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4.5Disassembly and Assembly Procedure

DX100 Service Manual

4.5 Disassembly and Assembly Procedure

4.5.1 Preparation for Dissembling

4.5.1.1 Unlocking the CR Unit

When removing the parts listed below, unlock the CR Unit manually or using the Service
Program.



Unlocking the CR Unit using the Service Program
See

"5.4.6 Release Carriage Lock"

(p242)



Unlocking the CR Unit manually
Unlock the CR Unit by turning the gear of the Capping Unit clockwise using a precision
flat-blade screwdriver.

Figure 4-19. Unlocking the CR Unit

Parts

Reference

Self Sealing Valve

p116

Print Head

p120

CR Scale

p123

CR Unit / CR Timing Belt

p124

Head FFC

p122

C A U T I O N

Take care not to damage the gear (white). (See

Figure 4-19

)

CR Unit

Flat-blade screwdriver

Capping Unit

Summary of Contents for Frontier-S DX100

Page 1: ...oduct Describes how to disassemble and assemble the product Describes how to adjust the product Describes the lubrication cleaning and other maintenance procedures Provides the additional information...

Page 2: ...ithout notice All effort have been made to ensure the accuracy of the contents of this manual However should any errors be detected the company would greatly appreciate being informed of them The abov...

Page 3: ...specific item or the expected result of the operation ADJUSTMENT REQUIRED Indicates an operating or maintenance procedure practice or condition that is necessary to keep the product s quality W A R N...

Page 4: ...let Otherwise a fire may result Make sure to perform grounding work to prevent accidental short circuit Otherwise a fire or electric shock may result Perform grounding work with either of the followin...

Page 5: ...a plate in the machine Always wear anti static wrist straps during maintenance The machine must be on a stable flat base to prevent damage caused by a fall and failure caused by an abnormal condition...

Page 6: ...nner Perfection V750 M Pro has been added Scanner Perfection V750 pro has been added Made change in Release Driven Pulley ASSY Gap Adjustment Grease G 74 has been added C 2014 6 6 Revised Chapter 1 1...

Page 7: ...r Calibration Adjustment p 243 Adjust name has been changed partially revised 5 5 6Cut position Adjustment p 269 revised 5 7 1Resistance Check p 275 revised Chapter 7 7 1Service Tool p 297 revised D 2...

Page 8: ...dded Chapter 4 4 5 4 4CR Scale p 123 Added caution Chapter 5 5 1 2Adjustment Items and the Order by Repaired Part p 210 Added the remedy of the Left Ink Cartridge Holder and Right Cartridge Holder whe...

Page 9: ...4 Chapter 3 3 4Troubleshooting by Error code p 58 Corrected the threshold value of CR Unit drive path count and changed the remedy of code 1102 Changed the remedy of code 1412 Changed the error name a...

Page 10: ...28 1 9 3 Ink Supply Parts 28 1 9 4 Replaced Parts 28 Chapter 2 OPERATING PRINCIPLES 2 1 Printer Mechanism 30 2 1 1 Carriage Mechanism 30 2 1 2 APG Mechanism 30 2 1 3 Ink Supply Mechanism Ink System M...

Page 11: ...4 5 5 5 Paper Width Guide Unit 139 4 5 5 6 Roll Width Guide Unit 139 4 5 5 7 Decurl Roller Driven Roller 1 2 140 4 5 5 8 Feed Roller 1 2 Inlet Roller 143 4 5 5 9 Paper Width Guide 148 4 5 5 10 U Guide...

Page 12: ...3 5 Firmware Update 229 5 4 Carriage Related Adjustment 230 5 4 1 Head ID Input 230 5 4 2 Head Incline Adjustment 231 5 4 3 Bi d Adjustment 233 5 4 4 PG Adjustment Mecha 234 5 4 5 Image Quality Adjus...

Page 13: ...13 DX100 Service Manual 7 3 Board Layout Diagram 299 7 4 Board Voltage List 303...

Page 14: ...C H A P T E R 1 PRODUCTDESCRIPTION...

Page 15: ...istinguish by Serial Number of printer 1 2 Basic Specifications 1 2 1 Basic Specifications 1 2 2 Electric Specifications Table 1 1 Area Ver 1 Ver 2 note Universal STD U5GE000001 U5GE010001 Ver 2 from...

Page 16: ...2 2006 Class A C Tick Mark Newzealand AS NZS CISPR22 2006 Class A China China Compulsory Certificate system Table 1 3 Electric Specifications Item Specification Table 1 4 Ink Specifications Item Speci...

Page 17: ...tank installed Notes on transportation after unpacking Remove the ink cartridge from the printer and pack and transport the printer with a new maintenance tank installed When transporting the printer...

Page 18: ...ndling Specifications Item Specification Maximum available paper length 66 m Maximum available paper width 210 mm A4 External dimensions of roll Within 170 mm Maximum weight 4 kg or less Table 1 8 Sup...

Page 19: ...h 127 mm 5 inch Yes 203 mm 254 mm 8 10 inch 203 mm 254 mm 8 inch 10 inch 203 mm 8 inch Yes 203 mm 305 mm 8 12 inch Wide 203 mm 305 mm 8 inch 12 inch 203 mm 8 inch Yes A4 210 mm 297 mm 8 3 inch 11 7 in...

Page 20: ...c Side Home 0 mm Side Full 0 mm Printing Area Preceding Page Subsequent Page b a a c c Auto Cut position Print Length Paper Width Auto Cut position Auto Cut position Auto Cut position Paper Feed Symbo...

Page 21: ...ymbol Item Value a Print Top Wasted Amount Standard 1 7 mm Small 0 84 mm Smaller 0 42 mm Print Bottom Wasted Amount Standard 1 7 mm Small 0 84 mm Smaller 0 42 mm b Print Top Cut Off Amount 5 mm c Side...

Page 22: ...nter error The buzzer can be set to ON OFF Table 1 10 System Requirement specifications OS System requirements specification 2 Windows XP Professional SP3 32bit Windows 7 SP1 Professional Ultimate 32b...

Page 23: ...r Recovery operation is being performed Printer system error 3 Orange ON No paper on the Roll Unit Flashing Paper jam on the Roll Unit 4 Orange ON Printing cannot be performed because there is not eno...

Page 24: ...Front Figure 1 5 Part Names Front 1 Table 1 14 Dimensions and Weight Dimensions Weight Width W Depth D Height H 460 mm 430 mm 354 mm Approx 23 kg printer only 430 mm 460 mm 354 mm Table 1 15 Part Nam...

Page 25: ...1 6 Part Names Front 2 Rear Figure 1 7 Part Names Rear 1 Table 1 16 Part Names Front 2 No Name 9 Ink cartridges 10 Roll unit 11 Maintenance Cartridge Table 1 17 Part Names Rear 1 No Name 1 Exhaust ve...

Page 26: ...ding Unit Figure 1 8 Part Names Feeding Unit Inner Figure 1 9 Part Names Inner Table 1 18 Part Names Feeding Unit No Name 1 Inner edge guide 2 Spindle Unit 3 Handle 4 Front edge guide 5 Paper LED 6 Pa...

Page 27: ...27 1 8 Dimensions and Main Components DX100 Service Manual Spindle Unit Figure 1 10 Part Names Spindle Unit Table 1 20 Part Names Spindle Unit No Name 1 Flange...

Page 28: ...andard paper The following specifications of the Cutter Unit have been changed for DX100 printer ver 2 and later Has changed from a periodic replacement part to one of the life parts Firmware has been...

Page 29: ...C H A P T E R 2 OPERATINGPRINCIPLES...

Page 30: ...sm 2 1 2 APG Mechanism The APG mechanism is driven by the APG motor to change the platen gap PG automatically within the five presettings The APG motor and APG position sensor drive the PG cam to auto...

Page 31: ...equence of actions adjusts the distance between the Upper Paper Guide Unit and SMAP roller The platen gap setting is controlled by the APG position sensor and the APG flag The APG position sensor read...

Page 32: ...tion of each component is as follows Decompression Pump Unit Suctions air in the ink supply mechanism to reduce the pressure Ink Passage Pump Ink Cartridge Holder Suctions ink in the Ink Cartridge to...

Page 33: ...rint Head from drying by capping it while printing is stopped Pump Mechanism Suctions ink for charging ink or cleaning Cleaner Mechanism Removes solidified ink dust and dirt near the nozzle Wiping Mai...

Page 34: ...t the Decurl Roller warps the roll paper to eliminate the curl of paper 4 Paper feeding stops when the leading edge of roll paper is detected by the Inlet Paper Edge Sensor 5 The Upper Paper Guide Uni...

Page 35: ...F Motor the Feed Roller 1 2 and Inlet Roller rotate and feed paper up to the print start position Figure 2 6 Figure 2 7 Paper Feed Mechanism 2 2 1 4 2 Paper Ejection Sequence Printed paper is fed by t...

Page 36: ...int quality When the ink in the Self Sealing Valve is supplied to the print head the pressure in the pressure chamber declines and the pressure plate and diaphragm moves the valve rod to the valve cha...

Page 37: ...value range Fatal error No Fatal error No Yes Yes Yes A 1 A 1 Yes CSIC power on sequence Waste ink cartridge CSIC power on sequence Waste ink Cartridge check Checks if an error occurs during CSIC powe...

Page 38: ...ump counter 2 Yes A 2 Yes A A 3 No A 4 Check if Jig mode Check if initial charge counter is 0 No Detection of ILS Replace flag 2 reset Detection of ink cartridge Detection of waste ink Cartridge A 4 Y...

Page 39: ...CW Checks if it has stopped after travelling the maximum operating distance Checks if Motor error occurs Check if cutter home sensor is shaded Cutter motor rotation CCW Cutter home positioning setting...

Page 40: ...e sensor is on Yes No Fatal error Cutter motor rotation CCW Checks if the sensor is designated Mechanism accumulated cut counter CUT CUT 1 Clears the leading edge value of paper Checks if Print start...

Page 41: ...otation 4412 EP Roll motor rotation 5239 EP Check if roll version flag is 1 Roll motor rotation 5576 EP Yes D 4 No D 4 D 5 D 5 D 5 Checks if it has stopped after travelling the maximum operating dista...

Page 42: ...cks if the leading edge of paper is at the start of feeding position Yes No F 2 Yes Checks if RE roll paper end detection sensor is on No Yes Roll motor rotation CCW PF motor rotation CCW Roll motor r...

Page 43: ...CR lock reset CR motor rotation Adjusts PW sensor sensitivity Detects paper end Home side Moves to the print start position F 2 F 3 Counts up power ON OFF counter Roll paper feed flag 1 Resets initial...

Page 44: ...l paper feed flag 0 A 3 Yes Cleaning forced termination No B 1 Roll motor rotation 4412 EP PF Motor stop Final cut line during feeding 1 Cuts paper Top end cut position or normal cut position Check if...

Page 45: ...vice Manual Figure 2 18 Power Off Sequence 2 Checks if Cap is applied when the printer starts Yes Pause operation No B 1 B 1 Power off time RTC Yes Sensor system Power system 42V OFF B 2 B 2 No B Chec...

Page 46: ...C H A P T E R 3 TROUBLESHOOTING...

Page 47: ...code When diagnosing failures from the lighting error code see 3 4 Troubleshooting by Error code p58 Diagnosing Failures by Fault Symptoms When diagnosing failures by fault symptoms see 3 5 Error and...

Page 48: ...ntermittent 3 Set specified roll paper Skew error Off On Intermittent 3 Remove paper and insert it again Ink end error Off On On 1 Intermittent 3 Replace the corresponding color s Ink Cartridge with a...

Page 49: ...ew one P 103 Maintenance cartridge CSIC Read Write error Off On On Intermittent 3 1 Replace the Maintenance Cartridge with a new one 2 Replace the Maintenance Cartridge Cover with a new one P 103 Main...

Page 50: ...oubleshooting by Error Message 3 3 1 How to Check Error Message 1 Start the Printer Driver 2 Click Property 3 Click Display Printer Status 4 Printer window appears Figure 3 1 Error Screen Printer wind...

Page 51: ...ace parts Ink Suction Pump Contact a technical representative You cannot print if parts have reached the end of their service life The replacement time of Ink Suction Pump Unit 1 Replace the Capping U...

Page 52: ...ed correctly Delete all print jobs remaining in the operating system s print queue Check the positions of the edge guides and then reload the paper Roll paper is not correctly installed Reset the roll...

Page 53: ...p Cover open Top Cover open Delete all print jobs remaining in the operating system s print queue Close the Top Cover The Top Cover is open The Top Cover Open Sensor is broken 1 Close the Top Cover 2...

Page 54: ...all nozzle clogging Cannot perform Detect Clogging correctly Delete all print jobs remaining in the operating system s print queue Perform Diagnostic Cleaning Contact service support if the error con...

Page 55: ...aintenance Cartridge not installed error Maintenance Cartridge not installed Delete all print jobs remaining in the operating system s print queue Install the Maintenance Cartridge The Maintenance Car...

Page 56: ...he product No communication between the Printer and the PC Re install the Printer Driver Select an available printer correctly in the printer driver settings W 5104 Offline Windows only Not ready You...

Page 57: ...er of the Ink Cartridge Holder P 219 E 2104 Suction Pump maintenance error Parts have reached the end of their service life Ink Suction Pump Contact a technical representative Delete all print jobs re...

Page 58: ...00 Service Manual 3 4 Troubleshooting by Error code When an error occurs the following error screen will be displayed the Error History on the Service Program see 5 2 10 Error History p225 Figure 3 2...

Page 59: ...objects on the roll Error reoccurs Replace the Cutter Unit with a new one P 163 1004 5V controller FAN lock error Cooling Fan 5V is not rotating 1 Check the connection between the Cooling Fan 5V and...

Page 60: ...the CR Motor and Main Board CN200 1 Replace the CR Unit with a new one P 124 2 Replace the CR Motor with a new one P 196 3 Replace the Printer with a new one 1139 Oscillation error The direction of th...

Page 61: ...ing direction Irregular load CR encoder sensor failure CR Motor failure CR Motor driver failure 1 Carry out Motor Measurement Adjustment to check if the CR Motor functions normally P 270 1 Replace the...

Page 62: ...2 Replace the PF Encoder Sensor with a new one P 165 122D PF Motor driving time out error Detects that the driving period is irregularly long Irregular load The firmware has a defect Replace the Main...

Page 63: ...annot detect its origin APG position sensor failure APG Motor failure 3 UR Unit is not moved to the PG adjustment position FFC connection failure 1 Check the connection between the APG position sensor...

Page 64: ...116 CN206 Take away the foreign objects Error reoccurs Replace the Main Board with a new one P 107 Replace the Roll motor with a new one P 198 152D Roll motor driving time out error Detects that the d...

Page 65: ...ts Error reoccurs Replace the Main Board with a new one P 107 Replace the Cutter Unit with a new one P 163 1549 Cutter motor disconnection error The direction of the electric current flowing in the Cu...

Page 66: ...w one P 163 154F Cutter motor lock error The direction of the electric current flowing in the Cutter motor repeats reversing in the set frequency Motor driver failure Encoder failure Motor failure 1 C...

Page 67: ...ion pump motor driving time out error Detects that the driving period is irregularly long Irregular load The firmware has a defect Replace the Main Board with a new one P 107 155E Decompression pump m...

Page 68: ...ard failure 1 Turn the power off once and turn it back on to check if the printer recovers from the error Ignore it if the error does not occur again 2 Check the connection between the Heater Unit and...

Page 69: ...FC if there is any loose or slant connection or ripped terminals or the breaking of the FFC 1 Replace the Head FFC with a new one P 122 2 Replace the Print Head with a new one P 120 3 If the printer d...

Page 70: ...als or the breaking of the FFC CN401 Check the connection between the Right Ink Cartridge Holder and the Main Board if there is any loose or slant connection or ripped terminals or the breaking of the...

Page 71: ...he Main Board with a new one P 107 Dxxy Service call for FW debugging This is an error for debugging in the design stage However it may occur due to unexpected reasons such as external noises Turn the...

Page 72: ...r still does not recover replace Power Distribution Board P 111 3 If the printer still does not recover replace Power Supply Board P 111 Printer not Recognized by Computer Connection cable is not plug...

Page 73: ...nozzles Perform Head Cleaning P 222 The pump is not operating normally Check the connection of the pump tube of Capping Unit Check if there is any broken or pressed part on the pump tube of Capping U...

Page 74: ...SMAP Roller with a new one if any contamination or scratch is found P 156 1 Replace the Paper Feed Encoder Sensor if any abnormality is found P 165 1 Perform the Motor Measurement PF Motor P 270 2 Per...

Page 75: ...ore repairing and click Run in the IES Detection Flag P 223 3 Eject ink P 272 4 Turn off the printer 5 Replace the Ink Cartridge Holder P 175 P 179 6 Turn on the printer and start the Initial Charge a...

Page 76: ...C H A P T E R 4 DISASSEMBLY ASSEMBLY...

Page 77: ...printer make sure to connect the connectors of the electric components or parts correctly and securely Use extreme care when connecting FFCs flexible flat cables Improper connection of the FFCs such...

Page 78: ...8 4 1Overview DX100 Service Manual 4 1 2 Orientation Definition Figure 4 1 Orientation Definition 4 1 3 Recommended Tools See 7 1 Service Tool p297 Top Bottom Front Rear Right Home side Left Full side...

Page 79: ...ts 1 Figure 4 2 Parts Diagram Exterior Parts 1 Right Frame p102 Left Frame p102 Upper Cover p100 Left IC Holder Cover p98 Trimmed Waste Paper Box p98 Rear Frame p101 Right IC Holder Cover p99 Top Cove...

Page 80: ...Diagram Electric Circuit Components AID Unit p113 Main Board p107 Heater Board p109 Power Supply Board p111 Power Distribution Board p111 Cooling Fan 5V p187 Cooling Fan 24V p188 Heater Unit p192 Lef...

Page 81: ...m DX100 Service Manual Carriage Related Parts Figure 4 4 Parts Diagram Carriage Mechanism APG Unit p128 Head FFC p122 CR Unit p124 Self Sealing Valve p116 Print Head p120 CR Scale p123 CR Timimg Belt...

Page 82: ...rts Diagram DX100 Service Manual Paper Feed Mechanism 1 Figure 4 5 Parts Diagram Paper Feed Mechanism 1 Middle Roller p150 Middle Paper Guide p149 SMAP Roller p156 U Guide p148 Release Unit p152 PF Mo...

Page 83: ...0 Service Manual Paper Feed Mechanism 2 Figure 4 6 Parts Diagram Paper Feed Mechanism 2 EJ Frame Unit p153 Cutter Unit p163 Upper Platen Unit p158 Lower Platen Unit p159 Upper Paper Guide Unit p155 Dr...

Page 84: ...ram Paper Feed Mechanism 3 Roll Width Guide Unit p139 Upper Roll Guide A p138 Upper Roll Guide B p138 Paper Width Guide Unit p139 Paper Width Guide p148 Inlet Roller p146 Driven Roller 2 p142 Driven R...

Page 85: ...Encoder Sensor p165 PE Sensor Unit p171 Inlet Paper Edge Sensor p166 Roll Motor p198 Left IC Holder Cover Open Sensor p168 Trimmed Waste Paper Box Open Sensor p169 Right IC Holder Cover Open Sensor p1...

Page 86: ...rvice Manual Ink System Mechanism Figure 4 9 Parts Diagram Ink System Mechanism Capping Unit p182 Left Ink Tube p186 Ink Tube Joint p174 Decompression Pump Unit p181 Left Ink Cartridge Holder p175 Rig...

Page 87: ...sembly Flowchart Housing Top Cover p97 Start Left IC Holder Cover p98 Rear Frame p101 Upper Cover p100 Left Frame p102 Right Frame p102 Trimmed Waste Paper Box p98 Maintenance Cartridge Cover p103 Tri...

Page 88: ...t Rear Frame p101 Upper Cover p100 Left Frame p102 AID Unit p113 Left Frame p102 Main Board p107 Cooling Fan 24V p188 Trimmed Waste Paper Box p98 Front Cover p100 Left Heater Duct Right Heater Duct p1...

Page 89: ...Flowchart Carriage Mechanism Top Cover p97 Start Rear Frame p101 Upper Cover p100 Trimmed Waste Paper Box p98 Front Cover p100 Self Sealing Valve p116 Print Head p120 CR Unit CR Timimg Belt p124 Head...

Page 90: ...tart Trimmed Waste Paper Box p98 Roll Unit p130 Inlet Roller p146 Driven Roller 1 p141 Paper Width Guide Unit p139 Decurl Roller p140 Paper Width Guide p148 Feed Roller 1 p143 Roll Width Guide Unit p1...

Page 91: ...der p154 Middle Paper Guide p149 PE Sensor Unit p171 Driven Release Holder p154 Upper Paper Guide Unit p155 Upper Platen Unit p158 PF Encoder Sensor p165 SMAP Roller p156 APG Unit p128 APG Unit p128 E...

Page 92: ...rimmed Waste Paper Box p98 Roll Unit p130 Slack Sensor Unit p167 Top Cover Open Sensor p164 PE Sensor Unit p171 Rear Frame p101 PF Encoder Sensor p165 Rear Cover Open Sensor p170 Left IC Holder Cover...

Page 93: ...Rear Frame p101 Left Frame p102 Left Ink Cartridge Holder p175 Decompression Pump Unit p181 Right Ink Cartridge Holder p179 Top Cover p97 Upper Cover p100 Maintenance Cartridge Cover p103 Right IC Ho...

Page 94: ...3 Left Frame p102 Rear Cover p99 Left IC Holder Cover p98 Right IC Holder Cover p99 Front Cover p100 Maintenance Cartridge Cover p103 Self Sealing Valve p116 Print Head p120 Left Heater Duct Right Hea...

Page 95: ...rts that can not be removed for the reason to maintain the quality of the product Make sure to check the following table of contents before disassembling the printer Figure 4 18 Parts cannot be remove...

Page 96: ...CR Unit using the Service Program See 5 4 6 Release Carriage Lock p242 Unlocking the CR Unit manually Unlock the CR Unit by turning the gear of the Capping Unit clockwise using a precision flat blade...

Page 97: ...ce Program see 5 6 3 1 Ink Discharge p272 4 5 2 Housing 4 5 2 1 Top Cover 1 Remove the Top Cover while sliding toward you Figure 4 20 Removing the Top Cover Parts Reference Self Sealing Valve p116 Ink...

Page 98: ...Trimmed Waste Paper Box toward you Figure 4 21 Removing the Trimmed Waste Paper Box 4 5 2 3 Left IC Holder Cover 1 Open the Left IC Holder Cover 2 Disengage the two tabs and remove the Left IC Holder...

Page 99: ...nd remove the Right IC Holder Cover Figure 4 23 Removing the Right IC Holder Cover 4 5 2 5 Rear Cover 3 Open the Rear Cover while holding the lock lever 4 Release the two tabs on the full side while h...

Page 100: ...s Figure 4 25 Removing the Upper Cover 4 5 2 7 Front Cover 1 Remove the Top Cover P 97 2 Remove the Upper Cover P 100 3 Remove the Trimmed Waste Paper Box P 98 4 Open the Left IC Holder Cover and Righ...

Page 101: ...onnectors Figure 4 27 Releasing the cable 4 5 2 8 Rear Frame 1 Remove the Top Cover P 97 2 Remove the Upper Cover P 100 3 Remove the six screws and remove the Rear Frame A Silver M3x6 S tite screw six...

Page 102: ...g the Left Frame 4 5 2 10 Right Frame 1 Remove the Top Cover P 97 2 Remove the Upper Cover P 100 3 Remove the Rear Frame P 101 4 Remove the six screws and remove the Right Frame A Silver M3x6 S tite s...

Page 103: ...t Heater Duct Right Heater Duct Step10 p190 9 Disconnect the FFC from the connector CN402 of the Main Board 10 Release the FFC from the two clamps 11 Peel off the FFC Figure 4 31 Removing the Maintena...

Page 104: ...topper then remove the two waste ink tube from the tube stopper 17 Slide the Maintenance Cartridge Cover in the direction of the arrow and remove it Figure 4 33 Removing the Maintenance Cartridge Cove...

Page 105: ...groove of the lower guide Route the decompression tube on the groove of the Maintenance Cartridge Cover Attach the FFC aligning the tab of the Maintenance Cartridge Cover with double sided tape Tab Ta...

Page 106: ...nter power OFF do not unplug the printer AC cable during power LED flashes Table 4 1 Board Name Function List Name Function Reference Main Board CD27 MAIN Controls the motors Controls the sensors Cont...

Page 107: ...disconnecting the cable 4 6 Connector Position Main Board p205 9 Peel off the FFC of the Right Ink Cartridge Holder 10 Remove the four screws that secure the main board fixing plate A Silver M3x6 Bind...

Page 108: ...M3x6 Bind machine screw six pieces D Silver M3x6 S tite screw one piece Figure 4 35 Removing the Main Board 14 Update the firmware only replacement P 229 15 Restore the NVRAM data only replacement P 2...

Page 109: ...efore disconnecting the cable 4 6 Connector Position Heater Board p206 7 Remove the four screws that secure the heater board fixing plate A Silver M3x6 Bind machine screw four pieces 8 Release the cab...

Page 110: ...ssembly and Assembly Procedure DX100 Service Manual 9 Remove the six screws and remove the Heater Board B Silver M3x6 Bind machine screw six pieces Figure 4 37 Removing the Heater Board B B B B B B He...

Page 111: ...d Be sure to unlock the connector CN1 before disconnecting the cable 4 6 Connector Position Power Supply Board p207 8 Unlock all the connectors of the cables connected to the Power Distribution Board...

Page 112: ...wer Supply Board B Silver M3x6 Bind machine screw six pieces 11 Remove the four screws and remove the Power Distribution Board C Silver M3x6 Bind machine screw four pieces Figure 4 39 Removing the Pow...

Page 113: ...128 Step 5 p128 7 Remove the two screws and remove the AID upper plate A Silver M3x6 S tite screw one piece B Silver M3x6 P tite screw one piece Figure 4 40 Removing the AID upper plate W A R N I N G...

Page 114: ...ews that secure the AID Unit D Silver M3x6 S tite screw three pieces 10 Release the cable from the wire saddle 11 Remove the AID Unit downward Figure 4 41 Removing the AID Unit 1 Make sure the termina...

Page 115: ...ter installing the AID Unit confirm the following Route the cable of the Heater Unit blue under the cables Secure the cable of the Heater Unit blue with two clamps of the Left Ink Cartridge Holder A D...

Page 116: ...ter lower cover 4 5 8 3 Left Heater Duct Right Heater Duct Step6 p189 to Step 7 p189 7 Remove the screw that secure the CR frame cover A Silver M3x6 S tite screw one piece 8 Insert a flat blade screwd...

Page 117: ...te 1 11 Disengage the two hooks and remove the grounding plate 12 Release the sheet first from the hook of the tube fixing plate and remove the two sheets and SUS plate 13 Remove the Head FFC 14 Relea...

Page 118: ...4 46 Removing the Self Sealing Valve 1 17 Remove the two screws that secure the Self Sealing Valve C Silver M2 6x8 P tite screw two pieces Figure 4 47 Removing the Self Sealing Valve 2 C A U T I O N...

Page 119: ...e Ink Tube make sure the O ring is attached to it O ring Ink Tube D D Attach the harness holder in the following order 1 Mark the Ink Tube at the point right next to the screw hole on the CR frame cov...

Page 120: ...M2 6x8 P tite screw three pieces 9 Disconnect the Head FFC from the Print Head while lifting the Print Head and remove the Print Head Figure 4 49 Removing the Print Head C A U T I O N When connecting...

Page 121: ...ad in the direction of the arrow and then secure it with the two screws Secure the screws in the order shown in Figure 4 49 A D J U S T M E N T R E Q U I R E D Carry out the adjustments referring to 5...

Page 122: ...P 101 8 Remove the clamp sheet 4 5 4 6 APG Unit Step3 p128 9 Disconnect the FFC from the connector of the CR encoder sensor 10 Release the Head FFC from the three tabs of the APG Unit 11 Peel off the...

Page 123: ...rees upward and remove it from the hook of the frame Figure 4 51 Removing the CR Scale C A U T I O N Take care not to bend the CR Scale when removing installing it because it is fragile When handling...

Page 124: ...the main press torsion spring and sub press torsion spring Figure 4 52 Removing the Main press torsion spring Sub press torsion spring 10 Remove the screw and remove the driven pulley holder stopper A...

Page 125: ...two PG cam bushings 16 Remove the spring and remove the right CR scale mount plate Figure 4 54 Removing the Right CR scale mount plate When installing the PG cam install it in the order shown below C...

Page 126: ...shown in the figure and remove it 21 Remove the CR belt holder from the CR Unit 22 Remove the CR Timimg Belt from the CR belt holder Figure 4 56 Removing the CR Timimg Belt CR Unit Driven pulley CR ma...

Page 127: ...ned with the holes on the frame using the cut washers 4 Secure the center of spur gear with cut washer Lubrication Lubrication Lubricate the parts before installing the CR Unit referring to 6 3 Lubric...

Page 128: ...Figure 4 57 Removing the Clamp sheet FFC guide frame 6 Release the FFC of the PF Encoder Sensor from the four tabs of the APG Unit 7 Disconnect the cable of the APG Motor from the relay connector 8 D...

Page 129: ...Lubrication Lubrication Lubricate the parts before installing the APG Unit referring to 6 3 Lubrication p280 when the APG Unit is replaced A D J U S T M E N T R E Q U I R E D Carry out the adjustment...

Page 130: ...5 Paper Feed Mechanism 4 5 5 1 Roll Unit 1 Remove the Trimmed Waste Paper Box P 98 2 Pull out the Roll Unit 3 Remove the two screws and remove the two stoppers A Silver M3x6 S tite screw two pieces F...

Page 131: ...step do not pull away the sheet too far or the hook on the sheet may be damaged Sheet Hooks When the Roll Unit is replaced with a new one remove the Intermediate Slide Rail P 132 from the existing Ro...

Page 132: ...the six screws and remove the two Intermediate Slide Rail from the Roll Unit A Silver M3x5 Cup S tite screw six pieces Figure 4 61 Removing the Intermediate Slide Rail C A U T I O N When the Intermed...

Page 133: ...tall the Intermediate Slide Rail to the Roll Unit in the following order 1 Press down the Intermediate Slide Rail 2 Pull the Intermediate Slide Rail in the front side direction 3 Tighten three screws...

Page 134: ...Step1 to Step4 to install the Intermediate Slide Rail on the right side of the Roll Unit Figure 4 65 Attaching the Intermediate Slide Rail 3 Step 3 1 Step 3 2 Dowel Make sure the dowel of the Roll Un...

Page 135: ...screw one piece Figure 4 66 Removing the Slack Sensor Unit Support 5 Remove the six screws and remove the two External Slide Rail Internal Slide Rail B Silver M3x4 machine screw six pieces Figure 4 67...

Page 136: ...stall the External Slide Rail to the printer in the following order 1 Pull the External Slide Rail in the front side direction 2 Tighten three screws in the order shown in Figure 4 70 while pressing d...

Page 137: ...me 5 Repeat Step1 to Step4 to install the External Slide Rail on the right side of the printer Figure 4 71 Removing the External Slide Rail 2 TBD Step 3 2 Step 3 1 Dowel 1 2 3 Screw Screw Screw Extern...

Page 138: ...age the two tabs at the right side and remove the Upper Roll Guide A Figure 4 72 Removing the Upper Roll Guide A 4 5 5 4 Upper Roll Guide B 1 Remove the Trimmed Waste Paper Box P 98 2 Remove the Roll...

Page 139: ...idth Guide Unit from the two grooves of the Roll Unit then remove the Paper Width Guide Unit in the direction of the arrow Figure 4 74 Removing the Paper Width Guide Unit 4 5 5 6 Roll Width Guide Unit...

Page 140: ...r Step4 p173 5 Remove the screw and remove the frame B Silver M3x6 Bind machine screw one piece Figure 4 76 Removing the frame 6 Remove the two torsion springs Figure 4 77 Removing the torsion spring...

Page 141: ...three pieces Figure 4 79 Removing the frame 4 Remove the two torsion springs Figure 4 80 Removing the torsion spring 5 Release both ends of the Driven Roller 1 from the holes on the right and left of...

Page 142: ...t P 139 4 Remove the two torsion springs Figure 4 82 Removing the frame 5 Release both ends of the Driven Roller 2 from the holes on the right and left of the frame Figure 4 83 Removing the Driven Rol...

Page 143: ...ear 6 Release the tab of the bush and remove the bush by rotating it in the direction of arrow Figure 4 84 Removing the gear 7 Remove the Cut washer and remove the handle Figure 4 85 Removing the hand...

Page 144: ...ease both ends of the Feed Roller 1 from the holes on the right and left of the frame 13 Remove the E ring and the plastic washer from the Feed Roller 1 Figure 4 87 Removing the Feed Roller 1 2 Parall...

Page 145: ...and remove the bush by rotating it in the direction of arrow Figure 4 88 Removing the gear 7 Remove the E ring remove the washer disc spring and plastic washer 8 Release the tab of the bush and remove...

Page 146: ...ve the Roll Unit P 130 3 Release the tab of the bush and remove the bush by rotating it in the direction of arrow Figure 4 91 Removing the bush 4 Remove the E ring remove the gear washer disc spring a...

Page 147: ...en the Upper Roll Guide A 8 Release both ends of the Inlet Roller from the holes on the right and left of the frame 9 Remove the E ring and the plastic washer from the Inlet Roller Figure 4 94 Removin...

Page 148: ...h Guide and the support guide A Silver M3x8 P tite screw two pieces Figure 4 95 Removing the Paper Width Guide 4 5 5 10 U Guide 1 Remove the Top Cover P 97 2 Remove the Rear Cover P 99 3 Remove the Up...

Page 149: ...Remove the U Guide P 148 7 Remove the APG Unit P 128 8 Remove the Driven release holder P 154 9 Remove the PE Sensor Unit P 171 10 Remove the Upper Paper Guide Unit P 155 11 Disengage the four tabs a...

Page 150: ...152 6 Remove the U Guide P 148 7 Remove the APG Unit P 128 8 Remove the Driven release holder P 154 9 Remove the PE Sensor Unit P 171 10 Remove the Upper Paper Guide Unit P 155 11 Remove the Middle P...

Page 151: ...151 4 5Disassembly and Assembly Procedure DX100 Service Manual 14 Release the Middle Roller from the holes on the frame and remove it Figure 4 99 Removing the Middle Roller 2 Hole Hole Middle Roller...

Page 152: ...M3x5 S tite screw four pieces 6 Release the cables of the Release Unit PE Sensor Unit and APG position sensor from the five tabs of the Release Unit 7 Press the two tabs on the Release Unit to releas...

Page 153: ...over P 100 3 Remove the Trimmed Waste Paper Box P 98 4 Remove the Front Cover P 100 5 Remove the Self Sealing Valve P 116 6 Remove the Print Head P 120 7 Remove the CR Unit P 124 8 Remove the two scre...

Page 154: ...lease Holder C A U T I O N In the following procedure be careful not to lose the parallel pin because it may drop off when sliding the Driven Release Holder Install the Driven Release Holder with its...

Page 155: ...it P 171 10 Remove the four PF spring from the four Upper Paper Guide Unit in the direction of the arrow 11 Lift the front side of the Upper Paper Guide Unit and slide it to the rear of the printer to...

Page 156: ...171 10 Remove the Upper Paper Guide Unit P 155 11 Remove the EJ Frame Unit P 153 12 Remove the Upper Platen Unit P 158 13 Remove the PF Encoder Sensor P 165 14 Remove the AID Unit 4 5 3 5 AID Unit St...

Page 157: ...e sure of the following Prevent the coated surface of the SMAP Roller from being scratched Do not touch the coated surface of the SMAP Roller with bare hands Be careful not to bend the PF scale SMAP R...

Page 158: ...13 Remove the screw and remove the cable of the AID Unit A Silver M3x6 P tite screw one piece 14 Disengage the tab of the Upper Platen Unit from the positioning hole of the Upper Platen Unit 15 Relea...

Page 159: ...Remove the Driven release holder P 154 9 Remove the PE Sensor Unit P 171 10 Remove the Upper Paper Guide Unit P 155 11 Remove the EJ Frame Unit P 153 12 Remove the Upper Platen Unit P 158 13 Remove t...

Page 160: ...moving the Lower Platen Unit 3 20 Remove the two E rings and remove the two washers and two disc springs from the front EJ roller and rear EJ roller 21 Disengage the tabs of the two right bushes Figur...

Page 161: ...he holes on the right and left of the frame Figure 4 113 Remove the Lower Platen Unit 3 23 Remove the two screws that secure the Lower Platen Unit A Silver M3x8 P tite screw one piece B Silver M3x8 S...

Page 162: ...oving the Lower Platen Unit 4 C A U T I O N Do not remove the Front EJ roller See 4 4 Parts that Cannot be Removed p 95 Lower Platen Unit Front EJ roller Insert the porous pad of the Lower Platen Unit...

Page 163: ...4 5 8 3 Left Heater Duct Right Heater Duct Step10 p190 8 Remove the four screws that secure the Cutter Unit A Silver M3x6 Bind machine screw four pieces 9 Remove the two relay connectors 10 Release th...

Page 164: ...per Cover P 100 3 Disconnect the cable from the connector of the sensor 4 Remove the screw and remove the frame A Silver M3x6 S tite screw one piece Figure 4 117 Removing the frame 5 Disengage the two...

Page 165: ...9 Removing the PF Encoder Sensor 1 7 Disconnect the FFC from the connector CN110 of the Main Board 8 Remove the FFC Figure 4 120 Removing the PF Encoder Sensor 2 FFC Tab A Tab Tabs PF Encoder Sensor A...

Page 166: ...Unit P 130 3 Remove the screw and remove the frame A Silver M3x6 S tite screw one piece 4 Disconnect the cable from the connector of the sensor Figure 4 121 Removing the frame 5 Disengage the four ho...

Page 167: ...Box P 98 2 Remove the Roll Unit P 130 3 Disconnect the cable from the connector of the sensor 4 Release the cable from the mini clamp 5 Remove the screw and remove the Slack Sensor Unit A Silver M3x6...

Page 168: ...e Front Cover P 100 5 Disengage the two hooks and remove the sensor 6 Disconnect the cable from the connector of the sensor Figure 4 124 Removing the Left IC Holder Cover Open Sensor Right IC Holder C...

Page 169: ...ste Paper Box P 98 4 Remove the Front Cover P 100 5 Remove the Left Heater Duct Right Heater Duct P 189 6 Remove the Cutter Unit P 163 7 Remove the Heater Unit P 192 8 Disengage the two hooks and remo...

Page 170: ...ve the screw and remove the frame A Silver M3x6 S tite screw one piece Figure 4 126 Removing the Rear Cover Open Sensor 1 6 Disengage the two hooks and remove the sensor Figure 4 127 Removing the Rear...

Page 171: ...the PE holder 9 Release the PE Sensor Unit from the frame while sliding the PE Sensor Unit in the direction of the arrow Figure 4 128 Removing the PE Sensor Unit 1 10 Release the cable from the tab of...

Page 172: ...P tite screw eleven pieces 4 Remove the screw and remove Roll Set Sensor from the grounding plate B Silver M3x6 S tite screw one piece Figure 4 130 Removing the sheet 5 Disconnect the cable from the c...

Page 173: ...o screws and remove the grounding wire and Roll End Sensor B Silver M3x6 S tite screw one piece C Silver M3x6 P tite screw one piece Figure 4 132 Removing the sheet 5 Remove the grounding plate 6 Disc...

Page 174: ...e two screws and remove the Right Ink Tube C Silver M2 5x12 Bind machine screw two pieces Figure 4 134 Removing the Ink Tube Joint 11 Remove the three O rings from the Ink Tube Joint Figure 4 135 Remo...

Page 175: ...e 4 136 Releasing the cable 1 11 Release the cable of the decompression pump from the three clamps and wire saddle 12 Disconnect the cable from the connector of the decompression pump sensor 13 Discon...

Page 176: ...Remove the supply pipe from the frame 20 Remove the tubes of the Left Ink Cartridge Holder and Decompression Pump Unit Figure 4 139 Releasing the tube Tilt the supply pipe at a 45 degree angle and in...

Page 177: ...ge Holder 23 Place the Left Ink Cartridge Holder beside the printer Figure 4 140 Removing the Left Ink Cartridge Holder 1 24 Remove the two screws and remove the Left Ink Tube and the O ring D Silver...

Page 178: ...en connecting the cables to the Ink end sensors make sure the cables and connectors are correct by checking the tags Red line Left Ink Tube Ink end sensor Tag Tag Tag Route the cable of the Heater Uni...

Page 179: ...Step 8 p116 10 Remove the Tube fixing plate 4 5 4 1 Self Sealing Valve Step9 p117 to Step 10 p117 11 Disconnect the cable from the three Ink end sensors Figure 4 142 Releasing the cable 12 Remove the...

Page 180: ...Figure 4 144 Removing the Right Ink Cartridge Holder 2 Right Ink Cartridge Holder Right Ink Tube When connecting the cables to the Ink end sensors make sure the cables and connectors are correct by c...

Page 181: ...t Ink Cartridge Holder beside the printer 4 5 7 2 Left Ink Cartridge Holder Step6 p175 Step 23 p177 7 Remove the three screws and remove the Decompression Pump Unit A Silver M3x12 Cup S tite screw thr...

Page 182: ...02 6 Remove the Maintenance Cartridge Cover P 103 7 Remove the Trimmed Waste Paper Box P 98 8 Remove the Front Cover P 100 9 Disconnect the cable of the Capping Unit from the connector CN203 of the Ma...

Page 183: ...ng Unit 1 13 Slide the Capping Unit to frontward Figure 4 148 Removing the Capping Unit 2 Attach the three tabs of the Capping Unit to the three positioning holes of the frame See Figure 4 147 After i...

Page 184: ...5 Move the Capping Unit in the direction of the arrow and remove the Capping Unit downward Figure 4 149 Removing the Capping Unit 3 16 Slide the Capping Unit in the direction of the arrow Figure 4 150...

Page 185: ...d Assembly Procedure DX100 Service Manual A D J U S T M E N T R E Q U I R E D Carry out the adjustments referring to 5 1 2 Adjustment Items and the Order by Repaired Part p210 when the Capping Unit is...

Page 186: ...Left Ink Tube from the two clamps 9 Remove the Ink Left Ink Tube and the O ring from the Tube Joint 4 5 7 1 Ink Tube Joint Step9 p174 Step 11 p174 Figure 4 152 Removing the Left Ink Tube C A U T I O...

Page 187: ...101 4 Remove the Left Frame P 102 5 Disconnect the cable from the connector CN26 of the Main Board 6 Release the cable from the wire saddle 7 Remove the two screws and remove the Cooling Fan 5V A Sil...

Page 188: ...e P 101 4 Remove the Left Frame P 102 5 Disconnect the cable from the connector CN24 of the Main Board 6 Release the cable from the clamp and the wire saddle 7 Remove the two screws and remove the Coo...

Page 189: ...tite screw three pieces Figure 4 155 Removing the heater upper cover 6 With a plate Remove the three screws and remove the plate B Silver M3x8 S tite screw with built in washer two pieces C Silver M3...

Page 190: ...e clamp 10 Remove the Left Heater Duct and the Right Heater Duct Figure 4 157 Removing the Left Heater Duct Right Heater Duct Insert the Left Heater Duct Right Heater Duct to the grooves of the cushio...

Page 191: ...uct P 189 6 Remove the two screws that secure the Right Heater Fan A Silver M3x35 P tite screw with built in washer two pieces 7 Remove the seal fan 8 Remove the Right Heater Fan Figure 4 158 Removing...

Page 192: ...r M3x6 S tite screw five pieces 9 Remove the screw that secure the grounding wire C Silver M4x5 S tite screw with external tooth washer one piece 10 Disconnect the relay connector at the left side 11...

Page 193: ...ce Manual 15 Move the heater Unit in the direction of the arrow and remove the heater Unit Figure 4 160 Removing the Heater Unit 2 When assemble the heater Unit the heater Unit drive gear do not touch...

Page 194: ...it with the two screws If no plate is mounted on the heater roller holder of the Heater Unit make sure to replace the heater lower cover with a new one together at this point secure it with two screws...

Page 195: ...Motor from the relay connector 10 Release the cable from the wire saddle 11 Remove the two screws and remove the reinforcement plate A Silver M3x6 Bind machine screw two pieces Figure 4 161 Removing t...

Page 196: ...t Step6 p189 to Step 7 p189 8 Remove the Right Heater Duct 4 5 8 3 Left Heater Duct Right Heater Duct Step10 p190 9 Disconnect the CR Motor cable from the connector CN200 of the Main Board 10 Release...

Page 197: ...al 12 Remove the CR Timimg Belt from the pinion gear of the CR Motor 4 5 4 5 CR Unit CR Timimg Belt Step10 p124 Step 12 p124 13 Remove the two screws and remove the CR Motor A Silver M3x4 machine scre...

Page 198: ...the Capping Unit P 182 19 Remove the AID Unit P 113 20 Remove the U guide P 148 21 Remove the Ink Tube Joint P 174 22 Remove the Roll Unit P 130 23 Remove the Slack Sensor Unit P 167 24 Release the L...

Page 199: ...s from the connectors of the Trimmed Waste Paper Box Open Sensor Left IC Holder Cover Open Sensor and Right IC Holder Cover Open Sensor 32 Release the cables from the six clamps 33 Pull out the cables...

Page 200: ...4 168 Releasing the cables 4 35 Release the cables from the four clamps Figure 4 169 Releasing the cables 5 36 Remove the six screws that secure the print unit A Silver M3x6 S tite screw six pieces 37...

Page 201: ...e DX100 Service Manual 38 Disconnect the cable from the connector 39 Remove the two screws and remove the Roll Motor B Silver M3x6 S tite screw six pieces Figure 4 171 Removing the Roll Motor B B Uppe...

Page 202: ...202 4 6Routing the cables and FFCs DX100 Service Manual 4 6 Routing the cables and FFCs 4 6 1 Left side Figure 4 172 Routing the cables and FFCs Left side...

Page 203: ...and FFCs DX100 Service Manual 4 6 2 Top left view on the rear Figure 4 173 Routing the cables and FFCs Top left on the rear 4 6 3 Bottom left view on the rear Figure 4 174 Routing the cables and FFCs...

Page 204: ...204 4 6Routing the cables and FFCs DX100 Service Manual 4 6 4 Top view on the rear Figure 4 175 Routing the cables and FFCs Top on the rear...

Page 205: ...r Roll Set Sensor Inlet Paper Edge Sensor Slack sensor Roll motor encoder CN114 10 White Ink end sensor right CN115 14 White Ink end sensor left Decompression Pump Unit encoder CN117 8 White Cutter ho...

Page 206: ...artridge CSIC CN501 14 Print Head CN502 14 Print Head CN503 14 Print Head CN504 14 Print Head Connector Pole Number Color Destination Connector Pole Number Color Destination CN1 2 White Power Distribu...

Page 207: ...d 4 7 4 Power Distribution Board Connector Pole Number Color Destination CN1 2 White Power Distribution Board CN5 6 White Main Board CN5 CN1 Connector Pole Number Color Destination CN1 2 White AC Inle...

Page 208: ...C H A P T E R 5 ADJUSTMENT...

Page 209: ...arts 5 1 1 Precautions Always observe the following cautions whenever making an adjustment on the printer C A U T I O N Always refer to 5 1 2 Adjustment Items and the Order by Repaired Part p210 and m...

Page 210: ...ad Incline Adjustment p231 Bi d Adjustment p233 Side Position Adjustment PW Sensor Adjustment p261 Image Quality Adjustment p238 Color Calibration Adjustment p243 Counter Reset p219 PF Adjustment p262...

Page 211: ...261 Image Quality Adjustment p238 Color Calibration Adjustment p243 Counter Reset p219 PF Adjustment p262 PF Belt Tension Adjustment p267 Motor Adjustment p270 APG Check p223 AID Inspection p224 Cut p...

Page 212: ...Reset p219 PF Adjustment p262 PF Belt Tension Adjustment p267 Motor Adjustment p270 APG Check p223 AID Inspection p224 Cut position Adjustment p269 APG Gear Phase Adjustment p266 NVRAM Data Backup Res...

Page 213: ...Nozzle Check Pattern Print p221 Head Cleaning p222 Head Incline Adjustment p231 Bi d Adjustment p233 Side Position Adjustment PW Sensor Adjustment p261 Image Quality Adjustment p238 Color Calibration...

Page 214: ...r remaining counter Save Restore Save restore the paper remaining value Yes No P 222 APG Check Execute the APG check Yes No P 223 AID Inspection Execute the AID Inspection Yes No P 224 Sensor Check Ch...

Page 215: ...ity Adjustment By printing while correcting the print setting value the amount of discharged ink per shot achieves both print quality to reduce banding according to the paper type and print resolution...

Page 216: ...on adjustments considering the heating value such as stopping the operation when the heating value reaches the specified level are executed The heating value is estimated from the power source charact...

Page 217: ...s Vista Windows 7 Windows 8 Windows 8 1 Interface USB Startup 1 Install the printer driver 2 Double click the DX100serviceprogram exe 3 When the LICENSE screen appears click OK Figure 5 1 LICENSE scre...

Page 218: ...n to confirm the following information Figure 5 3 Printer Status Table 5 5 Printer Status Item Explanation Status The status of the printer F W Ver Firmware version Ink Cyan Remaining ink level Magent...

Page 219: ...200 000 Decompression Pump Unit Pump operation time Capping Unit Ink Cartridge Holder Supplying suction operation Ink Tube 1 Select 1 Adjustment Maintenance Maintenance Counter Reset 2 Click Reset of...

Page 220: ...peration If the printer is turned off when this sequence is on the printer will be still in this sequence the next time the printer is turned on and will enter a stand by state To prevent this from ha...

Page 221: ...Nozzle Check Pattern Print 1 Select 1 Adjustment Maintenance Maintenance Nozzle Check Pattern Print 2 Click PRINT and print the nozzle check pattern Figure 5 6 Nozzle Check Pattern Print Screen Figur...

Page 222: ...te and click RUN Figure 5 8 Head Cleaning Screen 5 2 5 Paper remaining counter Save Restore 1 Select 1 Adjustment Maintenance Maintenance Paper remaining counter Save Restore 2 Click Save when saving...

Page 223: ...re that the status of the Current changed to Under repair 3 After replacing Ink Cartridge Holder make sure that Normal is displayed in the status of the Current Figure 5 10 IES Detection Flag Screen 5...

Page 224: ...ection AID Inspection 2 Click RUN Figure 5 12 AID Inspection Screen 3 If judged as NG re install the AID Unit and perform the AID Inspection again 5 2 9 Sensor Check 1 Select 3 Function Check Sensor C...

Page 225: ...dure of performing the Head Cleaning after Replacing Print Head 1 Select 6 Head Cleaning after Replacing Print Head 2 Click Run in the 1 Head Cleaning after Replacing Print Head It takes approx 10 min...

Page 226: ...arameters 3 Check the NVRAM information on site Click Disp Hist Info to display another screen of the NVRAM Viewer Store the NVRAM information Click Save The file is named as serial number acquisition...

Page 227: ...igure 5 17 Image Quality Adjustment Color Calibration Data Backup Restore screen 5 3 3 Serial No USB ID Input 1 Select 1 Adjust Maintenance Main board Exchange Serial No USB ID Input 2 Enter a serial...

Page 228: ...Service Manual 5 3 4 Initialize NVRAM 1 Select 1 Adjust Maintenance Main board Exchange Initialize NVRAM 2 Click Run Figure 5 19 Initialize NVRAM 1 3 Click OK on the message screen Figure 5 20 Initia...

Page 229: ...er are light and Firmware Update starts 5 All the LEDs of the printer are turned off and the Firmware Update is complete 6 Shut down the Service Program 7 Restart the printer Figure 5 21 Firmware Upda...

Page 230: ...rt the Service Program 5 Select 1 Adjust Maintenance Adjustment Head ID Input 6 Enter the ID into the edit boxes in the same way as indicated on the label Enter the digits continuously without pressin...

Page 231: ...ustment pattern Figure 5 24 Head Incline Adjustment screen 3 Measure the distance of overlapping section on each column using a scale loupe Figure 5 25 Head Incline Adjustment adjustment pattern 4 Ent...

Page 232: ...eck pattern 7 On the Pattern A and Pattern B make sure that the printed lines are overlapped Figure 5 27 Judgement of the Head Incline Check 8 If judged as NG re install the Print Head and perform Ste...

Page 233: ...ustment 2 Click Print to print the adjustment pattern Figure 5 28 Bi d Adjustment screen 3 Enter a number of the least gap pattern and then click Input 4 Perform Step 2 again and check the result Figu...

Page 234: ...ent Release Carriage Lock 6 Click Run to unlock the CR Unit 7 Set the thickness gauge to the position as shown Figure 5 32 Figure 5 32 PG Adjustment Mecha 1 8 Move the CR Timing Belt and slowly move t...

Page 235: ...the CR Unit comes over the thickness gauge approx 34 mm from the side of the CR Unit and to the end of gauge Top Front Print Head Thickness gauge Approx 34 mm CR Unit C H E C K P O I N T When it conta...

Page 236: ...4 Figure 5 34 PG Adjustment Mecha 3 14 Move the CR Timing Belt and slowly move the CR Unit to over the thickness gauge 15 When the platen gap is within standard go to Step 20 When the platen gap is ou...

Page 237: ...the CR Unit comes over the thickness gauge approx 30 mm from the side of the CR Unit and to the end of gauge Top Front Print Head Thickness gauge Approx 30 mm CR Unit C H E C K P O I N T When it conta...

Page 238: ...20 Remove the thickness gauge 21 Install the Upper Cover P 100 22 Install the Top Cover P 97 5 4 5 Image Quality Adjustment 1 Set the scanner on standby Refer to 7 1 Service Tool p297 for supported s...

Page 239: ...0 6 6 0 6 7 0 4 9 0 5 0 0 4 9 0 5 1 0 4 8 0 5 4 0 4 9 0 5 2 0 4 9 0 5 7 0 4 8 0 5 3 0 5 1 0 5 2 0 4 8 Cutoff line C A U T I O N Before performing the next step make sure to remove any foreign object...

Page 240: ...12 The correction value will be written C H E C K P O I N T Make sure of the following when setting the printed pattern Place the adjustment pattern with the characters toward you near the power swit...

Page 241: ...Set the adjustment pattern on the document glass correctly The setting position of the SCANNER ADJUSTMENT JIG is wrong Set the SCANNER ADJUSTMENT JIG on the document glass correctly Dirt foreign mater...

Page 242: ...iage Related Adjustment DX100 Service Manual 5 4 6 Release Carriage Lock 1 Select 1 Adjust Maintenance Adjustment Release Carriage Lock 2 Click RUN to unlock the CR Unit Figure 5 41 Release Carriage L...

Page 243: ...1Pro2 from X Rite The i1Sis from X Rite When using a color measurement device install the software for the measurement device in advance on the PC Do not touch the printable side of the correction cha...

Page 244: ...nt DX100 Service Manual 5 When the confirmation screen appears click Yes Figure 5 44 Confirmation screen 6 The connection printer screen appears Figure 5 45 Connection printer screen 7 The main screen...

Page 245: ...e 5 47 Condition Setting screen 11 The Heater Unit starts operating and the status on the main screen changes to ON 12 Confirm the status on the main screen changes to the following See Figure 5 46 13...

Page 246: ...246 5 4Carriage Related Adjustment DX100 Service Manual Correction chart i1 i1Pro i1Pro2 Figure 5 49 Correction chart i1 i1Pro i1Pro2 1 Figure 5 50 Correction chart i1 i1Pro i1Pro2 2...

Page 247: ...247 5 4Carriage Related Adjustment DX100 Service Manual Figure 5 51 Correction chart i1 i1Pro i1Pro2 3 Figure 5 52 Correction chart i1 i1Pro i1Pro2 4 matte paper...

Page 248: ...248 5 4Carriage Related Adjustment DX100 Service Manual Correction chart i1iSis Figure 5 53 Correction chart i1iSis 1 Figure 5 54 Correction chart i1iSis 2...

Page 249: ...249 5 4Carriage Related Adjustment DX100 Service Manual Figure 5 55 Correction chart i1iSis 3 Figure 5 56 Correction chart i1iSis 4 matte paper...

Page 250: ...the drying time displayed on status x Figure 5 58 Drying waiting time screen 18 Cut off the correction chart along the cutoff line Figure 5 59 Cut line of the correction chart C H E C K P O I N T Dry...

Page 251: ...e 5 46 5 When the confirmation screen appears click Yes Figure 5 62 Confirmation screen 6 Place the correction chart that matches the color chart ID and preset ID displayed on the screen on the measur...

Page 252: ...or measurement device to the measurement ruler being used hold down the button on the side and slowly move over the patch to scan When performing color measurement with Spot Scan adjust the measuremen...

Page 253: ...rrection chart is read When reading fails an is displayed on the screen where the correction chart is read In this case try reading again 11 When color measurement is complete click OK 12 Perform colo...

Page 254: ...46 4 When the confirmation screen appears click Yes Figure 5 68 Confirmation screen 5 When the screen is displayed check that the light on the right of the color measurement device is flashing green...

Page 255: ...e 5 71 Measure color screen 8 Perform color measurement three sheets of correction chart in the same manner as Step 5 to Step 7 9 When the confirmation screen appears click OK Figure 5 72 Confirmation...

Page 256: ...value 1 Click Write to Printer on the main screen See Figure 5 46 2 When the confirmation screen appears click Yes Figure 5 73 Confirmation screen 3 The correction value making screen appears 4 The c...

Page 257: ...rts 1 In the Print the Keep Sample column click Write to Printer See Figure 5 46 2 When the confirmation screen appears click OK Figure 5 74 Confirmation screen 3 The three sample correction charts ar...

Page 258: ...The drying waiting time appears and check the drying time displayed on status See Figure 5 58 6 Cut off the correction chart along the cut line See Figure 5 59 7 In the Check the precision column clic...

Page 259: ...Driven Pulley ASSY Gap Adjustment 5 4 9 CR Scale Gear Position Adjustment 1 Remove the Top Cover P 97 2 Remove the Upper Cover P 100 3 Remove the cut washer and remove the center of spur gear 4 Insta...

Page 260: ...Related Adjustment 5 5 1 PG Adjustment PW Sensor Adjustment 1 Select 1 Adjust Maintenance Adjustment PG Adjustment 2 Click RUN Figure 5 79 PG Adjustment PW Sensor Adjustment screen 3 If judged as NG r...

Page 261: ...nt is not necessary 4 Enter the measured values into the boxes in the PW Sensor Adjustment and the click Input Side HOME enter the value measured at the Home side Side FULL enter the value measured at...

Page 262: ...Refer to 7 1 Service Tool p297 for supported scanners 2 Connect the scanner with the PC and install the scanner driver on the computer 3 Select 1 Adjust Maintenance Adjustment Auto PF Adjustment 4 Sel...

Page 263: ...e concave of the scale Figure 5 85 Setting the Printed Pattern 2 C A U T I O N Before performing the next step make sure to remove any foreign object or dust from the document glass with a soft cloth...

Page 264: ...gure 5 86 Setting the Printed Pattern 3 10 Click Scan to scan the adjustment pattern See Figure 5 37 11 The correction value will be written C H E C K P O I N T If there is something wrong with the sc...

Page 265: ...rinted result and select the number of the pattern without any white line or overlapping between two patterns If all the patterns have a white line or overlapping select the optimal pattern and try pr...

Page 266: ...ully and check that the holes in the side matches with that in the APG gear Figure 5 89 APG Gear Phase Adjustment 1 5 In order to align the phase of the APG Unit with that of the Driven release holder...

Page 267: ...e the transmission EJ gear 90 degrees and measure the tension of the belt 11 Check the average of the four measured values falls within the standard range measurement value is within the standard Go t...

Page 268: ...268 5 5Paper Feed Related Adjustment DX100 Service Manual 17 Install the Upper Cover P 100 18 Install the Top Cover P 97...

Page 269: ...ut edge of paper and the printed base line at the three points right left and center with a steel scale See Figure 5 93 4 Enter the three measured values into the three boxes respectively and click In...

Page 270: ...DX100 Service Manual 5 5 7 Motor Adjustment 1 Select 1 Adjust Maintenance Adjustment Motor Adjustment 2 Select the motor you adjust in the displayed item and click Run 3 The selected measurement start...

Page 271: ...observe the following precautions before starting Do not unplug the printer AC cable during initial ink charge Do not unplug the USB cable that connects the printer to a computer during initial ink ch...

Page 272: ...leaking P 272 When transporting the printer or storing it over long periods of time Carry out the cleaning of the print head and the ink path with the cleaning fluid so as to prevent the ink from thi...

Page 273: ...l the Cleaning Cartridges in the printer 7 Take out all Cleaning Cartridges from the printer 8 Install the Draining Cartridges in the printer 9 Take out all Draining Cartridges from the printer C A U...

Page 274: ...274 5 6Ink System Related Adjustment DX100 Service Manual Figure 5 99 Ink Flushing Discharge screen...

Page 275: ...100 Checking Method No 1 1 No Item Judge Reference 1 Foreign material is in the AID cap or on the Print Head Print Head surface Foreign material is attached P 275 2 Insulation of the white and black...

Page 276: ...t Frame P 102 5 Measure the resistance between the white harness and black harness on the AID Board See Figure 5 102 6 Replace the AID Unit when the measured value is less than 1 M P 113 7 Replace the...

Page 277: ...e measured value is over 100 P 120 Figure 5 103 Checking Method No 3 No 4 1 Confirm there is no damage on the FFC between the AID Board and the Main Board or the FFC is not connected at a slant See Fi...

Page 278: ...er Head Cleaning Times Display the number of performing the new Power head cleaning Old Power Head Cleaning Times Display the number of performing the old Power head cleaning Head Cleaning Performing...

Page 279: ...C H A P T E R 6 MAINTENANCE...

Page 280: ...ess the instructions are described in this manual Table 6 1 List of Check Items Check Item Frequency Description Trimmed Waste Paper Box When replacing paper Refer to User s Manual Airflow vent Every...

Page 281: ...ing G 26 p291 Left CR scale mount plate G 26 p291 Frame base G 26 p292 p292 CR main shaft G 26 p293 CR sub shaft G 71 G 26 p293 Right CR scale mount plate G 26 p294 Main press torsion spring sub press...

Page 282: ...emark Spread it with brush after apply specified amount application with injector Middle roll frame Lubrication point Part Name Driven Roller 1 mount plate Lubrication Point Contact surface between th...

Page 283: ...1 0 mm 1 0 mm 4 points Remark Spread it with brush after apply specified amount application with injector Driven roller 2 mount plate Lubrication point Lubrication point Part Name Decurl roller mount...

Page 284: ...injector and spread around circumference of the shaft with brush Inlet Roller Lubrication point Lubrication point Part Name Feed Roller 1 Feed Roller 2 Lubrication Point Both ends of the Feed Roller...

Page 285: ...Remark Apply specified amount with an injector and spread around circumference of the shaft with brush Feed Roller 1 Lubrication point Feed Roller 2 Lubrication point Inlet Roller Lubrication point Pa...

Page 286: ...m 2 points Remark Apply specified amount with an injector and spread it with brush while rotating the spur gear 24 Right decurl roller cam Spur gear 24 Lubrication point Part Name Left decurl roller c...

Page 287: ...ant G 26 Amount 1 0 mm 2 0 mm 5 points Remark Apply specified amount with injector Release Unit Lubrication points Lubrication points Part Name Lower Platen Unit Lubrication Point Contact surface betw...

Page 288: ...ce between the Upper Platen Unit and the SMAP Roller rear EJ roller Lubricant G 26 Amount 1 1 0 mm 1 0 mm 5 points 2 1 0 mm 2 0 mm 4 points Remark Apply specified amount with injector Upper Platen Uni...

Page 289: ...ricant G 45 Amount 1 0 mm 4 0 mm 3 points Remark Apply specified amount with injector PF grounding spring Lubrication point Lubrication point EJ grounding spring Part Name Middle paper guide Lubricati...

Page 290: ...6 Amount 1 0 mm 4 0 mm 4 points Remark Apply specified amount with injector Driven Release Holder Lubrication points Lubrication points Part Name APG Unit Lubrication Point Spur gear 22 4 combination...

Page 291: ...nt Appropriate amount Remark Apply with brush PG cam bushing Lubrication point Lubrication point PG cam bushing Part Name Left CR scale mount plate Lubrication Point 1 Left CR scale mount plate 1 2 Le...

Page 292: ...Name Frame base Lubrication Point 1 Contact surface between the frame base and the CR main shaft CR sub shaft 2 Contact surface between the PG cam bushing and the CR main shaft CR sub shaft Lubricant...

Page 293: ...ad halfway around the shaft with brush CR main shaft Lubrication point Part Name CR sub shaft Lubrication Point 1 Contact surface between the CR sub shaft and the CR Unit 2 Contact surface between the...

Page 294: ...Amount 1 Once around 2 points 2 1 0 mm 2 0 mm 3 points 3 1 0 mm 1 0 mm 1 point 4 1 0 mm 5 0 mm 2 points Remark Spread halfway around the shaft with brush Right CR scale mount plate Lubrication points...

Page 295: ...lley 2 Contact surface between the driven pulley and the driven pulley shaft 3 Driven pulley shaft Lubricant G 26 Amount 1 1 0 mm 2 0 mm 8 points 2 1 0 mm 2 0 mm 2 points 3 1 0 mm 2 0 mm 1 point Remar...

Page 296: ...C H A P T E R 7 APPENDIX...

Page 297: ...sembly Assembly Electric Circuit Components p106 Achilles D 051 One touch Wrist Sonic Tension Meter U 507 GATES UNITTA Sonic Tension Meter U 507 PF Timing Belt Adjustment p267 Jig SCANNER ADJUSTMENT J...

Page 298: ...298 7 2Connector Summary DX100 Service Manual 7 2 Connector Summary PW sensor...

Page 299: ...299 7 3Board Layout Diagram DX100 Service Manual 7 3 Board Layout Diagram Main Board p300 Heater Board p301 Power Supply Board p302...

Page 300: ...300 7 3Board Layout Diagram DX100 Service Manual Main Board 42 V 1 2 F11 42 V_6 F15 42 V_5 5 V_SN 7 19 3 3 V_SN 9 13 24 V 3 4 3 3 V 8 13 5 V 2 11 42 V_PS 1 4 F6 42 V_3 F5 42 V_2 F4 42 V_1 F8 42 V_4...

Page 301: ...301 7 3Board Layout Diagram DX100 Service Manual Heater Board 3 3 V 8 10 5 V_IN 1 2 24 V_A 3 4 F5 24 V_A F6 5 V...

Page 302: ...302 7 3Board Layout Diagram DX100 Service Manual Power Supply Board...

Page 303: ...ose 24V F9 F13 CN11 4 CN11 3 24V 5 For FAN May be OFF in the power saving mode or when an error occurs 42V_1 F4 42V 5 For CR Motor APG Motor 42V_2 F5 42V 5 For Cutter motor DEP Motor 42V_3 F6 42V 5 Fo...

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