Roland vp540 vp-540 vp-300 vp300 complete service manual

SERVICE NOTES 70046-11 TERMS OF USE Users of this Service Note shall be deemed to agree 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 to the customers maintenance service of VP-540/VP-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 Authorized persons shall not copy, change or alter this Service Note without permission of Roland DG Corporation. 5. EFFECT OF VIOLATION Regardless of circumstances, we will vigorously respond to any violation hereof, through legal action. Conﬁdential Copyright © 2009 ROLAND DG CORPORATION

Windows and MS-DOS are registered trademark or trademark of Microsoft Corporation in the United States and/or other countries. Contents 1 Structure & Spare Parts 1-1 COVERS ............................................................................................................................................................. 1-1 1-2 FRAME .............................................................................................................................................................. 1-4 1-3 DRIVE UNIT ....................................................................................................................................................... 1-8 1-4 HEAD CARRIAGE (VP-540).............................................................................................................................. 1-12 1-5 HEAD CARRIAGE (VP-300).............................................................................................................................. 1-14 1-6 BASE FRAME.................................................................................................................................................... 1-16 1-7 CHASSIS .......................................................................................................................................................... 1-18 1-8 PINCH ROLLER ............................................................................................................................................... 1-19 1-9 STAND .............................................................................................................................................................. 1-20 1-10 TOOL CARRIAGE ............................................................................................................................................. 1-21 1-11 WIPER SYSTEM .............................................................................................................................................. 1-22 1-12 PUMP SYSTEM ................................................................................................................................................ 1-23 1-13 INK SYSTEM .................................................................................................................................................... 1-25 1-14 ACCESSORIES .................................................................................................................................................. 1-27 2 Electrical Section 2-1 WIRING MAP ...................................................................................................................................................... 2-1 2-2 MAIN BOARD ..................................................................................................................................................... 2-3 2-3 SERVO BOARD ............................................................................................................................................... 2-14 2-4 CARRAGE BOARD .......................................................................................................................................... 2-20 2-5 SUB BOARD...................................................................................................................................................... 2-23 2-6 MAINTENANCE PARTS LIST .......................................................................................................................... 2-28 3 Replacement of Main Parts 3-1 HEAD REPLACEMENT ...................................................................................................................................... 3-3 3-2 WIPER REPLACEMENT .................................................................................................................................... 3-9 3-3 CAP TOP REPLACEMENT ...............................................................................................................................3-11 3-4 TOOL CARRIAGE REPLACEMENT ................................................................................................................ 3-14 3-5 CARRIAGE MOTOR REPLACEMENT ............................................................................................................. 3-18 3-6 FEED MOTOR REPLACEMENT ...................................................................................................................... 3-22 3-7 PUMP REPLACEMENT ................................................................................................................................... 3-30 3-8 INK TUBE REPLACEMENT ............................................................................................................................. 3-37 3-9 BOARD REPLACEMENT (MAIN BOARD SW POWER SUPPLY).................................................................... 3-43 3-10 BATTERY REPLACEMENT .............................................................................................................................. 3-54 3-11 CARRIAGE BELT REPLACEMENT ................................................................................................................ 3-57 3-12 ENCODER SCALE REPLACEMENT ............................................................................................................... 3-62 3-13 GRIT ENCODER REPLACEMENT ................................................................................................................. 3-64 3-14 PINCH ROLLER REPLACEMENT ................................................................................................................... 3-67 3-15 CUTTER PROTECTION REPLACEMENT ....................................................................................................... 3-68 4 Adjustment 4-1 SERVICE MODE ................................................................................................................................................ 4-1 4-2 HOW TO UPGRADE FIRMWARE/INSTALL FIRMWARE ................................................................................. 4-15 4-3 HOW TO UPGRADE FIRMWARE OF THE NETWORK CONTROLLER .......................................................... 4-22 4-4 HEAD ALIGNMENT ........................................................................................................................................... 4-24 4-5 LIMIT POSITION & CUT DOWN POSITION INITIALIZE ................................................................................. 4-32 4-6 LINEAR ENCODER SETUP ............................................................................................................................. 4-34 4-7 FLUSHING POSITION ADJUSTMENT ............................................................................................................ 4-36 4-8 CROP MARK SENSOR ADJUSTMENT .......................................................................................................... 4-38 4-9 CROP-CUT ADJUSTMENT .............................................................................................................................. 4-40 4-10 PRINT/CUT POSITION ADJUSTMENT ............................................................................................................ 4-43 4-11 CALIBRATION(FEEDING DIRECTION) ........................................................................................................... 4-46 4-12 TOOL HEIGHT ADJUSTMENT ......................................................................................................................... 4-48 4-13 TOOL PRESSURE ADJUSTMENT .................................................................................................................. 4-50 4-14 BELT TENSION ADJUSTMENT ....................................................................................................................... 4-53 4-15 BELT POSITION ADJUSTMENT ...................................................................................................................... 4-56 4-16 TAKE-UP UNIT OPERATION CHECK .............................................................................................................. 4-62 5 Supplemental Information 5-1 SPECIAL TOOLS................................................................................................................................................. 5-1 5-2 SENSOR MAP ..................................................................................................................................................... 5-2 6 Troubleshooting 6-1 DEFECT OF PRINT QUALITY (BANDING/SCRATCHY PRINTING/BLURRED PRINTING).............................. 6-1 6-2 PARTICULAR COLOR IS NOT PRINTED AT ALL .............................................................................................. 6-2 6-3 SHIFTING IN PRINTING / COLOR SHIFTING.................................................................................................... 6-2 6-4 INK DROPS ON THE MEDIA .............................................................................................................................. 6-3 6-5 VERTICAL BANDING .......................................................................................................................................... 6-3 6-6 MISSING DOT OR DEFLECTED-FIRED DOT APPEARS WHEN PERFORMING PRINTING WITH LONG DELAY .......... 6-3 6-7 PRINT & CUT MISALIGHMENT .......................................................................................................................... 6-4 6-8 POOR CUTTING QUALITY(STITCH CUT, DISTORTED CUT, MISMATCHED START AND END POINTS) ..... 6-7 6-9 MEDIA SKEW ...................................................................................................................................................... 6-7 6-10 MOTOR ERROR ................................................................................................................................................. 6-8 6-11 HEATER/DRYER TEMPERATURE DOES NOT GO UP ..................................................................................... 6-9 6-12 PROBLEM IN NETWORK(RIP DOES NOT RECOGNIZE THE PRINTER) ........................................................ 6-9 6-13 ERROR MESSAGE ........................................................................................................................................... 6-10 6-14 SERVICE CALL ................................................................................................................................................. 6-10 7 Service Activities 7-1 INSTALLATION CHECK LIST ............................................................................................................................. 7-1 7-2 MAINTENANCE CHECK LIST .......................................................................................................................... 7-12 7-3 SPACIFICATION ................................................................................................................................................ 7-13 7-3 SPECIFICATION ............................................................................................................................................... 7-13

Revision Record Revision NO. Date Description of Changes Approval Issued 0 2007.3.9 First Edition Kato Uchiyama 1 2007.4.25 Sect1 : Parts have been revised. Sect3 : Procedures have been revised. Sect4 : Procedures have been revised. Sect7 : Installation Check List has been revised. Kato Mabuchi 2 2007.6.15 Sect1 : Parts have been revised. Sect3 : Procedures have been added. Kato Mabuchi 3 2007.8.24 Sect3 : Procedures have been revised. Kato Mabuchi 4 2007.10.12 Sect3 : Procedures have been revised. Sect4 : Service Mode has been revised. Kato Misako 5 2007.11.20 Sect1 : Parts have been revised. Sect7 : Procedures have been revised. Kato Yuki 6 2008.1.29 Sect1 : Parts have been revised. 2-1 : Wiring Map Cable has been added. Sect4 : Service Mode has been revised. Kato Yuki 7 2008.8.1 1-1: COVER,1-3 : DRIVE UNIT, 1-4 : HEAD CIARRIAGE(VP-540）、1-5 : HEAD CARRIAGE（VP-300)、1-7 : CHASSIS, 1-11 : WIPER SYSTEM Parts have been revised. Kato Misako 8 2008.11.18 1-3 : DRIVE UNIT, 1-4 : HEAD CIARRIAGE(VP-540）、1-7 : CHASSIS, 1-11: WIPER SYSTEM, 1-13 :INK SYSTEM 1-14 : ACCESSORY Parts have been revised. 4-14 : BELT POSITION ADJUSTMENT has been revised. Kato Misako 9 2009.1.16 2-1: WIRING MAP has been revised. Kato Misako 10 2009.2.12 1-13 : INK SYSTEM Parts have been revised. Kato Mabuchi 11 2009.8.28 1-1: COVER, 1-3 : DRIVE UNIT, 1-14 : ACCESSORY Parts have been revised. 2-2: MAINBOARD, 2-3: CARRIAGE BOARD circuit diagram have been revised. Kato Misako

To Ensure Safe Work About and Notices. Used for instructions intended to alert the operator to the risk of death or severe injury should the unit be used improperly. Used for instructions intended to alert the operator to the risk of injury or material damage should the unit be used improperly. * material damage refers to damage or other adverse effects caused with respect to the home and all its furnishings, as well to domestic animals or pets. About the Symbols The symbol alerts the user to items that must never be carried out (are forbidden). The speci c thing that must not be done is indicated by the design contained within the circle. The symbol at left means not to touch. The symbol alerts the user to things that must be carried out. The speci c thing that must be done is indicated by the design contained within the circle. The symbol at left means the power-cord plug must be unplugged from the outlet. The symbol alerts the user to important instructions or warnings. The speci c meaning of the symbol is determined by the design contained within the triangle. The symbol at left means “danger of electrocution”. In addition to the and symbols, the symbols shown below are also used. : Tips and advise before the adjustment.

About the Labels Afﬁxed to the Unit These labels are af xed to the body of this product. The following gure describes the location. Caution : Moving Print Heads The print heads move at high speed and pose a hazard. Caution : Pinching Hazard Contact during operation may cause the hand or ngers to become pinched, rsult- ing in injury. Caution : High Temperature The platen and dryer become hot. Exer- cise caution to avoid re or burns. Flammable Ink and discharged uid are ammable. Keep away from open ame. Ink Is Toxic Ink and discharged uid are toxic. Avoid contact with the body. Use only in a well- ventilated area. Flammable Ink and discharged uid are ammable. Keep away from open ame. Ink Is Toxic Ink and discharged uid are toxic. Avoid contact with the body. Use only in a well- ventilated area.

HIGH VOLTAGE, HANDLING ATTENTION • Do not touch during power on Electric shock, Compornents damage • Do not repair. Replace power unit. • Do not replace fuse. Can not be recovered. WARNING - FOR CONTINUED PROTECTION AGAINST RISK OF FIRE, REPLACE ONLY WITH FUSE OF THE SPECIFIED TYPE AND CURRENT RATING. F80L HS Electric charge. Do not touch when power is on. The wiring terminal untended for connec- tion of the protective earthing conductor associated with the supply wiring. Do not disconnect the cable of this terminal except the time of replacement.

1 Structure & Spare Parts PARTS LIST -Main Parts- Parts No. Parts Name Parts No. Parts Name 1 W700461210 ASSY,PANEL BOARD VP-540 17 1000002637 SHEET,PANEL VP-540 2 23505834 CABLE-ASSY MAINT-COVER SW FJ-540 18 1000002625 STAY,PANEL VP-540 3 1000002608 COVER,INK CARTRIDGE VP-540 19 1000003029 SHEET,LCD VP-540 4 1000002633 COVER,CHASSIS VP-540 20 22535347 LABEL,CAUTION PINCH-2 #LA423 5 1000002620 COVER,MAINTENANCE VP-540 21 1000001099 LABEL,HARMFUL FIRE #LA915 1000002550 COVER,MAINTENANCE INKHEAD VP-540 22 22535441 LABEL,SET INK SP-300 #LA634 1000006236 COVER,MAINTENANCE INKHEAD 2 VP-540I 23 1000001620 LABEL,USE ECO-SOL MAX#LA924 1000002676 COVER,RAIL B VP-300 24 22535444 LABEL,READ MANUAL #LA637 1000002624 COVER,RAIL B VP-540 25 23475212 CABLE-CARD,24P1 600L BB 8 1000002651 COVER,RAIL B-RIGHT VP-540 PARTS LIST -Supplemental Parts- 1000002150 COVER,RAIL F VP-300 Parts No. Parts Name 1000002146 COVER,RAIL F VP-540 S1 31289111AS CUPSCREW SET, M4*6 NI 100 PCS. 10 1000002619 COVER,SIDE L VP-540 S2 31289109AS CUPSCREW SET,M3*4 NI 100 PCS. 11 1000002621 COVER,SIDE R VP-540 S3 31139103 PLAPOINT,FE4*6 WH 12 1000002627 COVER,UNDER L VP-540 S4 31149601 RING SET,PUSH-ON CS CSTW-3 100 PCS 13 1000002628 COVER,UNDER R VP-540 S5 31019149 SCREW SET,BINDING M2.3*8 3CBC 100PCS 14 22495102 KEY TOP,CLEAR GX-24 S6 31019703 SCREW,BINDING P-TIGHT M3*8 3C 100P 15 22495101 KEY TOP,WHITE GX-24 S7 31139104 SCREW,PLAPOINT M4*6 BK FE 16 1000002626 LABEL,EMBLEM LOGO VERSACAMM 1-1 COVER ( VP-540：Below ZW65382, VP-300：Below ZW61509 ) 1-1 7 9 6 13 4 8 9 3 7 10 5 6 12 16 11 17 18 1 2 14 15 14 19 22 20 20 21 23 21 24 25 S2 S2 S2 S1 S2 S2 S2 S2 S2 S2 S1 S2 S2 S2 S5 S3 S1 S1 S1 S7 S7 S1 S1 S1 S1 S6 S4 Revised 1 Revised 1 Revised7 Revised7 Revised 11 Revised 11

1-2 1-1 COVER ( VP-540：Above ZW65383, VP-300：Above ZW61510) 13 4 8 9 3 7 10 5 6 12 16 11 17 18 1 2 14 15 14 19 22 20 20 21 23 21 24 25 35 S12 S8 S2 S2 S2 S1 S2 S2 S2 S2 S2 S2 S1 S2 S2 S2 S5 S3 S1 S1 S1 S7 S7 S1 S1 S1 S1 S6 S4 26 27 28 29 30 31 32 33 34 36 37 31 38 32 S5 S9 S10 S10 S11 Revised 1 Revised 6 Revised 6 Revised 7

PARTS LIST -Supplemental Parts- Parts No. Parts Name Parts No. Parts Name 1 W700461210 ASSY,PANEL BOARD VP-540 S1 31289111AS CUPSCREW SET, M4*6 NI 100 PCS. 2 23505834 CABLE-ASSY MAINT-COVER SW FJ-540 S2 31289109AS CUPSCREW SET,M3*4 NI 100 PCS. 3 1000002608 COVER,INK CARTRIDGE VP-540 S3 31139103 PLAPOINT,FE4*6 WH 4 1000002633 COVER,CHASSIS VP-540 S4 31149601 RING SET,PUSH-ON CS CSTW-3 100 PCS 5 1000002550 COVER,MAINTENANCE INKHEAD VP-540 S5 31019149 SCREW SET,BINDING M2.3*8 3CBC 100PCS 6 1000002620 COVER,MAINTENANCE VP-540 S6 31019703 SCREW,BINDING P-TIGHT M3*8 3C 100P 1000002624 COVER,RAIL B VP-540 S7 31139104 SCREW,PLAPOINT M4*6 BK FE 1000002676 COVER,RAIL B VP-300 S8 31049107AS SCREW SET,CAP M3*12 3CBC 20 PCS 8 1000002651 COVER,RAIL B-RIGHT VP-540 S9 31049169AS SCREW SET,CAP M4*8 3CBC+PW 20PCS 1000004207 COVER,RAIL F TYPE2 VP-540 S10 31289102AS CUPSCREW SET,M3*6 NI 50 PCS. 1000004208 COVER,RAIL F TYPE2 VP-300 S11 31289112AS CUPSCREW SET,M3*10 NI 100 PCS. 10 1000002619 COVER,SIDE L VP-540 S12 31029816AS BUSH SET,ROLL 3*4 100 3C PCS. 11 1000002621 COVER,SIDE R VP-540 12 1000002627 COVER,UNDER L VP-540 13 1000002628 COVER,UNDER R VP-540 14 22495102 KEY TOP,CLEAR GX-24 15 22495101 KEY TOP,WHITE GX-24 16 1000002626 LABEL,EMBLEM LOGO VERSACAMM 17 1000002637 SHEET,PANEL VP-540 18 1000002625 STAY,PANEL VP-540 19 1000003029 SHEET,LCD VP-540 20 22535347 LABEL,CAUTION PINCH-2 #LA423 21 1000001099 LABEL,HARMFUL FIRE #LA915 22 22535441 LABEL,SET INK SP-300 #LA634 23 1000001620 LABEL,USE ECO-SOL MAX#LA924 24 22535444 LABEL,READ MANUAL #LA637 25 23475212 CABLE-CARD,24P1 600L BB 1000004197 PLATE,COVER F VP-540 1000004204 PLATE,COVER F VP-300 27 22535390 LABEL,EMERGENCY STOP #LA496 28 22535286 LABEL,CAUTION COVER #LA265 1000004196 PLATE,NUT COVER F VP-540 1000004203 PLATE,NUT COVER F VP-300 30 21425110 WASHER,COVER FJ-50 31 1000004199 PAD, STOPPER VP-540 32 1000004198 SHAFT,COVER F VP-540 1000004195 FRAME,COVER F VP-540 1000004202 FRAME,COVER F VP-300 34 1000004361 COVER,INT SW VP-540 35 11879107 ABSORBER TK-12 36 13169102 COVER SW R (AVT32344) 37 1000004200 HOOK,INT SW VP-540 38 22535287 LABEL,CAUTION CARRIAGE #LA266 1-3 PARTS LIST -Main Parts- 1-1 COVER ( VP-540：Above ZW65383, VP-300：Above ZW61510 ) 7 9 33 29 26 Revised 1 Revised 6 Revised 6 Revised 7 Revised 7

1-4 1-2 FRAME ( VP-540：Below ZW65382, VP-300：Below ZW61509 ) 28 8 22 13 9 26 33 32 8 31 25 18 7 24 29 20 19 16 34 4 3 9 21 6 2 23 17 30 35 1 27 1 14 8 11 11 10 5 5 15 12 36 37 38 37 S6 S11 S16 S20 S10 S12 S17 S14 S8 S17 S4 S4 S13 S17 S14 S17 S17 S16 S20 S7 S20 S10 S10 S3 S9 S4 S10 S4 S10 S17 S10 S17 S17 S10 S18 S17 S20 S1 S2 S19 S17 S8 S5 S14 S5 S14 S1 S8 S6 S11 S6 S11 S10

Roland vp540 vp-540 vp-300 vp300 complete service manual

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