Ioline FJ Printer Service Manual Download

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Chapter 3: Troubleshooting & Testing

FJ Printer is not responding. Please check your cables and baud rate.

The

Control Center

did not get a response from a FJ Printer on the COM

port it is currently con

gured to use. If the FJ Printer is connected and the

power is on, click ‘

Yes

’. Follow the directions in the

FJ Printer User Guide

for

con

guring the COM port and baud rate.

NOTICE: Your

rmware is out of date. It is recommended that you

update it as soon as possible, but it is not required. This program will
work with new and old

rmware. Firmware upgrades are available

from Ioline Customer Service at (425) 398-8282 Paci

c Standard

Time USA.

The

rmware in the FJ Printer is obsolete. An upgrade is highly recommended.

Contact Ioline Customer Service to obtain the software and instructions.

The identi

cation numbers for this board have already been set. You

must use the ‘

Reset Machine ID

’ dialog to change them now.

The user is attempting to overwrite an internal license that is already set. Contact
Ioline customer service for assistance.

Summary of Contents for FJ Printer

Page 1: ...Service Manual Ioline FJ Printer StudioJet ...

Page 2: ...effort to make the StudioJet and all models of the FJ Printer easy to operate main tain and repair It is the responsibility of the operator of the printer to monitor the performance of the printer and maintain it in proper working condition by following the instructions in this manual and in the product User Guide and to follow all safety precautions and warnings that are described in these pub li...

Page 3: ...Service Manual Ioline FJ Printer StudioJet ...

Page 4: ......

Page 5: ...ge assembly with cover off 35 Figure 19 Printer carriage assembly with cover on 35 Figure 21 Keypad LED error codes 36 Figure 20 LED lights on the keypad 36 Figure 22 The correct paper feeding path on the Ioline FJ Printer 43 Figure 23 HP cartridges have an ink level indicator 44 Figure 24 The ink cartridge is dirty dry or empty 45 Figure 25 The ink cartridge requires cleaning 45 Figure 26 Damaged...

Page 6: ...7 Figure 47 Bottom cover removal steps 78 Figure 48 X axis belt replacement 80 Figure 49 Y axis belt replacement 81 Figure 50 X motor replacement 83 Figure 51 Y transmission replacement 84 Figure 52 FJ Printer chassis BOM exploded view A 96 Figure 53 FJ Printer chassis BOM exploded view B 97 Figure 54 FJ Printer Parts List BOM 98 Figure 55 FJ eX Printer chassis BOM exploded view A 102 Figure 56 FJ...

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Page 9: ...ted languages 21 FJ Printer Specifications 22 FJ eX Specifications 23 StudioJet Specifications 24 How the printer works 25 Paper movement 25 Carriage movement 25 Serial number identification 25 Glossary 26 Software setup options 26 Power on 28 Installing FlexPlot and the Control Center 28 The Control Center 29 Overview 29 Changing system settings 29 Control Center menu bar features 30 File 30 Comm...

Page 10: ...spond to the computer 41 Serial communication 41 Common problems 42 Paper problems 47 Regular or intermittent paper tearing 47 Media tracking 48 Print quality problems 48 Line quality 48 Dirty or damaged cartridge 50 Cartridge calibration 50 Calibration overview 50 Cartridge alignment 51 Motion adjustment 52 Frame Gap Adjustment 53 Unexplained frame gaps 54 Frame Size Adjustment 55 Ink cartridge s...

Page 11: ...72 Carriage Wheel Replacement 74 Flex Cable Replacement 76 Logic Board Procedures 78 Logic board replacement 78 Note Follow anti static procedures 79 Updating the firmware 80 Electrical Procedures 80 Power supply replacement 80 Keypad procedures 82 Keypad replacement 82 X axis belt replacement 84 Y axis belt replacement 86 X motor replacement 88 Y transmission replacement 90 Chapter 5 Parts Drawin...

Page 12: ......

Page 13: ...ration The car riage will automati cally move to touch the left end plate then back to the right end the Service Station position when the power is turned on Never insert hands or other objects into the Service Station area on the right side of the printer The carriage occasionally enters this area without warning and could collide with an obstruction potentially causing and injury Be careful when...

Page 14: ...r when it leaves the factory The warranty period is based on the serial num ber of the unit and extends from the date of manufacture up to 12 months plus an extra 3 months for shelf life Making the total war ranty period 15 months from the date of manufacture For warranty service the end user must work through their dealer Ioline Customer Service is available to assist Authorized Dealers with cust...

Page 15: ... Basic troubleshooting User Guide Advanced troubleshooting for qualified service personnel FlexPlot Service Manual Specifications part names drawings FlexPlot Service Manual What s in this Service Manual The FJ Printer StudioJet Service Manual provides extensive product specifications testing and repair procedures Chapter 1 Introductory information and general specifications Chapter 2 Descriptive ...

Page 16: ...Pinchwheel lever C Right End Cover D Take up Motor E Stand Leveling Foot F Feed Roll G Take up Shaft H Feed Shaft I Dancer Bar J Stand KEY Figure 2 The Ioline FJ shown and FJeX not shown Printers FrontView E A C F H J D G I B ...

Page 17: ...hown and FJeX not shown RearView head titled in maintenance position K L M N Q O P K Take up Motor Cable L Take up Motor Outlet M Power Switch N Serial USB Ports O Paper Out Sensor P Platen Leveling Pad Q Cross member The FJ eX has two cross members KEY ...

Page 18: ... R Drive Shaft Marker S Pinchwheel Lever T Pinchwheel U Traverse or Carriage Rail V Carriage Assembly W Platen X Ink Cartridge Latch Y Ink Cartridge Stall Z Keypad AA Service Station BB Bottom Sensor CC Top Sensor KEY T V AA Y X R U CC Z BB xviii S W ...

Page 19: ... A B C H G M L N K D E E F O I J A Left End Cover B Drive Shaft Marker C Pinchwheel Lever D Pinchwheel E Drive Shaft F Right End Cover G Keypad H Stand Leg I Inkjet Cartridge J Carriage K Stand Leveling Foot L Feed Shaft M Cross member N Platen O Traverse KEY xix ...

Page 20: ...Figure 6 Power and communications ports on the Ioline StudioJet are located on the back of the right cover P Power Switch Q Serial COM Port R Power Cord KEY P Q R xx ...

Page 21: ...different printing operations up to 72 inches wide and 600 yards long 85 8 inches and 349 9 yards for the FJ eX 44 inches and 600 yards for the StudioJet Two industry standard printer languages HPGL 7475 and DM PL are supported The Ioline FJ Printer also supports direct cable connection from many popular programs such as PAD Scanvec Optitex Polytro pon Ioline IPS software and other applications Su...

Page 22: ...r type Recycled to bond Feed roll position Front floor loading Paper take up roll position Ergonomic waist level off loading from front Line thickness Thin normal or thick Resolution Best mode Draft mode 600 dpi 300 dpi Ink cartridges Off the shelf HP 51645A cartridges PC interface USB Serial RS 232 Protocol HPGL DM PL Languages DM PL DXF HP GL HP GL 2 MicroJet STD ASTM Compatibility Gerber Accuma...

Page 23: ...ycled to bond Feed roll position Front floor loading Paper take up roll position Ergonomic waist level off loading from front Line thickness Thin normal or thick Resolution Best mode Draft mode 600 dpi 300 dpi Ink cartridges Off the shelf HP 51645A cartridges PC interface USB Serial RS 232 Protocol HPGL DM PL Languages DM PL DXF HP GL HP GL 2 MicroJet STD ASTM Compatibility Gerber Accumark MicroMa...

Page 24: ...cycled to 150 lb tag board Feed roll position Front floor loading Paper take up roll position Ergonomic waist level off loading from front Line thickness Thin normal or thick Resolution Best mode Draft mode 600 dpi 300 dpi Ink cartridges Off the shelf HP 51645A cartridges PC interface USB Serial RS 232 Protocol HPGL DM PL Languages DM PL DXF HP GL HP GL 2 MicroJet STD ASTM Compatibility Gerber Acc...

Page 25: ... X axis motor with a timing belt transmisison assembly The drive shaft rotates in one direction Carriage movement The Y Axis transmis sion powers a timing belt that transports a V wheel carriage along the Y Axis traverse extrusion The ink cartridges are attached to the carriage and are made to apply ink to the paper by actuating the electronics of the ink cartridge When not printing the carriage a...

Page 26: ...exible workflow available for creating output It s especially useful when many file formats are used a common situation for service bureaus To set up and learn how to use the software see the FlexPlot User Guide The FJ Printer is designed to work in many different production environments The type of marker printing you do will often deter mine your preferred communication method Two typical method...

Page 27: ...work HPGL DM PL DXF ASTM 6959 STD CAD Software HPGL DM PL Alternate Configuration CAD Software FlexPlot 2 Use FlexPlot software to convert files before sending them to the printer for output The FJ Printer includes the FlexPlot software which will con vert many compatible file formats It also provides an advanced marker queue management system and other tools to optimize the performance of the pri...

Page 28: ... operations The Control Center is an interface for adjusting parameters to optimize printer performance The printer comes with a CD ROM which has Microsoft Windows 98 2000 XP versions of the programs as well as PDF user guides and the required Adobe Acrobat reader 1 Power on the computer and Windows 2 Insert the Ioline CD ROM into the CD ROM drive usually D 3 The installation program should start ...

Page 29: ...computer Provides an interface to send completed files to the printer Changing system settings A variety of settings are adjustable to fit specific needs Make sure the printer power is on and that the initialization process is complete The carriage will park the keypad OK light will turn red and the Square light will turn green The Screen Menu displays the primary settings that are adjust able The...

Page 30: ...er Send Command Permits advanced users to manually enter commands Tools Aux Sensor Stops printer when paper runs out Cartridge Calibration Displays tools to adjust print car tridge alignment See the User Guide for more details Size Calibration Allows adjustment of the size cali bration settings See the User Guide for more details About Your FlexJet Displays license information and print head activ...

Page 31: ...se more ink to produce higher contrast lines Used in conjunction with the Quality Setting see below the FJ Print er provides six options for output quality to enable you to produce clearly visible lines using the least possible amount of ink Scale The printer scale ranges from 1 to 999 The factory default Scale is 100 A scale set to 50 prints at half size Changes do not take effect until the Set S...

Page 32: ...mode uses 600 DPI A lower DPI setting uses less ink by creating a fainter line Higher DPI uses more ink but makes a darker line Use this setting in conjunction with the Line Width see above to find a bal ance between saving ink and making clearly visible lines Measurement Units Choose between English or Metric units for settings display ...

Page 33: ...Chapter 2 Nomenclature Figure 13 The Ioline FJ Printer power supply Figure 14 Rear power panel assembly Product components Power cord plugin Power switch ...

Page 34: ...ure 17 FJ Printer logic board Main power Figure 15 Pinchwheel assembly Wheels Replaceable Fans 1 2 3 Motor power LEDs 4 X Motor encoder Y Motor encoder Roll feed encoder Paper out take up sensors Heads 1 2 3 Carriage power Paper out 2 sensor Keypad Comm RS 232 Board part number sticker ...

Page 35: ...e Figure 18 Printer carriage assembly with cover off Carriage stall Carriage V notch Carriage latch Base Ink cartridge Figure 19 Printer carriage assembly with cover on Carriage stall Carriage V notch below Carriage latch Base ...

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Page 37: ...een the machines and the PC is connected correctly The information in this chapter begins with the simplest and most common issues and progresses to more complex and invasive troubleshooting If you are unable to resolve a problem after consult ing this manual fill out the Diagnostic Record at the beginning of Chapter 4 then contact Ioline Customer Service Error messages Error messages that are spe...

Page 38: ...does not resolve the problem confirm that FJ Printer Control Center is displayed in the menu bar of the program If it is not obtain the correct version from Ioline Fatal Error COM port pointer is NULL Unable to recover A serious internal failure in the program or Windows has occurred Close all programs restart Windows then start the Control Center program Unable to change FJ Printer baud rate Do y...

Page 39: ...ommended that you update it as soon as possible but it is not required This program will work with new and old firmware Firmware upgrades are available from Ioline Customer Service at 425 398 8282 Pacific Standard Time USA The firmware in the FJ Printer is obsolete An upgrade is highly recommended Contact Ioline Customer Service to obtain the software and instructions The identification numbers fo...

Page 40: ...rflow Y Blink OFF R OFF Init from EPROM failed OFF R R OFF File syntax error Y Blink Y Blink Y Blink OFF Printer ready to receive firmware Y Blink OFF OFF OFF Motors off System Stop Legend G Green light R Red light Y Yellow light Y Blink Blinking yellow light OFF Unlit Figure 21 Keypad LED error codes Keypad error codes Figure 20 LED lights on the keypad If keypad errors are not shown on the chart...

Page 41: ...roper communications port on the computer 2 Change the computer COM port settings to match the printer s serial communications settings See Serial Communication below Serial communication The serial port on the printer has an adjustable baud rate Available speeds are 9600 19200 38400 57600 and 115200 It is critical that the Control Center FlexPlot or design software use the same baud rate that the...

Page 42: ...e 1 Ink cartridge is improperly installed 2 Frame Gap setting is incorrect 3 Carriage electronics or cables are damaged 4 Ink cartridge is dry Solution 1 Remove and reinstall ink car tridge 2 Use the Control Center to adjust frame gap as shown in the Routine Maintenance chapter of the FJ Printer User Guide 3 Contact Ioline customer service 4 Clean or replace cartridge The printer does not complete...

Page 43: ...n chapter of the FJ Printer User Guide to reset paper align ment Make sure the front silver dancer bar is BELOW the front optical sensor before plotting 6 Make sure the distance between the print heads and platen surface is the same at the right center and left side of the printer Adjust the platen levelers as de scribed in the FJ Printer Quick Start Guide if necessary 7 Use the Control Center to ...

Page 44: ... feed shaft 5 Loose paper hubs Solution 1 Reload and align paper 2 Replace the paper roll 3 With power off raise the pinchwheels and align them with the white driveshaft markers on the traverse 4 Center the paper roll on feed shaft Make sure screws are tight on both paper hubs 5 Tighten screws on the paper hubs No ink Cause 1 Ink cartridge empty 2 Clogged print head 3 Service Station failing to ca...

Page 45: ...ustomer service 5 Tighten or replace the ribbon cable following instructions under the Carriage Procedures section later in this chapter 6 Contact Ioline customer service 7 Contact Ioline customer service After plot is sent machine does not move Cause 1 Plotter is off or unplugged 2 Wrong baud rate or baud rate does not match on plotter or computer 3 Wrong settings in the software 4 Data cable is ...

Page 46: ... printer 2 Communication baud rate is set very low 3 Frame length is too big Solution 1 Reduce vector density use em bedded printer fonts or increase communication baud rate 2 Increase baud rate from the minimum of 9600 baud to the default of 38 400 or higher Make sure the FJ Printer and the soft ware are set to the same baud rate 3 Reduce frame length Set be tween 5 in and 35 in Carriage refuses ...

Page 47: ...was incorrectly loaded in the machine A pinchwheel s is positioned over a drive shaft bearing Figure 22 represents the proper paper path with the paper after it is inserted properly and taped to the take up shaft The illustration shows the dancer bar in place Platen Take up Shaft Feed Roll Proper Paper Path Pinchwheel Lever Front Dancer Bar The paper path and instruc tions for printing to the floo...

Page 48: ...to the traverse Check to make sure that the printer is level See the Quick Start Guide for more information The paper may slip when debris accumulates on the drive shaft Inspect and clean the drive shaft Refer to the Routine Mainte nance chapter in the User Guide for more information Contact an Ioline distributor or Ioline Customer Service if you are unable to resolve the problem or if the printer...

Page 49: ...e HP 45 cartridges as recommended by Ioline 6 Recalibrate cartridges as described below 7 Level the platen as outlined in the Quick Start Guide 8 Contact an Ioline distributor or Ioline Customer Service if you need further help Figure 24 The ink cartridge is dirty dry or empty Figure 25 The ink cartridge requires cleaning ...

Page 50: ...cuit from mishandling Cartridge calibration The Cartridge Calibration window is located in the Control Center and can be accessed in the Tools menu Step by step instructions on the calibration process are provided in the User Guide The examples below show different results and settings of the car tridge calibration window If the printer is printing poorly check some of the examples here for a poss...

Page 51: ... Center includes cartridge alignment settings Figure 27 These are used for other Ioline inkjet plotter models Since the FJ Printer only has one print head you do not need to perform ink cartridge alignment Figure 28 The Cartridge Calibration window in the Control Center ...

Page 52: ... pass doesn t line up with the previous one Lines will Stair Step back and forth and not look right When the carriage is in motion the Motion Adjustment will tell the ink cartridge to print sooner or later de pending on the number in the Motion Adjustment field in the FJ8 Control Center 1 Make sure the plotter is connected to the computer Press Set Origin to illuminate the green OK LED on the keyp...

Page 53: ...r overlap between each carriage pass If the lines are not solid e g appear dashed or dotted you will need to adjust the gap distance in the Control Center 1 Make sure the plotter is connected to the computer Press Set Origin to illuminate the green OK LED on the keypad 2 Open Control Center 3 Select Tools Cartridge Calibration on the toolbar 4 The Cartridge Motion and Gap Adjustment Window will op...

Page 54: ...ne Close the Control Center and plot normally Unexplained frame gaps If your plots exhibit occasional frame gaps like Figure 32 for instance may indicate that the printer body is not level Notice how the right and left lines are right on but the middle line mis aligned Try releveling the printer to see if this corrects the problem The Quick Start Guide provides detailed instructions You ll need to...

Page 55: ...een OK LED on the keypad 2 Open Control Center 3 In the upper right corner of the Control Center window you will see X and Y axis panel size fields 4 For most software to work properly the X axis panel needs to be set to 35 inches The default is 21 600 inches 5 Type 35 in the X axis panel field 6 In the Y axis field type the width of your paper in inches The default is 72 inches 7 Once you are don...

Page 56: ...ate Noisy carriage movement If you notice unusual noise coming from the carriage the wheel on the carriage assembly may need cleaning or replacement Remove the carriage assembly from the traverse and clean the wheel Also wipe the traverse rails before re installing the carriage assembly If cleaning does not resolve the noise contact Ioline Customer Service Figure 34 The ink stall can crack if the ...

Page 57: ... their bearings start to break down due to insuf ficient lubrication As this break down happens the transistors have to work harder to move the motor causing them to heat up and eventually fail Figure 36 In most cases both the transistor and motor will need replacement Contact Ioline Tech Support for more detailed instructions on testing a transistor Troubleshooting sensors The printer uses the sa...

Page 58: ...e is pointing 4 Remove the old sensor by removing the hardware or adhesive 5 Mount the new sensor in exactly the same orientation as the old one 6 Connect the plug to the sensor it is keyed to only connect one way 7 Power on and test the installation General mechanical electrical issues If you encounter any of the following problems try the diagnostics test outlined below The printer didn t initia...

Page 59: ...ne if a motor problem exists 1 Turn machine off and unplug the power and data cables 2 Follow the procedure for removing the right cover 3 Locate the Y axis motor behind the keypad of the plotter a b c d Figure 37 Testing theY Axis motor This test applies to all the motors on the FJ Printer Note If you find a bad motor contact Ioline Tech Support It s possible that a transistor on the main logic b...

Page 60: ... behind the main PCB inside the plotter body 3 Unplug the red and black wires from the motor 4 Using a piece of metal like a paperclip touch the two connec tor lugs on the motor Putting the paperclip through the holes in the lugs works well 5 Rotate the main drive shaft by hand 6 While rotating the shaft remove the paperclip from the lugs on the motor 7 You should notice a huge difference in resis...

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Page 62: ...ioning Erratic machine performance TP10 5VDC 5 volt regulated power supply is functioning Erratic machine performance D13 Dark light Y motor fault Solid red D14 Dark light X motor fault Solid red D15 Dark light Take up motor fault Solid red D17 Dark light Carriage power fault Solid red D9 D12 Blinking red pattern Motor control system functioning Solid lights or no lights Logic board troubleshootin...

Page 63: ...heat Check the motor connections and motor to ensure there are no shorts to ground A hardware problem with the motor drive circuit Return the board to Ioline for service Over current condi tion on circuit due to a short or high heat Check the motor connections and motor to ensure there are no shorts A hardware problem has occurred with the motor drive circuit Return the board to Ioline for service...

Page 64: ... under Customer Service in this chapter Any warranty servicing of this product not specifically described in this manual must be authorized in writing by Ioline Customer Service You may obtain service by calling or faxing Ioline Customer Service The technicians will help you determine the nature of the problem If factory repair is necessary you will receive a RMA Re turn Material Authorization Ple...

Page 65: ...support to our customers If you need assistance with an Ioline prod uct contact your local dealer or Ioline authorized service center You may also contact Ioline Customer Service Department Monday through Friday 7 00 A M 5 00 P M U S Pacific Time Voice 1 425 398 8282 Fax 1 425 398 8383 support ioline com www ioline com ...

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Page 67: ... troubleshoot ing repair issues with the printer and record the results of your diagnostic examination on the Diagnostic Record see below Computer Software Resolution LED Codes Communication Problem Computer Software Resolution Begin recording diganostic information Examine the external components Disassemble check cabling and connections Examine power supplies Examine logic board Examine motors C...

Page 68: ...is first turned on Does the carriage move smoothly Y N Does the fan come on Y N With power off slide the carriage from side to side Does the carriage slide easily to each side Y N Is there more resistance to move the carriage L e f t R i g h t E q u a l Were all cable connections securely fastened to the logic board Y N Was the power voltage within the tolerance Y N Record the power supply voltage...

Page 69: ...39 photos 1 2 3 Remove the left cover Figure 39 photo 3 Right Cover Removal 1 Power off and unplug the data and power cables 2 Remove the two black Phillips screws Figure 40 photos 1 2 3 Carefully pull the cover to the right to remove Figure 40 photo 3 Figure 39 Left cover removal Figure 40 Right cover removal Photo 1 Photo 2 Photo 1 Photo 2 Photo 3 Photo Photo Photo 3 ...

Page 70: ...ews on the rear of the machine Figure 41 photos 3 4 These hold the printer on the stand do not remove the front screws Figure 41 photos 5 6 4 Make sure the stop screws are installed on the take up plate on both sides of the machine Figure 41 photos 5 6 Figure 41 Bottom cover removal steps Photo 2 Photo 3 Photo 5 Photo 6 Photo 7 Photo 8 Photo 4 Photo 1 Photo 9 Right rear screw Rear screw Stop screw...

Page 71: ...ad stops Fig ure 41 photos 7 8 6 Remove the Phillips screws from the left bottom cover Figure 41 photos 9 10 7 Carefully unplug the fan and sensor cables Figure 41 photos 11 12 13 8 Remove the cover Figure 41 photo 14 Photo 12 Photo 11 Photo 13 Photo 14 Photo 10 Fan plug Sensor plug ...

Page 72: ... and tighten the nut Figure 42 photos 5 6 12 Clip Y belt clips to carriage Figure 42 photo 2 13 Tighten tensioner Figure 42 photo 1 using the mark made above 14 Test 15 Re install left carriage cover and left cover Phillips screwdriver 9 64 in 3 5mm Allen wrench 5 16 in 8mm open end wrench Small flat tipped screwdriver Parts tools included with the upgrade kit Replacement carriage assembly Tyraps ...

Page 73: ...73 Chapter 4 Repair Procedures Photo 6 Figure 42 Carriage replacement FJ Printer carriage shown Photo 7 Photo 8 Photo 5 Photo 4 Photo 1 Photo 2 Photo 9 ...

Page 74: ...3 photo 3 4 Install new wheels on the studs Figure 43 photo 3 5 Install the wheel stud nuts not too tight the wheels should move freely Figure 43 photo 1 6 Install the carriage by following the carriage replacement pro cedure Steps 9 15 listed earlier in this chapter 7 Move the carriage back and forth by hand to test 8 If it works properly re install the left side cover 9 If problems arise contact...

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Page 76: ...s is on the logic board end of the cable Fold the cable connectors as shown in Figure 44 Photo 6 before plugging in 9 Plug the new ribbon cable into the PCB Important Make sure the cable plugs are plugged in properly If a row of pins are missed you can cause damage to the carriage or logic board Figure 44 photo 6 10 Install left end and bottom covers 11 Rotate the machine back to upright position ...

Page 77: ...epair Procedures Photo 6 Figure 44 Flex cable replacement Photo 7 Photo 8 Photo 5 Photo 4 Photo 1 Photo 2 16 Install the ribbon cable cover on the left side of the machine Figure 44 photos 1 2 17 Test Photo 9 Photo 3 ...

Page 78: ...Printer StudioJet Service Manual Logic Board Procedures Logic board replacement Tools Required Phillips head screwdriver Tyrap 1 Figure 45 Main logic board replacement Photo 6 Photo 5 Photo 3 Photo 2 Photo 1 Photo 4 ...

Page 79: ...board Use caution and plug the connectors in properly a missed row of pins will dam age the board Figure 45 photos 2 1 9 Make sure the ribbon cables lay nicely and tighten the tyrap holding the ribbon cable but not so tight as to damage to the cable Figure 45 photos 3 1 10 Install the bottom cover and the rotate machine back to normal operating position Make sure to install screws that hold the ma...

Page 80: ...the future 9 Turn the plotter power off 10 While holding the button located directly above Set Origin turn the plotter back on Keep pressing the button 11 Once the carriage moves to the far left side of the machine let go of the button 12 Permit the machine to initialize normally 13 When you see the red OK LED illuminate on the keypad send a test plot to the printer 14 Contact Ioline Tech Support ...

Page 81: ... an example 7 Plug in the small connector Figure 46 photos 2 1 8 Route the wires making certain they lay out of the way of the bottom cover screws Figure 46 photo 6 9 Install the bottom cover and the rotate machine back to normal operating position Make sure to re install screws that hold the machine to the stand legs 10 Test the plotter 11 If problems arise contact Ioline Tech Support Figure 46 P...

Page 82: ...hrough the hole in the right end plate Figure 47 photos 1 2 4 Rotate the machine back to normal operating position 5 Remove the keypad resistor from the keypad Figure 47 pho tos 3 4 6 Follow the procedure for Y transmission replacement later in this chapter and set the transmission aside 7 Remove the two keypad mounting 11 32 nuts Figure 47 photo 6 Keypad procedures Keypad replacement Figure 47 Bo...

Page 83: ...ole in the end plate and plug it into the new keypad cable for the main logic board Take caution to plug the connector in properly A missed row of pins will damage the main logic board and keypad Figure 47 photos 2 1 Note Pin 1 is marked with a sticker on the cable Look on the main logic board for pin 1 and match pin to socket before plugging in the cable 14 Install the bottom cover as described e...

Page 84: ...ding the motor Figure 48 photos 1 2 3 Leave the screw shown in Figure 49 photo 1 loose Do not remove it 3 Rotate the small pulley toward the front of the machine Figure 48 photo 4 4 Remove X belt from both pulleys 5 Install the new belt around both pulleys 6 Rotate the small pulley toward the back of the machine Figure 48 photo 3 7 Install the two screws that hold motor leave all three screws loos...

Page 85: ...cedures 9 Tighten the motor mounting screws while keeping tension on the belt Do Not over tension the belt Figure 48 photo 1 10 Replace the right side cover 11 Test the plotter 12 If problems arise contact Ioline Tech Support ...

Page 86: ...reverse The teeth of the belt should face the shiny bearing surface Fig ure 49 photo 6 7 Install the Y belt through left end plate Figure 49 photo 2 8 Put the belt through the right end plate and around the Y trans mission pulley and back through the hole in the right end plate Figure 49 photo 1 9 Attach the Y belt to the carriage as described in the Carriage Replacement procedure earlier in this ...

Page 87: ...87 Chapter 4 Repair Procedures Photo 4 Photo 5 Photo 6 ...

Page 88: ... Install the new motor with the bottom screw only on the right end plate of the plotter See Figure 50 photo 5 for correct rota tion 11 Install the encoder and power wires to new motor Figure 50 photos 6 5 12 Install the main logic board by following the main logic board replacement procedure in reverse 13 Replace the bottom cover and flip machine back to normal operating position Re install the sc...

Page 89: ...89 Chapter 4 Repair Procedures Figure 50 X motor replacement Photo 4 Photo 5 Photo 7 Photo 1 Photo 2 21 Test the plotter 22 If problems arise contact Ioline Tech Support Photo 6 Photo 3 ...

Page 90: ...the top left nut where the keypad resistor is connected 4 Unplug the encoder and power wires from the motor 5 Loop the Y belt through the right end plate around the new trans mission pulley and back through the hole in the right end plate 6 Install the new transmission on the studs taking up the slack in the Y belt Figure 51 photos 4 5 7 Install nuts until tight Note place the keypad resistor on t...

Page 91: ...91 Chapter 4 Repair Procedures 10 Tighten the belt tensioner Do Not over tighten 11 Install the right and left side covers 12 Test the machine 13 If problems arise contact Ioline Tech Support ...

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Page 93: ... PINCHWHEEL ROHS 1 14 108901 TENSIONER ASSY FLANGED BEAR ROHS 1 15 109178 FAN ASSY 24 48V W CONN ROHS 2 16 108797 PCB ASSY MAIN 600FJ PROG 1 17 108794 PLATE END RIGHT FJ8 ROHS 1 18 108795 PLATE END LEFT 600FJ ROHS 1 21 107646 PLATE POWER SUPPLY 3X5 ROHS 2 25 106231 PLATE CAP RIGHT P600 ROHS 1 26 106232 PLATE CAP LEFT SUMMIT 97 ROHS 1 34 108777 POWER SUPPLY ROHS 15V 3X5 ROHS 2 36 106816 MOTOR SERVO...

Page 94: ...N 53ID 045 WIRE ROHS 1 81 108857 TAKE UP ASSY RIGHT FJ8 ROHS 1 82 109270 CABLE ASSY POWER SUPPLY FJ8 ROHS 1 88 108930 TAPE FOIL 2 IN ROHS 10 89 107044 LABEL WARNING SHOCK SMALL ROHS 2 90 107862 CABLE ASSY FAN LONG IJ02 ROHS 1 92 104179 SCREW 10 32 375 LG PHP SEMS ROHS 2 93 108799 BRACKET ASSY SERVICE STATION 600FJ ROHS 1 94 108801 CAP ASSY FJ8 ROHS 1 96 109269 CABLE ASSY PCB TU FJ8 ROHS 1 97 10883...

Page 95: ... 14 108823 PACKING LIST FJ8 1 15 108826 ACCY KIT FJ8 1 18 108822 LABEL CARTON END FJ8 2 19 103560 LABEL SHIPPING CARTON IOLINE 20 2 20 108287 LABEL CE FLEXJET ROHS 1 21 107114 LABEL FRONT LIGHT GRAY ROHS 1 23 104926 STANDOFF 8 32 5 25 LG ROHS 2 24 104725 STANDOFF 8 32 1 75 LG ROHS 2 25 106241 WSHR 8 32 190ID 416OD 080THK ROHS 8 26 101581 SCREW 8 32 375 FHP ROHS 6 30 106339 STRAIN RELIEF PLASTIC 30...

Page 96: ...8 2X 72 1 84 107 2X 58 2X 58 5X 10 18 SEE DETAIL F 2 21 2X 58 4X 36 58 5X 17 SEE DETAIL G SEE DETAIL K 59 8X 82 3 90 48 8X 38 REF 72 75 74 16 58 3X 92 2X 94 93 SEE DETAIL J 64 2X 101 2X 102 2X 89 98 106 110 5X 5 46 4X SEE DETAIL A 68 5X 108 34 82 REF 6 4X SEE DETAIL J 13 77 SEE DETAIL E 52 2X 66 76 39 Figure 52 Ioline FJ Printer chassis exploded viewA ...

Page 97: ...FAN CABLE 38 REF CARRIAGE CABLE 38 REF 7 REF 68 REF 5X 10 REF 10 REF 103 REF PAPER OUT SENSOR 66 10X PEN 1 38 REF POWER Y MOTOR ENC X MOTOR ENC 41 REF FAN CABLE 90 REF FAN CABLE 9 REF RS 232 CABLE 39 REF MOTOR POWER CABLE 8 REF KEYPAD 108 REF PAPER SENSOR 96 REF LEG SENSOR CABLE 82 REF POWER CABLE 67 3X DETAIL N 17 REF 9 REF RS 232 CABLE DETAIL D 7 REF 38 REF STRIPE STRIPE 36 REF 11 REF TU POWER 4...

Page 98: ...tudioJet Service Manual Ioline FJ Printer P N 108790 1 REF 1 2 34 35 12 5 6 8 9 10 13 14 15 18 2X 19 2X 21 23 2X 24 2X 26 2X 26 2X 25 4X 25 4X 26 2X 30 1 REF 37 38 2X 39 2X 39 2X 38 2X 20 41 Figure 54 FJ Printer Packing List ...

Page 99: ...1 107646 PLATE POWER SUPPLY 3X5 ROHS 2 25 106231 PLATE CAP RIGHT P600 ROHS 1 26 106232 PLATE CAP LEFT SUMMIT 97 ROHS 1 34 108777 POWER SUPPLY ROHS 15V 3X5 ROHS 2 36 106816 MOTOR SERVO 24V ROHS 1 38 109166 CABLE ASSY RBN 1 HD FJEX ROHS 1 39 109253 CABLE ASSY TU POWER INT ROHS 1 41 107861 CABLE ASSY FAN SHORT IJ02 ROHS 2 42 108757 BELT GT 2MM 105T 6MM W ROHS 1 43 108756 PULLEY GT 2MM 20T 6MM W 4MM R...

Page 100: ...HOCK SMALL ROHS 2 90 107862 CABLE ASSY FAN LONG IJ02 ROHS 1 92 104179 SCREW 10 32 375 LG PHP SEMS ROHS 2 93 108799 BRACKET ASSY SERVICE STATION 600FJ ROHS 1 94 108801 CAP ASSY FJ8 ROHS 1 96 109269 CABLE ASSY PCB TU FJ8 ROHS 1 97 108842 BOTTOM COVER ASSY RIGHT FJEX ROHS 1 98 108843 BOTTOM COVER ASSY LEFT FJEX ROHS 1 101 102219 LEVELER 1 5 PAD 3 IN ADJUST ROHS 2 102 102220 NUT 3 8 16 HEX ROHS 2 105 ...

Page 101: ... 1 14 108781 PACKING LIST FJEX 1 15 108826 ACCY KIT FJ8 1 18 108822 LABEL CARTON END FJ8 2 19 103560 LABEL SHIPPING CARTON IOLINE 20 2 20 108287 LABEL CE FLEXJET ROHS 1 21 107114 LABEL FRONT LIGHT GRAY ROHS 1 23 104926 STANDOFF 8 32 5 25 LG ROHS 2 24 104725 STANDOFF 8 32 1 75 LG ROHS 2 25 106241 WSHR 8 32 190ID 416OD 080THK ROHS 8 26 101581 SCREW 8 32 375 FHP ROHS 6 30 106339 STRAIN RELIEF PLASTIC...

Page 102: ... 1 107 2X 58 2X 58 5X 10 18 SEE DETAIL F 2 21 2X 58 4X 36 58 5X 17 SEE DETAIL G SEE DETAIL K 59 8X 82 3 90 48 12X 38 REF 72 75 74 16 58 3X 92 2X 94 93 SEE DETAIL J 64 2X 101 2X 102 2X 89 98 106 110 5X 5 46 6X SEE DETAIL A 68 5X 108 34 82 REF 6 6X SEE DETAIL J 13 77 SEE DETAIL E 52 2X 66 76 39 41 2X Figure 55 Ioline FJ eX Printer chassis exploded viewA ...

Page 103: ...41 REF FAN CABLE 90 REF FAN CABLE 38 REF CARRIAGE CABLE 38 REF 7 REF 68 REF 5X 10 REF 10 REF 108 REF PAPER OUT SENSOR 66 10X PEN 1 38 REF POWER Y MOTOR ENC X MOTOR ENC 41 REF FAN CABLE 90 REF FAN CABLE 9 REF RS 232 CABLE 39 REF MOTOR POWER CABLE 8 REF KEYPAD 108 REF PAPER SENSOR 96 LEG SENSOR CABLE 82 REF POWER CABLE 67 3X DETAIL N 17 REF 9 REF RS 232 CABLE DETAIL D 7 REF 38 REF STRIPE STRIPE 36 R...

Page 104: ...Jet Service Manual Ioline FJ eX P N 108860 1 REF 1 34 35 12 5 6 10 13 14 15 18 2X 19 2X 21 23 2X 24 2X 26 2X 26 2X 25 4X 25 4X 26 2X 30 1 REF 37 38 2X 39 2X 39 2X 38 2X 20 41 2 9 2 2X 8 Figure 57 Ioline FJ eX Printer Packing List ...

Page 105: ...S 11 19 104013 NUT 8 32 KEP ROHS 9 21 100279 CONN CABLE CLIP 1 IN ROHS 7 23 103740 TAPE FOAM 5 IN 025 THICK ROHS 2 25 106649 LABEL DRIVE AREA ROHS 2 26 104180 SCREW 8 50 LG SLF TAP PHP SE ROHS 25 29 107849 CAP VINYL 437 D X 1 5 L ROHS 2 30 106684 LEVER ASSY PINCHWHEEL ROHS 1 31 106688 PLATE END RIGHT SC98 ROHS 1 32 106689 PLATE END LEFT SC98 ROHS 1 33 108718 KEYPAD ASSY FJ8 ROHS 1 34 108901 TENSIO...

Page 106: ... X 3 IN BLACK ROHS 5 69 107044 LABEL WARNING SHOCK SMALL ROHS 1 70 107861 CABLE ASSY FAN SHORT IJ02 ROHS 1 71 107738 SENSOR OPTICAL 1 PIECE ROHS 1 72 108946 NUT 4 40 HEX THIN NYLOC ROHS 2 73 108600 CABLE ASSY PPR OUT FJ8 ROHS 1 74 109048 GROUND 1M OHM W TERM ROHS 1 75 104008 SCREW 8 32 375 LG PHP SEMS ROHS 1 76 103260 SCREW 4 40 75 LG PHP ROHS 2 77 109005 PLUG 7 8 X 10 PL ROHS 1 78 104726 GROMMET ...

Page 107: ... ROHS 2 10 106741 ROLLER LONG SC98 40 1 11 103560 LABEL SHIPPING CARTON IOLINE 20 2 12 106565 BOX SHIPPING SC98 40 1 13 101581 SCREW 8 32 375 FHP ROHS 4 14 104926 STANDOFF 8 32 5 25 LG ROHS 2 15 104725 STANDOFF 8 32 1 75 LG ROHS 2 16 104008 SCREW 8 32 375 LG PHP SEMS ROHS 1 17 106618 COVER LEFT END SC98 ROHS 1 18 106619 COVER RIGHT END SC98 ROHS 1 19 105921 TYRAP 28 CABLETIE NAT NYLON ROHS 1 20 10...

Page 108: ...E DETAIL E 30 60 7X 53 REF 54 REF DETAIL E 59 REF 30 REF 66 2X SEE DETAIL G 10 44 DETAIL G 41 53 54 23 64 67 18 8X 68 5X 23 69 33 19 2X 1 47 4X 43 2X 26 4X 6 2X 17 6X MOTOR POWER CABLE 11 REF Y MOTOR ENC X MOTOR ENC 36 REF TU POWER POWER CABLE 39 REF 67 REF 3 REF 70 REF 75 REF 33 REF PAPER SENSOR 73 REF STRIPE 10 REF 75 REF PEN 1 RS 232 CABLE KEYPAD STRIPE POWER FAN CABLE 73 REF 70 REF PAPER OUT S...

Page 109: ...109 Chapter 5 Parts Drawings Ioline StudioJet P N 109000 1 2X 2 4 REF 9 2X 10 2X 12 18 14 2X 17 15 2X 21 20 13 4X 16 4 5 2X 6 3 22 11 2X Figure 59 StudioJet Packing List ...

Page 110: ...110 Ioline FJ Printer StudioJet Service Manual This page intentionally left blank ...

Page 111: ...able replacement 76 Images Close up xviii Latch 35 Movement 25 Notched V See Set origin Problems 57 Replacement 72 73 Schematic 35 Stall xviii Wheel replacement 74 Carriage latch 35 Carriage rail xviii xix See Traverse Carriage stall 35 Cartridges See Ink cartridges Clean 48 Clipping limits frame 31 Communications Baud rate 30 31 38 39 41 46 Data bits 41 Flow control 41 Parity 41 Conflicts 29 41 E...

Page 112: ...mages Location xviii DXF 21 22 23 24 27 E End plate xiii Error codes 37 40 Firmware update 39 Keypad errors 40 F Feed Roll 47 Feed roll xvi Feed shaft xvi File formats 26 27 Files Conversion 27 Download firmware 30 File name extensions EPS 30 PLT 30 PLX 30 Plot file adjustments See Control Center Send plot file 30 Firmware 30 38 39 40 42 43 63 80 Software version 31 Updating 30 39 80 FJ eX xvii 21...

Page 113: ...K Keypad v xviii xix 26 28 29 39 40 46 48 82 Arrow keys xiii Cable 83 Clean 48 Error codes 40 Lights LED lights 40 OK light 28 29 41 Page advance 41 Replacement 82 83 Set origin 42 43 Square light 28 29 41 Start Stop 48 L Lectra 21 22 23 24 LED error codes 37 40 Left end cover xvi Leveling pads See Leveling foot Limit of liability statement ii Line quality See Printing Quality Line width 22 23 24 ...

Page 114: ...4 86 89 90 96 97 98 102 103 104 108 109 Paper sensor 43 Parity 41 PCB See Logic board Pinchwheel lever xviii xix 47 Images View from front xviii Pinchwheels xix 47 Assembly 34 Images Location xviii Platen xvii xviii xix 43 44 47 Platen leveling Foot xvii Plot 26 32 43 44 48 Frame 31 42 45 Frame size 31 Line width 29 31 32 Scale 29 31 Sending to printer 29 Send Plot File 30 Setup 26 27 X axis 31 Y ...

Page 115: ...enu options See Control Center Send Command 30 Send plot file 30 Sensor xviii 42 43 46 57 57 58 58 Replacing 58 Serial communication See Communications Serial number xiv 25 26 Serial port ix x xiv xvii xx 22 23 24 25 41 45 63 See also Communications Service 68 Service Station xiii xviii 28 44 45 46 Set Key Code 30 Set origin 42 43 Size calibration 30 Software 37 38 39 41 42 45 46 55 See also The F...

Page 116: ...e bay problems 56 Ink issues 44 45 Ink cartridge stall problems 56 Logic board 60 62 Loss of registration between frames 42 Mechanical electrical and electronic diagnostics 42 43 45 46 57 Media tracking paper advancement 42 44 Paper problems 47 Media tracking 48 Paper tears 43 47 Plot position 42 Power problems 41 46 Print quality 42 43 45 48 49 Dirty or damaged cartridge 50 Frame gaps 50 56 Line ...

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