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SERVICE NOTES

Confidential

TERMS OF USE
The use of this Service Note constitutes agreement with the following Terms of Use.

1. USERS
This Service Note is only for authorized persons with user ID and password issued by Roland DG Corporation.
2. PURPOSE
Authorized persons can use this Service Note only for the purposes of selling and providing the customers with maintenance
services of SG-540 / 300.
3. REUSE
Authorized persons shall not disclose, transfer, rent or distribute this Service Note to, or allow this Service Note to be used in
any manner by any third party other than authorized persons.
4. REPRODUCTION
This Service Note may not be copied or modified without permission of Roland DG Corporation.
5. EFFECT OF VIOLATION
Regardless of circumstances, we will vigorously respond to any violation hereof, through legal action.

Copyright © 2016 ROLAND DG CORPORATION

70422-09
Table of Contents

TABLE OF CONTENTS
Table of Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-1 Linear Encoder Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Revision History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-2 Flushing Position Adjustment . . . . . . . . . . . . . . . . . . . . . . . 2-26

Important Notes on Handling and Use. . . . . . . . . . . . . . . . . T-3 Crop Mark Sensor Adjustment. . . . . . . . . . . . . . . . . . . . . . . 2-29

Key Combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-4 Print Head Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-5 Tool Height Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Chapter 1 Replacement of Main Parts 1-1 Tool Pressure Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

Important Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

Print Head Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Carriage Belt Position Adjustment. . . . . . . . . . . . . . . . . . . 2-41

Cap Top Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Wiper Position Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

Tool Carriage Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Feed Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

Scan Motor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 Chapter 3  Electrical Parts 3-1


Feed Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 SG-540 Wiring Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Pressure Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . 1-34 SG-300 Wiring Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Pressure Control Valve Replacement. . . . . . . . . . . . . . . . . 1-39 Main Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Main Board Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41 Servo Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Servo Board Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44 Print Carriage Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Signal JC Board Replacement. . . . . . . . . . . . . . . . . . . . . . . . 1-46 Chapter 4 Supplemental Information 4-1


SW Power Supply Replacement. . . . . . . . . . . . . . . . . . . . . . 1-50 Motor Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Pump Drive Board Replacement. . . . . . . . . . . . . . . . . . . . . 1-52 Service Call Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Heater Control Board Replacement. . . . . . . . . . . . . . . . . . 1-54 Supplemental Information on Service Call 0400 ��������������4-6

Ink System RFID Board Replacement. . . . . . . . . . . . . . . . . 1-56 Sensor Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

RFID R/W Board Replacement . . . . . . . . . . . . . . . . . . . . . . . 1-58 Chapter 5 Service Activities 5-1


Carriage Belt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 1-62 Installation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Encoder Scale Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 1-68 Maintenance Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Linear Encoder Board Replacement. . . . . . . . . . . . . . . . . . 1-70

Battery Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-73

Ink Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-75

Chapter 2 Adjustment 2-1


Service Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

History Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Other Factory Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Firmware Upgrade Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Firmware Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Limit Position & Cut Down Position Initialization ��������� 2-22

T-1 SG -540/300
Revision History

TABLE OF CONTENTS
Revision Date Description Approver Author
0 September 1, 2016 First edition Kawai Shin
Chapter 1 Replacement of Main Parts [Print Head Replacement], [Tool Carriage
Replacement], [Pressure Pump Replacement], [Pressure Control Valve
Replacement], [Main Board Replacement], [Servo Board Replacement],
[Carriage Belt Replacement], [Encoder Scale Replacement], [Linear
1 November 9, 2016 Kawai Shin
Encoder Board Replacement], [Battery Replacement]
Chapter 2 Adjustment [Service Mode], [Print Head Alignment], [Tool Height
Adjustment], [Tool Pressure Adjustment], [Belt Tension Adjustment], [Belt
Position Adjustment], [Wiper Position Adjustment], [Feed Calibration]
Chapter 1 Replacement of Main Parts [Feed Motor Replacement], [Signal JC
Board Replacement], [SW Power Supply Replacement], [Pump Drive
Board Replacement], [Heater Control Board Replacement ] [Ink System
2 December 28, 2016 Kawai Shin
RFID Board Replacement], [RFID R/W Board Replacement], [Ink Tube
Replacement]
Chapter 2 Adjustment [Print Head Alignment]
3 February 3, 2017 Chapter 2 Adjustment [Tool Pressure Adjustment] Kawai Shin
4 April 3, 2017 Chapter 4 Supplemental Information [Motor errors] Nimura Saito
5 August 1, 2017 Chapter 1 Replacement of Main Parts [Print Head Replacement] Nimura Saito
6 September 15, 2017 Chapter 1 Replacement of Main Parts [Print Head Replacement] Nimura Saito
Chapter 1 Replacement of Main Parts [Print Head Replacement]
7 September 29, 2017 Nimura Saito
Chapter 2 Adjustment [Print Head Alignment]
8 February 6, 2018 Chapter 4 Supplemental Information [Service Call Errors] Nimura Saito
9 May 25, 2018 [Special Tools] Nimura Saito
10
11
12
13
14
15
16
17
18
19
20

T-2 SG -540/300
Important Notes on Handling and Use

TABLE OF CONTENTS
Service parts
For information on service parts required for the parts replacement or adjustment, refer to
Parts Finder Web.
https://365rolanddg.sharepoint.com/sites/extranet/Work-SitePages/GSV-PartsFinder.aspx

Warning Labels

labels are as follows. Be sure to heed their warnings. Also, never remove the labels or allow them to become dirty.

Caution: Pinching Hazard


Be careful not to allow the

when closing covers.

Caution: High Temperature


The platen and dryer become
hot. Exercise caution to avoid

it may be hazardous to the health. When performing


maintenance work, for example when disposing of dis-

gloves (refer to the safety data sheet (SDS)).

Flammable

Caution: High Voltage


Removing the cover may result in
high-voltage electric shock.

T-3 SG -540/300
Key Combinations

TABLE OF CONTENTS
Item Operation Operation

ON
Make sure that the power cord is connected
Main power ON
when the main power is turned on.

OFF
Make sure that the sub power is turned off
Main power OFF
when the main power is turned off.

For service engineers Combination key selection Description

Press the [MENU] [▼] keys to enter the service


Service mode + menu.

“UPDATE FIRMWARE?” is displayed.


Firmware upgrade mode + Press the [ENTER] key to upgrade firmware.

Use this key combination to install firmware


+ after replacing the main board.

Firmware installation
(When replacing the main board)
In case of a brand-new main board without
firmware installed, [SUM-ERROR] is displayed
ENTER when the sub power SW is turned on. Press
the [ENTER] key so that the printer will become
ready to load firmware.

System parameter initialization ENTER


+ All parameters will be initialized.
Press the [ENTER] key to start initialization.

Limit position/cut down position


initialization + Press the [ENTER] key to initialize limit position.
Then, set up cut down position.

For users Combination key selection Description

User mode Press the [MENU] to enter the user menu.

Language/unit selection MENU


+ Press the [▲] [▼] keys to select language/unit.

T-4 SG -540/300
Special Tools 9

TABLE OF CONTENTS
Parts No. ST-056
Parts Name TORQUE DRIVER N6

Print Head Replacement


Purpose
Print head alignment (Retaining print head)

Parts No. 1000015274


Parts Name BIT, PHILLIPS NO.2 L200MM

Print Head Replacement


Purpose
Print head alignment

Parts No. ST-001


Parts Name TENSION GAUGE 2000GF/2000CN

Purpose Belt tension adjustment

ST-037
Parts No.
1000003138
CLEANING STICK TX712A
Parts Name
SET,CLEANER STICK TX712A 10PCS.

Purpose Print head cleaning

Parts No. 21755107


Parts Name CLEANING LIQUID,(SL) 500ML

Purpose Print head cleaning (SL/CL)

Parts No. 22085118


Parts Name KIT, CLEANING(SL)

Print head cleaning (SL/CL)


Purpose
* Cleaning liquid + Cleaning sticks 10 pcs

Parts No. 21675102


Parts Name GREASE, FLOIL G-902 10ML

Purpose Grease

T-5 SG -540/300
Chapter 1 Replacement of 1

Main Parts

REPLACEMENT
Important Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50
To Ensure Safe Work. . . . . . . . . . . . . . . . . . . . . . . . 1-2 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50

Print Head Replacement . . . . . . . . . . . . . . . . . . . . . 1-3 Pump Drive Board Replacement. . . . . . . . . . . . . 1-52


Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52

Cap Top Replacement. . . . . . . . . . . . . . . . . . . . . . . 1-13 Heater Control Board Replacement. . . . . . . . . . 1-54


Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54

Tool Carriage Replacement. . . . . . . . . . . . . . . . . . 1-16 Ink System RFID Board Replacement. . . . . . . . . 1-56
Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-56
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-56

Scan Motor Replacement. . . . . . . . . . . . . . . . . . . . 1-20 RFID R/W Board Replacement . . . . . . . . . . . . . . . 1-58


Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58

Feed Motor Replacement . . . . . . . . . . . . . . . . . . . 1-26 Carriage Belt Replacement. . . . . . . . . . . . . . . . . . 1-62


Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62

Pressure Pump Replacement. . . . . . . . . . . . . . . . 1-34 Encoder Scale Replacement. . . . . . . . . . . . . . . . . 1-68


Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34 Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-68
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-68

Pressure Control Valve Replacement. . . . . . . . . 1-39 Linear Encoder Board Replacement. . . . . . . . . . 1-70
Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39 Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-70
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-70

Main Board Replacement. . . . . . . . . . . . . . . . . . . .1-41 Battery Replacement. . . . . . . . . . . . . . . . . . . . . . . . 1-73


Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41 Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-73
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-73

Servo Board Replacement. . . . . . . . . . . . . . . . . . . 1-44 Ink Tube Replacement . . . . . . . . . . . . . . . . . . . . . . 1-75


Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44 Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-75
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-75

Signal JC Board Replacement. . . . . . . . . . . . . . . . 1-46


Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46

SW Power Supply Replacement. . . . . . . . . . . . . . 1-50

1-1 SG -540/300
Important Points

To Ensure Safe Work


Turn off the sub power SW and main power SW,
and unplug the power cable of the printer
before per forming par ts replacement.
Performing the parts replacement while the 1

REPLACEMENT
power is on may result in injury by unintended
operation of the printer.

Static electricity can harm some electronic


devices. To prevent static damage, discharge
static electricity from your body before you
touch any of electronic devices. You can do so
by touching an unpainted metal surface on the
chassis. You can also take the following steps to
prevent damage from electrostatic discharge
(ESD):

zzWhen unpacking a static-sensitive device


from its shipping carton, do not remove the
device from the antistatic packing material
until you are ready to install the device to the
printer. Just before unwrapping the antistatic
packaging, be sure to discharge static
electricity from your body.

zzWhen transporting a sensitive device, first


place it in an antistatic container or packaging.

zzHandle all sensitive devices in a static-safe


area. If possible, use antistatic floor pads and
workbench pads.

1-2 SG -540/300
Print Head Replacement 1 5 6 7

Information Procedure
Print Head Assembling
Necessary tools
1. Insert the ribbon cable into the print head.
General tools 1
C AU TIO N

REPLACEMENT
No.2 Phillips screwdriver
Insert the ribbon cable with the orientation shown
Gloves (anti-slip)
in the figure.
Waste cloth

Service parts
ASSY,INKJET HEAD (HEAD ONLY) SV
6000003425
CG2048
1000015256 ASSY, DAMPER DOUBLE CIR 2 VG-640
HEAD TUBE 70MM+STOPPER SET SV
1000018253
CG2048

1000014627* CABLE-CARD,24P0.5 200L BB HIGH-V

3000000435 TAPE, 650S-25-20X20

*2 pcs are needed per print head.


Replace the above parts all at the same time. 2. Cut the protective tape (TAPE, 650S-25-20X20) into
20+/-3 mm, and attach it to the print head.
Special Tools
ST-056 TORQUE DRIVER N6
1000015724
BIT, PHILLIPS NO.2 L200MM
1000015274

Workflow

1. Print head assembling


2. Print head replacement
3. Clearing the print head information
C AU TIO N
4. Print head alignment
• Be sure to cover all the terminals indicated in red
when you attach the protective tape.
Typical work time

Contents of work Time


Print head assembling 5 min.

Print head replacement 45 min.

Clearing the print head information 1 min.

Print head alignment 25 min.

1-3 SG -540/300
Print Head Replacement

• Press the protective tape at the stepped parts of 4. Fold the protective tape to the back side.
the connector.

REPLACEMENT
3. Cut the protective tape into 50+/-3 mm and attach it
to the print head.

5. Attach the protective tape to the ribbon cable on the


other side in the same way by following the steps 1
C AUTI ON
through 4.
Attach the protective tape with the red line in the
figure as the reference position. 6. Attach the damper.
C AU TIO N
• Check the orientation of the damper.
• The resin spring side comes the filler side.
• Attach one of the two hooks indicated with the red
arrow first.

1-4 SG -540/300
Print Head Replacement

• Check that the hook has been caught securely. Print Head Replacement

1. Turn off the main power SW.


2. Remove six screws that secure the operation panel.
1

REPLACEMENT
7. Attach the head rank sticker to the right ribbon
cable.

C AU TIO N
Before removing the operation panel, make sure to
unlock the connector which is connected to the the
panel board.

N OTE
Attach the sticker near the terminal that will be
3. Loosen two screws. Remove the front cover while
connected to the print carriage board.
moving it to the left.

1-5 SG -540/300
Print Head Replacement

4. Remove the screws (SG-540: 10 locations, SG-300: 9 7. Open all the clamps that secure the ferrite cores, and
locations). then remove the plate.

REPLACEMENT
5. Loosen the second screw from the right. Remove 8. Disconnect all the ribbon cables from the print
the other screws (SG-540: 4 locations, SG-300: 3 carriage board.
locations) that secure the cover.

C AU TIO N
Open the cover in the direction of the arrow marked
"1". Then, disconnect the ribbon cable from the print
6. Remove two screws that secure the cover. carriage board.
Memo 1
The screws are on the right and left side of the cover.

1-6 SG -540/300
Print Head Replacement

9. Place waste cloth under the tube joints. Ink may C AU TIO N
spatter and cause stains. • Be sure to find head rank seal in rear (upper) side
of the ribbon cable.

2 1

REPLACEMENT
Rear side

793643
002231
0000
0516
10. Remove the ink tubes, which are attached to the print Front side

head you are going to replace, from the L-shaped


tubes.

C AUTI ON
Remove the ink tubes slowly to prevent ink from
12. Tighten one or a couple of screws to temporarily
fasten the operation panel.
dripping or spattering. Putting waste cloth under
the L-shaped tubes is recommended. Even after the
ink tubes are removed from the L-shaped tubes, ink
will not leak from the L-shaped tubes because the
pressure control valves prevent it.

Memo
Wipe off any ink from the ribbon cables and print
heads with waste cloth.

C AU TIO N
Connect the connector to the panel board.
13. Turn on the main power SW.
14. Turn on the sub power SW while pressing the [] []
[] keys to enter the service menu.

C AU TIO N
The machine may perform automatic cleaning if you
11. Connect all the ribbon cables to the print carriage do not turn on the sub power for a while and the
certain time interval has passed. To avoid automatic
board.
cleaning, be sure to put the machine into service
mode within 30 seconds after the main power is
switched on.
15. Go to [SERVICE MENU] > [SUB MENU] > [EMPTY
DAMPER] and drain ink from the ink damper.

*Required time for [EMPTY DAMPER]: approx. 3 min.

1-7 SG -540/300
Print Head Replacement

C AUTI ON 18. Disconnect the ribbon cables, which are connected


Be sure to perform [EMPTY DAMPER]. Otherwise, ink to the print head you are going to replace, from the
may leak from the dampers while you are removing print carriage board.
the print head.
C AU TIO N
Memo Open the cover in the direction of the arrow marked
1
• To save ink, refer to the figures below and remove "1". Then, disconnect the ribbon cable from the print

REPLACEMENT
the tubes, which are connected to the print heads carriage board.
NOT being replaced, from the pumps. Be sure
to reconnect them to the pumps when [EMPTY
1
DAMPER] is completed and after performing step
35.
• Be careful not to spatter ink on the feed encoder
when removing the tubes from the dampers. 2

1
2 19. Remove two screws that secure the print head.

16. Turn off the main power SW.


20. Detach the filler guard from the print head, and
17. Remove six screws that secure the operation panel. attach it to the new print head.

M emo
Pinch the upper part of the filler guard and detach it.

C AUTI ON
Before removing the operational panel, make sure
to disconnect the connectors from the panel board.

1-8 SG -540/300
Print Head Replacement

C AUTI ON 21-2. Then, press the spring against the head base until
Be careful not to touch the filler. the spring bends, and then push the rear side of
the print head into the head base.

REPLACEMENT
21. Attach the new print head to the head base.
C AUTI ON
Be careful not to touch the filler.

21-3. Make sure that the print head is attached to the


21-1. First, hook the spring, which is on the right front base firmly.
side of the print head, to the head base.
C AU TIO N
• If the print head is not attached firmly, it may crack
when you secure it with screws.
• Make sure that the print head is level to the head
base.

1-9 SG -540/300
Print Head Replacement

22. Tighten two screws in the order shown below to secure 25. Close the ends of the new tubes with lids. Then,
the print head (torque value: 0.2N・m/20cN・m). attach the tubes to the rear side of the print head.

REPLACEMENT
1

23. Attach the tubes came with the print head assembly
to the L-shaped tubes.

C AUTI ON 26. Disconnect all the ribbon cables from the print
• Do not apply cleaning liquid (SL-CL/CJ-CL). carriage board.
• Be sure to wear gloves (anti-slip).
• Hold the tube about 10 mm from the end and
insert it straight so that it does not bend.

27. Attach the ferrite core plate, and then connect the
ribbon cables to the print carriage board.
24. Attach the tubes, which are connected to the
L-shaped joint, to the print heads.

C AUTI ON
• Be sure to wear gloves (anti-slip).
• Hold the tube about 10 mm from the end and
insert it straight so that it does not bend.

H1 H2

CY MG YE BK 28. Tighten two screws to secure the cover.

1-10 SG -540/300
Print Head Replacement

Memo 31. Tighten six screws to secure the operation panel.


The screws are on the right and left side of the cover.

REPLACEMENT
C AU TIO N
• Tighten the two screws on ths panel side to make
gap of approx. 1.5 mm between the panel and the
29. Hitch the cover to the loosen screw, and then tighten flame by extending the flame to the left.
the screws (SG-540: 5 locations, SG-300: 4 locations)
to secure the cover. 1.5 mm Clearance

• Connect the connector to the panel board.

32. Turn on the main power SW.


33. Turn on the sub power SW while pressing the [] []
[] keys to enter the service menu.

34. Select [SERVICE MENU] > [PRINT MENU] > [HEAD


RANK], and input the head rank, which is written
30. Tighten the screws (SG-540: 10 locations, SG-300: 9 on the ribbon cable of the new print head. Input
the head rank by selecting the corresponding digit
locations) to secure the cover.
with [] [] keys and changing the parameters with
[▲] [] keys. Then press the [ENTER] key to save the
setting.

C AU TIO N
Make sure to input the head rank correctly. Even
when you input a wrong head rank, a warning
message will NOT appear.

1-11 SG -540/300
Print Head Replacement

35. Perform[SERVICE MENU] > [SUB MENU] > [FILL


DAMPER] and fill the damper with ink.
* Required time for [FILL DAMPER]: approx. 18 min.

C AUTI ON
Make sure that the amount of remaining ink is more 1
than approximately 50 cc before starting the [FILL

REPLACEMENT
DAMPER]. If ink runs out during the operation, it may
cause cleaning error and ink mixture occurs. If ink
mixture occurs, perform [FILL DAMPER] again after
performing super cleaning.
(The message "CHANGE TO NEW INK CARTRIDGE" is
displayed on the screen.)
36. Clearprint head information. Perform [SERVICE
MENU] > [HISTORY MENU] > [HEAD GROUP] > [SHOT
COUNT1] to [SHOT COUNT4] > [CLEAR].

37. Perform the following.


37-1. Test Print
• When the printing result has missing dots or
deflected-fired dots, perform the cleaning again.

37-2. Chapter 2 "Print Head Alignment"


38. (End of procedure)

1-12 SG -540/300
Cap Top Replacement

Information Procedure
1. Turn off the main power SW.
Necessary tools
2. Remove the screws that secure the covers shown in
General tools orange in the figure. 1

REPLACEMENT
No.2 Phillips screwdriver

Special Tools
None

Workflow

1. Cap top replacement

Typical work time


M emo
Easiest way to remove the cover shown below is to 1)
Contents of work Time
slide the cover to the front, 2) lift up the rear side of
Cap top replacement 10 min
the cover, and 3) remove the cover from the left side.

2
3
1

3. Remove the screw that secures the rear part of the


cap top.

1-13 SG -540/300
Cap Top Replacement

4. Loosen the screw that secures the front side of the 7. Slide the cap top to the front. Then, lift up the rear
cap top. side of the cap top, and remove it.

C AUTI ON
Do not remove the screw completely. Just loosen
them. If you remove it, the base part of the cap top 2 1
will fall off.

REPLACEMENT
1

C AU TIO N
There are springs under the cap top. Remove the cap
5. Slide the cap-base frame to the right, and then lift it top carefully so that these springs will not jump out.
up to remove it.

6. Detach the tube from the cap-base frame. 8. Tighten two screws to secure the new cap top.
Bottom view

1-14 SG -540/300
Cap Top Replacement

9. Check that the spring is attached properly. M emo


Easiest way to attach the cover shown below is to 1)
OK
insert the cover from the left side and 2) fit the rear
part of the cover in place as you lift the front part of
the cover.
1

REPLACEMENT
1 2

No Good

12. (End of procedure)

10. Attach the tube.


Bottom view

11. Fasten the covers with screws.

1-15 SG -540/300
Tool Carriage Replacement 1

Information Procedure
1. Turn off the main power SW.
Necessary tools
2. Remove two screws that secure the cover.
General tools 1

REPLACEMENT
No.2 Phillips screwdriver
2.5 mm hexagonal wrench

Special tools
None

Workflow

1. Tool carriage replacement


3. Remove the blade holder.
Typical work time

Contents of work Time


Tool carriage replacement 20 min

4. Unplug the solenoid cable and two connectors.

5. Release the cable from the clamp.

1-16 SG -540/300
Tool Carriage Replacement

6. Remove the screw that secures the sheet cutter 9. Remove two screws that secure the stay.
holder.

REPLACEMENT
10. Remove three screws that secure the tool carriage.
7. Remove two screws that secure the stay.

8. Unhook the spring from the black stay. 11. Tighten three screws to secure the new tool carriage.
C AUTI ON
When unhooking the spring, be careful not to lose it.

12. Tighten two screws to secure the stay.

1-17 SG -540/300
Tool Carriage Replacement

13. Attach the spring to the black stay. 17. Plug the solenoid cable into the tool carriage board.

REPLACEMENT
14. Tighten two screws to secure the stay. 18. Plug two connectors into the tool carriage board.

C AU TIO N
15. Tighten the screw to secure the sheet cutter holder. 1. Place the two CN103 connector (shown in yellow
in the figure) on top of the solenoid cable (shown in
red).
2. Place the three cables in between the two screws
as shown in the figure.

CN103

2
16. Bundle the cables with the clamp.

1-18 SG -540/300
Tool Carriage Replacement

19. Tighten two screws to secure the cover.

REPLACEMENT
20. Perform the following adjustments.
20-1. Limit Position & Cut Down Position Initialization
"" Refer to Chapter 2 "Limit Position & Cut Down
Position Initialization".

20-2. Tool Height Adjustment


"" Refer to Chapter 2 "Tool Height Adjustment".

20-3. Tool Pressure Adjustment


"" Refer to Chapter 2 "Tool Pressure Adjustment".

20-4. Crop Mark Sensor Adjustment


"" Refer to Chapter 2 "Crop Mark Sensor Adjustment".

20-5. Crop Cut Adjustment


* Adjust the crop cut position by selecting [SERVICE
MENU] > [CUTTING MENU] > [CROP-CUT ADJ.].

20-6. Print/cut position adjustment


* Adjust the print/cut position by selecting [SERVICE
MENU] > [CUTTING MENU] > [PRINT-CUT ADJ.].

21. (End of procedure)

1-19 SG -540/300
Scan Motor Replacement

Information Procedure
C AU TIO N
Necessary tools • A Phillips screwdriver with a length of 80 mm or
less is necessary.
General tools 1
80 mm or less

REPLACEMENT
No.2 Phillips screwdriver

No.2 Phillips screwdriver (80 mm or less)

3.0 mm hexagonal wrench


• An interlock mechanism ordinarily prevents
Special Tools carriage movement when the printer's cover is
1000009378 GREASE, FLOIL G-902 opened. To operate the printer with the front cover
open, press and hold the sensor switch.

Scan Motor Replacement


Workflow
1. Turn off the main power SW.
1. Scan motor replacement
2. Remove six screws that secure the operation panel.
2. Servo lock check
3. Aging check
4. Motor time clear

Typical work time

Contents of work Time


Scan motor replacement 30 min.

Servo lock check 1 min.

Aging check 5 min.

Motor time clear 1 min.


C AU TIO N
Before removing the operation panel, make sure to
unlock the connector which is connected to the the
panel board.

1-20 SG -540/300
Scan Motor Replacement

3. Remove two screws that secure the maintenance 6. Detach the rivet. Slide the cover to access the motor
cover sensor R. screw.

REPLACEMENT
4. Remove 18 screws that secure the cover.

7. Remove eight screws that secure the cover.


M emo
• The length of a Phillips screwdriver you can use is
limited to 80 mm or less because the cleaning liquid
pouch tray is just above it.
• Use a Phillips screwdriver with a length of 80 mm
or less.

5. Open the clamps.

1-21 SG -540/300
Scan Motor Replacement

8. Open the clamp and unplug the connector. 11. Unplug the connector from the motor.
Memo M emo
When unplugging the connector, make sure to When unplugging the connector, make sure to
unlock the connector. unlock the connector.
1

REPLACEMENT
9. Unhook the spring.

12. Remove four screws that secure the flange to the


motor. Then, fasten the new motor to the flange.

10. Remove three screws to remove the motor along


with its flange.

C AU TIO N
Be careful to correctly orient the flange in relation to
the motor cables.

1-22 SG -540/300
Scan Motor Replacement

13. Connect the connector to the motor. 16. Turn the drive gear more than three times by hand
and check that the gears mesh together.

C AU TIO N
Apply grease to the drive gear and the motor gear.
• Grease: FLOIL G-902 1
• Volume: as needed

REPLACEMENT
14. Temporarily fasten the flange with three screws.

17. Fully tighten three screws to secure the flange.


M emo
You can tighten the screws in any order.

15. Attach the spring.

18. Bundle the cables with the clamp. Then, plug in the
connector.

1-23 SG -540/300
Scan Motor Replacement

19. Bundle the cables with the clamps to attach the cover. 21. Temporarily fasten the maintenance cover sensor R
with two screws.

REPLACEMENT
20. Tighten 18 screws to secure the cover.
22. Tighten six screws to secure the operation panel.

23. Turn on the main power SW.


24. Turn on the sub power SW while pressing the [] []
[] keys to enter the service menu.

25. Select [SERVICE MENU] > [SENSOR CHECK].


26. Slide the maintenance cover sensor R to the front
until "*" under "D" disappears. Then, tighten two
screws to secure the sensor.
When the cover is open

FRSHODPULWwaVC
*

When the cover is closed

FRSHODPULWwaVC

1-24 SG -540/300
Scan Motor Replacement

Servo Lock Check

27. Select [SERVICE MENU] > [MOTOR MENU] > [SERVO


LOCK] > [S]. Move the head carriage left and right by
hand and confirm that the value on the LCD changes
as you move the print head.
1

REPLACEMENT
SERVO LOCK
S: 3

28. Press the [ENTER] key to energize the motor. Confirm


that the head carriage cannot be moved easily by
hand and that the value on the LCD returns to the
original value.

SERVO LOCK
S: 1688
ENTER

SERVO LOCK
S: * 1688

Aging Check

29. Go back to [MOTOR MENU]. Select [AGING] > [SCAN],


and press the [ENTER] key. Make sure the printer
performs aging, and then finish by pressing the
[ENTER] key.

C AUTI ON
Remove media before performing aging.

Motor Time Clear

30. Go back to [SERVICE MENU]. Select [HISTORY MENU]


> [MOTOR GROUP] > [MOTOR HOURS S] > [CLEAR],
and press the [ENTER] key. The motor working hours
will be reset to 0.

MOTOR HOURS S
1653 hours
[ ]

MOTOR HOURS S
CLEAR
ENTER

31. (End of procedure)

1-25 SG -540/300
Feed Motor Replacement 2

Information Procedure
C AU TIO N
Necessary tools An interlock mechanism ordinarily prevents carriage
movement when the printer's cover is opened. To
General tools operate the printer with the front cover open, press 1

REPLACEMENT
No.2 Phillips screwdriver and hold the sensor switch.
3.0 mm hexagonal wrench
1. Turn off the main power SW.
2.0 mm hexagonal wrench

1.5 mm hexagonal wrench


2. Open the maintenance cover R.

Special Tools
21675102 GREASE, FLOIL G-902

Workflow

1. Feed motor replacement

Time
3. Unlock the head carriage, and move it to the left by
Contents of work Time hand.

Feed motor replacement 45 min

Servo lock check 1 min

Grit encoder check 1 min

Aging check 5 min

Motor time clear 1 min

4. Remove the screws that secure the covers shown in


orange in the figure.

1-26 SG -540/300
Feed Motor Replacement

N OTE 7. Remove 18 screws that secure the cover.


Easiest way to remove the cover shown below is to 1)
slide the cover to the front, 2) lift up the rear side of
the cover, and 3) remove the cover from the left side.

2
1
3

REPLACEMENT
1

5. Remove six screws that secure the operation panel.

8. Remove the screw that secures the grit encoder


board.
6. Remove two screws that secure the maintenance
cover sensor R.

9. Remove three screws that secure the grit encoder


stopper and the grit encoder.

1-27 SG -540/300
Feed Motor Replacement

10. Detach three rivets from the motor cover. 13. Remove three screws to remove the motor along
with its flange.

REPLACEMENT
14. Slide the motor as shown in the figure below to
remove connector from the motor.

11. Remove two screws that secure the grit encoder stay
and the motor cover.

15. Unfasten the clamp to remove the cables of the


motor, and then unplug the connector.

12. Remove the spring.

16. Slide the cap-base frame to the right, and then lift it
up to remove it. Put it in the front side.

1-28 SG -540/300
Feed Motor Replacement

17. Remove the feed motor from the right side of the 20. Temporarily fasten the flange with three screws.
cap-base frame.

REPLACEMENT
21. Attach the spring.

18. Remove three screws that secure the flange to the


motor. Then, fasten the new motor to the flange.

C AUTI ON
Be careful to correctly orient the flange in relation to
the motor cables.

22. Rotate the drive gear more than three times by hand
and confirm that the gears mesh together.

19. Move the motor back to its original position. Then,


plug the connector into the motor.

C AU TIO N
Apply grease to the drive gear and the motor gear.
• Grease: FLOIL G-902
• Volume: as needed

1-29 SG -540/300
Feed Motor Replacement

23. Fully tighten three screws to secure the flange. And 25. Attach three rivets to secure the motor cover.
then, move the cap-base frame back to its original
position.

REPLACEMENT
24. Attach the grit encoder stay. Tighten two screws to 26. Tighten three screws to secure the grit encoder
secure the grit encoder stay. stopper and the grit encoder.

C AU TIO N
Be careful not to scratch or get grease on the grit
encoder when installing it.

C AUTI ON
Adjust the position so that the tip of the screw
touches the flat surface of the shaft.

27. Tighten the screw to secure the grit encoder board.

1-30 SG -540/300
Feed Motor Replacement

C AUTI ON 29. Temporarily fasten the maintenance cover sensor R


Secure the stay to keep the grit encoder sensor in the with two screws.
center position of the sensor. Make sure to keep the
gap is approximately 1 mm to the front and rear to
the sensor.
1. Grit encoder 1

REPLACEMENT
2. Grit encoder sensor

Approx. 1 mm
2
30. Tighten six screws to secure the operation panel.

28. Tighten 18 screws to secure the cover.

C AU TIO N
• Tighten two screws in the operation panel with
holding up to the left, and then make 1.5 mm
clearance between the frame and the operation
panel.

1.5 mm Clearance

1-31 SG -540/300
Feed Motor Replacement

31. Fasten the covers with screws. 33. Close the maintenance cover R, and then confirm the
cover is fixed.

REPLACEMENT
N OTE C AU TIO N
Easiest way to attach the cover shown below is to 1) If the cover is not fixed, then maintenance cover
insert the cover from the left side and 2) fit the rear sensor R does not work properly. Widen the clearance
part of the cover in place as you lift the front part of between the operation panel and the frame if the
the cover. maintenance cover is not fixed by shaking the right
and left ends of the cover back and forth with your
hands.
1 2 34. Turn on the main power SW.
3
35. Turn on the sub power SW while pressing the [] []
[] keys to enter the service menu.

36. Select [SERVICE MENU] > [SENSOR CHECK].


SERVICE MENU
SENSOR CHECK

32. Move the head carriage to the lock position. 37. Slide the maintenance cover sensor R to the front
until "*" under "D" disappears. Then, tighten two
screws to secure the sensor.
When the cover is open

FRSHODPULWwaVC
*

When the cover is closed

FRSHODPULWwaVC

1-32 SG -540/300
Feed Motor Replacement

Servo Lock Check Aging Check

38. Select [SERVICE MENU] > [MOTOR MENU] > [SERVO 41. Go back to [MOTOR MENU]. Select [AGING] > [FEED],
LOCK] > [F]. Rotate the grit roller by hand, and then and press the [ENTER] key. Make sure the printer
confirm that the value on the LCD changes according performs aging, and then finish by pressing the
to the grit roller rotation. [ENTER] key.
1
SERVICE MENU

REPLACEMENT
C AU TIO N
MOTOR MENU
Remove media before performing aging.
[ ][ ]
SERVICE MENU
MOTOR MENU MOTOR MENU
SERVO LOCK [ ]
[ ]
MOTOR MENU
SERVO LOCK AGING
F: 140 140 [ ] [ ]

39. Press the [ENTER] key to energize the motor. Confirm AGING
FEED
that the grit roller cannot be moved easily by hand
and that the value on the LCD returns to the original
value. Motor Time Clear
SERVO LOCK
F: 80 80 42. Go back to [SERVICE MENU]. Select [HISTORY MENU]
ENTER > [MOTOR GROUP] > [MOTOR HOURS F] > [CLEAR],
and press the [ENTER] key. The motor working hours
SERVO LOCK will be reset to 0.
F:* 80 80
SERVICE MENU
HISTORY MENU
Grit Encoder Check
[ ]
40. Select [MOTOR MENU] > [G-ENC. CHECK] and press
the [ENTER] key. Confirm that [G-ENC. CHECK HISTORY MENU
MOTOR GROUP
COMPLETED] is displayed and the grit encoder works
[ ]
properly. When [G-ENC. CHECK FAILED] is displayed,
check the followings.
MOTOR HOURS F
1. The grit encoder is attached properly. 7 hours
2. The feed motor is attached properly. [ ]

3. The grit encoder has no scratch or stain.


MOTOR HOURS F
SERVICE MENU
CLEAR
MOTOR MENU ENTER
[ ] [ ]

MOTOR MENU
43. (End of procedure)
G-ENC. CHECK
ENTER

M-ENC: 6654
G-ENC: 6653

G-ENC. CHECK
COMPLETED

G-ENC. CHECK
FAILED

1-33 SG -540/300
Pressure Pump Replacement 1

Information Procedure

Necessary tools Positon of pressure pump


1. Pressure pump
General tools 1
2. Pressure control valve

REPLACEMENT
No.2 Phillips screwdriver

Waste cloth

Gloves (anti-slip)

Special tools
None

Workflow 2
1
1. Pressure pump replacement

Typical work time C AU TIO N


If you are replacing multiple pumps at the same
Contents of work Time time, be sure to connect the ink tubes to the correct
Pressure pump replacement 90 min pumps as shown in the figure below.

1
2
3
4

1. Turn on the main power SW. Then, turn on the sub


power SW while pressing the [] [] [] keys to
enter the service mode.

2. Perform [SERVICE MENU] > [SUB MENU] > [PUMP UP]


and discharge ink from the ink lines.

C AU TIO N
Be sure to discharge ink in accordance with the
message on the panel. Failure to do so will cause ink
to spill out of the drain bottle.
SERVICE MENU
SUB MENU
[ ]

SUB MENU
PUMP UP

1-34 SG -540/300
Pressure Pump Replacement

N OTE 8. Release the ink tubes from the clamp which is on the
Required time for ink discharging: approx.30 min. back side of the pump drive board stay.

3. Turn off the main power SW.


4. Remove eight screws that secure the cover.
1

REPLACEMENT
9. Tighten the screw to attach the pump drive board
stay to the machine.

5. Unfasten two clamps and release all the cables from


the clamps.

10. Remove two screws, and then pull out the tray about
60 mm.

6. Unplug all the connectors from the pump drive


boards.

7. Remove two screws that secure the pump drive


board stay.

1-35 SG -540/300
Pressure Pump Replacement

C AUTI ON 13. Unplug the connector from the pump cable.


Do not pull out the tray more than 60 mm. Doing so Release the pump cable from the clamp. Then, unplug
may cause the ink tubes to bend. Be careful to avoid the connector from the pump cable.
bending the ink tubes when pulling out the tray.
1. Clamp

2. Connector 1

REPLACEMENT
1
60 mm or less  

11. If you are replacing the pumps other than cyan (on
the right end), remove two screws that secure the
pressure-control-valve stay.
14. Remove two screws that secure the pump, and then
remove the pump along with its stay.

12. Remove the ink tubes from the pump you are going
to replace.
15. Remove the pump from its stay, and then attach the
new pump to the stay.

Remove two screws and replace the pump with the


new one.

1-36 SG -540/300
Pressure Pump Replacement

16. Attach the pump along with its stay. 19. Connect the ink tubes to the pump.

REPLACEMENT
17. Plug the connector into the pump cable. C AU TIO N

Fasten the pump cable with the clamp. Then, plug the When you attach the tubes, do not apply cleaning
connector to the pump cable. liquid such as SL-CL. Be sure to wear anti-slip gloves.
Be careful not to put ink on the tube surface.
1. Clamp
20. Tighten two screws to secure the pressure-control-
2. Connector
valve stay.

18. Cut the ink tubes 5 mm from the end before 21. Insert the tray back into the machine, and tighten
connecting them to the pressure pump. two screws to secure it.

C AUTI ON C AU TIO N
Do not cut the ink tube end more than 5 mm. If you Be careful not to bend the tubes when inserting the
cut it more than 5 mm, the ink tube will become too tray.
short to reach the pressure control valve. If the ink
tube becomes too short, replace it with the new one.

5 mm

1-37 SG -540/300
Pressure Pump Replacement

22. Bundle the ink tubes with the clamp which is on the 26. Tighten eight screws to secure the cover.
back side of the pump drive board.

REPLACEMENT
27. Turn on the main power SW.
23. Tighten two screws to secure the pump drive board
stay. 28. Turn on the sub power SW while pressing the [] []
[] keys to enter the service menu.

29. Perform [SERVICE MENU] > [SUB MENU] > [FILL INK]
and fill the ink lines with ink.

N OTE
Required time for ink filling: approx. 20 min.
SERVICE MENU
SUB MENU
[ ]

24. Plug all the connectors into the pump drive boards. SUB MENU
FILL INK

30. (End of procedure)

25. Bundle the cables with two clamps.

1-38 SG -540/300
Pressure Control Valve Replacement 1

Information Procedure
C AU TIO N
Necessary tools If you are replacing multiple pressure control valves
at the same time, be sure to connect the ink tubes to
General tools the correct valves as shown in the figure below. 1

REPLACEMENT
No.2 Phillips screwdriver

Waste cloth

Gloves (anti-slip) 1
2
3
4

Special tools
None

Workflow 1. Turn on the main power SW. Then, turn on the sub
power SW while pressing the [] [] [] keys to
1. Pressure control valve replacement enter the service mode.

2. Perform [SERVICE MENU] > [SUB MENU] > [PUMP UP]


Typical work time and discharge ink from the ink lines.

C AU TIO N
Contents of work Time
Be sure to discharge ink in accordance with the
Pressure control valve replacement 90 min
message on the panel. Failure to do so will cause ink
to spill out of the drain bottle.
SERVICE MENU
SUB MENU
[ ]

SUB MENU
PUMP UP

N OTE
Required time for ink discharging: approx.30 min.
3. Turn off the main power SW.
4. Remove eight screws that secure the covers.

1-39 SG -540/300
Pressure Control Valve Replacement

5. Remove the ink tubes from the pressure control valve C AU TIO N
you are going to replace. When you attach the tubes, do not apply cleaning
liquid such as SL-CL. Be sure to wear anti-slip gloves.
Be careful not to put ink on the tube surface.

N OTE
1
If you are replacing the pressure control valve of

REPLACEMENT
black line (left end), remove the pressure-control-
valve stay and the pump drive board stay.
9. Tighten eight screws to secure the cover.

6. Remove two screws that secure the pressure control


valve, and replace it with the new one.

10. Turn on the main power SW.


11. Turn on the sub power SW while pressing the [] []
7. Cut the ink tubes 5 mm from the end before [] keys to enter the service menu.
connecting them to the new pressure control valve.
12. Perform [SERVICE MENU] > [SUB MENU] > [FILL INK]
C AUTI ON and fill the ink lines with ink.
Do not cut the ink tube end more than 5 mm. If you
N OTE
cut it more than 5 mm, the ink tube will become too
Required time for ink filling: approx. 20 min.
short to reach the choke valve, pressure pump, and/
or ink circulation pump. If the ink tube becomes too SERVICE MENU
short, replace it with the new one. SUB MENU
[ ]

SUB MENU
5 mm
FILL INK

13. (End of procedure)

8. Connect the ink tubes to the pressure control valve.

1-40 SG -540/300
Main Board Replacement 1

Information Procedure

Necessary tools Board layout (inside the cover)


1. Main board
Software 1
2. Servo board

REPLACEMENT
Peck
3. SW power supply
General tools
No.2 Phillips screwdriver

Special tools
1 2
None

3
Workflow

1. Main board replacement

Typical work time


1. Turn on the main power SW.
Contents of work Time
Main board replacement (When 2. Start Peck.
parameters cannot be transferred by 40 min
Peck) 3. Click [Get Report] and [Get Parameters], and save the
Main board replacement (When service report and the parameters.
20 min
parameters can be transferred by Peck)

4. Turn off the main power SW.

1-41 SG -540/300
Main Board Replacement

5. Remove 15 screws that secure the cover. C AU TIO N


Make sure to attach the removed battery to the new
main board.
8. Connect all the ribbon cables and plug in all the
connectors to the main board and the head board.
1
C AU TIO N

REPLACEMENT
• There are no connectors to plug into CN 2 and CN
15 (the location shown by the yellow arrow)

6. Disconnect all the ribbon cables and unplug all the


connectors from the main board.

Main board

9. Tighten 15 screws to secure the cover.

7. Remove five screws that secure the head board, and


fasten the new one. Attach the removed battery to
the new main board.

10. Perform the following adjustments and checks after


replacement.

10-1. Battery installation


"" Refer to Chapter 1 "Battery Replacement".

10-2. Firmware installation


"" Refer to Chapter 2 "How to Upgrade/Install
Firmware".

10-3. System parameter initialization


"" Refer to Chapter 2 "Other Factory Modes".

1-42 SG -540/300
Main Board Replacement

10-4. IP address setting 11-12. Linear encoder setup


* Start the printer in the service mode and set the IP "" Refer to Chapter 2 "Linear Encoder Setup".
address in the user menu.
11-13. Wiper position adjustment
10-5. Put parameters "" Refer to Chapter 2 "Wiper Position Adjustment".
"" Refer to Chapter 2 "How to Upgrade/Install
11-14. Print head alignment 1
Firmware".

REPLACEMENT
"" Refer to Chapter 2 "Print Head Alignment".
10-6. Time and date setting
* Only horizontal and bidirectional adjustment are
* Set the time and date from [SUB MENU] > [CLOCK] required.
> [DATE] > [TIME].
11-15. Calibration
* Set [DATE] in the order of [Year/Month/Day].
"" Refer to Chapter 2 "Calibration".
10-7. Sensor check
11-16. Crop mark sensor adjustment
* Set from [SERVICE MENU] > [SENSOR CHECK].
"" Refer to Chapter 2 "Crop Mark Sensor Adjustment".
11. Perform the following when parameters cannot be
transferred by Peck. 11-17. Crop cut adjustment
* Adjust the crop cut position by selecting [CUTTING
11-1. Battery installation
MENU] > [CROP-CUT ADJ.].
"" Refer to Chapter 1 "Battery Replacement".
11-18. Print/cut position adjustment
11-2. Firmware installation
* Adjust the print/cut position by selecting [CUTTING
"" Refer to Chapter 2 "How to Upgrade/Install MENU] > [PRINT-CUT ADJ.].
Firmware".
12. (End of procedure)
11-3. System parameter initialization
"" Refer to Chapter 2 "Other Factory Modes".

11-4. Time and date setting


* Set the time and date from [SUB MENU] > [CLOCK]
> [DATE] > [TIME].
* Set [DATE] in the order of [Year/Month/Day].

11-5. IP address setting


* Start the printer in the service mode and set the IP
address in the user menu.

11-6. Head rank setting


* Set from [PRINT MENU] > [HEAD RANK].

11-7. Serial number input


* Set from [SUB MENU] > [SERIAL NO.].

11-8. Ink type setting


* Set from [SUB MENU] > [CHANGE INKTYPE].

11-9. Sensor check


* Set from [SERVICE MENU] > [SENSOR CHECK].

11-10. Limit position & cut down position initialization


"" Refer to Chapter 2 "Limit Position & Cut Down
Position Initialization".

11-11. Flushing position adjustment


"" Refer to Chapter 2 "Flushing Position Adjustment".

1-43 SG -540/300
Servo Board Replacement 1

Information Procedure

Necessary tools Board layout (inside the cover)


1. Main board
General tools 1
2. Servo board

REPLACEMENT
No.2 Phillips screwdriver
3. SW power supply
Special tools
None

1 2
Workflow
3
1. Servo board replacement

Typical work time

Contents of work Time


Servo board replacement 20 min
1. Turn off the main power SW.
2. Remove 15 screws that secure the cover.

3. Open the clamps. Disconnect all the ribbon cables


and the connectors from the servo board.

1-44 SG -540/300
Servo Board Replacement

4. Remove four screws that secure the servo board, and 6. Bundle the cables with the clamps.
replace it to the new servo board.

REPLACEMENT
7. Tighten 15 screws to secure the cover.

5. Connect all the ribbon cables and plug in all the


connectors.

C AUTI ON
• There are no connectors to plug into CN 5, CN 11,
CN 12 (the location shown by the yellow arrow)

8. (End of procedure)

1-45 SG -540/300
Signal JC Board Replacement 2

Information Procedure
1. Turn off the main power SW.
Necessary tools
2. Open the maintenance cover R.
General tool 1

REPLACEMENT
No.2 Phillips screwdriver

Special tools
None

Workflow

1. Signal JC board replacement


3. Remove six screws that secure the operation panel.
Typical work time

Contents of work Time


Signal JC board replacement 18 min

4. Remove two screws that secure the maintenance


cover sensor R.

1-46 SG -540/300
Signal JC Board Replacement

5. Remove 18 screws that secure the cover. 8. Plug in all the connectors.
C AU TIO N
• There are no connectors to plug into CN 6 (the
location shown by the yellow arrow).
1

REPLACEMENT
9. Tighten 18 screws to secure the cover.

6. Unplug all the connectors.

7. Remove four screws that secure the interlock board.


Then, fasten the new interlock board.

1-47 SG -540/300
Signal JC Board Replacement

10. Temporarily fasten the maintenance cover sensor R 12. Close the maintenance cover R, and then confirm the
with two screws. cover is fixed.

REPLACEMENT
11. Tighten six screws to secure the operation panel. C AU TIO N
If the cover is not fixed, then maintenance cover
sensor R does not work properly. Widen the clearance
between the operation panel and the frame if the
maintenance cover is not fixed by shaking the right
and left ends of the cover back and forth with your
hands.
13. Turn on the main power SW.
14. Turn on the sub power SW while pressing the [] []
[] keys to enter the service menu.

15. Select [SERVICE MENU] > [SENSOR CHECK].


C AUTI ON
SERVICE MENU
• Tighten two screws in the operation panel with SENSOR CHECK
holding up to the left, and then make 1.5 mm
clearance between the frame and the operation
panel.

1.5 mm clearance

• Connect the ribbon cable to the panel board.

1-48 SG -540/300
Signal JC Board Replacement

16. Slide the maintenance cover sensor R to the front


until "*" under "D" disappears. Then, tighten two
screws to secure the sensor.
When the cover is open

FRSHODPULWwaVC
* 1

REPLACEMENT
When the cover is closed

FRSHODPULWwaVC

Aging/Checking the Interlock Mechanism

17. Go back to [MOTOR MENU]. Select [AGING] > [SCAN],


and press the [ENTER] key.

C AUTI ON
Remove media before performing aging.
SERVICE MENU
MOTOR MENU
[ ]

MOTOR MENU
AGING
[ ]

AGING
SCAN
[ENTER]

18. Confirm that the interlock mechanism works


properly. Open the front cover during aging and
confirm that emergency stop occurs.

19. Press the [ENTER] key to finish aging.


20. (End of procedure)

1-49 SG -540/300
SW Power Supply Replacement 2

Information Procedure

Necessary tools Board layout (Inside the cover)


1. Main board
General tool 1
2. Servo board

REPLACEMENT
No.2 Phillips screwdriver
3. SW power supply
Special tools
None
1 2
3
Workflow

1. SW power supply replacement

Typical work time


Removing the Chassis
Contents of work Time
1. Turn off the main power SW.
SW power supply replacement 15 min
2. Remove 15 screws that secure the cover.

3. Unplug all the connectors.

1-50 SG -540/300
SW Power Supply Replacement

4. Remove five screws to replace the SW power supply


with the new one.

REPLACEMENT
5. Plug in all the connectors.

6. Tighten 15 screws to secure the cover.

7. (End of procedure)

1-51 SG -540/300
Pump Drive Board Replacement 2

Information Procedure
1. Turn off the main power SW.
Necessary tools 2. Remove eight screws that secure the covers.
General tool 1

REPLACEMENT
No.2 Phillips screwdriver

Special tools
None

Workflow

1. Pump drive board replacement


3. Unplug all the connectors from the pump drive
board.
Typical work time

Contents of work Time


Pump drive board replacement 10 min

4. Remove four screws that secure the pump drive


board. Then, replace it with the new one.

1-52 SG -540/300
Pump Drive Board Replacement

5. Plug all the connectors into the pump drive board.

REPLACEMENT
6. Perform the following.
6-1. Perform powerful cleaning and check that the
filler sensor works properly.

7. (End of procedure)

1-53 SG -540/300
Heater Control Board Replacement 2

Information Procedure
Removing the Chassis
Necessary tools
1. Turn off the main power SW.
General tool 1
2. Remove 15 screws that secure the cover.

REPLACEMENT
No.2 Phillips screwdriver

Special tools
None

Workflow

1. Heater control board replacement

Time
3. Remove the screw that secures the carriage retainer.
Contents of work Time
Heater control board replacement 15 min

4. Remove four screws that secure the chassis tray.

1-54 SG -540/300
Heater Control Board Replacement

5. Unplug the connector highlighted with the red 8. Tighten the screw to secure the carriage retainer.
square in the figure below from the heater control
board.

REPLACEMENT
9. Tighten 15 screws to secure the cover.

6. Remove four screws that secure the heater control


board. Then, attach the new heater control board.

10. (End of procedure)


7. Tighten four screws to secure the chassis tray.

1-55 SG -540/300
Ink System RFID Board Replacement 2

Information Procedure
1. Turn off the main power SW.
Necessary tools 2. Remove the cover shown in orange in the figure.
General tool 1

REPLACEMENT
No.2 Phillips screwdriver

Special tools
None

Workflow

1. Ink system RFID board replacement

Typical work time

Contents of work Time


Ink system RFID board replacement 10 min 3. Unplug all the connectors from the ink system RFID
board.

4. Remove four screws that secure the ink system RFID


board. Then, replace it with the new one.

1-56 SG -540/300
Ink System RFID Board Replacement

5. Plug all the connectors into the ink system RFID


board.

C AUTI ON
• There are no connectors to plug into CN 25 (the
location shown by the yellow arrow). 1

REPLACEMENT
6. Turn on the main power SW.
7. Turn on the sub power SW while pressing the [] []
[] keys to enter the service menu.

8. Perform the following.


8-1. Go to [SERVICE MENU] > [I/S MENU] > [CARTRIDGE]
> [SLOT1] to [SLOT4], and check that the printer
has read the serial numbers of each ink cartridge
IC properly.

9. (End of procedure)

1-57 SG -540/300
RFID R/W Board Replacement 2

Information Procedure
1. Turn off the main power SW.
Necessary tools
2. Remove the cover shown in orange in the figure.
General tool 1

REPLACEMENT
No.2 Phillips screwdriver

Special tools
None

Workflow

1. RFID R/W board replacement

Typical work time

Contents of work Time C AU TIO N


RFID R/W board replacement 45 min Do not remove the upper screw. Remove only
the bottom screw. If you remove both upper and
bottom screws, a small plate that the two screws are
securing will fall off inside the printer.

3. Unfasten four clamps and release all the cables from


the clamps.

1-58 SG -540/300
RFID R/W Board Replacement

4. Unfasten three clamps to release all the ink tubes. 8. Remove two screws and remove the RFID R/W board
along with its stay.

REPLACEMENT
5. Remove two screws that secure the ink absorption
pad tray.

9. Unplug the connector from the RFID R/W board.

6. Slide the ink absorption pad tray to the left and


remove it.

C AUTI ON
When removing the pad tray, be careful not to get
the ink tubes and cables caught on the clamps. 10. Remove three screws that secure the RFID R/W board,
and then install the new one.

7. Slide and remove the ink cartridge.

1-59 SG -540/300
RFID R/W Board Replacement

11. Plug the connector into the RFID R/W board. 15. Tighten two screws to secure the ink absorption pad
tray.

REPLACEMENT
12. Tighten two screws to secure the RFID R/W board 16. Fasten three clamps to secure all the ink tubes.
along with its stay.

17. Bundle all the cables with four clamps.


13. Slide and set the ink cartridge.

18. Fasten the covers with screws.


14. Slide and insert the ink absorption pad tray.
C AUTI ON
When inserting the pad tray, be careful not to get the
ink tubes and cables caught on the clamps.

1-60 SG -540/300
RFID R/W Board Replacement

19. Turn on the main power SW.


20. Turn on the sub power SW while pressing the [] []
[] keys to enter the service menu.

21. Perform the following.


1
21-1. Go to [SERVICE MENU] > [I/S MENU] > [CARTRIDGE]

REPLACEMENT
> [SLOT1] to [SLOT4], and check that the printer
has read the serial numbers of each ink cartridge
IC properly.

22. (End of procedure)

1-61 SG -540/300
Carriage Belt Replacement 1

Information Procedure
1. Turn off the main power SW.
Necessary tools
2. Open the maintenance cover L and the maintenance
General tools cover R. 1

REPLACEMENT
No.2 Phillips screwdriver
1. Maintenance cover L
3.0 mm hexagonal wrench
2. Maintenance cover R
Tape

Special tools 1 2
1000009378 GREASE, FLOIL G-902

Workflow

1. Carriage belt replacement 3. Remove six screws that secure the operation panel.

Typical work time

Contents of work Time


Carriage belt replacement 45 min

C AU TIO N
Before removing the operational panel, make sure
to unlock the connector which is connected to the
panel board.

1-62 SG -540/300
Carriage Belt Replacement

4. Remove two screws that secure the maintenance 7. Loosen two fixing screws located at the left end of
cover sensor R. the belt. Then, loosen the adjustment screw.
<Top view> Left end of the belt

REPLACEMENT
Adjustment screw Fixing screw

8. Remove two screws that secure the cover.


5. Remove 18 screws that secure the cover.

9. Unplug the solenoid cable and two connectors.

10. Release the cables from the clamp.


6. Disconnect the tool carriage from the head carriage.

1-63 SG -540/300
Carriage Belt Replacement

11. Loosen two screws. Slide and remove the stay. 14. Remove the carriage belt from the stay. Then,
connect the new carriage belt to the old carriage belt
using scotch tape.

C AU TIO N
When replacing the carriage belt, make sure to
1
connect the new belt to the old belt, and then

REPLACEMENT
thread the new belt into place as you remove the
old belt. Failure to follow this procedure may make it
impossible to install the new belt.
12. Slide the tool carriage away from the stay.
1. Old carriage belt

2. New carriage belt

3. Tape

1 2

13. Remove four screws and remove the carriage belt. 3


C AUTI ON
When removing the carriage belt, make sure the
carriage belt does not touch the encoder scale. If 15. Slowly pull the end of the old belt that is not
the grease applied to the carriage belt gets on the connected to the new belt until the new belt reaches
encoder scale, printing problems may occur. the belt stay.

C AU TIO N
Check that the belt is not twisted.

1. Old carriage belt

2. New carriage belt

3. Tape

1 2

1-64 SG -540/300
Carriage Belt Replacement

16. Apply grease to the pulleys. 18. Tighten the adjustment screw to remove the slack in
• Grease: FLOIL G-902 the belt. Then, tighten two fixing screws.

• Volume: as needed C AU TIO N


Do not overtighten the screws.
<Top view> Left end of the belt 1

REPLACEMENT
17. Peel off the tape, and then tighten two screws Adjustment screw Fixing screw
as shown in the figure to fasten both ends of the
carriage belt to the belt holder with the plastic plate
and the metal plate. 19. Slide the tool carriage back to the original position,
and align the screws on the tool carriage and the
C AUTI ON screw holes of the stay.
• When fastening the carriage belt, make sure the
ends of the carriage belt are not overlapped.
• Be careful with the orientation in which you affix
the plastic plate and the order in which you affix
the plates.

1. Screw

2. Metal plate

3. Carriage belt

4. Plastic plate 20. Tighten two screws to secure the stay.


5. Belt holder

Cross-section diagram

OK
1 1
2 3 2

4 4 21. Plug the solenoid cable into the tool carriage board.
5

No Good
1 1
3
2 2

4 4
5

1 1
2 2
3 3
4 4
5

1-65 SG -540/300
Carriage Belt Replacement

22. Plug two connectors into the tool carriage board. 25. Tighten 18 screws to secure the cover.

REPLACEMENT
C AUTI ON
1. Place the two CN103 connectors (shown in yellow
in the figure) on top of the solenoid cable (shown in
red).
2. Place the three cables in between the two screws
as shown in the figure.

CN103

2
26. Temporarily fasten the maintenance cover sensor R
with two screws.

23. Bundle the cables with the clamp.

27. Tighten six screws to secure the operation panel.


24. Tighten two screws to secure the cover.

1-66 SG -540/300
Carriage Belt Replacement

C AUTI ON 33. Move the head carriage across the whole width of
• Plug the connector into the panel board. the guide rail several times to remove the slack in the
carriage belt. Perform the following adjustments.

33-1. Refer to Chapter 2 "Belt Tension Adjustment".


33-2. Refer to Chapter 2 "Belt Position Adjustment". 1

REPLACEMENT
33-3. Refer to Chapter 2 "Limit Position & Cut Down
Position Initialization".

33-4. Check cutting quality


34. (End of procedure)

28. Close the maintenance cover L and the maintenance


cover R.

1. Maintenance cover L

2. Maintenance cover R

1 2

29. Plug in the power cord, and turn on the power SW.
30. Turn on the sub power SW while pressing the [] []
[] keys to enter the service menu.

31. Select [SERVICE MENU] > [SENSOR CHECK].


SERVICE MENU
SENSOR CHECK

32. Slide the maintenance cover sensor R to the front


until "*" under "D" disappears. Then, tighten two
screws to secure the sensor.
When the cover is open

FRSHODPULWwaVC
*

When the cover is closed

FRSHODPULWwaVC

1-67 SG -540/300
Encoder Scale Replacement 1

Information Procedure
1. Turn off the main power SW.
Necessary tools
2. Open the maintenance cover L and the maintenance
General tools cover R. 1

REPLACEMENT
No.2 Phillips screwdriver
1. Maintenance cover L
Special tools
2. Maintenance cover R
None

1 2

Workflow

1. Encoder scale replacement


2. Linear encoder setup 3. Move the print carriage to the print area by hand.

Typical work time

Contents of work Time

Encoder scale replacement 15 min

Linear encoder setup 5 min

4. Remove the encoder scale by removing the plate


holding the encoder scale at its right end and the
spring on its left end.

1. Encoder scale

2. Encoder plate

3. Spring

3 1
2

1-68 SG -540/300
Encoder Scale Replacement

5. Remove the spring plate from the encoder scale and 7. Move the head carriage across the whole width of
fasten it to the end of the new encoder scale that the machine manually and confirm that the encoder
does not have a clipped corner. scale does not make contact with the encoder sensor.
Also, check that the encoder scale is in between the
C AUTI ON slit of the encoder sensor. Carry out Chapter 2 "Linear
Make sure not to scratch or get grease on the encoder Encoder Setup". 1
scale when installing it. Do not touch the surface of

REPLACEMENT
the encoder scale.

6. Put the encoder scale in between the encoder plate


and the guide rail. Then, fasten the right end with the
plate, and hook up the spring on the left end. Make
sure that the encoder scale is in place.
Close-up image of the encoder scale and the encoder sensor

1. Encoder scale
1. Encoder sensor
2. Encoder plate
2. Encoder scale
3. Spring

4. Screw

3 1 2 1
2
4 4

8. (End of procedure)

1-69 SG -540/300
Linear Encoder Board Replacement 1

Information Procedure
1. Turn off the main power SW.
Necessary tools
2. Remove the cover shown in orange in the figure.
General tools 1

REPLACEMENT
No.1 Phillips screwdriver

No.2 Phillips screwdriver

No.2 Phillips screwdriver (150 mm or less)

Special tools
None

3. Remove two screws that secure the cover.


Workflow M emo
The screws are on the right and left side of the cover.
1. Linear encoder board replacement
2. Linear encoder setup

Typical work time

Contents of work Time

Linear encoder board replacement 25 min

Linear encoder setup 5 min

4. Open the clamps of the ferrite cores, and then


remove all the ribbon cables of the print head.

1-70 SG -540/300
Linear Encoder Board Replacement

C AUTI ON 7. Remove the linear encoder board along with the stay.
Open the cover in the direction of the arrow marked
"1". Then, disconnect the ribbon cable from the print 1. Linear encoder board
carriage board. 2. Stay
1
1

REPLACEMENT
1
2

5. Remove two screws that secure the fan. 8. Unplug the connector from the linear encoder board.
Then, plug the connector into the new linear encoder
board.

Unlock the connector of the fan.


9. Remove the linear encoder board from the stay. Then,
attach the new linear encoder board to the stay.

1. Linear encoder board

2. Stay

6. Unplug the connectors and remove the screws.


2

1-71 SG -540/300
Linear Encoder Board Replacement

10. Fasten the linear encoder board along with the stay. C AU TIO N

C AUTI ON • Be sure to connect each ribbon cable to the


correct connector.
Make sure that the encoder scale does not make contact
with the encoder sensor. Also, check that the encoder • Make sure that the head rank is affixed on the rear
scale is in between the slit of the encoder sensor. side of the ribbon cable.
1

REPLACEMENT
1. Linear encoder board
2
2. Stay
Rear side

793643
002231
Encoder

0000
0516
sensor

Encoder
scale
Front side

13. Tighten two screws to secure the cover.


2
M emo
The screws are on the right and left side of the cover.

11. Tighten the screws and plug in the connectors.

12. Connect all the ribbon cables to the print carriage


14. Tighten the screws to secure the cover.
board, and then close the clamps to secure the ferrite
cores.

15. (End of procedure)

1-72 SG -540/300
Battery Replacement 1

Information Procedure
C AU TIO N
Necessary tools Danger of explosion if the lithium battery is
incorrectly replaced. Replace only with the same or
General tools equivalent type recommended by the manufacture. 1

REPLACEMENT
No.2 Phillips screwdriver Dispose of used batteries according to the
manufacturer's instructions.
Lithium battery: CR2032

Workflow AT TE N TIO N
ll y a danger d’explosion s’il y a remplacement

1. Battery replacement incorrect de la batterie. Remplacer uniquement avec


une batterie du méme type ou d’un type équivalent
2. Time and date setting recommandé par le constructeur. Mattre au rebut les
batteries usagées conformément aux instructions du
fabricant.
Typical work time Pile au lithium: CR2032

ADVAR SE L !
Contents of work Time
Lithiumbatteri – Eksplosionsfare ved fejlagtig
Battery replacement 7 min
handtering. Udskiftning ma kun ske med batteri af
Time and date setting 2 min samme fabrikat og type. Levér det brugte batteri
tilbage til laveranøren.
Lithiumbatteri: CR2032

CAUTION

Do not recharge, short-circuit, disassembly the lithium


battery, nor put it into fire. It may cause heat, explosion and
fire.

Put tape around the lithium battery for insulation for disposal
or preservation.
It may cause heat, explosion and fire.

1. Turn off the main power SW.


2. Remove 15 screws that secure the cover.

1-73 SG -540/300
Battery Replacement

3. Remove the battery on the main board by pushing it 7. Select [SUB MENU] > [CLOCK] > [DATE]. Set the date,
back and tilting upward. and press the [ENTER] key.

② SERVICE MENU
SUB MENU
SUB MENU
CLOCK
[ ][ ]

① CLOCK 1
DATE

REPLACEMENT
[ ]
DATE
Socket 00/00/00
[ ]
DATE
09/01/13
[ ENTER ]

4. Replace the battery with a new one. 8. Turn off the main power SW.
C AUTI ON 9. Tighten 15 screws to secure the cover.
Be sure to correctly orient the battery.

Battery

Socket

5. Turn on the main power SW. Turn on the sub power 10. Dispose of the removed battery.
SW while pressing the [] [] [] keys to enter the
service menu. 11. (End of procedure)
6. Select [SUB MENU] > [CLOCK] > [TIME]. Set the time,
and press the [ENTER] key.

C AUTI ON
The display of [B] which shows battery exhaustion
disappears by this step.
SERVICE MENU SUB MENU
SUB MENU CLOCK
[ ][ ]
CLOCK
TIME
[ ]
TIME
00:00:59 B
[ ]
TIME
13:01:59 B
[ ENTER ]

1-74 SG -540/300
Ink Tube Replacement 2

Information Procedure
C AU TIO N
Necessary tools The figures below show which color connects to
which tube. Be sure to observe the figures before
General tools replacing the ink tubes. 1

REPLACEMENT
No.2 Phillips screwdriver CMYK
Waste cloth (4 colors)
Gloves (anti-slip)

Tape CY MG YE BK

Special tools
None
Pressure control valve

Pressure pump
Workflow
Tube number No.1 No.2 No.3 No.4

1. Ink tube replacement

Typical work time

Contents of work Time


Ink tube replacement 120 min

H1 H2

1. Turn on the main power SW. Then, turn on the sub


power SW while pressing the [◀] [▼] [▶] keys to
enter the service mode.

2. Perform [SERVICE MENU] > [SUB MENU] > [PUMP UP]


and discharge ink from the ink lines.

C AU TIO N
Be sure to discharge ink in accordance with the
message on the panel. Failure to do so will cause ink
to spill out of the drain bottle.
SERVICE MENU
SUB MENU
[ ]

SUB MENU
PUMP UP

N OTE
Required time for ink discharging: Approx. 30 min
3. Turn off the sub power SW, and then turn off the
main power SW. Unplug the power cord.

1-75 SG -540/300
Ink Tube Replacement

4. Remove six screws that secure the operation panel. 6. Unlock the print carriage, and move it to the print
area by hand.

REPLACEMENT
5. Remove the five covers shown in orange in the
figures below.
7. Remove two screws that secure the cover.
Front view
N OTE
The screws are on the right and left side of the cover.

Rear view
8. Unfasten all the ferrite cores to remove the plate.

C AUTI ON
Do not remove the upper screw. Remove only the
bottom screw. If you remove both upper and bottom
screws, a small plate that the two screws are securing
will fall off inside the printer.

1-76 SG -540/300
Ink Tube Replacement

9. Disconnect all the ribbon cables of the print heads 11. Remove four screws that secure the print carriage
from the print carriage board. board.

REPLACEMENT
12. Unfasten two clamps and release all the cables from
C AUTI ON the clamps.
Open the cover in the direction of the arrow marked
"1". Then, disconnect the ribbon cable from the print
carriage board.
1

13. Unplug the connectors from the pump drive board.

10. Unplug the connectors and the ribbon cable.

14. Remove two screws that secure the pump drive


board stay.

1-77 SG -540/300
Ink Tube Replacement

15. Release the ink tubes from the clamp which is on the 19. Remove the tubes from the L-shaped joints.
rear side of the pump drive board stay.
C AU TIO N
Remove the ink tubes slowly so that ink will not drip
or spatter. Putting waste cloth under the L-shaped
tubes is recommended.
1
N OTE

REPLACEMENT
Wipe off any ink from the ribbon cables and print
heads with waste cloth.

16. Tighten the screw to attach the pump drive board


stay to the machine.

20. Close the tube end with tape so that ink will not
come out.

17. Unfasten the clamps.

21. Remove two screws.

18. Unfasten six clamps to release the tubes.

1-78 SG -540/300
Ink Tube Replacement

22. Lift up the head carriage plate and detach one tube 25. Remove the ink tubes along with the tube guides.
guide.

REPLACEMENT
26. Insert the new ink tubes through the tube guides.
23. Detach the rest of the tube guides from the cable Total number of tube guides:

guide plate and frame. SG-540: 27 pcs

The number of tube guides to remove in this step: SG-300: 21 pcs

SG-540: 26 pcs

SG-300: 20 pcs

Tube guide

Pressure pump side

Tube number
Cable guide plate
No.4
No.3
No.2 Insert the tube
Frame No.1
guides in this
Print carriage side orientation.

27. Insert the new ink tubes into the machine.

24. Remove the upper ink tube from the pressure pump,
and then close the tube end with tape.

1-79 SG -540/300
Ink Tube Replacement

28. Attach the tube guides to the tube guide plate and 31. Fasten six clamps to secure the tubes.
the frame.

The number of tube guides to attach in this step:


4 3
SG-540: 26 pcs

SG-300: 20 pcs 1
2

REPLACEMENT
1

1. Ink tube number: No.1

2. Ink tube number: No.2

3. Ink tube number: No.3

4. Ink tube number: No.4


29. Lift up the head carriage plate and attach the tube
guide to the print carriage. 32. Connect the ink tubes to the L-shaped joints.
C AUTI ON C AU TIO N
If you press the tube guide too hard, the tube guide • Be sure to wear gloves (anti-slip).
will break. Be sure to align the tube guide plate with
• Hold the tube about 10 mm from the end and
the cutout of the head carriage, and then attach the
insert it straight so that it does not bend.
tube guide.
• See the figure below and connect each tube to
the correct joint.

1 2 4
3

30. Tighten two screws.

1. Ink tube number: No.1

2. Ink tube number: No.2

3. Ink tube number: No.3

4. Ink tube number: No.4

1-80 SG -540/300
Ink Tube Replacement

33. Connect the ink tubes to the pressure pumps. 36. Bundle the ink tubes with the clamp which is on the
rear side of the pump drive board.
C AUTI ON
• Be sure to wear gloves (anti-slip).
• Hold the tube about 10 mm from the end and
insert it straight so that it does not bend. 1
• See the figure below and connect each tube to the

REPLACEMENT
correct joint.

4 3 37. Tighten two screws to secure the pump drive board


2 1
stay.

1. Ink tube number: No.1

2. Ink tube number: No.2

3. Ink tube number: No.3

4. Ink tube number: No.4

38. Plug all the connectors into the pump drive boards.

34. Move the head carriage across the whole width of


the guide rail several times and confirm that the tube
guides are securely attached and are not coming off.

35. Bundle the cables with the clamps. 39. Bundle the cables with two clamps.

1-81 SG -540/300
Ink Tube Replacement

40. Tighten four screws to secure the print carriage C AU TIO N


board. • Be sure to connect each ribbon cable to the
correct connector.
• Make sure that the head rank is affixed on the rear
side of the ribbon cable.
1

REPLACEMENT
2
Rear side

793643
002231
0000
0516
41. Plug in the connectors and the ribbon cable.
Front side

44. Fasten the clamps to secure the ferrite cores.

42. Attach the ferrite core plate.

45. Tighten two screws to secure the cover.


N OTE
The screws are on the right and left side of the cover.

43. Connect all the ribbon cables of the print heads to


the print carriage board.

46. Attach the five covers shown in orange in the figures


below.

1-82 SG -540/300
Ink Tube Replacement

Front view • Connect the ribbon cable to the panel board.

REPLACEMENT
Rear view 48. Close the maintenance cover R, and then confirm the
cover is fixed.

47. Tighten six screws to secure the operation panel.


C AU TIO N
If the cover is not fixed, then maintenance cover
sensor R does not work properly. Widen the clearance
between the operation panel and the frame if the
maintenance cover is not fixed by shaking the right
and left ends of the cover back and forth with your
hands.
49. Plug in the power cord, and turn on the main power
SW.

C AUTI ON
50. Turn on the sub power SW while pressing the [◀]
[▼] [▶] keys to enter the service mode.
• Tighten two screws in the operation panel with
holding up to the left, and then make 1.5 mm 51. Perform [SERVICE MENU] > [SUB MENU] > [FILL INK]
clearance between the frame and the operation and fill the ink lines with ink.
panel.
N OTE

1.5 mm clearance Required time for ink filling: Approx. 20 min


SERVICE MENU
SUB MENU
[ ]

SUB MENU
FILL INK

52. (End of procedure)


1-83 SG -540/300
Chapter 2 Adjustment

Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
2
Service Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Adjustment
History Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Belt Position Adjustment. . . . . . . . . . . . . . . . . . . . 2-41
Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Other Factory Modes. . . . . . . . . . . . . . . . . . . . . . . .2-16 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Firmware Upgrade Mode. . . . . . . . . . . . . . . . . . . . 2-17 Wiper Position Adjustment. . . . . . . . . . . . . . . . . . 2-48
Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Firmware Installation . . . . . . . . . . . . . . . . . . . . . . . 2-19 Feed Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Limit Position & Cut Down Position
Initialization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Linear Encoder Setup. . . . . . . . . . . . . . . . . . . . . . . 2-24


Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Flushing Position Adjustment . . . . . . . . . . . . . . . 2-26


Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Crop Mark Sensor Adjustment. . . . . . . . . . . . . . . 2-29


Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Print Head Alignment. . . . . . . . . . . . . . . . . . . . . . . 2-31


Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Tool Height Adjustment. . . . . . . . . . . . . . . . . . . . . 2-34


Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Tool Pressure Adjustment. . . . . . . . . . . . . . . . . . . 2-36


Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . 2-38


Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

2-1 SG -540/300
Service Mode 1

MENU
+ POWER ON [ MENU ] key SERVICE MENU

SERVICE MENU PRINT MENU HEAD RANK HEAD RANK 1


PRINT MENU HEAD RANK HEAD 1 00003E83E8

HEAD RANK HEAD RANK 2


HEAD 2 00003E83E8
- Returns to the previous menu when test print is finished.

PRINT MENU HEAD ADJUST BIAS/VERTICAL PERFORMING


HEAD ADJUST BIAS/VERTICAL TEST PRINT TEST PRINT

Printing a Test Pattern for Head Alignment


BIAS/VERTICAL - When you enter this menu, the machine automatically uncaps the print head.
--- VIEW --- The print head mechanism then moves to a position where it can be adjusted.
After moving, the machine becomes motor-free, in which the carriage is moved
freely to the position where it can be adjusted.
- When [TEST PRINT] is selected, the machine prints a test pattern. Then, the head
carriage returns to position where it can be seen and be easily adjusted.
- The machine feeds media for visual check of the test pattern by pressing the
[] [] keys. Press the [] [] keys again to go back to the [TEST PRINT]
menu. 2

Adjustment
HEAD ADJUST HORIZONTAL PERFORMING
HORIZONTAL TEST PRINT TEST PRINT

HORIZONTAL H1 No.1 has been deleted after Ver.1.30.


SETTING NO.1 **

- Use the [] [] keys to select a setting value.


Confirm the selected setting value by pressing the [ENTER] key. After this is
HORIZONTAL executed, the display will transition back to the previous screen.
SETTING NO.2 - The selected setting value is displayed with an underscore (_).
- The setting will be canceled when the [ ] is pressed while the setting is
selected.
- Adjustable range: -30 to +30 dots (0.5 dot intervals). 0.5 dot is expressed in %.
- Default value: * * (0)

HEAD ADJUST BI-DIR.DEFAULT PERFORMING


BI-DIR.DEFAULT TEST PRINT TEST PRINT

BI-DIR.DEFAULT H1 H2 No.1 and No.2 have been deleted


SETTING NO.1 ** ** after Ver.1.30.

Bidirectional Adjustment
- Each head can be selected with the [] [] keys, and value can be selected
BI-DIR.DEFAULT with the [] [] keys.
SETTING NO.4 Press the [ENTER] key to save the settings.
It returns to the former menu after setting.
- The value being selected is marked with an under bar.
- Adjustable range: 0 to +60 dot (changeable by 0.5dot which is indicated as %)
- Default: (0)
It can be changed with the [] [] keys.

Normal end
PRINT MENU NOW PROCESSING LINEAR ENCODER
LINEAR ENCODER POS: 1615.00mm SETUP COMPLETED
Error
LINEAR ENCODER
SETUP FAILED

Linear Encoder Setup


- This is menu is for checking the operation of the linear encoder.

- Procedure
Select the [LINEAR ENCODER] menu and press the [ENTER] key. When the setup is completed, the buzzer sounds once.
When the encoder reading is incomplete and the value read is clearly abnormal, an error will occur causing the buzzer to sound three times.
An error message appears if the pinch rollers are not lowered when entering this menu.
Lower the pinch rollers before performing this procedure.

Possible causes of linear encoder error


1 ) There is a failure in the encoder slit.
2 ) There is a failure in the encoder sensor.
3 ) There is a backlash between the carriage motor gear and drive gear.
4 ) The belt is not attached to the head carriage firmly.

This adjustment is required when:


- The linear encoder slit and encoder sensor are replaced.
- The position of the limit sensor, encoder scale, or encoder sensor is adjusted.

2-2 SG -540/300
Service Mode

PRINT MENU CALIB.DEFAULT PERFORMING


CALIB.DEFAULT TEST PRINT TEST PRINT

CALIB.DEFAULT SETTING Calibration (Feed Direction)


SETTING +0.00% +0.00% - Range: -2.00% to +2.00% (changeable by 0.01%)

PRINT MENU TEST PATTERN PERFORMING - Check if the horizontal head correction value is correctly entered and whether
TEST PATTERN HORIZONTAL TEST PRINT or not it is reflected on the print.

TEST PATTERN PERFORMING - Check if the bidirectional head correction value is correctly entered and
BI-DIR. TEST PRINT whether or not it is reflected on the print.

TEST PATTERN PERFORMING - It prints on the entire print range with solid single color by each head.
FILL TEST PRINT

TEST PATTERN PERFORMING - This print pattern is for checking a shifting error in bidirectional.
BI-DIR. CHECK TEST PRINT - Look at the mechanism's inclination.

Flushing Position Adjustment


2
PRINT MENU FLUSHING ADJ. - The head carriage automatically moves to the current flushing position.

Adjustment
FLUSHING ADJ. 0.00mm 0.10mm - Move the head carriage to the position where the slot of the carriage cap guide makes contact with the tip of the backup
cap base by pressing the [] [] keys. Or, start adjustment from the leftmost position, and press the [] key until the
position where arm part of cap unit starts to move. Press the [ENTER] key to set the flushing position.
- When you press the [ENTER] key, the machine performs the capping of the head carriage. Then it returns to the previous
menu.
- When you press the [] [] keys, the head carriage moves just a little. In order to move the head carriage a lot, press the
keys several times.
- When you press the [MENU] key before pressing the [ENTER] key to set the position, the flushing position is not updated
and exits the menu.
- The machine performs flushing at the flushing position set in this menu.
- Adjustable range: -3.00 [m] to 3.00 [mm] (It can be changed in increments of 0.1[mm].)

- Returns to the previous menu when completed.

SERVICE MENU I/S MENU PUMP CHECK NOW PROCESSING..


I/S MENU PUMP CHECK PUMP SUCTION

- Returns to the previous menu when completed.

PUMP CHECK NOW PROCESSING..


PUMP RELEASE

Pump Motor Check


- This menu is for checking the pump motor performance. As to check the rotating direction for ink suction and drainage.
- The check is performed by rotating the pump motor for 5 seconds before stopping the rotation.

I/S MENU I/S CONTROL MOVE CARRIAGE WIPER


I/S CONTROL WIPER TO AVOID WIPER ORIGIN

Wiper Performance Check


- This menu is for manually moving the wiper position.
- Options: ORIGIN/PREPAREWIPE/WIPE HIGH/WIPE LOW/WIPE END HIGH/WIPE END LOW/PAD/PRE WASH/
      DIP WASH/TRAY MAINTE/EXCHANGE WIPE
- Default: ORIGIN
*Caution
If this check is performed when the head carriage is above the wiper unit, the wiper and the felt wiper touch
the head carriage. This menu enables you to move the head carriage manually. Move it to a place where is
not above the wipe unit before checking the performance.

I/S CONTROL a
VALVE *

Solenoid Valve Continuity Check


- This menu is for solenoid valve continuity check.
- Select the solenoid valve number with [◀] [▶] keys, and select the conductive/non-conductive state of the solenoid
valve with [▲] [▼] keys. Then, press the [ENTER] key.
- “*” indicates the solenoid valve is conductive, whereas "(blank)" indicates it is non-conductive.
- Solenoid valve No.
a: Cleaning liquid valve

2-3 SG -540/300
Service Mode

Insert the ink cartridge to SLOT1

I/S MENU CARTRIDGE IC CHECK


CARTRIDGE IC CHECK SLOT1 INSERT
Remove the ink cartridge from SLOT1
Normal end

IC CHECK
SLOT1 OK
Error

IC CHECK
SLOT1 ERROR
Insert the ink cartridge to SLOT4
IC CHECK
SLOT4 INSERT
Remove the ink cartridge from SLOT4
IC CHECK
SLOT4 OK

IC CHECK
COMPLETED

IC Check
- All of the ink cartridges must be removed from the slots before you operate this menu.
2
- This menu is for detecting the ink cartridge IC, writing and loading the information, and checking if there is any trouble in electric devices and

Adjustment
communication channel.
- An communication check is performed for the ink cartridge IC of each slot. Once an ink cartridge is inserted, the communication is made
automatically and the check is done. When it is completed with no error, [OK] message is displayed.
- When the ink cartridge is removed, the number of the next slot is displayed.
Check for all ink cartridges by inserting and removing them from slot 1 through slot 4.
- After the IC check is properly completed through SLOT4, the screen shows [COMPLETED] and then shuts down.
Press the [ENTER] key to return to the IC CHECK menu.
- [ERROR] is displayed when there is a communication error with the ink cartridge IC.
Press the [ENTER] key to return to the IC CHECK menu.
- If the [] key is pressed to exit from this menu while any one of the ink cartridges is inserted or the sub power SW is turned off during the IC
CHECK, the following message is displayed.

REMOVE
ALL CARTRIDGE
Once all of the cartridges are removed, it returns to the IC CHECK menu and the sub power goes off.
NOTE:
- Any ink cartridge can be used for this check as long as it is equipped with an IC Chip.
- No information will be written into the IC chip during the check.
(The insert count is recorded while the machine is operating but not for the count during the check.)
- Check if the cartridge sensor works properly before performing the IC check.

CARTRIDGE SL1 : SERIAL


Indicates the serial No. of the ink cartridge IC
SLOT 1 0423275A493F81

SL1 : INK TYPE


Indicates the ink type of the ink cartridge IC
TrueVIS C

SL1 : CAPACITY
Indicates the ink capacity of the ink cartridge IC
450cc

SL1 : LOT NO.


Indicates the lot No. of the ink cartridge IC
15701 24

SL1 :START
Indicates the date, month, and year you first used the ink cartridge
16/01/01

SL1 :CONSUM.
Indicates the ink consumption amount
100.000cc

SL1 : INSERT
Indicates the insert count of the ink cartridge
3 times

SL1 :EMPTY
Indicates the number of times ink empty was detected
0 times
CARTRIDGE
SLOT 4

IC Check
- This menu is for reading the information written on the ink cartridge IC of each slot.
- In case an error is found, one of the following messages appears.

Ink cartridge is not set System error due to any trouble such as driver damage

SLOT1 SLOT1
NO CARTRIDGE SYSTEM ERROR
Ink cartridge without IC Data error

SLOT1 SLOT1
NO IC CHIP DATA ERROR

2-4 SG -540/300
Service Mode

I/S MENU WIPE ADJUST


WIPE ADJUST 0.00mm 0.10mm

Wiper Position Adjustment


- If you select this menu, the wiper starts rotating and stops at the straight up position. Also, the carriage moves to the left side of H2.
- Move the head carriage with [] [] keys so that the edge of the wiper touches the left side of the print head straight. Press the [ENTER] key to save the settings.
- After pressing [ENTER] key, the head carriage moves to the capping position. Then, it returns to the previous menu.
- If you do not want to save the settings, press the [MENU] key instead of the [ENTER] key to return to the previous menu.
- Adjustable range: -3.00 [m] to 3.00 [mm] (It can be changed in increments of 0.1[mm].)

SERVICE MENU CUTTING MENU CROPMARK SENSE MIN 0.7V MAX2.3


CUTTING MENU CROPMARK SENSE OUTLEVEL CHECK [2.0V]

Crop Mark Sensor Output Level Adjustment

The printer prints a crop mark on media, and the crop mark sensor automatically moves to above the crop mark to
detect output level. Before performing this menu, make sure to setup media. The head carriage automatically moves to
the position where the sensor is right above the crop mark.

The value displayed at the bottom part of the LCD screen is the current output voltage value of the crop mark sensor.
Adjust the voltage by adjusting the VR (VR500) on the cutting carriage board.
2
The values displayed at the upper part of the LCD screen are the minimum/maximum voltage values detected before.

Adjustment
Press the [ENTER] key to reset the maximum voltage value.

Procedures for crop mark sensor output level adjustment:


1. Lower the pinch roll, and setup media.
2. Perform [OUTLEVEL CHECK]. Adjust the VR so that the output voltage value becomes the right value.
3. Perform [OUTLEVEL CHECK] again. Confirm that the output voltage value is the right value.
If not, go back to step 2.

*Perform this adjustment when:


- the crop mark sensor is replaced or the part where the crop mark sensor is attached to is replaced or adjusted
- the carriage board is replaced
- voltage is accidentally tuned
- the distance between the crop mark sensor and the surface of the bed has been changed

The [OUTLEVEL CHECK] menu allows you to move the cut carriage freely by hand.
To detect the voltage value of blank space on media, move the carriage to the place where a crop mark is not printed
on.

CROPMARK SENSE ADJUST


ADJUST +2 +1

Adjusting the Sensitivity of the Crop Mark Sensor


To detect crop marks, the sensor first detects the voltage level of white area on media where no objects are printed on.
The voltage level of the area where crop marks are printed on is at least 0.7 V higher than that of white area.

In case the difference of the voltage level is below 0.7V, change the sensitivity of the sensor so that the sensor can detect
the crop marks.

This menu is to be used only when crop marks cannot be detected and you need to change the sensitivity of the sensor.
Avoid performing this adjustment unless you really need to.
Please note that changing parameters can affect the accuracy of crop mark sensor detection.

- Adjustable range: 0 to +2
- Default: 0

Sensitivity “0” : Difference between the voltage value of white area and the threshold value is 0.7.
Sensitivity “+1” : Difference between the voltage value of white area and the threshold value is 0.5.
Sensitivity “+2”: Difference between the voltage value of white area and the threshold value is 0.3.

CUTTING MENU FORCE ADJUST LOW


FORCE ADJUST LOW 30gf 16gf

FORCE ADJUST HIGH


HIGH 200gf 100gf

Tool Pressure Adjustment


This menu is for adjusting/setting the cutting force. Input the LOW/HIGH values scanned by DIAL TENSION METER.
The tool can be moved UP/DOWN by pressing the [PAUSE] key.

LOW
- Adjustable range: 0 - 100 (can be entered in increments of 1 gf)
- Default: 30gf

HIGH
- Adjustable range: 100 - 300 (can be entered in increments of 1 gf)
- Default: 200 gf

2-5 SG -540/300
Service Mode

CUTTING MENU CROP-CUT ADJ. PERFORMING


CROP-CUT ADJ. TEST PRINT TEST PRINT

CROP-CUT ADJ. F:+0.30 +0.30mm


SETTING S:-0.40 -0.40mm

CROP-CUT ADJ. PERFORMING


TEST PRINT 2 TEST PRINT

Adjusting the Position of the Crop Mark Sensor and the Position of the Blade
TEST PRINT
It prints a test pattern to align the position of the crop mark sensor and the position of the blade.
The machine prints a square crop mark, detects the crop mark, and then cuts a square along the crop mark.
If print & cut are misaligned, it means that the position of the crop mark sensor and the blade are not aligned.
After adjusting the position of the crop mark sensor and the blade in the [SETTING] menu, perform [TEST PRINT] to
confirm that the adjustment value you entered is reflected.

SETTING
This menu is for setting the correction values. The correction values for F (feed) and S (scan) are displayed.
The values on the left side of the LCD screen are the current correction values. And the values on the right are the new
correction values.
Press the [DOWN] key to move the cutting position to the near side (the F value increases).
2
Press the [UP] key to move the cutting position to the far side.

Adjustment
Press the [RIGHT] key to move the cutting position to the right (the S value increases).
Press the [LEFT] key to move the cutting position to the left.
Adjustable range: +/- 2.00 mm. (It can be entered in increments of 0.01 mm.)
Press the [MENU] key to go back to the previous menu.
Make sure to perform bidirectional adjustment before performing this adjustment.

*Perform this adjustment if:


- the crop mark sensor is replaced
- the sensitivity of the crop mark sensor is changed
- the position of the blade holder and the position of the crop mark sensor is changed

TEST PRINT 2
It prints a test pattern for crop mark sensor and cutting position adjustment.
First, the machine prints a square crop mark and then prints 0.1 mm scale marks in the scan and feed direction.
Then, the sensor detects the square crop mark and the blade cuts the media in a cross shape.
The point where the cutting line intersects the correction-value scale is the correction value.
Input the correction values in the [SETTING] menu.
The result of the test pattern is not affected by correction values set in the [SETTING] menu.

CUTTING MENU CROP-CUT ADJ. PERFORMING


PRINT-CUT ADJ. TEST PRINT TEST PRINT

CROP-CUT ADJ. F:+0.30 +0.30mm


SETTING S:-0.40 -0.40mm

CROP-CUT ADJ. PERFORMING


TEST PRINT 2 TEST PRINT

Print & Cut Position Adjustment


TEST PRINT
The machine prints a test pattern for print and cut adjustment.
First, the machine prints square crop marks, and then cuts square along the crop marks.
When the print & cut adjustment is finished, perform [TEST PRINT] to confirm that the adjustment value you entered is
reflected.

SETTING
This menu is for setting the correction values. The correction value at the upper part of the LCD screen is for “F” (feed),
and the correction values at the bottom is for S (scan). The values on the left are the current correction values, and the
values on the right are the new correction values.
Press the [DOWN] key to move the cutting position to the near side (the F value increases).
Press the [UP] key to move the cutting position to the far side.
Press the [RIGHT] key to move the cutting position to the right (the S value increases).
Press the [LEFT] key to move the cutting position to the left.
The adjustable range is +/- 5.00 mm. (It can be entered in increments of 0.01 mm.)
The default value is 0.00 mm.
Press the [MENU] key to go back to the previous menu.
Make sure to perform bidirectional adjustment before performing this adjustment.

*Perform this adjustment if:


- the print head is replaced
- the distance between the blade and the print head is changed

TEST PRINT 2
The machine prints a test pattern for print and cut adjustment.
First, the machine prints a test pattern and then prints 0.1 mm marks in the scan and feed direction.
Then, the blade cuts the media in a cross shape.
The point where the cutting line intersects the correction-value scale is the correction value.
The result of the test pattern is not affected by correction values set in the [SETTING] menu.

2-6 SG -540/300
Service Mode

SERVICE MENU FRSHODPULWwaVC Q F1234 C1234M


SENSOR CHECK L *EC

Sensor Check
- This menu is for showing the real-time state of each sensor. If there is a response, a * mark is displayed.
- The first display shows the status of each of the sensors.
Symbol Sensor name Description
  F Front paper sensor * is displayed when media is set.
  R Rear paper sensor * is displayed when media is set.
  S Crop mark sensor * is displayed when crop marks are detected.
  H Head lock sensor * is displayed when the print head is at the original position.
  O Limit sensor * is displayed when the cut carriage is connected.
  D Maintenance cover sensor R * is displayed when the cover is open.
P Maintenance cover sensor L * is displayed when the cover is open.
U Head UP/DOWN sensor “H” and “L” are displayed when the print head is up and down, respectively.
  L Sheet load sensor * is displayed when the pinch lever is lowered.
  W Pinch roller sensor * is displayed when the pinch rollers are detected.
  w Wiper sensor * is displayed when the wiper is at the starting position.
The real-time status of the TU motor is displayed when TU is connected.
a Extension input 1
(It displays blank while the motor is driving. * is displayed when it is not driving. )
V Waste valve sensor * is displayed when the valve is closed.
C Front cover sensor * is displayed when the cover is open.
Q Ink slot cover sensor * is displayed when the cover is open.
- The status of the filler sensor is displayed on the third page.
The left most one indicates nozzle A of HEAD 1, the second one from the left indicates nozzle B of HEAD 1, and so on.
* is displayed when the filler sensor is touched.

- The status of the cartridge sensor of each slot and the ink empty sensor are shown on the forth page.
2
Symbol Description

Adjustment
    blank No ink cartridge, Ink is filled
   C Ink cartridge is in, Ink is filled
E No ink cartridge, Ink is empty
   * Ink cartridge is in, Ink is empty
- In short, the message is blank when the both sensors are OFF and * is displayed when the both sensors are ON.
M indicates wiper cleaning cartridge.

- Setup will be canceled when you are out from the sensor check menu.

SERVICE MENU THERMISTOR CHK Thermistor check menu


THERMISTOR CHK AMP1:25゚C/76゚F - Performs the thermistor check.
 If you select this menu, it will display the temperature read from the thermistor attached to each board.
 The temperature on the left is shown in degrees Celsius and the one on the right is in degrees Fahrenheit.
- [AMP1] and [AMP2] are the thermistor attached to the print carriage board. [CARR] is the thermistor near the print head.
- Check whether the temperature is extremely low (around 0 degrees) or extremely high (around 100 degrees).
THERMISTOR CHK - When the temperature of CARR thermistor becomes abnormal, the high temperature or the low temperature errors occur.

CARR:25゚C/76゚F

SERVICE MENU SUB MENU SERIAL NO.


SUB MENU SERIAL NO. ZAA0000

Serial Number Input


- This menu is for inputting 7 digits of the serial number.
- Use [] [] keys to move to the next digit and [] [] keys to increment or decrement parameters.
  
   Z AA 0000

Indicates 4th to 7th digits of the lot number, given by numeric characters (0-9)

2nd and 3rd digits indicate the month of production, given by alphabetical and numeric characters
(ex.: 00-99, A0-Z9, AA-ZZ)
Indicates the 1st digit of the lot number, given by an alphabetical character (Z and A-X)

SUB MENU CHANGE INKTYPE


To setup view
CHANGE INKTYPE TrueVIS 4C

Changing Ink Type


- This menu is for changing the ink type manually.
- Unlike the user-menu ink type change, neither head wash nor ink fill is performed. Use this menu to reselect the ink type when unintended ink type is
selected.
- Once the ink type is changed, the ink system is internally reinitialized. This menu is then exited and setup is cancelled.
- If you select [UNKNOWN] in this menu and perform [FILL INK], the machine performs initial ink filling.

Ink type
TrueVIS 4C
UNKNOWN (The printer is not filled with ink.)

SUB MENU Fill Ink


FILL INK - Fill ink after [PUMP UP] and [HEAD WASH] are in the sequence. (without initial cleaning).
- After setting [UNKNOWN] on CHANGE INKTYPE, initial cleaning is included same as initial fill ink.

SUB MENU Pump Up


PUMP UP - Drain ink from the ink lines.

SUB MENU Head Wash

HEAD WASH - Clean the ink lines by TR-CL.


- TR-CL x 2 pcs are necessary.

SUB MENU EMPTY CLEANING... EMPTY


FILL DAMPER DRAIN BOTTLE > 11:30 DRAIN BOTTLE
* Error

CLEANING ERROR

Fill Damper
- It starts cleaning when you press the [ENTER] key.
- During cleaning, progress and the remaining time are displayed at the bottom of the LCD screen.
- “CLEANING ERROR” occurs when you remove ink cartridges or ink becomes empty while the machine is lowering the pressure inside the dampers.
In case the error occurs, make sure to perform [FILL DAMPER] again.

2-7 SG -540/300
Service Mode

SUB MENU NOW PROCESSING..


EMPTY DAMPER > 02:30

Empty Damper
- Press the [ENTER] key to start [EMPTY DAMPER].
- Perform [EMPTY DAMPER] before print head replacement. Do not carry out other menu operations before print head replacement.
- Be sure to perform [FILL DAMPER] as soon as [EMPTY DAMPER] is complete.

SUB MENU PERIODIC CL.


PERIODIC CL. NORMAL MEDIUM

Periodic Cleaning
- This menu is for setting the cleaning type of the periodic cleaning function.
[NORMAL] indicates normal cleaning, and [MEDIUM] indicates medium cleaning.
- Options: NORMAL/MEDIUM
- Default: NORMAL
- Cleaning frequency can be set from the [PERIODIC CL] menu in the user menu.

2
SUB MENU FAN CHECK

Adjustment
FAN CHECK VACUUM FAN

Fan Check
- This menu is for checking the fan operation.
- Turn the fan ON/OFF by pressing the [ENTER] key.
- Fan is automatically turned off if you exit this menu.

SUB MENU TU CHECK TU


TU CHECK TU START STOP

*When TU is not connected

TU IS
NOT CONNECTED

TU Check
- This menu is for checking if TU can be controlled properly. 
- Select [START] or [STOP] with [] [] keys. Default is [START]. Changes made in this menu will not be saved.
- When you select this menu, [START] is displayed. Even when you change it to [STOP], the setting goes back to [START] again once you leave this menu.
- The real-time status of the TU motor is displayed on the up right corner. When the motor is not driving, blank is displayed. When the motor is driving * is
displayed.
- Check that [START] is selected and then move the dancer roller up and down. The status can be check on the LCD screen.
Then, select [STOP] and confirm that the status does not change even if you move the dancer roller up and down.
- If the connector gets unplugged during TU check, the machine continues the operation as if the connector was plugged in.
If the connector was not plugged in from the beginning, the machine operates as if TU is not connected.

Display Setting

SUB MENU CLOCK DATE DATE


CLOCK DATE 16/01/01 16/01/01

Display Setting

CLOCK TIME TIME


DATE 01:01:59 01:01:59
[B] is displayed when battery is dead.

TIME TIME
01:01:59 B 01:01:59 B

Date and time setting


- This menu is for displaying and editing the date and time. When the machine detects a dead battery, “B” is indicated on the time display.
In this case, the batter needs to be replaced. “B” does not disappear automatically when the battery is replaced. “B” is deleted when the time is newly set up
with the [ENTER] key on the time edit menu.
- When the real time clock is not active due to a dead battery, the maintenance operation may be performed improperly. For instance, the machine performs
cleaning every time the secondary power is turned on.
- The time set here is used for the timing of maintenance operations and for recording the Event Log.
- When this setting is changed, it is recorded in the Event Log. The time before change is used for the log time, and the new time is recorded as reference
information.

DATE TIME
12/01/01 01:01:59

2-8 SG -540/300
Service Mode

SUB MENU DIP SW CHECK


DIP SW CHECK 0100 0000

Dip switch check


- This menu is for checking dip switch settings.
- It displays the real-time status of the No.1 to 8 dip switches in order from the left. [0] is OFF and [1] is ON.

SUB MENU KEY CHECK


KEY CHECK NONE

Key check
- This menu is for checking the operation of panel keys. It shows [NONE] on the lower line of the LCD when any key is not pressed. It shows the key name when
a key is pressed.
- You can exit this menu with the [] key. Therefore, the [] key needs to be the last button to be pressed in order to check all the keys. No operations for 10
seconds or pressing the [] key let you exit this menu. When you exit the menu, the names of the keys that were not pressed are displayed with buzzer.
If buzzer is not heard, all keys checked out properly.
- The message [KEY ERROR] appears if two or more keys are pressed at the same time.
- The power cannot be turned off by the [POWER] key while in this menu.

SUB MENU
2
Abbreviated
LCD/LED/BUZ CHK

Adjustment
LCD/LED/BUZZER Check
- This menu is for checking LCD, LED and buzzer. When this menu is selected, it sequentially checks the function of LCD, LED and buzzer. It checks ON/OFF of
all LEDs, LCD back light, ON/OFF of buzzer, and display of all dots of LCD. Confirm that all functions operate properly, visually and by the sound. In case of
serious failure, there should be major indications such as the LCD not turning on. In other words, you need to know in advance that the machine is operating
correctly.
- The buzzer is repeatedly turned ON/OFF for about one minute. You can exit this menu by pressing the [ENTER] key during this time.

Waiting for data input

SUB MENU DETECTING...


PORT CHECK 00: 0B
Receiving data from network

NETWORK
B3:1073741624B

Port check
- This menu is for checking the data input from network.
- The check sum and input data byte are shown on the lower LCD. [DETECTING...] means that there is no input during detection.
The machine displays [DETECTING...] if there is no data input in the last 3 seconds.
- Checksum and number of input data bytes are displayed on the lower part of the LCD. On the left, it displays the check sum in hexadecimal number of two
digits. On the right, it displays the input data byte in decimal number up to 10 digits.
- The check sum and input data byte are cleared when the [ENTER] key is pressed.
- The number of input data byte overflows upon reaching 4 GB (4,294,967,296 bytes) then returns to 0.

SUB MENU MAINTE.MSG.


MAINTE.MSG. NONE 100hours

Maintenance Reminder Setup


- When printing operations are performed for a certain time period, a message appears reminding you to perform maintenance operations. This message
appears right after you have tuned on the sub power SW.
Adjustable range: NONE, 10 to 990 hours (in increments of 10 hours)
Default: NONE

SUB MENU WIRELESS RFID TEST


WIRELESS RFID TEST NORMAL SLOT 1

RFID Test
- Checks each mode (NORMAL, SLOT n (1~8), RF OFF) and performs RFID test.
- Turn off the sub power SW when the RFID test is finished.
- Options: NORMAL, SLOT n (1~4), RF OFF
- Default: NORMAL
- NORMAL: Normal-operation mode
- SLOT n: The machine accesses a selected slot tag at one-second interval.
(During the test, the LED light of the selected slot stays on. If an error occurs, the light turns off.)
- RF OFF: It does not access tags.

SERVICE MENU MOTOR MENU AGING SCAN


MOTOR MENU AGING SCAN NOW AGING

AGING FEED
FEED NOW AGING

AGING BOTH
BOTH NOW AGING

2-9 SG -540/300
Service Mode

AGING CUTTING
CUTTING NOW AGING

Motor Aging
- To stop aging, press the [ENTER] key. The head carriage automatically returns to the capping position. After the head is capped, it returns to the previous
menu.
- Do not perform aging for a prolonged time with ink filled. Ink will dry out and damage the print head.
- When ink lines are filled with ink, the machine performs the flushing operation while performing aging.
When ink lines are not filled with ink, the machine does not perform the flushing operation.
SCAN
 Operation: Aging for the scan motor
 Speed: 1083 mm/s
 Range: The head carriage runs maximum printing width back and forth.
FEED
 Operation: Aging for the feed motor
 Speed: 100 mm/s
 Range: The grit roller runs 1000 mm back and forth.
BOTH
 Operation: The machine performs aging for SCAN and FEED at the same time.
 Speed: Same as above
 Range:
CUTTING
 Operation: The machine performs aging for SCAN and FEED at the same time. (cutting mode)
 Speed: 300 mm/s
 Range: The head carriage runs maximum printing width in the scan direction back and forth. Also, it runs half of the maximum printing width in the
feed direction.

Servo motor: LOCKED 2


MOTOR MENU SERVO LOCK SERVO LOCK
F: * 0

Adjustment
SERVO LOCK S: 100 0

Servo motor: FREE


SERVO LOCK SERVO LOCK
F: 240 20 F: 0 0

Servo Lock
- This menu is for checking whether the servo motor can be locked properly.
- While in this menu, the servo motor is free. If you manually move the motor (e.g. carriage) in this state, the displayed values change as long as the feedback
is properly running. You can toggle between locking and freeing the servo by pressing the [ENTER] key. Freeing it or locking it at this time helps in
identifying and investigating the axis causing the problem.
- The FEED value displayed on the left changes according to the grid encoder, and the FEED value on the right changes according to the motor encoder.

MOTOR MENU M-ENC:80000 OK G-ENC CHECK


G-ENC CHECK G-ENC:80004 NG COMPLETED

G-ENC CHECK
FAILED

Grit Encoder Check


- This menu is to check whether the grit encoder works properly.
- By performing this menu, you can identify problems such as read error of the grit encoder or loose screws.
- The feed motor operates during this check, so exercise caution.

SERVICE MENU HEATER MENU SVC.MODE HEAT.


HEATER MENU SVS.MODE HEAT. STOP STOP

Heater setting menu in service mode


- Control the heater ON/OFF when starting in service mode.
The heater is ON when selecting START. The heater is OFF when selecting STOP.
The setting in the menu is retained when sub power SW is turned off.
- Setting range: START / STOP
- Default value: STOP

HEATER MENU HEATER ADJUST PRE


HEATER ADJUST PRINT 0 0

HEATER ADJUST
DRYER

Heater Temperature Correction Value Setting


- Controlled by the temperature with which only the part set as the correction value is offset to higher than the temperature displayed on the LCD.
- Setting range: -5 to +5
- Default value: 0

HEATER MENU PREHEAT TEMP.


PREHEAT TEMP. 30°C 30°C

Heater Warm-Up Temperature Setting


- Sets the temperature of the PREHEAT (warm-up) in the PREHEATING menu of the user menu.
- Setting range: 20°C to 40°C
- Default value: 30°C

2-10 SG -540/300
Service Mode

HEATER MENU HEAT TIMEOUT


HEAT TIMEOUT 20min 30min

Heater Heating Confirmation Time Setting


- Time setting that displays a confirmation message during heater temperature control at the start of printing.
- Even if the time set during the heater temperature control at the start of printing elapses, temperature control does not end and the message
[HEATING TIMEOUT CONTINUE?] is displayed.
- Setting range: OFF, 10 to 30 minutes (10-minute increments)
- Default value: 20 minutes

HEATER MENU PRINT 25°C


HEATER CHECK DRYER 25°C

Heater Check
- Performs the heater and thermistor check. Selecting this menu displays the temperatures read from the dryer, and optional dryer thermistor, as well as the
ON (energized) and OFF (non-energized) states.
- Select a heater by moving the cursor using the [] [] keys.You can turn the selected heater ON/OFF by pressing the [ENTER] key. (ON/OFF here
means manually selecting whether or not to energize the heater, and not starting/stopping heater control. Thus, when it is left in the ON state, the heater
will continue to be energized and the temperature will continue to rise.)

2
- (If you exit this menu, this is automatically turned OFF (non-energized state))
- As a check method, check if the temperature rises only in the correct heater when this is ON, and check whether the temperature decreases when this is OFF.
- Temperature is only displayed in degree Celsius.

Adjustment
SERVICE MENU SYSTEM SWITCH PAGE1 System Switch
SYSTEM SWITCH PAGE1 00000000 - Each bit can be switched by the [] [] keys.
- Each bit can be selected by the [] []keys.
- Press the [ENTER] key to save the settings.
- The rightmost positioned bit on each page is shown as bit 1, the leftmost positioned is shown as bit 8.
- On each page, the [] key is disabled if the cursor is at the rightmost position.
SYSTEM SWITCH
PAGE1
PAGE16
00000000

SERVICE MENU HISTORY MENU MOTOR HOURS F MOTOR HOURS F


HISTORY MENU MOTOR GROUP 7 hours CLEAR

HISTORY MENU History Menu


HEAD GROUP - In the history menu, the parameters are separated in groups by categories. The parameters can be displayed or cleared by selecting the group.
- Press the [] []key to see each category. The parameters will be displayed below the group name.
- Refer to History Menu for details.
- If you press the [] key one more time, [CLEAR] appears. Press the [ENTER] key to clear the parameters.

HISTORY MENU
MAINTE.GROUP

HISTORY MENU
WIPE GROUP

HISTORY MENU
PRINT GROUP

WIPE GROUP
CUTTING GROUP

HISTORY MENU
INK GROUP

HISTORY MENU
ERROR GROUP

HISTORY MENU
HEATER GROUP

HISTORY MENU
SYSTEM GROUP

SERVICE MENU REPORT Report Menu


REPORT ALL - All the reports such as system report, service report, history report, and ink cartridge IC report can be printed at once.

2-11 SG -540/300
History Menu

MOTOR GROUP
Item Contents Unit Reference
MOTOR HOURS F Total time the feed motor rotated hour Brush life
MOTOR HOURS S Total time the scan motor rotated hour Brush life
S PUMP TIMES Number of times the cleaning pump rotated times Pump life
PUMP TIMES B Number of times the B-pump rotated times Pump life
P PUMP TIMES 1 Number of times the 1-pressure pump rotated times Pump life
P PUMP TIMES 2 Number of times the 2-pressure pump rotated times Pump life
P PUMP TIMES 3 Number of times the 3-pressure pump rotated times Pump life
P PUMP TIMES 4 Number of times the 4-pressure pump rotated times Pump life
CLEAR ALL Clear all values under MOTOR GROUP
 

HEAD GROUP
Item Contents Unit Reference
2

Adjustment
SHOT COUNT 1 Number of piezo drive times per nozzle (H1 A) times x 1000
SHOT COUNT 2 Number of piezo drive times per nozzle (H1 B) times x 1000
SHOT COUNT 3 Number of piezo drive times per nozzle (H2 A) times x 1000
SHOT COUNT 4 Number of piezo drive times per nozzle (H2 B) times x 1000
INKRENEW H1 Number of times ink was renewed (H1) times
INKRENEW H2 Number of times ink was renewed (H2) times
WIPE H1 Number of times wiping was performed (H1) times
WIPE H2 Number of times wiping was performed (H2) times
AUTO CL.H1 Number of times auto cleaning was performed (H1) times
AUTO CL.H2 Number of times auto cleaning was performed (H2) times
NORMAL CL.H1 Number of times normal cleaning was performed (H1) times
NORMAL CL.H2 Number of times normal cleaning was performed (H2) times
MEDIUM CL.H1 Number of times medium cleaning was performed (H1) times
MEDIUM CL.H2 Number of times medium cleaning was performed (H2) times
POWERFUL CL.H1 Number of times powerful cleaning was performed (H1) times
POWERFUL CL.H2 Number of times powerful cleaning was performed (H2) times
SUPER CL.H1 Number of times super cleaning was performed (H1) times
SUPER CL.H2 Number of times super cleaning was performed (H2) times
CLEAR H1 Clear all values of H1
CLEAR H2 Clear all values of H2
CLEAR ALL Clear all values under HEAD GROUP

2-12 SG -540/300
History Menu

MAINTE GROUP
Item Contents Unit Reference
MAINTE. COUNT Number of times head maintenance was performed times
This value is cleared automatically after
TOTAL TIME Elapsed time from the last head maintenance hour
the head maintenance is performed.
This value is cleared automatically after
PRINTING TIME Printing time from the last head maintenance hour
the head maintenance is performed.
CLEAR ALL Clear all values under MAINTE GROUP

WIPE GROUP
Item Contents Unit Reference
This value is cleared automatically after
WIPING COUNT Number of times wiping was performed times
the wiper is replaced.
WIPER REPLACE Number of times the wiper was replaced times
2
Number of times wiper was cleaned (Number of times wiping This value is cleared automatically after
WIPER WASH times
was performed) the tray is cleaned.

Adjustment
TRAY CLEANING Number of times tray was cleaned times
This value is cleared automatically after
SKIP TIME Maximum time which the cleaning liquid had not supplied hour
the wiper is replaced.
CLEAR ALL Clear all values under WIPE GROUP

PRINT GROUP
Item Contents Unit Reference
PRINTING TIME Total printing time hour Test print time is excluded.
PRINT PAGES Number of pages printed pages
PRINT AREA Total area of printing performed m2
CLEAR ALL Clear all values under PRINT GROUP

CUTTING GROUP
Item Contents Unit Reference
CUTTING TIME Cutting time hour Test print time is excluded.
Number of times the cutting carriage
DISCONNECT Number of times carriage was detached times and the print-head carriage were
detached
CLEAR ALL Clear all values under CUTTING GROUP

2-13 SG -540/300
History Menu

INK GROUP
Item Contents Unit Reference
CARTRIDGE 1 Number of times ink cartridge 1 was changed times
CARTRIDGE 2 Number of times ink cartridge 2 was changed times
CARTRIDGE 3 Number of times ink cartridge 3 was changed times
CARTRIDGE 4 Number of times ink cartridge 4 was changed times
EMPTY HIT 1 Number of times ink cartridge 1 was detected to be empty times
EMPTY HIT 2 Number of times ink cartridge 2 was detected to be empty times
EMPTY HIT 3 Number of times ink cartridge 3 was detected to be empty times
EMPTY HIT 4 Number of times ink cartridge 4 was detected to be empty times
CHANGE INK Number of times the Ink type was changed times
CLEAR ALL Clear all values under INK GROUP

ERROR GROUP
Item Contents Unit Reference 2
SERVICE CALL Number of times service call occurred times

Adjustment
Last five service call numbers are
S-CALL HISTORY Service call numbers of the last five service calls No.
retained.
Number of times the servo error
MOTOR ERROR F Number of times the feed motor error occurred times
occurred
Number of times the servo error
MOTOR ERROR S Number of times the scan motor error occurred times
occurred
Number of times the low temperature
LOW TEMP.ERR. Number of times the low temperature error occurred times
error occurred
Number of times the high temperature
HIGH TEMP.ERR. Number of times the high temperature error occurred times
error occurred
Number of times of forced capping
occurred to prevent head drying when
EMERG. CAPPING Number of times the emergency capping error occurred times
cap is left open for 10 minutes or more
due to cover open or other reasons
When the print head is left uncapped, it
START UNCAPPED Number of times the printer started uncapped times
is detected when printer is started.
CLEAR ALL Clear all values under ERROR GROUP

2-14 SG -540/300
History Menu

HEATER GROUP
Item Contents Unit Reference
PRINT USE TIME Total time the print heater was used hour Total time the print heater was used
DRY USE TIME Total time the dryer was used hour Total time the dryer was used
CLEAR ALL Clear all values under HEATER GROUP

SYSTEM GROUP
Item Contents Unit Reference
POWER ON COUNT Number of times the sub power SW was turned on times
POWER ON TIME Total time the sub power was on hour
SLEEP TIME Total time the printer was in the sleep mode hour
It counts auto sheet cut performed by
SHEETCUT COUNT Number of times the sheet cut was performed times
both printer and RIP.
CLEAR ALL Clear all values under SYSTEM GROUP
2

Adjustment

2-15 SG -540/300
Other Factory Modes

System parameter initialization

ENTER
+ Turn on the sub power SW while pressing the [▲] [▼] [ENTER]
keys to start the printer in system parameter initialization mode. A
confirmation message appears on LCD, then click [ENTER] to move
select machine menu. Select the model by pressing the [▲] [▼] keys,
and press the [ENTER] key to initialize system parameter. Press the sub
power SW for more than 1 second to cancel it. The printer turns off
automatically when the initialization is completed.
All the parameters are reset to the default and the history information
INITIALIZE ALL is cleared
SYS.PARAMETER The limit position is cleard, so it is necessary to initialize the limit 2
[ ] position after this procedure. [SERVICE CALL 0101] occurs if the limit

Adjustment
position is not initialized.
SELECT MODEL
SG-540
[ ]

INITIALIZATION
COMPLETED

Language/unit selection

MENU
+

Roland DG Corp.
    SG-540

MENU LANGUAGE
ENGLISH
[ ]

LENGTH UNIT
mm > INCH
[ ]

TEMP. UNIT
°C > °F

2-16 SG -540/300
Firmware Upgrade Mode

Information Procedure
C AU TIO N
Necessary tools It is necessary to prepare the following to upgrade/
install the firmware.
Software • Firmware
Peck • WindowsPC (Network port is required.)
Latest firmware • Peck.exe
• Network cable (A cross cable is required when you
connect the printer to a computer directly.)
Typical work time
1. Check the IP address of the printer. Turn on the main
Contents of work Time power SW, turn on the sub power SW, and then press
2
the [MENU] key. Select [SYSTEM INFO.] > [NETWORK]

Adjustment
Firmware Upgrade 5 min
> [IP ADDRESS].
MENU

[ ]

MENU
SYSTEM INFO.
[ ][ ]

SYSTEM INFO.
NETWORK
[ ]

NETWORK
IP ADDRESS
[ ]

IP ADDRESS
192.168.000.100

2. Turn off the sub power.

2-17 SG -540/300
Firmware Upgrade Mode

3. Start Peck on a computer. When the [Peck] screen 7. The printer goes into the firmware upgrade mode
appears, click [Select Port]. automatically. When the upgrade is completed, the
sub power SW turns off automatically.
FIRMWARE V1.10 NG DATA ERROR

ERASING NG DEVICE ERROR

WRITING NG DEVICE ERROR

VERIFYING DEVICE ERROR


2
NG

4. Select [Product] > [Type5]. Also, select [Select] > [via

Adjustment
Network]. Input IP address of the printer. Click [OK]. COMPLETED

8. (End of procedure)

5. The [PECK] screen is displayed. Click [Firmware


Upgrade].

6. [OPEN] screen is displayed. Select the firmware file.


Click [Open] The firmware will be sent to the printer.

VG

VG

2-18 SG -540/300
Firmware Installation

Information Procedure
C AU TIO N
Necessary tools Perform this procedure when a brand-new main
board without firmware is installed.
Software
Peck
1. Turn on the main power SW while pressing the [◀]
[▼] [▶] keys.
Latest firmware

UPDATE FIRMWARE?
Typical work time

Contents of work Time


2. Press the [ENTER] key to prepare the printer for 2
receiving the firmware.

Adjustment
Firmware Installation 10 min
UPDATE FIRMWARE?

[ ]

WAITING
000.000.000.000

3. Press the [MENU] key, and set [IP ADDRESS], [SUBNET


MASK], and [GATEWAY ADDR.]. Press the [◀] [▶] keys
for moving between digits, and the [▼] [▲] keys for
selecting values. After setting an address, press the
[ENTER] key to go to the next address setting. When
[GATEWAY ADDR.] is set, return to the waiting mode
for receiving the firmware by pressing the [ENTER]
key.

C AU TIO N
The setting made here is only temporary for the
firmware installation and it is not saved. Start Peck
on a computer.
WAITING
000.000.000.000
MENU

IP ADDRESS
192.168.000.100
[ ]

SUBNET MASK
255.255.255.000
[ ]

GATEWAY ADDR.
000.000.000.000
[ ]

WAITING
192.168.000.100

2-19 SG -540/300
Firmware Installation

4. When the [Peck] screen is displayed, click [Select 8. Firmware loading begins. The firmware installation
Port]. is completed when the [COMPLETED] message is
displayed. Turn off the sub power SW.
FIRMWARE V1.10 NG DATA ERROR

ERASING NG DEVICE ERROR

WRITING NG DEVICE ERROR

VERIFYING NG DEVICE ERROR 2


5. Select [Product] > [Type5]. Also, select [Select] > [via

Adjustment
Network]. Input IP address of the printer. Click [OK]. COMPLETED

9. Turn on the sub power SW while pressing the [▲]


[▼] [ENTER] keys to enter the [INITIALIZE ALL SYS.
PARAMETER] menu. Select the model by pressing
the [▲] [▼] keys, and press the [ENTER] key to
start initialization. The sub power SW turns off
automatically when it is completed.

6. The [Peck] screen is displayed. Click [Firmware


10. Turn on the sub power SW while pressing the [◀] [▼]
[▶] keys to enter the service mode.
Upgrade].
11. Turn off the sub power when the network setting is
completed.
MENU
SERVICE MENU
[ ]

MENU

[ ] [ ]

SYSTEM INFO.

[ ]

NETWORK [ ] IP ADDRESS
[ ]
192.168.000.100
[ ]
7. The [OPEN] screen is displayed. Select the firmware NETWORK [ ] SUBNET MASK
[ ]
file and click [Open]. The firmware will be sent to the 255.255.255.000

printer. [ ]

NETWORK [ ] GATEWAY ADDR.


[ ]
VG 000.000.000.000

VG

2-20 SG -540/300
Firmware Installation

12. Start Peck on a computer. When the [Peck] screen 14. Click [Get Report] to import the system report
appears, click [Put Parameters]. file. Confirm that system parameters are reloaded
properly.

M emo
The network settings set at step 11 are replaced
with the system parameters when [Put Parameters]
is executed. Please do the network settings again if
necessary.

2
13. [OPEN]

Adjustment
screen is displayed. Select the system
parameters saved before the main board
replacement. Click [Open]. Peck starts to send the
system parameters to the printer.

Parameters

Parameters

15. (End of procedure)

2-21 SG -540/300
Limit Position & Cut Down Position Initialization

Information Procedure
C AU TIO N
Necessary tools • A motor error occurs when moving the cut carriage
while the front cover or the maintenance cover are
General tools open. To operate the printer, press and hold the
None cover sensor switch.
• This adjustment is for adjusting the relative distance
Special tools
between the limit sensor and the capping position,
None and also detecting the distance from the cut down
position to the limit sensor after completing the
adjustment.
Workflow • When the limit position is not correctly set, it may 2
cause some problems such as a head capping

Adjustment
1. Limit position & cut down position initialization error and a head carriage lock error. Also, when the
cutter-down position is not correct, there will be
some problems such as a cutter down error when
Typical work time separating the sheet.

Contents of work Time


1. Open the maintenance cover L and the maintenance
Limit position & cut down
cover R.
3 min 1. Maintenance cover L
position initialization

2. Maintenance cover R

1 2

2. Turn on the sub power SW while pressing the [◀]


[▼] [▶] keys to enter the limit initialization mode.

LIMIT INITIALIZE
MENU

2-22 SG -540/300
Limit Position & Cut Down Position Initialization

3. Move the head carriage to the lock position. Confirm


that the head carriage is locked by pushing it lightly
to the left to eliminate looseness.

1 2

Adjustment
4. Confirm that the print head is capped properly,
6. Press the [ENTER] key to perform cut down position
and press the [ENTER] key. The tool carriage will initialization. After initialization is completed, the
be separated from the head carriage and limit message is displayed. Refer to Chapter 2 "Flushing
position initialization will start. After initialization is Position Adjustment" and perform flushing position
completed, the message is displayed. adjustment.

SETTING UP SETTING UP
THE LIMIT CUTTER DOWN POS
[ ] [ ]

DETECTING.. DETECTING..

SETTING UP INITIALIZATION
CUTTER DOWN POS COMPLETED

5. Move the cut carriage with your hand until it makes 7. (End of procedure)
full contact with the auto cutter frame with the cutter
in the down position.

2-23 SG -540/300
Linear Encoder Setup

Information Procedure
C AU TIO N
Necessary tools • An interlock mechanism ordinarily prevents
carriage movement when the printer's cover is
Special tools opened. To operate the printer with the front cover
None open, press and hold the sensor switch.
• This adjustment is for checking reading by the linear
encoder and for calibrating encoder expansion/
Workflow contraction caused by the operation environment.
This operation is required when the limit sensor,
encoder scale or encoder sensor is replaced or the
1. Linear encoder setup position is adjusted. 2
1. Turn on the main power SW. Then, turn on the sub

Adjustment
Typical work time
power SW while pressing the [] [] [] keys to
enter the service menu.
Contents of work Time
Linear encoder setup 5 min
+

MENU

MENU
SERVICE MENU

2. Make sure to unload the media. Lower the pinch


rollers. Also, be sure to remove the media clamps.

2-24 SG -540/300
Linear Encoder Setup

3. Select [PRINT MENU] > [LINEAR ENCODER], and press


the [ENTER] key.
SERVICE MENU
PRINT MENU
[ ] [ ]

PRINT MENU
LINEAR ENCODER
[ ]

NOW PROCESSING..
POS: 1361.00mm
2
4. One of the messages appears at the completion of

Adjustment
setup. In case of [SETUP FAILED] error, check the
following.
• Dirt/scratches on the encoder scale.
• Dirt/scratches on the encoder sensor.
• Limit position & cut down position initialization
error.
• Backlash of the scan motor gear and the drive gear.
• Fastening of the carriage and the carriage belt.
• Bad cable contact.
LINEAR ENCODER
SETUP COMPLETED

LINEAR ENCODER
SETUP FAILED

5. (End of procedure)

2-25 SG -540/300
Flushing Position Adjustment

Information Procedure
C AU TIO N
Necessary tools • An interlock mechanism ordinarily prevents carriage
movement when the printer's cover is opened. To
General tools operate the printer with the front cover open, press
None and hold the sensor switch.
• This adjustment is for adjusting the flushing
Special tools
position. Without this adjustment, the flushing
None may not be performed properly and that can cause
nozzle firing problem.

Workflow 1. Turn off the sub power SW, and then turn off the main 2
power SW. Unplug the power cord.

Adjustment
1. Flushing position adjustment 2. Set the head height to LOW.

Typical work time

Contents of work Time


Flushing position
3 min
adjustment

3. Unlock the head carriage.

4. Remove the covers shown in orange in the figure.


Then, lock the head carriage.

2-26 SG -540/300
Flushing Position Adjustment

Memo 7. Select [PRINT MENU] > [FLUSHING ADJ], and press


Easiest way to remove the cover shown below is to 1) the [ENTER] key. The head carriage automatically
slide the cover to the front, 2) lift up the rear side of moves to the current flushing position.
the cover, and 3) remove the cover from the left side. SERVICE MENU
PRINT MENU

2 [ ]
3
1
PRINT MENU
FLUSHING ADJ.

FLUSHING ADJ. 2
0.00mm -0.40mm
5. Slide the cap-base frame to the left by hand until it

Adjustment
does not go any further. 8. Move the head carriage to the position where
C AUTI ON the head base makes contact with the tip of
the cap base by pressing [◀] and [▶] keys.
Make sure that the shaft is touching the slide-cap
guide on the left side. 1. Cap base

2. Head base

2 1
Shafts

Slide cap guide

6. Turn on the main power SW. Then, turn on the sub 2 1


power SW while pressing the [] [] [] keys to
enter the service menu. 9. Press the [ENTER] key to set the flushing position. If
you press the [MENU] key, the flushing position will
not be updated, and display returns to the menu.

C AU TIO N
If flushing position adjustment is not performed
properly, inks may become mixed.

2-27 SG -540/300
Flushing Position Adjustment

10. Press the [] key once to move the head carriage 0.1
mm to the left from the flushing position.

11. Confirm that there is a 0.1 mm gap between the head


base and the backup cap base. If you do not see any
gap, go back to step 8 and adjust again.

N OTE
Check that there is a 0.1 mm gap by shining a
flashlight from behind the head carriage.

1. Cap base

2. Head base
2

Adjustment
2 1

12. (End of procedure)

2-28 SG -540/300
Crop Mark Sensor Adjustment

Information Procedure
C AU TIO N
Necessary tools • This adjustment is for adjusting the sensitivity of
the crop mark sensor. If it is not adjusted properly,
General tools crop marks cannot be read correctly, leading to
White sticker media problems such as print and cut misalignment.
Cases you need to perform this adjustment:
No.2 Phillips screwdriver
"" After replacing or adjusting the crop mark
Special tools sensor or tool carriage board

None "" In case you accidentally turn the voltage


adjustment VR
"" When the distance between the crop mark
2
sensor and the bed surface is changed

Adjustment
Workflow
The pre-heater, print heater and dryer must be
turned off during this adjustment.
1. Crop mark sensor adjustment • When you carry out this adjustment, you may use
the media the user uses instead of SV-G-1270G, and
optimize the sensitivity of the crop mark sensor just
Typical work time
for the particular type of media. However, if you do
this, crop marks printed on other types of media
Contents of work Time
may not be detected correctly. Also, in case you
Crop mark sensor adjustment 10 min
perform this adjustment using media other than
SV-G-1270G, the sensor may not be able to detect
crop marks printed on Roland original media.

1. Remove two screws that secure the cover.

2. Turn on the sub power SW while pressing the [] []


[] keys to enter the service menu.

3. Load SV-G-1270G and perform setup of media.

2-29 SG -540/300
Crop Mark Sensor Adjustment

4. Select [CROPMARK SENS] > [OUTLEVEL CHECK], and


press the [ENTER] key. A crop mark is printed.
SERVICE MENU
CUTTING MENU
[ ]

CUTTING MENU
CROPMARK SENSE
[ ]

CROPMARK SENSE
OUTLEVEL CHECK

[ ]
2
5. After printing the crop mark, the tool carriage moves

Adjustment
above the crop mark automatically. If the maximum
voltage is 2.7 +/- 0.2V, you do not have to carry out
this adjustment.

Min2.5V Max2.7V
[2.5V]

6. If the maximum voltage is not within the acceptable


range, adjust the VR on the tool carriage board so
that the value in square brackets shown on the
bottom of the LCD screen becomes 2.5 +/- 0.2V.

N OTE
In case you are using media other than SV-G-1270,
let the ink dry completely, and then carry out this
adjustment.

VR

Min2.5V Max2.7V
[2.5V]

7. Perform [OUTLEVEL CHECK] again and confirm that


the maximum voltage is 2.7 +/- 0.2V. If not, carry out
the adjustment again.

Min2.5V Max2.7V
[2.5V]

8. (End of procedure)

2-30 SG -540/300
Print Head Alignment 1 2 7

Information Procedure
C AU TIO N
Necessary tools • An interlock mechanism ordinarily prevents carriage
movement when the printer's cover is opened. To
General tools operate the printer with the front cover open, press
Media and hold the sensor switch.

No.2 Phillips screwdriver


• This adjustment is to obtain the good printing
quality. Make sure to perform this alignment after
1.5 mm hexagonal wrench print head replacement. If the print heads are not
aligned, printing problems such as banding, fine
Special tools lines and gap between bands may occur.
ST-056 TORQUE DRIVER N6 • PET-G is recommended for this alignment. 2
1000015724 • DO NOT use the take-up unit for this alignment.

Adjustment
BIT, PHILLIPS NO.2 L200MM
1000015274
1. Remove two screws that secure the cover.
M emo
Workflow
The screws are on the right and left side of the cover.

1. Print head alignment

Typical work time

Contents of work Time


Print head alignment 20 min

2. Turn on the sub power SW while pressing the [] []


[] keys to enter the service menu. Set up PET-G on
the printer.

3. Select[PRINT MENU] > [HEAD ADJUST] > [BIAS/


VERTICAL] > [TEST PRINT], and press the [ENTER] key.

4. A test pattern is printed.


N OTE
Press the [▼] key to feed the media forward so that
you can see the test pattern well. Press the [▲] key to
move it back to the original position.
VERTICAL BIAS

K M K MK

2-31 SG -540/300
Print Head Alignment

N OTE 6. Turn the adjustment screw using a 1.5 mm hexagonal


VERTICAL adjustment is not necessary since the wrench and adjust the print head base position so
VERTICAL position of head will be automatically that the misalignment of the BIAS test pattern will be
aligned to the correct position when you perform whithin 1/2 dot.
BIAS adjustment. If the VERTCAL position is not
aligned, check that the print head is attached to the
base correctly.

BIAS Adjustment

5. Loosen four screws that secure the print head base.


C AUTI ON
Loosen the screw about one turn in the order below.
2
If you loosen them too much, print head alignment

Adjustment
cannot be performed properly.

When the top half of the lines are shifting left side:
4 Turn the adjustment screw CW.
1

3 2

SG-540: Serial No. KCV0587 or earlier


SG-300: Serial No. KCV0479 or earlier MK
If the head guards are fixed on the machine, loosen
the two nuts. When the top half of the lines are shifting right
side:
Turn the adjustment screw CCW.

MK

2-32 SG -540/300
Print Head Alignment

7. Tighten the fixing screws to secure the print head base No.1 has been deleted after Ver.1.30.
using a torque driver (torque value 0.6N・m/60cN・m). SERVICE MENU
PRINT MENU
C AUTI ON [ ][ ]

Do not overtighten the screws.


HORIZONTAL PERFORMING
TEST PRINT TEST PRINT
1
3 [ENTER]

HORIZONTAL H1
SETTING NO.1 **
[ ][ ] [ENTER]

2 4 HORIZONTAL
SETTING NO.2

SG-540: Serial No. KCV0587 or earlier 2


SG-300: Serial No. KCV0479 or earlier

Adjustment
Bidirectional Adjustment
If you loosen two nuts on step 5, tighten them.
11. Select [PRINT MENU] > [HEAD ADJUST] > [BI-DIR.
DEFAULT] > [TEST PRINT], and press the [ENTER] key.

SERVICE MENU
PRINT MENU
[ ][ ]

HEAD ADJUST
BI-DIR.DEFAULT
[ ]
Horizontal Adjustment
BI-DIR.DEFAULT
8. Select [PRINT MENU] > [HEAD ADJUST] > TEST PRINT
[HORIZONTAL] > [TEST PRINT], and press the [ENTER]
key.

9. A test pattern in the figure below is printed. Find the 12. A test pattern is printed. Find the position where the
position where the two lines are overlapping and two lines are overlapping and check the number of
check the number of each color. In case of problems each color. In case of problems selecting one of two
selecting one of two numbers, half values are also numbers, half values are also available for inputting.
available for inputting. The number with [▲] is the The number with [▲] is the current setting.
current setting. BI-DIR No.1
H1

+2 +4 +6 +8 +10 +12 +14 +16 +18 +20 +22 +24 +26 +28 +30 +32 +34 +36 +38 +40 +42 +44 +46 +48
Horizontal No.1
H2

-15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 +1 +2 +3 +4 +5 +6 +7 +8 +9 +10 +11 +12 +13 +14 +15

+1 +3 +5 +7 +9 +11 +13 +15 +17 +19 +21 +23 +25 +27 +29 +31 +33 +35 +37 +39 +41 +42 +45 +47
Horizontal No.1
H1

-15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 +1 +2 +3 +4 +5 +6 +7 +8 +9 +10 +11+12 +13 +14 +15

13. Select [No.1] to [No.4] from the [HEAD ADJUST] >


10. Select [No.1] to [No.2] from the [HORIZONTAL] menu [BIDIR. DEFAULT] > [SETTING] menu and enter the
parameters checked at step 12 with the [▲] [▼]
and enter the parameters checked at step 9 with [▲]
keys. Press the [ENTER] key to save the settings.
[▼] keys. Press the [ENTER] key to save the settings.
N OTE
N OTE
Parameters can be entered in increments of 0.5.
Parameters can be entered in increments of 0.5.
No.1 and No.2 have been deleted after Ver.1.30.
14. (End of procedure)

2-33 SG -540/300
Tool Height Adjustment 1

Information Procedure
C AU TIO N
Necessary tools An interlock mechanism ordinarily prevents carriage
movement when the printer's cover is opened. To
General tools operate the printer with the front cover open, press
No.2 Phillips screwdriver and hold the sensor switch.
Thickness gauge
1. Turn on the sub power SW while pressing the [] []
1.5 mm hexagonal wrench
[] keys to enter the service menu. Select [FORCE
ADJUST].
Special tool
MENU
ST-006 WHITE DUMMY PEN
SERVICE MENU 2
[ ][ ]

Adjustment
Typical work time SERVICE MENU
CUTTING MENU
Contents of work Time [ ][ ]
Tool Height Adjustment 10 min
CUTTING MENU
FORCE ADJUST

N OTE
When you enter the [FORCE ADJUST] menu, the tool
carriage automatically moves to the position shown
below.

2. Place the pinch rollers above the grit areas as shown


in the figure below. Then, lower the pinch rollers.

Pinch roller

Grit area

2-34 SG -540/300
Tool Height Adjustment

3. Fasten the white dummy pen to the tool carriage.

Adjustment
4. Remove two screws that secure the cover.

5. Using the 1.5 mm hexagonal wrench, turn the


adjustment screw so that the space between the pen
tip and the bed becomes 2.5 mm to 2.6 mm.

6. Refer to Chapter 2 "Tool Pressure Adjustment".


7. (End of procedure)

2-35 SG -540/300
Tool Pressure Adjustment 1 3

Information Procedure
C AU TIO N
Necessary tools • An interlock mechanism ordinarily prevents
carriage movement when the printer's cover is
General tool opened. To operate the printer with the front cover
No.2 Phillips screwdriver open, press and hold the sensor switch.
• This adjustment must be performed after tool
Special tools carriage replacement.
ST-002 TENSION GAUGE 300g (3N) • Make sure to perform Chapter 2 "Tool Height
ST-006 WHITE DUMMY PEN Adjustment" before performing this adjustment.
ST-012 DIAL TENSION METER DTB-50 N OTE 2
This adjustment is for adjusting the current supplied

Adjustment
to the solenoid of the tool carriage to ensure that
Workflow correct pressure would be added to the blade when
cutting.
1. Tool pressure adjustment 1. Turn on the sub power SW while pressing the [] []
[] keys to enter the service menu. Select [FORCE
Typical work time ADJUST].

MENU
Contents of work Time
SERVICE MENU
Tool pressure adjustment 15 min
[ ][ ]

SERVICE MENU
CUTTING MENU
[ ][ ]

CUTTING MENU
FORCE ADJUST

N OTE
When you enter the [FORCE ADJUST] menu, the tool
carriage automatically moves to the position shown
below.

2-36 SG -540/300
Tool Pressure Adjustment

2. Place the pinch rollers above the grit areas as shown 5. Lift the tool holder with the dial tension meter and
in the figure below. Then, lower the pinch rollers. measure the pressure when the pen tip leaves the
bed. Then, input the value indicated by the dial
tension meter with the [] [] keys. Then press the
[ENTER] key to save the setting.

Pinch roller

Grit area

3. Fasten the white dummy pen to the tool carriage.


2
LOW

Adjustment
30gf 32gf
[ ] [ ]
ENTER

6. Select[FORCE ADJUST] > [HIGH]. Then, press the


[PAUSE] key to lower the tool carriage.

CUTTING MENU
FORCE ADJUST
[ ][ ]

FORCE ADJUST
HIGH
4. Select[FORCE ADJUST] > [LOW]. Then, press the
[ ][ ]
[PAUSE] key to lower the tool carriage.
HIGH
CUTTING MENU 200gf 205gf
FORCE ADJUST
[PAUSE]
[ ][ ]
7. Lift the tool holder with the tension gauge and
FORCE ADJUST measure the pressure when the pen tip leaves the
LOW bed. Then, input the value indicated by the tension
[ ][ ] gauge with the [] [] keys, and press the [ENTER]
key to save the setting.
LOW
30gf 32gf
[PAUSE]

8. (End of procedure)

2-37 SG -540/300
Belt Tension Adjustment 1

Information Procedure
C AU TIO N
Necessary tools An interlock mechanism ordinarily prevents carriage
movement when the printer's cover is opened. To
General tools operate the printer with the front cover open, press
No.2 Phillips screwdriver and hold the sensor switch.

3.0 mm hexagonal wrench 1. Open the maintenance cover L.

Workflow
2
1. Belt tension adjustment

Adjustment
Typical work time

Contents of work Time


Belt tension adjustment 40 min

2. Move the head carriage to the lock position.


3. Confirm that the head carriage is locked by pushing it
lightly to the left to eliminate looseness.

1 2

2-38 SG -540/300
Belt Tension Adjustment

4. Measure the tension of the belt at the position in 5. Loosen two fixing screws which are located on the
the center between the 4th and 5th grit area (SG- left end of the belt halfway turn.
540)/3rd grit area (SG-300) from the left using the
tension gauge. Pull the belt up to the height of the C AU TIO N
cut-ribbon-cable guide as viewed from the machine Be careful with the sharp edges around the belt
front (Figure). The tension is correct if the measured when loosening the screws. It may cause injury.
value is within the range below. If the tension is not
correct, move on to the next step and adjust the belt
tension.

Adjustment value:
SG-540: 1.2 kgf to 1.4 kgf
SG-300: 1.7 kgf to 1.9 kgf
2
1. Belt

Adjustment
2. Cut-ribbon-cable plate

6. Insert a wrench through the holes on the side frame


and loosen two adjustment screws to make a gap
of three millimeters between the tip of the screw
and idle pulley holder. (The belt tension cannot be
adjusted higher when the screw contacts the idle
pulley holder.)

N OTE
2 The gap between the screws and idle pulley can
1 be seen from both front side and rear side of the
machine.

3mm

2
1

Idle pulley holder

N OTE
If the tension is not correct, move on to step 5.

2-39 SG -540/300
Belt Tension Adjustment

7. Turn the adjustment screw to adjust the value of the


tension gauge within acceptable range.
* Turn the screw CW: Tension is increased
* Turn the screw CCW: Tension is decreased

Adjustment
Idle pulley holder

8. Tighten two fixing screws, and again confirm that the


tension is within the proper range.

9. Tighten two screws until they slightly touch the


idle pulley holder. Refer to Chapter 2 "Belt Position
Adjustment" and adjust the belt position.

C AUTI ON
Do not overtighten the screws. Overtightening could
move the fixed idle pulley holder.

Idle pulley holder

10. (End of procedure)

2-40 SG -540/300
Carriage Belt Position Adjustment 1

Information Procedure
C AU TIO N
Necessary tools • An interlock mechanism ordinarily prevents carriage
movement when the printer's cover is opened. To
General tools operate the printer with the front cover open, press
No.2 Phillips screwdriver and hold the sensor switch.
3.0 mm hexagonal wrench • This adjustment is to prevent the belt wear which
is caused by the belt contacting the pulley flanges
excessively. The belt position needs to be checked
after the belt tension adjustment and adjusted if
Workflow
necessary.
• When adjusting the drive pulley side, the pressure 2
1. Carriage belt position adjustment of engagement between the white gear of the drive

Adjustment
pulley and the scan motor gear is changed, possibly
Typical work time resulting in teeth breaking on the white gear or
failure of the scan motor. After the belt position
adjustment, be sure to loosen the screws holding
Contents of work Time
the scan motor and re-tighten them again.
Carriage belt position
40 min
adjustment

1. Open the maintenance cover L and the maintenance


cover R.

1. Maintenance cover L

2. Maintenance cover R

1 2

2-41 SG -540/300
Carriage Belt Position Adjustment

Scan Motor Adjustment 5. Remove 18 screws that secure the cover.


2. Turn off the main power SW.
3. Remove six screws that secure the operation panel.

Adjustment
C AUTI ON
Before removing the operational panel, make sure to
disconnect the ribbon cable from the panel board.

6. Tighten one or a couple of screws to temporarily


fasten the operation panel.

4. Remove two screws that secure the maintenance


cover sensor R.

C AU TIO N
Connect the ribbon cable to the panel board.
7. Turn on the main power SW. Then, turn on the sub
power SW while pressing the [] [] [] keys to
enter the service mode.

2-42 SG -540/300
Carriage Belt Position Adjustment

Adjustment on the Drive Pulley Side 12. Press the [ENTER] key to restart aging.
8. Perform the aging test for the scan motor. Select AGING
[MOTOR MENU] > [AGING] > [SCAN] and press the SCAN
[ENTER] key.
[ ]
9. Check the position of the belt. Position is correct
when the belt is not touching the flanges excessively. 13. Adjust the belt position by turning the adjustment
When positioning is correct, the adjustment on the screw as follows.
drive pulley side is not necessary. When positioning
is correct, skip this adjustment and go to Chapter C AU TIO N
2 "Adjustment on the Idle Pulley Side" without The work space is narrow. Be careful not to touch the
stopping the aging. When positioning is not correct, spinning drive pulley and belt.
perform the following adjustment.
When the belt is shifted toward the front side of the 2
Memo machine:

Adjustment
Belt partly touching the flange is acceptable. "" Turn the screw carefully CW (tightening).

10. Press the [ENTER] key to interrupt aging. When the belt is shifted toward the rear side of the
machine:
SCAN "" Turn the screw carefully CCW (loosening).
NOW AGING
[ ]
11. Loosen two fixing screws located on the right end of
the belt.

C AUTI ON
Loosen the screws a few turns to make a small gap
between the bottom of the screw head and stay.

2-43 SG -540/300
Carriage Belt Position Adjustment

14. Tighten two screws until the bottom of the screw Adjustment on the Idle Pulley Side
heads slightly touch the stay.
16. Check the position of the belt. Position is correct
C AUTI ON when the belt is not touching the flanges excessively.
Do not overtighten the screws. Overtightening could When positioning is correct, the adjustment on the
move the fixed idle pulley holder. idle pulley side is not necessary. So, you may end
this belt position adjustment at this point. When
positioning is not correct, perform the following
adjustment.

N OTE
Belt partly touching the flange is acceptable.

Adjustment
15. Confirm that the belt is not touching the pulley
flanges excessively. Confirm that the belt is not
touching the pulley flanges excessively. When the
belt is properly positioned, leave the belt aging on,
and proceed to "Adjustment on the Idle Pulley Side".

17. Press the [ENTER] key to interrupt aging.


SCAN
NOW AGING
[ ]
18. Loosen two fixing screws located at the left end of the
belt by a quarter turn.

C AU TIO N
If you loosen the screws too much, it will make it
difficult to adjust the belt position. Be careful with
the sharp edges around the belt when loosening the
screws. It may cause injury.

2-44 SG -540/300
Carriage Belt Position Adjustment

19. Insert a wrench through the holes on the side frame When the belt is shifted toward the rear side of the
and loosen two adjustment screws to make a gap of machine:
three millimeters between the tip of the screw and "" Turn screw 2 carefully CW to where it touches to the
idle pulley holder. idle pulley holder.
* Make sure that there is a gap of three millimeters
N OTE
between screw 1 and the idle pulley holder when
The gap between the screws and the idle pulley
turning screw 2.
holder can be seen from both the front side and rear
side of the machine.

3mm

Adjustment
Idle pulley holder

Idle pulley holder 22. Tighten one of the screws that have no contact with
the idle pulley holder until the screw slightly touches
20. Press the [ENTER] key to restart aging. the idle pulley holder.

AGING C AU TIO N
SCAN Do not overtighten the screws. Overtightening could
[ ] move the idle pulley holder.

21. Insert a wrench through the holes on the side frame


and adjust the belt position by turning screw 1 and 2
as follows.

When the belt is shifted toward the front side of the


machine:
"" Turn screw 1 carefully CW to where it touches to the
idle pulley holder.
* Make sure that there is a gap of three millimeters
Idle pulley holder
between screw 2 and the idle pulley holder when
turning screw 1.

Idle pulley holder

2-45 SG -540/300
Carriage Belt Position Adjustment

23. Confirm that the belt is not touching the pulley is correct when the belt is not touching the flanges
flanges excessively. When the belt is improperly excessively. When positioning is correct, end this belt
positioned, adjust it again. When positioning is position adjustment. When it is not correct, go back
correct, press the [ENTER] key to interrupt aging. to step17 and re-adjust the belt position.

AGING
SCAN
[ ]

27. Remove the screws that secures the operation panel.

2
SCAN

Adjustment
NOW AGING
[ ]
24. Tighten two fixing screws.

C AU TIO N
Before removing the operational panel, make sure to
disconnect the ribbon cable from the panel board.
28. Tighten 18 screws to secure the cover.

25. When the drive pulley side adjustment has been


done, loosen the fixing screw holding carriage motor
once, and tighten them again while referring to
Chapter 1 "Carriage Motor Replacement".

26. Press the [ENTER] key to restart aging. Positioning

29. Temporarily fasten the maintenance cover sensor R

2-46 SG -540/300
Carriage Belt Position Adjustment

with two screws. 33. Slide the maintenance cover sensor R to the front
until "*" under "D" disappears. Then, tighten two
screws to secure the sensor.
When the cover is open

FRSHODPULWwaVC
*

When the cover is closed

FRSHODPULWwaVC

34. (End of procedure) 2


30. Tighten six screws to secure the operation panel.

Adjustment
C AUTI ON
• Tighten the two screws on ths panel side to make
a gap of approximately 1.5 mm between the panel
and the flame by extending the flame to the left.

1.5 mm clearance

31. Turn on the sub power SW while pressing the [] []
[] keys to enter the service menu.

32. Select [SERVICE MENU] > [SENSOR CHECK].


SERVICE MENU
SENSOR CHECK

2-47 SG -540/300
Wiper Position Adjustment 1

Information Procedure
Set the reference position for wiping.

Necessary tools C AU TIO N


• An interlock mechanism ordinarily prevents
General tools carriage movement when the printer's cover is
None opened. To operate the printer with the front cover
open, press and hold the sensor switch.
Special tools
None 1. Turn on the sub power SW while pressing the []
[] [] keys to enter the service menu. Select [WIPE
ADJUST].

Workflow 2
MENU
SERVICE MENU

Adjustment
1. Wiper position adjustment
[ ][ ]

Typical work time SERVICE MENU


I/S MENU
Contents of work Time [ ][ ]
Wiper position adjustment 3 min

I/S MENU
WIPE ADJUST

2. Move the print carriage with [] [] keys so that


the edge of the wiper touches the left side of the
print head straight. Press the [ENTER] key to set the
reference position for the wiper.

1. Wiper

2. Print head

1 2

3. (End of procedure)

2-48 SG -540/300
Feed Calibration 1

Information Procedure
C AU TIO N
Necessary tools • This adjustment is for calibrating the feed amount
of media. It allows the media to be fed in proper
General tool amount by calibrating the variation in grit roller
SP-M (Matte-PET artificial paper) diameter. Calibration is made based on the value in
feeding media [SP-M]. Without proper calibration,
Special tools it may cause misalignment in the feed amount of
None media, and it results in the problems such as white
banding, banding of overlap or the dimension error
of print result compared to the original data.

Workflow • When you don’t have SP-M, use PET film for solvents. 2
• Take-up unit must not be used during this

Adjustment
adjustment.
1. Feed calibration
1. Turn on the sub power SW while pressing the [] []
Typical work time [] keys to enter the service menu. Set up SP-M on
the printer.

Contents of work Time 2. Select [PRINT MENU] > [CALIB.DEFAULT] > [TEST
Feed calibration 15 min PRINT], and press the [ENTER] key.

C AU TIO N
Test print requires 510 mm or more of the media
setup width.
SERVICE MENU
PRINT MENU
[ ][ ]

PRINT MENU
CALIB.DEFAULT
[ ][ ]

CALIB.DEFAULT
TEST PRINT
[ ]

2-49 SG -540/300
Feed Calibration

3. Measure the length of the feed direction and use 6. (End of procedure)
the value to calculate the correction value with the
formula shown at step 4.

C AUTI ON
Test pattern is always printed with correction value
0.00%. Even if a correction is made in the [SETTING]
menu, the test pattern is not affected.
400mm

Feed 2

Adjustment
500mm
Scan

4. Calculate the correction value with the formula.


400 - Measured value
Correction value = x 100
Measured value

Example)
400 - 395
1.27 = x 100
395

5. Select [PRINT MENU] > [CALIB.DEFAULT] > [SETTING],


and enter the correction value with the [▲] [▼] keys.
Then press the [ENTER] key to save the setting.

N OTE
The correction value can be entered in increments of
0.01%.
(MAX +2.00 % to MIN -2.00 %)
SERVICE MENU
PRINT MENU
[ ][ ]

PRINT MENU
CALIB.DEFAULT
[ ][ ]

CALIB.DEFAULT
SETTING
[ ]

SETTING
+0.00% + 0.15%
[ ]

2-50 SG -540/300
Chapter 3  Electrical Parts

SG-540 Wiring Map . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

SG-300 Wiring Map . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Main Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4


Arrangement Diagram (Component Side). . . 3-4

Servo Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5


Arrangement Diagram (Component Side). . . 3-5 3
Print Carriage Board . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Electrical
Arrangement Diagram (Component Side). . . 3-6

Parts

3-1 SG- 540/300


51 GROUNDING CABLE * 2
CN200 HEAD U/D SENSOR 13
CN102 CROP SENSOR 35 FRONT HEAD 1 HEAD 0 FILLER 44 PRESS MOTOR 1
BOARD COVER SW SENSOR * 4 CN9
CUT CARRIAGE 37 CN3
34 45
PRESS MOTOR 2
BOARD CN103 PINCH POS MAINTENANCE 41 CN1 CN10
CL CARTRIDGE 36 SENSOR COVER SW L PRESS MOTOR 3
CUT SOLENOID 33 MAINTENANCE 42 12 PUMP DRIVE 46
EXIST SENSOR CN101 CN11
EMPTY SENSOR COVER SW R CN8 CN6 CN7 CN5 0.6*4 BOARD
CN10 47 PRESS MOTOR 4
CN100 LIMIT SENSOR CN4 CN12
CN11
38 FEED MOTOR SCAN MOTOR PAPER SENSOR PRINT CARRIAGE 43
FRONT
BOARD CN4
REAR

CN300
HEAD LOCK SENSOR

GRIT 18 PINCH U/D SENSOR CN14 CN13


CLEANING VALVE ENCODER CN1 CN2
BOARD 17 32 LINEAR CARTRIDGE COVER SW
COOLING FAN
PUMP MOTOR0 21 20 54 19 ENCODER BOARD 39 PRINT CARRIAGE
CN7 CN8 CN3 CN5 CN4
CN24
CN3 CN13CN21 CN9 SIGNAL JUNCTION BOARD
SG-540 Wiring Map

22 CN15 CN6 CN5


CN9 CN2 40 11
CN28
16 14
THERMISTOR BOARD
WIPER MOTOR CN18 CN23 CN18
VACUUM FAN1 53
23
15 CN23 CN18 CN19 CN22
CN29
SERVO BOARD CN14
24 CN3
WIPER SENSOR CN4 CN24
VACUUM FAN0
WIPER TRY 25 CN19 CN9
(WASTE VALVE SENSOR) CN27
26 CN2 MAIN BOARD INKSYSTEM RFID
CN23 52
CN1 BOARD

3-2
27
CN28 CN4
30 28 CN11 50
CN5 CN8 CN2 CN5 CN13 CN14 CN17 CN29
THERMOSTAT CN2 49
CN1
PRINT 9
HEATER CN4 COOLING FAN 10
31
Service parts

SERVO BOARD 8 48 RFID R/W BOARD (M) * 4


HEATER HEATER CONTROL
THERMISTOR BOARD 30 BOARD CN402 CN3
THERMOSTAT CN7
DRYER PANEL BOARD
CN6
31 HEATER CN8 CN11 EXT IF
HEATER BOARD COOLING FAN
29 BLE JUNCTION BOARD MAIN BOARD
THERMISTOR BOARD COOLING FAN
POWER UNIT
CN401
38 38 38 38

TAKE UP(TU2)
INK CARTRIDGE * 4
EXIST SENSOR
EMPTY SENSOR

5
INLET
For detailed information on the cables shown below, refer to Parts Finder Web.

1
https://365rolanddg.sharepoint.com/sites/extranet/Work-SitePages/GSV-PartsFinder.aspx

SW 6
4
AC-DC POWER UNIT
ZWD225PAF-0537/J
2 7
3

SG- 540/300
Parts
3

Electrical
51 GROUNDING CABLE * 2
CN200 HEAD U/D SENSOR 13
CN102 CROP SENSOR 35 HEAD 1 HEAD 0 FILLER 44 PRESS MOTOR 1
FRONT
BOARD COVER SW SENSOR * 4 CN9
CUT CARRIAGE 37 CN3 PRESS MOTOR 2
PINCH POS 34 45
BOARD CN103 MAINTENANCE 41 CN1 CN10
36 SENSOR COVER SW L PRESS MOTOR 3
CL CARTRIDGE 33 12 PUMP DRIVE 46
EXIST SENSOR CN101
CUT SOLENOID MAINTENANCE 42
COVER SW R CN8 CN6 CN7 CN5 0.6*4 BOARD CN11
EMPTY SENSOR 47
PRESS MOTOR 4
CN100 LIMIT SENSOR CN10 CN11 CN12
CN4
38 PAPER SENSOR PRINT CARRIAGE 43
FEED MOTOR SCAN MOTOR
FRONT CN4
REAR BOARD
HEAD LOCK SENSOR
CN300

GRIT 18 PINCH U/D SENSOR CN14 CN13


CLEANING VALVE CN1 CN2
ENCODER
BOARD 17 32 CARTRIDGE COVER SW
LINEAR COOLING FAN
PUMP MOTOR0 21 20 54 19 PRINT CARRIAGE
CN7CN8CN3CN5CN4 ENCODER BOARD 39
CN24
CN3 CN13 CN21 CN9
SG-300 Wiring Map

22 CN15 CN6 CN5 SIGNAL JUNCTION BOARD 11


CN28 CN9 CN2 40
16 14 THERMISTOR BOARD
WIPER MOTOR CN18 CN23 CN18
53
23 15
CN29 CN23 CN18 CN19 CN22
VACUUM FAN0 SERVO BOARD CN14
24 CN3
WIPER SENSOR CN4 CN24
WIPER TRY 25 CN19
(WASTE VALVE SENSOR) CN27
26 CN9 INKSYSTEM RFID
CN2 CN23 52 MAIN BOARD
CN1 BOARD

3-3
27
CN4
CN28
30 28 CN11 50
CN5 CN8 CN26 CN5 CN13 CN14 CN17 CN29
THERMOSTAT CN1 CN2 49
Service parts

PRINT CN4 9
31 HEATER COOLING FAN 10
HEATER CONTROL SERVO BOARD 8 48 RFID R/W BOARD (M) * 4
HEATER
30 BOARD
THERMISTOR BOARD CN7 CN402 CN3
THERMOSTAT
DRYER CN6
PANEL BOARD
31 HEATER CN8 CN11 EXT IF
HEATER BOARD COOLING FAN
29 BLE JUNCTION BOARD MAIN BOARD
THERMISTOR BOARD COOLING FAN
POWER UNIT
CN401
38 38 38 38

TAKE UP(TU2)

INK CARTRIDGE * 4
EXIST SENSOR
EMPTY SENSOR
For detailed information on the cables shown below, refer to Parts Finder Web.
https://365rolanddg.sharepoint.com/sites/extranet/Work-SitePages/GSV-PartsFinder.aspx

5
INLET
1 6
SW 4
AC-DC POWER UNIT
ZWD225PAF-0537/J
2 7
3

SG- 540/300
Parts
3

Electrical
Main Board

Arrangement Diagram (Component Side)

Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7 Bit 8


DIP SW
OFF OFF OFF OFF OFF OFF OFF OFF

Electrical
Parts

3-4 SG- 540/300


Servo Board

Arrangement Diagram (Component Side)

Electrical
Parts

3-5 SG- 540/300


Print Carriage Board

Arrangement Diagram (Component Side)

Electrical
Parts

3-6 SG- 540/300


Chapter 4 Supplemental
Information

Motor Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Service Call Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Supplemental Information on Service Call 0400. . . . 4-6

Sensor Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

supplemental
Information

4-1
SG -540/300
Motor Errors 4

Error Description

SCAN MOTOR ERROR


CODE : 0000 0000

Current error Initial error

Code Meaning Cause


Feed motor deviation error
0001 (The directive from the CPU does not match the feedback of
1. Remove causes of media jams.
the feed motor.)
Feed motor overcurrent error 1 2. Use appropriate media.
0002 (Extremely large instantaneous load is placed on motor *When the machine is feeding hard-to-unroll or heavy media with a basis
movement.) weight greater than 30 kg, excess load is applied, resulting in the motor
Feed motor overcurrent error 1 error.
0004
(Large load is placed on motor movement for a short time.)
3. Clean the scan motor and the drive gear.
Feed motor overcurrent error 2 *The motor error occurs when dirt is on the part where the scan motor and
0008
(Small load is placed on motor movement for a long time.) the drive gear mesh together.
Scan motor deviation error
4. Replace the motor.
0010 (The directive from the CPU does not match the feedback of
*When the motor is broken or worn out, the motor cannot follow the
the scan motor.)
directives from CPU, resulting in the motor error.
Scan motor overcurrent error 1
0020 (Extremely large instantaneous load is placed on motor 5. Replace the servo board.
movement.) *When the motor driver is broken, the power supply voltage for the motor
Scan motor overcurrent error 1 is not supplied, and the motor cannot move. This will lead to the motor
0040 error.
(Large load is placed on motor movement for a short time.)

0080
Scan motor overcurrent error 2 6. Replace the SW power supply. 4
(Small load is placed on motor movement for a long time.) *When the power supply voltage for a motor is not supplied, the motor

supplemental
Information
cannot move and it results in a motor error.
0100 Feed motor position error

This error occurs when you move the head carriage by hand with the front
1000 Scan motor position error
cover open.

4-2
SG -540/300
Service Call Errors

Action (You do not have to perform everything


Code Error name Contents Possible causes listed below. Sometimes performing just one or
some of the following can solve the problem.)
• The servo board does not work
correctly. • Check the cable connection between main
• Disorder of communication with the
• Sub CPU does not work board and servo board.
sub CPU
Sub CPU correctly. • Check other cable connections of servo board.
0002 • This occurs when the Sub CPU is
error • There is a bad connection • Replace the servo board.
not detected after turning on the
between the main board and • Replace the main board.
machine.
servo board. • Replace the ribbon cable.
• Noise in signal
• DIP switch setting error • Check the DIP switch setting on the main
DIP switch • The DIP switch setting is
0003 • Defective DIP switch board.
setting error inappropriate.
• Main board defective • Replace the main board.
• The servo board does not work
correctly. • Check the cable connection between main
• Sub CPU does not work board and servo board.
Communication • There is a problem with synchronizing correctly. • Check other cable connections of servo board.
0008
error serial communication to the sub CPU. • There is a bad connection • Replace the servo board.
between the main board and • Replace the main board.
servo board. • Replace the ribbon cable.
• Noise in signal

0011 Memory error • Memory error • Breakdown of memory • Replace the main board.

• Defect of switching power


• The power voltage does not achieve supply • Switching power supply replacement
Power voltage
0012 41V at the time of turning the • Defect of the cable connection • Check the cable connection between
error
secondary power on. between switching power switching power supply and main board.
supply and main board
Initialization • Initialization has not been
0013 • Initialization has not been performed. • Initialize all the parameters.
error performed.

• Limit position initialize has not


Limit position • Limit position initialize in the service
0101 been done or ended before it is • Complete limit position initialize correctly.
initialize error mode has not been done.
completed.
4
Limit sensor • The limit sensor does not work • The limit sensor is not working • Replace the limit sensor.
0102

supplemental
Information
error correctly. properly or broken. • Check the backlash and looseness.

Cutting limit • Cutting limit sensor does not work • Cutting limit sensor is not
0103 • Initialize all the parameters.
sensor error properly. working properly or is defective.

• The joint parts of the carriages


are defective.
• Check if the carriages are distorted or loose.
Carriage • The cut carriage and the head • Carriages are distorted.
0105 • Replace the joint part.
attaching error carriage are not attached properly. • Limit position adjustment was
• Adjust the limit position.
not performed properly.
• Defective sensor
• The joint parts of the carriages
are defective.
• Check if the carriages are distorted or loose.
Carriage • The cut carriage and the head • Carriages are distorted.
0106 • Replace the joint part.
detaching error carriage did not detach properly. • Limit position adjustment was
• Adjust the limit position.
not performed properly.
• Defective sensor
• The wiper unit hits the head
• Move the head carriage and confirm that the
carriage.
wiper unit does not hit the head carriage.
• Wiper motor error
• The wiper unit does not work Replace the wiper motor.
0109 Wiper unit error • Defect of the wiper unit
correctly. • Replace the wiper unit.
• Defect of the wiper sensor
• Replace the wiper sensor.
• Cut-line or short-circuit of cables
• Replace cables and the flexible cable.
and the ribbon cable

4-3
SG -540/300
Service Call Errors

Action (You do not have to perform everything


Code Error name Contents Possible causes listed below. Sometimes performing just one or
some of the following can solve the problem.)
• Confirm whether the encoder scale is in the slit
of the encoder sensor in a whole width of the
• Input value from the linear encoder machine.
is not changed by the linear encoder • Read error of the linear encoder.
• Check the cable connection between the
• Read error of the encoder on the
Linear encoder origin setup. carriage board and linear encoder board.
0110 scan motor side.
error • When the motor stops during • Check the connection between the belt and
• The belt is not attached to the
printing, expected movement is not head carriage.
head carriage firmly.
completed on the print head. • Replace the linear encoder.
• Replace the scan motor.
• Replace the main board.
The position
of the tool • You performed crop-cut adjustment
• You have not performed [CROP-
0111 crop sensor is before performing [CROP-CUT ADJ.] > • Perform [SERVICE MENU] > [CROP-CUT ADJ.].
CUT ADJ.] > [SETTING].
not properly [SETTING].
adjusted.
• Check the cable connection between the main
• Communication error with the • The cartridge IC driver is broken.
Cartridge IC board and RFID R/W board.
0112 cartridge • The cartridge IC driver cable has
driver error • Replace the ink system board.
• IC driver short circuited or cut-line.
• Replace the RFID R/W board.
• Thermistor has a problem.
Thermistor error • There is a problem with the • Check cable connection around thermistor.
0130 • Thermistor cable has short
(Print heater) thermistor for print heater • Replace the thermistor.
circuited or cutline.
• The pre-heater cable connection
• Check the pre-heater.
Heater error • Pre-heater temperature has reached has a problem.
0135 • Check the thermostat.
(Pre-heater) 60 ºC and above. • The thermostat has a problem.
• Check the thermistor.
• The thermistor has a problem.
• Thermistor has a problem. • Check the cable connection around the
Thermistor error • There is a problem with the
0140 • Thermistor cable has short thermistor.
(Dryer) thermistor for dryer.
circuited or cutline. • Replace the thermistor.
• The pre-heater cable connection
0145
Heater error • Pre-heater temperature has reached has a problem.
• Check the pre-heater.
• Check the thermostat.
4
(Pre-heater) 80 ºC and above. • The thermostat has a problem.

supplemental
• Check the thermistor.

Information
• The thermistor has a problem.
• Option eryer cable connection
• Check option dryer.
Heater error • Option heater temperature has has a problem.
0146 • Check thermostat.
(Option dryer) reached 80 ºC and above. • Thermostat has a problem.
• Check thermistor
• Thermistor has a problem.
Head device • Blowout of the fuse in the head
0250 • Head device has detected a problem. • Replace the fuse in the head board.
error board

• Replace the head board.


* Check the followings cable connection.
• Sub CPU does not work
correctly. • Between the main board and the head board
Head board • There is a bad connection with sub • There is a bad connection • Between the head board and the pump drive
0300 board
error CPU on head board. between the main board and the
servo board. • Between the pump drive board and the
• Noise in signal maintenance board
• Between the maintenance board and the ink
system board
• The connectors of the print • Check that the connectors of the print carriage
Print carriage • AMP thermistor on the print carriage
0305 carriage fan are unplugged. board are plugged in completely.
board error board detected high temperature.
• AMP thermistor is defective. • Replace the print carriage board.

• Replace the pump board.


* Check the followings cable connection.
• Sub CPU does not work correctly. • Between the main board and the head board
• There is a bad connection between • Between the head board and the pump drive
Pump drive • There is a bad connection with the sub
0315 the main board and pump drive board
board error CPU on pump drive board.
board. • Between the pump drive board and the
• Noise in signal maintenance board
• Between the maintenance board and the ink
system board

4-4
SG -540/300
Service Call Errors

Action (You do not have to perform everything


Code Error name Contents Possible causes listed below. Sometimes performing just one or
some of the following can solve the problem.)
• Replace the ink system board.
* Check the followings cable connection.
• Sub CPU does not work
correctly. • Between the main board and the head board
Ink system • There is a bad connection with sub • There is a bad connection • Between the head board and the pump drive
0320 board
board error CPU on ink system board. between the ink system and the
servo board. • Between the pump drive board and the
• Noise in signal maintenance board
• Between the maintenance board and the ink
system board
• The connector of the
• Replace the servo board.
Servo motor • The amount of load placed on the servo motor is plugged in
0360 • Check the cable connection of the servo motor
A/D read error servo motor cannot be read correctly. incompletely.
and the servo board.
• Servo board defective
• Replace the servo board.
• A signal from the hall sensor
Servo motor • Hall sensor of the scan motor is • Check the cable connection of the servo motor
0361 cannot be read properly.
hall sensor error defective. and the servo board.
• Scan motor defective
• Replace the scan motor.
• The connector of the cut
• Replace the servo board.
Cut solenoid • The amount of load placed on the cut solenoid is plugged in
0370 • Check the cable connection of the cut solenoid
A/D read error solenoid cannot be read correctly. incompletely.
and the servo board.
• Servo board defective
• The connector of the
• Replace the servo board.
Cut solenoid cut solenoid is plugged
0371 • Large load is placed on solenoid. • Check the cable connection of the cut solenoid
load error incompletely.
and the servo board.
• Servo board defective
Cut solenoid • Driver IC of the cut solenoid is
0372 • Cut solenoid driver IC is defective. • Replace the servo board.
driver IC error defective.
• Even though the damper is now • Filler sensor is defective.
filled with ink, the filler sensor is still • Connector of the filler sensor is
detecting the filler. defective.
• The filler sensor cannot detect how • Pressure motor and pump are • Replace the filler sensor or check the cable 4
much ink is being supplied from the defective. connection of the filler sensor.

supplemental
Information
pressure pump to the damper. • Connector of the pressure motor • Check the cable connection of the pressure
• Although the pressure pump has is defective. pump motor.
Pressure pump
0380 rotated certain times, ink is not • Some cables are making contact • Replace the pressure pump.
time out
supplied to the damper. Or, the with the filler, preventing it from • Check the tube layout from the ink cartridge to
8 damper is filled with ink, but the filler operating properly. the print head.
sensor cannot detect it because the • The spring on the rear side of the * Ink lines with problems are shown in the
filler does not open. filler has popped out. event log.
• Nozzle line code is displayed on LCD • Two tubes are swapped and
(nozzle line code indicates which inserted incorrectly to the print
nozzle the error occurred to). head.
• Even though the damper is empty,
the filler does not hit the filler sensor.
• Cap is not installed properly.
• Ink in the damper cannot be • Replace the filler sensor or check the cable
• Cap is broken.
discharged properly during cleaning connection of the filler sensor.
• Print head is broken.
or flushing operations. • Check the cable connection of the pressure
Pump suction • Some cables are making contact
0400 • Signals from the filler sensor cannot pump motor.
error with the filler, preventing it from
be received correctly during pump up • Replace the pressure pump.
operating properly.
(e.g. cleaning). • Readjust the cap position or replace the cap.
• The spring on the rear side of the
• Nozzle line code is displayed on LCD • Replace the print head.
filler has popped out.
(nozzle line code indicates which
nozzle the error occurred to).

4-5
SG -540/300
Supplemental Information on Service Call 0400

When the error "0400" occurs, the message below appears on the operation panel screen.

SERVICE CALL
0400 [000C]

SERVICE CALL No. Nozzle line code


(It indicates which nozzle the error occurred to.)

How to read the nozzle line code

In case the error "0400" occurs to multiple nozzle lines, nozzle line code will be displayed in total.
Example: When the error "0400" occurs to both nozzle lines (nozzle line code "0400" and "0800") of H2
0040 + 0080 = 000C
Therefore, "000C" will be displayed on the operation panel screen.

H1 H2

supplemental
Information
CY MG YE BK

Nozzle line code 0001 0002 0004 0008

4-6
SG -540/300
Sensor Map

Sheet load sensor


It detects whether the sheet loading lever is up
or down.

Limit sensor
Thermistor (heater) It detects the starting position of the carriage.
It measures the temperature of the heater.

Bluetooth board
It communicates with a mobile panel.

Head lock sensor


It detects whether the head
carriage is at the lock position or
not.

supplemental
Information

Front paper sensor


It detects the front edge of media.

Grit encoder sensor


Thermistor (dryer) It detects the rotation speed of the
grit roller.
It measures the temperature of the dryer.

Waste valve sensor Maintenance cover sensor R


It detects the open/close state of the waste valve of It detects the open/close state of the
the wiper cleaning tray. maintenance cover R.
(It prevents scan motor operation when the
right maintenance cover is open.)

4-7
SG -540/300
Sensor Map

Ink slot cover sensor L Ink slot cover sensor R


It detects whether the ink slot cover L is open or It detects whether the ink slot cover R is open or
closed. closed.

Thermostat (heater)
Power supply to the heater will be cut off
when the temperature exceeds allowable
temperature limit.

supplemental
Information
Front cover sensor
It detects the open/close state of the front cover.
(It prevents scan motor operation when the front cover is open.)

Thermostat (dryer)
Power supply to the dryer will be cut off when the temperature
exceeds allowable temperature limit.

Maintenance cover sensor L


It detects the open/close state of the maintenance cover L.
(It prevents scan motor operation when the left maintenance
cover is open.)

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Sensor Map

Ink cartridge sensor Ink empty sensor


It detects whether the ink cartridge is installed or not. It detects whether the ink pouch and/or cleaning
liquid pouch is empty or not.

supplemental
Information

Ink cartridge RFID sensor


It communicates information such as the remaining ink
amount.

4-9
SG -540/300
Sensor Map

Linear encoder sensor


It detects the coordinates of the carriage and sends
print signals.

Head up/down sensor


It detects the position of the
print head.

Filler sensor
It detects the pressurization of
print head dampers.
Thermistor (print head)
It measures the temperature around the print 4
head.

supplemental
Information
Pinch roller sensor
During media setup, it detects whether the pinch
rollers and the media clamps are set or not.

Wiper sensor
It detects the starting position of
the wiper movement. Crop mark sensor
It detects crop marks.

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Chapter 5 Service Activities

Installation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Maintenance Checklist. . . . . . . . . . . . . . . . . . . . . . 5-13

5
Service
activities

5-1 SG -540/300
Installation Checklist

SG-540/SG-300 Installation Checklist

Date:

User name: Serial number:

Check the Place of Installation

□□The space shown in the figure is required in order to use this machine.
4,250 mm (167.3 in) (54-inch model)
3,750 mm (147.6 in) (30-inch model)

3,250 mm (127.9 in) (54-inch model)


2,750 mm (108.2 in) (30-inch model)

1,000 mm (39.4 in)

2,000 mm (78.7 in)


Unit space

Work space

5
Service
activities

5-2 SG -540/300
Installation Checklist

Unpacking

Unpack each part in the order shown below.

SG-300: 1 piece 5
Service
activities

5-3 SG -540/300
Installation Checklist

Unpack the machine.

Plastic bag

5
Service
activities

5-4 SG -540/300
Installation Checklist

(1) Unpack the stand leg, caster, arm R etc.

Media holder R

Arm R

Caster

5
Service
activities
Stand leg

5-5 SG -540/300
Installation Checklist

(2) Unpack the stand leg, caster, arm L etc.

Media holder L

Arm L

Caster

5
Service
activities
Stand leg

5-6 SG -540/300
Installation Checklist

(3) Remove the shaft and the paper tube.

Shaft

5
Service
activities

5-7 SG -540/300
Installation Checklist

Assembling and Installation

□□Ink fillingInk
C AUTI O N
• Make sure to shake the ink pouch before setting it in the pouch tray.

Hook -

Check that the hook has caught.

C AUTI O N
When the message "EMPTY DRAIN BOTTLE" appears, be sure to discard. If not discarded at this step, the discharged ink
will overflow.

Upgrading the firmware

Upgrade the firmware to the latest version.

Time and date setting

Set from [SERVICE MENU] > [CLOCK] > [DATE]/[TIME]

Installing RIP

5
Install and configure the setting of the RIP software in reference to the Install Guide.
Service
activities

Installing Roland OnSupport

Install and configure the setting of Roland OnSupport in refenence to the Startup Guide.

Basic operations

Refer to the User's Manual and explain following to the user.

□□Switch on
C AUTI O N
Always leave the main power on. Maintenance operation is automatically carried out every eight hours while the machine
is not in use. Use the sub power switch for the daily powering on and off.

5-8 SG -540/300
Installation Checklist

□□Loading media
□□Setup of media
□□Setting the output-start location
□□Printing Tests and Normal cleaning
□□Pausing and cancelling output
□□Cutting off the media
□□Switch Off
Lower the sheet loading lever when the machine is not in use.

Maintenance

□□Checking for Remaining Ink


C AUTI O N
The remaining ink amount displayed on the operation panel screen is slightly different from the actual remaining
amount.

□□How to replace the ink pouch


C AUTI O N
• Shake the ink pouch gently before installing it.
• Be sure to replace with an item of identical type. Never mix items of different types.
5
Service
activities
• Never leave the machine with any ink pouch removed. The print heads may become clogged.
• When printing is paused, the coloring at the seam may be altered when printing resumes. Before you perform lengthy
printing, check the amount of ink remaining in the ink pouches.

□□Disposing of Discharged fluid


• The message "EMPTY DRAIN BOTTLE" appears when a certain amount of discharged fluid has collected in the bottle.
Make sure to discard the discharged ink.

C AUTI O N
• "EMPTY DRAIN BOTTLE" message disappears when "NO" is selected without disposing of discharged fluid.
• If "NO" is selected continuously, the hand or the work floor may get soiled by overflowing discharged fluid from drain
bottle.

5-9 SG -540/300
Installation Checklist

□□Cleaning
• Pinch roller
• Grit roller
• Platen
• Front paper sensor
• Rear paper sensor
• Front cover
• Media clamp

□□Care and Maintenance of the Print Heads


C AUTI O N
• Super cleaning consumes a large amount of ink. Perform super cleaning only when normal, medium, powerful, and
manual cleaning cannot solve missing dot problems.

□□Manual cleaning of the print head


C AUTI O N
• To keep the stable output condition at all times, perform the manual cleaning more than once a week.
• The cut rail is not detected by the sensor. Be sure to put it back when completing the manual cleaning.

□□Wiper replacement
C AUTI O N
• Refer to User’s Manual "Replacing Consumable Parts" under Chapter 3 “Maintenance” and check the orientation of the
wiper when installing it.

□□Cleaning the wiper tray and replacing the tray pads


C AUTI O N
• Place the tray pad with an orientation that matches the shape of the wiper tray. 5
Service
activities

□□Replacing the blade


□□Installing the cutting tool
□□When the machine is not in use for a prolonged period
C AUTI O N
• Turn on the sub power SW once a month.
• Even when the machine is not in use, keep it at a temperature of 5 to 40 °C (41 to 104 °F) and at a relative humidity of
20 to 80% (with no condensation).
• Temperatures that are too high may degrade the ink and cause malfunction. Temperatures that are too low may cause
the ink to freeze and damage the print heads.

5-10 SG -540/300
Installation Checklist

□□Uneven colors
• Super Cleaning
Perform when damper cleaning is not effective in solving uneven color problems.

Fully utilizing the machine

□□Preset function
• Saving various settings as a name assigned preset
• Loading a saved preset

□□Correcting for misalignment in bidirectional printing *1

□□Reducing horizontal banding (feed calibration function) *1

□□Adjusting the head height to match media thickness *1

C AUTI O N
*1 Perform these procedures for each media individually. Bidirectional adjustment
and feed calibration are required after changing the head height.
If you are setting feed calibration on your machine, check in advance that
[Use Printer Settings] is selected on Roland VersaWorks Dual.

□□Accommodating to the types and conditions of media


□□Fully utilizing the cutting function
C AUTI O N
When you perform print & cut, be sure to set [CALIBRATION] in the [CUTTING MENU] to “0.00%”. Otherwise, the printing
and cutting positions may become misaligned. This calibration is to be used only when performing cutting only.
5
□□ Correcting the misalignment of the printing and cutting positions
Service
activities

• [PRINT-CUT ADJ.] (Print & cut position alignment)

□□Prioritize the settings of the machine to the settings of RIP software.


• [CUTTING PRIOR]

□□Viewing the automatic environment correction function settings


C AUTI O N
This function is for correcting the print & cut misalignment caused by the stretch/shrinkage of encoder scale. Make sure
to set it to [ENABLE] at all times. [AUTO ENV. MATCH]: ENABLE (default)

□□Printing with crop marks


• Aligning automatically and cutting
• Aligning manually and cutting

5-11 SG -540/300
Installation Checklist

□□Correcting misalignment for printing and cutting when using crop marks
C AUTI O N
• If misalignment occurs when performing print & cut with crop marks printed, perform this correction.
• Perform bidirectional adjustment before doing this correction.

□□Roland Mobile Panel


C AUTI O N
• Download Mobile Panel from App Store and Google Play.
• Turn on Bluetooth communicatioin on the machine. (Default: OFF)
• Check that sub power SW is on and the machine's operation panel display shows one of the following screens.

W1100mm   W1100mm   SETUP SHEET


B

Administrator Menu

□□Reinstallation from preparing


Troubleshooting

□□Tell the user to see the User's Manual when error messages are displayed.
• If a service call occurs, switch off and on the machine and see if the problem is solved before calling for inquiry. Sometimes errors can be
recovered just by restarting the machine.

□□Explain how to cap the print heads. 5


• If the print heads do not return to the standby position, the user needs to perform capping. Refer to the User's Manual "If the Print Heads
Service
activities
Still Do Not Move" under Chapter 6 "Print Heads Stop Moving".

5-12 SG -540/300
Maintenance Checklist

SG-540/SG-300 Maintenance Checklist
Date:

User name: Serial number:

Check items Operation points Check


Interview the customer Ask the customer if there is something that he/she is concerned about. □ Done
Output/Get report before maintenance GET REPORT] by Peck, or print both Service Report and History Report. □ Done
If large amount of ink is discharged in the drain bottle, dispose of it and □ Good
Check drain bottle give an explanation to the customer. Make sure to reset the discharged □ Relacement □ Reset
ink count. done
Upgrade the firmware to the latest version Upgrade the firmware if the installed firmware is not the latest version.
□ OK
Determine if it should be replaced based on the SHOT COUNT in the □ Good
History Report, the test print result and the customer's interview. □ Relacement □ Reset
Replacemnet Cycle: 6 billions shots done
Print head
Perform manual cleaning by using cleaning sticks and cleaning liquid. □ Perform cleaning
Output the test patterns of BIAS to check the error, and perform □ Adjustment
□ Good
adjustment if necessary. done
Determine if it should be replaced based on MOTOR ERROR and MOTOR
HOURS S in the History Report, or on the motor sound when performing □ Good
Scan motor a print and the customer's interview. Put grease on the gear if you replace □ Relacement □ Reset
the motor. done
Replacement Cycle: 3,000 hours
Determine if it should be repalced on the performance of the cleaning or
□Perform □ Relacement
Cleaning wiper the wiping times of the history report.
Check cleaning done
Replacement Cycle: Wiping count 3,000 times
Consumable
Check if the Encoder Scale has any dirt or dust or any ink on. And, check
□Perform □ Relacement
Parts Linear Encoder Scale 1
the Encoder Module, too. cleaning done
Check the Linear Encorder Sheet with [SERVICE MENU]>[PRINT □ Good
□ Relacement
Linear Encoder Scale 2 MENU]>[LINEAR CHECK]. If result is not good, upgrade the firmware and □Perform
done
perform cleaning and replacement if necessary. cleaning
Determine if it should be replaced based on the performance of the
□ Good
cleaning or the period from the time when the Cap Top was repalced □ Relacement
Cap top □Perform
last time. done
cleaning
Replacement Cycle: 6 months
Determine if it should be replaced based on the performance of the
cleaning or the period from the time when the Cap Top was repalced □ Relacement
Tray pad □ Good
last time. done
Replacement Cycle: WIPING COUNT 1,000 times

Lithium battery Replacement Cycle: 24 months □ Good


□ Relacement
done
5
Service
Check if the carriage belt does not touch the upper end or lower end of activities
□ Adjustment
Carriage belt the drive pulley and idle pulley when the head carriage moves in the full □ Good
done
width. Adjust the belt position, if necessary.
Check □ Relacement
Blade protection Replace it depending on the scratches. □ Good
Mechanical Parts done
Check if it is not worn out or not dirty, or not deformed. Check if it rotates □ Relacement
Pinch roller □ Good
smoothly. done
Grit roller Remove foreign substances put on it by using a brush. □ Done
Check that there is no problem with the printing operation and printing
Check printing □ Done
result.
Check that there is no problem with the cutting operation and cutting
Check cutting □ Done
result.
Output/Get Report after maintenace [GET REPORT] by Peck, or print both Service Report and History Report. □ Done
Remarks

5-13 SG -540/300