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Roland Advanced Jet AJ-1000 User Manual

Roland Advanced Jet AJ-1000
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SERVICE NOTES
Contents
4 Adjustment
4-1 SPECIAL TOOLS
...............................................

4-2 SERVICE MODE
...............................................

4-3 HOW TO UPGRADE FIRMWARE
.............................

4-4 HEAD ALIGNMENT
.............................................

4-5 CAPPING POSITION ADJUSTMENT
.........................

4-6 LINEAR ENCODER SETUP
...................................

4-7 PAPER SIDE SENSOR ADJUSTMENT
........................

4-8 CALIBRATION (FEEDING DIRECTION)
......................

4-9 BELT TENSION ADJUSTMENT
...............................

4-10 BELT POSITION ADJUSTMENT
...............................

4-11 NETWORK BOARD INITIALIZE
...............................

4-12 LIMIT POSITION & MAX SCAN WIDTH INITIALIZE
..........


5 Supplemental Information

5-1 SENSOR MAP
..................................................

5-2 HOW TO REMOVE THE AIR IN THE INK LINE
..............


6 Troubleshooting

6-1 WHITE FINE LINE / BANDING / MISSING DOT / 
SCRATCHY PRINTING / BLURRED PRINTING
..............
6-2 PARTICULAR COLOR DOES NOT PRINT AT ALL
............
6-3 SHIFTING IN PRINTING/COLOR SHIFTING
.................
6-4 INK DROPS ON THE MEDIA
..................................
6-5 VERTICAL BANDING
..........................................

6-6 MISSING DOT OR DEFLECTED-FIRED DOT APPEARS 
WHEN PERFORMING PRINTING WITH LONG DELAY
.....
6-7 INK EMPTY MESSAGE APPEARS 
EVEN IF THE INK HAS NOT RUN OUT
.......................
6-8 THE INK OR MAINTENANCE LIQUID NEVER COMES
BY PERFORMING FILL INK
....................................
6-9 MOTOR ERROR
................................................

6-10 HEATER TEMPERATURE DOES NOT GO UP
...............

6-11 DRYER TEMPERATURE DOES NOT GO UP
................
6-12 THE BLOWER FAN DOES NOT MOVE
.......................
6-13 THE TAKE-UP/FEED OUT UNIT DOES NOT MOVE
.........
6-14 ERROR MESSAGE
..............................................
6-15 SERVICE CALL
..................................................


7 Service Activities
7-1 INSTALLATION CHECK LIST
..................................

7-2 MAINTENANCE CHECK LIST
.................................

7-3 PREPARATION FOR TRANSPORTATION 1
..................
7-4 PREPARATION FOR TRANSPORTATION 2
..................
7-5 SPECIFICATIONS
..............................................
4-1
4-2
4-17
4-20
4-29
4-31
4-32
4-35
4-37
4-43
4-55
4-57
7-1
7-15
7-16
7-24
7-35
6-1
6-3
6-3
6-4
6-4
6-4
6-5
6-6
6-7
6-8
6-9
6-10
6-10
6-11
6-11
5-1
5-5
Windows and MS-DOS are registered trademark or trademark of Microsoft Corporation in the United States and/or other countries.
First Edition
Unauthorized coplying or transferral, in whole or in part, of this manual is prohibited.
70010-00
1 Structure & Spare Parts
1-1 COVERS
.......................................................
1-2 FRAME
.........................................................
1-3 CARRIADGE
...................................................
1-4 DRIVE UNIT
....................................................
1-5 BED
............................................................
1-6 CHASSIS
.......................................................
1-7 PINCH ROLLER
...............................................
1-8 MAINTENANCE LIQUID CARTRIDGE
.......................
1-9 WIPER SYSTEM
...............................................
1-10 INK SYSTEM
...................................................
1-11 SUB TANK SYSTEM
...........................................
1-12 DRYER
.........................................................
1-13 STAND
..........................................................
1-14 TU UNIT
........................................................
1-15 TU ROLL
........................................................
1-16 ACCESSORIES
................................................
2 Electrical Section
2-1 WIRING MAP
...................................................
2-2 MAIN BOARD
..................................................
2-3 HEAD BOARD
..................................................
2-4 SERVO BOARD
................................................
2-5 HEATER BOARD
...............................................
2-6 PUMP DRIVE BOARD
.........................................
2-7 SUB BOARD
...................................................
2-8 MAINTENANCE PARTS LIST
.................................
3 Replacement of Main Parts
3-1 HEAD REPLACEMENT
........................................
3-2 WIPER REPLACEMENT
.......................................
3-3 CAP TOP REPLACEMENT
....................................
3-4 CARRIAGE MOTOR REPLACEMENT
........................
3-5 SUPPLY PUMP REPLACEMENT
.............................
3-6 INK TUBE REPLACEMENT
...................................
3-7 BOARDS REPLACEMENT
....................................
(Main Board / SW Power Supply)
3-8 BATTERY REPLACEMENT
....................................
3-9 CARRIAGE BELT REPLACEMENT
...........................
3-10 ENCODER SCALE REPLACEMENT
.........................
3-11 TU BOARD REPLACEMENT
..................................
1-1
1-3
1-5
1-7
1-9
1-11
1-13
1-14
1-15
1-17
1-19
1-20
1-21
1-23
1-25
1-27
2-1
2-3
2-11
2-19
2-26
2-34
2-42
2-54
3-3
3-11
3-13
3-18
3-23
3-30
3-40
3-50
3-53
3-59
3-62

Table of Contents

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Roland Advanced Jet AJ-1000 Specifications

General IconGeneral
ConnectivityEthernet
Ink ColorsCyan, Magenta, Yellow, Black, Light Cyan, Light Magenta
Maximum Print Width104 inches
Print Resolution1440 x 1440 dpi
Number of Ink Colors6 colors
Media TypesVinyl, banner, canvas, paper
Media ThicknessUp to 0.8 mm
Media HandlingRoll feed
Operating System CompatibilityWindows
Print TechnologyPiezoelectric Inkjet
Ink TypeEco-Sol MAX

Summary

Revision Record

To Ensure Safe Work

General Safety Warnings

Alerts users to potential risks, including death, injury, and material damage from improper use.

About the Symbols

Explains the meaning of warning symbols like danger of electrocution and forbidden actions.

About the Labels Affixed to the Unit

Describes the location and meaning of various labels affixed to the product body.

Structure & Spare Parts

1-1 COVERS

Details the various covers and external panels of the AJ-1000 printer.

1-2 FRAME

Lists components of the main structural frame and its assembly.

1-3 CARRIAGE

Identifies parts related to the print head carriage and its movement system.

1-4 DRIVE UNIT

Covers components of the drive system, including motors, pulleys, and belts.

1-5 BED

Details the printer's bed assembly and associated parts.

1-6 CHASSIS

Lists internal chassis components and electrical mounting points.

1-7 PINCH ROLLER

Identifies parts for the pinch roller assembly used for media feeding.

1-8 MAINTENANCE LIQUID CARTRIDGE

Lists components of the maintenance liquid cartridge and its system.

1-9 WIPER SYSTEM

Details the parts that make up the print head wiper and capping system.

1-10 INK SYSTEM

Covers components of the ink delivery system, including tubes and dampers.

1-11 SUB TANK SYSTEM

Lists parts for the sub ink tank and associated pump mechanisms.

1-12 DRYER

Identifies components of the dryer unit, including heaters and blowers.

1-13 STAND

Lists parts for the printer's stand and leveling adjusters.

1-14 TU UNIT

Details the parts comprising the Take-Up (TU) unit for media handling.

1-15 TU ROLL

Lists parts related to the TU roll assembly, including shafts and holders.

1-16 ACCESSORIES

Lists various included accessories such as media clamps, tools, and software.

Electrical Section

2-1 WIRING MAP

Provides a diagram illustrating the electrical connections and wiring layout.

2-2 MAIN BOARD

Details the arrangement and components of the primary main control board.

2-3 HEAD BOARD

Shows the layout and component identification for the head control board.

2-4 SERVO BOARD

Illustrates the arrangement and components of the servo motor control board.

2-5 HEATER BOARD

Details the components and layout of the heater control board.

2-6 PUMP DRIVE BOARD

Shows the arrangement and components of the pump drive control board.

2-7 SUB BOARD

Details the layout and components of various auxiliary sub-boards.

2-8 MAINTENANCE PARTS LIST _ Electrical Parts

Lists electrical parts used in maintenance, including ICs, fuses, and SSRs.

Replacement of Main Parts

3-1 HEAD REPLACEMENT

Step-by-step guide for replacing the print head, including necessary adjustments.

3-2 WIPER REPLACEMENT

Procedure for replacing the wiper assembly, including cover removal and hook attachment.

3-3 CAP TOP REPLACEMENT

Instructions for replacing the cap top components, involving head carriage movement.

3-4 CARRIAGE MOTOR REPLACEMENT

Steps for replacing the carriage motor, including cover removal and flange adjustment.

3-5 SUPPLY PUMP REPLACEMENT

Procedure for replacing the supply pump, focusing on ink evacuation and tube connections.

3-6 INK TUBE REPLACEMENT

Guide for replacing ink tubes, involving cover removal and flexible cable disconnection.

3-7 SW POWER SUPPLY REPLACEMENT

Steps for replacing the 41V and 5V/24V switching power supplies.

3-8 MAIN BOARD REPLACEMENT

Instructions for replacing the main board, including firmware and parameter setup.

3-9 BATTERY REPLACEMENT

Procedure for replacing the main board's lithium battery, with safety warnings.

3-10 ENCODER SCALE REPLACEMENT

Guide for replacing the encoder scale and module, detailing tension and position adjustments.

3-11 TU BOARD REPLACEMENT

Steps for replacing the TU (Take-Up) board, involving cover removal and cable disconnection.

Adjustment

4-1 Special Tools

Lists recommended tools for various adjustment procedures, such as torque drivers and tension gauges.

4-2 Service Mode

Details how to access and navigate the service mode menu for various machine adjustments.

4-3 HOW TO UPGRADE FIRMWARE

Guides on upgrading the machine's firmware using PC software via network or direct connection.

4-4 HEAD ALIGNMENT

Comprehensive guide for aligning print heads, covering bias, vertical, and bi-directional adjustments.

4-5 CAPPING POSITION ADJUSTMENT

Procedure to adjust the head capping position to ensure proper sealing and prevent drying.

4-6 LINEAR ENCODER SETUP

Steps for calibrating the linear encoder to ensure accurate media width and position reading.

4-7 PAPER SIDE SENSOR ADJUSTMENT

Guide to adjust the paper side sensor's sensitivity for correct media edge detection.

4-8 CALIBRATION (FEEDING DIRECTION)

Procedure for calibrating the media feeding direction using test patterns and mathematical formulas.

4-9 BELT TENSION ADJUSTMENT

Instructions for adjusting the carriage belt tension using a tension gauge and specific torque values.

4-10 BELT POSITION ADJUSTMENT

Steps for adjusting the belt's position on pulleys to ensure proper alignment and prevent shifting.

4-11 NETWORK BOARD INITIALIZE

Describes how to reset the network board to default settings if communication issues occur.

4-12 LIMIT POSITION & MAX SCAN WIDTH INITIALIZE

Procedure to initialize the carriage limit positions and the maximum scan width.

Supplemental Information

5-1 SENSOR MAP

Identifies and locates various sensors on the machine, detailing their function.

5-2 HOW TO REMOVE THE AIR IN THE INK LINE

Provides a flowchart for purging air from the ink lines using a syringe and adapter screws.

5-3 HOW TO REMOVE AIR IN PRESSURE PUMP OR IN INK TUBE BETWEEN HEAD AND PRESSURE PUMP

Explains procedures for removing air from the ink path between the pressure pump and print head.

5-4 HOW TO REMOVE AIR IN SUPPLY PUMP OR INK TUBE BETWEEN SUPPLY PUMP AND SUB TANK

Details steps for purging air from the ink path between the supply pump and sub tank.

Troubleshooting

6-1 WHITE FINE LINE / BANDING / MISSING DOT / SCRATCHY PRINTING / BLURRED PRINTING

Addresses print quality issues like banding and missing dots, suggesting media and calibration checks.

6-2 PARTICULAR COLOR DOES NOT PRINT AT ALL

Troubleshooting steps for specific colors not printing, including ink tube and head checks.

6-3 SHIFTING IN PRINTING/COLOR SHIFTING

Discusses causes and solutions for print shifting and color misalignment issues.

6-4 INK DROPS ON THE MEDIA

Explains causes for ink drops on media, such as foreign substances and media issues.

6-5 VERTICAL BANDING

Addresses vertical banding issues related to encoder scale, LM guide, and gear cleanliness.

6-6 MISSING DOT OR DEFLECTED-FIRED DOT APPEARS WHEN PERFORMING PRINTING WITH LONG DELAY

Troubleshooting for missing dots after idle periods, focusing on power and self-cleaning.

6-7 INK EMPTY MESSAGE APPEARS EVEN IF THE INK HAS NOT RUN OUT

Solutions for false ink empty messages, related to air in the supply pump or low sub tank ink.

6-8 THE INK OR MAINTENANCE LIQUID NEVER COMES BY PERFORMING FILL INK

Troubleshooting for ink or maintenance liquid flow issues, typically due to air in the system.

6-9 MOTOR ERROR

Explains motor error codes and their causes, including media jams and board issues.

6-10 HEATER TEMPERATURE DOES NOT GO UP

Troubleshooting for heater temperature issues, checking settings, connections, and fuses.

6-11 DRYER TEMPERATURE DOES NOT GO UP

Addresses dryer temperature problems, checking power, wiring, and resistance values.

6-12 THE BLOWER FAN DOES NOT MOVE

Troubleshooting for blower fan issues, checking settings and control board.

6-13 THE TAKE-UP/FEED OUT UNIT DOES NOT MOVE

Explains reasons for the take-up/feed out unit not moving, checking covers, switches, and cables.

6-14 ERROR MESSAGE

Lists common error codes and their meanings, including communication and hardware faults.

6-15 SERVICE CALL

Details error codes that require professional service intervention, such as board failures.

Service Activities

7-1 INSTALLATION CHECK LIST

A checklist for verifying proper installation conditions, including space, power, and environment.

7-3 Preparation for Transportation 1

Steps for preparing the machine for transport, including package disassembly and tool requirements.

7-4 Preparation for Transportation 2

Procedures for preparing the machine for transport, including media removal and head wash.

7-5 Specifications

Provides technical specifications for the AJ-1000, including dimensions, power, and environmental requirements.

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