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Roland GX-500/400/300 Sign Maker Service Notes
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SERVICE NOTES Contents 1 Structure & Spare Parts 1-1 COVERS 1-2 FRAME 1-3 DRIVE UNIT 1-4 CARRIAGE 1-5 CHASSIS 1-6 PINCH ROLLER 1-7 ACCESSORIES 2 Electrical Section 2-1 WIRING MAP 2-2 MAIN BOARD 2-3 OTHER CIRCUIT BOARDS 1-1 1-2 1-4 1-5 1-6 1-7 1-8 2-1 2-3 2-11 3 Replacement of Main Parts 3-1 TOOL CARRIAGE REPLACEMENT 3-2 CARRIAGE WIRE REPLACEMENT 3-3 MAIN BOARD REPLACEMENT 3-4 PINCH ROLLER REPLACEMENT 3-5 CROP MARK REPLACEMENT 3-1 3-8 3-13 3-17 3-19 4 Adjustment 4-1 SPECIAL TOOL 4-2 SERVICE MODE 4-3 HOW TO UPGRADE FIRMWARE 4-4 TOOL HEIGHT ADJUSTMENT 4-5 BED HEIGHT ADJUSTMENT 4-6 TOOL PRESSURE ADJUSTMENT 4-1 4-2 4-6 4-8 4-11 4-14 4-7 WIRE TENSION ADJUSTMENT 4-8 CALIBRATION 4-9 CROP MARK SENSOR ADJUSTMENT 4-10 AUTO CROP-CUT ADJUSTMENT 4-11 MANUAL CROP-CUT ADJUSTMENT 4-12 SHEET CUTTER DOWN POSITION ADJUSTM 4-16 4-18 4-21 4-24 4-26 4-27 5 Supplemental Information 5-1 OPERATIONAL SEQUENCE 5-2 SENSOR MAP 5-1 5-2 6 Troubleshooting 6-1 START AND END POINTS DO NOT MATCH 6-2 STITCH CUT 6-3 MEDIA SHIFTING 6-4 TOOL UP/DOWN ERROR 6-5 FAN REVOLUTION 6-6 MOTOR ERROR 6-7 DISTORTED FIGURE / WAVY LINE 6-8 CANNOT DETECT CROP MARK 6-9 PRINT DOES NOT MATCH WITH CUT 6-1 6-2 6-3 6-3 6-4 6-4 6-5 6-6 6-7 7 Service Activities 7-1 INSTALLATION CHECK LIST 7-2 MAINTENANCE CHECK LIST 7-3 SPECIFICATION 7-1 7-8 7-9 Windows and MS-DOS are registered trademark or trademark of Microsoft Corporation in the United States and/or other countries. Second Edition GX-500 ‘07 Apr. Unauthorized coplying or transferral, in whole or in part, of this manual is prohibited. Copyright © 2007 ROLAND DG CORPORATION 70029-1 Revision Record Revision No. Date Description of Changes 0 2006.9.5 First Edition Kato Sasai 1 2007.4.3 1-7 ACCESSORIES : Parts have been revised. Kato Mabuchi Approval Issued To Ensure Safe Work To Ensure Safe Work About WARNING and CAUTION Notices. WARNING Used for instructions intended to alert the operator to the risk of death or severe injury should the unit be used improperly. CAUTION Used for instructions intended to alert the operator to the risk of injury or material damage should the unit be used improperly. * material damage refers to damage or other adverse effects caused with respect to the home and all its furnishings, as well to domestic animals or pets. About the Symbols The symbol alerts the user to important instructions or warnings. The specific meaning of the symbol is determined by the design contained within the triangle. The symbol at left means Òdanger of electrocutionÓ. The symbol alerts the user to items that must never be carried out (are forbidden). The specific thing that must not be done is indicated by the design contained within the circle. The symbol at left means not to touch. The symbol alerts the user to things that must be carried out. The specific thing that must be done is indicated by the design contained within the circle. The symbol at left means the power-cord plug must be unplugged from the outlet. In addition to the WARNING and CAUTION symbols, the symbols shown below are aloso used. : Tips and advise before the adjustment. About the Labels Affixed to the Unit WARNING Turn off the primary power SW before servicing. Do not recharge, short-circuit, disassemble the lithium battery, nor put it into fire. It may cause heat, explosion and fire. Put tape around the lithium battery for insulation for disposal or preservation. It may cause heat, explosion and fire. About the Labels Affixed to the Unit These labels are affixed to the body of this product. The following figure describes the location. Also, never remove the labels or allow them to become obscured. Caution:Entanglement Hazard Never inadvertently allow hands, hair, clothing such as neckties, or the like near rotating parts while in operation Caution:Moving Carriage The cutting carriage moves at high speed and pose a hazard. Keep your hands away from it. GX-500/400 GX-300 Electric charge. Do not touch when power is on. Electric charge. Do not touch when power is on. 1 Structure & Spare Parts 1-1 COVERS S2 S2 S2 S2 S1 9 3 1 S1 5 S2 S2 S2 S2 6 2 S2 4 S2 S1 8 7 8 S1 PARTS LIST -Main Parts- PARTS LIST -Supplemental Parts- Parts No. Parts Name 1000001369 APRON,B GX-300 S1 31019146 SCREW SET,BINDING M4*8 NI 100PCS 1 1000001368 APRON,B GX-400 S2 31289102 CUPSCREW SET,M3*6 NI 50 PCS. 1000001367 APRON,B GX-500 1000001366 APRON,F GX-300 2 1000001365 APRON,F GX-400 1000001364 APRON,F GX-500 3 1000001379 COVER,L GX-500 4 1000001378 COVER,R GX-500 1000001360 COVER,RAIL GX-300 5 1000001359 COVER,RAIL GX-400 1000001358 COVER,RAIL GX-500 6 22535307 LABEL,CAUTION LEVER BRAKE #LA329 7 22535117 LABEL,POWER CM-500 NO.893 8 22535308 LABEL,SET FILM #LA334 9 1000001380 TRAY,GX-500 Parts No. 1-1 Parts Name S6 26 S8 15 5 1-2 10 S12 S2 22 S8 28 6 S4 S14 S7 21 10 S16 S1 S13 7 20 1 S8 9 21 27 13 S13 S4 28 6 30 20 S5 S5 21 14 S14 19 S6 21 S3 23 S12 S17 S3 S7 S8 S2 1 2 17 S1 S14 31 S11 S8 S11 23 18 S8 16 S11 S11 3 S10 S11 S11 8 S10 4 S11 S11 29 S11 S11 8 S8 S3 S5 1-2 FRAME 1-2 FRAME PARTS LIST -Main PartsParts No. 1 11879107 PARTS LIST -Supplemental Parts- Parts Name Parts No. Parts Name ABSORBER TK-12 S1 31029816 BUSH,ROLL 3X4 22805435 ASS'Y,G-ROLLER CX-300 S2 31119904 PIN,SPRING 2.5X8 SUS STRAIGHT 2 22805434 ASS'Y,G-ROLLER CX-400 S3 31299102 RIVET,NYLON P2655B 22805433 ASS'Y,G-ROLLER CX-500 S4 31019116 SCREW SET,BINDING M3*6 3CBC 100 PCS 3 22175870 BEARING 10-19ZZ S5 31289111 CUPSCREW SET, M4*6 NI 100 PCS. 4 22115106 BEARING HOUSING A 211-106 S6 31019702 SCREW,BINDING HEAD P-TIGHT M3X6 BC 22005133 BED CX-300 S7 31049171 SCREW SET,CAP M3*12 NI 50 PCS. 5 22005132 BED CX-400 S8 31049117 SCREW,CAP M4*12 NI+PW 4*9*0.8 22005131 BED CX-500 S10 31089110 SCREW,PAN HEAD M3X4 C WASHER 6 21985129 BRACKET,SENSOR CX-500 S11 31199701 SCREW,SOCKET SET WP M3X3 C 7 1000001341 CABLE-ASSY,FAN MOTOR GX-500 S12 31289112 CUPSCREW SET,M3*10 NI 100 PCS. 8 22165165 COLLAR S13 31019124 SCREW SET,BINDING M3*35 NI 50 PCS 9 W700293020 ASSY,FAN BOARD GX-500 S14 31289102 CUPSCREW SET,M3*6 NI 50 PCS. 10 1000001330 FAN,BG1203-B054-000-15 S16 31369101 SPACER,PCB SUPPORT PCB-8L S17 31409801 SADDLE,LOCKING WIRE LWS-0711Z 22115858 FRAME,CABLE CX-300 13 22115857 FRAME,CABLE CX-400 22115856 FRAME,CABLE CX-500 22115861 FRAME,GUIDE RAIL CX-300 14 22115860 FRAME,GUIDE RAIL CX-400 22115859 15 1000001372 FRAME,GUIDE RAIL CX-500 FRAME,L GX-500 16 1000001373 FRAME,R GX-500 17 22045160 GEAR COVER 18 21685117 GEAR,H150S15(B8) 19 22535305 LABEL,G-ROLLER 160 #LA327 20 22535304 LABEL,G-ROLLER 30 #LA326 21 22535115 LABEL,G-ROLLER20 CM-500 NO.891 1000001385 PAD,CUTTER GX-300 22 1000001384 PAD,CUTTER GX-400 1000001383 PAD,CUTTER GX-500 23 W700293060 ASSY,PLATE A GX-500 22055491 PLATE,SHUTTER CX-300 26 22055490 PLATE,SHUTTER CX-400 22055489 PLATE,SHUTTER CX-500 22185396 RAIL,GUIDE CX-300 27 22185392 RAIL,GUIDE CX-400 22185377 28 15099115 RAIL,GUIDE CX-500 SENSOR-INTERRUPTER GP2A25NJ 22075124 SET,G-ROLLER CX-300 29 22075123 SET,G-ROLLER CX-400 22075122 SET,G-ROLLER CX-500 22295237 SHAFT,FEED DRIVE CX-300 30 22295236 SHAFT,FEED DRIVE CX-400 22295235 SHAFT,FEED DRIVE CX-500 22325433 SUPPORT,CABLE CX-300 31 22325432 SUPPORT,CABLE CX-400 22325431 SUPPORT,CABLE CX-500 1-3 1-3 DRIVE UNIT S2 S10 4 2 S1 S10 12 22 13 4 S18 S5 S19 7 S15 17 S7 S11 19 14 S8 S17 S9 S13 16 3 S4 6 S12 11 20 S12 1 S15 23 5 S9 21 S6 S11 15 S11 18 10 S15 16 1 9 8 S3 S5 15 S15 PARTS LIST -Main PartsParts No. S6 PARTS LIST -Supplemental Parts- Parts Name Parts No. Parts Name 1 22805436 ASS'Y,MOTOR CX-500 S1 31279104 LABEL,CAUTION CS-20 NO.598 2 22805350 ASS'Y,PULLEY HD42.2S16 CM-500 S2 31149704 RING,E ETW-6 SUS 3 22355758 BASE,SCAN DRIVE CX-500 S3 31159904 RIVET,NYLON P3065B 4 22175815 BEARING F8-16ZZ S4 31409702 SADDLE,LOCKING EDGE LES-1010 5 21995117 FLANGE,MOTOR FEED CX-500 S5 31409801 SADDLE,LOCKING WIRE LWS-0711Z 6 21995118 FLANGE,MOTOR SCAN CX-500 S6 31289102 CUPSCREW SET,M3*6 NI 50 PCS. 7 21685149 GEAR,H235S20(B8)T2 S7 31019703 SCREW,BINDING P-TIGHT 3*8BC 100P 8 22495208 KEYTOP,FS-SX1H MCG S8 31049172 SCREW SET,CAP M3*20 NI 20PCS 9 W700293012 ASSY,PANEL BOARD GX-500 S9 31049170 SCREW SET,CAP M3*8 NI 50 PCS. 10 W700293070 PLATE B GX-500 S10 31049174 SCREW SET,CAP M4*15 NI 20 PCS. 11 22055488 PLATE,ORG CX-500 S11 31049117 SCREW,CAP M4*12 NI+PW 4*9*0.8 12 21975106 PULLEY HD42.2 S16(B30C35.5) S12 31049169 SCREW SET,CAP M4*8 3CBC+PW 20PCS 13 12179723 PULLEY WITH BEARING 217-723 S13 31289107 CUPSCREW SET,M3*12 NI 100 PCS 14 22145345 SHAFT,PULLEY PNC-1860 S15 31289111 CUPSCREW SET, M4*6 NI 100 PCS. 15 1000001382 SHEET,PANEL GX-500 S17 31249207 WASHER,3*8*0.5 3CBC 16 22175157 SPRING,C P-ROLLER CM-500 S18 31249203 WASHER SET,PLAIN 4*10*0.8 C 100P 17 22035168 STAND,PULLEY CX-500 S19 31249209 WASHER SET,PLAIN 4*8*0.5 NI 100 PCS 18 1000001375 STAY,PANEL GX-500 19 22715279 STAY,SHAFT CX-500 20 W022135346 STOPPER,CAM CM-500 21 1000001374 STOPPER,CARRIAGE GX-500 21945142 WIRE CX-300 22 21945141 WIRE CX-400 21945140 WIRE CX-500 23 22535287 LABEL,CAUTION CARRIAGE #LA266 1-4 1-4 CARRIAGE S4 S4 S4 S12 15 S4 8 9 S11 21 22 23 12 S12 7 14 S11 S3 S11 1 6 11 13 5 17 18 S7 4 S8 S10 3 S15 S1 10 S9 S5 S17 2 24 25 S6 S2 20 19 16 S5 S12 PARTS LIST -Main PartsParts No. PARTS LIST -Supplemental Parts- Parts Name Parts No. Parts Name 1 22805288 ASS'Y,CARRIAGE CM-500 S1 31029801 BUSH,ROLL 2X4 2 22805292 ASS'Y,CLAMP BLADE CM-500 S2 31029803 BUSH,ROLL 3X5 3 22805291 ASS'Y,HOLDER BLADE CM-500 S3 31289109 CUPSCREW SET,M3*4 NI 100 PCS. 4 22805287 ASS'Y,PLATE CAM SLIDE CM-500 S4 31299102 RIVET,NYLON P2655B 5 22355656 BASE,CUTTER CM-500 S5 31019148 SCREW SET,BINDING M2.6*4 NI 100 PCS 6 21815101 BOLT,PENHOLDER S6 31019118 SCREW SET,BINDING M3*10 3CBC 100PCS 7 23505735 CABLE-ASSY G-ROLLER SENS CX-500 S7 31019116 SCREW SET,BINDING M3*6 3CBC 100 PCS 1000001343 CABLE-CARD,11P 1545L BB S8 31799107 SCREW,CAP M4*6 NI 8 1000001344 CABLE-CARD,11P 1835L BB S9 31169103 SCREW,FLAT HEAD M3X6 3CBC 1000001345 CABLE-CARD,11P 2020L BB S10 31229103 SCREW,TRUSS HEAD M2X6 NI 9 W700293040 ASSY,CARRIAGE BOARD GX-500 S11 31289108 CUPSCREW SET, M3*8 NI 100 PCS. 10 1000001381 COVER,CARRIAGE GX-500 S12 31289102 CUPSCREW SET,M3*6 NI 50 PCS. 11 22175828 GUIDE BEARING 2 S15 31249402 WASHER,TOOTHED LOCK M4 NI 12 22175343AS GUIDE BEARING ASS'Y S17 31679902 SCREW SET C-SEMS M2*8 NI 100 PCS 13 22285503 NUT,PENHOLDER 14 W700293030 ASSY,PINCH SENS BOARD GX-500 15 W700293060 ASSY,PLATE A GX-500 16 21495115 SCREW,BLADE SET CM-500 17 22175122 SPRING,BACK UP PNC-960 18 22175154 SPRING,BLADE UP CM-500 19 22175155 SPRING,SCREW CM-500 20 1000001371 STAY,CROP BOARD GX-500 21 22715280 STAY,CARRIAGE BOARD CX-500 22 22135386 STOPPER,BEARING STAY CM-500 23 22805437 ASS'Y,TOOL CARRIAGE 2 CX-500 24 W700293050 ASSY,CROP SENS BOARD GX-500 25 22165198 SPACER,SENSOR CX-24 1-5 1-5 CHASSIS S7 S3 26 25 3 S7 S7 S7 20 S8 S10 1 S7 S11 2 S7 S7 S12 6 S10 17 S4 (Only for GX-300) S10 28 21 24 S10 1 27 S10 S2 S10 S11 9 S7 S8 S6 S1 S10 S8 16 4 5 2 8 7 23 PARTS LIST -Main PartsParts No. Parts Name 1 2215052400 2 21985128 3 S8 S7 S10 19 S9 S10 PARTS LIST -Supplemental PartsParts No. Parts Name BOSS NUT L=8MM S1 31029101 BUSH,NB-19 BRACKET,COVER UNDER CX-500 S2 31279116 LABEL,EARTH MARK-1 NO.E-580 21985130 BRACKET,FRAME CENTER L CX-500 S3 31109802 NUT SET,HEXAGON M4 NI 100PCS 4 21985131 BRACKET,FRAME CENTER R CX-500 S4 31409801 SADDLE,LOCKING WIRE LWS-0711Z 5 21985132 BRACKET,INLET CX-500 S6 31329501 CLAMP SET,PUSH MOUNT RT30SSF5 20P 6 21985127 BRACKET,SPACER BED CX-500 S7 31049117 SCREW,CAP M4*12 NI+PW 4*9*0.8 7 23505631 CABLE ASS'Y JUNBI A PC-600 S8 31049169 SCREW SET,CAP M4*8 3CBC+PW 20PCS 8 23505632 CABLE ASS'Y JUNBI B PC-600 S9 31169103 SCREW SET,FLAT M3*6 3CBC 100 PCS 9 23505633 CABLE ASS'Y JUNBI C PC-600 S10 31289102 CUPSCREW SET,M3*6 NI 50 PCS. 1000001363 COVER,UNDER GX-300 S11 31289111 CUPSCREW SET, M4*6 NI 100 PCS. 16 1000001362 COVER,UNDER GX-400 S12 31279121 LABEL,FLASH-LIGHTING NO.E-582 1000001361 COVER,UNDER GX-500 1000001357 FRAME,CENTER GX-300 17 1000001356 FRAME,CENTER GX-400 1000001355 FRAME,CENTER GX-500 19 13429702 INLET AC P01CF01 15A250V 20 22535257 LABEL,CAUTION VOLTAGE #LA167 21 6700292020 ASSY,MAIN BOARD GX-500 23 13129170 POWER SW AJ7201B 24 1000001331 POWER UNIT,LEP100F-48-D41 25 22165204 SPACER,BED LOWER CX-500 26 22165203 SPACER,BED UPPER CX-500 27 1000001377 STAY,MAIN BOARD GX-500 28 1000001376 STAY,POWER BOARD GX-500 1-6 1-6 PINCH ROLLER ' ! 5 ! 5 " ' ! ! & & 5 5 5 $ 5 # # 5 5 % & 5 % 5 & 5 5 5 5 5 PARTS LIST -Main PartsParts No. 5 PARTS LIST -Supplemental Parts- Parts Name Parts No. Parts Name 1 7561714000 ASS'Y,P-ROLLER C CX-500 S1 31149702 RING,E ETW-ES3 UNI-C 2 7561712000 ASS'Y,P-ROLLER L/R CX-500 S2 31249211 WASHER,PLAIN 4.3X7X0.5 C 3 22115854 FRAME,P-ROLLER CX-500 4 22535306 LABEL,C-PINCH MARK #LA328 5 22145404 LEVER OF PINCH ROLL 6 22395125 MAGNET 7 22145831 PIN NO.1 (214-831) 8 22145832 PIN NO.2 214-832 9 22175105 PINCH ROLL SPRING 10 22145616 PNC-900 SET LEVER 11 21565103 P-ROLLER FD16S4(B10) TYPE2 12 21565102 P-ROLLER TD16S4(B10) TYPE2 13 22175157 SPRING,C P-ROLLER CM-50 1-7 1-7 ACCESSORIES 19 17 20 18 15 14 21 16 Revised 1 117V 230V 10 22 11 7 23 230VC 240VA 240VE 9 1 2 3 5 8 12 13 Parts No. Parts Name 6 4 PARTS LIST -Main PartsParts No. Parts Name 1 23495124 AC CORD 3ASL/100 240VA 10A SAA 2 13499111 AC CORD H05VV-F 240VE 10A S 3 13499109 20 22135316 STOPPER, PNS-186 Product PNS-502 AC CORD SJT 117V 10A 3P-S 21 Product PNS-402 4 23495214 AC CORD VCTF 100V 7A 3P-S Product PNS-302 5 23495125 AC-CORD H05VV 230V 10A S 22 21935110 TOOL ALIGNMENT PNC-5000 6 13499209 ADAPTER PLUG (100V) 23 12329503 CASTER PNS-186 7 11849102 BLADE,OLFA AUTO CUTTER XB10 8 1000000089 CABLE,USB 2.0M BK TW 9 13439801 CABLE-AC 3P CHINA 10A/250V S 1000001388 CARTON,GX-300 10 1000001387 CARTON,GX-400 1000001386 CARTON,GX-500 11 31379111 CLAMP,CABLE CKS-13-H 1000001398 MANUAL,INS EN GX-500 1000001397 MANUAL,INS JP GX-500 1000001396 MANUAL,USE EN GX-500 1000001395 MANUAL,USE JP GX-500 14 1000001394 PAD,CARRIAGE GX-500 15 1000001393 PAD,L-LEFT GX-500 16 1000001392 PAD,L-RIGHT GX-500 17 1000001391 PAD,U-LEFT GX-500 18 1000001390 PAD,U-RIGHT GX-500 19 31179101 SCREW,RESIN KNURL M4*8 WH 12 13 1-8 Revised 1 2-1 AC INLET AC - P 0 1 C F 01 1 3 42 9 7 0 2 C A B POWER SW A J 7 2 01 B F 13129170 D SCAN MOTOR D S E 3 8 BE 2 0 +41V CN2 D S E3 8 B E 2 0 FEED MOTOR CN1 SWIT CHING POWER SUPPLY LEP100F-48 G E F CN6 CN10 B G 12 0 3 - B 0 54 B G 12 0 3 - B 0 5 4 CN7 FAN MOTOR CN8 CN6 H FAN BOARD 5V 3.3V 1.5V 1. 2V CN9 41V 24V +41V F A N M O TO R CN11 C N2 CN7 PINCH S E N S OR BOARD CROPCN9 S EN S O R B OA R D CN4 K C N5 VC30A S OL E N O I D C N3 CN12 N S W- 1 3 L ED - 3 V R- 1 L C D 2 0* 2 CN1 P AN E L B O A R D M C N8 PAPERSENS R PAPERSE NS F CARRIAGE BOARD L J USB M66592FP A L T E R A M A X II E PM 2 4 0 T 1 0 C 5 N F LA SH ROM 2 MB yt e s S DR AM 8 MBy t e s C LK =6 6. 6 6 6M Hz M A I N + S E R V OCPU S H - 2A : S H 7 2 0 6 2 0 0 MH z MAIN BOARD SERIAL CN13 15099115 GP2A25NJ CN14 1 50 99 115 G P2 A2 5NJ USB 1.1 2 Electrical Section 2-1 WIRING MAP 2 GX-500 WIRING MAP Cable List 2 Parts Name Parts No. A 23505631 CABLE-ASSY JUNBI A PC-600 B 23505632 CABLE-ASSY JUNBI B PC-600 C 23505633 CABLE-ASSY JUNBI C PC-600 D 1000001337 CABLE-ASSY,POWER AC GX-500 E 1000001338 CABLE-ASSY,POWER DC GX- 500 1000002015 CABLE-ASSY,POWER DC GX- 300 F 1000001339 CABLE-ASSY,F MOTOR GX-500 G 1000001340 CABLE-ASSY,S MOTOR GX-5 00 H 1000001341 CABLE-ASSY,FAN MOTOR GX-500 J 1000001342 CABLE-ASSY,CROP SENS GX-500 K 23505735 CABLE-ASSY,G- ROLLER SENS CX-500 L 1000001343 CABLE-C ARD,11P 1545L BB 1000001344 CABLE-C ARD,11P 1835L BB 1000001345 CABLE-C ARD,11P 2020L BB M 1000001346 CABLE-C ARD,25P 210L BB N 1000001347 CABLE-ASSY,PAPER- SENS GX- 500 2-2 500 400 300 2-2 MAIN BOARD MAIN BOARD_Arrangement Diagram (Component Side) 2 2-3 MAIN BOARD_Arrangement Diagram (Soldering Side) It indicates the version of the Main Board. 2 2-4 TP146 TP139 TP140 TP141 TP142 TP143 TP144 TP145 /RESET Fan eed Motor Scan Motor 5267-02A 1 2 CN9 5267-07A 1 2 3 4 5 6 7 CN10 5267-08A 1 2 3 4 5 6 7 8 CN11 VCC VCC SERIAL I/ F (RS232C) XM2F-2540-232L 1 14 2 15 3 16 4 17 5 18 6 19 7 20 8 21 9 22 10 23 11 24 12 25 13 CN13 53398-1471 1 2 3 4 5 6 7 8 9 10 11 12 13 14 CN5 R126 1.0K TP137 1 2 3 4 Feed_Motor+ Feed_Motor- Feed_Encoder_Phase_A Feed_Encoder_Phase_B Scan_Motor+ Scan_Motor- Scan_Encoder_Phase_A Scan_Encoder_Phase_B IF_C_DTR IF_C_DSR IF_C_CTS IF_C_RTS IF_C_/RXD IF_C_/TXD /ASEMD CPU_TCK CPU_TRST CPU_TDO /ASEBRK CPU_TMS CPU_TDI VCC TP138 Power U_CPU CPU.SCHDOC TP41 Sol_PWM+ Sol_PWMSol_En B6P-VH 6 5 4 3 2 1 CN6 TP45 VCC U_SRV_DRV SRV_DRV.SCHDOC Sol_PWM+ Sol_PWMSol_En Reserve_TxD_out Reserve_RxD_in Scan_PWM+ Scan_PWMScan_En Scan_PWM+ Scan_PWMScan_En Moni_RxD_in Moni_TxD VCC3 Feed_PWM+ Feed_PWMFeed_En Feed_PWM+ Feed_PWMFeed_En 1 2 3 4 5 TP42 TP43 TP44 Fan_PWM Fan_PWM R119 4.7K CROPMARK CropMark X_En_Pha X_En_Phb Y_En_Pha Y_En_Phb +41V Power_ON Slow_Power_ON U_POWER POWER.SCHDOC Pinch_sens /Crop_ON Crop_sens Sol- Sol+ Pinch_Pos /CropOn LCDCONT Pen_Force_VR_AD /IRQUSB_0 LCD_BUSY CLK66_2 4KHz_out VCC CE0.1u C64 Pinch_Pos /CropOn Limit X_En_Pha X_En_Phb Y_En_Pha Y_En_Phb DB[0..15] MA[1..25] /WWR /RRD /WWE0 /WWE1 /CCS4 Limit PinchPos /Crop_ON CropMark Sol- Sol+ Carriage 52808-1171 1 2 3 4 5 6 7 8 9 10 11 CN7 LCDCONT PenForce_VR_AD /IRQUSB_0 LCD_BUSY RA[1..25] /RD /WE0 /WE1 /WR /CS0 /CS1 /CS4 /RESET DD[0..15] U_BASS_IF BASS_IF.SchDoc CLK66_2 4KHz_out /CS0 /CS1 /CS4 /CS5 /CS8 /CS5 /CS8 /CS8 /RESET RA[1..25] /RD /WE0 /WE1 /WR /CS0 /CS1 /CS4 /RESET DD[0..15] /RESET H-UDI R120 4.7K Y_CURNT X_CURNT SOL_CURNT Y_CURNT X_CURNT Sol_CURNT /GATE2 /GATE1 /GATE2 /GATE1 R121 4.7K Power_ON Slow_Power_ON R122 4.7K TP61 TP60 R28 10K CN2 TP62 VCC3 R14 10K VCC3 TP65 U_IF_CONT IF_CONT.SCHDOC MA[1..25] /WWE0 /RRD /WWR isp_TCK R123 4.7K MA[1..25] isp_TDO VCC3 DB[0..15] isp_TMS CN1 53398-0590 isp_TDI CN453398-04 non VF FAN 2-5 TP66 TP64 R_Paper F_Paper 53398-1090 1 2 3 4 5 6 7 8 9 10 Reserve SERIAL MONITORSERIAL R11 1.0K PenForce_VR LCD_CONT Panel_RESET LCD_RS_out LCD_RW_out LCD_E_out Panel_D0 Panel_D1 Panel_D2 Panel_D3 Panel_D4 Panel_D5 Panel_D6 Panel_D7 LCD_CS_out /LED /SW0 /SW1 /INTUSB_0 /INTUSB_1 VCC 53014-06 1 2 3 4 5 6 CN12 Paper Sens TP107 TP108 TP122 TP109 TP123 TP110 TP124 TP111 TP125 TP112 TP126 TP113 TP127 TP114 TP128 TP115 TP129 TP116 TP130 TP117 TP131 TP118 TP132 Vcc_USB -Data +Data TO PANEL BOARD 52808-2591 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 CN8 /CS /RRD /WWE0 /WWE1 /RESET /INTUSB_0 /INTUSB_1 /RESET VCC DB[0..15] MA[13..18] USB usb_if.SchDoc MA[13..18] FL1 EXCML20A390U R5 0 1 2 3 4 5A 5B 6A 6B 7A USB DUSB-BRD42-T12 VCC -Data +Data Ground CASE1A CASE1B CASE2A CASE2B CASE3A CN14 MAIN BOARD_Circuit Diagram 1/6 2 R81 CLK66_1 R82 CLK66_2 5 6 7 8 RA21 RA22 RA23 RA24 RA21 EXBV8V330J RA23 EXBV8V330J 2 4 3 5 6 7 8 RA17 RA18 RA19 RA20 PC63 CE0.1u VCC3 5 6 7 8 RA13 RA14 RA15 RA16 RA18 EXBV8V330J 33 33 5 6 7 8 RA9 RA10 RA11 RA12 RA13 EXBV8V330J RA10 A21 A22 A23 A24 4 3 2 1 5 7 4 8 3 9 2 10 0 4 13 5 12 S1 S2 VDD VDD GND GND 5 Cd RN5VD29A 1 OUT PC62 CE0.1u CE1.0u PC42 2 33 A17 A18 A19 A20 A10 A11 A12 A13 A14 A15 A16 A1 A2 A3 A4 A5 A6 A7 A8 A9 74LVC14 IC24A SW2 1 R85 R88 CKIO CE1.0u PC28 3 /CS4 74LVC14 4 CE1.0u CE1.0u PC32 TP93 EXBA10E103J R165 1.0K VCC3 VCC3 RA20 CE1.0u CE1.0u PC46 PC38 PC35 IC24B VCC3 10K 10K 10K 10K 10K 10K 10K 10K 10K 10K 10K /WE0 33 R117 /RASL 33 33 R27 R26 R25 R24 R23 R22 R21 R20 R19 R18 R17 R109 RD RDWR/IRQ2/TCLKC/PA8 PVss A1/PC1 A2 A3 A4 A5 A6 A7 A8 A9 Vcc Vss PVss PVcc A10 A11 A12 A13 A14 A15 A16 Vcc Vss A17 A18 A19 A20 BREQ/TEND0/PINT2/PA18 PVcc CKIO PVss PLLVss PLLVcc PVcc RES PVss XTAL EXTAL PVss PVcc NMI PVss CE1.0u PC31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 CE1.0u PC29 EVQ21305R 10K 10K VCC3 CE1.0u CE1.0u PC53 VCC1.2 PC49 CE1.0u VCC3 PC50 VCC3 /RESET R38 VCC3 T57 R167 1.0K TP94 VCC3 9 8 REF CY2308-2non CLBA1 CLKB2 CLKB3 CLKB4 16 R132 10K 1 FBK 0 6 7 10 11 0 VCC3 R173 IC21 A9 A10 A11 A12 A13 A14 A15 A16 A1 A2 A3 A4 A5 A6 A7 A8 CKIO Y2 16.666MHz CLKA1 CLKA2 CLKA3 CLKA4 VDD NC GND A17 A18 A19 A20 4 3 2 1 5 7 4 8 3 9 2 10 A13 A14 A15 A16 4 3 2 1 A25 A9 A10 A11 A12 4 3 2 1 33 A5 A6 A7 A8 4 3 2 1 Feed_En RA17 2 3 14 15 IC28 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 R41 1 6 1 6 5 6 7 8 5 6 7 8 5 6 7 8 5 6 7 8 5 6 7 8 A1 A2 A3 A4 4 3 2 1 R40 CE10p C18 CE10p C14 VCC3 RA25 R47 5 6 7 8 RA5 RA6 RA7 RA8 RA11 EXBV8V330J EXBA10E103J EXBA10E103J /WR /RD /WR 33 33 10K 10K 4 3 2 1 /RESET /RESET T33 Scan_PWM- 5 6 7 8 T38 T42 5 6 7 8 6 EXBA10E103J EXBA10E103J SH7206 IC13 SH7206 VCC3 VCC3 VCC3 VCC3 2 VCC3 Fan_PWM RA1 RA2 RA3 RA4 220 R75 Q5 DTA114EKA VCC3 PC30 PC27 PC40 PC51 PC33 PC44 PC48 D23/IRQ7/AUDSYNC/PD23 PVcc D24/DREQ0/TIOC4DS/PD24 D25/DREQ1/TIOC4CS/PD25 D26/DACK0/TIOC4BS/PD26 D27/DACK1/TIOC4AS/PD27 PVss PVcc D28/CS2/TIOC3DS/PD28 D29/CS3/TIOC3BS/PD29 D30/TIOC3CS/IRQOUT/PD30 D31/TIOC3AS/ADTRG/PD31 TDO ASEMD PVss PVcc TMS Vcc Vss PVss TDI TRST TCK BACK/TEND1/PINT3/PA19 PVcc ASEBCK WDTOVF TxD3/TIOC4A/PE12 ASEBRKAK/ASEBRK RxD3/TIOC3D/CTS3/PE11 Vss Vcc TxD2/TIOC3C/PE10 AVcc AVref AN7/DA1/PF7 AN6/DA0/PF6 AN5/PF5 AN4/PF4 AN3/PF3 AN2/PF2 AN1/PF1 AN0/PF0 AVss VCC3 PC52 132 131 130 129 128 127 126 125 124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101 100 99 98 97 96 95 94 93 92 91 90 89 T24 T25 C17 + 10u/16V C12 + 0 CE0.01u C19 VCC3 CE0.01u C11 10K 10K Sol_PWM- Pen_Force_VR_AD Moni_TxD CROPMARK_AD +41V_AD X_CURNT_AD Y_CURNT_AD SOL_CURNT_AD T26 LCDCONT R37 VCC3 /ASEBRK CPU_TDI CPU_TRST CPU_TCK CPU_TMS VCC3 R129 T23 T19 T20 T21 T22 D9 1SS355 E1 E2 D1 D2 D3 D4 D5 D6 D7 D8 1 19 2 3 4 5 6 7 8 9 C47 CE1000p 74LVC541 Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 IC4 PC5 CE0.1u VCC3 Reserve_RxD 18 Moni_RxD 17 SIF_DSR 16 SIF_CTS 15 SIF_RxD 14 13 12 11 R67 4.7K X_CURNT_AD Y_CURNT_AD T48 R69 4.7K 100 TP72 VCC C41 CE1u/16V SIF_DTR SIF_RTS SIF_TxD Reserve_RxD_in Moni_RxD_in +41V_AD D4 1SS355 C1V+ 11 VCC C1+ 12 9 T4I T3I T2I T1I 10 R4O R3O R2O R1O IC5 21 19 18 5 17 22 4 6 33 PC11 CE1.0u R55 33 PC8 CE1.0u R30 C2- C2+ V- GND T4O T3O T2O T1O R4I R3I R2I R1I D8 1SS355 VCC3 X_CURNT Y_CURNT PC20 DS14C238WMX CE0.1u NC D13 1SS355 VCC3 TP63 D11 1SS355 100 100 VCC3 C49 CE0.022u CROPMARK_AD C40 CE1u/16V C48 CE1000p R4 10K VCC R68 4.7K D10 1SS355 R134 R135 1 3 9 14 27 43 49 2 4 5 7 8 10 11 13 42 44 45 47 48 50 51 53 14 13 15 8 20 24 1 2 16 23 3 7 R29 3.3K C43 CE1u/16V C42 CE1u/16V IF_C_DTR IF_C_RTS IF_C_/TXD IF_C_DSR IF_C_CTS IF_C_/RXD R53 1.0K R54 22K C46 CE0.022u CROPMARK T47 R32 2.2K +41V R66 2.2K R133 47K VM PC23 CE0.1u VCC3 DD0 DD1 DD2 DD3 DD4 DD5 DD6 DD7 DD8 DD9 DD10 DD11 DD12 DD13 DD14 DD15 41V_SENSE M12L64164A-7TG VCC3 VCC3 VCC3 VCC3 VCC3 VCC3 VCC3 D0 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 SOL_CURNT Feed_PWM+ T49 R136 GND GND GND GND GND GND GND 6 12 28 41 46 52 54 SOL_CURNT_AD CKE CLK 37 38 RAS CAS WE CS UDQM LDQM A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10/AP A11 BA0 BA1 IC8 CKE CLK66_1 23 24 25 26 29 30 31 32 33 34 22 35 20 21 18 17 16 19 39 15 T50 RA1 RA2 RA3 RA4 RA5 RA6 RA7 RA8 RA9 RA10 RA11 RA12 RA13 RA14 /RASL /CASL /WR /CS3 DQMLU DQMLL RA[1..25] DD[0..15] T15 T16 T17 T18 CPU_TDO /ASEMD VCC3 DD[0..15] T14 R130 10u/16V T34 VCC1.2 PC43 CE1.0u CE1.0u CE1.0u CE1.0u PC41 CE1.0u CE1.0u CE1.0u CE1.0u CE1.0u CE1.0u CE1.0u PC39 RA5 RA2 EXBV8V330J EXBV8V330J RA3 RA1 EXBV8V330J EXBV8V330J LED2 LNJ308G8LRA Sol_En R111 R124 R31 R33 RA7 10K R64 RA8 EXBV8V330J 10K R48 A21 A25 10K 10K R43 R46 RA4 SIF_DSR R118 R110 DQMLL 33 /WE1 33 R116 DQMLU 33 R108 10K SIF_CTS 10K R60 33 R49 /CS8 10K A21 A22 A23 A24 A25 R59 SIF_TxD RA[1..25] 6 /CS3 T31 T30 R115 R114 R107 R113 R106 R105 R112 VCC3 /CS0 /CS1 LCD_BUSY RA[1..25] 10K R143 R174 T36 10K 10K 10K R45 R145 33 33 R65 R146 Scan_PWM+ A17 A18 A19 A20 T29 CKE /CASL 33 33 33 33 33 33 33 /CS5 D0 1 D11 1 T37 T41 10K R175 SIF_DTR SIF_RTS 10K R131 Moni_RxD /IRQUSB_0 T40 1 3 Sol_PWM+ Scan_En R58 SIF_RxD 10K R73 Reserve_RxD A22 A23 A24 D12 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 Reserve_TxD_out 5 7 4 8 3 9 2 10 1 D1 D2 6 10 2 9 3 8 4 7 5 D8 D9 D10 D11 D12 D13 D14 D15 D13 D14 D15 10 2 9 3 8 4 7 5 D0 D1 D2 D3 D4 D5 D6 D7 D3 D4 D5 D6 D7 D8 D9 D10 DD0 DD1 DD2 DD3 4 3 2 1 5 6 7 8 D0 D1 D2 D3 T11 T8 T7 T10 T6 T9 T13 176 175 174 173 172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149 148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 PVcc RASU/PINT4/CS4/PA20 RASL/IRQ2/POE2/PB4 WE0/DQMLL/POE6/PA12 WE1/WE/DQMLU/POE7/PA13 WE2/ICIORD/DQMUL/TIC5V/PA22 WE3/ICIOWR/AH/DQMUU/TIC5W/PA23 CS3/TCLKB/PA7 CS2/TCLKA/PA6 WE3/ICIOWR/AH/DQMUU/DREQ2/CKE/AUDSYNC/PA16 CASL/IRQ3/POE3/PB5 CASU/PINT5/CS5/CE1A/TIC5U/PA21 D0 PVcc PVss D1 D2 Vcc Vss D3 D4 D5 D6 D7 D8/TIOC3AS/PD8 D9/TIOC3BS/PD9 D10/TIOC3CS/PD10 PVcc D11/TIOC3DS/PD11 PVss D12/TIOC4AS/PD12 Vcc Vss D13/TIOC4BS/PD13 D14/TIOC4CS/PD14 D15/TIOC4DS/PD15 D16/IRQ0/POE4/AUDATA0/PD16 D17/IRQ1/POE5/AUDATA1/PD17 D18/IRQ2/POE6/AUDATA2/PD18 D19/IRQ3/POE7/AUDATA3/PD19 D20/IRQ4/TIC5WS/PD20 D21/IRQ5/TIC5VS/PD21 D22/IRQ6/TIC5US/AUDCK/PD22 PVss 4KHz_out DD4 DD5 DD6 DD7 4 3 2 1 5 6 7 8 D4 D5 D6 D7 4 3 2 1 DD8 DD9 DD10 DD11 4 3 2 1 5 6 7 8 4 3 2 1 4 3 2 1 5 6 7 8 5 6 7 8 D8 D9 D10 D11 5 6 7 8 DD12 DD13 DD14 DD15 4 3 2 1 4 3 2 1 5 6 7 8 5 6 7 8 D12 D13 D14 D15 Feed_PWM- PVss A21/IRQ7/ADTRG/POE8/PB9 A22/DREQ1/IRQ1/SCK1/PA5 A23/TxD1/PA4 A24/RxD1/PA3 A25/DREQ0/IRQ0/SCK0/PA2 A0/PC0 CS8/PE16 DACK1/CKE/TIOC4D/IRQOUT/PE15 MD_CLK2 MD_CLK0 Vss Vcc MD2 MD0 FRAME/CKE/TCLKD/IRQ3/PA9 SCK3/TIOC3B/RTS3/PE9 WAIT/DACK2/PA17 PVcc PVss PVss MRES/TIOC4B/PE13 CS0 CS1/POE5/PA11 SCK2/TIOC3A/PE8 CE2A/DREQ3/PINT6/PA24 CE2B/DACK3/PINT7/POE8/PA25 IRQ1/POE1/SDA/PB3 IRQ0/POE0/SCL/PB2 BS/RxD2/TIOC2B/UBCTRG/PE7 DREQ0/TIOC0A/AUDCK/PE0 PVcc PVss Vss Vcc TEND1/TIOC0D/AUDATA3/PE3 CS5/CE1A/PINT1/TxD0/PA1 CS6/CE1B/TxD3/TIOC1B/AUDATA1/PE5 TEND0/TIOC0B/PE1 CS7/SCK3/TIOC2A/AUDATA0/PE6 CS4/PINT0/RxD0/PA0 IOIS16/RxD3/TIOC1A/AUDATA2/PE4 DREQ1/TIOC0C/PE2 WE3/ICIOWR/AH/DQMUU/DACK0/TIOC4C/PE14 10K 10K 10K 2-6 R74 R57 R56 2 VM_Voltage DD[0..15] MAIN BOARD_Circuit Diagram 2/6 /WR DD[0..15] /WR DD[0..15] DD7 DD6 DD5 DD4 DD3 DD2 DD1 DD0 DD15 DD14 DD13 DD12 DD11 DD10 DD9 DD8 DD14 DD15 DD12 DD13 DD10 DD11 DD6 DD7 DD8 DD9 DD4 DD5 DD2 DD3 DD0 DD1 PC9 CE0.1u 18 17 16 15 14 13 12 11 18 17 16 15 14 13 12 11 VCC3 B0 B1 B2 B3 B4 B5 B6 B7 IC2 B0 B1 B2 B3 B4 B5 B6 B7 IC6 LAB/BA /LOE LB0 LA0 LB1 LA1 GND GND LB2 LA2 LB3 LA3 VCC3 VCC3 LB4 LA4 LB5 LA5 GND GND LB6 LA6 LB7 LA7 HB0 HA0 HB1 HA1 GND GND HB2 HA2 HB3 HA3 VCC3 VCC3 HB4 HA4 HB5 HA5 GND GND HB6 HA6 HB7 HA7 HAB/BA /HOE 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 19 1 E DIR 2-7 19 1 E DIR 74LVC245 2 3 4 5 6 7 8 9 A0 A1 A2 A3 A4 A5 A6 A7 74LVC245 2 3 4 5 6 7 8 9 A0 A1 A2 A3 A4 A5 A6 A7 DB7 DB6 DB5 DB4 DB3 DB2 DB1 DB0 DB15 DB14 DB13 DB12 DB11 DB10 DB9 DB8 SN74LVCH16245ADGG-EL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 IC10 VCC3 DB7 DB6 DB5 DB4 DB3 DB2 DB1 DB0 5 6 7 8 5 6 7 8 5 6 7 8 5 6 7 8 5 6 7 8 5 6 7 8 5 6 7 8 5 6 7 8 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 TP46 TP59 TP85 TP57 TP55 TP52 TP84 TP83 TP47 TP48 TP49 TP50 TP51 TP53 TP54 TP56 DB[0..15] R13 10K VCC3 DB15 DB14 DB13 DB12 DB11 DB10 DB9 DB8 DB[0..15] RA6 RA9 RA12 RA14 PC24 CE0.1u 4 3 2 1 T2 /GATE1 R2 10K VCC3 MD12 MD13 MD14 MD15 EXBV8V330J MD0 MD1 MD2 MD3 EXBV8V330J MD4 4 MD5 3 MD6 2 MD7 1 EXBV8V330J MD8 4 MD9 3 MD10 2 MD11 1 EXBV8V330J 4 3 2 1 /GATE2 PC14 CE0.1u VCC3 PC16 CE0.1u VCC3 /CS0 TP1 TP2 JP1 2 VCC DSP03-003-432G 1 3 TP11 R127 0 VCC3 RA[1..25] /CS4 /RD /WE1 /WE0 /WR /CS1 /WE1 /WE0 /CS1 RA22 RA23 RA24 RA25 RA20 RA21 RA18 RA19 RA16 RA17 PC55 CE0.1u VCC3 RA14 RA15 RA12 RA13 RA10 RA11 RA6 RA7 RA8 RA9 RA4 RA5 RA2 RA3 RA1 VCC3 LAB/BA /LOE LB0 LA0 LB1 LA1 GND GND LB2 LA2 LB3 LA3 VCC3 VCC3 LB4 LA4 LB5 LA5 GND GND LB6 LA6 LB7 LA7 HB0 HA0 HB1 HA1 GND GND HB2 HA2 HB3 HA3 VCC3 VCC3 HB4 HA4 HB5 HA5 GND GND HB6 HA6 HB7 HA7 HAB/BA /HOE TP40 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 LAB/BA /LOE LB0 LA0 LB1 LA1 GND GND LB2 LA2 LB3 LA3 VCC3 VCC3 LB4 LA4 LB5 LA5 GND GND LB6 LA6 LB7 LA7 HB0 HA0 HB1 HA1 GND GND HB2 HA2 HB3 HA3 VCC3 VCC3 HB4 HA4 HB5 HA5 GND GND HB6 HA6 HB7 HA7 HAB/BA /HOE IC16 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 SN74LVCH16245ADGG-EL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 PC56 CE0.1u MA1 MA2 MA3 MA4 MA5 MA6 MA7 MA8 MA9 MA10 MA11 MA12 MA13 MA14 MA15 MA16 MA17 MA18 MA19 MA20 MA21 MA25 MA[1..25] VCC3 VCC3 PC25 CE0.1u TP21 TP22 TP23 TP24 TP25 TP26 TP27 TP28 TP29 TP31 TP32 TP33 TP34 TP35 TP36 TP37 TP38 TP39 TP71 TP70 TP68 TP20 VCC3 SN74LVCH16245ADGG-EL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 37 13 15 47 25 24 23 22 21 20 19 18 8 7 6 5 4 3 2 1 48 17 16 9 10 IC14 VCC NC RY/BY BYTE A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 S29AL016D70TFI020 VSS VSS WP/ACC CE OE WE RESET D0 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 IC12 PC47 CE0.1u 27 46 14 26 28 11 12 29 31 33 35 38 40 42 44 30 32 34 36 39 41 43 45 /CS4 /RD RA[1..25] TP30 /RRD /WWE0 /RESET TP19 TP18 TP17 TP16 TP15 TP14 TP13 TP12 TP10 TP9 TP8 TP7 TP6 TP5 TP4 TP3 /RESET MD0 MD1 MD2 MD3 MD4 MD5 MD6 MD7 MD8 MD9 MD10 MD11 MD12 MD13 MD14 MD15 5 6 7 8 5 6 7 8 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 MA12 MA13 MA14 MA15 EXBV8V330J 4 3 2 1 TP69 TP58 MA16 MA17 MA18 MA19 EXBV8V330J MA20 4 MA21 3 2 MA22 MA23 1 EXBV8V330J MA24 4 MA25 3 2 1 EXBV8V330J 4 3 2 1 4 3 2 1 MA1 MA2 MA3 EXBV8V330J MA4 4 MA5 3 MA6 2 MA7 1 EXBV8V330J MA8 4 MA9 3 MA10 2 MA11 1 EXBV8V330J 4 3 2 1 EXBV8V330J 5 6 7 8 RA26 5 6 7 8 RA27 5 6 7 8 5 6 7 8 5 6 7 8 5 6 7 8 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 RA29 RA28 5 6 7 8 5 6 7 8 5 6 7 8 5 6 7 8 5 6 7 8 5 6 7 8 5 6 7 8 RA19 RA22 RA24 RA25 5 6 7 8 PC10 CE0.1u /CCS4 /RRD MA[1..25] /WWR /WWR /WWE1 /WWE1 /WWE0 /WWE0 TP67 TP75 TP73 /CCS4 /RRD MA24 TP76 MA23 TP81 MA22 TP79 MA21 TP77 MA20 TP78 MA19 TP80 MA[1..25] MAIN BOARD_Circuit Diagram 3/6 2 MAIN BOARD_Circuit Diagram 4/6 VCC3 VCC3 + C5 10u/16V VCC3 PC6 CE1.0u VCC3 PC18 CE1.0u VCC3 PC17 CE1.0u VCC1.5 PC15 CE1.0u VCC1.5 PC21 CE1.0u VCC1.5 PC22 CE1.0u PC7 CE1.0u VCC3 PC19 CE1.0u VCC3 VCC1.5 FL2 DB[0..15] 57 59 58 /INTUSB_1 62 60 61 10K /INTUSB_1 R9 10K LCD_RS LCD_RW LCD_E /LCD_CS /LED /SW0 /SW1 /RESET 2 3 4 5 6 7 8 9 VCC 1 19 PC61 CE0.1u 18 17 16 15 14 13 12 11 4 3 2 1 TC74VHCT541AFT 4 3 2 1 D1 D2 D3 D4 D5 D6 D7 D8 Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 5 6 7 8 LCD_RS_out LCD_RW_out LCD_E_out Panel_D0 Panel_D1 Panel_D2 Panel_D3 Panel_D4 Panel_D5 Panel_D6 Panel_D7 LCD_CS_out /LED /SW0 /SW1 EXBV8V330J E1 E2 RA35 IC27 40 13 6 VDD AFED15V AFEA15V Y1 DP0 DP1 DP2 DP3 DP4 DP5 DP6 DP7 VCC3 PC60 CE0.1u 24MHz C3 8p 5.6K 1% 5 6 7 8 4 3 2 1 5 6 7 8 5 6 7 8 Panel_RESET DP[0..7] 1M R3 560 R1 4 3 2 1 EXBV8V330J R7 M66592FP RA32 IC26 R8 10 11 XIN XOUT RST VCC3 R10 AFEA15G AFED15G 63 RERIN /RESET Vcc_USB -Data +Data ACM2012 17 16 MPBUS TEST CS WR1 WR0 RD INT 7 14 56 55 54 53 51 DEND1 DREQ1 DACK1/DSTB0 41 /RESET /USBCS /WWE1 /WWE0 /RRD /INTUSB_0 C2 CE1.0u FL3 4 43 44 45 46 47 48 49 50 52 DP SD0 SD1 SD2 SD3 SD4 SD5 SD6 SD7 SOF DREQ0 DEND0 DACK0 A1 A2 A3 A4 A5 A6/ALE AFED33G AFEA33G /CS /WWE1 /WWE0 /RRD /INTUSB_0 18 19 20 21 22 23 IC9 5 VBUS 3 DM 10K 8 T5 MA13 MA14 MA15 MA16 MA17 MA18 D0 D1/AD1 D2/AD2 D3/AD3 D4/AD4 D5/AD5 D6/AD6 D7 D8 D9 D10 D11 D12 D13 D14 D15 1 9 MA[13..18] MA[13..18] 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 15 42 64 2 12 2 DB0 DB1 DB2 DB3 DB4 DB5 DB6 DB7 DB8 DB9 DB10 DB11 DB12 DB13 DB14 DB15 VIF1 VIF2 VIF3 AFED33V AFEA33V EXCML20A390U DGND DB[0..15] 18 17 16 15 14 13 12 11 B0 B1 B2 B3 B4 B5 B6 B7 C4 8p RA33 1 1 2 2 3 3 4 4 2 3 4 5 6 7 8 9 A0 A1 A2 A3 A4 A5 A6 A7 1 2 3 4 19 1 E DIR 1 2 3 4 RA34 LCD_CONT EXBV8V330J 8 7 6 5 8 7 6 5 8 7 6 5 PenForce_VR 8 7 6 5 EXBV8V330J 74LVC245 /PANEL /WRP VCC PenForce_VR R187 3 LCDCONT 0 + 2 SW1 KHS82E VCC R185 PC45 CE0.1u 5.6K R186 9 10 11 12 13 14 15 16 1 - 4 8 7 6 5 4 3 2 1 C45 CE10p IC15A BA10358F 8 T60 12K VCC3 RA16 Power_ON Slow_Power_ON T32 4 3 2 1 4 3 2 1 VCC3 EXBV8V103J RA15 4 5 4 3 6 3 2 7 2 1 8 1 IC15B TP136 7 PenForce_VR_AD 6 + 5 6 7 8 5 6 7 8 - 5 6 7 8 5 T28 BA10358F D7 1SS355 R94 100 R42 0 R95 CE100p C13 CE100p EXBV8V103J PC54 CE0.1u CLK66_2 /RESET T39 T43 isp_TMS isp_TDI isp_TCK isp_TDO DP6 DP7 X_En_Phb X_En_Pha /GATE1 /GATE2 /WRP /IRQUSB_0 LCD_RS LCD_E LCD_RW VCC3 /LCD_CS /CS5 R140 10K 4KHz_out /INTUSB_1 /LED /SW0 /SW1 T53 /CropOn VCC3 R158 10K /PANEL /INTUSB_0 /SENSOR1 PC59 CE0.1u VCC DB[0..15] 5 4 6 3 7 2 8 1 4 3 2 1 PC12 CE0.1u 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 T54 DB[0..15] RA36 EXBV8V103J 5 6 7 8 R76 10K DB15 DB14 DB13 DB12 DB11 R61 10K IC20 EPM240T100C5N T52 T55 T51 LCD_BUSY /RESET T56 MA21 MA22 MA23 MA24 MA25 I/O I/O I/O I/O I/O I/O I/O I/O I/O I/O GNDINT IO/GCLK3 VCCINT IO/GCLK2 I/O GNDIO VCCIO2 I/O I/O I/O I/O I/O I/O I/O I/O DB10 DB9 DB8 DB7 DB6 DB5 DB4 DB3 DB2 DB1 DB0 MA[1..25] I/O I/O I/O I/O I/O I/O I/O I/O VCCIO1 GNDIO GNDINT IO/GCLK0 VCCINT IO/GCLK1 I/O I/O I/O I/O I/O I/O I/O TMS TDI TCK TDO I/O I/O I/O I/O I/O VCCIO1 GNDIO I/O I/O I/O I/O I/O I/O I/O I/O I/O I/O IO/DEV_OE IO/DEV_CLRn VCCIO1 GNDIO I/O I/O I/O I/O MA[1..25] 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 /CS0 /CS1 /CS4 /CS8 T35 /WWR /RRD /WWE0 PC58 CE0.1u I/O I/O I/O I/O I/O I/O VCCIO2 GNDIO I/O I/O I/O I/O I/O I/O I/O I/O I/O I/O I/O I/O VCCIO2 GNDIO I/O I/O I/O VCC3 100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 DP0 DP1 DP2 DP3 DP4 DP5 Y_En_Phb Y_En_Pha DP[0..7] DB[0..15] IC25 DB0 DB1 DB2 DB3 DB4 DB5 DB6 DB7 18 17 16 15 14 13 12 11 RA37 Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 D1 D2 D3 D4 D5 D6 D7 D8 E1 E2 2 3 4 5 6 7 8 9 4 3 2 1 5 6 7 8 5 6 7 8 EXBV8V330J C34 C35 C37 CE100p CE100p CE100p /SENSOR1 VCC3 PC13 CE0.1u C38 CE100p 1 19 74LVC541 2-8 4 3 2 1 Limit PINCH_SENS FRONT_PAPER REAR_PAPER TP98 TP97 TP133 TP134 Limit Pinch_Pos F_Paper R_Paper R184 Feed_En X_CURNT R159 10K R166 10K X_CURNT TP135 33 Sol_En R183 Sol_En 33 33 33 33 R180 R181 R182 Sol_PWMFeed_PWM+ Feed_PWM- TP86 TP87 TP92 TP82 C50 CE0.22u/50V C51 CE0.22u/50V IN1 IN2 IN3 IC22 8 EN1 3 EN2 13 EN3 7 4 14 C54 CE1.0u D14 DAN217U 3 2 1 /CropOn Fan_PWM L6234 6 OUT1 5 OUT2 15 OUT3 9 VS 12 VS 8 /CropOn 7 3403A IC19B 6 5 VCC 3403A IC19C VCC E1 E2 1 19 18 17 16 15 14 13 12 11 TC74VHCT541AFT D1 D2 D3 D4 D5 D6 D7 D8 2 3 4 5 6 7 8 9 Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 330 680 IC18 R148 10 X_En_Phb R147 9 12 X_En_Phb X_En_Pha 330 680 VCC PC57 CE0.1u /Crop_ON@ R142 4.7K 0.1% R160 47K 0.1% T45 T46 R161 4.7K 0.1% R153 47K 0.1% R92 0.1ohm/1W R83 R84 R63 4.7K 0.1% 10 X_En_Pha Y_En_Phb 5 9 11 13 47K 0.1% 74LVC14 IC24F 74LVC14 IC24E 74LVC14 IC24D 74LVC14 R71 4.7K 0.1% R91 1.0ohm/1W 8 7 6 5 8 7 6 5 R138 R137 FL6 EXCML20A390U 100 100 TP100TP99 TP102TP101 EXBV8V470J 1 2 3 4 FL7 EXCML20A390U CE1000p CE1000p CE1000p CE1000p C28 C29 C32 C33 1 2 3 4 RA31 VCC 5 6 7 8 4 5 3 6 2 7 1 8 Feed_Motor+ Feed_Motor- 1 2 3 4 UPA1759 Source1 Drain1 Gate1 Drain1 Source2 Drain2 Gate2 Drain2 IC17 Feed_Encoder_Phase_A Feed_Encoder_Phase_B 8 7 6 5 RA30 EXBV8V102J To F EED MOTOR 4 3 2 1 IC24C R87 47K 0.1% R86 8 Y_En_Phb R80 100K 0.1% 6 Y_En_Pha R151 100K 0.1% 100K 0.1% R152 100K 0.1% Fan_PWM C30 CE0.22u/50V CE0.01u C24 VM C58 Sol_CURNT 16 VREF 17 VCP 18 VBOOT R78 + Sol_CURNT - 1 GND 11 GND 10 20 GND GND + 19 SENSE2 2 SENSE1 - CE0.22u/50V Y_En_Pha C39 10u/100V D2FS6 L RCH895-181K L3 D17 CropMark + non R51 1 T59 T58 R89 1.2ohm/1W 0 33 R179 Sol_En Y_CURNT 33 33 33 R176 R177 R178 +24V R44 Y_CURNT Scan_En Scan_PWM+ Scan_PWMSol_PWM+ 2 3 IC19A 3403A VF FAN 8 3 13 7 4 14 C22 CE0.1u R77 non R141 0 VCC 100 C20 CE470p D15 DAN217U EN1 EN2 EN3 IN1 IN2 IN3 IC23 C55 CE1.0u 14 /Crop_ON@ R52 +24V To FAN R90 10K TP88 TP91 C52 CE0.22u/50V C53 CE0.22u/50V TP89 TP74 TP90 + C56 CE0.1u - 11 2 1 3 17 12 VCC 13 R72 non Pinch_Pos 3403A IC19D R170 10K CE0.22u/50V R172 10K 0 VM R149 4.7K 0.1% R144 47K 0.1% R150 4.7K 0.1% R157 47K 0.1% R93 0.1ohm/1W TP121 TP119 TP120 330 R154 C57 C31 CE0.22u/50V R156 100K 0.1% R171 VCC 680 L6234 6 OUT1 5 OUT2 15 OUT3 9 VS 12 VS C25 CE0.01u R155 R139 100K 0.1% + 2-9 4 16 VREF 18 VBOOT 1 GND 11 10 GND GND 20 GND VCP 19 SENSE2 2 SENSE1 - VCC3 FL8 EXCML20A390U EXCML20A390U FL4 TP95 Scan_Motor+ Scan_Motor- Scan_Encoder_Phase_A Scan_Encoder_Phase_B Sol- Sol+ TP96 Pinch_sens /Crop_ON Crop_sens Sol- Sol+ To CUTTING CARRIAGE BOARD TP105 TP106 TP103 TP104 FL5 EXCML20A390U FL9 EXCML20A390U To SCAN MOTOR MAIN BOARD_Circuit Diagram 5/6 2 + CE0.1u C36 +41V C63 CE0.1u C27 220u_50V RT 7 SS VIN IC29 2 1 6 T27 D6 DE3L20U FB INV 5 3 BD9002HFP-TR 2 SW Q2 DTA114EKA R39 100 R35 15K Q1 Comment: 2SJ553S R36 2.2K/0.5W C62 CE0.22u Q3 DTA114EKA Slow_Power_ON Power_ON 2 R34 1K/0.5W 3 1 C9 CE1000p 120K C23 1000u/63V 8.2K C61 CE1000p D16 D2FS6 T44 1 R163 82K R164 150K Q4 2SK2796S +41V + C26 220u/35V EEEFK1V221P 3 2 R70 47/1W R79 47/1W TP148 VM TP151 +24V C21 CE470p R50 100 D12 PTZ43A CE0.22u C60 C59 CE2200p R168 L2 CDRH105 181 180uH + 1.0K R62 +41V R169 C15 R162 10K 220u_50V + VCC PC3 CE0.33u R6 0 VCC 330K 100K 2 Vcc IC3 28 26 25 27 ampVref CHOUT amp out PC26 C6 + R100 10K TP149T4 VCC3 CE0.01u MD1620F IC11 M1FL20U D5 220u/6.3V EEEFK0J221P BA33DD0WHFP 4 Vout 1SS355 D3 R128 R125 CE1000p PC37 220u_50V VDD VCC 1 TAB2 5 6 VBoot S/S CE0.1u GND GND 4 24 23 3 2 22 VG VOUT OCL+ TAB1 CE0.01u PC36 F/B OCL- VB P.GND P.GND P.GND P.GND 8 9 10 11 + C16 CTL 1 GND 3 N.C. 5 VIN VC 1SS355 D2 2 IC7 VC VIN 1 2 1 D1 R15 R16 0.15/1W 0.15/1W 4 3 4 3 T12 R104 1K 1% 100 1% R101 R102 100 1% R99 1K 1% 120 1% R96 R97 120 1% C7 100u_25V C1 100u/25V + C8 1000u/10V EEEFK1A102P VCC5 PQ015YZ01Z VADJ VO VADJ VO 1SS355 IC1 PQ070XZ1HZPH PC2 CE0.33u VCC3 VCC3 CDRH104-330 L1 GND 5 3 1 GND 4 2-10 GND 2 5 PC34 + + TP147 PC4 CE0.1u TP152 T3 PC1 CE0.1u VCC R103 10K VCC1.2 R98 10K VCC1.5 R12 270 1% TP150 T1 LED1 LNJ308G8LRA JP2 JP2 non 2 1 B2P-VH non CN3 MAIN BOARD_Circuit Diagram 6/6 2-3 SUB BOARD SUB BOARD_Arrangement Diagram (Component Side) F D B C F A E F G 2 It indicates the version of the Board. 2-11 U1 SUB BOARD_Arrangement Diagram (Soldering Side) CN9 CN1 2 2-12 PFVR LCDCONT /RESET LCD_RS LCD_R/W LCD_E PD0 PD1 PD2 PD3 PD4 PD5 PD6 PD7 /LCD_CS /LED /SW0 /SW1 FROM MAIN BOARD 52806-2510 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 CN1 PC5 CE0.1u non R13 0 D1 PC3 CE0.1u PD[0..7] PC4 CE0.1u PD0 PD1 PD2 PD3 PD4 PD5 PD6 PD7 PD0 PD1 PD2 PD3 PD4 PD5 PD6 PD7 PD2 PD3 PD0 PD1 PD0 PD1 PD2 PD3 PD4 PD5 PD6 PD7 2 3 4 5 6 7 8 9 19 1 A0 A1 A2 A3 A4 A5 A6 A7 E DIR CLK CLR 11 1 Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 2 5 6 9 12 15 16 19 E DIR 19 1 B0 B1 B2 B3 B4 B5 B6 B7 18 17 16 15 14 13 12 11 E DIR 19 1 B0 B1 B2 B3 B4 B5 B6 B7 18 17 16 15 14 13 12 11 PC2 CE0.1u VCC TC74VHCT245AFT A0 A1 A2 A3 A4 A5 A6 A7 2 3 4 5 6 7 8 9 IC1 TC74VHCT245AFT A0 A1 A2 A3 A4 A5 A6 A7 2 3 4 5 6 7 8 9 IC3 SN74HCT273APWR-EL D1 D2 D3 D4 D5 D6 D7 D8 IC2 TC74VHCT245AFT B0 B1 B2 B3 B4 B5 B6 B7 3 4 7 8 13 14 17 18 18 17 16 15 14 13 12 11 IC4 PAUSE MENU ENTER ORIGIN SHEET CUT TEST CUT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 LCD1 RA3 EXBV8V103JV RA1 EXBV8V103JV VCC VCC LED5 TLWH1100 LED4 TLWH1100 2 TLWH1100 LED7 R8 82 RA2 EXBV8V103JV TLWH1100 LED6 R7 82 2 RA4 EXBV8V103JV LCD BACK Light R6 82 2 RCM2234M-B 20X2 PC6 CE0.1u LCD_RS LCD_R/W LCD_E DB0 DB1 DB2 DB3 DB4 DB5 DB6 DB7 VCC R5 82 VCC PRESET FORCE SPEED LEFT CURSOR TOP CURSOR DOWN CURSOR RIGHT CURSOR SETUP_LED POWER_LED PAUSE_LED R14 100 VCC PANEL BOARD PC1 CE0.1u 3 1 + C1 47u/16V 8 7 6 5 1 2 3 4 8 7 6 5 1 2 3 4 VCC 8 7 6 5 1 2 3 4 8 7 6 5 1 2 3 4 8 7 6 5 8 7 6 5 1 2 3 4 1 2 3 4 8 7 6 5 8 7 6 5 1 2 3 4 2-13 1 2 3 4 SEL6E10C-TH12E LED1 SEL6E10C-TH12E R10 82 EVQ21305R EVQ21305R EVQ21305R SW6 SW12 SW3 TLWH1100 LED9 EVQ21305R SW4 TLWH1100 LED10 R11 82 EVQ21305R EVQ21305R SW13 EVQ21305R SW9 EVQ21305R EVQ21305R EVQ21305R SW10 SW7 SW8 EVQ21305R EVQ21305R EVQ21305R SW1 SW2 SW11 SETUP POWER PAUSE VCC TLWH1100 LED11 R12 82 PAUSE MENU ENTER ORIGN SHEET CUT TEST CUT MEMORY FORCE SPEED LEFT CURSOR TOP CURSOR DOWN CURSOR RIGHT CURSOR RS20M113JA03(10KB) VR1 R2 4.7K VCC 1.5K R3 1.5K R1 1.5K R4 SW5 TLWH1100 LED8 R9 82 DTD113EK Q2 SEL6E10C-TH12E LED2 DTD113EK Q1 DTD113EK Q3 LED3 52793-1170 11 10 9 8 7 6 5 4 3 2 1 Limit 2 non C2 R19 560 U1 CNZ1120 R15 82 CAVCC R16 0 VR2 RH0614CJ5J01A R17 1.0K CAVCC 1 2 3 U2 NJL5265KL NRS-701-2025TF PINCH SENS BOARD RS1 FAN BOARD 5267-02AX 1 2 CN8 5267-02AX 1 2 CN7 5267-02AX 1 2 CN6 CROP BOARD CABLE-ASSY,CROP SENS GX-500 CN9 CARRIAGE BOARD 53014-0210 R18 330 CAVCC Q4 DTD113EK CN4 PinchSens Crop_ON Crop_sens 1 2 IL-S-2P-S2T2-EF 1 2 CN2 Sol- Sol+ CAVCC 4 1 3 1 3 4 3 1 3 2 3 1 1 2 CN5 non C3 Crop_ON Crop_sens 53014-0310 1 2 3 CN3 SUB BOARD_Circuit Diagram 2 3 Replacement of Main Parts The necessary adjustments after the replacement of each part, and the referential time for each work are described as follows. TOOL CARRIAGE REPLACEMENT : 30min. 1. TOOL HEIGHT ADJUSTMENT 2. TOOL PRESSURE ADJUSTMENT 3. CROP MARK SENSOR ADJUSTMENT 4. AUTO CROP-CUT ADJUSTMENT 5. SHEET CUTTER DOWN POSITION ADJUSTMENT Adj. Time : 60min. < Total Time : 90min. > CARRIAGE MOTOR REPLACEMENT : 5min. 1. AGING Adj.Time: 1min. < Total Time : 6min. > GRIT MOTOR REPLACEMENT : 5min. 1. AGING <Total Time : 6min.> Adj. Time : 1min. PINCH ROLLER REPLACEMENT : 5min. < Total Time : 5min. > CARRIAGE WIRE REPLACEMENT : 25min. 1. WIRE TENSION ADJUSTMENT 2. SHEET CUTTER DOWN POSITION ADJUSTMENT Adj. Time : 20min. < Total Time : 45min. > CUTTER PROTECTION REPLACEMENT : 5min. <Total Time : 5min.> CROP MARK SENSOR REPLACEMENT : 15min. 1. TOOL HEIGHT ADJUSTMENT 2. TOOL PRESSURE ADJUSTMENT 3. CROP MARK SENSOR ADJUSTMENT 4. AUTO CROP-CUT ADJUSTMENT 5. SHEET CUTTER DOWN POSITION ADJUSTMENT Adj. Time : 60min. < Total Time : 75min. > MAIN BOARD REPLACEMENT : 10min. 1. FIRMWARE INSTALLATION 2. SYSTEM PARAMETER INITIALIZE 3. TOOL PRESSURE ADJUSTMENT 4. CALIBRATION 5. AUTO CROP-CUT ADJUSTMENT 6. SERIAL NUMBER INPUT 7. SHEET CUTTER DOWN POSITION ADJUSTMENT Adj. Time : 60min. < Total Time : 70min. > 3-1 TOOL CARRIAGE REPLACEMENT 1 Remove the Guide Rail Cover. Guide Rail Cover 2 Remove the Support Cable. Support Cable Be careful not to scratch the Carriage Cable. 3-1 3 Remove the Carriage Cover. 4 Disconnect the Cables of Crop Mark Sensor, Pinch Roller Sensor, Solenoid and Carriage. Carriage Cover Carriage Board Carriage Cable Screw Remove the Carriage Board. Solenoid Cable 5 Remove the Screw and the Washer fixing the Tool Carriage. 6 Remove the 2 Screws to remove the Tool Carriage from the Guide Rail. 3-2 Crop Mark Sensor Cable Pinch Roller Sensor Cable Screw Cut the Cable Tie. 7 Tube CableTie Remove the Screw1 and 2 shown in the figure to remove the Separating Knife and Crop Mark Sensor together with the Crop Mark Sensor Stay from the Tool Carriage. 8 Separating Knife Crop Mark Sensor Crop Mark Sensor Stay Screw2 Screw1 < Bottom View> Remove the Screw fixing the Pinch Roller Sensor Board and the Tool Carriage. 9 < Bottom View> Pinch Roller Sensor Board 10 Screw Remove the Pinch Roller Sensor Board from the Tool Carriage by the either of the 2 methods below. Tube 1) Disconnect the Pinch Roller Sensor Wire from the Connector using the Tweezers. Then, pull out the Pinch Roller Sensor Wire from the Tube. Pinch Roller Sensor Wire 3-3 2) Remove the Pinch Roller Sensor Wire from the Pinch Roller Sensor Board using the Soldering-iron. Then, pull out the Pinch Roller Sensor Wire from top of the Tube. Tube Pinch Roller Sensor Wire Pinch Roller Sensor Board 11 Screw Remove the 2 Screws fixing the Guide Bearing 2. < Rear View> Screw Carriage Bearing 2 12 Fix the Carriage Bearing 2 with 2 Screws to the New Tool Carriage. < Rear View> Screw Carriage Bearing 2 13 Fix the Separating Knife to the New Tool Carriage with the 2 Screws. Separating Knife < Bottom View > 3-4 Fix the Separating Knife, while pushing it to the circled part of the right figure. Separating Knife Screw < Bottom View > 14 Fix the Pinch Roller Sensor Board to the Tool Carriage by the either of the 2 methods below. Tube 1) Put the Pinch Roller Sensor Wire through the Tube and connect it to the Connector. Pinch Roller Sensor Wire 2) Put the Pinch Roller Sensor Wire through the Tube. And solder the Pinch Roller Sensor Wire to the pinch Roller Sensor Board using the Soldering-iron. Pinch Roller Sensor Board Be careful with the direction of the Pinch roller Sensor Board when soldering. 3-5 15 Fix the Pinch Roller Sensor Board. < Bottom View > Pinch Roller Sensor Board 16 Screw Fix the Crop Mark Sensor together with the Crop Mark Sensor Stay to the Tool Carriage with the Screw2. Crop Mark Sensor Crop Mark Sensor Stay Screw2 < The bottom of the Tool Carriage> 17 Fix the 2 Tubes with the Cable Ties. Tube Cable Tie 18 Put the Tool Carriage on the Wire and fix it with the Screw and Washer. * Lift up the Tool Carriage and fix it. * The mark of the Washer on the Wire is the position where the Tool Carriage should be fixed. 3-6 19 Fix the Tool Carriage to the Guide Rail with the 2 Screws while fitting the screw hole of the Carriage Board Stay Assy and Guide Bearing Assy. Screw Guide Bearing Assy 2 1 If the Right Screws is fixed first, the Tool Carriage can be fixed easily. Carriage Board Stay Assy 20 Connect the Cables of the Carriage, Pinch Roll Sensor, Solenoid and the Crop Mark Sensor. And fix the Carriage Board with the Screw while fitting the screw hole of the Carriage Board with the projection part. Projection part Perform the followings. 1. [4-4 TOOL HEIGHT ADJUSTMENT] 2. [4-6 TOOL PRESSURE ADJUSTMENT] 3. [4-9 CROP MARK SENSOR ADJUSTMENT] 4. [4-10 AUTO CROP-CUT ADJUSTMENT] 5. [4-12 SHEET CUTTER DOWN POSITION ADJUSTMENT] 3-7 Carriage Cable Screw Solenoid Wire 21 Carriage Board Crop Mark Sensor Cable Pinch Roller Sensor Cable 3-2 CARRIAGE WIRE REPLACEMENT 1 Remove the Guide Rail Cover, Right Side Cover and Left Side Cover. Left Side Cover 2 Guide Rail Cover Right Side Cover Remove the Support Cable. Support Cable Be careful not to scratch the Carriage Cable. 3 Remove the Carriage Cover. Carriage Cover 4 Remove the Screw and the Washer fixing the Tool Carriage. 3-8 5 Loosen the Screw A and Screw B in order to loosen the Carriage Wire Tension. 2 ScrewB 1 6 Remove the Carriage Wire from the Pulley. 7 Loosen the Screws fixing the Carriaage Motor. ScrewA Carriage Wire Spring Screw Carriage Motor 8 Remove the Screw while holding the Shaft. Then, loosen the 2 Screws fixing the Shaft Stay No.1 and remove the Drive Gear from the Motor Base. Shaft Screw Drive Gear Shaft Stay No.1 Screw 3-9 9 10 11 Remove the 4 Screws fixing the Drive Gear and Pulley. Then, pull out the tip of the Carriage Wire from the cut end of the Pulley. Put the tip of the New Carriage Wire into the cut end of the Pulley. Then, fix the Pulley and the Drive Gear with the 4 Screws. Fix the Drive Gear to the Motor Base with the screw while holding the Shaft. Then, tighten the 2 Screws while pushing the Pulley against the Shaft Stay No.1. Carriage Wire Pulley Carriage Wire Shaft Screw Drive Gear Shaft Stay No.1 Screw 12 Fix the Carriage Motor temporarily with the 3 Screws and the Spring. Spring Screw Carriage Motor 3-10 13 Fix the New Carriage Wire. Wind the Carriage Wire around the Pulley from the bottom to the top (14times). Make sure to wind without overlap or twists. 1 Process 2 will be easier, if putting scotch tape on the wound wire to prevent it from coimg loose. Carriage Wire 2 3 14 Turn the Pulley until the Carriage Wire comes to the middle of the Pulley (7th from the bottom). 15 Fix the Tool Carriage with the Screw and the Washer at the middle of the Guide Rail. 3-11 16 Mesh the Carriage motor Gear with the Drive Gear. Then, tighten the 3 Screws securely. And move the Tool Carriage to left and right several times so that the Carriage Motor Gear meshs with the Drive Gear better. Move the Tool Carriage to left and right several times after meshing. In case this work is not done, the Carriage Motor could be shaky. Spring Screw Carriage Motor 17 Perform the followings. 1. [4-7 WIRE TENSION ADJUSTMENT] 2. [4-12 SHEET CUTTER DOWN POSITION ADJUSTMENT] 3-12 3-3 MAIN BOARD REPLACEMENT 1 Turn on the Power SW while pressing the Left, Right and Down keys to enter the Service Mode. [ ],[ ],[ ] + POWER ON SERVICE MODE VER 1.00 FORCE 30gf 2 Start the PIT. Perform [Get Report] and [Get Parameters], and save them as files. 3 Remove the Front Guide Cover. Front Guide Cover 4 Disconnect all of the Cables from the Main Board. 3-13 5 Remove the 2 Screws on the Main Board and the 4 Screws from the rear side of the Machine. Then, remove the Main Board together with the Plate. < Front > Plate 6 Screw Remove the 2 Screws to remove the Main Board from the Plate. Fix the New Main Board to the Plate. Screw 7 Fix the New Main Board together with the Plate. < Front > The work will be easier if the 4 Screws at the rear are fixed temporarily before fixing the 2 Screws at the front. Plate 3-14 Screw 8 Connect 7 Cables to the Main Board. CN9 CN10 CN11 CN7 CN12 CN8 SW Power Supply Cable : CN6 Carriage Cable : CN7 Panel Board Cable : CN8 Fan Cable : CN9 Feed Motor Cable : CN10 Scan Motor Cable : CN11 Paper Sensor Cable : CN12 9 CN6 Change the DIP SW on the Main Board depending on the model type. GX-500 ... bit#1 On GX-400 ... bit#2 On GX-300 ... All off DIP SW 4 GX-300 3 2 ON 1 4 3 GX-400 2 ON 1 4 3 GX-500 2 ON 10 Fix the Front Guide Cover. Front Guide Cover 3-15 1 11 Perform the following operations after replacement. 1. FIRMWARE INSTALLATION 2. SYSTEM PARAMETER INITIALIZE 3. SHEET CUTTER DOWN POSITION ADJUSTMENT After performing these operations, perform [Put Parameters] with PIT and write the parameter that is saved before replacement to the Main Board. Perform the following operations if it is not possible to transfer the parameters by PIT. 1. FIRMWARE INSTALLATION 2. SYSTEM PARAMETER INITIALIZE 3. TOOL PRESSURE ADJUSTMENT 4. CALIBRATION 5. AUTO CROP-CUT ADJUSTMENT 6. SERIAL NUMBER INPUT* 7. SHEET CUTTER DOWN POSITION ADJUSTMENT * Input the serial number in the [SERVICE MENU] > [SERIAL NO.]. 3-16 3-4 PINCH ROLLER REPLACEMENT 1 Remove the Screw and the 3 Pinch Roller Assys from the cut part. Cut part The GX-300 does not have a middle pinch roller. Screw 2 Remove the E-Ring of one side of the Pinch Roller using the Flat Head Driver. E-Ring 3 Remove the Pin. Pin 4 Put the 2 Washers to both sides of the New Pinch Roller and put the Pin through the Pinch Roller. Pin In case of the Pinch Roller with a sensor, the marked side of the Pinch Roller must be outside. Mark 3-17 5 Fix the E-Ring using a pare of Pliers. E-Ring 6 Fix the 3 Pinch Roller Assys carefully with their fixing positions. The right figure is the Left Pinch Roller Assy. * Left Pinch Roller Assy With the Magnet and the mark on the Left * Middle Pinch Roller Assy No Magnet or the mark * Right Pinch Roller Assy With the Magnet and the mark on the Right Mark Put the 3 Pinch Roller Assys from the cut part and fix the Screw. Screw 3-18 3-5 CROP MARK SENSOR REPLACEMENT 1 Remove the Guide Rail Cover. Guide Rail Cover 2 Remove the Support Cable. Support Cable Be careful not to scratch the Carriage Cable. 3 Remove the Carriage Cover. 4 Disconnect the Cable of the Crop Mark Sensor, Pinch Roller Sensor , Solenoid and Carriage. Carriage Cover Carriage Board Carriage Cable Screw Remove the Screw sown in the figure and the Carriage Board in order. Solenoid Cable 3-19 Crop Mark Sensor Cable Pinch Roller Sensor Cable 5 Remove the Screw and the Washer fixing the Tool Carriage. 6 Remove the 2 Screws to remove the Tool Carriage from the Guide Rail. 7 Cut the Cable Tie. Screw Tube Cable Tie 8 Remove the Screws shown in the figure to remove the Crop Mark Sensor together with the Crop Mark Sensor Stay from the Tool Carriage. Crop Mark Sensor Crop Mark Sensor Stay Screw2 < Bottom View> 3-20 9 Remove the 2 Screws to remove the Crop Mark Sensor Board from the Crop Mark Sensor Stay. Crop Mark Sensor Board Screw Fix the New Crop Mark Sensor Board to the Crop Mark Sensor Stay with the 2 Screws. Cropmark Sensor Stay 10 Fix the Crop Mark Sensor together with the Crop Mark Sensor Stay to the Tool Carriage with the 2 Screws. Crop Mark Sensor Crop Mark Sensor Stay Screw2 < Bottom View> 11 Fix the 2 Tubes with the Cable Ties. Tube Cable Tie 12 Put the Tool Carriage on the Wire and fix it with the Screw and the Washer. * Lift up the Tool Carriage and fix it. * The mark of the Washer on the Wire is the position where the Tool Carriage should be fixed. 3-21 13 Fix the Tool Carriage to the Guide Rail with the 2 Screw swhile fitting the screw hole of the Carriage Board Stay Assy and Guide Bearing Assy. Screw Guide Bearing Assy 2 1 If the ight Screw is fixed first, the Tool Carriage can be fixed easily. Carriage Board Stay Assy 14 Connect the Carriage Cable, the Pinch Roller Sensor Wire, the Solenoid Wire and the Crop Mark Sensor Cable. And fix the Carriage Board with the Screw while fixting Projection part Carriage Board Carriage Cable Screw the screw hole of the Carriage Board with the projection part. Solenoid Wire 15 Perform the followings. 1. [4-4 TOOL HEIGHT ADJUSTMENT] 2. [4-6 TOOL PRESSURE ADJUSTMENT] 3. [4-9 CROP MARK SENSOR ADJUSTMENT] 4. [4-10 AUTO CROP-CUT ADJUSTMENT] 5. [4-12 SHEET CUTTER DOWN POSITION ADJUSTMENT] 3-22 Crop Mark Sensor Cable Pinch Roller Sensor Cable 4 Adjustment 4-1 Special Tool Table shows a list of special tools recommended by Roland DG Corp. Tool No. ST-002 Tool Name TENSION GAUGE 3N (300gf) Purpose TOOL PRESSURE ADJUSTMENT Tool No. ST-006 Tool Name WHITE DUMMY PEN Purpose TOOL HEIGHT ADJUSTMENT SPACER BED ADJUSTMENT TOOL PRESSURE ADJUSTMENT Tool No. ST-011 Tool Name TENSION METER Purpose WIRE TENSION ADJUSTMENT Tool No. ST-012 Tool Name DIAL TENSION METER DTB-50 (0.5N/50gf) Purpose TOOL PRESSURE ADJUSTMENT 4-1 4-2 Service Mode Service Mode [ ], [ ], [ ] + POWER ON SERVICE MODE VER 1.00 Firmware Version FORCE 30gf FORCE *7 30gf The Min. tool pressure can be adjusted by [ ],[ ] keys. The tool pressure becomes stronger as the value increases. The Tool moves up or down by [TEST] key. FORCE 200gf FORCE *8 200gf The Max. tool pressure can be adjusted by [ ],[ ] keys. The tool pressure becomes stronger as the value increases. The Tool moves up or down by [TEST] key. FORCE LEVER FORCE LEVER [-----*-----] This menu is for checking the status of the PEN FORCE Slider. KEY CHECK KEY START ********** This menu is for checking the Panel Keys. Press [TEST],[ORIGIN], [PAUSE], [ ], [ ], [ ], [ ], [MENU],[MEMORY], [ENTER], [SPEED], [FORCE], [SHEET CUT] in order. KEY CHECK OK! KEY CHECK NG! SENSOR CHECK SENSOR CHECK F0 R0 P0 L0 C235 This menu is for checking the Sensor. F : Front Paper Sensor, R : Rear Paper Sensor, P : Pinch Roller Sensor, L : Carriage Limit Sensor, 1 : ON 0 : OFF C : Sensibility of Crop Mark Sensor Value : 0 ~ 1023 Check the difference of the values are more than 500 when the sensor detects the Crop Mark (Black) and the Sheet (White). Make sure to use the matt sheet for this check. LED CHECK LED CHECK BLINKING This menu is for checking the function of LEDs. There is no problem if all LEDs blink, the check will be completed. FAN CHECK FAN CHECK ON This menu is for checking the FAN. ON/OFF can be changed by pressing the [ENTER] key. CALIB-G<-0.14> CALIB-G<-0.14> *CHANGE CALIB-G<-0.14> *-0.14% CALIB-G<-0.14> DATA 2 Select the Calibration Checking DATA and press the [ENTER] key to draw the figure. DATA2:750x550 mm CALIB-G<-0.14> DATA 1 CALIB-C<+0.04> This menu is for Calibration of the Feed direction. DATA1:420x420 mm CALIB-C<+0.04> *+0.04% CALIB-C<+0.04> *CHANGE This menu is for Calibration of the Carriage moving direction. The value is %. Select the Calibration Checking DATA and press the [ENTER] key to draw the figure. CALIB-C<+0.04> DATA 2 DATA2:750x550 mm CALIB-C<+0.04> DATA 1 DATA1:420x420 mm 4-2 CROP AUTO CROP AUTO START CROP MANUAL CROP MANUAL *CROP-G <-5> CROP-G <-5> *-5 CROP MANUAL *CROP-C <-7> CROP-C <-7> *-7 This menu is for AUTO CROP-CUT ADJUSTMENT This menu is for MANUAL CROP-CUT ADJUSTMENT. 1 step = 0.025mm * This menu is not used normally. AGING AGING START This menu is for Aging. Aging can be stopped by pressing the [ PAUSE] key or turning the power off. MOTOR-G TIME MOTOR-G TIME *3000.0H This menu shows the working time of the Grid Motor. MOTOR-G TIME RESET OK ? This menu is for reseting the working time of the Grid Motor. MOTOR-G TIME INFORMATION MOTOR-C TIME MOTOR-C TIME *3000.0H This menu shows the working time of the Scan Motor. MOTOR-C TIME RESET OK ? This menu is for reseting the working time of the Scan Motor. MOTOR-C TIME INFORMATION SERIAL NO. SERIAL NO. ZT00000 SYSTEM SWITCH SYSTEM SWITCH 00000000 Bit# This menu shows the total working time and total reset times of the Grid Motor. T : Total working time of the Grid Motor. R : Total reset times of the Grid Motor. MOTOR-G INFO T5000 R3 Items This menu shows the total working time and total reset times of the Scan Motor. T : Total working time of the Scan Motor. R : Total reset times of the Scan Motor. MOTOR-C INFO T5000 R3 This menu is for inputing the SERIAL NO. when you replace the Main Board. Use the [ ] [ ] key to input the SERIAL NO. and the [ENTER] key to save the setting. Outline Changing the resolving the The resolving power of the arc command will Bit0 power of the arc command. change from 5dgr to 1 dgr. Setting Default 0:5dgr 1:1dgr. 0 The sheet will not move by its weight even 0:Standard if it is [UN SETUP] when the heavy sheet is 1:Adaptation set, such as the sandblast. 0 Bit2 This menu can change the correspondence Default setting for the !FS 0:Disable when the machine received FS command command and VS command 1:Enable and VS command. 0 Bit3 This menu can change the feed speed for Default setting for the !PG 0:Standard the sheet when the machine received !PG command 1:High speed command. 0 Bit1 Magnetizes the Motor I/O CHECK USB CHECK **** Byte SERIAL CHECK **** Byte 4-3 This menu is for changing the functions of the machine. Normally, It is not necessary to change any switches. Each bit is selected by [ ],[ ] keys and it can be changed by [ ],[ ] keys. This menu is for checking that the machine can read the data sent from the PC through the USB or the SERIAL cable. The number of bytes that was received will be shown on the LCD. Special Key Operation Sheet Cutter Down Position Adjustment Displayed Language System Parameter Initialize It initializes the all parameters. Lower the Sheet Cutter by pushing the Tool Carriage against the Left Frame. [ ],[ ] , [SHEETCUT] [ MENU ] + POWER ON [ ],[ ] , [ ORIGIN ] + POWER ON + POWER ON LANG. ENGLISH *ENGLISH INITIALIZING CUT DOWN POS INIT ALL EEROM Languages: English,Japanese,German,French, Spanish,Italian and Portuguese. ARE YOU SURE? ARE YOU SURE? COMPLETED COMPLETED Firmware Upgrade Initialize for customers [ ] , [ ] , [ ] + POWER ON It initializes the all parameters set in the user menu. OTHERS BOOT VERSION 1.0 [ ] FACTORYDEFAULT ARE YOU SURE? [ ] FACTORYDEFAULT *PRESET WAITING [ RECEIVING 99% SELECT SHEET *ROLL WRITING 99% COMPLETED 4-4 ] SERVICE REPORT << SYSTEM REPORT >> MODEL : GX-500 SERIAL NO: ZU60100 VERSION MAIN : A100 BOOT : B100 SERVICE INFORMATION FORCE: 30g=17 200g=20 FACT CALIB. : C=-0.06% G=0.00% KNIFE ADJ. : 650step CROP SENSOR OFFSET: C=-16step G=-51step MOTOR TIME : C=0.2H G=0.2H MOTOR TOTAL TIME : C=0.2H G=0.2H MOTOR RESET COUNT : C=0 G=0 DIPSW : 00000001 SYSTEMSW: 00000000 SCcmd: OFF O?cmd: ON MENU INFORMATION : FORCE[gf] SPEED[cm/s] OFFSET[mm] UPSPEED[cm/s] CONDITION: 90 15 0.250 AUTO MEMORY USER1 USER2 USER3 USER4 USER5 USER6 USER7 USER8 : USER1 : 50 : 50 : 50 : 50 : 50 : 50 : 50 : 50 20 20 20 20 20 20 20 20 0.250 0.250 0.250 0.250 0.250 0.250 0.250 0.250 AUTO AUTO AUTO AUTO AUTO AUTO AUTO AUTO CROPMARK : MANUAL BASE X: 0.0mm BASE Y: 0.0mm WIDTH : 180mm LENGTH: 210mm I/O : AUTO SERIAL BAUD : 9600 DATA : 8 STOP : 1 PARITY: NONE HAND : H-WIRE AUTOCUT SPEED : 50cm/s AUTOCUT MARGIN : 30mm AUTOCUT PASSES : 1 AUTOCUT COMMAND : DISABLE VS COMMAND : DISABLE !FS COMMAND : DISABLE SP COMMAND : DISABLE SMOOTHING: ON DISP UNIT: mm CONTRAST : 5 TESTCUT PATTERN : TYPE1 OVER CUT : DISABLE USER CALIB. : C=0.00% G=0.00% LANGUAGE: ENGLISH << END >> *Please use the monospaced font like the [Courier] font when you see it. 4-5 QUALITY ROTATE[deg] AREA[m] NORMAL 0 1.0 NORMAL NORMAL NORMAL NORMAL NORMAL NORMAL NORMAL NORMAL 4-3 HOW TO UPGRADE FIRMWARE (Reference Time:5min.) Connect PC and GX-500/400/300 with the USB Cable. It is necessary to prepare the followings to upgrade the FIRMWARE. 1. FIRMWARE 2. WindowsPC (OS:Windows98SE/Me/2000/XP) 3. USB Cable 4. PIT.exe Turn on the power while pressing [ ],[ ],[ ] keys. [ ] , [ ] , [ ] + POWER ON The machine is ready to receive data when [WAITING] is displayed. BOOT VERSION 1.0 ARE YOU SURE? [ENTER] WAITING Start up PIT. PIT window is displayed. Click [Firmware Upgrade] button. [Open] screen is displayed. Select the firmware file and click [Open]. PIT starts to send the firmware to the GX-500/400/300. 4-6 When the Firmware Upgrade is completed, [COMPLETE] will be displayed on the LCD. RECEIVING 99% Turn off the power. WRITING 99% COMPLETED [POWER OFF] 4-7 4-4 TOOL HEIGHT ADJUSTMENT (Referential Time : 20min.) TOOL HEIGHT ADJUSTMENT is for adjusting the tool height to avoid the tool-bouncing in the cutting operation. This adjustment must be performed after replacement of the TOOL CARRIAGE. Roland Special Tool WHITE DUMMY PEN (ST-006), Thickness Gauge and 1mm Hexagonal wrench are necessary for this adjustment. 1 2 3 Remove the Guide Rail Cover. Guide Rail Cover Remove the Carriage Cover. Carriage Cover Fix the White Dummy Pen (ST-006) to the Tool Carriage. ST-006 White Dummy Pen Move the 2 Pinch Rollers to the both sides of the Grit 4 Roller and lower them. Pinch Roller(middle) Raise only the middle Pinch Roller. Pinch Roller 4-8 Cover the Front and Rear Paper Sensors with the sheet. Front Paper Sensor Rear Paper Sensor Turn on the Power and select [ROLL] by the [ keys. And press the [ENTER] key. ],[ ] SELECT SHEET *ROLL Use [ ] or [ ] to select. Press [ENTER] to enable the setting. NOW LOADING W:1195mm L:- - - - - - Measure the clearance between the tip of the Pen and the Bed at the 5 positions as shown in the right figure. (the 3 positions for GX-300) If the clearance is 2.5mm ~ 3.0mm at all 5 positions (3 positions for GX-300), it is not necessary to perform this adjustment. The Tool Carriage can be moved by hand. Move the Tool Carriage to the position where the clearance is the smallest. Then, adjust the clearance to be 2.5 mm ~ 2.6 mm with the Adjusting Screw. If turning the Adjusting Screw to left, the clearance becomes bigger. 4-9 Adjusting Screw Confirm that the clearance is 2.5mm ~ 3.0mm between 9 the tip of the Pen and the Bed at the other 4 positions (2 positions for GX-300). The Tool Carriage can be moved by hand. If the clearance between the tip of the Pen and the Bed is not 2.5mm ~ 3.0mm, perform the following. 1. [4-5 BED HEIGHT ADJUSTMENT] 10 Perform the following. 1. [4-6 TOOL PRESSURE ADJUSTMENT] 4-10 4-5 BED HEIGHT ADJUSTMENT (Reference Time:20min.) This adjustment is necessary when the clearance between the tip of the Pen and the Bed is not 2.5mm - 3.0mm checked in 9 of the TOOL HEIGHT ADJUSTMENT. Be careful not to touch the Switching Power Unit when performing this adjustment. Remove the Guide F Cover. Guide F Cover Remove the Guide R Cover. Guide R Cover Fix the White Dummy Pen (ST-006) to the Tool Carriage and lower the Pinch Rollers. Cover the Front and Rear Paper Sensors with the sheet. (Refer to [4-4 TOOL HEIGHT ADJUSTMENT] 3 ~ 5 .) 4-11 Turn on the Power and select [ROLL] by the [ 4 keys. ],[ ] SELECT SHEET *ROLL Then, press the [ENTER] key. Use [ ] or [ ] to select. Press [ENTER] to enable the setting. NOW LOADING W:1195mm L:- - - - - - 5 Loosen the 2 Screws. Screw 6 Loosen the 2 Nuts with the 7mm Spanner. Nut Adjust the 2 Screws so that the clearance between the 7 tip of the Pen and the Bed is 2.5 mm ~ 3.0 mm at the 5 positions (3 positions for GX-300). The Tool Carriage can be moved by hand. 4-12 Screw 8 Tighten the 2 Nuts with the 7mm Spanner. Nut 9 Tighten the 2 Screws. Screw 10 Perform [4-4 TOOL HEIGHT ADJUSTMENT] 7 ~ 10 again. 4-13 4-6 TOOL PRESSURE ADJUSTMENT (Referential Time : 15 min.) TOOL PRESSURE ADJUSTMENT is for adjusting the current supplied to the solenoid of the TOOL CARRIAGE to ensure that correct pressure would be added to the blade when cutting. This adjustment must be performed after replacement of the TOOL CARRIAGE. Roland Special Tool TENSION GAUGE (ST-002), WHITE DUMMY PEN (ST-006) and DIAL TENSION METER (ST-012) are necessary for this adjustment. Turn on the power while pressing [ enter the Service Mode. ], [ ], [ ] keys to [ Carry out [4-4 TOOL HEIGHT ADJUSTMENT] before doing this adjustment. ],[ ],[ ] + POWER ON SERVICE MODE VER 1.00 FORCE 30gf Move the TOOL CARRIAGE to the position where the clearance between the Pen Tip and the BED is the smallest. [H] mark is written at the position where the Tool Height was adjusted in the factory. It is written at the position where the BED is at the highest. In other words, where the clearance between the Pen and the BED is the smallest. Tool Carriage Select [FORCE 30gf] menu and move the TOOL down by pressing the [TEST] key. FORCE 30gf [ ] FORCE 30gf *7 [TEST] 4-14 Pull up the TOOL HOLDER with the DIAL TENSION METER (ST-012) and measure the pressure when the pen tip leaves the BED. Adjust the parameter in the [FORCE 30gf] menu with the Up and Down keys so that the pressure will be 25gf ~ 35gf . Press the [ENTER] key to save the settings. FORCE 30gf *7 [ ] [ ] [ENTER] Select [FORCE 200gf] menu and move the TOOL down FORCE 200gf by pressing the [TEST] key. [ ] FORCE 200gf *8 [TEST] Pull up the TOOL HOLDER with the TENSION GAUGE (ST-002) and measure the pressure when pen tip leaves the BED. Adjust the parameter in the [FORCE 200gf] menu with the Up and Down keys so that the pressure will be 200gf ~ 208gf. Press the [ENTER] key to save the settings. FORCE 200gf *8 [ ] [ ] [ENTER] Select [FORCE 30gf] menu and move the TOOL down by pressing the [TEST] key. Confirm that the pressure is 25gf ~ 35gf when the tip of the PEN leaves the BED by lifting theTOOL HOLDER with the DIAL TENSION METER(ST-012). In case of NG, adjust again. 4-15 4-7 WIRE TENSION ADJUSTMENT (Reference Time:15min.) Remove the Left Side Cover. Left Side Cover Turn off the Power and move the Tool Carriage to the left end. Tool Carriage Loosen the Screw at the left end of the machine. Screw Measure the Wire Tension with the Tension Meter (ST011) in the middle. ST-011 4-16 Tension Meter Adjust the Screw at the left end of the machine so that the Wire Tension will be 12~14 pound. If the Screw is loosened, the Wire Tension will be weak. If the Screw is tightened, the Wire Tension will be strong. Screw Move the Tool Carriage within a whole width about 10 times by hand. And measure the Wire Tension again. Guide Rail In case of NG, adjust the Screw B again. Tool Carriage Tighten the Screw at the left end of the machine. Screw Measure the Wire Tension again. In case of NG, adjust it again. 4-17 4-8 CALIBRATION (Referential Time : 20 min.) CALIBRATION is for calibrating the media feeding amount. This adjustment must be performed after replacement of the MAIN BOARD or in case you like to improve the distance accuracy. Change the value of the Calibration to 0 in the User Mode and the Service Mode before performing this adjustment. Sheet of A1 size, 0.25mm Standard Ceramic Pen (SD-25-XX), and Scale more than 800mm are necessary for this adjustment. Put the 0.25mm Standard Ceramic Pen to the TOOL CARRIAGE. Set A1 size paper (841mm x 594mm) on the machine. Turn on the power while pressing [ enter the Service Mode. ], [ ], [ ] keys to [ ],[ ],[ ] + POWER ON SERVICE MODE VER 1.00 FORCE 30gf 4-18 Select [DATA2] under [CALIB - *] menu and press the [ENTER] key. CALIB-C<+0.04> [ ] CALIB-C<+0.04> *CHANGE Either [CALIB-G] or [CALIB-C] can be used for [CALIB-*] menu. [ ] CALIB-C<+0.04> DATA2 [ENTER] The right figure will be drawn. 50mm 100mm GRIT 750mm 50mm 100mm 550mm CARRIAGE Measure the length of CARRIAGE DIRECTION /GRIT ROLLER DIRECTION by using the figure. If the measured length is within the following range, it does not need to be calibrated. Carriage Direction : 548.9mm ~ 551.1mm Grit Direction : 748.5mm ~ 751.5mm If the measured length is beyond the range, carry out the next step. Calculate the amount to be calibrated with the formula shown in the right figure. FORMULA CA = Calibrating Amount CL = Commanded Length (Carriage Direction : 550mm Grit Direction : 750mm) ML = Measured Length CL - ML CA (%) = X 100 ML 4-19 Select the directions, GRIT ROLLER DIRECTION or CARRIAGE DIRECTION. (Grit Direction) CALIB-G<-0.04> [ (Carriage Direction) ] CALIB-C<+0.04> Press [ ] key to enter the adjusting menu and change the Calibrating Amount with [ ] and [ ] keys. Then, press the [ENTER] key to save the setting. CALIB-G<-0.14> [ ] CALIB-G<-0.14> *CHANGE Calibrating Amount can be entered in increments of 0.01%. [ ] CALIB-G<-0.14> *-0.14 [ENTER] Set the paper again. Select [DATA2] under [CALIB - *] menu and press the [ENTER] key to start drawing the figure. CALIB-C<+0.04> [ ] CALIB-C<+0.04> *CHANGE [ ] CALIB-C<+0.04> DATA2 [ENTER] Measure the length of CARRIAGE DIRECTION /GRIT ROLLER DIRECTION by using the figure. Make sure that the measured length is within the following range. Carriage Direction : 548.9mm ~ 551.1mm Grit Direction : 748.5mm ~ 751.5mm If the measured length is beyond the range, carry out the calibration again. 4-20 4-9 CROP MARK SENSOR ADJUSTMENT (Referential Time : 10 min.) This adjustment is for adjusting the sensitivity of the CROP MARK SENSOR. If not adjusted, the crop marks cannot be read correctly and it results in a problem of the position error of the cutting. MATT BLACK VINYL SHEET (the backing paper color:white, A4 size or larger), knife and tweezers are necessary for this adjustment. Remove the Guide Rail Cover. Turn on the power while pressing [ enter the Service Mode. Guide Rail Cover ], [ ], [ ] keys to [ ],[ ],[ ] + POWER ON SERVICE MODE VER 1.00 FORCE 30gf Select [SENSOR CHECK] menu and press the right key. SENSOR CHECK The menu as the picture is displayed. [ ] SENSOR CHECK F0 R0 P0 L0 C235 4-21 The crop mark sensor irradiates the red light. Cut a part of the surface on the vinyl sheet (mat black) with using the knife and peel it off. Install the matt black vinyl sheet whose portion is peeled off to the GX-500/400/300. Move the Tool Carriage or the sheet to the place where the black surface of the sheet is irradiated. Make sure that the value for [C] is within 630 ± 30. If this value is not within 630 ± 30, adjust the value by turning the VR on the carriage board using the screw driver. VR SENSOR CHECK F0 R0 P0 L0 C629 Move the carriage to the place where this red light can hit the white backing paper area of this sheet is irradiated. 4-22 Make sure that the measured value of [ C ] is 100 or below. After that, carry out 4 - 5 again and make sure that the measured value of [ C ] for the black surface of the sheet is within 630 ± 30. SENSOR CHECK F0 R0 P0 L0 C96 If the measured value of [ C ] for the white area can not be 100 or below, adjust the value for the black area so that the difference between the black area and the white area becomes 500 or more. SENSOR CHECK Black F0 R0 P0 L0 C629 White SENSOR CHECK F0 R0 P0 L0 C143 SENSOR CHECK Black F0 R0 P0 L0 C645 White 4-23 SENSOR CHECK F0 R0 P0 L0 C143 4-10 AUTO CROP-CUT ADJUSTMENT (Referential Time : 10 min.) This adjustment is for calibrating the shifting in the relative positions of Tool and Crop Mark Sensor. If it is not adjusted, the cut position to the position of the detected crop mark becomes inaccurate, gap arises in the print and cut when detection of a crop mark is performed. There are two adjusting ways prepared in Service Mode, [4-10 AUTO CROP-CUT ADJUSTMENT] and [411 MANUAL CROP-CUT ADJUSTMENT]. [AUTO CROP-CUT POSITION ADJUSTMENT] is done only in our factory. MATT BLACK VINYL SHEET (the backing paper : white, A4 size or larger), cutter blade and cutter holder for GX500/400/300, and tweezers are necessary for this adjustment. Set the Sheet and fix the Blade Holder with a blade to the TOOL CARRIAGE. Turn on the power while pressing [ enter the Service Mode. ], [ ], [ ] keys to [ ],[ ],[ ] + POWER ON SERVICE MODE VER 1.00 FORCE 30gf Select [START] under [CROP AUTO] menu and press the [ENTER] key to start adjustment. CROP AUTO [ ] CROP AUTO START [ENTER] 4-24 Peel the sheet off leaving 2 squares after cutting. Please carry out this without taking off the sheet from the machine. Press [ENTER] key to continue the adjustment. Sensor detects the center of the left square firstly and detects the center of the right square. Then, the machine cuts inside of the right square. Peel off the inside part of the right square and check the line of the right square. Check the difference of length between A and B, C and D is 0.6mm and below. If the difference is beyond the range, carry out this adjustment again. When it is still NG even if you carry out this adjustment several times, the CROP MARK SENSOR might have a problem (bad sensitivity/damage) or the Sheet might not be appropriate for Crop Mark detection. 4-25 Peel off this area. 4-11 MANUAL CROP-CUT ADJUSTMENT (Referential Time : 20 min.) If you perform this adjustment, the distance between the Tool and the Crop Mark Sensor can be calibrated more preciselly than [4-10 AUTO TOOL/CROP MARK SENSOR POSITION ADJUSTMENT]. We recommend to carry out [Crop Mark Adjustment] of Roland CutStudio to do the fine adjustment in stead of this adjustment. Turn on the power while pressing [ enter the Service Mode. ], [ ], [ ] keys to [ ],[ ],[ ] + POWER ON SERVICE MODE VER 1.00 FORCE 30gf Select [CROP-*] under [CROP MANUAL] menu and press [ ] key to enter the adjustment menu. CROP MANUAL [ Select [CROP-G] when adjusting the Grit Direction. ] CROP MANUAL *CROP-G <-5> [ Select [CROP-C] when adjusting the Carriage Direction. ] CROP-G <-5> *-5 [ENTER] Change the parameter and press [ENTER] key to save the setting. Parameter 1step = 0.025mm CROP-G <-5> *-5 When adjusting the cutting position to the right / up, the parameter is [+]. When adjusting the cutting position to the left /down, the parameter is [-]. [ ] CROP-G <-5> *-15 [ENTER] 4-26 4-12 SHEET CUTTER DOWN POSITION ADJUSTMENT (Reference Time:5min.) 1 Push the Tool Carriage against the Left Frame to lower the Sheet Cutter. In case the Tool Carriage is not at correct position, this adjustment will not be done correctly. 2 Turn on the Power while pressing the [ ],[ ] and [SHEET CUT] keys to enter the mode. [ ],[ ] , [SHEETCUT] + POWER ON INITIALIZING CUT DOWN POS 3 When [ARE YOU SURE] is displayed, press the [ENTER] key. When the Tool Carriage moves to the right end, this adjustment is completed. ARE YOU SURE? [ENTER] COMPLETED 4-27 5 Supplemental Information 5-1 Operational Sequence POWER ON OK Checks Firmware. NG Firmware upgrade mode. OK Special key is pushed CHECK Processing for the key GX-500 Roland DG Corp. or GX-400 Roland DG Corp. Displays Model Name. or GX-300 Roland DG Corp. OK Detects origin NG ORIGIN ERROR NG SHEET UNLOADED NG BAD POSITION OK Displays Sheet Selection Menu. Detects Media OK Detects PINCH ROLLER position. OK When Selecting [PIECE] SHEET UNLOADED Detects the front edge and the rear edge of media. NG or BAD POSITION OK When Selecting [F-EDGE] SHEET UNLOADED Detects the front edge of media. NG or BAD POSITION OK When Selecting [R-EDGE] SHEET UNLOADED Detects the rear edge of media. OK Carriage moves to origin. Ready to cut. 5-1 NG or BAD POSITION 5-2 Sensor Map Bottom view of the Tool Carriage Front PINCH ROLLER SENSOR This sensor detects the Pinch Roller Position. CROP MARK SENSOR This sensor detects the Crop Mark. Rear Front view of the machine Top view of the machine CARRIAGE LIMIT SENSOR REAR PAPER SENSOR This sensor detects the Carriage limit. This sensor detects the rear edge of the sheet and also whether the sheet is set or not. FRONT PAPER SENSOR This sensor detects the front edge of the Media. 5-2 6 Troubleshooting 6-1 START AND END POINTS DO NOT MATCH NO CHECKING POINT ACTION REFERENCE OUTLINE 1 In appropriate offset setting Match Offset User's Manual The blade used on the machine has the offset and therefore, the tip is shifted from its center. When the offset setting done on the machine doesn't match with the blade offset, the offset correction won't be done. Therefore, the starting and ending points won't match because the direction of the blade slightly shifts from the correct direction. 2 Blade Holder is set loose on Carriage Secure Blade Holder User's Manual When the Blade Holder is set loose on the carriage, the blade tip becomes very shaky when cutting and the starting and ending points won't match. 3 Blade tip is wearing out Replace Blade User's Manual When the blade tip wears out, the offset will be changed. Therefore, as same as 1, the starting and ending point won't match especially when cutting circles. 4 Scratch in Cutter Protection Replace Cutter Protection The Cutter Protection is the place for blade landing. If there are scratches on the Cutter Protection, the blade doesn't rotate smoothly and therefore, the starting and ending point won't match. 5 Bearing inside Blade Holder doesn't rotate smoothly Replace Blade Holder There are bearings inside the Blade Holder. When the bearings don't rotate smoothly, the direction of the blade slightly shifts from the correct direction and therefore, the starting and ending points do not match. 6 Tool Carriage is loose Fix Tool Carriage again When the Tool Carriage is loose, the cutting is unstable and the starting and ending points do not match. 7 Holder part of the Tool Carriage is loose 8 Tool Height is not correct [3-1 Tool Carriage When the Holder part of the Tool Carriage is loose, the cutting is Replacement] unstable and the starting and ending points do not match. Tool Height Adjustment [4-4 Tool Height Adjustment] When the Tool Height is not adjusted, the blade hits the Bed strongly and bounces. Therefore, the cutting at the very beginning won't be done and causes the starting and ending points to be shifted. 9 Tool Pressure is not correct Tool Pressure Adjustment When the Tool Pressure is not adjusted, the blade hits the Bed strongly and bounces. Therefore, the cutting at the very beginning won't be done and cause the starting and ending points to be [4-6 Tool Pressure shifted. And also, when the Tool Pressure is set too high by the Adjustment] user, the blade offset changes because the blade tip goes deep into the vinyl. Therefore, the starting and ending points will be shifted. 10 Motor Gear is meshed too loose Adjust Backlash When Motor Gear is meshed too loose, the Tool Carriage and Grit Roller will be driven unstable and results in the starting and ending points to shift. 6-1 6-2 STITCH CUT NO CHECKING POINT ACTION 1 Blade tip is wearing out Replace Blade When the blade wears out, it will be caught by the vinyl and results in the stitch cut. 2 Scratch in Cutter Protection Replace Cutter Protection The Cutter Protection is the place for blade landing. If there is scratch in the Cutter Protection, the blade is caught by the vinyl because it sticks deeper into the vinyl and results in the stitch cut. 3 Bearing inside Blade Holder Replace Blade Holder doesn't rotate smoothly There are bearings inside the Blade Holder. When the bearings don't rotate smoothly, the direction of the blade slightly shifts from the correct direction and therefore, it will be caught by the vinyl which results in the stitch cut. There are dusts or the Clean Guide Bearing or scratches on Guide Bearing Guide Rail or Guide Rail When there is dust on the Guide Bearing or the Guide Rail, the movement of the Tool Carriage is caught by the dust and results in the stitch cut. Replace Guide Bearing When there are scratches on the Guide Bearing, the movement of the Tool Carriage is caught by those scratches and results in the stitch cut. Replace Guide Rail When there are scratches on the Guide Rail, the movement of the Tool Carriage is caught by those scratches and results in the stitch cut. 4 5 Tool Carriage is loose REFERENCE OUTLINE When the Tool Carriage is loose, the cutting is unstable and results in the stitch cut. Fix Too Carriage again 6 Holder part of Tool Carriage Fix Holder part of Tool is loose Carriage again [3-1 Tool Carriage When the Holder part of the Tool Carriage is loose, the cutting is Replacement] unstable and results in the stitch cut. 7 Tool doesn't move up/down smoothly Replace the Tool Carriage When the Tool doesn't move up and down smoothly, the blade [3-1 Tool Carriage sometimes hits the Bed strongly and bounces which results in Replacement] the stitch cut. In most cases, the stitch cut at the beginning is caused by this reason. 8 Tool Height is not correct Tool Height Adjustment 9 Tool Pressure is not correct Tool Pressure Adjustment 10 Solenoid Driver IC is broken Replace Main Board [4-4 Tool Height Adjustment] When the Tool Height is not adjusted, the blade hits the Bed strongly and bounces which results in the stitch cut. In most cases, the stitch cut at the beginning is caused by this reason. [4-5 Tool Pressure When the Tool Pressure is not adjusted, the blade hits the Bed Adjustment] strongly and bounces which results in the stitch cut. [3-3 Main Board Replacement] 6-2 When the Solenoid Driver IC breaks, the high pressure will be generated occasionally. In this case, the blade hits the Bed strongly and bounces which results in the stitch cut. 6-3 MEDIA SHIFTING NO CHECKING POINT ACTION REFERENCE OUTLINE Explain to the customer User's Manual The most effective measure for media shifting is to load the media straight to the machine. The small tilting of the media when loading it could result in the big shifting especially doing the long print. It is recommended to load the media adding tension forward and to checking the shifting by the prefeed function before start cutting actually. [3-4 Pinch Roller Replacement] When the Pinch Rollers wear out, the power to hold the media will be weakened and results in the media shifting. The referential time for the replacement of the Pinch Roller is 24 months. 1 Media is not loaded straight to the machine 2 Pinch Roller wears out / is broken Replace Pinch Roller 3 Pieces of Media Cleaning pieces of the media When dust such as pieces of media are stuck to the feeding place, the media makes contact with the dust during the cutting and it results in the media shifting. 4 Grit Roller is dirty Clean Grit Roller When dust such as pieces of vinyl are stuck to the Grit Roller, the power to hold the media will be weakened and results in the media shifting. Use a brush to clean the Grit Roller. 5 Fan revolution When the Fan does not rotate correctly, it doesn't suck the media to the Apron and the media lifts up at the Bed and results in the media shifting. 6-4 TOOL UP/DOWN ERROR NO CHECKING POINT ACTION 1 Cable is not connected correctly Connect the cable again REFERENCE OUTLINE When there is a bad contact on the connector or cable, the signal is not sent and causes the tool up and down error. [4-6 Tool Pressure When the Tool Pressure Adjustment is not done correctly, the Adjustment] tool doesn't down. 2 Tool Pressure is not correct Tool Pressure Adjustment 3 Cut-line in Carriage Cable 4 Load on Carriage up/down movement Replace Tool Carriage When the media is jammed, the Tool Carriage hits the jammed [3-1 Tool Carriage media and results in the shifted position of the Solenoid. The Replacement] mechanical load by rubbing the coil and bobbin causes the tool up/down error. 5 Cut-line in Solenoid Coil Replace Tool Carriage When there is a cut-line in the Solenoid Coil, there is no function [3-1 Tool Carriage as the electrical magnet because of no current and results in the Replacement] tool up/down error. 6 Solenoid Driver IC is broken Replace Main Board [3-3 Main Board Replacement] When there is a cut-line in the Carriage Cable, the current is not supplied from the Main Board to the Solenoid and the tool doesn't up/down. Replace Carriage Cable 6-3 When the Solenoid Driver IC is broken, the current is not supplied to the Solenoid and results in the tool up/down error. 6-5 FAN REVOLUTION NO CHECKING POINT ACTION 1 Bad Contact in connector Connect the connector again When there is a bad contact in the connector, the signal doesn't pass and results that the Fan doesn't rotate. 2 Main Board is broken Replace Main Board The Fan is controlled by the Main Board. If the Main Board is broken, it doesn't control correctly and causes the Fan rotation error. Replace Fan Fan doesn't need to be replaced normally, however there is a possibility the motor doesn't rotate because it wears out. Therefore, if there is no problem in the above, replace the Fan to check. 3 Fan is broken REFERENCE OUTLINE 6-6 MOTOR ERROR NO CHECKING POINT ACTION REFERENCE OUTLINE 1 Use Break Release Break When the media is loaded to the machine and fed without releasing the Break, the load is on the media feeding performance and results in the Motor Error. 2 Grit Roller is dirty Clean Grit Roller When dusts such as pieces of vinyl are stuck to the Grit Roller or the Guide Rail, the power to hold the media will be weakened and results in the media shifting. Use a brush to clean the Grit Roller. 3 Power Cable is not Connect the cable again connected correctly / has a / replace it. cut-line. The cable between the Switching Power Supply and the Main Board is not connected correctly or has a cut-line, the current cannot flow to the Motor and results in the Motor Error. 4 Motor Cable is not Connect the cable again connected correctly / has a / replace it. cut-line. The cable of the Scan or Feed Motor is not connected correctly or has a cut-line, the current cannot flow to the Motor and results in the Motor Error. 5 There is dusts in teeth of Drive Gear Clean Drive Gear When there is dusts in the teeth of the Drive Gear and it cannot rotate, the Motor Error occurs. 6 Motor Gear is meshed too tight Adjust Backlash When Motor Gear is meshed too tight, it cannot rotate, and results in the Motor Error. 7 Motor Driver IC is broken Replace Main Board [3-3 Main Board Replacement] The Motor Driver IC flows the current to drive the Motor. When it is broken, the Motor can not drive and it causes the Motor Error because the IC can not flow the current to drive the Motor. 8 Motor Controller IC on Main Board is broken. Replace Main Board [3-3 Main Board Replacement] The Motor Controller IC controls the current which the Motor Driver IC flows to the Motor. When it is broken, the Motor can not drive and it causes the Motor Error because the IC can not control the current to flow to the Motor. 9 Life of Motor. / Motor is broken. When the Motor is broken, the Motor can not drive and it causes the Motor Error. The lifetime of the Motor is 1500 hours with continuous use. Reset the [MOTOR-G TIME] or [MOTOR-C TIME] in Service Mode after replacing the Motor. Replace Motor. 6-4 MOTOR ERROR MESSAGE ERROR DISPLAY MEANING MOTOR ERROR [01] Feed Motor Deviation Error MOTOR ERROR [02] Feed Motor Overcurrent Error 0 (Ultra-Excessive load is put on the motor movement instantaneously.) MOTOR ERROR [04] MOTOR ERROR [08] CAUSE Feed Motor Overcurrent Error 1 (Excessive load is put on the motor movement < External Factors > in a short period of time.) 1. The Media Jam 2. Pull or Move the Tool Carriage by hands. Feed Motor Overcurrent Error 2 3. The Tool Carriage runs into a thing/hands. (Big load is put on the motor movement 4. The media is stuck because of some reasons. continuously.) 5. The heavy media is used. MOTOR ERROR [10] Scan Motor Deviation Error MOTOR ERROR [20] Scan Motor Overcurrent Error 0 (Ultra-Excessive load is put on the motor movement instantaneously.) MOTOR ERROR [40] Scan Motor Overcurrent Error 1 (Excessive load is put on the motor movement in a short period of time.) MOTOR ERROR [80] Scan Motor Overcurrent Error 2 (Big load is put on the motor movement continuously.) < Machine Factors > 1. There is a bad contact/cut-line in the cable. 2. Screw fixing the Tool carriage to wire is shifted. 3. Motor is broken./Life 4. Servo Board is broken. 6-7 DISTORTED FIGURE / WAVY LINE NO CHECKING POINT ACTION REFERENCE OUTLINE 1 There are pieces of the media in the cap part of Cutter Holder. / The cap part of Cutter Holder wears out. Clean the cap part of Cutter Holder. / Replace XD-CH3. When there are pieces of the media in the cap part of the Cutter Holder, the blade does not rotate smoothly. Therefore, the cutting can not be done correctly. When the tip of the blade adjustment is carried out and the cutting is carried out, the tip of the blade is getting worn out because the cutting is done while the cap part of the Cutter Holder is touching the sheet. Therefore, the tip of the blade adjustment can not be carried out correctly in such state that the tip of the blade wears out. And the cutting cannot be carried out correctly. 2 Bearing inside Blade Holder does not rotate smoothly. Replace XD-CH3. When the Bearing inside the Blade Holder does not rotate smoothly, the direction of the blade is not changed and the blade catches on the sheet. Therefore, the cutting line becomes distorted and the cutting can not be carried out correctly. 3 Tool Carriage /Holder part of Tool Carriage is shaky. Fix Tool Carriage / Holder part of Tool Carriage again. When the Tool Carriage / the Holder part of the Tool Carriage is shaky, the cutting is unstable and the cutting can not be carried out correctly. 4 Scratch in Cutter Protection Replace Cutter Protection The Cutter Protection is the place for blade landing. If there is scratches on the Cutter Protection, the blade doesn't rotate smoothly and therefore, the cutting line becomes distorted and the cutting can not be performed correctly. 5 Drive Gear does not mesh with Motor Gear. Mesh them again. When the Drive Gear does not mesh with the Motor Gear correctly, the cutting can not be carried out correctly because the accuracy of the repetition is not correct. 6 Wire Tension is not correct. Adjust Wire Tension. 7 Middle Pinch Roller is not used. Use Middle Pinch Roller. [4-7 Wire Tension Adjustment] When the Wire Tension is loose, the cutting line becomes distorted. The sheet feeding becomes stable by using the Middle Pinch Roller. Therefore, the cutting accuracy becomes stable. 6-5 6-8 CANNOT DETECT CROP MARK NO CHECKING POINT ACTION REFERENCE OUTLINE When the media is not loaded correctly as follows, the machine cannot detect the Crop Mark occasionally. 1 Media is not loaded correctly. Explain to the cutomer. Users Manual / Advanced Guide 1. The left and right Crop Marks are slanted by 5 degrees or more with respect to the moving direction of the Tool Carriage. 2. The Crop Marks are offset by 15 mm or more in the materialfeed direction. 3. The Crop Marks are not placed on the Cutter Protection. The media sometimes curls if it was printed by a printer. When the media curls, the crop marks may not be detected. Load the media after correcting the curl of the media. 2 Media Condition Explain to the cutomer. Users Manual / Advanced Guide And, when the media has creases or wrinkles, the Crop Marks also may not be detected. Flatten them or straighten out the media before loading the media. Or, use another media and print the data again. The Crop Mark Sensor detects by sensing the difference between the white color of the media and the black color of the Crop Mark. When decorations or colors are on the media, the Crop Marks cannot be detected. 3 Color / Luster of the media Explain to the cutomer. Users Manual / Advanced Guide The Crop Marks also cannot be detected on the glossy or laminated media even if it is white. In those cases, select the [TOOL MODE] in [CROP MARK] menu and output the cutting data. 4 Condition of the Printed Crop Mark Explain to the cutomer. Users Manual / Advanced Guide When the Crop Marks are printed by the colors except black or the Crop Marks are not printed correctly, the Crop Marks cannot be detected. Set the color of crop marks to black, specify 100% density, and print the data again. 5 The direct sunlight or the indoor light hits the Tool Explain to the cutomer. Carriage Sensor. When the direct sunlight or the indoor light hits the Tool Carriage Sensor, the Crop Marks may not be detected. Users Manual / Advanced Guide Move the machine to a location where the direct sunlight or the indoor light does not hit the machine. Check that the red sensor light of the Crop Mark Sensor lights the media. Clean Crop Mark Sensor 6 Replace Crop Mark Sensor 7 When the Crop Mark Sensor is dirty or has foreign substances, the Crop Mark Sensor cannot light correct position or may not work. The Light of Crop Mark Sensor Crop Mark Sensor Sensitivity Adjust Crop Mark Sensor Sensitivity [3-5 Crop Mark Sensor Replacement] When the Crop Mark Sensor cannot light correct position or does not work even if the Crop Mark Sensor is cleaned or foreign substances on the Crop Mark Sensor are removed, the Crop Mark Sensor may be broken. [4-9 Crop Mark When the sensitivity of the Crop Mark Sensor is low, the Crop Sensor Adjustment.] Mark Sensor may not detect the Crop Mark. 6-6 6-9 PRINT DOES NOT MATCH WITH CUT NO 1 CHECKING POINT ACTION REFERENCE OUTLINE Explain to the cutomer. Users Manual / Advanced Guide When the image is not printed at the correct position, adjust the cuttting loction against the printing image by [File] > [Printing Setup] in CutStudio. Printing result shifts. When the printed image is shifted widely, the setting of [File] > [Printing Setup] in CutStudio may not cover the shifting. Print the data again. In this case, print the data again. [4-11 Auto Tool/Crop When the position of printed image has no problem, carry out the Mark Sensor Position Auto Tool/Crop Sensor Position Adjustment and check that the Adjustment] error of the test print result is 0.6mm and below. Tool/Crop Mark Sensor Position Adjustment 2 Crop Mark Sensor [4-12 Manual Tool/Crop Mark Sensor Position Adjustment] When the shifting amount of the cutting result are the same and constant, carry out the Manual Tool/Crop Mark Sensor Position Adjustment and compensate the shifting by inputting the value for Manual Tool/Crop Mark Sensor Position Adjustment. Adjust the Sensitivity of Crop Mark Sensor When the the error of the test print result does not become [4-10 Crop Mark 0.6mm and below even if you carry out the Auto Tool/Crop Sensor Adjustment] Sensor Position Adjustment, check the sensitivity of Crop Mark Sensor. Replace Crop Mark Sensor When the the error of the test print result does not become 0.6mm and below even if you carry out the Auto Tool/Crop [3-5 Crop Mark Sensor Position Adjustment several times and the value of the Sensor Replacement] Crop Mark Sensor sensitivity does not become within 630 ± 30, replace the Crop Mark Sensor. 6-7 7 7 Service Activities 7-1 INSTALLATION CHECK LIST GX-500/400/300 INSTALLATION CHECK LIST Date : User : Serial Number : Checking for Installing Place Be sure to ensure a sufficient amount of installation space for the machine. GX-500:1200mm (47-1/4 in.) high, 1700mm (66-15/16 in.) wide, and 900mm (35-7/16 in.) depth GX-400:1200mm (47-1/4 in.) high, 1500mm (59-1/16 in.) wide, and 900mm (35-7/16 in.) depth GX-300:1200mm (47-1/4 in.) high, 1250mm (49-1/4 in.) wide, and 900mm (35-7/16 in.) depth 60cm 60cm Unpacking Manual, CD-ROM etc. 7-1 Checking the Accessories Pin Power cord:1 Blade Holder (XD-CH2):1 Setup Guide:1 User’s Manual:1 Replacement blade for separating knife:1 Blade:1 USB cable(2mm):1 Alignment Tool:1 Roland Software Package:1 Cable Clamp:1 Checking the Accessories for Stand Stay:1 Caster Flats:2 Stand Leg:2 Shafts:2 Screws with Washers:8 (for Stand assembly) Cap:8 (for Stand assembly) With brake No brake Mounting Fixtures:2 Sheet Hunger:2 Screws with Washers:16 (for Mounting Fixtures) Hexagonal Wrenches:2 (Large and Small) (L) Screws : 10 (for installing the sheet hangers and GX-500/ 400/300) (S) 7-2 Manual:1 Assembling the Stand Assemble the Caster Flats and the Stay. Fix the Caster Flats and the Stay with the 4 Long Screws and the Washers. Then, attach the 4 Caps. * Orient the Stay so that the surface with eight holes faces up. * Assemble the Caster Flats and the Stay with the side of each Caster Flat that has small holes touching the ends of the Stay. Caster Flat Orient so that the surface with four holes each on the left and right faces up. Cap Screw and Washer Cap Screw and Washer Cap Cap Stay Inner side Outer side Fix the Stand Legs to the Caster Flats. Each Stand Leg has an inner side and an outer side. Fix the 2 Mounting Fixtures with the 16 Screws and the Washers temporarily. Stand Leg Inner side Outer side 8 Screws with Washers Stand Leg Mounting Fixture Fix the Caster Flats and the Stand Legs. Turn the Stand Legs you assembled in the previous step upside-down. Use four screws to install in the holes on the bottom surfaces of the Caster Flats. Securely tighten up all screws (including the screws loosely tightened in step 2), then fit on the caps. 7-3 Mount the GX-500/400/300 on the Stand. The orientation when mounting the Main Unit is not important (that is, there is no difference between front and back). There is no difference between the left and right Stand Legs. Be careful not to let the Main Unit fall down the Main Unit. And, fix the 6 Cap Screws. Front View Cap Screw Cap Screw Fix the 2 Sheet Hangers to the outside of the Stand Legs. Orient so that the bent portions face outward. Fix the Sheet Hanger that is provided with the brake to the left side at the back of the unit. Brake Sheet Hanger Brake Install the Shafts. Remove the Brake of the Sheet Hanger temporarily. Then, set the Shaft without the Stopper to the inside and the Shaft with the Stopper to the outside. And fix the Brake to the Sheet Hanger again. Rear View Shafts Release Lock 7-4 Fix the Cable Clamp to the Stand. Cable Clamp Push it into the hole of the Stand. Removing the packing materials Remove all packing materials. Any that remain may cause faulty operation or breakdown when the power is switched on. Front View Tape Packing Cardboard Rear View Tape 7-5 Preparation Connecting the Cable. Installing the Software Explain the following contents in reference to the Setup Guide. Installing the [Advanced Guide] (Windows) or [Mac OS installation and Setup Guide](Macintosh). Connecting the machine to the Computer and installing the Windows Driver. (Windows) Use the included USB cable. (If you’re using Windows, you can also use a serial cable.) USB : Be sure to make the connection between the machine to the computer during installing the Windows Driver. The Windows Driver installation may be failed and the machine may become unstable if you connect the machine to the computer with the USB cable before installing the Windows Driver. Never use a USB hub or the like. <System Requirements for USB Connection> - Operating system : Windows 98 SE (Second Edition)/Me/2000/XP - Computer : 1) Computers preinstalled with Windows 98 SE/Me/2000/XP at the time of purchase (This includes such computers later upgraded to Windows Me/2000/XP.) 2) Computers on which USB operation is assured by the manufacturer of computers. Installing the [Roland CutStudio] (Windows) . <System Requirements for the Roland CutStudio> Operating system : Windows 98 SE (Second Edition)/Me/2000/XP Computer : Computer running Windows Drive : CD-ROM drive Monitor : Windows-compatible monitor capable of displaying of 16 bit color (High Color) or more Memory (RAM) : 128MB or more recommended Free hard-disk space required for installation : 10MB Installing the Roland CutStudio Plug-in (Windows/Macintosh) * It is necessary that Adobe Illustrator 9/10/CS/CS2 run without problem. * It is necessary that CorelDRAW 10/11/12 run without problem. *1, *2 *1. It is necessary that Corel Draw10/11/12 is installed as [Typical install]. *2. In case of using Corel Draw10, it is necessary that VBA 6.0 is installed into the PC from CD-ROM of Corel DRAW10 in advance. Explain to refer to HELP and Advanced Guide about the operating procedure for each software and Plug-In. Functions / Operations Explain the following contents in reference to User’s Manual and the Setup Guide. Loading the Material (Roll Material) Installing the Blade 7-6 Functions / Operations Adjusting the Blade Force and Cutting Speed Setting the Origin Point Starting Cutting When Cutting is Completed Detailed Cutting-condition Settings Details of the Origin-point Location and Cutting Area To Perform Lengthy Cutting Loading Flat Material (Standard-size Material, Cut Material, Etc.) Repeating the Same Cutting Front Loading The Overcut Feature The Memory Feature The Crop Mark Feature Blade and Material Combinations About Special Materials Maintenance Explain the following contents about the maintenance for the machine in reference to User’s Manual . Cleaning - Machine itself and Display. Platen Grid Rollers Pinch Roller Blade Holder Cap Consumable Parts Explain the consumable parts. And explain that the following Life Expectancy should be referred only as a guide. It changes depending on the usage condition. Life Expectancy Parts Name Blade Blade Holder The Blade tip is broken. Uncut areas remain even when Blade force is raised 50 to 60 gf. Cutting traces are not smooth unlike before. The vinyl layer peels away at the cutting details or the corners from the backing paper. The Blade tip becomes worn. The end of the cap for Blade Holder becomes worn. The blade can not rotate smoothly even if you clean the cap for Blade Holder. The stitch cut problem happens even if you clean the cap for Blade Holder. Cutter Protection There are many scratches on the Cutter Protection. Separating Knife The sheet cannot be cut well. 7-7 7-2 Maintenance Check List GX-500/400/300 MAINTENANCE CHECK LIST Date : Serial Number User Check Items Operation Points Check Interview the customer Ask the customer if there is something that he/she is concerned about. Done Get report before maintenance Get report with [Get Report] of the PIT.exe. Done Upgrade the firmware to the latest version Upgrade the firmware if the installed firmware is not the latest version. OK Check Parts Cutter Protection Replace it depending on degree of scratches on it. Pinch Roller Check if it is not worn out, it does not have dirt on it and it rotates smoothly. Good Motor Determine if it should be replaced based on MOTOR TIME in the Service Report, the motor sound heard while printing the report and the customer's interview. Replacement Cycle : 1,500 hours Replacement Done Reset Good Replacement Done Reset Good Replacement Done Reset Put the grease on the gear if you replace the Motor. Parts Number : 21675102 Parts Name : GREASE,FLOIL G-902Y 10ML Grit Roller Remove foreign substances stuck on it by using a brush. Done Fix the backlash or lubricate depending on the performance of the machine; Good Drive Gear Put the grease on the Drive Gear if you replace the Drive Gear. Parts Number : 21675102 Parts Name : GREASE,FLOIL G-902Y 10ML Carriage Wire Check if it is not damaged. Check if it has correct Wire Tension. Head Carriage Check if the fixing of the Head Carriage does not have loose. Check if the Tool Holder does not have loose or worn. Tool Holder Head Carriage should be replaced if you replace the Tool Holder. After replacing the Tool Holder, carry out [4-4 TOOL HEIGHT ADJUSTMENT], [4-6 TOOL PRESSURE ADJUSTMENT], [4-10 AUTO TOOL/CROP MARK SENSOR POSITION ADJUSTMENT] and [4-12 SEPARATING KNIFE ADJUSTMENT]. Check if there is a dirt on the Guide Rail where the Flexible Cable is fixed. A dirt on the Guide Rail could cause the stitch cut. Put the A dirt on the Guide Rail grease on the Drive Gear if the movement of the Tool Carriage is not where the Flexible Cable smooth. is fixed. Adjust the backlash Lubrication Done Replacement Done Good Adjustment Done Good Modify the loose Good Replacement Done Adjustment Done Good Cleaning Done Lubrication Parts Number : 21675102 Parts Name : GREASE,FLOIL G-902Y 10ML Blade Check if the tip of it is not worn out or broken. Good Replacement Done Cutter Holder Check if the cap of it is not worn out or the Blade can rotate smoothly. Done Replacement Done Separating Knife Check if it can cut the sheet smoothly. . Good Replacement Done Check cutting Check that there is no problem with the cutting operation and cutting result. Done Get report after maintenance Get report with [Get Report] of the PIT.exe. Done 7-8 7-3 Specification GX-500 GX-400 GX-300 Media-movement method Mechanism Digital control servo motor Driving method Maximum cutting area Acceptable media widths Width: 737 mm (29 in.) Width: 1195 mm (47 in.) Width: 1000 mm (39 in.) Length: 24998 mm (984-1/8 in.) Length: 24998 mm (984-1/8 in.) Length: 24998 mm (984-1/8 in.) Min. 90 mm (3-1/2 in.) / Min. 90 mm (3-1/2 in.) / Min. 50 mm (2 in.)/ Max. 915 mm (36 in.) Max. 1372 mm (54 in.) Max. 1178 mm (46 in.) (50 to 540 mm (2 in. to 21 in.), 582 to 915 mm (23 in. to 36 in.)) Width of material that 0 to 812 mm (0 in. to 32 in.) 0 to 1067 mm (0 in. to 42 in.) 0 to 1270 mm (0 in. to 50 in.) can be cut off Special blade for CAMM-1 series Tool s Maximum cutting speed During cutting: 850 mm/sec. (in all directions) During tool-up: 1202 mm/sec. (in 45 Cutting speed 10 to 850 mm/sec. (in increments of 10 mm/sec.) Blade force 20 to 350 gf Mechanical resolution 0.0125 mm/step (0.000492 in./step) Software resolution 0.025 mm/step (0.000984 in./step) Distance accuracy (*1) direction) Error of less than – 0.2% of distance traveled, or 0.1 mm (0.00394 in.), whichever is greater 0.1 mm or less Repetition accuracy (*1)(*2)(*3) Serial (RS-232C-compatible), USB (Rev 1.1) Interface 2 MB (buffer size: 8 MB) Replot memory Dedicated system (CAMM-GLIII-compatible) Instruction system AC 100V to 240V – 10% 50/60 Hz 1.2A Power supply Power consumption AC 100V to 240V – 10% 50/60 Hz 1.1A Approx. 100W Approx. 95W Cutting mode: 62dB (A) or less Acoustic noise level Standby mode: 40dB (A) or less (according to ISO 7779) Dimensions Main unit 1602 mm (W) x 264 mm (D) x 398 mm (H) 1407 mm (W) x 264 mm (D) x 398 mm (H) 1144 mm (W) x 264 mm (D) x 398 mm (H) (63-1/16 in. (W) x 10-3/8 in. (D) x 15-11/16 in. (H)) (55-3/8 in. (W) x 10-3/8 in. (D) x 15-11/16 in. (H)) (45-1/16 in. (W) x 10-3/8 in. (D) x 15-11/16 in. (H)) With stand 1602 mm (W) x 727 mm (D) x 1113 mm (H) 1407 mm (W) x 727 mm (D) x 1113 mm (H) 1144 mm (W) x 727 mm (D) x 1113 mm (H) (63-1/16 in. (W) x 28-5/8 in. (D) x 43-13/16 in. (H)) (55-3/8 in. (W) x 28-5/8 in. (D) x 43-13/16 in. (H)) (45-1/16 in. (W) x 28-5/8 in. (D) x 43-13/16 in. (H)) Weight Main unit 35 kg (77.2 lb.) 31 kg (68.3 lb.) 26 kg (57.3 lb.) With stand 55kg (121.2 lb.) 51 kg (112.4 lb.) 44 kg (97 lb.) Operating temperature Operating humidity Accessories 5 to 40 degree C (41 to 104 F) 35 to 80% (non-condensing) Power cord, blade holder (XD-CH2), pin, blade, alignment tool, cable clamp, replacement blade for separating knife, USB cable, Roland software package CD-ROM, setup guide, user s manual *1 According to material and cutting conditions as specified by Roland DG Corp. (refer to the following page). *2 Excluding stretching/contraction of the material *3 Range for assured repetition accuracy For materials with a width exceeding 610 mm (24 in.): Length 4,000 mm (157-7/16 in.) (GX-500/400 only) For materials with a width of 610 mm (24 in.) or less : Length 8,000 mm (314-15/16 in.) 7-9 (*1) The following conditions must be satisfied: Material type: 3M Scotchcal Mastercut Special stand (a roll material must be set at the rear and on the sheet hanger) Side margins: 25 mm (1 in.) or more for both the left and right margins Front margin: 30 mm (1-3/16 in.) or more (After loading the material, using the display menu to select [F-EDGE] as the material type automatically sets a front margin of 30 mm (1-3/16 in.).) Use of the display menu’s [AREA] function to perform feed of the material length plus 0.2 m and set the material correctly Cutting the following data one time (1) The letters are cut in order starting with "R" (2) After the last letter "P" has been cut, the machine returns to the origin point and the outer border is cut Side margins: 25 mm (1 in.) or more Front margin: 30 mm (1-3/16 in.) or more Cut width Fills the hard clip Blade protector Origin Movable pinch roller (left) Movable pinch roller (right) Y Side margins: 25 mm (1 in.) or more X Feed length Material with a width exceeding 610 mm (24 in.): 4,000 mm (157-7/16 in.) Material with a width of 610 mm (24 in.) or less: 8,000 mm (314-15/16 in.) The origin is rotated 90 degrees ([ROTATE] on the display menu is set to [90deg]). 7-10 [Serial] Standard Transmission method Transmission speed Parity check Data bits Stop bits Handshake RS-232C specifications Asynchronous, duplex data transmission 4800, 9600 (Selected using panel keys.) Odd, Even, or None (Selected using panel keys.) 7 or 8 bits (Selected using panel keys.) 1 or 2 bits (Selected using panel keys.) Hardwire (power on) or XON/XOFF (Selected using panel keys.) [USB] Standard Universal Serial Bus Specification Revision 1.1 Universal Serial Bus Device Class Definition for Printing Device Version 1.1 12Mbps (Full Speed Device) NRZI Series B Transmission speed Data format Compatible connector [USB connector] [Serial connecter (RS-232C)] Signal number Terminal number Signal number NC 25 13 NC NC 24 12 NC NC 23 11 NC NC 22 10 NC NC 21 9 NC DTR 20 8 NC NC 19 7 SG NC 18 6 DSR NC 17 5 CTS NC 16 4 RTS NC 15 3 RXD NC 14 2 TXD 1 FG Pin Connection Remark VCC Cable power 2 - Data 3 + Data 4 GND Cable ground Pin #2 Pin #1 Pin #3 Pin #4 14 25 Note: When making a serial connection using a cable other than a XY-RS-34 cable from Roland DG Corp., use a serial cable wired as shown in the figure below. 1 2 3 4 5 6 7 Signal 1 1 13 [XY-RS-34 serial cable connection] D-sub 9-pin (female) Pin number D-sub 25 pin (male) 1 FG 2 3 4 5 6 7 8 8 NC 9 20 7-11
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