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SERVICE MANUAL

SUBLIMATION TYPE RETRANSFER PRINTER

EDI secure XID580i

SPECIFICATIONS
Recording method : Sublimation type retransfer Feed format : Automatic feed Recording density : 300 dpi Expression gradation : 256 gradations for each color Printing time : Approx. 29 seconds (for single-sided printing, excluding data transfer time) Interface : USB2.0 (standard) Operating environment conditions Temperature: 15C ~ 30C Humidity: 35% ~ 70% (no condensation) Storage environment conditions Temperature: -15C ~ 55C Humidity: 20% ~ 80% Power supply : 100 120 V AC/ 220 240 VAC (allowance10%) Current dissipation : 7.0A (for 100V system)/ 5.0A (for 200V system) Mass : Standard 22.0kg Excluding the built-in magnetic encoder Accessories : Power cable For 120 V AC x1 Dark gray (North America) For 220 to 240 V AC x1 (Europe) Instruction manual English x1 * The detached power cords and the Instruction manual vary according to model and country of purchase. Card stacker 1 Ink ribbon cassette 1 Retransfer film cassette 1 Jog lever (contained in the card tray) 1 CX21ICL Series (Large-type IC unit) Power supply : Fed from the printer. 5V5% DC, 12V5% DC, 24V5% DC Current dissipation : 500mA, 300mA, 1A Mass : 3.5kg Dimension (mm) : 110(W) 221(D) 255(H) Accessories : Joint plate 1 Inter-unit cable 1 CX21ICS Series (Small-type IC unit) Power supply : Fed from the printer. Mass : 0.5kg Dimension (mm) : 50(W) 152(D) 115(H) Accessories : Screw (with washer) 3 Screw (without washer) 2 Products sold separately : Ink ribon, retransfer film : Cleaning card 1,000 frames/set 10 card /set Model : CY-P340A Model : CX210-CC1 : Laminator Unit : Model : ILU : Card tray When setting paper feeding feature on the right Model: CF-3NTR : Hand gloves M Size (U105-M) L Size (U105-L)

KAS-T099-002 May 2006

CONTENTS
IMPORTANT SAFETY PRECAUTIONS INSTRUCTIONS MODEL NAME ................................................................................. 1
1. Detailed specifications .................................................................... 1 2.10.1 Installation of the Platen Solenoid .................................. 22 2.11 REMOVAL OF THE POWER SUPPLY UNIT ........................ 22 2.12 REMOVAL OF SENSORS AND SWITCHES ....................... 23 2.12.1 Removal of the Cam Sensor .......................................... 23 2.12.2 Removal of the Card Outlet Sensor ............................... 23 2.12.3 Removal of the Ink Encoder Circuit Board ..................... 23 2.12.4 Removal of the External Unit Power Circuit Board ........ 23 2.12.5 Removal of the Turnover Initial Position sensor ............. 24 2.12.6 Removal of the Card Near-empty Sensor ...................... 24 2.12.7 Removal of the No Card Sensor .................................... 24 2.12.8 Removal of the Retransfer roller/ Remedial Roller Sensor ....................................... 24 2.12.9 Removal of the Retransfer Film Mark/Ink Start Position Sensor Circuit Board and the Card Edge Sensor ... 25 2.12.10 Removal of the C.L. Interlock Circuit Board and the Card Supply Sensor ....................................... 25 2.12.11 Removal of the Door Interlock Circuit Board .............. 26 2.12.12 Removal of the Cassette Interlock Circuit Board ....... 26 2.12.13 Removal of the Card Tray Interlock Circuit Board ...... 27 2.12.14 Removal of the Turnover Card Sensor Circuit Board ........................................................ 27 2.13 REMOVAL OF THE TURNOVER UNIT ................................ 27 2.14 FAN REMOVAL .................................................................... 28 2.14.1 Removal of the Thermal Head Cooling Fan ................... 28 2.14.2 Removal of the Suction Fan ........................................... 28 2.14.3 Removal of the Card Cooling Fan .................................. 28 2.14.4 Removal of the Ventilation Fan ....................................... 29 2.15 ROLLER REMOVAL ............................................................. 30 2.15.1 Feed Roller Removal ..................................................... 30 2.15.2 Platen Roller Assy Removal .......................................... 31 2.16 CIRCUIT BOARD REMOVAL ............................................... 32 2.16.1 Removal of the Main Circuit Board ................................ 32 2.17 Thermal Head Exchange Method ......................................... 33

HOW TO CONNECT SEPARATELY SOLD PARTS .................. 2


1. Connecting the Small IC Unit .......................................................... 2 2. Connection of the Magnetic/Contact-type IC Encoder .................... 3 3. Connecting card tray ....................................................................... 4

BLOCK DIAGRAM .......................................................................... 5


1. OVERALL BLOCK DIAGRAM ......................................................... 5 2. BLOCK DIAGRAM OF PRIMARY SIDE OF POWERUNIT ............. 6 3. INTERLOCK SW BLOCK DIAGRAM .............................................. 7 4. BLOCK DIAGRAM OF THE FPGA CIRCUMFERENCE ON A CPU BOARD ................................................................... 8

WIRING DIAGRAM ....................................................................... 9 Main Parts Layout .......................................................................... 10


1. Sensor-related ............................................................................... 10 2. Related to Thermal Head and Rollers ........................................... 10 3. Motor-related ................................................................................. 11 4. Solenoid-RELATED ....................................................................... 11 5. Switch-related ............................................................................... 12 6. Related to Circuit Boards, Power Supply Unit, and Fans .............. 12 7. RF-ID ............................................................................................. 14

REMOVAL AND EXCHANGE OF THE MAIN PARTS ............ 15


1. CHECKING AT THE TIME OF SERVICING .................................. 15 1.1 REMOVE THE TOP COVER AND THE REAR PANEL. .......... 15 1.2 REMOVE THE MG CIRCUIT BOARD. .................................... 15 1.3 SWING DOWN THE POWER SUPPLY UNIT. ........................ 16 2. REMOVAL AND EXCHANGE OF THE MAIN PARTS ................... 16 2.1 REMOVAL OF THE HEAT ROLLER ....................................... 16 2.1.1 Removal of the Bend Remedy Roller ............................... 16 2.1.2 Removal of the Heat Roller .............................................. 16 2.2 REMOVAL OF THE CAM MOTOR .......................................... 17 2.2.1 Installation of the Cam Motor ........................................... 18 2.3 REMOVAL OF THE RETRANSFER FILM SUPPLY MOTOR ............................................................................ 18 2.3.1 Installation of the Retransfer Film Supply Motor ............... 19 2.4 REMOVAL OF THE RETRANSFER FILM TAKE UP FILM WINDING MOTOR .................................................. 20 2.5 REMOVAL OF THE CARD FEED MOTOR ............................. 20 2.5.1 Installation of the Card Feed Motor .................................. 20 2.6 REMOVAL OF THE INK SUPPLY MOTOR AND THE INK TAKE-UP MOTOR ............................................. 21 2.7 REMOVAL OF THE TURNOVER MOTOR AND THE TURNOVER CARD FEED MOTOR .......................... 21 2.8 REMOVAL OF THE CARD PICKUP MOTOR ......................... 21 2.9 REMOVAL OF THE FRONT PANEL ....................................... 21 2.10 REMOVAL OF THE PLATEN SOLENOID ............................ 22

USE OF SERVICE MODE ........................................................... 35


1. Entry into Service Mode ................................................................ 35 2. Explanation of the Various Modes ................................................. 37 2.1 Download ................................................................................ 37 2.2 Maintenance ........................................................................... 37 2.2.1 Offset Prt Y Setting ........................................................... 37 2.2.2 Offset Prt X Setting ........................................................... 37 2.2.3 Offset Trf X Setting ........................................................... 38 2.2.4 Card Stop Position Setting (Offset Card X) ...................... 38 2.2.5 Default LUT Setting .......................................................... 38 2.2.6 Device Type Setting .......................................................... 38 2.2.7 Card Fan Setting .............................................................. 38 2.2.8 TUR Response Setting ..................................................... 38 2.2.9 Compatible Mode Setting ................................................. 38 2.2.10 Setting of the ink sensor level ........................................ 38 2.3 Off-line Test ............................................................................. 39 2.3.1 Pattern setting .................................................................. 39 2.3.2 Printing Side ..................................................................... 40

2.3.3 Times ................................................................................ 40 2.3.4 Test Select ........................................................................ 40 2.4 Diag. Test ................................................................................ 40 2.4.1 Sensor .............................................................................. 40 2.4.2 Actuator ............................................................................ 40 2.4.3 Memory ............................................................................ 41 2.4.4 SIO ................................................................................... 41 2.4.5 Display .............................................................................. 41 2.4.6 Back Color ........................................................................ 41 2.4.7 Buzzer .............................................................................. 41 2.4.8 Registers .......................................................................... 41 2.5 Information .............................................................................. 41 2.6 Parameter Push and Pop ........................................................ 41

LARGE IC UNIT .................................................................... 73


1. Removal of Each Part ................................................................... 73 1.1 Removal of the Top Cover ....................................................... 73 1.2 Removal of the Front Panel .................................................... 73 1.3 Removal of the Mechanical Unit ............................................. 73 1.4 Removal of the IC Main Circuit Board ..................................... 73 1.5 Others ..................................................................................... 73 2. Block Diagram ............................................................................... 74 3. DIP Switch Specifications ............................................................. 75 3.1 Specifications .......................................................................... 75 3.2 IC Card Stop Position Adjustment .......................................... 75 4. Error Messages ............................................................................. 76 5. Specifications of Connector on the IC Main Board ....................... 77

OPERATION OF THE MECHANISM ......................................... 42


1. Single-side Printing ....................................................................... 42 2. Double-side Printing ...................................................................... 42 3. Initial Operation ............................................................................. 42 4. Card Supply and Card Feed .......................................................... 43 5. Printing Operation ......................................................................... 45 6. Retransfer Operation ..................................................................... 47 7. Operation in Case of Peeling with Return in Direction Towards the Turnover Unit ..................................................................... 49 8. Operation of the Turnover Unit ...................................................... 50 9. Others ........................................................................................... 51 9.1 Position Relation with Ink Ribbon and Retransfer Film ........... 51 9.2 Ink Ribbon and Retransfer Film End Treatment ...................... 51

EXPLODED VIEW AND ASSEMBLY LISTS ............................ 78


HOPPER ASSEMBLY1/2 2/2 ................................................... 79 FRAME ASSEMBLY1/7 7/7 ..................................................... 81 PLATEN ASSEMBLY1/1 ............................................................... 88 PICK UP MOTOR ASSEMBLY1/1 ................................................ 89 FEED MOTOR ASSEMBLY1/1 ..................................................... 90 MEDIA W MOTOR ASSEMBLY1/1 ............................................... 91 MEDIA S MOTOR ASSEMBLY1/2 2/2 ..................................... 92 INK S&W MOTOR ASSEMBLY1/1 ............................................... 94 HEATER CAM MTR ASSEMBLY1/1 ............................................. 95 TURN MOTOR ASSEMBLY1/1 ..................................................... 96 TURN UNIT ASSEMBLY1/1 ......................................................... 97 MECHANISM ASSEMBLY1/12 12/12 ...................................... 98 FRONT PANEL ASSEMBLY1/2 2/2 ....................................... 109 PR COMMON ASSEMBLY1/4 4/4 ......................................... 111 FINAL ASSEMBLY1/14 14/14 ................................................ 115

TROUBLESHOOTING .................................................................. 52
1. LCD Error Code Correspondence ................................................. 52 2. Printing Defects and Countermeasures ........................................ 57 3. Power Supply Check ..................................................................... 61

MAINTENANCE INSPECTIONS ................................................ 62


1. Cleaning ........................................................................................ 62 2. Lubrication ..................................................................................... 62 3. Maintenance Inspections for Main Parts and Execution Standard ................................................................. 62 4. Periodic Inspection Items .............................................................. 63 5. Trouble Diagnosis Sheet ............................................................... 64

ADJUSTMENT ............................................................................... 65
1. Layout of the adjustment elements ............................................... 65 2. Adjustment .................................................................................... 65 3. Caution Items for the Time of Exchange of the CPU Circuit Board ............................................................ 65

MG ENCODING UNIT .................................................................. 66


1. MG Encoding Specifications ......................................................... 66 1.1 Magnetic Encoder Specifications ............................................ 66 1.2 General Equipment Specifications .......................................... 66 2. Block Diagram ............................................................................... 67 2.1 MG Unit Block Diagram .......................................................... 67 2.2 Connection Diagram ............................................................... 68 3. MG Encoding Unit Exchange Method ........................................... 69 3.1 Repair Classification ............................................................... 69 3.2 Exchange Method ................................................................... 69 3.3 DIP Switch Specifications ....................................................... 71 3.4 MG-related Error Messages ................................................... 72

Important Safety Precautions


Prior to shipment from the factory, VDS products are strictly inspected to conform with the recognized product safety and electrical codes of the countries in which they are to be sold. However, in order to maintain such compliance, it is equally important to implement the following precautions when a set is being serviced.

Precautions during Servicing


1. Locations requiring special caution are denoted by labels and inscriptions on the cabinet, chassis and certain parts of the product. When performing service, be sure to read and comply with these and other cautionary notices appearing in the operation and service manuals. 2. Parts identified by the ! symbol and shaded ( ) parts are critical for safety. Replace only with specified part numbers. Note: Parts in this category also include those specified to comply with X-ray emission standards for products using cathode ray tubes and those specified for compliance with various regulations regarding spurious radiation emission. 3. Fuse replacement caution notice. Caution for continued protection against fire hazard. Replace only with same type and rated fuse(s) as specified. 4. Use specified internal wiring. Note especially: 1) Wires covered with PVC tubing 2) Double insulated wires 3) High voltage leads 5. Use specified insulating materials for hazardous live parts. Note especially: 1) Insulation Tape 3) Spacers 5) Barrier 2) PVC tubing 4) Insulation sheets for transistors 6. When replacing AC primary side components (transformers, power cords, noise blocking capacitors, etc.) wrap ends of wires securely about the terminals before soldering.

12. Crimp type wire connector In such cases as when replacing the power transformer in sets where the connections between the power cord and power transformer primary lead wires are performed using crimp type connectors, if replacing the connectors is unavoidable, in order to prevent safety hazards, perform carefully and precisely according to the following steps. 1) Connector part number : E03830-001 2) Required tool : Connector crimping tool of the proper type which will not damage insulated parts. 3) Replacement procedure (1) Remove the old connector by cutting the wires at a point close to the connector. Important : Do not reuse a connector (discard it).

cut close to connector


Fig.3 (2) Strip about 15 mm of the insulation from the ends of the wires. If the wires are stranded, twist the strands to avoid frayed conductors.
15 mm

Fig.4 (3) Align the lengths of the wires to be connected. Insert the wires fully into the connector. Fig.1 7. Observe that wires do not contact heat producing parts (heatsinks, oxide metal film resistors, fusible resistors, etc.) 8. Check that replaced wires do not contact sharp edged or pointed parts. 9. When a power cord has been replaced, check that 10-15 kg of force in any direction will not loosen it.
Connector Metal sleeve

Fig.5 (4) As shown in Fig.6, use the crimping tool to crimp the metal sleeve at the center position. Be sure to crimp fully to the complete closure of the tool.

Power cord
1.2 5 2.0 5.5

Crimping tool

Fig.2 10. Also check areas surrounding repaired locations. 11. Products using cathode ray tubes (CRTs) In regard to such products, the cathode ray tubes themselves, the high voltage circuits, and related circuits are specified for compliance with recognized codes pertaining to X-ray emission. Consequently, when servicing these products, replace the cathode ray tubes and other parts with only the specified parts. Under no circumstances attempt to modify these circuits. Unauthorized modification can increase the high voltage value and cause X-ray emission from the cathode ray tube.

Fig.6 (5) Check the four points noted in Fig.7.

Not easily pulled free

Crimped at approx. center of metal sleeve

Conductors extended Wire insulation recessed more than 4 mm


Fig.7

S40888-01

Safety Check after Servicing

Examine the area surrounding the repaired location for damage or deterioration. Observe that screws, parts and wires have been returned to original positions, Afterwards, perform the following tests and confirm the specified values in order to verify compliance with safety standards.

1. Insulation resistance test Confirm the specified insulation resistance or greater between power cord plug prongs and externally exposed parts of the set (RF terminals, antenna terminals, video and audio input and output terminals, microphone jacks, earphone jacks, etc.). See table 1 below. 2. Dielectric strength test Confirm specified dielectric strength or greater between power cord plug prongs and exposed accessible parts of the set (RF terminals, antenna terminals, video and audio input and output terminals, microphone jacks, earphone jacks, etc.). See table 1 below. 3. Clearance distance When replacing primary circuit components, confirm specified clearance distance (d), (d) between soldered terminals, and between terminals and surrounding metallic parts. See table 1 below.

Fig. 8 4. Leakage current test Confirm specified or lower leakage current between earth ground/power cord plug prongs and externally exposed accessible parts (RF terminals, antenna terminals, video and audio input and output terminals, microphone jacks, earphone jacks, etc.). Measuring Method : (Power ON) Insert load Z between earth ground/power cord plug prongs and externally exposed accessible parts. Use an AC voltmeter to measure across both terminals of load Z. See figure 9 and following table 2.

b c

Externally exposed accessible part

Z V

Fig. 9 5. Grounding (Class 1 model only) Confirm specified or lower grounding impedance between earth pin in AC inlet and externally exposed accessible parts (Video in, Video out, Audio in, Audio out or Fixing screw etc.). Measuring Method: Connect milli ohm meter between earth pin in AC inlet and exposed accessible parts. See figure 10 and grounding specifications.

Fig. 10
Region Japan USA & Canada Europe & Australia Insulation Resistance (R) R 1 M/500 V DC 1 M R 12 M/500 V DC R 10 M/500 V DC

AC Line Voltage 100 V 100 to 240 V 110 to 130 V 110 to 130 V 200 to 240 V

Dielectric Strength AC 1 kV 1 minute AC 1.5 kV 1 miute AC 1 kV 1 minute AC 3 kV 1 minute (Class 2) AC 1.5 kV 1 minute (Class 1)

Clearance Distance (d), (d') d, d' 3 mm d, d' 4 mm d, d' 3.2 mm d 4 mm d' 8 mm (Power cord) d' 6 mm (Primary wire)

Table 1 Specifications for each region

Table 2 Leakage current specifications for each region Note: These tables are unofficial and for reference only. Be sure to confirm the precise values for your particular country and locality.

II

S40888-01

MODEL NAME
The letters and numbers following the model name are used to differentiate between destinations and specifications.

Model name: XID580i - # 1. Detailed specifications


# Portion Internal option Nil ......... No option (Standard model) B ........... Equipped with ISO magnetic encorder / IC contact

HOW TO CONNECT SEPARATELY SOLD PARTS


1. Connecting the Small-type IC Unit
1. Remove the cover on the side of the printer.
Remove the screw, and then raise the cover to remove it.

2. Connect the connector.


Please note that the connector has directionality.

3. Install the unit with three screws.


Install the screws so that the cable of the connector is not caught.

Pass the cable through the notch.

Screw with washer (provided)

4. Install the cover with two screws.


Screw (provided)

2. Connection of the Magnetic/Contact-type IC Encoder


When the separately sold magnetic/contact-type IC encoder is to be connected to a standard printer, connect it according to the following procedure. For details in regard to the removal method for each part, refer to Removal and exchange of the Main Parts. 1) Remove the top cover. 2) Swing down the power supply. 3) Remove the front panel. 4) Install the magnetic unit. Fix with three black screws 8 at the front and four black screws 8 at the rear. 5) Install the bracket fixing the MG circuit board with four screws 6.
6
Pass the wires of power switch.
CN3

13

KWS0744-001

x6

9 14
KWS0767-002

J10

Explanation drawing 1
J14

15 8
J10 J14

KWS0768-001

CN12

11
KWR17110-001

Clamp

Clamp

J14 J10 J10 KWR18416-001

12 8
Clamp
J9

8 1
(TFA0023) (TSA0141)

Explanation drawing 1 G.NO.004

CLAMP

Explanation drawing 2

6
MG PWB SA

Explanation drawing 1

3pin J1 J8 J4

CLAMP
Make the cable routed away from the rail

J5 J3 J7

6
Explanation drawing 2

CLAMP

3. Connecting card tray


Upon issuing the card using paper feeding feature on the right, as the NG cards transported to the printer will be ejected, replace the standard hopper unit with an optional card tray. Mount the card tray according to the following procedures: 1. Pull out the standard hopper unit diagonally upwards. 2. Insert the optional card tray diagonally downwards. (Note: The cleaning roller should be left as it is.)

3. Enter the service mode of the printer main unit, select Card Loading under the maintenance items and switch from standard to Right Side. 4. Settings other than this and operating procedures are dependent to the user system. Note: If there are 10 cards accumulated continuously in the card tray, the printer will display Card Tray Full. Remove the cards immediately. 5. Keep the removed hopper unit safely.

MAIN PWB DRIVE PWB


U3 FLASH ROM 16Mbit U7 EEPROM 32Kbit U5 FLASH ROM 16Mbit U7 CLK DRIVER U1 CPU X1 XTAL 66.67MHz U2 SDRAM 64Mbit U5 SDRAM 64Mbit

U7 STEP MOTOR DRIVER U8 STEP MOTOR DRIVER U11 STEP MOTOR DRIVER U13 DC MOTOR DRIVER U14 DC MOTOR DRIVER U15 DC MOTOR DRIVER Q5 TRANSISTOR Q6 TRANSISTOR Q7 TRANSISTOR

SENSORS

FILM MOTOR

CARD MOTOR

CAM MOTOR

CPU BUS
U11 FPGA U12 SDRAM 64Mbit

INK MOTOR

INK MOTOR

FILM MOTOR

X2 XTAL 32MHz

FAN (PRINTER)

FAN (CARD)

USB I/F
X1 XTAL 48MHz

U17 USB chip

FAN (THERMAL HEAD) Q2 Q3 TRANSISTOR U9 STEP MOTOR DRIVER U10 STEP MOTOR DRIVER U16 DC MOTOR DRIVER

NO CARD CARD IN CARD (MG POSITION) (PWB) (OPTION(MGIC)) CARD (TURN) (PWB) TURN POSITION EDJE (PWB) CARD OUT (PWB) CARD NEAR EMPTY FILM MARK (PWB) CAM POSITION TR POSITION RR POSITION INK FG (PWB) INK FG (MOTOR built-in) FILM FG (MOTOR built-in)

U14~16 BUFFER

FAN (PRINTER) SOLENOID (PLATEN ROLLER)

SOLENOID (IC CONTACT(OPTION))

TURN MOTOR

FRONT PWB
COLOR LED LCD module (16columX2line) U19 INVERTER U2 Serial to Parallel U22,36~U39 BUFFER

CARD MOTOR (TURN)

CARD MOTOR (PICK UP )

HEATER PROTECTOR PWB

1. OVERALL BLOCK DIAGRAM

TR THERMISTOR RR THERMISTOR

THERMISTOR & CONNECTOR (PWB) U1 DAConverter SWX6 LEDX2 BUZZER U13 ADConverter

EXTERNALUNIT

BLOCK DIAGRAM

THERMAL HEAD

DC-DC circuit
DOOR INTERLOCK SW CASSETTE INTERLOCK SW CLEANING ROLLER INTERLOCK SW CARD TRAY INTERLOCK SW U10 U8 REGULATOR REGULATOR (1.8 V) (3.3V) Q11 Q13 REGULATOR REGULATOR (1.5V) (A+5V) U2 RESET IC (5V)

HEAD U1 EEPROM CONN PWB 32Kbit

HEAD BLOCK
U32,U33 COMPARATOR SENSORS

RF-ID UNIT

POWER SUPPLY UNIT

MG/IC UNIT(OPTION)

EXTERNALUNIT

EXTERNALUNIT

2. BLOCK DIAGRAM OF PRIMARY SIDE OF POWERUNIT

THERMISTOR (to DRIVE PWB)


t

HEATROLLER (REMEDIAL)

THERMOSTAT

POWER SUPPLY UNIT

THERMISTOR (to DRIVE PWB)


t

HEATROLLER (RETRANSFER)

SSR2N SSR2L CN5 SSR1N SSR1L N(AC OUT) L(AC OUT) CN2 CN6 N(AC IN) L(AC IN) CN7

(to ANALOG POWER PWB)

SSR

THERMOSTAT

SSR

CN2 24V

FAIL SIGNAL (to DRIVE PWB) PHOTO COUPLER

SSR1L SSR2L ON/OFF

CN8 24V_RC

CN1 5V 12V

ABNORMAL CURRENT DETECT

PHOTO COUPLER

AC VOLTAGE DETECT Primary

CN1

POWER SWITCH

CN4 CONTROL SIGNAL

CN3 VTH

Secondary

HEATER PROTECTOR PWB

J18 24V_RC Door SW (PWB)

J16

CN8 24V_RC

CN2 24V

POWER SUPPLY UNIT


Cassette SW (PWB) CN4

CN1 5V 12V

MAIN PWB

Vth_RC

CN3 Vth

3. INTERLOCK SW BLOCK DIAGRAM

24V J7 Cleaning roller SW (PWB)


U9 TURN MOTOR DRIVER U10 CARD MOTOR DRIVER

Specification of Interlock Switch Door SW (PWB) OPEN and Cassette SW (PWB) OPEN

J6 Card Tray SW (PWB)


U16 PICK UP MOTOR DRIVER

24V OFF

Cleaning roller SW (PWB) OPEN

Turn Motor STOP Card Motor STOP Pick up Motor STOP

DRIVE PWB

Card Tray SW (PWB) OPEN

Pick up Motor STOP

4. BLOCK DIAGRAM OF THE FPGA CIRCUMFERENCE ON A MAIN BOARD


Flash Memory

CPU

32bit CPU BUS 16bit Data SDRAM 4MWordx16bit

1
CPU I/F BLOCK INTERNAL CLOCK GENERATOR Step Motor Speed Up/Down Table (CPU generates the table data.)

Motor Solenoid Control Signals Sensor input Retransfer Heater Temperature 7 Bend Remedial Heater Temperature 8 TPH Temperature

MOTOR CONTROL BLOCK

2
SDRAM I/F BLOCK Heater control Table(*2)

1 3
16bit Data

AD CONVERTER CONTROL BLOCK

TPH Control Table(*2) (Strobe)

2 4 56
PRINT BLOCK (Temperature correction, Outline emphasis, LUT) Data Processor Microcode Memory(*1) 512Word x 16bit

4 3
Tables for Print Data Correction(*2)

7 8

9
Retransfer Heater Control Signal HEATER CONTROL BLOCK (The Heaters are controlled by each temperature.)

5
Work Memory for PRINT BLOCK

Bend Remedial Heater Control Signal

Plane Memory 2MByte TPH I/F BLOCK

INK Sensor LED Driver

D/A Interface

Line Buffer Memory x2

Print Data Strobe Lutch

(*1)(*2)These data are copied from Flash Memory.

Thermal Print Head

*FPGA =
Field Prgramble Gate Array

AC IN
AC

Option2 I/F

Option1 I/F

USB I/F

Serial I/F

POWER SUPPLY
AC AC DC24V CTL2 CTL1 VTH DC5/12V

J6

J7

J4

POWER SWITCH

J8 CN1
HEATER PROTECTOR PWB CN2 CN3

J14

RF-ID PWB

J13 J1 J13 J15 J2


DC5/12V/24V

CN8 CN9

J12 J11

J17

DRIVE PWB
J4 J24 J23 J10 J3
Cooling fan

J10 J7 J6

MAIN PWB
J9 J15 J5 J22 J21 J2

J16

J18

J8 J11 J12 J16J14

J9

to J13

CN4

CN5

Door interlock

Cassette interlock

CN6

CN7
Card tray interlock

No card sensor

CN3
HEAD PWB
Thermal Head

Turnover initial position sensor

Card near empty sensor

J9 J12
Cleanning roller interlock

Step Motor
DC Motor

KWS0644-001

J1
Turnover feed motor Ink takeup motor

to J11

CN1 CN1
Platen roller solenoid

OPTION (MG/IC Block)


Retransfer Heat roller
Thermostat

to J15
Thermal Head cooling fan

CN3

CN301

Retranfer film mark sensor

Ink start position sensor

Card edge sensor

Thermostat

WIRING DIAGRAM

to
Remedial Heat roller

KWR16003-001

J16
DC Motor

to J9 to J12
DC Motor

card supply sensor

CN2

Step Motor

S3
Cam sensor Head position3 Head position1 Head position2 Card position 210Encode

S1
Retransfer Heatroller Positionning sensor

S2
Remedial Heatroller Positionning sensor

Turnover card sensor

Pick up motor Turn over motor

Ink supply motor

to J8
Step Motor Step Motor

to J8
F1

75Encode

to J8 to J16
to J13
Step Motor DC Motor

IC FLAG 5V 12V

CN201

to J10
Solenoid For IC CONTACT

CN1
Card feed motor

CN2 Step Motor


Retransfer film Take up motor Cam motor

Retransfer film supply motor

T2

T1

INK FG sensor

IC R/W
MG Feed Motor

FRONT PWB

Cooling fan

Card Cooling Fan

to J13 IC CONTACT MG HEAD

Remedial Heat Roller Thermistor

CN1

Retransfer Heat Roller Thermistor

Card outlet sencer

XID580i BLOCK DIAGRAM

AC

Main Parts Layout


1. Sensors
Ink FG sensor (encorder circuit board)

Retransfer film mark sensor (circuit board) Ink start position sensor (circuit board) Retransfer roller sensor Turnover card sensor (circuit board) Card outlet sensor Bend remedial roller sensor Turnover initial position sensor Card supply sensor No card Cam sensor Card edgesensor (Circuit board) Card near empty sensor

2. Thermal Head and Rollers

Platen roller

Turnover unit Bend remedial roller Retransfer roller Thermal head Card supply roller NG card outlet roller

10

3. Motors
Retransfer film supply motor Ink take-up motor

Retransfer film take-up motor

Ink supply Motor

Turn over motor Turn over feed motor

Cam motor

Card feed motor

Card pick up motor

4. Solenoid

Platen Solenoid

Rear veiw

11

5. Switches
Door interlock switch

Cassette interlock switch

Cleanning roller interlock switch Card tray interlock switch

6. Circuit Boards, Power Supply Unit, and Fans

Front PWB Drive PWB

Power supply unit

Heater protector PWB

MAIN PWB

12

Ventilation fan

Ventilation fan

Thermal head cooling fan

Card cooling fan

13

7. RF-ID

RF-ID unit

14

REMOVAL AND EXCHANGE OF THE MAIN PARTS


1. CHECKING AT THE TIME OF SERVICING
When confirming the symptoms, swing the power supply unit down as shown in the following figure and check the inside.

1.1 REMOVE THE TOP COVER AND THE REAR PANEL.


1) Remove the filters on both sides of the top cover. Caution: If they are not removed, the filters will be damaged when the top cover is moved. 2) Remove the seven screws A and pull the top cover to the rear to remove it. 3) Remove the screw B and take off the rear panel.
Filter ScrewB

1.2 REMOVE THE MG CIRCUIT BOARD.


1) Remove the three screws A and the screw B. 2) After the power supply unit has been swung down, use the screw B for provisional fixing, so that the MG circuit board does not move.
Screw B

ScrewA

Screw A
15

1.3 SWING DOWN THE POWER SUPPLY UNIT.


1) 2) 3) 4) Remove the two screws B on both sides. Loosen the four screws A on both sides. Raise the power supply unit and swing it down. Remove the thermostat cable from the clamper, raise the power supply unit once, and then swing it down.

Screw A

Thermostat wire

Power supply unit

Power connector

Thermistor wire

2.1.2 Removal of the Retransfer Roller 1) Disconnect the right side of the spring. 2) Remove the screw A and bring the sensor bracket to free condition. For installation, match the notches so that they engage. 3) Disconnect the junction connectors of the thermistor and the thermostat of the retransfer roller. Remove the power connector. 4) Remove the two screws B and remove the roller by pulling it slowly to the front.
Notch Spring Screw A

Screw B Screw A

2. REMOVAL AND EXCHANGE OF THE MAIN PARTS


2.1 REMOVAL OF THE HEAT ROLLER
CAUTION: Immediately after the power has been switched OFF, the retransfer roller and the bend remedial roller are still hot. Please perform the work after these rollers have cooled down sufficiently, as otherwise burns may be caused. 1) Refer to section 2.2 and remove the cam motor. 2) Remove each roller individually. 2.1.1 Removal of the Bend Remedial Roller 1) Disconnect the junction connectors of the thermistor and the thermostat of the bend remedial roller. Remove the power connector. 2) Remove the two screws A. 3) The bend remedial roller can be removed when the roller is turned upwards and slowly pulled to the front.

Power connector

Screw B

16

CAUTIONS FOR INSTALLATION AND CLEANING OF BOTH ROLLERS


1) The oil bearing % is on the tip of the roller assembly. Do not forget it at the time of installation and removal. 2) When installing a new roller, take care that it will not hit the bracket. 3) AC 100 V is impressed to this heater. Use sufficient care for the wire processing. 4) Do not turn the roller by hand. The thermistor may become damaged when the roller is turned by hand. Accordingly, when a roller is to be turned for cleaning etc., do the turning while the bracket on which the thermistor is installed has been raised a little.

2.2 REMOVAL OF THE CAM MOTOR


1) Remove the two screws A. Please use a long screwdriver for the lower screw. If the power supply unit is in the way, raise it once and use the gap underneath to perform the work. 2) Remove the screw B from front side. Refer to section 2.9 to remove the front panel. 3) Insert the screwdriver to the hole fixing the card cooling fan, and remove another screw B. (Refer to section 2.14.3) 4) Disconnect the flat wire and the other cables. 5) Raise the bend remedial roller and pull out the motor, taking care that the motor bracket will not hit circuit boards etc.
Screw B (Front side)

screw B

Screw A
Clamp

17 17

KJJ46271-003

KJJ46271-003

18
QYSPSPD 4008N F1

A B T1

Bend remedial roller


(TSS0182)

T2

15

(-010)

3
Clamp (T2,H2) T2 Clamp (F1)

H2

15

Cam motor
12 1
(TSS0181) KJJ46271 -003x2

Bearing

(-010)

Thermistor bracket

T1

P4 Clamp (P4) (FD M.MOTOR ASY)

(TSS0189)

Pass the wires behind the lever

Retransfer roller

H1

17
KJJ46271 -003x2

17
KJJ46271 -003x2

Screw A

17

2.2.1 Installation of the Cam Motor 1) The gear of the cam motor has a phase. When it is removed at the time of roller cleaning, exchange, etc., it can be installed again in the same condition, but setting in the following way should be done when the cam gear is exchanged.
Apply grease to this side also

2.3 REMOVAL OF THE RETRANSFER FILM SUPPLY MOTOR


1) Remove the ink ribbon and the retransfer film cassette. 2) Remove the bobbin holder 7 on the film supply side. Perform the work while using your hand to prevent that the E-ring drops down.

20
Apply grease to this side also

Upper side 14
Cam gear Slit Double gear QYREE4000X

Apply grease to this side also

Apply sufficient grease to the hole for the shaft.

12
Install so that the slit of the cam gear comes to the gear edge of the double gear when seen from above.

Lower side
Engage with the cam gear.

QYREE4000X

Gear setting method 20


Apply grease to a small gear by one grain of rice.

Apply grease to this side also


Please use care, as the

10 13 installation orientation
can be mistaken easily. Apply a sufficient quantity

Bobbin holder

20 of grease to the two


QYSPSPD3006Nx2

holes for the shaft.

17 6

Before installing the gear, install it on the bracket.

18

3) Remove the drive circuit board. Disengage the clampers and the connector. Disengage the two clampers fixing the circuit board and remove the circuit board by pulling it in diagonal direction.
DRIVE PWB is attached after checking that the wire passes along 3set in EDGE SADDLE

Stepping motor SA P4 Cam motor


(Front sensor)

2) When installing the cam motor, first insert the longest shaft into the hole while raising the bend remedial roller a little. Next, insert the second shaft into its hole while turning the motor bracket a little. The bend remedial roller will move down. Finally, confirm that the projecting part is in the heater lever hole. At this time, raise the bend remedial roller by hand, confirm that it is locked, and tighten the screws. 3) Check the cam movement as described in Service mode "Diag. TEST cam motor".

F2 P5 P1 D1 D2 J5 D4 P2 P3

J7 J6 (Tray interlock) The relay connector confirms and connects with number as which the connector number is same. F3 Clamp F1 DRIVE PWB SA

D3

J7 P4 J6 J11 J5 F2 D3

D1 D2 (KWS0751-002) (Door interlockSA) Clampx3

J11 P5 P3 F1 P1 D4

(KWS0757-002)

P2

P4

4) Remove the tensioning spring @ . (Refer to the figure on the lower part of next page.) 5) When the five screws &, ( are removed, the film supply motor assembly can be removed. (Refer to the figure on the lower part of next page.)
18

2.3.1 Installation of the Retransfer Film Supply Motor 1) When the motor has been disassembled or exchanged, first the belt @ tension must be adjusted. 2) After assembly has been performed, leave the screw # tightened provisionally. 3) Turn the motor all the way in arrow direction and tighten the screw # securely.
QYSPSPD3006Nx2 Tighten provisionally.

Tighten the screw B securely to turn the motor in arrow direction to tighten the belt, and then tighten the screw A securely.

A B

13

7 11
F689ZZ F689ZZ

11 15
80S2M224 QYSBST3006Nx2

14 10

8 15
80S2M224

4) When installing the motor assembly, the tension adjustment of another belt % is required. 5) Install the two screws &. 6) Tighten the four screws (, ) provisionally. 7) Hook the tension spring @. 8) Tighten the four screws securely. 9) Install the bobbin holder.
Clanp

(TSS0187)

Retransfer film supply motor 19

11

(-007)

12

20
Clanp P3

19
QYSPSPD4008Nx3 Tighten provisionally.

17
QYSPSPD4008Nx2

Retransfer film take up motor

18
D3

KJJ46271 -003x2

19

2.4 REMOVAL OF THE RETRANSFER FILM TAKE UP FILM WINDING MOTOR


With the drive circuit board removed, the Retransfer film take up motor can be removed after the screw * in the above figure has been removed. (Refer to a front page.)

Ink supply motor Ink take-up motor

18

KJJ46271-001x2

2.5 REMOVAL OF THE CARD FEED MOTOR


1) Remove the tensioning spring %. 2) Remove the two screws (. Disengage the belt from the roller. 3) The card feed motor can be removed by pulling it to the front. 2.5.1 Installation of the Card Feed Motor 1) When the motor has been disassembled or exchanged, first the belt tension must be adjusted. 2) After assembly has been performed, leave the screw 8 tightened provisionally. 3) Turn the motor all the way in arrow direction and tighten the screw 8 securely. 4) Engage the belt and tighten the screw ( provisionally. 5) Apply the tensioning spring %. 6) Securely tighten the screws ( which have been tightened provisionally.
QYSBST3006Zx2

D1 D2

Clamp

Clamp

(-006) Set the belt to the pulley. P5

15

P1 P2

Turnover motor 3 20
KJJ46271 -001x3

Card feed motor


Tighten provisionally DPSP4008Nx2

19

8 7

Turnover card feed motor

Set the springs to tighten the belt, and then tighten securely.

11

12

(M180)

13

(M224)

10

Tighten the screw B securely to turn the motor in arrow direction to tighten the belt, and then tighten the screw A securely.

11 15
Tighten provisionally

A 16
DPSP3006Nx2

Motor SA

20

2.6 REMOVAL OF THE INK SUPPLY MOTOR AND THE INK TAKE-UP MOTOR
1) When there is an MG circuit board, remove the circuit board screws and move the circuit board to the side. 2) Disengage the hook on the left side of the drive circuit board. Disengage the wire clamp. 3) The ink motor assembly can be removed after the two screws * have been removed. (Refer to a front page.)

2.9

REMOVAL OF THE FRONT PANEL

1) Remove the retransfer film and the ink ribbon cassette. 2) Remove the card tray. 3) Remove the cleaning unit. 4) When the six screws 4 and the screw 5 for earth wire have been removed, the front panel can be removed. Installation of the Front Panel 1) There are two claws at the rear of the front panel. Insert into the frame by lightly hitting on the claws. And then secure the six screws 4.

2.7 REMOVAL OF THE TURNOVER MOTOR AND THE TURNOVER CARD FEED MOTOR
1) The turn over motor and the turn over card feed motor assembly can be removed after the three screws ) have been removed. (Refer to a front page.) Remove the spring, as one of the screws is hidden by the spring.

Front Panel 5

2.8 REMOVAL OF THE CARD PICKUP MOTOR


1) The card pickup motor assembly can be removed after the two screws * have been removed.
Insert the front panel into the frame by lightly hitting on the claws. 4
SDSP4008Nx6
M G IS O IC

Insert the gear shaft

Card pikup motor 18


KJJ46271 -001x2

21

2.10 REMOVAL OF THE PLATEN SOLENOID


1) Remove the drive circuit board. 2) Disengage the wire from the clamp. (2 places) 3) Remove the two screws ( and then remove the solenoid support @ and #. 4) Remove the two screws &, raise the solenoid body once, and pull it to the rear. 5) Be careful not to damage the disk of ink encoder located above when removing the screw (. 2.10.1 Installation of the Platen Solenoid 1) Insert the plunger by itself into the cutout.
H1

2.11 REMOVAL OF THE POWER SUPPLY UNIT


1) Disconnect the wires and the connectors. 2) Remove the two screws 0. 3) When ordering a power supply unit, also order the wire clamps around it at the same time.

100V/200VCommon
H1=Retransfer heater H2=Bend Remedial heater

H1

H2

6
H2

KWS0639-001

2) Fix the solenoid body with two screws &. 3) Fix the solenoid support with two screws (. At this time, Pay attention to the following item. 4) Before tightening the screws, adjust the gap uniformly so that there will be no interference with the platen lever and the solenoid support when the plunger moves in and out. 5) Be careful not to damage the disk of ink encoder located above when securing the screw (.

H1

F3

H2

CN2 CN8 CN4 CN3 CN8 CN4 CN5 CN6 CN7 POWER SUPPLY SA CN1

10

KJJ46271-003x2

Gap

19

QYSPSPD4008Nx2

Explanation drawing 1 Platen lever Solenoid support Before tightening the screws, adjust the gap uniformly so that there will be no interference with the platen lever and the solenoid support when the plunger moves in and out. Explanation drawing 1 Caution for the time of installation of the solenoid support

12

Plunger

Platen solenoid
(TSS0179)

11

17
Clamp

QYSPSPD 4008Nx2

Engage the bearing with the rear frame.

Lead the wire along the bracket so that it does not become an obstacle on the inside of the bracket.

22

2.12 REMOVAL OF SENSORS AND SWITCHES


2.12.1 Removal of the Cam Sensor Function This sensor decides the origin position for pressurizing the retransfer roller and the bend remedial roller. 1) Refer to section 2.2 and remove the cam motor. 2) The sensor can be removed after the screw * has been removed. 2.12.2 Removal of the Card Outlet Sensor Function This sensor detects card jams. An error will be caused when no card passes the sensor within a fixed time after completion of retransfer. 1) The sensor can be removed after the screw ( has been removed. 2.12.3 Removal of the Ink Encoder Circuit Board Function The ink feed quantity is decided by the pulses of this encoder. Start position is decided by the ink start position sensor. 1) The bracket can be removed after the two screws ) have been removed. 2.12.4 Removal of the External Unit Power Circuit Board Function When a small external IC unit is connected, power is supplied from this power supply. The thermistor detecting the environment temperature is installed on this board. 1) Refer to section 2.2 and remove the cam motor. 2) The circuit board can be removed after the screw has been removed.

F1

20

KJJ46271 -003x2

Ink Encoder

19
KJJ46271-003

11

Card outlet sensor Yellow Cam sensor


S3

18
KJJ46271 -003

EXT. unit power 7

21

KJJ46271-003

23

2.12.5 Removal of the Turnover Initial Position sensor Function This sensor decides the origin position for the turn unit. 1) Refer to section 2.7 and remove the turnover and card feed motor. 2) The sensor can be removed after the screw & has been removed. 2.12.6 Removal of the Card Near-empty Sensor Function When the number of remaining cards drops to about 20 cards (for the card 0,76mm thick) , the electronic buzzer sounds. 1) Refer to section 2.16.1 and remove the Main circuit board. 2) Remove the card tray. 3) The sensor can be removed after the screw ( has been removed with a long screwdriver from the hole in which the Main circuit board is located. 2.12.7 Removal of the No Card Sensor This sensor checks whether there are remaining cards or not. An error is caused when the remaining quantity becomes zero. 1) Refer to section 2.7 and remove the turnover and card feed motor. 2) The sensor can be removed after the screw * has been removed.

2.12.8 Removal of the Retransfer roller/Remedial Roller Sensor Function This sensor detects the origin of the retransfer roller and the bend remedial roller. Energization is performed only when a roller is in this position. 1) Remove the screw &. 2) Slide the sensor to the side, as the lever is inserted into the sensor.

DR PCB BKT SA TSS0239-V

17 17
A B TSS0239-U F1 HEATER SENSOR SA T2 (TSS0182) T1

15

(-010)

3
CLAMP (T2,H2) T2 CLAMP (F1) H2

15
(-010)

12 1
(TSS0181) T1 (TSS0189) P4

5
CLAMP (P4)

H1

17

(FD M.MOTOR ASY)

17

Head cooling fan

KWS0757-002

15

11 12 1

11
No Card sensor Card near-empty sensor

17
Turnover initial position sensor
KJJ46271 -003

18

KJJ46271 -003

19

KJJ46271-003

24

2.12.9 Removal of the Retransfer Film Mark/Ink Start Position Sensor Circuit Board and the Card Edge Sensor Function Card edge sensor This sensor decides the card position at the time of card retransfer. Retransfer Film mark sensor This sensor detects the black bar on the film and selects the panel for printing. Ink start position sensor This sensor detects the boundary between magenta and cyan ink. Next, the pulses of the rotary encoder are detected and movement is made to yellow. 1) When a magnetic encoder is built-in, refer to "Connection of optional parts" and remove the encoder. Remove the feed roller marked with* in the lower drawing of section 2.15.1 feed roller removal. 3) The sensor bracket holding the sensor can be removed when the screw # has been removed. 2)

2.12.10 Removal of the C.L. Interlock Circuit Board and the Card Supply Sensor Function C.L. interlock switch This sensor detects the presence or absence of the cleaning unit. When the switch is OFF, no power is supplied to the driver IC for the card supply motor and the turnover motor. Card supply sensor This sensor checks whether cards are being supplied or not. 1) Refer to section 2.9 and remove the front panel. 2) The sensor bracket holding these two sensors can be removed when the screw 6 has been removed.

REAR PLATE SA

F1

side)

Ink start position sensor


Explanation drawing 4 Explanation drawing 4

Route the edge sensor wire underneath the film mark sensor between the circuit boards.

13

Card edge sensor Retransfer film mark sensor

Pass the wire through the notch in the bracket.

Card supply sensor C. LInterlock switch

25

2.12.11 Removal of the Door Interlock Circuit Board Function This circuit board detects opening of the front door. The DC 24 V power put out from the power supply unit is cut off when the door interlock switch and the cassette interlock switch are not both ON. 1) Refer to section 2.9 and remove the front panel. 2) The door interlock circuit board can be removed after the screw (15) has been removed.
15 KJJ46271-003 8
Door interlock RED

2.12.12 Removal of the Cassette Interlock Circuit Board Function This circuit board detects the presence or absence of the retransfer film and the ink ribbon cassette. The DC 24 V power put out from the power supply unit is cut off when the door interlock switch and the cassette interlock switch are not both ON. 1) Refer to section 2.10 and remove the platen solenoid. 2) The cassette interlock circuit board can be removed after the screw (16) has been removed.

J4 J3

Cassette interlock

16

KJJ46271-001x2

26

2.12.13 Removal of the Card Tray Interlock Circuit Board Function This circuit board detects whether the card tray is presence or absence. When the tray is absence, the power is not supplied to the driver IC for the card pickup motor. 1) Remove the card tray. 2) Remove the three screws 9 and the rail on the left side of the card tray. 3) When the screw is removed with a small screwdriver, the cassette interlock circuit board can be removed.
QYREE4000X

2.13 REMOVAL OF THE TURNOVER UNIT


1) Refer to section 2.9 and remove the front panel. 2) Refer to section 2.8 and remove the turnover motor and the turnover card feed Motor. 3) Remove the E-rings $ and %. 4) The turnover unit can be removed after the oil bearing # has been removed by sliding it along the shaft. Installation 1) Install the front E-ring and the oil bearing first. 2) As the gears 5 and 6 are not fixed, hold them by hand while installing the oil bearing and the E-ring. 3) Turn the turnover unit by hand and check that the wire does not get caught.
Attachment position of the serial number

10

5 4

KJJ46271-003 x3

9 5 10
QYREE4000X

Install so that the bracket of the turn unit goes under the plate of the rear frame. QYREE4000X QYREE5000X

15 7

14

8 13
(-002)

QYREE5000X

11 10 13
(-002)

15

KWR 10303-010

Explanation drawing 2

15
Card tray interlock
KJJ46271-003 L. FRAME SA

QYREE5000X

13 16

(-002)

1
Q03093-836

Turnover Card Sensor Board

Connect the connector.

5
Pass the wire underneath the sumi tube.

x2

Pay attention to the wire passing direction. Explanation drawing 2

Install the gear, holding it so that it will not drop down.

Explanation drawing 1

2.12.14 Removal of the Turnover Card Sensor Circuit Board Function This sensor checks for correct card storage at the time of card supply and card turning. 1) Refer to section 2.9 and remove the front panel. 2) Turn the turn unit so that the sensor circuit board comes to the top. 3) The sensor circuit board can be removed after the two screws 1 have been removed.
27

2.14 FAN REMOVAL


2.14.1 Removal of the Thermal Head Cooling Fan 1) Remove the two screws and the air duct 2. 2) The thermal head cooling fan can be removed after the two screws $ have been removed. 2.14.2 Removal of the Suction Fan 1) The Suction fan can be removed after the two screws # have been removed. 2.14.3 Removal of the Card Cooling Fan 1) Refer to section 2.9 and remove the front panel. 2) The card cooling fan can be removed after the two screws 6 have been removed.

Insert the red wire first, so that the wires will be arranged nicely after connector insertion.

Pass the fan wire through the notch.

Loosen the two screws of the duct frame for joint tightening.

F1

Card cooling fan


2

Red

14
Clamp the wire of suction fan.

QYSPSPD 3012Nx2

KJJ46271-003x2

13
QYSDSP 3030Rx2

Thermal head cooling fan

Suction fan

28

2.14.4 Removal of the Ventilaion Fan 1) Remove the rear panel and the junction connector. 2) Remove the two screws for the fan.

Remove the clump

11
Remove the junction connctor
F3

QYSDSP 4008N

F3

Rear Panel SA

QYSPSPD3030N X2

12

Rear Panel SA

29

2.15 ROLLER REMOVAL


2.15.1 Feed Roller Removal 1) Refer to section 2.9 and remove the front panel. 2) Remove the card feed motor and the retransfer roller as required. 3) Tension adjustment is required for the belt at the front. Please refer to the following figure.
12 (Use for 5 only) 20 6 3 1 2
A side with the stage x2 x1 (-011) QYYASPW4004F (-011) A side with the stage

JOG DIAL SA
17

20

21 14

22

4 22
QYYASPW4004F MAIN ROLLER SA

15 25
QYREE5000X

14

1 3
(-002)

(-002)

ANTI BEND ROLLER SA QYYASPW4004Fx3

QYREE5000X (-011)

21

25

22

14

Explanation drawing 1 JOG DIAL SA

Please (Insert from the front.)


ANTI BEND ROLLER SA (EPDM) Hardness : 60

QYYASPW4004F
Hardness : 77

(M116)

17
11 6
x3

10 20

9 10
x4

x4

(M118)

20
x3 (-011)

4
MAIN ROLLER SA

7
(50S2M192)

At the time of installing the main roller SA, also engage the front belt.

16
KJJ46271 -003 x2

Belt setting

11

13

REE5000

8
(M132)

Engage the bearing with the frame, pull it to the front, and fix it with an E-ring.
19 17 7
(M266) (-012)

Tension the belt and tighten the screw securely.


Belt setting Tension the belt and tighten the screw securely.

22

QYYASPW4004F

QYREE5000X

15
QYREE5000X

QYREE5000X

15 15 12 2

(-002)

12 12
(-002)

(-002)

CARD OUT ROLLER SA

AL ROLLER SA

*
x2

QYREE5000X

15
QYREE5000X

15 3 3

MAIN ROLLER SA CARD OUT ROLLER SA (EPDM) QYREE5000X

15
(-002)

12

AL ROLLER SA

x2

30

2.15.2 Platen Roller Assy Removal 1) Remove the thermal head to prevent damage to it. 2) After removing the thermal head, remove the front panel , E-ring ^ and the worm screw *, then the platen roller can be removed. Be careful not to damage the platen roller, otherwise print quality may be affected. 3) After assembling, remove the protection sheet.

13
Platen roller (With protection sheet)
QYREE5000X

16

short
B QYSPSPD 4008N x2 3

long

9
(-007)

15

14
(-007)

14
QYYASPW3004F

18 17

9
PLATEN ARM SA (F)

PLATEN ARM SA(F)

2
A C

Projected side

7 5
(-003) PLATEN ARM SA (R)

8
(-010) A

20

PLATEN ARM SA(R)

(-003)

10
QYREE7000X

3
QYSPSPD4008N

31

2.16 CIRCUIT BOARD REMOVAL


2.16.1 Removal of the Main Circuit Board 1) When the three screws 0 are removed and the circuit boards are pulled out.

Caution at the time of exchange of the Main circuit board


1) Values set in user mode and service mode are stored on the Main circuit board.Accordingly, when the circuit board has been replaced by a new one, these set values must be stored. For details, refer to Service Mode Parameter Push and Pop.
From power supply unit

1
MAIN PWB SA TPS0242-001

J23,J24through the inner part of the cable

J18 J22

10

J11

KJJ46271-003x3

J23

J24

J22 J18 J11 J23 J24

J15

J21 J17

J2 J5 MAIN PWB SA

2) The connectors tend to break in performing removal and attachment of a Main circuit board, please work carefully enough.

32

2.17 Thermal Head Exchange Method


1) Remove the ink ribbon and the retranster film cassette. 2) When the locking claws on both sides of the head are spread, the connector can be disconnected. Remove the connector by pulling it. 3) Remove the screw !. Pull the thermal head to the front to remove it.

Installation method
1) Install a new thermal head. 2) Tighten the screw. 3) Press the connector near its center and insert it. The claws will lock. When a part of the connector is difficult to see at this time, the work can be facilitated by removing the head exchange cover of the enclosure. The head exchange cover can be removed by removing the screw and sliding the cover to the rear.

Head exchange cover

*Notes: 1) When the connector at the time of installation is inserted with the pins not correctly aligned, the connector will be damaged. Please insert it after aligning it correctly. 2) When the heater element on the thermal head is hit at the time of exchange, it can become scratched white streaks etc. can be caused for the printing results. Please handle the thermal head with sufficient care. 3) When the thermal head is touched by someone with an electrostatic charge, it may be damaged. Please touch the frame of the unit before the start of work.

Locking claw

Thermal head

11

QYSDSP4008N

33

The check after head exchange


After thermal head is exchanged, a printing position may move in the direction of Y. In this case, please adjust in the following procedures. Enter into Service mode, Maintenance and Offset Prt Y. See the next page. 1) Determines the displacement amount according to the print results (those owned by the user). Every step corresponds to a displacement of about 0.17 mm. The step can be varied in the range between -15 and +15. 2) Press ENTER to save the setting. 3) Print and check the result. 4) To adjust to the standard setting: In the service mode, print color patterns on single sides of 4 to 5 sheets. Adjust so that the distance from the card edge to the box enclosing the line (A) is about 2.15 mm. (Check the third to fifth cards.)

A=2.15mm
R

(+)

(-)

Card shifting direction

Printing start

34

USE OF SERVICE MODE


At the time of operation by the user, the "User mode" is used, while the "Service mode" is used at the time of servicing. Refer to the instruction manual for the user mode. 1) Fine adjustment of the printing position 2) Printing of the built-in test pattern 3) Individual operation of motors

1. Entry into Service Mode


In ready condition, in preheating condition, or in error condition, press the buttons and button [MENU] is released first, the printer will enter into the following service mode.
>Service Mode>
After 1 sec
MENU

simultaneously. When the

>Download>

OK?

>Download Ready
[ENTER] [EXIT]

Completion Start

Downloading.. Keep Power On

Start of the firmware download function The new firmware becomes effective after power OFF or rebooting.

[MENU]

>Download Ready
Power off

The new firmware becomes eflective after power off. [EXIT] End of Service mode. Setting of the printing position Y [-15(Front) -1(Front),0,+1(Back) - +15(Back)] Select with [][] and save with [ENTER]. Setting of the printing position X [-7(Left) -1(Left),0,+1(Right) +7(Right)] Select with [][] and save with [ENTER]. Setting of the retransfer position X [-7(Left) -1(Left),0,+1(Right) +7(Right)] Select with [][] and save with [ENTER]. Setting of the card stop position X [-7(Left) -1(Left),0,+1(Right) +7(Right)] Select with [][] and save with [ENTER]. Setting of the Vth gain (Supplementary function for the future : Always set to 8. ) [0 - +15] Select with [][] and save with [ENTER]. Setting of the printing density [Standard Density,Low Density, High Density,User's LUT] Select with [][] and save with [ENTER]. Card cooling fan ON/OFF [On, Off] Select with [][] and save with [ENTER]. Different type of JIS magnetic encoding [Lo-Co, Hi-Co] Select with [][] and save with [ENTER]. Card supplying direction [Standard, Right Side] Select with [][] and save with [ENTER]. Under user mode, when the IC Antenna Pos. is Ext. Unit/Ad.on or the IC Contact Pos. is Ext. Unit, the Right Side cannot be selected.

>Maintenance>
[MENU]

[EXIT] [ENTER]

>>Offset Prt Y
0 [MENU]

>>Offset Prt X
0 [MENU]

The positions where the setting value of 15 was actually setup by the version of a firmware differ.

>>Offset Trf X
0 [MENU]

>>Offset Card X
0 [MENU]

>>VGAIN

8 [MENU]

>>Default LUT
Standard Density [MENU]

>>Card Fan
On [MENU]

>>MG JIS TYPE


Lo-Co [MENU]

>>Card Loading
Standard [MENU]

>>Ink Sensor OFF


107 [MENU] [EXIT] [ENTER]

Ajust the threshold level of the ink-Sensor Select with [][] and save with [ENTER]. Answered On or Off. [off:transmission,on:interruption.]

>Off-line Test>
[MENU]

>>Pattern
Color [MENU]

Test pattern setting [Step,Vth,Registration,Addres,Color,Black,Gray,All,(YMCK+K),(K+YMCK)] Select with [][] and set with [ENTER]. Switching between printing single side and both sides [Single, Both] Select with [][] and set with [ENTER]. Setting of the number of times for testing [1,2,3,4,5,6,7,8,9,10,20,30,40,50,100,200,300,400,500,Endless] Select with [][] and set with [ENTER]. [EXIT] [ENTER]

>>Printing Side
Single [MENU]

>>Times

1 [MENU]

>>Test Select
Print [MENU]

>>Test Select
OK? [ENTER]

Testing...

Setting the test type [Print,Feed,IC(Contact),IC(Antenna),MG(JIS), MG(ISO),] Select with [][] and set with [ENTER].

>Diag. Test>
[MENU]

[EXIT] [ENTER]

>>Sensor
1000010101010110 [MENU]

>>Actuator>
[MENU]

[EXIT] [ENTER]

>>>Ink TUP Mo.


OK? [MENU] [ENTER]

>>>Ink TUP Mo. Testing.. >>>Ink SPY Mo. Testing.. >>>Media TUP Mo.

Ink take-up motor

>>>Ink SPY Mo.


OK? [MENU] [ENTER]

Ink supply motor

>>>Media TUP Mo.


OK? [MENU] [ENTER]

Testing..

Retransfer Film take-up motor

>>>Media SPY Mo.


OK? [MENU] [ENTER]

>>>Media SPY Mo.


Testing..

Retransfer Film supply motor

35

3
>>>Card Feed Mo.
OK? [MENU] [ENTER]

>>>Card Feed Mo.


Testing..

Card feed motor

>>>Turn Over Mo.


OK? [MENU] [ENTER]

>>>Turn Over Mo.


Testing..

Turnover motor

>>>Turn Feed Mo.


OK? [MENU] [ENTER]

>>>Turn Feed Mo.


Testing..

Turnover card feed motor

>>>Heat Cam Mo.


OK? [MENU] [ENTER]

>>>Heat Cam Mo.


Testing..

Cam motor

>>>Pick Up Mo.
OK? [MENU] [ENTER]

>>>Pick Up Mo. Testing.. >>>Platen Sol. Testing.. >>>Ink TUP Enc. Testing.. >>>Ink SPY Enc. Testing.. >>>Media TUP Enc.

Card pikup motor

>>>Platen Sol.
OK? [MENU] [ENTER]

Platen solenoid

>>>Ink TUP Enc.


OK? [MENU] [ENTER]

Ink take-up encoder In case of an error, the buzzer sounds and the red LED lights. When there is no error, the indication just returns to the initial indication. Ink supply encoder In case of an error, the buzzer sounds and the red LED lights. When there is no error, the indication just returns to the initial indication. Retransfer Film take-up encoder In case of an error, the buzzer sounds and the red LED lights. When there is no error, the indication just returns to the initial indication.

>>>Ink SPY Enc.


OK? [MENU] [ENTER]

>>>Media TUP Enc.


OK? [MENU] [ENTER]

Testing..

>>Memory
OK? [MENU] [ENTER]

>>Memory
Testing..

In case of an error, the buzzer sounds and the LED lights. When there is no error, the indication just returns to the initial indication.

>>SIO
OK? [MENU] [ENTER]

>>SIO Testing..

In case of an error, the buzzer sounds and the LED lights. When there is no error, the indication just returns to the initial indication.

>>Display
OK? [MENU] [ENTER] Display for 5 sec

>>Back Color
OK? [MENU] [ENTER] Display for 3 sec The buzzer sounds Display for 3 sec Display for 3 sec

>>Buzzer
OK? [MENU]

>>Registers>
[MENU]

[EXIT] [ENTER]

>>ADPORT0
C277 [MENU]

>>ADPORT1 >Informations>
[MENU] Version [EXIT] [ENTER] FCFC [MENU]

Value obtained by A/D conversion of the thermistor value of the heater or head

>>Firmware
Version

123 [MENU]

Firmware version

>>FPGA Config. >>FPGA Table


Version

12 [MENU]

FPGA config version

12 [MENU]

FPGA table version

>>Thermal Head
12345678/ 24.00 [MENU]

Thermal Head serial No. and Vth

>>MG Firmware
Version 1234 [MENU]

MG encoder firmware version

>>Laminator
Version ___ [MENU]

Firmware version of laminator when connected

>>Ext. Unit
Version 1234/5 [MENU]

External unit firmware version

>>HR PwrOn Time

[EXIT] [ENTER]

>>>Retransfer
[MENU]

Displayed the total lighting time of the heat roller

>>>Bend Remedy
[MENU] [MENU] [EXIT] [ENTER] [MENU]

>>HR POT Reset

>>>Retransfer
[MENU]

Cleared the total lighting time of the heat roller

>>>Bend Remedy
[MENU]

>Parameter Push>
[MENU]

[EXIT] [ENTER] [EXIT] [ENTER]

>Parameter Push
OK? [ENTER]

>Parameter Push
Running..

Parameter settings save in the head EEP-ROM. * The buzzer beeps in case of an error. Loading the parameter settings from the head EEP-ROM. * If the correct data is not stored by the head EEP-ROM, "No Data" is displayed and the buzzer beeps.

>Parameter Pop
[MENU] Assistance 12345678 [MENU]

>Parameter Pop
OK? [ENTER]

>Parameter Pop
Running..

Ancillary data, 8-digit display (read only)

36

2. Explanation of the Various Modes


LEFT X

B=2.07mm RIGHT

2.1 Download
When changing the version of firmware inside the printer, FPGA table or FPGA firmware, refer to the XID580i maintenance CD-ROM distributed separately.
A=2.15mm BACK
R

2.2 Maintenance
2.2.1 Offset Prt Y Setting For example, when printing with this printer is to be done on preprinted cards and the position relation is not correct, the entire screen can be shifted. The print position can be varied using the four items listed below. Changing any of the following items varies the print position. However, do not touch the Card X because this is the standard for the X-direction. Use items (3) and (4) for fine adjustments. * Items for varying the print position in the latitudinal direction of the card: (1) 2.2.4, Offset Card X: Adjusts the card feed amount from the card edge sensor. (2) 2.2.2, Offset Print X: Adjusts the feed amount from the black marker to the start of printing. (3) 2.2.3, Offset Trf X: Adjusts the feed amount to the start of a retransfer. * Item varying the print position in the longitudinal direction of the card: (4) 2.2.1, Offset Print Y: Adjusts the start position among the 1152 head heater elements. (1) Determines the displacement amount according to the print results (those owned by the user). Every step corresponds to a displacement of about 0.17 mm. The step can be varied in the range between -15 and +15. (2) Press ENTER to save the setting. (3) Print and check the result. (4) To adjust to the standard setting: In the service mode, print color patterns on single sides of 4 to 5 cards. Adjust so that the distance from the card edge to the box enclosing the line (A) is about 2.15 mm. (Check the third to fifth cards.)

FRONT

Card shifting direction

Printing start

2.2.2 Offset Prt X Setting 1) Determine the displacement amount according to the print results (those owned by the user). Every step corresponds to a displacement of about 0.17 mm. The step can be varied in the range between 7 and +7. (The displacement amount of one step changes with versions of a firmware.) 2) Press ENTER to save the setting. 3) Print and check the result. 4) To adjust to the standard setting: In the service mode, print color patterns on single sides of 4 to 5 cards. And then remove the film cassette. Adjust so that the distance from the black marker on the film to the remaining vertical line (P) is about 8.5 mm. (Check the third to fifth cards.)
P
Take-up side Supply side

37

2.2.3 Offset Trf X Setting 1) Determine the displacement amount according to the print results (those owned by the user). Every step corresponds to a displacement of about 0.17 mm. The step can be varied in the range between 7 and +7. 2) Press ENTER to save the setting. 3) Print and check the result. 4) To adjust to the standard setting: In the service mode, print color patterns on single sides of 4 to 5 cards. Adjust so that the distance from the card edge to the box enclosing the line (A) is about 2.07 mm. (Check the third to fifth cards.) 2.2.4 Card Stop Position Setting (Offset Card X) This adjustment is made when special cards are used. In the same way as in the preceding item, the card stop position is adjusted and the transfer position is changed. When standard cards are used, the cards may be flicked out. Accordingly, this setting normally should not be changed. 2.2.5 Default LUT Setting When printing data with a high density are to be printed over the entire area, wrinkles may be caused. In such a case, switch the setting to Standard or Low.

2.2.6 Device Type Setting The device type of SCSI Standerd is switched. Normally "Printer" is used. 2.2.7 Card Fan Setting At the time of separating the card and the retransfer film, the card is cooled with a fan. Depending on the card, the transfer may be better when there is no cooling. In such a case, change this setting. 2.2.8 TUR Response Setting This mode selects the response that the printer returns to the "Test unit ready" command from the host computer while the printer is executing printing. Normally the setting is changed according to the application software on the side of the host computer. 2.2.9 Compatible Mode Setting This mode is set when application software created for the model CX710 is to be used with the XID580i. However, care is required as the compatibility is not perfect. 2.2.10 Setting of the ink-sensor level Set the threshold level of the ink sensor so that the ink sensor defect the ink color yellow and magenta as transmission, and cyan and Bkas interruption. Select threshold value by using and buttons, and press the ENTER button to save the select Value.

[High]
Output Y.M.C O.D. = 2.1 Output

[Standard]
Output Y.M.C O.D. = 1.9

[Low]
C M Y

Input

Input

Input

When black omitted characters are to be put out with high density

Setting at the time of shipping from the factory

When changed to close to the hue of a CRT

Select Users LUT when the print density similar to that of CX710 is needed.

38

2.3 Off-line Test


This is used to print the built-in test pattern of this printer and for execution of an MG self-test. 2.3.1 Pattern setting This printer has seven types of built-in printing patterns. Select a pattern and press the "ENTER" button to store it. Return to the initial pattern is made when the power is cut. 1) Step This is for confirmation of uniform gradation. 2) Vth A and B are printed with the same data values. This is used to confirm that the power supply voltage compensation (Vth) has been done correctly (same density). 3) Registration This is used to confirm that each color overlaps correctly. 4) Address The head has 1152 heater elements. This is used to confirm the uniformity of the density for each heater element. 5) Color This is a pattern for overall evaluation 6) Black For checking of black ink blurring, drop-outs, etc. 7) Gray For checking of feed irregularities caused by mechanical trouble etc. 8) ALL The above patterns 1) to 7) are printed in sequence. (Each pattern is printed on separate card.)
A B

Step

Vth

Registration

Address

Color

Black

Gray

39

2.3.2 Printing Side Selection whether test printing is to be done on one side or both sides. 2.3.3 Times The number of cards for the test contents selected by "Test select" of the following item is selected. 2.3.4 Test Select The test to be executed is selected. 1) Print Select this for printing and press "ENTER" twice to start. 2) Feed Select this to test only the card feed. 3) IC (contact) The cards are fed and the contact for clip card is lowered. There is no data communication. 4) IC (Antenna) The card is fed and stops under the antenna for contact-free clip card. 5) MG (JIS), MG (ISO) Data actually are written to and read from magnetic stripe cards. An error is displayed on the LCD panel in case of abnormalities.

2.4 Diag. Test


2.4.1 Sensor Correct operation of the sensor is checked. Confirm the valve is changed, when the sensor is interrupted or reflected.

>>Sensor 1000010101010110
D15 D0
D0: NOCD (no card) ................................................. Reflection: 0 D1: CDIN (card supply) ............................................ Interruption: 0 D2: MGCDPOS (MG card position) ......................... Reflection: 0 D3: TURNCD (turnover card) ................................... Interruption: 0 D4: TURNPOS (turnove initial position) ................... Interruption: 0 D5: EDGE (card edge) ............................................. Interruption: 0 D6: CDOUT (card outlet) .......................................... Interruption: 0 D7: CDNE (card near empty) ................................... Reflection: 0 D8: INK (ink start position) .................... Transmission (yellow,magenta):0,Interruption: 1 D9: MEDIA (retransfer film mark) ............................. Interruption: 0 D10: CAM (cam position) ......................................... Interruption: 0 D11: HR0POS (retransfer heat roller position) ......... Interruption: 0 D12: HR1POS (bend remedial heat roller position) . Interruption: 0 D13: Not used D14: Not used D15: Not used 40

2.4.2 Actuator It is possible to operate each motor individually and to check for motor defects and to check the operation of the mechanisms. When two cassettes or a door are open, the power supply to the motor is cut, it will not operate, and inspection should be performed. 1) Ink TUP Mo. (ink take-up motor) ** Remove the inkribbon cassette. When OK? is displayed, press the ENTER button to perform take-up operation. 2) Ink SPY Mo. (ink supply motor) ** Remove the inkribbon cassette . When OK? is displayed, press the ENTER button to perform supply operation. 3) Media TUP Mo. (retransfer film take-up motor) ** Remove the retransfer film cassette. When OK? is displayed, press the ENTER button to perform film take-up operation. 4) Media SPY Mo. (retransfer film supply motor) ** Remove the retransfer film cassette. When OK? is displayed, press the ENTER button to perform film supply operation. 5) Card Feed Mo. (card feed motor) The card feed motor operates and the roller rotates. 6) Turn Over Mo. (turnover motor) The turnover motor operates and the turn unit moves through one cycle. 7) Turn Feed Mo. (turnover card feed motor) The turnover card feed motor operates and the roller in the turnover unit rotates. 8) Heat Cam Mo. (cam motor) The cam motor operates and the retransfer roller and the bend remedial roller move through one cycle. 9) Pick Up Mo. (card pickup motor) ** The card pickup motor does not rotate when there is no cleaning roller unit. The card pickup motor operates and the card supply roller rotates. 10) Platen solenoid The solenoid becomes ON (plunger pulled) once and pushes the platen against the thermal head. 11) Ink TUP Enc. (ink take-up encoder) ** Remove the ink ribbon cassette . The ink FG sensor is checked. The buzzer sounds in case of an abnormality. 12) Ink SPY Enc. (ink supply encoder) ** Remove the ink ribbon cassette. The ink supply encoder (inside the motor) is checked. The buzzer sounds in case of an abnormality. 13) Media TUP Enc. (retransfer film take-up encoder) ** Remove the retransfer film cassette. The film take-up (inside the motor) is checked. The buzzer sounds in case of an abnormality.

2.4.3 Memory The picture memory SDRAM on the Main PWB is tested. The buzzer sounds in case of an error. The error LED also will light. 2.4.4 SIO A special jig is connected and the terminals OPTION 1 and 2 are tested. Normally this is used for inspection at the time of shipping from the factory. 2.4.5 Display All the dots of LCD are displayed black. Conferm that there is no missing dot. 2.4.6 Back Color The back colors red, green, and blue are displayed for 3 seconds and correct display of the back colors is tested. 2.4.7 Buzzer Correct sounding of the electronic buzzer is tested. 2.4.8 Registers This printer has four temperature-detecting thermistors: 1) Retransfer heat roller thermistor 2) Bend remedial heat roller thermistor 3) Thermal head thermistor 4) Ambient temperature thermistor These thermistors output analog signals, which are applied to the circuits for four channel 8bit A/D converter IC. Each of these converted value in a hex decimal number as shown below. Note that the following values are the values at the moment the ENTER button is pressed.
>>ADPORT0 C277
>>ADPORT1 FCFC

The following table shows reference values.


Heat roller thermistors Ambient temperature thermistor Thermal head thermistor

Temperature Indicated Temperature Indicated Temperature Indicated (C) Value (C) Value (C) Value 0 20 50 80 100 130 140 150 160 170 180 190 200 210 220 FE FC F6 E4 CF A3 93 82 72 64 56 4A 3F 36 2E -5 0 10 15 20 25 30 35 40 45 50 55 60 65 75 F2 D9 AC 98 86 76 68 5B 50 46 3D 36 2F 2A 25 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 E8 E2 DB D3 C9 BF B4 A8 9C 90 83 77 6C 61 57

2.5 Information
The information for the various firmware versions can be confirmed. For the thermal head, the serial No. and the head supply voltage (Vth) are displayed. And the total lighting time of the heaters (retransfer and bend remedy) can be displayed. And it is possible to clear the total lighting time to zero after replacing those heaters.

2.6 Parameter Push and Pop


This printer has two EEPROMs for storage of data for the thermal head and for user and service mode. When the Main PWB is exchanged, the settings for user and service mode must be done over again. The Parameter Push/Pop function is provided to shorten this operation. When initially Push is selected and the [ENTER] button is pressed, the set values (including head, total countor) in the EEPROM on the Main PWB are written to the EEPROM in the head. When then Pop is selected after the Main PWB has been exchanged and the [ENTER] button is pressed, these set values are copied to the EEPROM on the Main PWB.

Ambient temperature Thermal head

Retransfer heat roller Bend remedial heat roller

41

OPERATION OF THE MECHANISM


The operation from card supply via card transport and printing to retransfer will be explained using a timing chart. The entire timing chart is shown below. The individual tasks (programs) operate independently.

1. Single-side Printing
Printing Printing task Printing Positioning to the start Retransfer

Ink task

Rewinding

Transport task

Card supply

Retransfer 1

2. Double-side Printing
Printing (front) Printing task Printing Retransfer (front) Printing (back) Printing Retransfer (back)

Ink task

Rewinding

Positioning to the start Retransfer 2

Rewinding

Positioning to the start Retransfer 1

Transport task

Card supply

Turn

3. Initial Operation
At the time of power ON, the mechanism is initialized. 1) The platen solenoid is pulled once. 2) The turnover unit is returned to the initial position. 3) The cam motor is returned to the initial position. 4) The card feed motor is run to discharge any intermediate cards. 5) Ink ribbon and retransfer film are positioned to the start position. Error stop is performed in case of an abnormality.

42

4. Card Supply and Card Feed

Period 2 : The turnover motor operates and the turnover unit is moved to the card supply position. (Vertical position) Period 3 : The card pick-up motor operates and a card is supplied from the hopper. The turnover card feed motor also operates at the same time. At this time, the cleaning roller and the roller in the turnover unit also rotates and the card is stored in the turnover unit. Period 4 : The turnover unit turns once from the card supply position to the printing position. Period 5 : The card is fed from the turnover unit to the card edge sensor. Period 6 : The card feed to the retransfer standby position and waits for complation of printing operation.

43

Turnover card sensor

Card supply sensor

Turnover card feed motor

Cleaning roller

Card edge sensor

Card supply roller

Card feed motor

Card pickup motor

Turnover unit (printing position)

NG card outlet roller

Card supply roller

44

5. Printing Operation
3 1 2 4 5

ON

Platen solenoid
OFF CW

Retransfer film supply motor

OFF

CCW CW

Retransfer film take-up motor

OFF

CCW CW

Ink take-up motor

OFF

CCW CW

Ink supply motor

OFF

CCW

Period 1 : The thermal head energization ON signal is sent to the power supply unit. Head voltage (Vth) is put out from the power supply unit. Period 2 : The retransfer film take-up motor runs to take up film slack. Period 3 : The platen is pushed against the thermal head. Then thermal head is energized and printing is start. Period 4 : Delay time for separation of ink ribbon and film Period 5 : After printing, the ink ribbon and the film stick to each other, and during this period the ink take-up motor operates to separate them.

56 664dot

87.6 1036dot

Card size 85.6 x 54

67

*Notes: The printing position is shown in the figure on the right. The value of X and Y are adjustment items.

45

Retransfer film supply motor

Ink take-up motor

Retransfer film take-up motor

Ink supply motor

Thermal head Platen roller

Retransfer film Ink ribbon

Platen roller

Thermal head

46

6. Retransfer Operation
1 2 3 4 5 6 7 8 9

FWD

Card feed motor

OFF N1 REV CW N2

Retransfer film supply motor

OFF

CCW CW

Retransfer film take-up motor

OFF

CCW Rep

Cam motor

OFF

Fix Hi

Card edge sensor


Lo Hi

Card outlet sensor


Lo Hi

Retransfer film mark sensor


Lo

Period 1 : The printed panel on the film and the card are transported to the retransfer position. Also, the cam motor operates and the retransfer roller is moved to the standby position. Period 2 : The cam motor operates, the retransfer roller is lowered, and the film and the card are pressed against each other. Period 3 : The card feed motor operates and retransfer starts. Period 4 : The cam motor operates and the bend remedial roller is moved to the standby position. Period 5 : The user mode has the item Cooling time setting, and during this period, the operation is stopped for the set time of 1 to 15 seconds. ** There is no card feed roller between the retransfer roller and the bend remedial roller. Card movement in this interval is done sticking to the film.

Period 6 : The film is moved to the peeling start position. (At this time, the card is close to directly under the bend remedial roller.) Also, the cam motor operates and the bend remedial roller is pushed down. Period 7 : Film peeling and card bend remedial are performed. Period 8 : After the card has been discharged, the cam returns to the stand-by position. Also, one screen is taken up looking at the film mark sensor. Period 9 : The film is returned for another screen for the next printing.

47

Retransfer film supply motor

Retransfer film take-up motor

Retransfer film mark sensor

Platen roller

Card outlet sensor

Card edge sensor

Cam motor

Card feed motor

FRONT VIEW CAM MODE

INITIAL MODE

RETRANSFER MODE

BEND REMEDIAL MODE

48

7. Operation in Case of Peeling with Return in Direction Towards the Turnover Unit
In case of printing on both sides, separation of card and film is done in the opposite direction. Up to retransfer, the operation is the same as in the above items. Then the operation becomes as shown below.
1 2 3 4 5

FWD

Card feed motor

OFF

REV CW

Retransfer film supply motor

OFF N1 CCW CW

Retransfer film take-up motor

OFF

CCW Rep

Cam motor

OF F

Fix Hi

Retransfer film mark sensor


Lo

Period 1 : The cam is returned to the intial position. Period 2 : In the same way as for the preceding item, a card cooling period exists. Period 3 : The card is fed in the direction towards the turnover unit to separate card and film, and peeling is performed. Periods 4 and 5 : Searches a start position of the next panel and becomes to the standby mode.

49

8. Operation of the Turnover Unit


In case of printing on both sides, the card is turned. The card which has been printed to front side is fed to the turnover unit.

Period 1 : The card feed motor and the turnover card feed motor operate and the card is fed. Period 2 : The turnover motor operates and the turnover unit is turned 180. Period 3 : The card is fed to the retransfer standby position. Period 4 : The turnover unit is initialized.
1 2 3 4

CW

n3

Turnover motor

OFF

CCW FWD

Turnover card feed motor

OFF

n1

REV FWD

Card feed motor

OFF

n2

REV

Hi

Turnover card sensor


Lo Hi

Card edge sensor


Lo

Period 1 : The turnover motor operates to the position sensor detection. Period 2 : The turnover motor is reversed and the position of turnover unit is fine adjusted.
1 2

CW

Turnover motor

OFF

CCW

Hi

Turnover intial position sensor


Lo

50

9. Others
9.1 Position Relation with Ink Ribbon and Retransfer Film
Film supply Ink take-up

B
Ink supply

B B
Platen Film take-up Head

A C

Film mark sensor

Ink start position sensor

C
Retransfer roller

Cartridge shaft

D
Bend remedial roller

Cartridge shaft

9.2 Ink Ribbon and Retransfer Film End Treatment


End marks as shown below are provided near the end of the ink ribbon and the retransfer film. The respective sensor detects the mark and RUN OUT is displayed.
L H H L L H

Ink ribbon transport direction Ink start position sensor

End mark 2.5cm

H L
.............

H L

Ink FG sensor

case of positioning the ink ribbon to the start position In The boundary between magenta and cyan is detected by the sensor for the ink ribbon start position. The output pulse of the ink feed quantity sensor is counted, and the start position of yellow is decided.

51

TROUBLESHOOTING
1. LCD Error Code Correspondence
No. Error item 1 Please Power off Error detection contents When recovery is not possible even when the RESET button is pressed. When the feed rollers are is to be cleaned, cleaning mode is not entered as the transfer film cassette is present. In the same way as above, this message is displayed when the heat roller temperature is 50C or more at the time of entry into cleaning mode. An error will be caused when the card supply sensor is not passed within a fixed time after start of card supply. Treatment contents This display appears for example when there is hardware trouble, as with the following trouble of No. 18-26. Remove the retransfer film cassette. This prevents sticking of the cleaning card to the film. Exchange parts

Please Remove Media Cassette

HR is too hot!

1) Switch off the power and wait for the temperature to drop. 2) When the retransfer film is in the unit, the heat roller is heated even in this mode. Always remove the retransfer film first. 1) Check for sticking of the cards in the card tray because of static electricity. Try to separate the cards from each other. Check that the cards are aligned. 2) Is the card push Plate of the card tray in the lock position? Check the force with which this Plate presses onto the cards. If it is weak, check for spring elongation etc. 3) In the case of 0.25 mm cards, the number of cards which can be set in the tray is limited according to the used cards. Test by trying to set about 50 cards into the tray. 4) Clean the card supply roller with alcohol. Touch the surface to check if it is slippery. 5) Check the thickness of the thickness adjustment plate and the card. Also check for correct thickness adjustment in case of special card thickness (turn the gear of the card supply roller and check for individual card supply). 6) Perform the diagnostic test in service mode and check for operation of the card pickup motor. Also confirm correct operation of intermediate gears. 7) When this message appears at the time of power ON, the sensor is broken. Use the sensor check of service mode for confirmation. 8) Check for contamination of the cleaning roller. Clean the roller if it is dirty. The life of the cleaning roller is about one year. The adhesive power gets lost with use for many years. It is also possible that the roller becomes worn and no longer can feed the cards correctly. 9) After the cleaning roller, the cards are transported by the turnover card feed motor. Perform the diagnostic test of the service mode and check the operation of the turnover card feed motor. 10)Does the turn over unit come to the card supply position (vertical position) at the time of card supply? The pulses of the turnover motor are counted and rotation to the card supply position is done. When the turnover unit is not pointing straight down, the card will not enter the rail and an error will be caused. Perform the diagnostic test in service mode and check the operation of the turnover unit. 11)Check for correct rotation of the roller in the turnover unit. Clean the roller in case of rotation. Perform the diagnostic test in service mode and check the operation of the turnover card feed motor. * Card

Jam (Hopper) Card jam (hopper part)

* Card supply roller * Adjustment

* Motor, Drive circuit board Main circuit board * Sensor, Main circuit board * Cleaning roller

* Motor, Drive circuit board, Main circuit board * Motor, Drive circuit board, Main circuit board

* Motor, Drive circuit board, Main circuit board, roller

52

No. Error item 5 Jam (TurnOver) Card jam (turnover unit)

Error detection contents When the card does not enter to or depart from the sensor inside the turnover unit within a specified time.

Jam (MG) Card jam (encoder)

Jam (Retransfer) Card jam (retransfer section)

When the card does not arrive at the card edge sensor within a specified time after leaving the turnover unit. Also, in case of magnetic encoding, when detection by the start position sensor of the MG unit is not possible. When the card outlet sensor is not reached within a specified time after leaving the card edge sensor.

Treatment contents 1) When this message appears at the time of power ON, the sensor is broken. Use the sensor check of service mode for confirmation. 2) Confirm the operation of the turnover unit until the card reaches the sensor. Perform the diagnostic test in service mode and check the operation of the turnover unit. 3) Check for correct rotation of the roller in the turnover unit. Clean the roller with alcohol in case of rotation. Perform the diagnostic test in service mode and check the operation of the turnover card feed motor. 4) Check that card feed is OK when the turnover unit is oriented in the print mode direction. Perform the diagnostic test in service mode and check the operation of the card feed motor. 1) When this message appears at the time of power ON, the sensor is broken. Use the sensor check of service mode for confirmation. 2) Check the operation until the card enters to the sensor. Perform the diagnostic test in service mode and check the operation of the card feed motor. Check belts, gears, and rollers for wear. Clean the rollers with alcohol. 1) Check if the card sticks to the film. * If the card sticks to the film, check for correct operation of the card cooling fan (rotates only at the time of retransfer). * If the card sticks to the film, replace the film by a different film and try printing. 2) Check the condition of the rubber on the retransfer roller surface. 3) Perform the diagnostic test in service mode and check the operation of the card feed motor. Check belts, gears, etc. 1) When this message appears at the time of power ON, the sensor is broken. Use the sensor check of service mode for confirmation. 2) Check the condition of the rubber on the bend remedial roller. 3) Perform the diagnostic test in service mode and check the operation of the card feed motor. Check belts, gears, out roller, etc. 4) For bend remedy at the time of one-sided printing, there is the temperature setting for the bend remedial roller. Is double-sided printing being done with this temperature setting too high? In this case, the cards may become deformed and jams may be caused, 1) Perform the diagnostic test in service mode and check the operation of the retransfer film supply motor. 2) Perform the diagnostic test in service mode and check the operation of the retransfer film take-up motor.

Exchange parts * Sensor, Main circuit board * Motor, Drive circuit board, Main circuit board * Motor, Drive circuit board, Main circuit board, roller * Motor, Drive circuit board, Main circuit board *Sensor x 2,Main circuit board MG circuit board * Motor, drive circuit board, Main circuit board * Belts, gears, rollers

* Film

* Retrnsfer roller * Motor, Drive circuit board, Main circuit board * Belts, gears * Sensor, Drive circuit board * Bend remedial roller * Motor, Drive circuit board, Main circuit board * Belt, gear, roller

Jam (Discharge) Card jam (discharge)

In case of stopping at the card outlet sensor.

Media Broken Torn retransfer film Media Search Retransfer film detection error

Detection of the retransfer motor rotation condition, pulses, marks, etc.

* Motor, Drive circuit board, Main circuit board * Motor, Drive circuit board, Main circuit board

53

No.

Error item Media Run Out End of the retransfer film

Error detection contents

10 Ink Broken Torn ink ribbon Ink Search Ink ribbon detection error Ink Run Out End of the ink ribbon

Detection of ink motor rotation condition, pulses, marks, etc.

11 Turn Over Unit Defective operation of the turn-over mechanism 12 Heater Cam Defective heat roller operation

Detection of the motor rotation condition and operation of the turnover initicl position sensor. Detection of the motor rotation condition and the cam sensor operation.

Treatment contents 3) The retransfer film take-up motor has a encoder for output of pulses when the motor operates. Perform the diagnostic test in service mode and check the output of the encoder of the retransfer film take-up motor. 4) When this message appears at the time of power ON, the sensor is broken. Use the sensor check of service mode for confirmation. 5) Remove the cassette and confirm the retransfer film installation condition. Confirm that there is no winding deviation or similar to prevent error of the sensor, In case of winding deviation, check the shaft, the bobbin holder, etc. of the retransfer film cassette. 6) If winding eleviation is serious,then replace the retransfer film with a new one. 1) Perform the diagnostic test in service mode and check the operation of the ink supply motor. 2) Perform the diagnostic test in service mode and check the operation of the ink take-up motor. Perform the diagnostic test in service mode and check the output of the encoder coupled with the ink take-up gear. 3) The ink supply motor has a encoder for output of pulses when the motor operates.Perform the diagnostic test in service mode and confirm the output of the encoder of the ink supply motor. (Ink SPY Enc) 4) When this message appears at the time of power ON, the sensor is broken. Use the sensor check of service mode for confirmation. 5) Remove the cassette and confirm the ink installation condition. Confirm that there is no winding deviation or similar to prevent error of the sensor, In case of winding deviation, check the shaft, the bobbin holder, etc. of the ink cassette. 6) If winding eleviation is serious,then replace the ink ribbon with a new one. 1) Perform the diagnostic test in service mode and confirm the operation of the turn over motor. 2) When this message appears at the time of power ON, the sensor is broken. Use the sensor check of service mode for confirmation. 1) Perform the diagnostic test in service mode and confirm the cam motor operation. 2) When this message appears at the time of power ON, the sensor is broken. Use the sensor check of service mode for confirmation of the cam sensor retransfer roller sensor, and remedial roller sensor. 3) Check the cam mechanism etc. 4) Check the installation and the wire routing for retransfer roller and bend remedial roller. 1) When this message appears at the time of power ON, the sensor is broken. Use the sensor check of service mode for confirmation of the no card sensor.

Exchange parts * Motor, Drive circuit board, Main circuit board

* Sensor, Main circuit board * Retransfer film, cassette

* Motor, Drive circuit board, Main circuit board * Motor, Drive circuit board, Main circuit board, INK FG circuit board * Motor, Drive circuit board, Main circuit board * Sensor, Main circuit board * Ink ribbon, Cassette

* Motor, Drive circuit board, Main circuit board * Sensor, drive circuit board * Motor, drive circuit board, Main circuit board * Sensor, drive circuit board

13 No Card There is no card, the tray is empty.

Card presence is detected by a reflection sensor.

* Cam * Roller, wire * Sensor, Main circuit board

54

No. Error item 14 Door open The printer door is open. 15 No Cleaning Ro. There is no cleaning roller.

Error detection contents The door interlock switch is detected.

The cleaning roller interlock switch is detected.

Treatment contents 1) Check that the door interlock switch is pressed normally. When it is pressed normally, the cooling fan on the left side of the printer operates. 2) Check the mechanism pressing the switch. 1) Check that the cleaning roller interlock switch is pressed normally.

Exchange parts * Door interlock switch, Main circuit board * Door * Cleaning roller interlock switch, Main circuit board * Cleaning roller unit * Cassette interlock switch, Main circuit board * Ink cassette, Retransfer cassette * Thermal head * Power supply unit * Main circuit board * Main circuit board * Heater protector circuit board * Heat roller unit

16 No Cassette There is no cassette.

The cassette interlock switch is detected. Ink and retransfer cassette switch are connected in series. Vth (Voltage supplied to the thermal head ) is not determined. Circuit trouble is detected. The temperature of the retransfer roller is detected with a thermistor, and an error is caused when this temperature exceeds about 240C. When this temperature is exceeded, the thermostat operates and the circuit is cut. 1) When the temperature does not rise even after about 30 sec. have passed since heater ON. 2) When the temperature at the time of READY is about 40C lower than the set temperature.

2) Check the mechanism pressing the switch. 1) Check that the cassette interlock switches for ink and retransfer film both are pressed correctly.

2) Check the mechanism pressing the switch. 1) Check that the connector is connected correctly to the thermal head. 2) When Vth power can not be put out from the power supply unit. 3) When the A/D circuit of the analog power circuit board is defective. This is a defect of the heater control system. 1) Analog power circuit board: Defect of the circuit performing A/D conversion for the thermistor. 2) Heater protector circuit board. 3) Heat roller unit: Defective thermistor etc.

17 Hardware

18 TR Overheat Retransfer roller overheat

19 TR Broken Defective retransfer roller

This is a defect of the heater control system. 1) Analog power circuit board: Defect of the circuit performing A/D conversion for the thermistor. 2) Heater protector circuit board. 3) Retranser roller unit: Defective thermistor etc. Thermistor: Measure with a tester - about 220 k at normal temperature and about 1 k at 200C. 4) Measure the thermostat with a tester and confirm a value of about 2 or 3 . The resistance is infinite in case of abnormalities. 5) Defective power supply unit.

* Main circuit board * Heater protector circuit board * Heat roller unit *Heat roller unit

* Power supply unit

20 TR Sensor Broken Defective retransfer roller thermistor

The retransfer roller temperature is detected with a thermistor. When the temperature has dropped about 10C from READY.

Check for a wire break of the thermistor. 1) Thermistor: Measure with a tester - about 220 k at normal temperature and about 1 k at 200C. 2) When the thermistor is normal: Defective analog power circuit board, CPU circuit board.

* Heat roller unit * Main circuit board

55

Error item No. 21 RR Overheat Bend remedial roller overheat

22 RR Broken Defective bend remedial roller

Error detection contents The temperature of the bend remedial roller is detected with a thermistor, and an error is caused when this temperature exceeds about 220C. When this temperature is exceeded, the thermostat operates and the circuit is cut. 1) When the temperature does not rise even after about 30 sec. have passed since heater ON. 2) When the temperature at the time of READY is about 40C lower than the set temperature.

Treatment contents This is a defect of the heater control system. 1) Analog power circuit board: Defect of the circuit performing A/D conversion for the thermistor. 2) Heater protector circuit board: Only the 200 V system is confirmed. The 100 V system is passed through. 3) Heat roller unit: Defective thermistor etc. This is a defect of the heater control system. 1) Analog circuit board: Defect of the circuit performing A/D conversion for the thermistor. 2) Heater protector circuit board. 3) Bend remedial roller unit: Defective thermistor etc. Thermistor: Measure with a tester - about 220 k at normal temperature and about 1 k at 200C. 4) Measure the thermostat with a tester and confirm a value of about 2 or 3 . The resistance is infinite in case of abnormalities. 5) Defective power supply unit. 1) Thermistor: Measure with a tester - about 220 k at normal temperature and about 1 k at 200C. 2) When the thermistor is normal: Defective analog power circuit board, CPU circuit board.

Exchange parts * Heater protector circuit board * Heat roller unit * Main circuit board * Heater protector circuit board

* Heat roller unit * Heat roller unit * Power supply unit * Heat roller unit

23 RR Sensor Broken Defective bend remedial roller thermistor

The bend remedial roller temperature is detected with a thermistor. When the temperature has dropped about 10C from READY. 24 Overcool The TPS0220-001-H Overcooling circuit board has a sensor for detection of the ambient temperature. When detection by this sensor has become impossible. 25 Head Overheat The thermal head has a Head overheat built-in thermistor, and the density is kept constant according to the temperature of the head. When head temperature exceeds 70C 26 EEPROM Broken This unit has two Defective EEPROM EEPROMs. 27 28 29 30 31 32 33 34 35 36 37 Printer CFG Err MG Unconnected MG Mechanical MG Hardware MG Write MG Read MG Communicate EXT.Unconnected EXT.SW Setting EXT.Jam EXT.Communicate

* Main circuit board, Thermistor circuit board

1) Exchange the thermistor circuit board. 2) Analog power circuit board, CPU circuit board.

* Raise circumference temperature. * Cooling fan, Filter

3) When the circumference temperature is 5C or less. 1) Does the cooling fan operate? Check that the filters on both sides are not clogged. In case of clogging, clean or exchange the filters. 2) Does the thermal head cooling fan operate normally? Perform cleaning. 3) In case of reoccurrence, the thermal head is defective. Exchange the head. 1) When the head EEPROM is defective. 2) When the EEPROM on the CPU circuit board is defective. * Thermal head cooling fan * Thermal head

* Main circuit board * Thermal head.

Refer to subsection 3.4 in "MGI encode unit" and subsection 4 in "Large-type IC unit"

56

2. Printing Defects and Countermeasures


Printing defect
The printing result has horizontal lines (pulling wrinkles).

Cause
1) When large areas have been printed with high density. 2) When the back tension is strong.

Countermeasure
1) When large areas are to be printed, set "Default LUT" of maintenance in the service mode to "Standrd" or "Low". 2) Check for smooth turning of the spring of the ink cassette. Disassembly and clean if the spring does not turn smoothly. 3) Check for smooth turning of the bobbin on the supply side. Exchange the cassette if the bobbin is not turning smoothly.

Spring

KXL46255-001

11

Bobbin holder for supply

4) Check for a heavy load of mechanism, motor, etc. on the ink supply side. No transfer to the left or the right side of the card. 1) Retransfer position is wrong. 2) Card stop position is wrong. 1) Confirm if the operation of the card edge sensor and the film sensor is normal, and if these sensors are firmly secured. 2) When sensors are replaced, setting Offset Trf X for the film sensor and/or setting Offset Card X for the card edge sensor shall be adjusted.

Large card bend (in case of single-sided printing)

Heat deformation occurs easily especially with PVC cards.

(in case of double-sided printing)

1) The environmental temperature to use is adjusted to the temperature range of specification. If this is still not sufficient, additionally lower the temperature setting for the retransfer roller to reduce deformation by heat. 2) Adjust the temperature setting and the cooling time setting for the bend remedial roller. 3) When double-sided printing is done with the temperature setting for the bend remedial roller set to a high value, the cards will become deformed. When the card is deformed with a convex face and a concave reverse-side, make the reverse retransfer speed higher or change the setting of the bend remedy mode.
57

Printing defect
Characters or photos appear as double images.

Cause
The ink ribbon feed system is not constant.

Countermeasure
1) Use the off-line test of service mode to print registration patterns. Confirm that the horizontal and vertical lines are within two dots. 2) Check the take-up condition of ink ribbon and retransfer film. If the take-up is not uniform, check the condition of the shaft of the ink cassette. 3) Check that ink ribbon and retransfer film are set correctly when they are installed in the cassette. For the retransfer film, check that the film is in the guide. 4) Check that the platen solenoid is pulled completely. 5) Check the belt tension and the screw tighteness of the drive pully on the retransfer film supply motor.

Defective registration

Some part is not transferred correctly (remains on the film side).

1) The card is dirty. 2) The use environment temperature is low. 3) The card material is not suitable.

1) Check that the card surface has not been touched with bare hands. 2) Use the unit at a higher use environment temperature. 3) Raise the temperature setting for the retransfer roller. 4) Lower the retransfer speed. 5) Wipe the card surface with alcohol. 6) In case of small retransfer defects, check for dirt and dust. * Cleaning roller * Fan and filter

(Retransfer defect)

There are white lines in the printing result or the printing is thin.

Defective thermal head.

1) Clean the thermal head. 2) When perfectly white lines occur, there are some broken heater element and the head must be exchanged. 3) When the same pattern is printed continuously, only those lines become thin.

58

Printing defect
The picture position is shifted vertically or horizontally.

Cause
1) Setting of the retransfer film 2) Ink ribbon, retransfer film 3) Card

Countermeasure
1) Refer to page 31 of the instruction manual and check the film type setting. 2) Check the winding condition of the ink ribbon and the retransfer film. If the winding is not uniform, check the condition of the shaft of the ink cassette. 3) In case of preprinted cards, use "Offset Prt Y" or "Offset Trf X" of maintenance in service mode to adjust the position to that design.

123456789 123456789

123456789

123456789

Resin characters are blurred Resin characters are thin. Resin characters are missing parts.

1) Character font 2) Head or platen roller wear

ABCDE

ABCDE

ABCDE

1) When small characters are printed with a fine font, the characters may become blurred or may be missing some parts. In such a case, increase the character size or use bold characters. In case of using small characters due to print image design , refer to page 30 of the instruction manual. 2) When the head or the platen roller is worn out due to long time use, characters may be printed with some parts missing. In that case replace with a new head or platen roller.

* Resin character : When a character is printed in black ink.

The printing result shows white spots.

1) 2) 3) 4)

Dust on the card Dirty cleaning roller Dirty internal rollers Dirty filter

This case occurs with printing to film. (This is different from defective retransfer.) 1) Remove any dirt from the cards. 2) Clean the cleaning roller. Exchange the cleaning roller if needed. 3) Clean the internal rollers with cleaning card. 4) Clean the fan filters. Exchange the filters if needed. 5) When this occurs every time at the same position in horizontal direction, a dent in the platen roller or retransfer roller can be considered.

59

Printing defect
Lines appear. (In case of lines at uniform intervals)

Cause
1) Uneven feed.

Countermeasure
1) When this is notable with thin background colors, the ink ribbon is not being wound uniformly. Check the ink take-up motor and the mechanism. Check for smooth rotation of the bobbin holder of the ink cassette.

(In case of random occurrence)

1) When this is notable with normal printing, the ink cassette has not been inserted completely. Confirm that it has been inserted until a cassette button locks.

60

3. Power Supply Check


1. The power supply unit outputs the following four kinds of voltages.
Source Device 5V 12V 24V Vth Power Supply Unit Power Supply Unit Power Supply Unit Power Supply Unit H.T.Protector Target PWB MAIN MAIN MAIN MAIN DRIVE DRIVE DRIVE FRONT FRONT Usage 5V Logic IC Analog IC (Amp, Comp etc) Actuator Thermal Head

2.

The voltages output from the power supply unit can be checked with the LEDs on the PWB of the unit.
The LED lights only during printing. The LED lights when the ink cassette and film cassette are present and the door is closed. The LED lights when the power switch is ON.

1) Vth: 2) 24 V: 3) 5 V:

TOP

5V 24V Vth

3.

The voltages generated in the MAIN PWB are output to their target PWBs. For details, see the overall block diagram.
3.3V 1.9V 2.5V 5VREF 3.3VREF Shunt Regulator (12V to 5V) Regulator IC (5V to 3.3V) Regulator IC (5V to 1.9V) Regulator IC (5V to 2.5V) CPU CPU CPU CPU USB IF MAIN MAIN DRIVE 3.3V LV IC (CPU, Memory etc) CPU(only) FPGA(only) Reference Voltage (ADC etc) Reference Voltage (ADC in CPU (only))

61

MAINTENANCE INSPECTIONS
1. Cleaning
The following parts should be cleaned as instructed of the list when you repair the unit. No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 Thermal head Cleaning roller Feed roller Card feed rollers Platen roller Fan filters (three places) MG head Bobbin inner Shaft of Ink Cassette / Film Cassette Bearings of each rotating part and around them Card housing of hopper and around it Interior of hopper Inner side of front door, cassette slot Dust inside set and on inner side of top cover

Part name

Cleanning metod
Clean with alcohol .(dehydrated ethanol.) Wash it after repair. Clean with alcohol .(dehydrated ethanol.) Use alcohol (anhydrous alcohol), or use a cleaning card and then implement CLEANING in USER MODE. Clean with alcohol. (dehydrated ethanol.) Clean with the vacuum cleaner etc. Use a cleaning card. Clean with the vacuum cleaner etc. Alcohol (Use anhydrous alcohol) Clean with a vacuum cleaner, or wipe with a dry cloth Clean with a vacuum cleaner, or wipe with a dry cloth Clean with a vacuum cleaner, or wipe with a dry cloth Clean with a vacuum cleaner, or wipe with a dry cloth Remove the top cover, then clean the dust on the inner side and inside the set with a vacuum cleaner. Film cassette(green) Apply the grease by four grains of sesame between the white sheet and the spring of the bobbin.And rotate the bobbins to make the grease uniformly spread over the white sheet.Wipe out the excessive grease. Supply bobin (green)

2. Lubrication
Apply the grease as illustrated to the ink ribbon cassette after every 5,000 pcs of cards are printed. There is no need for periodic application of oil or grease except this parts , but application should be made to the new parts at the time of parts exchange. When the oil or grease on the opposite part appears dirty, wipe it off and apply new oil or grease. Caution Refer to the "Parts table" in the disassembly drawing for the locations for application of oil or grease and the oil or grease to be used.

3. Maintenance Inspections for Main Parts and Execution Standard


This standard table applies for standard conditions, and there may be large differences according to the use environment and the use conditions. When the maintenance inspections are not performed suitably, the following times will not only be shortened considerably, but there may also be other bad influences. However, deformation or ageing may occur for rubber parts also when they are stored or not used for a long time. Part No.
CX320-HD1 TFS0116-002 TSS0181-002 TSS0182-002 CX220-FFK1 KEF1041-002 CX220-FAN2 KEF1037 KEF1042-002 CX220-PIM1 CX220-INW1 CX220-INS1 CX220-MWM1 TSS0179-002 KJY32771-045 KJY32771-030 KJY32771-044 KJY32771-032 KJY32771-035 62

Part name
Head assembly C.L. roller assembly Heater assembly Reform heater assembly Fan filter assembly Suction Card cooling fan Head cooling fan Ventilation Card pick up motor Ink take-up motor Ink supply motor Film take-up motor Platen solenoid Timing belt Timing belt Timing belt Timing belt Timing belt

Replacement
30,000 screens About one year 2,000 hours 2,000 hours About one year 40,000 hours 20,000 hours 40,000 hours 40,000 hours 200,000 cards or more 180,000 screens 180,000 screens 120,000 screens 100,000 screens 100,000 screens 100,000 screens 100,000 screens 100,000 screens 100,000 screens

Remarks
At the time of YMCK printing Half a year with a high use frequency With power save OFF With power save OFF

Operates only for retransfer.

DC motor DC motor DC motor DC motor Belt for film supply motor and card feed motor Belt for card feed motor Belt for card feed motor Belt for card feed motor Belt for card feed motor

4. Periodic Inspection Items


In case of performing periodic inspections by means of a maintenance contract, please use a copy of the following sheet.
No. Item 1 Checks before the inspection Inspection contents Serial No. Total No. of prints. Head printing colors. Confirmation of the take-up condition for ink ribbon and retransfer film. Sample data printing (operation confirmation before the inspection). 1. Color pattern 2. Step pattern. Both sides, one card each Inspection contents Check that the card passage opening permits only a single card to pass. Check the operation of the card push lever. Check for deformation of the lever of the supply tray detection switch. Inspection standard Work contents Remarks (Cleaning, exchange, adjustment) prints No. of normally discharged cards colors Counted for each color Uneven winding within 2 mm Registration within 2 dots. No thermal head wire break. Inspection standard Work contents Remarks Supply of only one card Thickness switching plate Push lever Check for smooth movement when moved by hand. Switch An error is caused when the tray is removed.

No. Item 2 Related to the supply tray No. Item 3 Cassetterelated No. Item 4 Related to the turn unit No. Item 5 Roller-related

Inspection contents Inspection standard Work contents Remarks Check for a bent or broken cassette shaft. No visual abnormalities Cassette Check the rotation of the bobbin holder of the cassette. Check for smooth movement when moved by hand. Cassette Is the grease applied between the white sheet and the spring periodically.(every 5,000pcs cards) Check for uneven feed Gray pattern Inspection contents Use the turn unit motor test in service mode to turn the turn unit. Inspection contents Check the card supply feed roller surface for damage and deterioration and clean it. Check the surface of the cleaning roller for damage, check the adhesive power, and clean it. Check the surface of the roller in the turn unit for damage and deterioration and clean it. Check the surfaces of the six card transport main rollers for damage and deterioration and clean them. Check the surface of heat roller for damage and deterioration. Remove the bend remedy roller and check the surface for damage and deterioration. Clean the platen roller and finally print a gray pattern and check for white on a colored background. Inspection contents Disassembly/cleaning of the platen solenoid Cleaning of the thermal head Inspection contents Clean the slit of the ink start position sensor with a cotton swab. Cleaning of the disk and the sensor for detection of the ink feed amount Perform the "Ink Tup Enc" test in service mode. Perform the "Ink SPY Enc" test in service mode. Perform the "Media Tup Enc" test in service mode. Inspection contents Confirm that the head cooling fan is operating at all times. Confirm operation of the card cooling fan at the time of film separation at the time of retransfer operation. Confirm that the suction fan is operating at all times. Confirm that the ventilation fan is operating at all times. Clean all filters. Inspection contents Check the motor with the ink take-up motor test in service mode. Check the motor with the ink supply motor test in service mode. Check the motor with the retransfer film take-up motor test in service mode. Check the motor with the card pick up motor test in service mode. Inspection contents Check all belts for stretching and lost teeth. Inspection standard Smooth operation of the turn unit Work contents Turn unit Remarks Card supply roller With normal use, the life is about one year. Remarks

Inspection standard Work contents There shall be a peak. There shall be adhesive power after cleaning. No visual defects No visual defects No visual defects No visual defects There shall be no white on a colored background. Inspection standard Smooth movement of the plunger No visual dirt Inspection standard Start from Y of the ink No color deviation No error No error No error Inspection standard Operation at all times Operation at the time of retransfer Operation at all times Operation at all times No clogging Inspection standard Smooth rotation at the time of start Smooth rotation at the time of start Smooth rotation at the time of start Smooth rotation at the time of start Inspection standard No elongation or lost teeth Inspection standard Cleaning No errors. No scratches. Work contents

Exchange when the life has been exceeded. Exchange when the life has been exceeded. Platen Remarks Exchange if the life has been exceeded. The life is 30,000 screens. Remarks

No. Item 6 Head-related No. Item 7 Sensorrelated

Work contents

No. Item 8 Fan-related

Work contents

Remarks

With normal use, the life is about one year. Work contents Remarks The life is about 180,000 screens. The life is about 120,000 screens. The life is about 200,000 cards. Work contents Work contents Remarks Remarks

No. Item 9 Motor-related

No. Item 10 Belt-related

No. Item Inspection contents 11 MG-related Perform MG head cleaning in user mode. (when built in) Perform the read/write test for the MG encoder in service mode. In this case, there shall be no scratches to the stripe. No. Item 12 IC-related No. Item 13 Printingrelated

Inspection contents Inspection standard Perform the contact ON/OFF test for the contact IC encoder in service mode. Contact cleaning Disassembly/cleaning of the contact ON/OFF solenoid Cleaning Inspection contents Measure the position of an enclosure line. Check that there is no uneven density of the Vth pattern. Resin black confirmation Confirm that there are no wrinkles. Check that there are no scratches and no dirt. Check that there are no retransfer defects. Check for feed deviations. Inspection standard X= , Y= Check for uneven density. Black ink confirmation No wrinkles No scratches, no dirt No retransfer defects No notable feed deviations. Inspection standard Error display on the LCD. Error display on the LCD. Inspection standard Communication test Registration within 2 dots. No thermal head wire break.

Work contents

Remarks

Work contents

Remarks Color pattern Vth pattern Black pattern Step pattern

Gray pattern Work contents Remarks

No. Item Inspection contents 14 Interlock-related Check that the buzzer sounds when the printer door is opened. Confirm the following operations. 1. Cassette 2. Cleaning roller unit 3. Card tray No. Item 15 Final confirmations Inspection contents Perform printing of sample data from the personal computer (several cards continuously). Printing of sample data (for storage) 1. Color pattern 2. Step pattern, one card each Final cleaning. Switch off the power and clean the cleaning roller.

Work contents

Remarks

63

5. Trouble Diagnosis Sheet


When there has been a repair request from a user, copy the following sheet and distribute it to the users to increase the repair efficiency.
Entry date: Installation location: Trouble reception Date: Trouble item Defective printing Symptom Superimposed printing of characters or photos Blurred characters or photos Tel. No. or fax No. Unit serial No. Person in charge Printer print counter value TOTAL HEAD Occurrence frequency Sometimes ( / ) Always At the time of film exchange (before, after) Unknown Sometimes ( / ) Always At the time of film exchange (before, after) Unknown Sometimes ( / ) Always At the time of film exchange (before, after) First time in the morning Unknown Sometimes ( / ) Always At the time of film exchange (before, after) Unknown Sometimes ( / ) Always At the time of film exchange (before, after) First time in the morning Unknown

Concrete contents *Mark close symptoms with a circle, and not applicable draw a simple sketch in the frame.

Lines or wrinkles appear in the characters or photos.

Screen position deviation in vertical direction (about mm) Screen position deviation in horizontal direction (about mm)

a
123456789

b
123456789

c
123456789

d
123456789

Blurred characters Smudged characters Missing parts of characters Ink serial No. ( ) Missing printing or color as caused by sticking dirt Comparatively large missing printing Nothing is printed. The film is/is not transferred. (Large missing parts) Film serial No. ( ) Card jam Where did the card jam occur? Mark the location in the figure on the right.

ABCDE
a

ABCDE
b

ABCDE
c d

Retransfer film cassette

Ink ribbon cassette

Thermal head Magnetic head Card turn table Card feed roller

Cleaning roller Card supply roller

Retransfer roller (heat roller) Bend remedy roller (heat roller)

Others

Enter the symptoms as concretely as possible.

Provide more details in regard to the conditions at the time of occurrence. 1. LCD error message ( ) 2. At what kind of operation did the trouble occur? At the time of power ON During continuous printing At the time of ink ribbon/film exchange After card supply After the installation conditions had changed because of a layout change etc. Others ( ) 3. Occurrence frequency Continuously Sometimes Unknown 4. Has the same trouble occurred in the past? First time Yes

64

ADJUSTMENT
1. Layout of the adjustment elements
Main circuit board

VR1 GND

REAR MAIN PWB VR1 Reference voltage for thermal head automatic adjustment

2. Adjustment
1) Never turn VR1 on the main circuit board . The service repair circuit board has been adjusted before shipping.

3. Caution Items for the Time of Exchange of the Main Circuit Board
1) When the main circuit board is exchanged, the user mode and service mode settings must be stored on the new circuit board. For details, refer to the item "2.6 Parameters Push/Pop" of service mode. 2) For the other circuit boards and units, there is only exchange.

65

MG ENCODING UNIT
1. MG Encoding Specifications
1.1 Magnetic Encoder Specifications
1) Suitable cards (1) Type ID-1 magnetic stripe cards as specified in ISO 7810, 7811, 7812 Coercivity : Hi-co : 218 x 103 A/m (2750 Oe) (high coercive force) Lo-co : 238 x 102 A/m (300 Oe) (low coercive force) Recording density : Track 1, 3 : 210 bpi 10% Track 2 : 75 bpi 5% Recording method : F2F modulation (specified in ISO 7811/7812) Card dimensions : 85.6 mm x 54.0 mm x 0.76 mm 2) Suitable cards (2) Type JIS-II magnetic stripe cards as specified in JIS-X6301/6302 Coercivity : Lo-co : 515 x 102 A/m (650 Oe) (low coercive force) Recording density : 210 bpi 10% Recording method : F2F modulation (specified in JIS-X6302) Card dimensions : 85.6 mm x 54.0 mm x 0.76 mm 3) IC encoder specifications Suitable cards : IC cards with external terminals as specified in ISO 7816 Contact specifications : 8 contacts (corresponding to ISO 7816 specifications)

1.2 General Equipment Specifications


External dimensions : 140 (W) x 260 (D) x 170 (H) mm Mass : 1.5 kg (only MG unit) Card feed speed : 150 mm/s 10% Power supply : DC 5 V 5% 0.3 A, DC 24 V 5% 1.6 A Use environment conditions: Temperature: 15C to 30C Humidity : 35% to 70% Storage environment conditions: Temperature: -15C to 55C Humidity : 20% to 80%

66

2. Block Diagram
2.1 MG Unit Block Diagram
Serial Port

Main PWB

CN1

Printer I/F SW1

MG MAIN PWB

SW2

SW3

CPU H8/3039F

LED

Micro SW

5V

Error

(for Test)

MG Encode Curcuit

Solenoid Drive

Motor Drive

J3

J7

J4
J6 (Only producton line use)

J5

C-PWB
CN9 CN8 CN11 CN10 CN12

B-PWB

F- PWB

Motor

MG Write Encode sensor

CN6 CN7 CN5

E-PWB

(JIS)

MG Head(ISO)

Card Contact

Contact

I/F

IC Card

DC Power

Head detect sensor x3

PWB

Encode PWB

< User Option>


Solenoid Drive PWB Main PWB

67

Serial I/F

DRIVE PWB

MAIN PWB

J10 J9

J14

J15

MG/IC BLOCK
MG MAIN PWB

CN01 J1 J7
CONTACT IC ENCODER PWB (OPTION)

CN10 ICC02

J8

J3

J4

J5
A

CN10 CN9 CN12 CN11 CN8


Relay PWB

KWH4139-10
Head Sensor Head Sensor Head Sensor

2.2 Connection Diagram

Sensor PWB
CN13

Sensor PWB Sensor PWB


CN1

Contact PWB
CN2 CN3 J CN4

CN6 CN5 CN7

Head I/F PWB I Card Sensor Stepping Motor B C

210 Encode Sensor

75 Encode Sensor

Solenoide IC Contact

ISO MG Head

PRINTER UNIT

68

3. MG Encoding Unit Exchange Method


3.1 Repair Classification
For the repair of MG encoding unit, send-back the whole printeri ncludeing the MG encoding unit to the factory .

3.2 Exchange Method


For each MG unit, the track position (TRK), the IC contact position (IC), and the MG write start position (STX) are different. Accordingly, when the circuit board or the MG unit has been exchanged, the DIP switches on the MG main circuit board must be switched. The DIP switch specifications are shown on the next page.

1. Check the contents of the seal on the MG unit. 2. Switch the DIP switches.
1) TRK position Switch the bits 1 to 4 of SW2 on the MG main circuit board. Set the switches with a black mark to ON. 2) IC contact position Switch the bits 5 to 8 of SW2 on the MG main circuit board. Set the switches with a black mark to ON. 3) STX position Switch the bits 1 to 4 of SW3 on the MG main circuit board. Set the switches with a black mark to ON.

3. Install the MG main circuit board or the MG unit in


the printer. Depending, on the way how the MG unit was installed, an error in the value of track position may happen. In that case, confirm of each value and re-adjust in the following steps.
Seal

ISO
TRK SW1 - 2 - - ON SW2 1 2 3 4 ON IC SW2 5 6 7 8 ON STX SW3 1 2 3 4 ON
KXL46276-004

JIS
or
TRK SW1 - 2 - - ON SW2 1 2 3 4 ON IC SW2 5 6 7 8 ON STX SW3 1 2 3 4 ON
KXL46276-005

69

4. Execute the MG read/write test after selecting MG(JIS/ISO) in the Test Select(Off-line Test of Service mode).
Apply the magnetic medium developing liquid on the magnetic stripe of the tested card so as to be able to see the track. And confirm that the positions of the tracks are within the specification, by measuring with slide calipers. If out of the specification, compensate the values according to the DIP. Switch Specifications. When the setting of DIP. Switch is changed, turn the power off and on, and execute the read/write test again to re-confirm of the track positions.

Specification

a: 5.66mm or less b: 8.46~8.97mm c: 8.46~8.97mm d: 11.76~12.27mm e: 12.01~12.52mm f: 15.32~15.82mm


1st track magnetic stripe

Card edge a b c d e f

ISO Track Position

measure at the center (holizontal direction)

2nd track magnetic stripe 3rd track magnetic stripe

Specification JIS Track Position

a: 6.3mm or less b: 6.0mm or more c: 11.7mm or more

Card edge a 1st track magnetic stripe c b

measure at the center (holizontal direction)

5. Confirm IC contact position in the following steps.


Attach the contact label(KXL46372-001) on the IC chip of IC card. Use the service mode Off-line Test to execute IC Contact Test. After completing the test, measure the contact scratches on the contact label with slide calipers and confirm that they are within the specification. If out of the specification, compensate the values according to the DIP. Switch Specifications.When the setting of DIP. Switch is changed, turn the power off and on, and execute the IC Contact Test again.
CONTACT LABEL:(PART NO.KXL46372-001)

Specification
direction c d e f

IC Contact Position

direction a b

a : 10.25~12.25 mm b : 17.87~19.87 mm c : 19.23~20.93 mm d : 21.77~23.47 mm e : 24.31~26.01 mm f : 26.85~28.55 mm

70

3.3 DIP Switch Specifications


SW1 No 1 3 4 5 6 7 8 SW2 No 1 2 3 4 5 6 7 8 IC card stop position adjustment Specifications MG card stop position adjustment (TRK) Fixed to ON Specifications MG head select

MG head select No.1 ON OFF

2 MG card stop position adjustment (TRK) SW1No.2 ON ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF No.4 ON OFF Track TRK minus direction No.5 ON OFF ON TRK plus direction OFF ON OFF ON STX plus direction STX minus direction OFF No.8 ON SW3 No 1 2 3 4 STX position adjustment Specifications OFF No.1 ON OFF ON OFF ON OFF ON OFF No.4 ON OFF

Never touch the bits 2 to 8. Head specifications Always use the unit with these ISO head installed switches set to ON. When these switches are set to OFF, JIS head installed an MG-related error will be caused at the time of power ON.

MG card stop position adjustment (track position) No.1 Adjustment value (mm) No.2 No.3 ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON ON ON OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5

MG card stop position adjustment Adjustment direction Plus direction Minus direction No.6 ON ON OFF OFF ON ON OFF OFF No.7 ON ON ON ON OFF OFF OFF OFF Adjustment value (mm) 0 0.2 0.4 0.6 0.8 1 1.2 1.4

IC card stop position adjustment (IC contact position)

IC card stop position adjustment Adjustment direction Plus direction Minus direction No.2 ON ON OFF OFF ON ON OFF OFF No.3 ON ON ON ON OFF OFF OFF OFF Adjustment value (mm) 0 0.25 0.5 0.75 1 1.25 1.5 1.75

STX position adjustment (data write start position)

STX position adjustment Adjustment direction Plus direction Minus direction

71

3.4 MG-related Error Messages


There are four LEDs on the MG main circuit board. The error contents and the countermeasures are explained according to the lighting of these LEDs.
No LCD indication on the printer 1 2 Door Open MG Unconnected LEDs on the MG main circuit board D1 D2 D3 D4 Cause Printer door open DC 24 V wire break Treatment 1) Close the printer door. 1) Does the power supply unit put out 24 V? 2) Is the I/F cable connected correctly? 1) Is the flexible wire deformed? 2) Defective MG head feed motor or sensorrelated defect. 3) Defective MG main circuit board

MG Mechanical

Mechanical error

MG Hardware

Hardware error On the side of the MG unit 1) Clean the MG head. 2) Check the stripe of the MG card for scratches. Card Scratches are caused for new cards MG head 3) Is the flexible wire deformed? 4) Check the DIP switch settings on the MG main circuit board. 5) Defective MG main circuit board 6) Life of the MG head On the side of the printer 1) Check the setting direction of the MG cards 2) Confirm the Hico and Loco settings. 3) Defective drive circuit board 4) Confirm the operation of the card feed motor. 5) Check the card feed roller for dirt and clean as required. 6) Is there burr or similar at both ends of the MG stripe?

MG Write

MG write error

MG Read

MG read error 1) Is the I/F cable connected correctly? 2) Defective MG main circuit board Communication error 3) Confirm the DIP switch settings on the MG with the printer main circuit board. On the side of the MG unit 1) Confirm the DIP switch settings on the MG main circuit board. 2) Defective MG main circuit board 3) IC contact life 4) Defective IC I/F circuit board On the side of the printer 1) Confirm the IC card setting direction. 2) Defective drive circuit board 3) Confirm the operation of the card feed motor. 4) Check the card feed roller for dirt and clean as required.

MG Communicate

No error message (when an error has been detected on the side of the personal computer)

IC encoding error

: Blinking

: OFF

72

LARGE IC UNIT
1. Removal of Each Part
1.1 Removal of the Top Cover
The top cover can be removed after the nine screws (3) have been removed.
3 QYSDSP3006Nx5

1.2 Removal of the Front Panel


The front panel can be removed after the four screws (15) have been removed.
3
QYSDSP4008Nx4

1.3 Removal of the Mechanical Unit


The mechanical unit can be removed after the six screws (16) have been removed. Remove the mechanical unit for solenoid exchange.

1.4 Removal of the IC Main Circuit Board


1) Remove the two screws (17). 2) Disconnect the connectors from the circuit board and pull the circuit board to remove it.

15
QYSDSP3006Nx2

Caution
Before exchange, set the DIP switches SW1 and SW2 according to the circuit board setting.
BASE SA

15
QYSDSP3006Nx2

QYSPSPD3006Nx2

IC MAIN PWB SA

16
QYSPSPD 3006Nx2 QYSPSPD3006Nx2
CN6 CN7 CN3

16

17

CN6 CN7

CN3

16
QYSPSPD3006Nx2

1.5 Others
For removal of other parts, refer to the Parts table.

73

2. Block Diagram
PRT I/F SERIAL1 SERIAL2

CN1

5V

Error LED

SW1

SW2

IC MAIN PWB
CN3/CN8 CN4/CN9 CN5/CN10

DC5V DC12V DC24V

CPU H8/3039F

DC24V
CN7

Motor

Motor Drive

CN12

Solenoide Drive
CN11 CN13 CN6

PWB

Antenna Card Position Sensor Card IC Contact


PWB

Contact

DC Power

Serial I/F

Antenna

IC Card Encode PWB (Contact or Contactless)

<User Option>
Solenoid

74

3. DIP Switch Specifications


3.1 Specifications
Do not touch bits 1 to 4 of SW1 and SW2. Always use the unit with these bits set to ON. When these are set to OFF, an IC-related error will be caused at the time of power ON.
SW1 No 1 2 3 4 5 6 7 8 IC card stop position adjustment Fixed to ON Specifications Contact IC card stop position adjustment No.5 ON OFF No.6 ON OFF ON OFF ON SW2 No 1 2 3 4 Fixed to ON Specifications OFF ON OFF Adjustment direction Plus direction Minus direction No.7 ON ON OFF OFF ON ON OFF OFF No.8 ON ON ON ON OFF OFF OFF OFF Adjustment value (mm) 0 0.18 0.36 0.54 0.72 0.90 1.08 1.26

Contact IC card stop position adjustment

3.2 IC Card Stop Position Adjustment


This adjustment is required when the positioning sensor for contact IC cards or the IC contact has been exchanged.

1. Contact label is attached on the IC chip.

CONTACT LABEL:(PART NO.KXL46372-001)

2. Use the service mode Offline Test to test the external IC unit. Repeat the test 2 or 3 times, so that contact scratches
can be observed easily.

75

(Standard)

direction c d e f

direction

a b

a : 10.25~12.25 mm b : 17.87~19.87 mm c : 19.23~20.93 mm d : 21.77~23.47 mm e : 24.31~26.01 mm f : 26.85~28.55 mm

3. After completion of the test, measure the contact scratches on the CONTACT LABEL with slide calipers and confirm 4.
that the above a and f are within the standard. When the values of c to f are outside the standard, first set the direction with bit 5 of SW1, and then set the adjustment value with bits 6 to 8. The value of c to f can be adjusted, and "a" and "b" are only checked because it cannot adjust.

4. Error Messages
No 1 Printer LCD indication EXT.Unconnected IC unit LED (D1) Lit Cause Disconnection 24V line 1) 2) 3) 1) Treatment Is the printer I/F cable connected correctly? Defective IC main circuit board Is 24V output by the printer? Are the DIP switch settings on the IC main circuit board correct? 2) Defective IC main circuit board 1) Is card feed performed correctly? Card feed motor Defective IC main circuit board Defective card position sensor Dirty feed roller 1) Is the printer I/F cable connected correctly? 2) The IC main circuit board or the analog circuit board of the printer unit is defective. (Caused by connecting/disconnecting the printer I/F cable while the power is on,) 1) Are the DIP switch settings on the IC main circuit board correct? 2) Confirm the IC card setting direction. 3) Defective IC main circuit board 4) Check the card feed roller for dirt and clean

EXT.SW Setting

Blinking

Switch setting error

EXT.jam

Blinking

Jam error

EXT.Communicate

Blinking

Communication error with the printer

No error message (when an error has been detected on the side of the personal

Not lit

IC encoding error

76

5. Specifications of Connector on the IC Main Board


Printer I/F Connector (CN1)
Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Type I I I O O I Signal GND RxD nFWD nRST GND GND DC24V DC24V TxD nMODE DC12V DC5V GND DC24V Send Data Control Signal for CPU STATUS 0V Receive Data Control Signal for CPU Reset Spec.

5V DC Connectors (CN3/CN8)
Pin 1 2 Name DC5V GND (max 500mA Unit Total)

12V DC Connectors (CN4/CN9)


Pin 1 2 3 Name DC12V N.C GND (max 300mA Unit Total)

24V DC Connectors (CN5/CN10)


Pin 1 2 Name DC24V GND (max 1mA Unit Total)

IC Encode PWB I/F Connector (CN11)


Pin 1 2 3 4 5 6 7 8 9 10 Name GND Card set Signal 5V supply voltage Signal ground Reset Supply Voltage Clock Data RFU RFU Short GND CTL VCC GND RST VPP CLK I/O (C2) (C6) (C3) (C7) (C4) (C8) (C1) Chip card

77

EXPLODED VIEW AND ASSEMBLY LISTS


ATTENTION
Parts marked with ! are very important in terms of safety. When replacing any of these parts, be sure to use only the specified parts to maintain safety. We do not supply any parts that are not listed or show a "-" in the parts column. This price may be changed to reflect fluctuations in the market price. There is a label on the rear panel of the printer which lists the version of the mechanism and power supply. When placing an order for a part, be sure to check the version before ordering to avoid any possible incompatibilities.

MECHANICAL REV. 1 2 3 4 5 6 7 8 9 A B C

ELECTRICAL REV. KXL46226-001 1 2 3 4 5 6 7 8 9 A B C

For example, in the above-mentioned case, the revision notation for the parts table is "M-B4".

78

< HOPPER ASSEMBLY


8 9
About 0 - 2 mm from the top. Long side

19
PICK UP SA Explanation drawing 1

15
Hook to case.

Explanation drawing 1 PICK UP SA

16

16

16 3

CARD CASE SA Explanation drawing 2 (-002) Screw thread on the tip

Outside

17 4 16

17

(-002)

12

Hang it on TOK BEARING after hooking the both end.

14 12

13

7 6 5 6

10 18

Attachment position of the slide sheet Match here with the position of embossing.

Approx. 35 mm

Explanation drawing 2 CARD CASE SA

Stick it to 0 - 1 mm inside embossing, and not to overflow embossing

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

PART NO. KJM34161-A01 KJV45558-A0A CM46294-00A KJJ46271-002 KJP10891-D01 KJZ46403-A01 KXL34095-A01 KJM33100-001 KJM33101-001 KJD45577-001 KJY45486-001 QYWLS61C215N KJS33103-A03 QYSPSPD3006N QYREE5000X KJY44486-002 0081 KXC44641-001

REVISED PART NO. Rev.

PART NAME PICK UP ROL BASE PICK UP ROLLER ONE WAY GEAR ASY TAP. SCREW CARD CASE SLIDE SHEET CARD SET LABEL SLIDER CARD PUSH HOPPER SHAFT TOK BEARING LOCK WASHER TENSION SPRING ASY SCREW E RING OIL BEARING STRIKE2 CAUTION LABEL

PRICE

QTY 1 1 1 2 1 2 1 1 1 1 1 1 1 1 4 2 1 1

DESCRIPTION

79

< HOPPER ASSEMBLY


7
PICK UP BASE

0.76

Explanation drawing 1

0.25

11

10

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

PART NO.

REVISED PART NO. Rev.

PART NAME

PRICE

QTY

DESCRIPTION

KJP45490-B01 KJM45489-B02

SEPARATOR PLATE SEPARATOR

1 1

KJJ46271-004 QYSDSP3006N

ASY SCREW SCREW

1 1

80

< FRAME ASSEMBLY

11 11 7 3 5 7 10

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

PART NO. KJP22167-D0A KJM33124- A01 KJM33124-A02 KJS33103-002

REVISED PART NO. Rev.

PART NAME PLATE F ASY CASSETTE BUTTON CASSETTE BUTTON TENSION SPRING

PRICE

QTY 1 1 1 2

DESCRIPTION

YMC-05-H-0 QYREE5000X

MINI CLAMP E RING

1 2

81

< FRAME ASSEMBLY


Explanation drawing 1

17

Apply the bond to the three claws of a sensor.

10
DUCT FRAME SA

10 3

1
Apply a bond not to overflow downward.

18

19 10

20

TPS0248-001-F

15 10 29
KWS0764-002 1 9 KWS0614-003

x2

Match four corners with the hole on the BKT.

22

6 14 10 5

21
(Connector of 9-pin side)

Explanation drawing 6 F1 R F1 1p FRONT SENSOR SA

Explanation drawing 2 CENTER FRAME SA

11

24

INK FRAME SA Explanation drawing 4

(Side view)

HEAD RAIL SA Explanation drawing 3

7 8
Clamp

14 27

13
Explanation drawing 7

Sticking

13
Sticking

13

Sticking

SYMBOL NO. 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

PART NO. KJP33126-C01 KJP33127-B01 KJP33128-B01 KJP22165-B01 KJP46606-001 KJP33145-B01 KJP33132-B01 KJJ46271-003 QYSPSPD3020N KJZ45597-A01 YMC-05-H-0 LWS-1.5MS -----KJP45512-C01 GP1S09J0000F TPS0248-001-F KWS0614-003 KWS0764-002 CX220-FAN2 KJP33142-B01 KJZ45597-A02

REVISED PART NO. Rev.

PART NAME DUCT A DUCT B DUCT FRAME CENTER FRAME STOPPER PLATE INK FRAME HEAD RAIL TAP SCREW ASY SCREW BRUSH MINI CLAMP LOCKING WIRE SA BOND SENSOR BKT PHOTO SENSOR CL.ROL.INTER.SW PWB WIRE ASY WIRE ASY FAN MOTOR FAN BKT BRUSH

PRICE

QTY 1 1 1 1 1 1 1 7 2 3 2 2 1 1 1 1 1 1 1 1

DESCRIPTION

Card supply sensor Ci.roller interlock switch

Card cooling fan

82

< FRAME ASSEMBLY


DUCT FRAME SA Explanation drawing 1

Refer to front page for Explanation drawing 1 to 7.

MEDIA FRAME

1
HEAD RAIL SA Explanation drawing 3

Explanation drawing 9

Pass the wire through the notch in the bracket.

INK FRAME SA Explanation drawing 4

GUIDE SA Explanation drawing 8

F1

Explanation drawing 6 FRONT SENSOR SA

6
Explanation drawing 9

2 3

6
CENTER FRAME SA

Explanation drawing 9
GUIDE SA

Explanation drawing 7

F1

Explanation drawing 2

6 6 6
Explanation drawing 9

Wire clamping
1

5 6
Explanation drawing 8

Explanation drawing 8

1.Bind the sensor cable with a binder using the hole in the blacket. Front side 2.Clamp the sensor cable so that the edges of the connector and the adjacent bracket are on the same level.

Take out the cable from a front side and clamp it.

8
Note that the half punch does not get on BKT when you fix the BKT by screw.

About 10mm

SYMBOL NO. 1 2 3 4 5 6 7 8 9

PART NO. KJP33144-C01 KJP45549-B01 KJM33160-001 YMC-05-H-0 KJJ46271-003 AN-1

REVISED PART NO. Rev.

PART NAME MEDIA FRAME GUIDE BKT SIDE GUIDE MINI CLAMP TAP SCREW BINDER

PRICE

QTY 1 1 1 1 12 2

DESCRIPTION

83

< FRAME ASSEMBLY


29 22 23 29 24 25 21 25 25 6 30 25
Explanation drawing 2 SIDE ADJUSTER SA

31 10 29
31

29

31

29

26

29 6 11 31 11

1 16 19
Explanation drawing 3

19

5 6 3

17 18 6
Explanation drawing 1

31

33

6
Explanation drawing 4

ADJUST ROLLER SA
Explanation drawing 3 Explanation drawing 1

31
Apply grease on the edge and inside the pipe.

12 28 14 28 14

13

ADJUST ROLLER SA
Explanation drawing 2

2
34 35 35

34

SIDE ADJUSTER SA Explanation drawing 3 BOBBIN SA


Used by one set (pair)

7
Explanation drawing 4 BOBBIN SA
Attachment position

8 27

SYMBOL NO. 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 33 34 35

PART NO. KJP22168-D0A 0082-3-D-001-01 TB-1920 YMC-10-0 EDS-3 KJS45482-001 CM46291-001 KJM46348-A0A KJM45493-002 KJD45496-A01 KJD45607-001 KJM33108-D01 KJP45543-B01 KJD45536-001 KJM45513-001 KJS45585-001 KJP46208-B01 KJV45545-A0A KJM34135-A01 KJD45546-A01 KJY44486-002 KJP46406-B01 QYREE3000X QYREE4000X QYREE5000X QYSPSPD3008N KJJ46271-003 GB-TS-1 KJP46352-A01 KJY46337-003

REVISED PART NO. Rev. PART NAME PLATE R ASY LATCH SNAP BUSH CLAMP EDGE SADDLE COMP. SPRING INK DOUBLE GEAR MEDIA BUSH INK BUSHING BOBBIN SHAFT INNER I. GEAR SHAFT INK BOBBIN INNER ADJUST ROLLER BKT PRESS ROLLER SHAFT PRESS ROLLER ROLLER TORSION SPRING ADJUST ROLLER BKT-B ADJUST ROLLER SIDE ADJUSTER ADJUST PULLEY SHAFT OIL BEARING TOP SUPPORT BKT E RING E RING E RING ASY SCREW TAP SCREW GREASE GASKET HOLDER GASKET

PRICE

QTY 1 1 1 1 5 1 1 1 2 2 1 3 1 1 1 2 1 1 1 1 4 1 1 3 6 1 13 (1) 2 2

DESCRIPTION

84

< FRAME ASSEMBLY


Explanation drawing 1 Wiring
Clamp

Explanation drawing 4 Apply the grease onto cog.

Apply the grease onto shaft.

Apply the grease onto cog.

Apply the grease onto cog.

Explanation drawing 1 Card presence sensor

Explanation drawing 2 Card near-empty sensor

8 6 7
Side B Side A

6 11
Explanation drawing 3

Clamp

4
Apply the grease onto shaft of No.12 double gear by one grain of rice.

Apply the grease onto three shafts by one grain of rice.

Turn sensor

10

Explanation drawing 4

Head cooling fan

4
Apply the grease onto cog each gear fully. (until it comes to look yellow). Explanation drawing 4

18 20 15
(Translucent)

2 1 3
Side A

19 2

Clamp (SM-9p) Film mark sensor

11

12 13
Side B

19

Bearing can be seen.

11
HEATER P. PWB Explanation drawing 3 Turn sensor Explanation drawing 1 Card presence sensor Clamp Explanation drawing 2 Card near-empty sensor

Clamp

Bearing is hidden.

17

17

17 19

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

PART NO. KJM45492-001 KJM45499-00A KJM45604-A0A GB-TS-1 SG113 KJP45488-B01 KJP45589-B01 GP1S09J0000F KJP45511-B01 YMC-05-H-0 KJM45506-001 CM45196-001 KWS0757-002 KJJ46271-003 QYYASPW4004F QYREE5000X KJM45492-001

REVISED PART NO. Rev.

PART NAME DOUBLE GEAR ONEWAY GEAR ASY GEAR ASY GREASE PHOTO SENSOR EMPTY SENSOR BKT EMPTY SENSOR BKT-B PHOTO SENSOR TURN SENSOR BKT MINI CLAMP DOUBLE GEAR DOUBLE GEAR WIRE ASY TAP SCREW W. SET SCREW E RING DOUBLE GEAR

PRICE

QTY 2 2 1

DESCRIPTION

2 1 1 1 1 3 1 1 1 3 1 3 1

85

< FRAME ASSEMBLY


Pass the wire inside a shaft.

13
Stick so that gaps on right and left are covered.

FRONT PLATE SA

Explanation drawing 1 L. FRAME SA

6 Sticking
Sticking

Match the projection on the shaft, and the attachment hole on the frame.

3
x2 Attachment direction (x 2)

2 5 KWR 10303-010 4

13
REAR PLATE SA

13
F1 Explanation drawing 1 L. FRAME SA

13

O side Clamp Fix the side to 12 rear frame by screw.

side

13

Clamp Clamp

13
Fixing positions of shaft and sensor Explanation drawing 2 Explanation drawing 3
Explanation drawing 4

Explanation drawing 2

10
Explanation drawing 4

14 8 13
Explanation drawing 2

14

Explanation drawing 3

Pass the wire of edge sensor under the INK BKT.

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

PART NO. KJP22171-B01 KJP22164-B01 YMC-05-H-0 TPS0248-001-G KWR10303-010 KJU46278-001 KJP46356-A01 TPS0248-001-C KJD46209-001 KJJ46271-003 QYSPSPD2606N

REVISED PART NO. Rev.

PART NAME RIGHT FRAME LEFT FRAME MINI CLAMP CARD TRAY INTER.PWB WIRE ASY SHEET INK SENSOR BKT C.INK/FILM SENS.PWB ADJUST SHAFT TAP SCREW ASY SCREW

PRICE

QTY 1 1 2 1 1 2 1 1 1 21 2

DESCRIPTION

Card edge/lnk start/Film mark

86

< FRAME ASSEMBLY


Enlarged Affix QYREE5000X

18

Affix QYREE5000X

19 15
Explanation drawing 2 Enlarged Enlarged Affix

15

1 2

19
Explanation drawing 1 Enlarged Explanation drawing 2 Affix NG CARDPULLEY SA

19
Explanation drawing 2 Explanation drawing 2 Gasket sticking position

14
QYREE4000X

5 6 16
KJJ46271 -003x2 Explanation drawing 1

10 16

10

Explanation drawing 1

Affix KJJ46271 -003x2

16
KJJ46271-003

Explanation drawing 3

19 14
QYREE4000X

Explanation drawing 3 ROLLER COVER SA Affix

12 6

7 7

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

PART NO. KJD45588-001 KJM45513-001

REVISED Rev. PART NO.

PART NAME ROLLER SHAFT PRESS ROLLER

PRICE

QTY 2 2

DESCRIPTION NG CARD NG CARD

KJM33159-005 KJM33159-006 KJM33159-B03 KJP34310-001 KJP46261-00B KJZ45597-A02 QYREE4000X QYREE5000X KJJ46271-001 KJY46337-001 KJY46337-002

GUIDE G GUIDE Y GUIDE B ROLLER COVER B. T. PLATE ASY BRUSH E RING E RING TAP SCREW GASKET GASKET

2 2 2 1 2 1 2 4 5 1 4

(Pale Green) (Orange) (Blue)

87

< PLATEN ASSEMBLY


13
16
short

3
(-013)

long

(-007)

9 15 14
(-007)

14 18
1

17
(-013)

9
Explanation drawing 1

PLATEN ARM SA (F)


Explanation drawing 1

PLATEN ARM SA(F)

2
A C

Projected side
Explanation drawing 1

7 5
(-003)
Explanation drawing 2

PLATEN ARM SA (R)

8
(-010) A

20

Explanation drawing 2

PLATEN ARM SA(R)

(-003)

10

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

PART NO. KJP33113-B01 KJD33137-B01 QYSPSPD4008N KJP33112-D01 KJP33112-D02 KJY44486-003 KJY32775-001 KJS33103-013 QYREE7000X

REVISED PART NO. Rev.

PART NAME PLATEN LEVER PLATEN PRS SHAFT ASY SCREW PLATEN ARM PLATEN ARM OIL BEARING OIL BEARING TENSION SPRING E RING

PRICE

QTY 1 1 3 1 1 2 1 2 1

DESCRIPTION

FRONT SIDE REAR SIDE B-F8-23 MF128ZZ

KJV33111-B0A KJY32775-007 KJJ46364-001 QYREE5000X KJD46363-A01 QYYASPW3003F KJP45561-B01

PLATEN ROLLER BEARING WASHER E RING STOPPER RING W.SET SCREW PLATEN SH LEVER

1 2 1 2 1 1 1

B-F8-146

88

< PICK UP MOTOR ASSEMBLY


10 9

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12

PART NO. CX220-PIM1

REVISED PART NO. Rev.

PART NAME PICK UP MOTOR

PRICE

QTY 1

DESCRIPTION Card pick up motor

KJP45480-A01 QYSPSPD2604N

PICK UP MO BKT ASY SCREW

1 3

89

< FEED MOTOR ASSEMBLY


8 7

11

12

(M180)

13

(M224)

Tighten the screw B securely

10

to turn the motor in arrow direction to tighten the belt, and then tighten the screw A securely.

11 15
MOTOR SA Explanation drawing 1 Tighten provisionally Explanation drawing 2 Finally, tighten securely as this drawing. Tap hole

A 16

5
Tap hole

4 18
Put the pulling out hole to the motor side.

1
Explanation drawing 1 MOTOR SA

P5

P5

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

PART NO. KBM1029-002

REVISED PART NO. Rev.

PART NAME FEED MOTOR

PRICE

QTY 1

DESCRIPTION Card feed motor

WM46269-A01 QYSPSPL3006N KJP45541-B01 QYSBST3006Z CM33154-00A KJY32775-016 KJY32771-030 KJY32771-033 KJP33138-A01 QYSPSPD3006N HL-18-0

MOTOR DAMPER ASY SCREW FEED MOTOR BASE TAP SCREW M. PULLEY ASY BEARING TIMING BELT TIMING BELT FEED MOTOR BKT ASY SCREW HARNESS LIFTER

1 2 1 2 1 2 1 1 1 2 1

90

< MEDIA W MOTOR ASSEMBLY


10 9

D3

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12

PART NO. CX220-MWM1

REVISED PART NO. Rev.

PART NAME MEDIA W MOTOR

PRICE

QTY 1

DESCRIPTION Retransfer film take-up motor

KJP45497-B01 QYSPSPD2604N

DC MOTOR BKT ASY SCREW

1 3

91

< MEDIA S MOTOR ASSEMBLY


Tighten the screw A securely to turn the motor in arrow direction to tighten the belt, and then tighten the screw B securely.

MOTOR SA Explanation drawing 1

A
Tighten provisionally

13

Explanation drawing 2 Finally, tighten securely as this drawing.

P3 P3

7 11
F689ZZ MOTOR SA F689ZZ

11 12
S2M224 QYSBST3006Nx2

Explanation drawing 1 Tap hole

14 10

Note the direction.

4
Draw in the direction of the arrow and install. Put the pulling out hole to the motor side.

8 12
S2M224

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

PART NO. KBM1030-002

REVISED PART NO. Rev.

PART NAME MEDIA S MOTOR

PRICE

QTY 1

DESCRIPTION Retransfer film supply motor

WM46269-A01 QYSPSPL3006N KJP33152-A01 KJP33153-A01 CM33154-00A KJY32775-016 KJY32771-033 QYSPSPD3006N QYSBST3006N KJY32771-045

MOTOR DAMPER ASY SCREW M. SUPPLY BKT A M. SUPPLY BKT B M. PULLEY ASY BEARING TIMING BELT ASY SCREW TAP SCREW TIMING BELT

1 2 1 1 1 2 1 2 2 1

F689ZZ 60S2M224 (Width : 6mm)

80S2M224 (Width : 8mm)

92

< MEDIA S MOTOR ASSEMBLY


9 5 13

12

11
Tighten provisionally

Bring the bracket on the motor side to free.

Loosen this screw enough.

2
Tighten by specified torque 2.16 N/m (22 kgf/cm)

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

PART NO. KJM34367-00A QYYASP4004F

REVISED PART NO. Rev.

PART NAME PLATEN PULLEY W. SET SCREW

PRICE

QTY 1 3

DESCRIPTION

KJP33154-B01 KJY32775-016 KJY32775-007 KJD45503-001 QYSPSPD4008N QYWBS438505N PHD-14

M. PULLEY BKT C BEARING BEARING M. SUPPLY SHAFT ASY SCREW P.L. WASHER HOLDER

1 1 1 1 1 1 1

93

< INK S&W MOTOR ASSEMBLY

1 2

10

D2

D1

D2

11

D1 D2

D1

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12

PART NO. CX220-INS1 CX220-INW1

REVISED PART NO. Rev.

PART NAME INK S MOTOR INK W MOTOR

PRICE

QTY 1 1

DESCRIPTION Ink supply motor Ink take-up motor

KJP33102-B01 QYSPSPD2604N KGES-14 LWS-3S-2W

DC MOTOR BKT2 ASY SCREW SPACER LOCKING WIRE SA

1 6 1 1

94

< HEATER CAM MTR ASSEMBLY


Apply grease to this side also

20
Apply grease to this side also

Upper side

14
Apply grease to this side also
CAM GEAR Slit DOUBLE GEAR

Apply sufficient grease to the hole for the shaft.

12
Lower side

Install so that the slit of the cam gear comes to the gear edge of the double gear when seen from above.

Apply grease to this side also


Apply grease to a small 20 gear by one grain of rice. Engage with the cam gear. Please use care, as the installation orientation can be mistaken easily.

10

13 9 20 7
Apply a sufficient quantity of grease to the two holes for the shaft.

17 6

P4

Before installing the gear, install it on the bracket.

18

P4

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

PART NO. CX220-HCAM1

REVISED PART NO. Rev.

PART NAME HEATER CAM MOTOR

PRICE

QTY 1

DESCRIPTION Cam motor

KJP33135-C0A QYSPSPD3006N KJM45506-001 KJM45507-001 KJM33119-B01 KJP45530-B0A QYREE4000X

H CAM BKT ASY ASY SCREW DOUBLE GEAR DOUBLE GEAR CAM GEAR CAM LEVER ASY E RING

1 2 1 1 1 1 1

UAMS-07-0 HL-18-0 GB-TS-1

MINI CLAMP HARNESS LIFTER GREASE

1 1

95

< TURN MOTOR ASSEMBLY


14 14
Top

9
Under

10 12 7 7

17
Explanation drawing 1

P1

1
Explanation drawing 1 P1

2 18

P2

P2

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

PART NO. CX220-CTM1 CX220-TUM1

REVISED PART NO. Rev.

PART NAME TURN ROLLER MOTOR TURN UNIT MOTOR

PRICE

QTY 1 1

DESCRIPTION Turnover card feed motor Turnover motor

KJP33115-A0A QYSPSP3006N KJM45505-001 KJM45506-001 KJS45482-004 QYREE3000X

T. MOTOR BKT ASY ASY SCREW GEAR DOUBLE GEAR COMP. SPRING E RING

1 4 1 1 1 2

YMC-05-H-0 LWS-5S-2W

MINI CLAMP LOCKING WIRE SA

1 1

96

< TURN UNIT ASSEMBLY


16 16 12
KWR16003-001

12

Fit the claw onto bracket.

22 1
Explanation drawing 1 PRESS ROLLER SA

Install this so that it may be passed under the springs. PRESS ROLLER SA Explanation drawing 1

20 18

Sensor SA Explanation drawing 2

Explanation drawing 2

5 16

Sensor SA

QYSBST 3006Nx2

21

5 19
Hook side

4
1

11

16

Spring side Attach each rail so that a hook side is turned up and a spring side is turned down.

15 15 8

The brush center shall be positioned on the center between the two hole.

(-002)

13

The brush edge shall be higher than the edge of the hole.

(-002)

6
13
Explanation drawing 2 Sticking Brush Stick the brush as shown from inside of the blacket to the outside

x2

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

PART NO. KJU46323-A01 KJD45509-A01 KJP33133-E0A KJS33103-001 KJM33118-B01 KJV45580-B0A KJY44486-002 KJM45516-001

REVISED PART NO. Rev.

PART NAME PRESS ROLLER PRESS ROLL SHAFT TR UNIT BKT ASY TENSION SPRING CARD GUIDE T FEED ROLLER OIL BEARING D GEAR

PRICE

QTY 1 1 1 2 2 1 2 1

DESCRIPTION

KJM45598-001 KJZ45597-A02 QYREE4000X QYREE5000X TPS0248-001-B KJU46204-001 KJM45508-001 QYSBST3006N KWR16003-001

EDGE COVER BRUSH E RING E RING TURN.CARD SENS.PWB PWB SHEET WIRE GUARD TAP SCREW WIRE ASY

2 2 2 4 1 1 1 2 1 Turnunit card sensor

97

< MECHANISM ASSEMBLY


Install so that the bracket of the turn unit goes under the plate of the rear frame.

15 7

14

8 13
(-002)

11 10 13
(-002)

15

Explanation drawing 2

2
NG CARD ROLLER Explanation drawing 1

15 13 16
Connect the connector.

(-002)

12

(-002)

15 5
x2

Pass the wire underneath the sumi tube.

Pay attention to the wire passing direction. Explanation drawing 2

Install the gear, holding it so that it will not drop down. Explanation drawing 1

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PART NO.

REVISED PART NO. Rev.

PART NAME

PRICE

QTY

DESCRIPTION

KJV33141-A0B

FEED ROLLER

KJM45481-A01 KJM45514-001 KJM45506-001 WM46066-001 KJS45547-001 QXTE500-020 KJY44485-008 KJY44486-002 QYREE4000X QYREE5000X Q03093-836

M GEAR DOUBLE GEAR DOUBLE GEAR CORE GEAR WIRE HOLD SUMI TUBE OILLESS BEARING OIL BEARING E RING E RING SPACER

2 1 1 1 1 1 1 3 1 2 1

98

< MECHANISM ASSEMBLY


15 5 12
(-002) Explanation drawing 1 CARD OUT ROLLER SA

15 15 2

12 12
(-002)

(-002) Explanation drawing 2 AL ROLLER SA

Explanation drawing 4

x2

CARD OUT ROLLER SA (EPDM) Explanation drawing 1

Explanation drawing 6 Explanation drawing 3 MAIN ROLLER SA

15
(-002)

11 15
Explanation drawing 2 AL ROLLER SA x2

15 8 3 3

7
Explanation drawing 5

Explanation drawing 7

MAIN ROLLER SA Explanation drawing 3

Same on the rear

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

PART NO. KJD45552-A01 KJA45555-002 KJM45551-002 KJV33141-A0B KJS45600-001 KJS45544-001

REVISED PART NO. Rev.

PART NAME ROLLER SHAFT AL ROLLER PRESS ROLLER FEED ROLLER ROLLER TENSION SPRING ROLLER TENSION SPRING

PRICE

QTY 3 1 4 1 2 4

DESCRIPTION

KJY44485-008 KJY44486-002

OILLESS BEARING OIL BEARING

1 3

QYREE5000X

E RING

99

< MECHANISM ASSEMBLY


(-011) Side with steps

20 6
14

(-011)

20 6 3 2

(-011)

21 22

3 12 2
Side with steps

Side with steps

4 22
Explanation drawing 1

15 25
Explanation drawing 2

4
Explanation drawing 3

22
25 22

ANTI BEND ROLLER SA

21
(Please insert from the front.) (-011) ANTI BEND ROLLER SA (EPDM) Explanation drawing 2

1 5

Explanation drawing 3

11 9 20
x3 (-011) x4

6
x3

10
x4

(30S2M118)

Explanation drawing 1 MAIN ROLLER SA At the time of installing the main roller SA, also engage the front belt.

13

Explanation drawing 3

8
(30S2M132) Explanation drawing 4

Explanation drawing 4 Belt setting

19 17 7
(30S2M266) Explanation drawing 4 (-012)

Tension the belt and tighten the screw securely.

Explanation drawing 4

22

SYMBOL NO. 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

PART NO. KJV33139-A0A QYWFM62C050 KJS45482-A03 KJM45542-00A KJM34366-00A Q03093-836 KJY32771-032 KJY32771-035 KJY32771-029 KJJ44854-001 KJM46126-00A KJM46547-001 KJJ46771-001 KJV33141-A0B KJM45562-00A CM45182-001 KJY44486-012 KJY32775-011 KJY44486-011 QYYASPW4004F

REVISED PART NO. Rev.

PART NAME MAIN ROLLER WASHER COMP. SPRING PULLEY MAIN ROLLER SPACER TIMING BELT TIMING BELT TIMING BELT WASHER PULLEY SPACER WASHER FEED ROLLER PULLEY GEAR IDLE PULLEY OIL BEARING BEARING OIL BEARING W. SET SCREW

PRICE

QTY 2 3 3 4 1 6 1 1 1 4 4 1 1 1 1 1 1 6 2 8

DESCRIPTION

30S2M266 (Width : 3mm) 30S2M132 (Width : 3mm) 30S2M118 (Width : 3mm)

QYREE5000X

E RING

100

< MECHANISM ASSEMBLY


JOG DIAL SA
17 20 14

1 3
(-002)

(-002)

14

Explanation drawing 1 JOG DIAL SA (30S2M116)

17 10
Explanation drawing 2

20

JOG DIAL SA Explanation drawing 1

4 7
(50S2M192)

16
3

11
Explanation drawing 3

Explanation drawing 3

Engage the bearing with the frame, pull it to the front, and fix it with an E-ring.

Explanation drawing 2

Tension the belt and tighten the screw securely.

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

PART NO. KJD45566-001 KJP46738-001 KJM45562-00A KJM45563-001 KJY32771-028 KJY32771-044

REVISED PART NO. Rev.

PART NAME JOG DIAL SHAFT JOG DIAL BKT PULLEY GEAR JOG DIAL TIMING BELT TIMING BELT

PRICE

QTY 1 1 2 1 1 1

DESCRIPTION

30S2M116 (Width : 3mm) 50S2M192 (Width : 5mm)

KJM45542-00A CM45182-001

PULLEY IDLE PULLEY

1 1

KJY44486-002 KJJ46271-003 QYYASPW4004F QYREE4000X QYREE5000X

OIL BEARING TAP SCREW W. SET SCREW E RING E RING

2 3 2 1 2

101

< MECHANISM ASSEMBLY


Gap Explanation drawing 1 Platen lever SOLENOIDE SUPPORT Before tightening the screws, adjust the gap uniformly so that there will be no interference with the platen lever and the solenoid support when the plunger moves in and out. Explanation drawing 1 Caution for the time of installation of the solenoid support

12

17
Plunger

(TSS0179)

11

(TSS0183)

Clamp

Door interlock

Explanation drawing 2 KWS0747-001

17 2
(-010) Clamp Lead the wire along the bracket so that it does not become an obstacle on the inside of the bracket.

Cassette interlock TPS0248-001-E

8
Engage the bearing with the rear frame.
Explanation drawing 2

15

Door interlock

Cassette interlock

16

16

Explanation drawing 3 Clamp the wires of film mark sensor and edge sensor as drawing of solenoid bracket.

Explanation drawing 2

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

PART NO.

REVISED PART NO. Rev.

PART NAME

PRICE

QTY

DESCRIPTION

KJY44486-010 QYREE7000X KJS33103-012 KJP23071-A01 TPS0248-001-E KWS0747-001 TSS0179-002 KJP45586-B01

OIL BEARING E RING TENSION SPRING HEATER FRAME CASSTE.INTER.SW PWB WIRE ASY SOLENOID ASY SOLENOID SUPPORT

1 1 1 1 1 1 1 1 Cassette interlock switch

QYSPST3005N KJJ46271-003 QYSPSPD4008N

TAP SCREW TAP SCREW ASY SCREW

3 4 4

102

< MECHANISM ASSEMBLY


Card Outlet sensor (FEED OUT) Explanation drawing 1 Explanation drawing 2 Cam sensor

19

QYSPSPL 3006Nx2

Apply the grease on two positions inserting the oilless bearing.

16 25 24

The photo sensor tends to break with static electricity, handle it carefully.

30 21

28

TPS0248-001-M

7 1

27 23 17 22 26
(Thrusts) Explanation drawing 4 KWR15204-003 Ink encoder

29

13

F1

Ink encoder Explanation drawing 4

18

Explanation drawing 1 Card discharge sensor


T2 T1 Thermistor Thermistor

18

18
Remedy roller position sensor Retransfer roller position sensor.

KWS0751-002

11

Explanation drawing 2 Cam sensor S3

13

10

KWS 0757-002

18

EXT. POWER PWB

18

SYMBOL NO. 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

PART NO. KJP46292-B01 KJP45535-B01 GP1S09J0000F TPS0248-001-H TPS0248-001-A KWS0751-002 KWS0757-002 KJP46206-C01 HL-18-0 QYYASPW3004F QYSPSPL2606N KJJ46271-003 QYSPSPL3006N KJD46629-A01 KJM45481-A01 KJY44485-007 KJY44485-004 KJP46258-002 QYREE3000X KJM46479-001 TPS0248-001-M (KWS0757-001) GB-TS-1

REVISED PART NO. Rev.

PART NAME FEED OUT SENSOR BKT CAM SENSOR BKT PHOTO SENSOR EXT.POWER PWB CARD OUT SENS. PWB WIRE ASY WIRE ASY RELEASE SPRING HARNESS LIFTER W. SET SCREW ASY SCREW TAP SCREW ASY SCREW ENC. SHAFT M. GEAR OILLESS BEARING OILLESS BEARING ENCODER BKT E RING ENCODER DISK INK ENCODER PWB WIRE ASY GREASE

PRICE

QTY 1 1 1 1 1 1 1 1 2 1 2 6 2 1 1 1 1 1 1 1 1 (1)

DESCRIPTION

Cam sensor Ext.power pwb Card outlet sensor

ink encoder pwb

103

< MECHANISM ASSEMBLY


7
Fix the wire by screw as drawing. Refer to Explanation drawing 1.

11

18

4
(-007)

KWS0668-002 D1 D2

12

Refer to Explanation drawing 1.

Clamp

Refer to Explanation drawing 1.

19
Clamp P3

Tighten provisionally

19

1 2

Explanation drawing 1. Media supply motor installing procedurer and caution After hooking the spring, check that the bracket is not touch with this screw. Check that the motor bracket is not projected higher than the rear bracket.
3

Shall be in parallel

18
D3 (-006) Set the belt to the pulley. P5

15 Install procedures
1 2

2 2

Check that the screw is loosely secured.

Secure the two screws. (Check that he shaded parts of the two brackets are in parallel.)
Insert the shaft of gear.

Loosely secure the three screws Hook the both ends of the spring. Firmly secure the four screws
1

1
P1 P2

4 5

and

18 3

14
Tighten provisionally

18

19
Engage and tension the belt then tighten the screw securely.

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

PART NO.

REVISED PART NO. Rev.

PART NAME PICK UP MOTOR ASY TURN MOTOR ASY MEDIA W MOTOR ASY INK S&W MOTOR ASY WIRE ASY

PRICE

QTY 1 1 1 1 1

DESCRIPTION

KWS0668-002

KJS33103-007

MEDIA SUPPLY MOTOR ASY TENSION SPRING FEED MOTOR ASY TENSION SPRING

1 1 1 1

KJS33103-006

KJJ46271-003 QYSPSPD4008N

TAP SCREW ASY SCREW

9 7

104

< MECHANISM ASSEMBLY


DR PCB BKT SA TSS0239-V

Explanation drawing 1 HEATER SENSOR SA HEAT ROLLER

Explanation drawing 2 DR PCB BKT SA

10 11

8 9 12

17 17 18
TSS0239-U F1 HEATER SENSOR SA T2 (TSS0182) A B T1

15

(-010)

3
CLAMP (T2,H2) T2 CLAMP (F1) H2

15
(-010)

12 1
(TSS0181) T1 (TSS0189) P4

Insert the lever of retransfer heat roller to between the sensors. Explanation drawing 4 Position of heater lever Clamp the wires of thermistor and thermostat. Insert the lever of remedy heater to between the sensors. Clamp the wires of thermistor. T1

5
CLAMP (P4)

H1

17
Pass the wires behind the lever. Explanation drawing 3

(FD M.MOTOR ASY)

17

19
Wiring for retransfer heat roller Explanation drawing 5 Apply grease to the hole of the heater lever, especially to the gray part (about the size of a grain of rice).

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

PART NO. TSS0181-002 TSS0182-002

REVISED PART NO. Rev.

PART NAME HEATER ASY REFORM HEATER ASY HEATER CAM MOTOR ASY

PRICE

QTY 1 1 1 1 2 1 1 1 1 1 2 8 1

DESCRIPTION

KJP45591-C01 GP1S09J0000F UAMS-07-0 KJP45569-B01 PHD-08 LWS-5S-2W KJS33103-008 KJY44486-010 KJJ46271-003 QYSPSPD4008N GB-TS-1

HEATER SENSOR BKT PHOTO SENSOR WIRE CLAMP DR PCB BKT HOLDER LOCKING WIRE SA TENSION SPRING OIL BEARING TAP SCREW ASY SCREW GREASE

Heat roller position sensor

105

< MECHANISM ASSEMBLY


Pass the wire of ink encoder between the INK S&W MOTOR and plate of motor.

QYSDSP3030Rx2

(243-1)

Before installing the drive PWB, check that the wire 3 sets passed through EDGE SADDLE.

5
CLAMP

16

KWS0753-001

13
KWS0752-001

12
J16 J13 J12 J9 J8

10

(FRONT SENSOR)
CLAMP

KWS0748-001

11
KWS0749-001 DRIVE PWB SA

14
KWS0754-001

CN201

F2 P5

J7 P3 J6 (TRAY INTERLOCK)

P1 D1 D2

D3
CLAMP

F3

J5 D4 P2 P4

F1

DRIVE PWB SA J7 J6

J11
Explanation drawing 2

J5 F2 D3

Installing the spring of pulley for NG card

Explanation drawing 3

D1 D2 (KWS0751-002)
Explanation drawing 1

J11 P5 P3 F1 P1 D4

Installing the spring of pulley for NG card

(DOOR INTERLOCK SA)


CLAMPx3 CLAMP

P2

P4

Clamp the cam sensor wire as shown

3
(KWS0757-002

3
Check that each mating connector has the same number.

Explanation drawing 3

Installing the spring of pulley for NG card Explanation drawing 3

Explanation drawing 4 Installing the spring of pulley for NG card

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PART NO.

REVISED PART NO. Rev.

PART NAME

PRICE

QTY

DESCRIPTION

KJS33103-010 KEF1041-002

TENSION SPRING FAN MOTOR

1 1 Cooling fan

TPS0243-001 KWS0748-001 KWS0749-001 KWS0752-001 KWS0753-001 KWS0754-001 QYSDSP3030R

DRIVE PWB ASY WIRE ASY WIRE ASY WIRE ASY WIRE ASY WIRE ASY ASY SCREW

1 1 1 1 1 1 2

106

<MECHANISM ASSEMBLY
KWS0756-001

Only the J8 cable shall be inserted between the J3 and J4 cable.


CLAMP CLAMP

11
KWS0769-001

J4 CLAMP J8 KWR18412-001 KWR18430-001

4
J2 CLAMP J1

J3

14

TURN OVER FEED MOTOR

CLAMP

Pass the wire of head through the snap bush then clamp it.

CLAMP

The spiral tube shall fully cover the area where wires are separated on the cable.
CLAMP

6
KWS0742-002

Explanation drawing 1

Head wire treatment

Clamp the orange wire (for the card near empty sensor) and the red wire (for the turn over positioning sensor) together as shown

7 1
KWS0685-001 KWS0743-002

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

PART NO. KWS0685-001 KWR18412-001 KWR18430-001 KWS0742-002 KWS0743-002 KWS0756-001 KWS0769-001 QGH2502A2-06

REVISED PART NO. Rev.

PART NAME WIRE ASY WIRE ASY WIRE ASY WIRE ASY WIRE ASY WIRE ASY WIRE ASY HOUSING

PRICE

QTY 1 1 1 1 1 1 1 1

DESCRIPTION

ZCAT3035-1330

FERRITE CORE

107

< MECHANISM ASSEMBLY


Insert the red wire first, so that Pass the fan wire the wires will be arranged through the notch. nicely after connector insertion.

Loosen the two screws of the duct frame for joint tightening.

14
Clamp the wire of suction fan

7 8

11

10

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

PART NO. KEF1037 KJU34171-002

REVISED PART NO. Rev.

PART NAME FAN MOTOR AIR DUCT

PRICE

QTY 1 1

DESCRIPTION Head cooling fan

KJM33108-D01 QYREE4000X KJM34134-001 CX220-FFK2

INK BOBBIN INNER E RING FILTER CAP IN FAN FILTER ASY

1 1 1 1

As 1 set including 3kinds / 4 sheets of filters

QYSPSPD3012N

ASY SCREW

108

< FRONT PANEL ASSEMBLY


7 19 18 15 15

17

15 6 2

15

10 5 12

10

12 9 11

4 15 11

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

PART NO. KKM11036-001 KKM34086-001 KKM34139-001 KJM34087-001 KJS46162-001 KJM34088-001 KJM34090-001 KJP46156-B01 KJP46157-A01 KJD46158-001

REVISED PART NO. Rev.

PART NAME FRONT PANEL PUSH BUTTON SLIDE KNOB LOCK SLIDER COMP. SPRING SLIDE SUPPORTER SHOCK ABSORBER HINGE HINGE HOLDER SHAFT

PRICE

QTY 1 1 1 1 1 1 2 2 2 2

DESCRIPTION

QYSDSF3008N KJP46274-A01 KJP46275-001 QYSPSPL2004N

TH. TAP SCREW EARTH HOLDER EARTH PLATE ASY SCREW

9 1 1 2

109

< FRONT PANEL ASSEMBLY


Explanation drawing 1
DOOR SA

2 8 5

DOOR SA

Explanation drawing 1 Explanation drawing 2

Explanation drawing 2 Check opening-andclosing operation after an assembly.

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10

PART NO. KKM11037-002 KKP23060-002

REVISED PART NO. Rev.

PART NAME FRONT DOOR HINGE SUPPORTER

PRICE

QTY 1 1

DESCRIPTION

KKM34089-002

WINDOW

QYSDSF3008N

TH. TAP SCREW

110

< PR COMMON ASSEMBLY


6

x4

Pass the wire as shown in the figure.

8
Pass the cable under the bent part of the botton bracket.

12

Explanation drawing 1 POWER SW SA POWER SW SA Explanation drawing 1 KWS0626-001

3
WHITE

BLACK BLUE

Wiring after installing the power SW onto bracket.

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

PART NO. KSE1221 KJP46161-B01 KWS0626-002

REVISED PART NO. Rev.

PART NAME POWER SW POWER SW BKT WIRE ASY

PRICE

QTY 1 1 1

DESCRIPTION

KJP11043-002 KJY44287-047 QYSPSPH4016N

BOTTOM FRAME FOOT SCREW

1 4 4

KJJ46271-003

TAP. SCREW

111

< PR COMMON ASSEMBLY


1
Explanation drawing 1 Explanation drawing 2

10

5 4 9 5 10

9
Explanation drawing 2

10

10

Explanation drawing 1

Installing the hopper guide

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12

PART NO.

REVISED PART NO. Rev.

PART NAME MECHA ASY

PRICE

QTY 1 1 1 4

DESCRIPTION

KJP23056-C01 KJP23056-C02 KJY44486-014

HOPPER GUIDE BKT HOPPER GUIDE BKT OIL BEARING

KJJ46271-003 QYREE4000X

TAP. SCREW E RING

10 4

112

< PR COMMON ASSEMBLY


Parts side About 3mm PWB

KWR15107-001

Affix the tape so that the letter "V" is positioned at the center of the tape.

KWS0745-001

8
KWR15106-001

10
Affix the tape from the surface of the PWB to the back side.

12
J13 J16 J12 J8

9
KWR15208-001

2 1
(TPS0242)

11
MAIN PWB ASY

Explanation drawing

Pass the cables J11,J18 and J22 under the cables J23 and J24.

J18 J22 J23 J24

J11

J22 J18 J11 J23 J24

J15

J21 J17

J2 J5

Explanation drawing
(MAIN PWB ASY)

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

PART NO. TPS0242-002 KKC34326-001

REVISED PART NO. Rev.

PART NAME MAIN PWB ASY CONNECTOR PANEL

PRICE

QTY 1 1

DESCRIPTION Main pwb

KWR15106-001 KWR15107-001 KWR15208-001 KWS0745-001 KJJ46271-003 QYSDSP3006N SCOTCH#898

WIRE ASY WIRE ASY WIRE ASY WIRE ASY TAP. SCREW SCREW FILAMENT TAPE(W:18mm)

1 1 1 1 3 1

113

< PR COMMON ASSEMBLY

15 8
Door interlock

(F2,D3,P3) Affix

10

J4 J3 (F1)

16

Clamp the cables J3,J4 and F1 together with the cables F2,D3 and P3

Pass the cable T2 outside the other cables not clamping around here. Clamp the cables T1 and T2 together making them positioned at the front

About 30mm T2

16

T1

J13 J8 J23 J24

Make the cables J8 and J13 routed away from the outer hopper guide by bending them inwards at the root.

17
Rear plate

16
Clamp the cables at the root of the spiral tube making the cables routed outside of the head cable (covered by the spiral tube.)

Clamp the cable(expect for the cable(expect for the cable T1) at the distance of 30mm from the harness lifter.

Clamp the cables making the cable T1 positioned at the front.

Hit the lower side of the seal to bottom. Insert the end of the protection sheet under the bottom bracket.

Explanation drawing 2

Attachment position of protection sheet

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

PART NO.

REVISED PART NO. Rev.

PART NAME

PRICE

QTY

DESCRIPTION

TPS0248-001-D KJZ34168-001

DOOR INTER.SW PWB PROTECT SHEET

1 1

Door interlock switch

KJY46271-003 OLS-150BK OLS-115

TAP SCREW BINDER BINDER

1 3 1

114

< FINAL ASSEMBLY


4
XID580i-B
USB PWB SA

Explanation drawing 1 G.NO.002 only

USB PWB SA

KWS0784-001

13
QYSDSP 3006N (TPS0254)

XID580i

2 1

15

12

2
QYSDSP 3006N

14 11
3

(247-1)

16
CN1

8
KWS0666-001

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

PART NO. KJP23058-B01 KJP45330-A01 QYSDSP3006N EDS-17L TPS0247-001-A UAMS-07-0 KWS0666-001

REVISED PART NO. Rev.

PART NAME POWER UNIT BKT SA MASK PLATE SCREW EDGE SADDLE HEATER P. PWB ASY WIRE CLAMP WIRE ASY

PRICE

XID580i 1 2 4 1 1 1 1

QTY XID580i-B 1 1 4 1 1 1 1

DESCRIPTION

KJP46797-001 TPS0254-001 KWS0784-001 QYSDSP3006N QYSPSP3006N KJJ46271-003

USB OPTION BKT USB CONN PWB ASY WIRE ASY SCREW SCREW TAP SCREW

1 1 1 1 1 4

115

< FINAL ASSEMBLY


Explanation drawing 1

11
CN12

KWS0785-001

CLUMP
Pass the wires of power switch

CN3

13

KWS0744-001

9 14
KWS0767-002

J10

J14

15
QYSPSPD 3006Mx3

KWS0768-001

J10 J14

J14 J10 J10


KWR18416-001

12

QYSPSPD3006Mx2

8
CLUMPx2

J9
QYSPSPD3006Mx2

8 1
(TFA0023) (TSA0141)

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

PART NO. TFA0023-002 TSA0141-001-S

REVISED PART NO. Rev.

PART NAME PR COMMON ASY MG/IC UNIT ASY(ISO)

PRICE

XID580i 1

QTY XID580i-B 1 1

DESCRIPTION

lncluding ISO/IC contact

QYSPSPD3006MA KJJ46271-003 KWS0785-001 KWR18416-001 KWS0744-001 KWS0767-002 KWS0768-001

ASY SCREW TAP SCREW WIRE ASY WIRE ASY WIRE ASY WIRE ASY WIRE ASY

7 6 1 1 1 1 1

Color : Black

116

T0137-2/12

< FINAL ASSEMBLY

CLAMPx2

J14

CLAMPx2
Explanation drawing 1
WIRING

CLAMP

KWR17606-001

Explanation drawing 1

J2

2 7
QYSPSPD 3006Nx3

SYMBOL NO. 1 2 3 4 5 6 7

PART NO. KBB0007-001 KJU46660-A01 KWR17606-001 EDS-3 QYSPSPD3006N

REVISED PART NO. Rev.

PART NAME RF-ID UNIT RFID COVER-M WIRE ASY EDGE SADDLE ASY SCREW

PRICE

QTY 1 1 1 1 3

DESCRIPTION

T0164-3/12

117

< FINAL ASSEMBLY


1 3
Explanation drawing 2 Wiring

G.NO.004 (244-1) G.NO.002 (245-1)

2 5

10 6
J1

Clamp the USB wire with the wire from the encorder

Explanation drawing 1 MG PWB SA

KJJ46271-001x4

CLAMP

Explanation drawing 2

MG PWB SA

Explanation drawing 1

KJJ46271 -003 3pin J1 CN1 J8

USB

CLAMP

J4

J5 J3 KJJ46271-003 J7

6
Explanation drawing 2
CLAMP

Be careful not to make the nearby cable pinched by the screw.

Clamp the USB wire at the CORD CLIP

KJJ46271-003

KJJ46271 -003

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10

PART NO. TPS0244-001-A KJP34092-B01 LWS-3S-2W UAMS-07-0 KJJ46271-003 QGH2502A2-10 CS-8U

REVISED PART NO. Rev.

PART NAME MG MAIN PWB MG PWB BKT LOCKING WIRE SA WIRE CLAMP TAP SCREW CONNECTOR CORD CLIP

PRICE

XID580i

QTY XID580i-B 1 1 1 1 8 1 1 ISO

DESCRIPTION

118

< FINAL ASSEMBLY


Pull up the cable coming from the power switch, to reduce the slack.

Explanation drwing 2

POWER SUPPLY SA

100V-120V/220V-240V model
H1=Retransfer Heater H2=Bend Remedy Heater H1 H2

3
7
H2 H1
Explanation drwing 1

KWS0639-001

H1

F3

H2

CN2 CN8 CN4 CN3 CN8


Explanation drwing 2

CN1

CN4 CN5 CN6 CN7


Explanation drwing 1

POWER SUPPLY SA

10

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12

PART NO. KBS14404-003 LWS-3S-2W CKN-10 CKN-05

REVISED PART NO. Rev.

PART NAME POWER SUPPLY LOCKING WIRE SA WIRE CLAMP WIRE CLAMP

PRICE

QTY 1 1 2 1

DESCRIPTION

KWS0639-001

WIRE ASY

100V-120V/220V-240V

KJJ46271-003

TAP SCREW

119

< FINAL ASSEMBLY


(TPS0219)

2
Remove the protection sheet

Note that neither dust nor garbage are placed.

Explanation drawing 1

FRONT PANEL SA

11

Pass the cables coming from the front panel together with the fan wires through the ferrite core.

FRONT PANEL SA Explanation drawing 1

Be careful not to damage connectors when connecting

Hit two claws on the rear of the front panel lightly to engage it into the frame.

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12

PART NO. TFS0114-003 TPS0246-001 QYSDSF3008N QYSDSP4008N

REVISED PART NO. Rev.

PART NAME FRONT PANEL ASY FRONT PWB ASY TH. TAP SCREW SCREW

PRICE

QTY 1 1 3 6

DESCRIPTION

KQY2006

FERRITE CORE

120

< FINAL ASSEMBLY


HOPPER SA Explanation drawing 1

15

5 15

x6

(TSS0177)

1 3

x6

15 7 15

15

10

Explanation drawing 1
HOPPER SA

Apply the grease (the volume of one pieve of sesame) uniformly on the surface.

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

PART NO. TSS0177-002 KJP23057-D01 KJP23057-D02 0456 KKM11038-001 KKM11039-001 KJP46284-001

REVISED PART NO. Rev.

PART NAME HOPPER ASY HOP. RAIL BKT HOP. RAIL BKT CANOE CLIP HOPPER DOOR HOPPER COVER JOG LEVER

PRICE

QTY

DESCRIPTION

1 1 12 1 1 1

GB-TS-1 QYSPSPD3006N

GREASE ASY SCREW

12

121

< FINAL ASSEMBLY

1
MEDIA CASSETTE (TFS0134)

11

(TFS0116)

4
(TFS0133) INK CASSETTE

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

PART NO. CX320-HD1

REVISED PART NO. Rev.

PART NAME THERMAL HEAD ASY

PRICE

QTY 1

DESCRIPTION

TFS0133-001 TFS0134-001 TFS0116-002

INK CASSETTE ASY MEDIA CASSETTE ASY CLEANING ROLLER ASY

1 1 1

QYSPSP4008N

SCREW

122

< FINAL ASSEMBLY


12 REAR PANEL SA 12
TSS0239-AB FAN BKT SA

FAN BKT SA
2

Affix

13

Affix

11
F3

F3

REAR PANEL SA

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PART NO. KKP11041-002 KJP34339-001

REVISED PART NO. Rev.

PART NAME REAR PANEL FAN BKT

PRICE

QTY 1 1

DESCRIPTION

KEF1042-002 KJY46337-001 KJY46337-003

FAN MOTOR GASKET GASKET

1 1 1

QYSDSP4008N KJJ46271-003 QYSPSPD3030N

SCREW TAP SCREW SCREW

1 2 2

123

< FINAL ASSEMBLY


Affix the label with its window positioned just on the top cover window.
Caution
This is a card exit. Install the card stacker to the lower slot.
CARD EXIT

KXL46398-001

Throw away the shaded area of the label.

x2

Explannation drawing 1 FILTER R SA

Explannation drawing 2 FILTER L SA

Sheet edges shall be on the same level as the edges of the rectangular window.

9
Explannation drawing 3 R.COVER SA R.COVER SA

10 11 10

FILTER R SA Explannation drawing 1

FILTER L SA Explannation drawing 2

14

6 14 15 15 7 14

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PART NO. KKP11040-B02

REVISED PART NO. Rev.

PART NAME TOP COVER

PRICE

QTY 1

DESCRIPTION

KJU46277-001 KXL46415-001 KKM34105-001 KKM34085-001 KJM33129-001 CX220-FFK1 KJM33130-001

STATIC SHEET ST CAUTION LABEL MENTE COVER DUMMY COVER FILTER CAP R FAN FILTER ASY FILTER CAP L

2 1 1 1 1 1 1

English

As 1 set including 3 kinds 4 sheets of filters

QYSDSP4008N QYSDSP3006N

SCREW SCREW

7 2

124

< ANNEX ASSEMBLY


1
10
(-006)

13

10

(-006)

KWS0623-001

Check part number

Cleaning card

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

PART NO. QAM0812-001 QMP4908-200R KDH40058 CX210-CC1 CX-120-STK2 KAT-T230 KD41811-006 KD41811-011 KD41811-012 KWS0623-001

REVISED PART NO. Rev.

A
Card stocker

Instructions

pp x. ro 22 cm
6 5 10
(-006)

11

(-011)

Instruction Manual

(-012)

12

PART NAME USB CABLE POWER CORD POWER CORD CLEANING CARD STOCKER INSTRUCTION MANUAL POLY BAG POLY BAG POLY BAG WIRE ASY

PRICE

QTY XID580i XID580i-B 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 3 2 1 1

DESCRIPTION

200V 120V/UL 10 sheets/set

125

< FINAL ASSEMBLY


Affix

6
M G IC JIS O IS

MG

JIS

ISO IC

Mark with black pen in the way same as the old CA CAUTION LABEL

As a protection for shipment

7
SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 REVISED PART NO. Rev.

PART NO.

PART NAME

PRICE

QTY

DESCRIPTION

KPZ46408-001 KXL34240-002 NO.3800A

PROTECT SHEET CA CAUTION LABEL TAPE

1 1 (1)

126

< FINAL ASSEMBLY


1

As a protection for shipment

Be careful not to break or not to be caught into the door.

Align the notches.

As a protection for shipment

Insert it between the printing side of a head and platen.

After installing the ink cassette, paste tape onto ink cassette.

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

PART NO. KPZ34180-001 KJU45126-003

REVISED PART NO. Rev.

PART NAME PROJECT SHEET HEAD CUSHION

PRICE

QTY 1 1

DESCRIPTION

127

< FINAL ASSEMBLY


Fig.1 (LT)

Fig.1 Assembling the CUSHION (E.g. upper right) (Other 3 cushions also same)

2
Wide
(RT) Cut 90 towards the joint portion respectively.

Fig.1

14 Seal with tape

The end of the portion cut should be left outside.

Paste the label on front. Check the model name.

Front mark

5 2 Base plate

(TFS0136-005)

(TFS0136-011)

(LB) Fig.1

(RB)

Fig.1

CX 21 0J ^^ ^

^ ^ ^ 0J 21 X C

UP

H sealing on top

Wide

15

This-side-up
UP

1 1 1
4

x2 10

This-side-up
UP

15
H sealing on bottom

SYMBOL NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

PART NO. KPA34199-002 KPC34368-A0A CP30182-001 TFS0136-005 TFS0136-011 KPP44128 KXT44142-001

REVISED PART NO. Rev.

PART NAME PACKING CASE CUSHION ASY P CASE JOINT ANNEX ASY ANNEX ASY POLY BAG PACKING LABEL POLY BAG

PRICE

XID580i 1 1 2 1

QTY XID580i-B 1 1 2

DESCRIPTION

1 1 2 1 2 Label printer

NO.29-18 NO.375

NITTO C TAPE NITTO D TAPE

(1) (1)

(1) (1)

Auxiliary material Auxiliary material

T0140-12/12

128

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