carriage Assembly (Beneath Cover) Figure 4. The Ioline FlexJet Printer front view close-up (safety cover lifted for clarity.) xviii...

  • Page 19: Chapter 1 Overview

    The Ioline FlexJet can handle many different printing operations up to 72 inches wide and 600 yards long. Three industry standard printer languages (HPGL 7475, and DM/PL) are supported. The Ioline FlexJet also supports direct cable connection from many popular programs such as PAD , Scanvec...

  • Page 20: Specifications

    Ioline FlexJet Service Manual Specifications Metric Empirical Max. plotting width 1.83 m 72-in Media width min. .91-m 36-in max. 1.88-m 74-in Marker length 548.6-m 600 yds (Unattended) (Unattended) Floor space requirements 2.4-m x .7-m 96-in x 26-in Height 1.2-m 46-in Width 2.4-m...

  • Page 21: Figure 6. Paper Direction

    The Ioline FlexJet combines paper and ink cartridge motion to create vector outputs in a wide 72-in format. The data are sent to the FlexJet via either a standard RS-232 serial or USB cable. When a file is sent to the printer, the electronic system translates the vectors into instruc- tions for the “X”...

  • Page 22: Glossary

    This method works if your CAD software includes a driver for any Ioline product, such as the Ioline 600Ae or the Summit 2200. It will also work if the CAD software can create a...

  • Page 23: Figure 8. Workflow: Output Direct From Cad Software (Without Flexplot)

    Use FlexPlot software to convert files before sending them to the FlexJet for output. The FlexJet includes the FlexPlot software which will convert many different files into a format that is compatible with the FlexJet. It also provides an advanced marker queue manage- ment system and other tools to optimize the performance of the printer.

  • Page 24: Power On

    The printer power switch is located next to the power cord on the moving parts of the back of the machine, behind the keypad. When the FlexJet is pow- printer. Make sure the Service ered up, the carriage will move toward the left side of the machine, Station opening in the right end then return to the opposite side to park in the Service Station.

  • Page 25: Figure 10. Flexjet Control Center Main Menu

    To avoid communication port conflicts, do not simultaneously Overview run more than one application The FlexJet Control Center is a utility program that does two things: that communicates with the printer. Allows you to adjust settings to tailor output (e.g. scale, line width) from the computer.

  • Page 26: Control Center Menu Bar Features

    Control Center menu bar features File Download Firmware Allows the user to download the lat- est firmware version for the FlexJet. See the FlexJet User Guide for more information. Send Plot File Print a PLT or PLX file. Exit Exit the Control Center.

  • Page 27: Control Center Menu Options

    The Frame Size setting establishes clipping limits for each data frame. If the printed size of a plot frame exceeds the frame size set in the FlexJet, the excess is clipped or thrown away. (If the plot is clipped, try increasing the Frame Size manually.) The factory-set X-axis (paper direction) frame size is 46-in (116.8-cm), maximum is...

  • Page 28: Quality Setting

    Ioline FlexJet Service Manual Quality Setting Choose Draft or Best to control line density. Draft mode uses 300 DPI. Best mode uses 600 DPI. A lower DPI setting uses less ink by creating a fainter line. Higher DPI uses more ink but makes a darker line. Use this setting in conjunction with the Line Width (see above) to find a bal- ance between saving ink and making clearly visible lines.

  • Page 29: Chapter 2 Nomenclature

    Chapter 2 Nomenclature Product components Figure 11. The Ioline Flexjet power supply. Power cord plugin Power switch Figure 12. Rear power panel assembly.

  • Page 30: Figure 13. Service Station Assembly

    Ioline FlexJet Service Manual Cartridge Carriage stop wipers adjustment Servo motor screw Cartridge caps Cartridge “spit wells” Figure 13. Service Station assembly. Wheels (Replaceable) Figure 14. Pinchwheel assembly. Figure 15. Ink cartridges: HP 51645A.

  • Page 31: Figure 16. Flexjet Logic Board (Rev 1, Above; Rev 2 Below)

    Fans: encoder Main Service Take-up 1,2 & 3 power encoder station Y-Axis encoder motor power Keypad Y axis encoder Take-up port Sensor Serial port Ribbon Cable Secondary Socket sensor Figure 16. FlexJet logic board (Rev 1, above; Rev 2 below).

  • Page 32: Figure 17. Carriage Assembly With Cover On

    Ioline FlexJet Service Manual Carriage cover cartridges Figure 17. Carriage assembly with cover on. Carriage latch Cartridge catch bracket Carriage stall Red Light alignment indicator Base V-notch Figure 18. Carriage assembly with cover off.

  • Page 33: General Troubleshooting

    Ioline dealer. If the problem is with the FlexJet, begin by making sure power is on and that the cable between the machines and the PC is connected correctly.

  • Page 34: Control Center Software Errors

    The FlexJet did not respond. Do you wish to continue anyway? The Control Center did not get a response from a FlexJet on the COM port it is currently configured to use. If the FlexJet is connected and the power is on, click ‘Yes’.
  • Page 35 FlexJet is not responding. Please check your cables and baud rate. The Control Center did not get a response from a FlexJet on the COM port it is currently configured to use. If the FlexJet is connected and the power is on, click ‘Yes’.

  • Page 36: Figure 19. Led Lights On The Keypad

    Ioline FlexJet Service Manual Keypad error codes Figure 19. LED lights on the keypad. Legend G = Green light R = Red light Y = Yellow light Y-Blink = Blinking yellow light* OFF = Unlit Problem/Status Ready to Print, Origin Set Paused / Offline, Keypad Active Power on reset finished.

  • Page 37: Power Problems

    Continue holding the Page Advance key until the OK light turns red and the Square light turns green. If using a terminal program like TeraTerm to communicate with ™ the FlexJet, make sure to use 8 Data Bits, No Parity, 1 Stop Bit, and Xon/Xoff (software) Flow Control.

  • Page 38: Common Problems

    It is important to load paper in the FlexJet—and maintain it—ac- cording to the guidelines in the FlexJet User Guide. The table below summarizes the some of the most common difficulties users encounter.
  • Page 39 Paper not loaded correctly. Correct paper loading is vital. Follow the steps in the Opera- tion chapter of the FlexJet User Guide to reset paper align- ment. Make sure the front silver dancer bar is BELOW the front optical sensor before plotting.
  • Page 40 Frame Gap setting is incorrect. Use the Control Center to adjust frame gap as shown in the Routine Maintenance chapter of the FlexJet User Guide. Ink cartridge is out of ink, dirty Check ink level indicator. or the print head is plugged.
  • Page 41 Increase baud rate from the very low. minimum of 9600 baud to the default of 38,400 or higher. Make sure the FlexJet and the soft- ware are set to the same baud rate. Frame length is too big. Reduce frame length. Set be-...

  • Page 42: Figure 21. The Correct Paper Feeding Path On The Ioline Flexjet Printer

    Common situations that cause paper tearing while the FlexJet is operat- ing include: The paper was incorrectly loaded in the machine. The rear, heavy dancer bar was not loaded in the FlexJet after the paper was loaded. Figure 21 represents the proper paper path. The diagram on the left shows the paper after it is inserted properly and taped to the take-up shaft.

  • Page 43: Media Tracking

    (e.g. under the white markers affixed to the traverse.) Check to make sure that the printer is level. See the FlexJet Quick Start Guide for more information. The paper may slip when debris accumulates on the drive shaft.

  • Page 44: Figure 22. Hp Cartridges Have An Ink Level Indicator

    Use genuine HP 45 cartridges as recommended by Ioline. Recalibrate cartridges as described below. Level the platen as outlined in the FlexJet Quick Start Guide. Contact an Ioline distributor or Ioline Customer Service if you need further help. Figure 23. The ink cartridge is dirty, dry, or empty.

  • Page 45: Figure 24. The Ink Cartridge Requires Cleaning

    Chapter 3: Troubleshooting & Testing Figure 24. The ink cartridge requires cleaning. Dirty or damaged cartridge Sometimes a cartridge will go bad for no apparent reason. The cartridge may look perfect and be full of ink, but it will not plot. If this occurs first try pressing the Clean button on the keypad.

  • Page 46: Cartridge Calibration

    Cartridge alignment Cartridge alignment will align the ink cartridges with each other. This adjustment is only good for 2 or more heads. A one-head FlexJet does not need ink cartridge alignment. Figure 26 shows a plot from a two head machine with a frame gap of -30 and all cartridges set to zero in the Cartridge Alignment win- dow.

  • Page 47: Adjusting The Cartridge Alignment Value

    Start with a frame gap of -30, and To align the cartridges on a two- all cartridges set to zero so you head FlexJet, run the plot file can see a separation between the heads. This will make it easier to 70x8.plt for 72-in wide paper, or...

  • Page 48: Figure 31. The Motion Adjust Window

    “pass”. With every pass, each adjustment. head draws a line -in long. If the FlexJet has 2 heads, it draws a 1-in line for each pass. A four-head machine will draw a 2-in line. If the Motion Factor is too low, the FlexJet will draw the line too late.

  • Page 49: Figure 34. Frame Gaps On The Plot

    FlexJet body is not be level. Notice how the right and left lines are right on, but the middle line mis-aligned. Figure 35. Occasional frame gaps may indicate that the FlexJet platen or stand is not level. Try releveling the FlexJet to see if this corrects the problem.

  • Page 50: Figure 37. The Ink Stall Can Crack If The Cartridge Door Is Not Closed And Locked

    Also wipe the traverse rails before re-installing the carriage assembly. If cleaning does not resolve the noise, contact Ioline Customer Service. Figure 38. If the carriage makes noise, you may need to clean or replace the wheel.

  • Page 51: Mechanical, Electrical, And Electronic Diagnostics

    Make sure the flat end is facing out. No power to the FlexJet If you should power the machine up and nothing happens, check the fuse in the power entry module (Figure 39a) on the back of the right side cover.

  • Page 52: Figure 40. A Good Transitor On The Left; The One On The Right Is Blown

    Ioline FlexJet Service Manual Electrical problems If, during power on, the FlexJet experiences one or all of the follow- ing, it may have a blown transistor: Smoke coming from inside the machine. The carriage won’t move. The carriage hits the right or left side hard.

  • Page 53: General Mechanical / Electrical Issues

    The FlexJet didn’t initialize (No LEDs, fans not running, car- riage didn’t move, small jerking motion during power up) The FlexJet has been working but did not initialize after being reset by turning the power off them back on. Jam messages occur without media or other objects obstructing normal operation.

  • Page 54: Figure 41. Testing The Y-Axis Motor

    Note Turn the power to the machine off. This test applies to all the motors Inspect the FlexJet for any obvious damage or signs of mechani- on the FlexJet. cal malfunction. Measure the voltage at the wall socket. Verify that the AC volt- age is between 85 and 250 VAC.

  • Page 55: Logic Board Assembly Troubleshooting

    Straighten out a paperclip so it looks like Figure 41c. Caution Attach the paperclip to the power lugs as shown in Figure 41d. Ensure that the FlexJet is Now, move the carriage back and forth by hand. unplugged from the wall...

  • Page 56: Logic Board Troubleshooting Steps (Revision 2)

    Ioline FlexJet Service Manual Logic board troubleshooting steps (Revision 2) LED/Test Normal Indicates Error Point ID 30 VDC 30 volt main Erratic machine power supply is performance. functioning 3.3 VDC 3.3 volt regulated Erratic machine power supply is performance. functioning...
  • Page 57 On-board regulator DC voltage measurement between TP9 (ground) and TP7 failed. Main power should read 3.3 volts +/- 5%. Return logic board to Ioline supply failed. for service. On-board regulator DC voltage measurement between TP9 (ground) and TP8 failed.

  • Page 58: Service & Support

    Getting help Ioline is committed to providing the highest quality service and sup- port to its customers. If you need assistance with an Ioline FlexJet, a number of resources are available: First, refer to this FlexJet User Guide and FlexJet Quick Start Guide for answers to your specific questions.

  • Page 59: Customer Service

    Chapter 3: Troubleshooting & Testing Customer service Ioline Corporation is committed to providing quality service and support to our customers. If you need assistance with an Ioline prod- uct, contact your local dealer or Ioline authorized service center. You may also contact:...
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  • Page 61: Chapter 4 Repair Procedures

    FlexJet until it you determine that simpler solutions fail to resolve the problem (see Troubleshooting). Follow the recommended sequence in Figure 42 when troubleshoot- ing repair issues with the FlexJet and record the results of your diag- nostic examination on the Diagnostic Record (see below). Computer...

  • Page 62: Requesting Service

    Ioline FlexJet Service Manual Requesting service If the suggestions and guidelines in this manual don’t fix the prob- lem, fill out the form below and contact Ioline Customer Service. Diagnostic Record What is the serial number for this unit? ______________...

  • Page 63: Carriage Procedures

    Grounding wrist strap these procedures. Step 1: Prepare the printer Turn power off to the FlexJet. Caution Clear paper from around the carriage. The FlexJet is heavy and Remove inkjet cartridges. There is no need to store or cover the could cause injury if it falls.

  • Page 64: Figure 43. Removing The Right End Cover

    Ioline FlexJet Service Manual Remove cover Figure 43. Removing the right end cover. Step 3: Loosen the carriage belt Find the belt tensioner on the right side above the white cables. Loosen the carriage belt tensioner by rotating the -in HEX screw 4 full counterclockwise turns.

  • Page 65: Figure 45. The Carriage Cover Screw

    Chapter 4: Repair Procedures Remove the carriage cover screw Figure 45. The carriage cover screw. Unclip the carriage belt ends at the left and right sides of the carriage base. (Figure 46.) Using a -in (8-mm) open-end wrench, loosen the #6-32 hex nut one-half turn under the right and left swing arms until the washers and round spacers move freely.

  • Page 66: Figure 47. Loosen The Carriage Wheel Lock

    Ioline FlexJet Service Manual Loosen this nut Figure 47. Loosen the carriage wheel lock. Step 5: Install the new carriage Caution Press down here Connect the ribbon cable on both sides Do not hold the carriage ends to the new carriage by the inkjet head stalls and secure with tyraps.

  • Page 67: Figure 50. Carriage Installation

    Chapter 4: Repair Procedures Figure 50. Carriage installation. Step 6: Tighten the carriage swing arms Gently hold the spacer up against the bottom of one of the upper v-wheel swing-arms. The spacer can be held up with a finger or a small screwdriver inserted from the right side of the carriage.

  • Page 68: Figure 52. The Carriage Belt Tensioner

    Ioline FlexJet Service Manual the carriage belt to maintain slight belt tension so that the car- Note riage belt tensioner doesn’t move out of place. Make sure the belt is not twisted While maintaining tension on the carriage belt, attach the car- before attaching the clips.

  • Page 69: Figure 54. Remove The Cover

    Small flat-tipped screwdriver Caution Step 1: Prepare the printer Turn the FlexJet power off. Remove the AC power cable and The FlexJet is heavy and could cause injury if it falls. any other cables connected to the rear of the printer.

  • Page 70: Figure 55. Install The Carriage Cover

    Ioline FlexJet Service Manual Caution Loosen this The logic board cover will -in screw swing down when the last screw is removed. Make sure to support it with one hand and let it slowly rotate. Figure 55. Install the carriage cover.

  • Page 71: Figure 57. Unplug The Feed Motor And Encoder Cables From The Logic Board

    Chapter 4: Repair Procedures Unplug the roll feed motor power and encoder cables from the logic board. Set the logic board cover aside. (Figure 57.) Unplug take-up wires from the logic board Figure 57. Unplug the feed motor and encoder cables from the logic board. Find the white flex cable connections.

  • Page 72: Figure 59. Make A Loop In The Ribbon Cable To The Left Of The Carriage

    Ioline FlexJet Service Manual Step 5: Remove the old flex cables With the carriage secured, clip the plastic ties that hold the white flex cables against the right side of the printer. Pull the bundle of cables out of the grey clips (if present).

  • Page 73: Figure 60. Carriage Installation

    Chapter 4: Repair Procedures Gently move the carriage right then left to ensure that the wheels move smoothly. Figure 60. Carriage installation. Step 7: Replace tensioner and attach the carriage belt. Caution Guide the ribbon cable bundle under the carriage belt tensioner. Make sure the belt is not Place the new belt tensioner next to the old one.

  • Page 74: Figure 62. Install The Carriage Cover

    Repeat this process near the right end plate, but place the tape This process is important for proper operation of the FlexJet. to the left of the existing tape (if present). Remove the tape The sleeved ribbon cables require backing so that the side facing up is exposed.

  • Page 75: Figure 63. There Should Be A Small Gap In The Ribbon Cable Loop

    Chapter 4: Repair Procedures Ribbon Cable Figure 63. There should be a small gap in the ribbon cable loop. With the right hand, smooth the ribbon cable bundle beyond the tape at the middle of the traverse so that the black sleeving is stretched and lays relatively flat and taut.

  • Page 76: Figure 65. Secure The Sleeving With Tape

    Install the right side plastic cover. Connect the power and communication cables. Test the machine for proper functioning. Press the arrows on the keypad to make sure all directions are working. If problems arise call Ioline Customer Service.

  • Page 77: Figure 66. Remove The Right End Cover

    Chapter 4: Repair Procedures Service station procedures Caution The discharge of static electricity may damage the Y Fine adjustment for the Service Station keypad and components. This procedure must always be done after replacing or upgrading Use the included ground strap during all procedures.

  • Page 78: Figure 69. Install The Ink Cartridges And Turn The Power On

    Ioline FlexJet Service Manual Make sure the ink cartridges are installed. Power the FlexJet on. Figure 69. Install the ink cartridges and turn the power on. Loosen Carriage (do not remove) catch the car- bracket riage catch bracket. Loosen nut Figure 70.

  • Page 79: Figure 73. Use The Plastic Thumbscrew To Adjust The Lines If Necessary

    Chapter 4: Repair Procedures Press the “Clean” button on the keypad. You should see two lines in the middle of the spit well holes. Lines on the tape Figure 72. After you press the clean button, you should see two lines in the spit well holes.

  • Page 80: Figure 74. Y Fine Adjustment Is Performed Within The Control Center

    Also, proper adjustment assures the inkjet heads will be capped so they don’t dry out. Turn on the FlexJet and let it initialize. Open the FlexJet Control Center software. When the window opens press Ctrl-Alt-B. You should see the following window.

  • Page 81: Figure 76. The Service Station Stop Screw

    Chapter 4: Repair Procedures Click the Move carriage out from SS button. The carriage will Note move out of the Service Station. A Y Fine Adjust change of 25 mils Change the Y Fine Adjust number to -800 and click the Set fine results in a gap change that is adjust button.

  • Page 82: Figure 78. Tighten The Nut To Hold The Stop Bracket

    Figure 78. Tighten the nut to hold the stop bracket. If you are happy with the adjustments, turn FlexJet power off. Let the machine sit for 5 seconds, then turn the power back on. When the carriage initializes into the service station check all the gaps and stop brackets to make sure the adjustments are still right.

  • Page 83: Figure 79. Unplug The Take-Up Motor

    Make sure you are grounded with a static grounding strap. For now, leave the new logic board in its packaging. Remove the logic board cover on the FlexJet. Carefully unplug the take-up connector from the logic board before completelly removing the cover.

  • Page 84: Figure 83. Carefully Unplug Connections To The Board

    Ioline FlexJet Service Manual Support the logic board hand when removing the last screw to Caution prevent it from falling onto the floor. (Figure 83.) When removing the new logic board from the packaging make sure you have the static grounding strap on correctly.
  • Page 85 Install the right side plastic cover. Connect the power and communication cables. Test the machine for proper functioning. Press the arrows on the keypad to make sure all directions are working. If problems arise call Ioline Customer Service.

  • Page 86: Updating The Firmware

    Ensure that the serial cable connects the PC to the FlexJet. Make sure there is a Green light on the keypad of the FlexJet and open the Control Center. The main screen shows the current firmware version in the up- per right corner.

  • Page 87: Figure 86. Remove The Keypad Screws And Bracket. Unplug The Keypad Cable

    Chapter 4: Repair Procedures Keypad procedures Keypad replacement Tools Required Phillips head screwdriver Remove the right end cover. Remove the four screws holding the logic board cover. Unplug the connector from the logic board and set the cover aside. Remove the four Phillips screws holding the keypad to the bracket.

  • Page 88: Y-Axis Procedures

    Ioline FlexJet Service Manual Y-Axis procedures Y-Axis transmission adjustment This procedure covers tightening the setscrews on the Y-Axis trans- mission. If you are experiencing size or skipping problems while printing, follow this procedure as one possible fix. Tools Required -in Hex wrench Tighten the setscrews shown on the Y-Axis transmission.

  • Page 89: X-Axis Procedures

    Chapter 4: Repair Procedures X-Axis procedures If you are experiencing variable frame gap or shifting of the paper in the Y direction this may indicate that the motor or driveshaft pulley setscrews have loosened or that the belt tension is too low. Using a 1/16-in Hex wrench, tighten the 2 setscrews per pulley.
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  • Page 91: Flexjet Bom (Bill Of Materials)

    Chapter 5 Parts & Drawings FlexJet BOM (Bill of Materials) Part Description SEQN Number 107758 SERVICE STATION ASSY, FJ 107215 PINCHWHEEL ASSY, 6 LB, 1:1, PLASTIC 108495 KEYPAD ASSY, FJ 108270 CARRIAGE ASSY, FJ, FRAME-UP 108227 ASSY, Y TRANS, GT...
  • Page 92 Ioline FlexJet Service Manual Part Description SEQN Number 103027 TYRAP, .1 IN X 5 3/4 LG 106816 MOTOR, SERVO, 24V 103740 TAPE, FOAM, .5 IN, .025 THICK 100705 PAD, PEN CAP, 1/4 DIA 106649 LABEL, DRIVE AREA 106652 RIVET, PLASTIC, .2 GR X .169 OD 106693 BUSHING, NYLON,.52ID, .62OD, .75FL...
  • Page 93 Chapter 5: Parts & Drawings Part Description SEQN Number 101601 NUT, #4-40, HEX, THIN NYLOCK 102219 LEVELER, 1.5 PAD, 3 IN ADJUST 108271 SHIELD, LOGIC BOARD, FJ 104471 TAPE, UHMW, .43 WIDE 103726 TYRAP, .1 IN X 3 IN, BLACK 104726 GROMMET STRIP, CONTINUOUS 7/64 108453...

  • Page 94: Ioline Flexjet (Exploded View)

    Ioline FlexJet Service Manual...

  • Page 95: Ioline Flexjet (Electronics View)

    Chapter 5: Parts & Drawings...
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  • Page 97 Index Symbols xviii, 21, 22, 24, 25, 27, 30, 32, 36, 38, 39, 44, 61, 63, Carriage 64, 66, 67, 69, 72, 73, 74, 78, 82 Assembly 40x8.plt Close-up view xviii Latch 70x8.plt Magnetic stop plate — Notched ‘V’ See Set origin Red light alignment indicator 63–68 Replacement...
  • Page 98 Ioline FlexJet Service Manual Cartridge count Download firmware 34–35 Error messages End covers Exit Frame size Error codes Get plotter data Firmware update Help about Keypad errors Installation Error messages Line width Main Menu 25 Measurement units Menu Bar Menu Options...
  • Page 99 40, 44 Empty cartridge 44 Maintenance and handling Stalls xviii Upgrading number of stalls Machine ID Investronica 19, 20 ® Main Power Ioline Corporation Maintenance xv, 38, 40, 43, 44 IPS software Markers Length Removing — Scale See Control Center...
  • Page 100 Ioline FlexJet Service Manual Measurement Units Platen leveling foot xvii Media Plot 22, 28, 39, 40, 43 Paper type Adjustments with Control Center 25–27 27, 38, 40 Tracking Frame Width Frame size 25, 27, 28 Line width Media tracking Scale...
  • Page 101 Index Index Red light alignment indicator Set Machine ID Repair xiii, 58 Set origin 38, 39 Cable replacement 69–76 Shaft xvi, xviii, 42 63–68 Carriage replacement Diagnostic Record Size calibration Diagnostics flow chart Software — See also The FlexPlot User Guide Factory authorization xiii Apparel design software...
  • Page 102 Ioline FlexJet Service Manual Treads Y-Axis 21, 22, 54, 88 Logic board encoder Troubleshooting Logic board motor power Alignment issues 38–41 Chart of common problems Y-Axis belt adjustment Communications Error messages Ink cartridge bay problems Keypad error codes 55–57 Logic board...

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