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Ioline FJ Printer, StudioJet, FJeX Service Manual

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Page 1
Service Manual
Ioline
FJ Printer™
& StudioJet™
Page 2
User Notice
Trademarks
Ioline, StudioJet, FJ Printer, FJ-F, FJ-8, FJ-FeX and FJ-8eX are trademarks of Ioline Corporation. HP is a trademark of the Hewlett-Packard Company. Other product names, logos, designs, titles, words or phrases mentioned within this publication may be trademarks, service marks, or trade names of Ioline Corporation or other entities and may be registered in certain jurisdictions including internationally.
Ioline Disclaimer
IOLINE CORPORATION PROVIDES THIS MANUAL “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OR CONDITIONS OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL IOLINE, ITS DIRECTORS, OFFICERS, EMPLOYEES OR AGENTS BE LIABLE FOR ANY INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES (INCLUDING DAMAGES FOR LOSS OF PROFITS, LOSS OF BUSINESS, LOSS OF USE OR DATA, INTERRUPTION OF BUSINESS AND THE LIKE), EVEN IF IOLINE HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES ARISING FROM ANY DEFECT OR ERROR IN THIS MANUAL OR PRODUCT.
Limit of Liability Statement
This manual is provided for informational purposes only. The contents are subject to change without notice and Ioline Corporation assumes no responsibility for any errors that may be contained herein.
Ioline has made every effort to make the StudioJet and all models of the FJ Printer easy to operate, main­tain, 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 pub­lications. Ioline Corporation is not responsible for injuries that may occur as a result of unsafe use. Ioline Corporation is not responsible for substandard operational performance as a result of failure to maintain the printer as described in this manual and in the User Guide.
© 2003-2007 Ioline Corporation. All rights reserved. This manual may not be copied, photocopied, repro­duced, translated, transmitted or converted to any electronic or machine-readable form in whole or in part without prior written approval of Ioline Corporation.
Service and Support
If you require assistance with an Ioline product, your local Ioline dealer or authorized service center is ready to help. Support information is also available 24/7 on the Ioline Web site—or you may contact Ioline directly:
Ioline Corporation
14140 NE 200th Street
Woodinville, Washington 98072 U.S.A.
Ioline Customer Service Department
Monday through Friday
7:00 A.M. - 5:00 P.M. U.S. Pacifi c Time
Voice: 1.425.398.8282
Fax: 1.425.398.8383
support@ioline.com
www.ioline.com
Part Numbers: (Print) 109308 Rev. 0 • (File) 109307 Rev. 0
Page 3
Ioline FJ Printer™
& StudioJet™
Service Manual
Page 4
Page 5
Images & Illustrations
Figure 1. Proper lifting procedure ...................................................................................... xiii
Figure 2. The Ioline FJ (shown) and FJeX (not shown) Printers Front View. ............ xvi
Figure 3. The Ioline FJ (shown) and FJeX (not shown) Rear View............................. xvii
Figure 4. The Ioline FJ Printer Front View Close-up .................................................... xviii
Figure 5. The Ioline StudioJet Front View .........................................................................xix
Figure 6. Power and communications ports on the Ioline StudioJet .............................. xx
Figure 7. The Ioline FJ Printer. .............................................................................................. 21
Figure 8. Paper direction. ......................................................................................................25
Figure 9. Carriage movement. .............................................................................................. 25
Figure 10. Workfl ow: output direct from CAD software (without FlexPlot). ............ 27
Figure 11. Workfl ow using FlexPlot for fi le conversion and output. ............................. 27
Figure 12. Control Center main menu. ................................................................................ 29
Figure 13. The Ioline FJ Printer power supply. ....................................................................33
Figure 14. Rear power panel assembly..................................................................................33
Figure 15. Pinchwheel assembly..............................................................................................34
Figure 16. Ink cartridges: HP 51645A. ..................................................................................34
Figure 17. FJ Printer logic board. ...........................................................................................34
Figure 18. Printer carriage 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 and dirty print cartridge. ................................................................... 46
Figure 27. The Cartridge Calibration window in the Control Center. ......................... 47
Figure 28. The Motion Adjust window. ................................................................................... 48
Figure 29. The heads are drawing the lines too late on this plot. ..................................48
Figure 30. The Frame Gap window. ...................................................................................... 50
Figure 31. Frame gaps on the plot. ........................................................................................ 50
Figure 32. Occasional frame gaps may indicate that the stand is not level. .................50
Figure 33. The height-adjusting spacer. ................................................................................. 51
Figure 34. The ink stall can crack if the cartridge door is not closed and locked. .....52
Figure 35. If the carriage makes noise, clean or replace the wheel. ............................... 52
Figure 36. A good transitor on the left; the one on the right is blown ........................ 53
Figure 37. Testing the Y-Axis motor. ...................................................................................... 55
Page 6
Figure 38. Mechanical, electrical and electronic diagnostics fl ow chart. ....................... 63
Figure 39. Left cover removal. ................................................................................................ 65
Figure 40. Right cover removal. ............................................................................................. 65
Figure 41. Bottom cover removal steps. ..............................................................................66
Figure 42. Carriage replacement. ...........................................................................................69
Figure 43. Carriage wheel replacement. ............................................................................... 70
Figure 44. Flex cable replacement. ........................................................................................73
Figure 45. Main logic board replacement. ............................................................................ 74
Figure 46. Power supply replacement. .................................................................................. 77
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-eX Printer chassis BOM (exploded view B) .....................................................103
Figure 57. FJ-eX Printer Parts List BOM. .......................................................................................104
Figure 58. StudioJet chassis BOM (exploded). .............................................................................108
Figure 59. StudioJet Packing List .........................................................................................................109
Page 7
Page 8
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Table of Contents
Safety & Cautions
Warranty
Policy
Ioline warranty policy ........................................................................................................... xiv
How to use this manual
Where to fi nd information ................................................................................................ xv
What’s in this Service Manual ...................................................................................... xv
Visual Reference Guide
Chapter 1
Overview
Product overview .................................................................................................................. 21
Supported languages ............................................................................................................ 21
FJ Printer Specifi cations ...................................................................................................... 22
FJ-eX Specifi cations .............................................................................................................. 23
StudioJet Specifi cations ....................................................................................................... 24
How the printer works ....................................................................................................... 25
Paper movement .................................................................................................................. 25
Carriage movement ............................................................................................................. 25
Serial number identifi cation ............................................................................................... 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
Communications .................................................................................................................. 30
Tools ........................................................................................................................................ 30
Help ......................................................................................................................................... 30
Page 10
Control Center menu options ........................................................................................ 31
Software Version ................................................................................................................... 31
Cartridge Count ................................................................................................................... 31
Get Plotter Data .................................................................................................................. 31
Plotter Data (check box) .................................................................................................... 31
Line Width .............................................................................................................................. 31
Scale ......................................................................................................................................... 31
Frame Size .............................................................................................................................. 31
Quality Setting ...................................................................................................................... 32
Measurement Units .............................................................................................................. 32
Chapter 2
Nomenclature
Product components ........................................................................................................... 33
Chapter 3
Troubleshooting & Testing
General troubleshooting .................................................................................................... 37
Error messages ....................................................................................................................... 37
Control Center software errors ..................................................................................... 38
Keypad error codes .............................................................................................................. 40
Legend ..................................................................................................................................... 40
Power problems ..................................................................................................................... 41
Communications ................................................................................................................... 41
The Printer won’t respond 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 stall problems ............................................................................................... 56
Noisy carriage movement ................................................................................................. 56
Mechanical, electrical, andelectronic diagnostics ................................................... 57
Electrical problems ............................................................................................................ 57
Troubleshooting sensors .................................................................................................. 57
General mechanical / electrical issues ............................................................................. 58
Simple electrical diagnostics test: ........................................................................... 59
Motor problems ................................................................................................................... 59
Page 11
Service & support ................................................................................................................. 64
Getting help ............................................................................................................................. 64
Customer service .................................................................................................................. 65
Chapter 4
Repair Procedures
Maintenance procedures ................................................................................................... 67
Repair procedures ................................................................................................................. 67
Requesting service ................................................................................................................ 68
Cover removal procedures ............................................................................................... 69
Carriage Procedures ............................................................................................................ 72
Logic Board Procedures ..................................................................................................... 78
Electrical Procedures .......................................................................................................... 80
Power supply replacement ................................................................................................ 80
Keypad procedures ............................................................................................................... 82
Testing the servo (Y-axis) motor ...................................................................................... 59
Testing the X-axis servo motor ........................................................................................ 60
Logic board assembly troubleshooting ............................................................................ 60
Logic board troubleshooting steps (Revision 2) ............................................................ 62
Left cover removal ............................................................................................................... 69
Right cover removal ............................................................................................................. 69
Left bottom cover removal ................................................................................................ 70
Carriage replacement .......................................................................................................... 72
Carriage Wheel Replacement ............................................................................................ 74
Flex Cable Replacement ..................................................................................................... 76
Logic board replacement .................................................................................................... 78
Note: Follow anti-static procedures ................................................................................ 79
Updating the fi rmware ........................................................................................................ 80
Keypad replacement ............................................................................................................ 82
X-axis belt replacement ...................................................................................................... 84
Y-axis belt replacement ....................................................................................................... 86
X-motor replacement ......................................................................................................... 88
Y-transmission replacement ............................................................................................... 90
Chapter 5
Parts & Drawings
FJ Printer chassis (exploded view A) ............................................................................ 96
FJ Printer Chassis (exploded view B) .......................................................................... 95
FJ Printer Packing List ........................................................................................................ 97
FJ-eX chassis (exploded view A) ................................................................................ 102
FJ-eX chassis (exploded view B) ................................................................................ 103
FJ-eX Packing List .............................................................................................................. 104
StudioJet Chassis ................................................................................................................ 108
StudioJet Packing List BOM .......................................................................................... 109
Index
Page 12
Page 13
The Ioline FJ printer and StudioJet have many fast moving compo-
nents. Please read and follow these safety guidelines before begin­ning operation of the printer:
Do not try to repair the machine without factory authoriza-
tion. Only qualified service personnel should attempt any
disassembly or access to internal components. If external mechanical adjustments are necessary, turn off the printer and disconnect it from all power sources (both the computer and the wall outlet).
Be careful with hair, jewelry, or loose clothing near the printer.
They can become caught in the mechanical parts.
Safety &
Cautions
Never attempt to move the carriage by hand when the power is
on. Always use the Arrow keys to move the carriage.
To park the carriage safely in the Service Station and protect the print cartridges, press the Clean but­ton.
Keep hands away
from the carriage when the printer is in operation. The car-
riage will automati­cally 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 moving or lifting the printer. Moving the print-
er requires at least 2 people. To avoid injury to your fingers, do not lift the printer by the end plates. Hold the bottom surfaces of the end covers to lift or move it. See Figure 1.
Keep fingers away from the drive shaft when the printer is in
operation. Serious injury could result.
Figure 1. Hold the bottom sur­faces of the end covers to avoid injury to your fi ngers.
To improve readability, the StudioJet is mentioned in this manual only when necessary to clarify differences in service or maintenance procedures vis à vis the FJ Printer. Unless otherwise noted, instructions pertaining to the FJ Printer are identical for the StudioJet.
Note
xiii
Page 14
Warranty Policy
Ioline warranty policy
Ioline Corporation provides a 12 month parts and labor warranty on all new equipment and 90 days on repaired units, unless specifi cally noted otherwise. Every unit is recorded by serial number when it leaves the factory. The warranty period is based on the serial num­ber 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 war­ranty 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 customer and equipment support.
xiv
Page 15
How to use
Four publications are available to assist you in setting up, operating maintaining and servicing the FJ Printer:
FJ Printer Quick Start Guide (or StudioJet Quick Start Guide*)
FJ Printer & StudioJet User Guide
FJ Printer Service Manual
FlexPlot User Guide
Where to fi nd information
The table below provides a quick directory of topics and resources:
Topic Manual
Assembly & setup Quick Start Guide
Paper loading Quick Start Guide
Removing markers User Guide
The Ioline Control Center (adjusting plot parameters)
Ioline FlexPlot software FlexPlot User Guide
Design software set-up guides FlexPlot User Guide
Maintenance User Guide
Basic troubleshooting User Guide
Advanced troubleshooting for qualifi ed service personnel
Specifi cations, part names, drawings FlexPlot Service Manual
User Guide
FlexPlot Service Manual
this manual
What’s in this Service Manual
The FJ Printer & StudioJet Service Manual provides extensive product specifi cations, testing and repair procedures.
Chapter 1 Introductory information and general specifi cations.
Chapter 2 Descriptive drawings listing part names for the FJ
Printer. This section is intended to supplement the FJ Printer User’s Guide.
Chapter 3 Troubleshooting and testing guide.
Chapter 4 Details for repair and maintenance of the FJ Printer.
Chapter 5 Technical drawings and reference material.
* The FJ Printer and Studio- Jet have separate Quick Start
Guides. When directed to consult the Quick Start Guide, please select the publication relevant to your Ioline product.
Note
xv
Page 16
KEY
A
A. Left End Cover B. 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
C
B
G
J
I
H
Figure 2. The Ioline FJ (shown) and FJeX (not shown) Printers Front View.
F
D
E
xvi
Page 17
Visual Reference Guide
KEY
K. Take-up Motor Cable L. Take-up Motor Outlet M. Power Switch N. Serial & USB Ports
M
N
O. Paper Out Sensor P. Platen Leveling Pad Q. Cross-member*
* The FJ-eX has two cross-members
O
P
L
K
Figure 3. The Ioline FJ (shown) and FJeX (not shown) Rear View (head titled in maintenance position.)
Q
*
xvii
Page 18
KEY
R. Drive Shaft Marker S. Pinchwheel Lever T. Pinchwheel U. Traverse or Carriage Rail V. Carriage Assembly W. Platen
S
X. Ink Cartridge Latch Y. Ink Cartridge Stall Z. Keypad
AA. Service Station BB. Bottom Sensor CC. Top Sensor
X
Y
Z
R
T
Figure 4. The Ioline FJ Printer Front View Close-up
xviii
U
V
W
AA
CC
BB
Page 19
Visual Reference Guide
KEY
A. Left End Cover B. Drive Shaft Marker C. Pinchwheel Lever D. Pinchwheel E. Drive Shaft
A
O
F. Right End Cover G. Keypad H. Stand Leg I. Inkjet Cartridge J. Carriage
B
C
D E
K. Stand Leveling Foot L. Feed Shaft M. Cross-member N. Platen O. Traverse
F
G
H
N
M
L
K
E
Figure 5. The Ioline StudioJet Front View.
J
I
xix
Page 20
KEY
P
P. Power Switch Q. Serial (COM) Port
R. Power Cord
Q
R
Figure 6. Power and communications ports on the Ioline StudioJet are located on the back of the right cover.
xx
Page 21
Product overview
The FJ Printer is most com­monly used in conjunction with popular apparel soft­ware for print­ing marker patterns, used in the manufac­ture of cloth­ing. The Printer also comes with FlexPlot software that allows print­ing of the most popular formats such as AutoCAD® ( DXF), CorelDraw!® ( PLT), Adobe® Illustrator® ( DXF), Lectra® ( ASTM), Investronica® ( ASTM). In addition, it plots direct to Gerber® and reads Gerber®-compatible fi le formats ( STD, PLT or ASTM).
Figure 7. The Ioline FJ Printer.
Chapter 1
Overview
The Ioline FJ Printer can handle many 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-
®
, Ioline IPS software, and other applications.
pon
Supported languages
Language Application
HPGL Direct from software or Ioline FlexPlot.
DM/PL Direct from software or Ioline FlexPlot.
DXF Ioline FlexPlot only.
STD Ioline FlexPlot only.
ASTM 6959 Ioline FlexPlot only.
Ioline syntax Direct special control characters for FJ Printer.
Page 22
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Ioline FJ Printer & StudioJet Service Manual
FJ Printer Specifi cations
Metric Empirical
Throughput 422 m/hour 502 lineal yd/hour
Max. plotting width 1.83 m 72 in
Media width
min.
max.
Marker length 548.6 m
Floor space requirements
Height
Width
Depth
.91 m
1.88 m
(Unattended)
2.4 m x .7 m
.7 m
2.3 m
1.17 m
36 in
74 in
600 yds
(Unattended)
96 in x 26 in
27.5 in
90.5 in
46 in
Weight
Actual
Dimensional (US)
Dimensional (Int’l)
106 kg
156 kg
158.2 kg
234 lbs
344 lbs
348.8 lbs
Paper type Recycled to bond
Feed roll position Front fl oor 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®, MicroMark®, and Micro-
®
dynamics Investronica
), Assyst®, AutoDesk® ( AutoCAD®),
®
, IPS, Lectra®, Scanvec® ( Optitex®),
PAD®, Polygon®, Polytropon® ( PolyPattern®),
®
Vetigraph
and others
Power requirements 85-264 VAC, 0.25 KVA, Single phase, 47-440 Hz
Humidity Non-condensing
Warranty 1-year parts and labor
Page 23
FJ-eX Specifi cations
Metric Empirical
Throughput 452 m/hour 542 lineal yd/hour
Max. plotting width 2.18 m 85.8 in
Media width
Chapter 1: Overview
23
min.
max.
Marker length 320 m
Floor space requirements
Height
Width
Depth
1.2 m
2.18 m
(Unattended)
2.62 m x .7 m
.7 m
2.6 m
1.17 m
47 in
85.8 in
349.9 yds
(Unattended)
103 in x 27.5 in
27.5 in
102.3 in
46 in
Weight
Actual
Dimensional (US)
Dimensional (Int’l)
125 kg
180 kg
190 kg
276 lbs
397 lbs
418.9 lbs
Paper type Recycled to bond
Feed roll position Front fl oor 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®, MicroMark®, and Micro-
®
dynamics Investronica
), Assyst®, AutoDesk® ( AutoCAD®),
®
, IPS, Lectra®, Scanvec® ( Optitex®),
PAD®, Polygon®, Polytropon® ( PolyPattern®),
®
Vetigraph
and others
Power requirements 85-264 VAC, 0.25 KVA, Single phase, 47-440 Hz
Humidity Non-condensing
Warranty 1-year parts and labor
Page 24
24
Ioline FJ Printer & StudioJet Service Manual
StudioJet Specifi cations
Metric Empirical
Throughput 332 m/hour 33.372 lineal yd/hour
Max. plotting width 1.01 m 40 in
Media width
min.
max.
Marker length 548.6 m
Floor space requirements
Height
Width
Depth
.2 m
1.11 m
(Unattended)
2.4 m x .7 m
1.17 m
2.26 m
.66 m
8 in
44 in
600 yds
(Unattended)
96 in x 26 in
46 in
89 in
26 in
Weight
Actual
Dimensional (US)
Dimensional (Int’l)
53 kg
54 kg
53.1 kg
116 lbs
117 lbs
117.1 lbs
Paper type 27# recycled to 150 lb tag board
Feed roll position Front fl oor 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®, MicroMark®, and Micro-
®
dynamics Investronica PAD graph
), Assyst®, AutoDesk® ( AutoCAD®),
®
®
, IPS, Lectra®, Scanvec® ( Optitex®),
, Polygon®, Polytropon® ( PolyPattern®), Veti-
®
and others
Power requirements 90-264VAC, 0.25 KVA, Single phase, 47-66 Hz, 80W
Humidity Non-condensing
Warranty 1-year parts and labor
Page 25
How the printer works
The Ioline FJ Printer combines paper and ink cartridge motion to create vector outputs in a wide 72 in format. The data are sent to the printer via either a standard RS- 232 serial or USB cable. When a fi le is sent to the printer, the electronic system translates the vectors into instructions for the “X” ( paper motion) and “Y” ( Ink cartridge mo­tion) motors. At the same time instructions are sent to the carriage assembly to apply ink to the paper.
Paper movement
Paper motion is ac­complished by pull­ing paper through the machine with a trac­tion shaft. The shaft is connected to the X-axis motor with a timing belt transmisison assembly. The drive-shaft rotates in one direction.
Figure 8. Paper direction.
Chapter 1: Overview
25
Carriage movement
The Y-Axis transmis­sion 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 assembly is stored in the Service Station to keep the ink cartridges clean and capped so they don’t dry out.
Figure 9. Carriage movement.
Serial number identifi cation
Identifi cation of Ioline Corporation products is accomplished by use of a serial number located on the back of the right side cover on the printer. You can determine the model and date of manufacture us­ing the following guidelines:
Page 26
26
Ioline FJ Printer & StudioJet Service Manual
* FJ-eX model serial numbers begin with the code “FJEX”:
Note
FJEX
StudioJet models begin with “STUDIOJET”:
STUDIOJET
FJ8* 03 26 01
{
Glossary
BOM Bill(s) of Material for Assembly
Bottom Pan Metal housing protecting the underside of the printer.
Carriage The component that holds the ink cartridges. It traveles
Keypad Where the user controls simple printer functions. Carriage
Traverse Assembly The structure that supports and guides the carriage as-
{
along the Y-Axis on the traverse assembly.
and media motion is accessible from here during stop mode.
sembly.
{
{
Number of machine manu­factured in that week
Week of manufacture
Year of manufacture
Model number
An expanded Glossary is available in the User Guide.
Note
X-Axis The direction of the paper moving through the machine.
Y-Axis The direction of the carriage moving back and forth.
Software setup options
Ioline recommends using FlexPlot for marker making on the FJ Printer. FlexPlot offers the most robust and fl exible workfl ow available for creating output. It’s especially useful when many fi le 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 deter­mine your preferred communication method. Two typical methods for sending markers are:
1. Plot directly from the marker or design software to the
printer. (See Figure 10.)
Unlike other marker printers, the FJ Printer is capable of oper-
ating as a stand-alone device with no extra software running on the computer. This method works if your CAD software in­cludes a driver for any Ioline product, such as the Ioline 600Ae or the Summit 2200. It will also work if the CAD software can create a compatible HPGL- or DM/ PL- formatted fi le.
Page 27
CAD
Software
HPGL
DM/PL
FJ Printer
Figure 10. Workfl ow: output direct from CAD software (without FlexPlot).
Chapter 1: Overview
27
2. Use FlexPlot software to convert fi les before sending them to the printer for output.
The FJ Printer includes the FlexPlot software which will con-
vert many compatible fi le formats. It also provides an advanced marker queue management system and other tools to optimize the performance of the printer.
CAD
Software
[Network]
FlexPlot
HPGL
DM/PL
DXF
ASTM 6959
STD
(Alternate Confi guration)
CAD
Software
+
FlexPlot
Figure 11. Workfl ow using FlexPlot for fi le conversion and output.
FJ Printer
Page 28
28
Ioline FJ Printer & StudioJet Service Manual
Caution
Keep hands and loose clothing away from all moving parts of the
printer. Make sure the Service
Station area is not obstructed.
Power on
Turn on the computer and the printer to make sure they both work. The printer power switch is located next to the power cord on the back of the machine, behind the keypad. When the printer is pow­ered up, the carriage will move toward the left side of the machine, then return to the opposite side to park in the Service Station. The OK light will turn red and the Square light will turn green on the front panel after the start-up process has fi nished.
Installing FlexPlot and the Control Center
The FJ Printer includes two software interfaces: FlexPlot and the Control Center. FlexPlot will import and queue marker fi les from
many design programs to optimize production 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 automatically. If it does not:
a. Select the Start button.
b. Choose Run.
c. Type D:\IOSETUP (substitute the correct letter if the CD-
ROM drive letter is not D:) and Click OK.
4. Follow the instructions that appear on the screen.
5. The FlexPlot User Guide has details on using the FlexPlot software. In this manual, see the section The Control Center for more details about the Control Center software.
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Chapter 1: Overview
29
The Control Center
Overview
The Control Center is a utility program that does two things:
Allows you to adjust settings to tailor output (e.g. scale, line
width) from the computer.
Provides an interface to send completed fi les to the printer.
To avoid communication port confl icts, do not simultaneously run more than one application that communicates with the printer.
Note
Figure 12. Control Center main menu.
Changing system settings
A variety of settings are adjustable to fi t specifi c 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 Menu Bar contains utilities for setting up the Control Center and calibrating the pinter.
Changes only take effect after one of the Send buttons is
pushed.
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Ioline FJ Printer & StudioJet Service Manual
Control Center menu bar features
File
Download Firmware Allows the user to download the
latest fi rmware version. See the User Guide for more information.
Send Plot File Print a PLT or PLX fi le.
Exit Exit the Control Center.
Communications
Settings Select the COM port and baud rate
to match the printer.
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 activation status.
FlexJet Licensing Enter new license information for
upgrades in this window.
Help
About Displays Control Center version
information.
Page 31
Control Center menu options
Software Version
Displays the current fi rmware version installed in the printer.
Cartridge Count
Displays how many cartridges are in active use by the printer.
Get Plotter Data
Reads and displays the current settings stored in the printer in the input boxes.
Plotter Data (check box)
Indicates when the displayed settings were successfully downloaded from the printer. If this box is unchecked, the Control Center was unable to connect with the printer and cannot display current settings. Check the connections, baud rate and COM port. Press the Get Plotter Data button to attempt to download settings if the process failed during startup.
Chapter 1: Overview
31
Line Width
Controls the weight of the plotted line using line width. Three levels are available; Thin, Normal, and Thick. Thin lines use less ink and make fi ne details like Asian text and small pieces easier to see. Thick lines use more ink to produce higher contrast lines.
Used in conjunction with the Quality Setting (see below), the FJ Print­er 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 Scale button is pressed. Note: Both X- and Y-Axes are set independently.
Frame Size
Most design software sends long plots to printers by breaking them into smaller pieces called frames. In general, design software does this automatically and adjusts the Frame Size in the printer to match. The Frame Size setting establishes clipping limits for each data frame. If the printed size of a plot frame exceeds the frame size set in the printer, the excess is clipped or thrown away. (If the plot is clipped, try increasing the Frame Size manually.) The factory-set X-axis (paper direction) frame size is 46 in (116.8-cm), maximum is 21600 in (54,864-cm). Default and maximum Y-axis ( carriage direc­tion) frame size is 72 in (182.9-cm).
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Ioline FJ Printer & StudioJet Service Manual
Quality Setting
Choose Draft or Best to control line density. Draft mode uses 300 DPI. Best 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 fi nd a bal- ance between saving ink and making clearly visible lines.
Measurement Units
Choose between English or Metric units for settings display.
Page 33
Product components
Chapter 2
Nomenclature
Figure 13. The Ioline FJ Printer power supply.
Figure 14. Rear power panel assembly.
Power cord pluginPower switch
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Ioline FJ Printer & StudioJet Service Manual
Wheels
(Replaceable)
Figure 15. Pinchwheel assembly.
Figure 16. Ink cartridges: HP 51645A.
X Motor encoder
Y Motor encoder
Main power
Roll feed encoder
Motor power
Fans: 1,2 & 3
LEDs (4)
Carriage power
Paper out
/ take-up
sensors
Paper out
2 sensor
Keypad
Comm.
(RS-232)
Heads 1,2 & 3
Board part
number sticker
Figure 17. FJ Printer logic board.
Page 35
Carriage latch
Carriage
Ink
cartridge
Chapter 2: Nomenclature
35
Base
Figure 18. Printer carriage assembly with cover off.
Carriage stall
V-notch
Carriage
Carriage
latch
Carriage
stall
Base
Figure 19. Printer carriage assembly with cover on.
V-notch (below)
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Ioline FJ Printer & StudioJet Service Manual
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Page 37
General troubleshooting
This section contains guidelines and testing procedures for resolving basic operatioinal diffi culties and diagnosing mechanical, electri- cal and electronic processes. Chapter 4 also contains related repair procedures.
If the system isn’t functioning correctly, fi rst determine which com- ponent is causing the problem. Likely diffi culties may involve:
 The computer
Chapter 3
Troubleshooting &
Testing
 The power cord or communication cables
 The apparel/marker design software
 The FJ Printer
Changes to the computer operating system or the installation of new peripherals or software can cause confl icts. If the problem appears to be with the computer or apparel design software, consult the appro­priate documentation or an Ioline dealer.
If the problem is with the printer, begin by making sure power is on and that the cable between 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 consult­ing this manual, fi ll out the Diagnostic Record at the beginning of Chapter 4, then contact Ioline Customer Service.
Error messages
Error messages that are specifi c to the Ioline FJ Printer are divided into two catagories: Control Center software errors and LED codes. Software errors present themselves on the computer screen and usu­ally indicate a communication problem. LED codes are visible on the keypad and can be a green light, a red light or a combination of both.
The keypad LED code table (Figure 21) is helpful for isolating the cause of obvious external or communication problems. Comprehen­sive information later in the chapter can help troubleshoot mechani­cal and electrical diffi culties. Errors caused by the operating system or the plotting software should be resolved with the software author.
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Ioline FJ Printer & StudioJet Service Manual
Control Center software errors
The FJ Printer did not respond. Do you wish to continue anyway?
The Control Center did not get a response from a FJ Printer on the COM port it is currently confi 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 confi guring the COM port and baud rate.
Unable to open communication port. You may need to select a differ­ent COM port. Do you wish to continue?
The Control Center did not get a response from a FJ Printer on the COM port it is currently confi 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 confi guring the COM port and baud rate.
Incorrect plotter model. Do you wish to continue?
The Control Center did not recognize the printer model connected to the COM port. Upgrade the Control Center to the latest version. If that does not resolve the problem, confi rm 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
Unable to change FJ Printer baud rate Do you wish to change baud rate in Control Center?
The Control Center did not get a response from a FJ Printer on the COM port it is currently confi 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 confi guring the COM port and baud rate.
Warning: Unable to open log fi le; Status messages will not be saved.
®
then start the Control Center program.
This error occurrs if the Control Center is unable to write the fi rmware up- grade process log in the same folder where the fi rmware source fi le is stored on the PC. It is typical if installing fi rmware from a CD-ROM or if the user does not have ‘Modify’ or ‘Full’ permissions to the PC fi le system. Copy the fi rmware to the hard disk and make sure permissions are correct before installing.
Page 39
NOTICE: Your fi 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 fi rmware. Firmware upgrades are available from Ioline Customer Service at (425) 398-8282 Pacifi c Standard Time USA.
The fi rmware in the FJ Printer is obsolete. An upgrade is highly recommended. Contact Ioline Customer Service to obtain the software and instructions.
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 confi 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 confi guring the COM port and baud rate.
The identifi cation numbers for this board have already been set. You must use the ‘ Reset Machine ID’ dialog to change them now.
Chapter 3: Troubleshooting & Testing
39
The user is attempting to overwrite an internal license that is already set. Contact Ioline customer service for assistance.
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Ioline FJ Printer & StudioJet Service Manual
Keypad error codes
Figure 20. LED lights
on the keypad.
Legend
G = Green light
R = Red light
Y = Yellow light
* First generation FJ Printer keypad
lights do not blink.
Y-Blink = Blinking yellow light*
OFF = Unlit
OK
G OFF OFF OFF Ready to Print, Origin Set
R OFF OFF OFF Paused / Offl ine, Keypad Active
R G OFF OFF Power-on reset fi nished.
R OFF Y-Blink OFF Paper Feed Out / Jammed
Y-Blink RROFF X- (paper) axis jam
Y-Blink G R OFF Y- ( carriage) axis jam
Y-Blink G G OFF TU (take-up) jam
OFF R Y-Blink OFF Buffer Overfl ow

Problem/Status
If keypad errors are not shown on the chart to the right, update the fi rmware. For more information, please contact Ioline Customer Service.
Note
Y-Blink OFF R OFF Init from EPROM failed
OFF RROFF File syntax error
Y-Blink Y-Blink Y-Blink OFF Printer ready to receive fi rmware
Y-Blink OFF OFF OFF Motors off / System Stop
Figure 21. Keypad LED error codes.
Page 41
Power problems
If the printer won’t power on or initialize—or if the fan does not spin—follow these initial diagnostic steps:
1. Check the power cord. Make sure that it is fi rmly plugged into the wall and into the back of the printer.
2. Check the voltage at the wall outlet and verifi y that it is within the operating limits as specifi ed in Chapter 1, Specifi cations.
If there are no obvious power problems, proceed to the Mechanical, Electrical, and Electronic Diagnostics later in this chapter.
Communications
The Printer won’t respond to the computer
If the printer doesn’t accept commands from the computer, try the following:
Chapter 3: Troubleshooting & Testing
41
1. Verifi y that the communication cable is correctly connected to the printer and to the proper 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 printer is using.
If there is ever any doubt about what baud rate the printer is using, Ioline recommends resetting it to the default of 38400. To reset the baud rate:
1. Turn off the power to the printer.
2. Press and hold the Page Advance key (the key below Set Origin) while turning power on.
3. Continue holding the Page Advance key until the OK light turns red and the Square light turns green.
If using a terminal program like TeraTerm™ to communicate with the printer, make sure to use 8 Data Bits, No Parity, 1 Stop Bit, and Xon/Xoff ( software) Flow Control.
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Ioline FJ Printer & StudioJet Service Manual
Common problems
Good print quality is dependant upon several factors. The type of paper, environmental conditions, and operator habits are only a few of the variables that can affect the quality of the plot.
It is important to load paper in the printer—and maintain it—ac­cording to the guidelines in the User Guide. The table below sum­marizes the some of the most common diffi culties users encounter. The sections following the table examine each issue in greater depth.
A marker plot doesn’t start at the correct point on the paper
Cause:
1. The origin is not set correctly.
Poor line quality.
Cause:
1. Ink cartridge is improperly installed.
2. Frame Gap setting is incorrect.
3. Carriage electronics or cables are damaged.
4. Ink cartridge is dry.
The printer does not complete the marker.
Cause:
1. Outdated software.
2. The frame/panel size is mis­matched between the printer and the design software.
Solution:
1. Position the V-notch where the
Solution:
1. Remove and reinstall ink car-
2. Use the Control Center to
3. Contact Ioline customer service.
4. Clean or replace cartridge.
Solution:
1. For updated fi rmware, please
2. Check the panel size in the
plot should start. Press the Set Origin key.
tridge.
adjust frame gap as shown in the Routine Maintenance chapter of the FJ Printer User Guide.
contact Ioline Customer Service.
software. It should be equal to the printer panel size.
Take-up shaft stops turning; No take-up during plotting.
Cause:
1. Paper sensor or motor failed.
When paper is out, machine keeps plotting.
Cause:
1. Paper sensor failed.
Solution:
1. Contact Ioline customer service.
Solution:
1. Contact Ioline customer service.
Page 43
Regular or intermittent paper tearing or paper bunches up at bottom.
Chapter 3: Troubleshooting & Testing
43
Cause:
1. Front dancer bar is not installed.
2. Paper gets “yanked” by the machine during take up.
3. Paper buckles when plotting to fl oor.
4. Paper roll damaged.
5. Paper not loaded correctly.
6. Platen not level.
7. Outdated fi rmware does not advance paper at startup.
8. Pinchwheels press on a drive shaft bearing.
9. Paper sensor failed.
Solution:
1. Install front dancer bar.
2. Make sure the front dancer bar is below the Take-up Sensor, then press Set Origin.
3. Clear paper path. Refer to the FJ Printer User Guide for proper loading procedures.
4. Inspect the feed paper roll. Dropping the paper roll on an end can wrinkle the edge which can catch the carriage and cause a tear.
5. Correct paper loading is vital. Follow the steps in the Opera-
tion 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 de­scribed in the FJ Printer Quick Start Guide if necessary.
7. Use the Control Center to check the fi rmware version and ensure it is 324 or greater.
8. With power off, raise the pinchwheels and align them with the white driveshaft markers on the traverse.
9. Contact Ioline customer service.
When Set Origin is pressed, paper is pulled tight and rips.
Cause:
1. Paper sensor failed.
When Set Origin is pressed, paper runs quickly and stops.
Cause:
1. Motor failure.
Drive shaft refuses to move when keypad button is pressed.
Cause:
1. Machine is off or unplugged.
2. Motor failure.
Solution:
1. Contact Ioline customer service.
Solution:
1. Contact Ioline customer service.
Solution:
1. Turn on or plug in machine.
2. Contact Ioline customer service.
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Ioline FJ Printer & StudioJet Service Manual
When changing paper rolls make sure you let the paper rest out­side the packaging overnight fi rst.
Note
Jagged scan alignment.
Cause:
1. Cartridge alignment is incorrect.
2. Motion alignment is incorrect.
3. Platen or stand is not level.
4. Loose carriage pulley causing ran­dom/uneven gaps between scans.
Poor paper tracking.
Cause:
1. Paper is improperly loaded.
2. Bad paper roll or paper quality.
3. Pinchwheels not in correct location.
4 Feed paper roll isn’t centered on
feed shaft.
5. Loose paper hubs.
Solution:
1. Use the Control Center to adjust cartridge alignment as shown later in this chapter.
2. Use the Control Center to ad­just motion alignment as shown later in this chapter.
3. Follow the directions in the FJ Printer Quick Start Guide to level the stand and platen.
4. Contact Ioline customer service.
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 cap print head (FJ Printer only).
4. Broken ribbon cable.
5. Logic board failure.
Solution:
1. Replace cartridge.
2. Clean the print head, follow­ing the instructions under
Cartridge Maintenance and Handling in the User Guide.
3. Contact Ioline Tech Support for assistance.
4. Replace the ribbon cable fol­lowing instructions under the Carriage Procedures section later in this chapter.
5. Contact Ioline customer service.
Page 45
Gap between each scan, broken or dotted lines or sections of plot are missing.
Chapter 3: Troubleshooting & Testing
45
Cause:
1. Frame gap setting is incorrect.
2. Ink cartridge is out of ink, dirty or the print head is plugged.
3. Ink cartridge is damaged.
4. Ink cartridge bay pins are dirty.
5. Ribbon cable is loose or broken.
6. Service Station refuses to cap cartridges (FJ Printer only).
7. Logic board failure.
Solution:
1. Use the Control Center to adjust frame gap as shown in the Routine Maintenance chapter of the FJ Printer User Guide.
2. Check ink level indicator. Replace cartridge if indicator is black. If cartridge is not empty, see Cartridge Maintenance
and Handling under the Rou­tine Maintenance chapter in
the FJ Printer User Guide.
3. Replace cartridge.
4. Contact Ioline customer 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 bad.
5. Wrong port being used.
6. Bad fi le.
7. Communication chip on plotter failed.
During power-up, carriage doesn’t move or moves quickly to the left or right, then stops.
Cause:
1. Motor failure.
Solution:
1. Plug machine in and turn on.
2. Refer to the Serial Communica- tion section earlier in this chapter.
3. Check the frame size and other settings in the software.
4. Replace data cable.
5. In the Control Center, verify that the assigned port matches the physical port.
6. Check or recreate the plot fi le.
7. Contact Ioline customer service.
Solution:
1. Contact Ioline customer service.
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Ioline FJ Printer & StudioJet Service Manual
No power when printer is turned on; Keypad lights stay dark.
Cause:
1. The power cord is damaged or disconnected.
2. Check power supply voltage.
3. The printer is damaged and needs professional service.
4. A fuse has blown.
5. Power supply failure.
Pauses during printing.
Cause:
1. Vector density is very high due to fi ne detail or the design soft- ware is not using fonts embed­ded in the printer.
2. Communication baud rate is set very low.
3. Frame length is too big.
Solution:
1. Check the power connection.
2. See Repair Procedures later in chapter 4.
3. Contact an Ioline distributor or Ioline Customer Service.
4. Replace fuse.
5. Contact Ioline customer service.
Solution:
1. Reduce vector density, use em­bedded 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 soft­ware are set to the same baud rate.
3. Reduce frame length. Set be­tween 5-in and 35-in.
Carriage refuses to move all the way to the right.
Cause:
1. Service Station failure.
Carriage hits the Service Station.
Cause:
1. Service Station spring is broken.
2. Service Station slider sticks.
Take-up motor will not stop turning.
Cause:
1. Paper sensor failed.
Solution:
1. Contact Ioline Tech Support for assistance.
Solution:
1. Contact Ioline customer service.
2. Contact Ioline customer service.
Solution:
1. Contact Ioline customer service.
Page 47
Chapter 3: Troubleshooting & Testing
47
Paper problems
Regular or intermittent paper tearing
Common situations that cause paper tearing while the printer is operat­ing include:
The paper 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.
Pinchwheel Lever
The paper path and instruc­tions for printing to the fl oor is illustrated in the FJ Printer User Guide.
Note
Front Dancer Bar
Take-up Shaft
Platen
Feed Roll
Proper Paper Path
Figure 22. The correct paper feeding path on the Ioline FJ Printer.
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Ioline FJ Printer & StudioJet Service Manual
Media tracking
Tracking is the process that controls media motion over the platen and assures accurate lines. If the paper slips under the pinchwheels or is out of alignment, printing quality will degrade. To resolve tracking diffi culties try the following suggestions:
Install paper correctly. See the Operation chapter in the User
Guide for more details.
Make sure the paper path and dancer bars are set correctly (as
shown in Figure 22 (and in the User Guide.)
Inspect the paper for wrinkles or folds. Never use paper that is
folded, wrinkled, or torn in any way. It may cause paper jams.
Make sure the pinchwheels are spaced across the paper as out-
lined in the User Guide.
The pinchwheels should never be positioned over bearings on
the drive shaft as paper tearing and bunching will occur. Verify that the pinchwheels are positioned over treads (e.g. under the white markers affi xed 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 is damaged.
Print quality problems
Line quality
In most cases, poor line quality is caused by one of several things:
The ink cartridge is empty, dirty, damaged or dried up.
The Motion Factor or Carriage Calibration needs adjustment.
The platen is not level
If line quality is uneven, try the following:
1. Press Start/Stop then the Clean keys on the keypad to automatically clean the cartridges.
2. Inspect the ink level window on cartridge. If it is black, then the cartridge is empty. Replace it with a new one.
3. Remove the cartridge(s) and manu­ally clean the print head with a (de­ionized) water-moistened, lint-free cloth. (See Cartridge Maintenance and Handling in the User Guide.)
Figure 23. HP cartridges have an ink level indicator.
Page 49
Figure 24. The ink cartridge is dirty, dry, or empty.
Chapter 3: Troubleshooting & Testing
49
4. Plot on higher quality or undamaged (free of wrinkles and bubbles) paper.
5. Use genuine 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 25. The ink cartridge requires cleaning.
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Ioline FJ Printer & StudioJet Service Manual
Dirty or damaged cartridge
Sometimes a cartridge will go bad for no apparent reason. The cartridge may look perfect and be full of ink, but it will not plot. If this occurs fi rst try pressing the Clean button on the keypad. Install a new cartridge and the tests to see if this fi xes the problem.
If this has no effect remove, clean, inspect for damage, then test. If the cartridge fails again replace it.
Broken circuit from mishandling
Figure 26. Damaged and dirty print cartridge.
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 car­tridge calibration window. If the printer is printing poorly, check some of the examples here for a possible fi x.
Calibration overview
Cartridge Alignment: Aligns the ink cartridges with each other.
On 1-head machines, cartridge calibration is not neccessary.
Motion Adjustment: Aligns (side to side) each pass of the car-
riage with the next pass.
Frame Gap: Aligns (from top to bottom) each pass of the
carriage.
Page 51
Cartridge alignment
The Control Center includes cartridge alignment settings ( Figure
). These are used for other Ioline inkjet plotter models. Since the
27
FJ Printer only has one print head, you do not need to perform ink cartridge alignment.
Chapter 3: Troubleshooting & Testing
51
Figure 28. The Cartridge Calibration window in the Control Center.
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Ioline FJ Printer & StudioJet Service Manual
Motion adjustment
To understand Motion Adjustment, think of each reversal in car­riage direction as a “pass”. With every pass, each head draws a line
1/2
-in long. If the FJ Printer has 2 heads, it draws a 1-in line for each
pass. A four-head machine will draw a 2-in line.
If the Motion Factor is too low, the printer will draw the line too late. Visu­ally, this appears as if the line drifts to the right, as shown in Figure 29. Mo- tion Factor set too high results in drift to the left.
Motion Adjustment is done when each carriage 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 de­pending on the number in the ‘Motion Adjustment fi eld’ in the FJ8 Control Center.
Figure 28. The Motion Adjust window.
Poor motion adjustment
Scan
Scan
= Direction of carriage travel
Figure 29. The heads are drawing the lines too late on this plot.
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 open.
5. In the fi eld for Motion Adjustment, type in the number 40 to start.
Page 53
6. Click the Set Motion button.
7. Click the Close button.
8. Click the File menu then Send File…
9. In the folder C:\ioline\calibration, double-click on the fi le Cali- bration Grid.plt.
10. The machine will start plotting the fi le.
11. Look at the lines as the carriage goes back and forth. If they line up, skip to Step 14.
12. Wait for the plot to fi nish and follow Steps 3 and 4 again.
13. In the Motion Adjustment fi eld try a different number. See the Motion Adjustment chart below for help with the numbers for this fi eld.
14. Once the lines match you are done. Close the Control Center and plot normally.
Chapter 3: Troubleshooting & Testing
53
Frame Gap Adjustment
Frame Gap indicates a gap or 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 open.
5. In the fi eld marked Frame Gap, type the number 2 to start.
6. Click Set Gap button.
7. Click the Close button.
8. Click the File menu then Send
File…
9. In the folder C:\ioline\calibra­tion, double-click on the fi le labeled Calibration Grid FlexJet. plt.
10. The machine will start plotting the fi le.
11. Look at the lines as the carriage goes back and forth. If they line up, skip to Step 14.
12. Wait for the plot to fi nish and fol- low Steps 3 and 4 again.
Figure 30. The Frame Gap window.
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Ioline FJ Printer & StudioJet Service Manual
Frame
Gap
One Scan
Figure 31. Frame gaps on the plot.
13. In the Frame Gap fi eld try a different number. See the Frame Gap Adjustment chart below for help with the numbers for
this fi eld.
14. Once the lines match you are done. Close the Control Center
and plot normally.
Figure 32. Occasional frame gaps may indicate that the FJ Printer platen or stand is not level.
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 locate the height-adjust­ing spacer in the Accessory Kit for this task (see Figure 33).
If the leveling procedure does not cor­rect the problem, see Ink cartridge stall problems later in this chapter.
Figure 33. The height-adjusting spacer.
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Chapter 3: Troubleshooting & Testing
55
Frame Size Adjustment
Panel size is based on older pen plotters and the software that runs them. Pen plotters plot on a fi xed panel before pulling more paper through the machine to plot on the next panel. Although the printer runs continuously, panel size still applies.
Most software, like PAD® and Optitex®, have a Panel or Frame Size setting. Both the software and the plotter must match for the plot to look right. If a gap forms in the plot, then the panels should be adjusted.
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. In the upper right corner of the Control Center window, you will see X- and Y-axis panel size fi elds.
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 fi eld
6. In the Y-axis fi eld, type the width of your paper in inches. (The default is 72 inches.)
If you use Flex Plot software to send the plot to the plotter, you can skip the Panel Size Adjust-
ment procedure.
Note
7. Once you are done click the Set Size button
8. Close the Control Center.
9. Open the software you use to design your plot fi les ( PAD®, Optitex®, etc.)
10. Change the X- and Y-axis panel sizes to match the values in the Control Center.
11. If you are unsure of how to do this, contact your software ven­dor for help.
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Ink cartridge stall problems
Always remember to close and lock the cartridge doors after remov­ing or replacing an ink cartridge. Failure to do so can damage the print electronics. Ink cartridge stalls can also crack from mishandling, causing print misalignment that is diffi cult to calibrate.
Cracked stall
Figure 34. The ink stall can crack if the cartridge door is not closed and locked.
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 35. If the carriage makes noise, you may need to clean or replace the wheel.
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Mechanical, electrical, and electronic diagnostics
Electrical problems
If, during power on, the printer experiences one or all of the follow­ing, it may have a blown transistor:
Smoke coming from inside the machine.
The carriage won’t move.
The carriage hits the right or left side hard.
The carriage moves in only one direction.
Motors only move in one direction
A motor on the machine will try to keep turning after it stops.
The most common reason for a transistor to fail is a bad or old mo­tor. As motors age, their bearings start to break down due to insuf­fi cient 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).
Chapter 3: Troubleshooting & Testing
57
Solder
Figure 36. A good transitor on the left; the one on the right has failed. The presence of
solder bubbling out of the chip indicates it overheated.
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 same sensor in multiple places for tracking pa­per path status. The sensors are industrial-grade and will withstand many years of use. If a sensor ever fails, the following conditions might occur:
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Ioline FJ Printer & StudioJet Service Manual
1. The paper take up motor will not stop rotating and will pull the paper tight against the platen. This might result in an X motor jam and a ‘popping’ noise during printing.
2. The Paper Out sensors will not detect that the paper feed roll is empty and printing may continue with no paper in the printer.
To replace a defective sensor:
IMPORTANT: Never disconnect or connect sensors to the machine or electronics when power is on. This will permanently damage the sensor and might affect the logic board.
1. Power off the printer.
2. Disconnect the plug from the sensor.
3. Note the orientation of the old sensor, specifi cally where the optical ‘eye’ 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 one­way.
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 initialize (No LEDs, fans not running, car-
riage didn’t move, small jerking motion during power up)
The printer works, but did not initialize after being reset (e.g.
after printer was turned off, then back on).
Jam messages occur without media or other objects obstructing
normal operation.
The carriage is making loud or unusual sounds.
Required tools
Multimeter capable of reading AC voltage
Phillips head screwdriver
Allen wrenches:
1/16
Nut driver or socket wrench with extension:
and 5/
64
11/32
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Chapter 3: Troubleshooting & Testing
59
Simple electrical diagnostics test:
1. Turn the power to the machine off.
2. Inspect the printer for any obvious damage or signs of mechan­ical malfunction.
3. Measure the voltage at the wall socket. Verify that the AC volt­age is between 85 and 250 VAC.
4. Clear all paper from the machine and make sure that nothing is obstructing movement of the front take-up roll.
5. Move the carriage from side to side by hand. If the carriage resists easy movement, the motor may be bad or there could be a short on the main board. (See Motor Problems and Testing the Logic Board later in this chapter.)
Motor problems
The following are possible motor problems:
1. Bad or burned motor components.
2. The motor brushes are worn down.
3. A transistor has blown on the logic board.
4. The motor is unplugged.
5. The encoder is dirty, damaged or unreadable.
Testing the servo ( Y-axis) motor
Perform the following simple test to determine if a motor problem exists.
This test applies to all the motors on the FJ Printer.
Note
Caution
Ensure that the FJ Printer is unplugged from the
wall outlet and that all AC power cables are removed from the printer before replacing the cable.
The discharge of static electric­ity may damage the carriage and logic board components. Use the included ground strap throughout the procedure. Attach one end of the ground strap (included in the Upgrade Kit) to your wrist and the other end to a bare metal portion of the printer (like the frame the holds the service sta­tion.) Keep plastic objects away from the carriage and logic board assemblies. Remove the wrist strap only after the new carriage is attached to the traverse, the cover is installed, and the metal cover is secured over the main logic board.
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
Figure 37. Testing the Y-Axis motor.
c
d
If you fi nd a bad motor, contact Ioline Tech Support. It’s possible that a transistor on the main logic board (PCB) is blown.
Note
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Ioline FJ Printer & StudioJet Service Manual
4. Unplug the yellow and black wires from the motor.
5. Using a piece of metal (like a paperclip) touch the two connec­tor lugs on the motor. (Putting the paperclip through the holes in the lugs works well.)
6. Move the carriage back and forth slowly by hand.
7. While moving the carriage back and forth, remove the paper­clip from the lugs on the motor.
8. You should notice a huge difference in resistance when touch­ing the lugs together and not. If this is the case, the servo motor is good and does not need replacing.
9. If you notice NO difference when touching the two lugs to­gether and and not, the motor is most likely bad and needs to be replaced.
Testing the X-axis servo motor
1. Follow the procedure for removing the bottom cover.
2. Locate the X axis motor 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 connec­tor 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 resistance when touch­ing the terminal lugs together and not. If this is the case, the servo motor is good and does not need replacing.
9. If you notice NO difference when touching the two terminal lugs together, the motor is most likely bad and needs to be replaced.
Logic board assembly troubleshooting
The electronic logic board is constructed of many advanced electron­ic components with fi ne pitch connections. Very few of the compo- nents are user serviceable.
The table below explains indicator lights and test points on the logic board and some troubleshooting steps to resolve user serviceable issues.
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61
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Logic board troubleshooting steps (Revision 2)
LED/Test
Point ID
TP8 30 VDC 30 volt main
TP9 3.3 VDC 3.3 volt regulated
TP10 5 VDC 5 volt regulated
D13 Dark light Y motor fault Solid red
D14 Dark light X motor fault Solid red
Normal Indicates Error
Erratic machine power supply is functioning
power supply is functioning
power supply is functioning
performance.
Erratic machine
performance.
Erratic machine
performance.
D15 Dark light Take up motor
fault
D17 Dark light Carriage power
fault
D9-D12 Blinking red
pattern
Motor control system functioning
Solid red
Solid red
Solid lights or no
lights
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Causes Troubleshooting Steps
Chapter 3: Troubleshooting & Testing
63
A short on the PCB. Main power supply voltage is not adjusted properly. Main power supply has failed.
On-board regulator failed. Main power supply failed.
On-board regulator failed. Main power supply failed.
Over-current condi­tion on circuit due to a short or high heat.
Over-current condi­tion on circuit due to a short or high heat.
Over-current condi­tion on circuit due to a short or high heat.
DC voltage measurement between TP11 (ground) and TP8 should read 30 volts +/- 1%. If voltage is out of specifi ca- tion, check power supply connections and main power supply output. Contact Ioline Customer Service for more information if the voltages are out of specifi cation.
DC voltage measurement between TP11 (ground) and TP8 should read 3.3 volts +/- 5%. Return logic board to Ioline for service.
DC voltage measurement between TP11 (ground) and TP10 should read 5 volts +/- 5%. Return logic board to Ioline for service.
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.
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.
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.
Over-current condition on circuit due to a short or high heat.
Motor jam. Software error.
Check the carriage cables and the carriage logic board to ensure there are no shorts to ground. A hardware prob­lem has occurred with the power switch for the carriage printhead power. Return the board to Ioline for service.
Remove issue causing motor jam. Cycle power on ma­chine. Update to latest fi rmware.
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Ioline FJ Printer & StudioJet Service Manual
Service & support
Ioline has many years of experience working with designers, graders and marker makers. Feel free to contact us if you have questions—or to share information.
Getting help
Ioline is committed to providing the highest quality service and sup­port to its customers. If you need assistance with an Ioline printer, a number of resources are available:
1. First, refer to this User Guide and Quick Start Guide for answers to your specifi c questions.
2. Many detailed troubleshooting and repair issues are listed in the Service Manual, available upon request from Ioline Cus­tomer Service.
3. Consult the support section of the Ioline Web site: www.ioline.
. FJ Printer users must have a User Name and Password to
com
log into the site. Please contact Ioline customer service to set up your free account.
4. For additional assistance, contact your local dealer or Ioline Customer Service. Contact information is listed under Customer Service in this chapter.
Any warranty servicing of this product not specifi cally 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 (Re­turn Material Authorization). Please gather the information indicat­ed on the next page before contacting Ioline or your dealer.
1. When returning a machine, carefully package the equipment in its original container or packaging equivalent. You may purchase shipping containers from Ioline by contacting Ioline Customer Service. Ioline is not responsible for any damage
due to inadequate or improper packaging.
2. Carefully wrap and secure all items in the shipping container to prevent damage. Seal the container and note the RMA number near the address block.
3. Ship the container using FED-EX or another approved carrier. COD shipments ARE NOT ACCEPTED. An Ioline representa­tive will contact you prior to the start of work with an estimate of repair cost. All repairs are warranted for 90 days.
Page 65
Customer service
Ioline Corporation is committed to providing quality service and support to our customers. If you need assistance with an Ioline prod­uct, 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. Pacifi c Time
Voice: 1.425.398.8282
Fax: 1.425.398.8383
support@ioline.com
www.ioline.com
Chapter 3: Troubleshooting & Testing
65
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Maintenance procedures
See the User Guide for information on maintaining the printer and storing inkjet cartridges.
Repair procedures
The diagnostic processes that follow are detailed and invasive. Do not attempt to service the printer until it you determine that simpler solutions fail to resolve the problem (see Troubleshooting).
Chapter 4
Repair Procedures
Follow the recommended sequence in Figure 38 when troubleshoot­ing repair issues with the printer and record the results of your diagnostic examination on the Diagnostic Record (see below).
Computer
Software
Resolution
LED Codes
Begin recording
diganostic information
Examine the external
components
Disassemble, check cabling
and connections
Examine power supplies
Examine logic board
Communication
Problem
diagnostic information
Power On Test
Computer
Software
Resolution
Power On Test
Begin recording
Examine motors
Contact Ioline Customer
Service (if required)
Figure 38. Mechanical, electrical and electronic diagnostics fl ow chart.
Power On Test
Power On Test
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Ioline FJ Printer & StudioJet Service Manual
Requesting service
If the suggestions and guidelines in this manual don’t fi x the prob- lem, fi ll out the form below and contact Ioline Customer Service.
Diagnostic Record
What is the serial number for this unit? ______________
What is the logic board revision #? ______________
Name of dealer who sold the machine to you? ______________
Any lights on the logic board associated with this problem? Y / N
Any lights on the keypad associated with this problem? Y / N
Has the unit worked properly up to the point of this recent failure? Y / NIf yes, please describe them: _________________________________
Any communications or software problems? Y / NIf yes, please describe them: _________________________________
When the printer is fi rst 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: Left / Right / Equal
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 readings here:
TP8 (+30V) ____________
TP9 (+3.3V) ____________
TP10 (+5.0V) ____________
Were any encoders bad? If yes, which ones? Y / N
X-motor ____ Y motor ____ Roll Feed motor ____
Please list any other problems. (Be specifi c about the nature of the problem
and the symptoms associated with it.
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
Page 69
Cover removal procedures
o
o
Left Cover Removal
1. Power off and unplug the data and power cables.
2. Remove the two black Phillips screws (Figure 39, photos 1 & 2).
3. Remove the left cover (Figure 39, photo 3).
Chapter 4: Repair Procedures
69
Photo 1 Photo 2
Figure 39. Left cover removal.
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).
Photo 3
Phot
Photo 1
Figure 40. Right cover removal.
Photo 2
Photo 3
Phot
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Ioline FJ Printer & StudioJet Service Manual
Left Bottom Cover Removal
1. Power off and unplug the data and power cables.
2. Unplug the take-up motor cable from the bottom right side of the machine (Figure 41, photos 1 & 2).
3. Remove the right and left screws 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).
Right rear
screw
Rear screw
Photo 1
Photo 4
Photo 2 Photo 3
Stop screw
Photo 5 Photo 6
Front screw
Front screw
Stop screw
Philips screw
Photo 7 Photo 8
Photo 9
Figure 41. Bottom cover removal steps.
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5. Carefully rotate the machine forward until the head stops (Fig­ure 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).
Chapter 4: Repair Procedures
71
Photo 10
Sensor plug
Fan plug
Photo 12 Photo 11
Photo 13 Photo 14
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Ioline FJ Printer & StudioJet Service Manual
Caution
Ensure that the FJ Printer is unplugged from the
wall outlet and that all AC power cables are removed from the printer before replacing the cable.
The discharge of static electric­ity may damage the carriage and logic board components. Use the included ground strap throughout the procedure. Attach one end of the ground strap (included in the Upgrade Kit) to your wrist and the other end to a bare metal portion of the printer (like the frame the holds the service sta­tion.) Keep plastic objects away from the carriage and logic board assemblies. Remove the wrist strap only after the new carriage is attached to the traverse, the cover is installed, and the metal cover is secured over the main logic board.
Carriage Procedures
Carriage replacement
Required tools
Phillips screwdriver
9
/64-in (3.5mm) Allen wrench
5
/16-in (8mm) open-end wrench
Small, fl at-tipped screwdriver
1. Follow procedure for left cover removal earlier in this chapter.
2. Mark the Y-belt tensioner screw and bracket with Whiteout® so that it is easy to properly tighten the screw after re-installation. Loosen the Y-belt tensioner (Figure 42, photo 1).
3. Unclip Y-belt from carriage (Figure 42, photo 2).
4. Remove the carriage cover by removing both cover screws (Figure 42, photos 3 & 4).
Parts/tools included with the upgrade kit:
Replacement carriage assembly
Tyraps (8)
Grounding wrist strap
Caution
Do not hold the carriage by the inkjet head stalls.
Improper removal or instal­lation of the carriage can damage the carriage wheels.
Make sure the belt is not twisted before attaching the clips.
Note
5. Loosen the carriage locking nut until the thick washer drops (Figure 42, photos 5 & 6). Don’t remove.
6. Push down on carriage and pull the bottom toward you. Re­move from machine (Figure 42, photo 7).
7. Unplug ribbon cable from carriage (Figure 42, photos 8 & 9). Cut all tyraps holding cable on carriage.
8. Plug in new ribbon cable to new carriage. 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 43, photos 8 & 9). arrange as shown in Figure 42,
Photo 8. Use new tyraps (included) to secure cable to top of car­riage. Ensure the black sleeve is secured by 3 cable tyraps.
9. Put top wheel on traverse (Figure 42, photo 7).
10. Push down. Put bottom wheels on traverse.
11. Lift up on carriage locking nut washer 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.
Page 73
Photo 1 Photo 2
Chapter 4: Repair Procedures
73
Photo 4
Photo 5
Photo 7 Photo 8
Photo 6
Photo 9
Figure 42. Carriage replacement (FJ Printer carriage shown).
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Ioline FJ Printer & StudioJet Service Manual
Carriage Wheel Replacement
1. Follow carriage replacement procedure (Steps 1, 2, 3, 4, 5 & 6 only).
2. Locate the wheels (Figure 43, photo 1) and unscrew the wheel stud nuts on back of carriage (Figure 43, photo 2).
3. Remove the wheels (Figure 43, 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 pro­cedure (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 Ioline Tech Support.
Photo 1
Photo 3 Photo 4
Figure 43. Carriage wheel replacement.
Photo 2
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Chapter 4: Repair Procedures
75
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Ioline FJ Printer & StudioJet Service Manual
Flex Cable Replacement
Required tools
Phillips screwdriver
9
/64-in (3.5mm) Allen wrench
5
/16-in (8mm) open-end wrench
Small, fl at-tipped screwdriver
1. Follow the procedures for left cover removal and carriage re­moval (Steps 1–7) earlier in this chapter.
2. Remove the ribbon cable cover (held on with double-stick tape) (Figure 44, photos 1 & 2).
3. Pull the ribbon cable through the left side of the machine (Figure 44, photos 3 & 4).
4. Follow the procedure for bottom cover removal earlier in this chapter.
5. Cut the tyraps holding the ribbon cable to the main logic board and other cables (Figure 44, photo 5). Remove cable from cable cups under platen.
6. Unplug the old ribbon cable from main logic (PCB) board (Fig- ure 44, photo 6).
7. Remove from machine.
8. Put new cable through left end plate. Make sure the end with the black, thick ferrites 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. Make sure to install screws that hold machine on the stand.
12. Route the new cable into the opening on left end plate (Figure 44, photo 4).
13. Connect the new ribbon cable to the carriage. (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, photos 7 & 8).
14. Install the carriage. (Follow the carriage replacement proce­dure, Steps 9–15).
15. Slide the carriage to the right side of the machine to check the ribbon cable loop (Figure 44, photo 9). Caution: The loop of
the ribbon cable must not hit the right end plate when the carriage is pushed all the way to the right end plate.
Page 77
16. Install the ribbon cable cover on the left side of the machine (Figure 44, photos 1 & 2).
17. Test.
Chapter 4: Repair Procedures
77
Photo 1 Photo 2
Photo 4
Photo 5
Photo 3
Photo 6
Photo 7 Photo 8
Figure 44. Flex cable replacement.
Photo 9
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Ioline FJ Printer & StudioJet Service Manual
Logic Board Procedures
Logic board replacement
Tools Required:
Phillips head screwdriver
Tyrap (1)
Photo 4
Photo 1
Photo 2
Photo 3
Photo 6Photo 5
Figure 45. Main logic board replacement.
Page 79
Chapter 4: Repair Procedures
79
Note: Follow anti-static procedures
1. Follow procedure for bottom cover removal earlier in this chapter.
2. Unplug all connectors from Main logic (PCB) board (Figure 45, photos 1 & 2).
3. Cut the tyrap holding the ribbon cables (Figure 45, photo 3).
4. Remove the three Phillips screws holding the main logic board (Figure 45, photo 4).
5. Carefully remove the logic board from the machine (Figure 45, photo 5).
6. Install the new PCB. Make sure you place the logic board behind the rib in the body as shown. (Figure 45, photos 6 & 4).
7. Loop a tyrap through the hole in the upper right corner of the main logic board. Wrap it around the ribbon cable. Do not tighten yet. (Figure 45, photo 3).
8. Connect all wires to new main logic board. (Use caution and plug the connectors in properly, a missed row of pins will dam­age 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 machine on the stand legs.
Caution
When removing the new logic board from the pack-
aging make sure you are wearing the static grounding strap correctly. and have attached it to a metal chassis ground. If there is a static discharge to the new board it may not function properly. The strap is included in the replace­ment kit.
If fi rmware is a lower number than version 253.2, use the Manu­al fi rmware update procedure
Note
11. Follow the procedure for Motion Adjustment in Chapter 3.
12. If problems arise, contact Ioline Tech Support.
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Ioline FJ Printer & StudioJet Service Manual
Caution
Never disrupt the fi le upload to the machine.
when installing fi rmware. Doing so will damage the main PCB and will make it diffi cult to re-install or update the fi rmware in the future.
Updating the fi rmware
1. Place the fi rmware installation fi le in the C:\ioline folder
2. Make sure the plotter is connected to the computer. Press the Set Origin on the keypad to illuminate the green OK LED.
3. Open the Control Center.
4. Click the File menu.
5. Click Download Firmware.
6. Locate the fi rmware installation fi le and double-click it. Never disrupt the fi le upload to the machine. when installing fi rm- ware. Doing so will damage the main PCB and will make it more diffi cult to re-install or update the fi rmware in the future.
7. The fi rmware will install on the machine. Wait for it to fi nish.
8. Close the Control Center. Caution: Never disrupt the fi le up-
load to the machine. when installing fi rmware. Doing so will damage the main PCB and will make it diffi cult to re-install or update the fi rmware in 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 if the plotter refuses to power up after installation.
Electrical Procedures
Tools Required
Phillips head screwdriver
Power supply replacement
1. Follow procedure for bottom cover removal earlier in this chapter.
2. Unplug the small connectors from the power supply (Figure 46, photos 1 & 2).
3. Unscrew the two power supply screws. (Figure 46, photo 3).
4. Unplug the large connector from the power supply. (Figure 46, photos 4 & 5) and remove the power supply from the platen.
Page 81
5. Plug the big connector into the new power supply (Figure 46, photos 5 & 4).
6. Install the new power supply into the plotter body. Make sure you insert the bottom tab into the gap built into the body of the machine (Figure 46, photo 3). Check the other power supply for 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.
Chapter 4: Repair Procedures
81
Connector
Photo 1 Photo 2 Photo 3
Connector
Photo 4
Photo 5 Photo 6
Figure 46. Power supply replacement.
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Ioline FJ Printer & StudioJet Service Manual
Keypad procedures
Keypad replacement
Tools Required
Phillips head screwdriver
11/32” wrench
1. Follow procedure for right cover removal.
2. Follow the procedure for bottom cover removal.
3. Unplug keypad cable from the main logic board and gently push through the hole in the right end plate (Figure 47, photos 1 & 2).
4. Rotate the machine back to normal operating position.
Connector
5. Remove the keypad resistor from the keypad (Figure 47, pho­tos 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).
Photo 1
Photo 3
Photo 2
Figure 47. Bottom cover removal steps.
Page 83
8. Remove keypad from the studs (Figure 47, photo 6).
9. Install the new keypad on the studs and tighten the nuts. Do Not over tighten. (Figure 47, photo 6).
10. Install the Y-axis transmission. (Follow Y-transmission proce­dure replacement in reverse).
11. Connect the keypad resistor to the hole in the keypad Do Not over tighten. (Figure 47, photos 3 & 4 & 5).
12. Rotate the machine to access the main logic board.
13. Loop the new keypad cable through the hole 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 earlier in this chapter.
15. Rotate the machine back to normal operating position and re­install screws that hold machine to stand legs.
Chapter 4: Repair Procedures
83
16. Replace the right side cover.
17. Test the plotter.
18. If problems arise, contact Ioline Tech Support.
Resistor
Hole for resistor
Photo 5
Photo 13
Photo 4
Nuts
Photo 6
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Ioline FJ Printer & StudioJet Service Manual
X-axis belt replacement
Tools Required
Phillips head screwdriver 11/32” wrench
1. Follow the right side cover removal procedure.
2. Hold the X-motor and unscrew two of the Phillips screws holding 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).
Photo 1
7. Install the two screws that hold motor (leave all three screws loose for now). (Figure 48, photos 2 & 1).
8. Push the pulley toward the back of machine and hold (for tension).
Leave loose
Photo 2 Photo 3
Photo 4
Photo 5
Figure 48. X-axis belt replacement.
Page 85
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.
Chapter 4: Repair Procedures
85
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Ioline FJ Printer & StudioJet Service Manual
Y-axis belt replacement
Tools Required
Phillips head screwdriver 11/32” wrench
1. Follow the procedure for the left cover removal.
2. Follow the procedure for the right cover removal.
3. Follow the procedure for the carriage removal (Steps 1, 2 & 3 only).
4. Remove the Y-axis belt from the machine (Figure 49, photos 1 & 2).
5. Remove the Y-axis belt from the tensioner. (See Figure 49, photos 3–5)
6. Install the new belt, following the instructions above in 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-trans­mission 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 chapter.
10. Tighten the Y-axis belt tensioner.
11. Replace the right and left side covers.
12. Test the machine. If everything works properly.
13. If problems arise, contact Ioline Tech Support.
Photo 1 Photo 2 Photo 3
Figure 49. Y-axis belt replacement.
Page 87
Chapter 4: Repair Procedures
87
Photo 4 Photo 5 Photo 6
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Ioline FJ Printer & StudioJet Service Manual
X-motor replacement
Tools Required
Phillips head screwdriver 11/32” wrench
1. Follow right cover removal procedure.
2. Unscrew two of the Phillips screws holding the X-motor. Leave the bottom screw loose; don’t remove it. (Figure 50, photos 1, 2 & 3).
3. Rotate the small pulley toward the front of the machine (Figure 50, photo 4).
4. Remove X-belt from both pulleys and set aside.
5. Follow procedure for main logic board removal and set the board aside.
6. Unplug the encoder and power wires from the motor (inside the machine). (Figure 50, photos 5 & 6).
7. Unscrew the last Phillips screw holding the motor.
8. Remove the motor from the right end plate of the plotter.
9. Remove the motor pulley from the old motor and install on the new motor in approximately the same position. Lightly tighten one set screw for now.
10. Install the new motor with the bottom screw only on the right end plate of the plotter. (See Figure 50, photo 5 for correct rota­tion).
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 fl ip machine back to normal operating position. Re-install the screws that hold the machine on the stand.
14. Install the X-belt on both pulleys, following Steps 3–4 (above) in reverse (Figure 50, photo 4).
15. Rotate the small pulley toward the back of the machine (Figure 50, photo 3).
16. Install the two remaining screws that hold the motor. Leave loose for now. (Figure 50, photo 2).
17. Loosen and adjust the small motor pulley to line up with big pulley and belt. Tighten both set screws.
18. Push the pulley toward back of machine and apply tension. Take caution not to make the belt too tight, as this will cause excessive wear.
19. Tighten the motor mounting screws (Figure 50, photos 2 & 1).
20. Install the right side cover.
Page 89
21. Test the plotter.
22. If problems arise, contact Ioline Tech Support.
Chapter 4: Repair Procedures
89
Photo 1 Photo 2
Photo 4 Photo 5
Photo 3
Photo 6
Figure 50. X-motor replacement.
Photo 7
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Ioline FJ Printer & StudioJet Service Manual
Y-transmission replacement
Tools Required
Phillips head screwdriver 11/32” wrench
1. Follow procedure for carriage replacement (Steps 1, 2 & 3 only).
2. Pull Y-belt through right end plate (Figure 51, photo 1).
3. Remove the nuts holding the Y-transmission (11/32”) nuts (Figure 51, photos 2 & 3). Note: Take care unscrewing 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 trans­mission 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).
Photo 1
7. Install nuts until tight. Note: place the keypad resistor on the top left stud and tighten the nut. Do Not over tighten the resistor nut.
8. Plug the encoder and power wires into the bottom of the motor. Yellow = + (Positive, Red 501), Black = - (Negative, Black 502).
9. Install the belt ends on the carriage.
Photo 2 Photo 3
Photo 5
Figure 51. Y-transmission replacement.
Photo 4
Page 91
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.
Chapter 4: Repair Procedures
91
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This page intentionally left blank.
Page 93
FJ Printer Chassis BOM
( Bill of Materials—108792)
Part
SEQ
Number Description QTY
1 108859 PLATEN ASSY, FJ8, ROHS 1
2 106756 TRAVERSE, I/S 600/28, ROHS 1
3 106858 DUST COVER, I/S-600/28, ROHS 1
4 108886 SHAFT, SQUARE, CAM, 15.0 LG, ROHS 1
5 108764 DRIVE SHAFT ASSY, FJ8 1
6 108769 PWHEEL ASSY, DOUBLE WHEEL, 12LB, ROHS 4
7 108806 CARRIAGE ASSY, 600FJ 1
8 108718 KEYPAD ASSY, FJ8, ROHS 1
9 108719 REAR PANEL ASSY, 600 FJ, ROHS 1
10 108900 ASSY, Y BELT, GT, 2MM, FJ8, ROHS 1
11 108758 Y TRANS ASSY, GT, 5080 CPI, ROHS 1
13 106684 LEVER ASSY, PINCHWHEEL, ROHS 1
14 108901 TENSIONER, ASSY, FLANGED BEAR, ROHS 1
15 109178 FAN ASSY, 24-48 V, 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, 24V, ROHS 1
38 109165 CABLE ASSY, RBN, 1 HD, FJ8, ROHS 1
39 109253 CABLE ASSY, TU & POWER, INT, ROHS 1
41 107861 CABLE ASSY, FAN, SHORT, IJ02, ROHS 1
42 108757 BELT, GT 2MM, 105T, 6MM W, ROHS 1
43 108756 PULLEY, GT 2MM, 20T, 6MM W,4MM,ROHS 1
46 106649 LABEL, DRIVE AREA, ROHS 4
47 100705 PAD, PEN CAP, 1/4 DIA, ROHS 5
48 106652 RIVET, PLASTIC,.2 GR X .169OD, ROHS 8
Chapter 5
Parts & Drawings
Page 94
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Ioline FJ Printer & StudioJet Service Manual
FJ Printer Chassis BOM
(Cont.’d—108792)
Part
SEQ
Number Description QTY
49 106695 FERRITE, SPLIT, 100MHZ, .74IDX1.6L, ROHS 1
52 107849 CAP, VINYL, .437”D X 1.5”L, ROHS 2
54 106241 WSHR,#8-32,.190ID,.416OD,.080THK,ROHS 2
58 104180 SCREW,#8,.50 LG,SLF TAP,PHP,SE ROHS 25
59 100026 SCREW #6-32, .5 LG, PHP, SEMS, ROHS 11
61 104590 SCREW #8, .50 LG, ST, FHP, ROHS 10
63 102726 SETSCREW #10-32, .75 LG, STEEL,ROHS 6
64 104013 NUT, #8-32, KEP, ROHS 15
66 100279 CONN, CABLE CLIP, 1 IN, ROHS 13
67 103026 CONN, CABLE CLIP, .18 DIA, ROHS 3
68 103027 TYRAP, .1 IN X 5 3/4 LG, ROHS 20
69 104726 GROMMET STRIP, CONTINUOUS 7/64, ROHS 6
72 108437 TAPE, FOAM, VHB, 5925, .025T, .625W, ROHS 9
74 106786 TAPE, DOUBLE COATED, .25 WIDE, ROHS 81
75 106686 STRIP, CUTTING, SC98, ROHS 81
77 106951 SPRING, TORSN, .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 108839 BOTTOM COVER ASSY, RIGHT, FJ8, ROHS 1
98 108840 BOTTOM COVER ASSY, LEFT, FJ8, ROHS 1
101 102219 LEVELER, 1.5 PAD, 3 IN ADJUST, ROHS 2
102 102220 NUT, #3/8-16, HEX, ROHS 2
105 108836 MAGNET, NEO, .50 OD, .25 LG, ROHS 1
106 108796 CHANNEL, RIBBON CABLE, 600FJ, ROHS 1
107 108771 SPACER, DSHAFT, PL, 32.30LG, ROHS 2
108 108600 CABLE ASSY, PPR OUT, FJ8, ROHS 1
109 100046 SCREW #8-32, 1.25 LG, SHC, ROHS 1
110 103740 TAPE, FOAM, .5 IN, .025 THICK, ROHS 2
111 109048 GROUND, 1M OHM, W/TERM, ROHS 1
112 104008 SCREW #8-32, .375 LG, PHP SEMS,ROHS 1
Page 95
FJ Printer Packing List BOM
(Bill of Materials—108790)
Part
SEQ
Number Description QTY
1 108792 CHASSIS, FJ8 1
2 106174 CROSSMEMBER, 600/28, ROHS 1
5 108261 COVER, RIGHT, APPAREL, ROHS 1
6 105166 COVER, LEFT END, S88, ROHS 1
8 106264 SHAFT ASSY, FEED, 600, ROHS 1
9 106833 TAKE-UP SHAFT ASSY, I/S 28, ROHS 1
10 106244 DANCER BAR ASSY, FRONT P600, ROHS 1
12 108386 COVER, TAKE-UP APPAREL, ROHS 1
13 106284 BOX, SHIP, 600/28, ROHS 1
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-.35ID ROHS 1
34 108727 LEG ASSY, RIGHT, FJ8, ROHS 1
35 108728 LEG ASSY, LEFT, FJ8, ROHS 1
37 108837 TAKE-UP ASSY, LEFT, FJ8, ROHS 1
38 100113 NUT, #1/4-20, HEX, NYLOC, ROHS 4
39 104008 SCREW #8-32, .375 LG, PHP SEMS,ROHS 4
41 108824 KIT, QUICK START, FJ8 1
Chapter 5: Parts & Drawings
95
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Ioline FJ Printer & StudioJet Service Manual
2X
107
REF
38
C
3X
59
2X
SEE DETAIL E
52
77
SEE DETAIL G
13
17
4X, SEE DETAIL J
6
74
36
D
4X, SEE DETAIL A
46
72
4
3
5X
2
110
106
7
5X
68
10
72
5X
58
75
76
2X
58
43
5X
58
B
6X
63
1
38
5
84
C
Ioline FJ Printer (P/N: 108792)
42
2X
58
39
B
REF
82
82
8X
4X
59
58
2X
21
72
10X
61
98
SEE DETAIL J
2X
94
93
92
108
D
2X
64
34
2X
15
SEE DETAIL K
2X
102
3X
58
16
97
90
8X
48
2X
101
89
66
REF
14
10
58
72
58
Figure 52. Ioline FJ Printer chassis (exploded view A).
SEE DETAIL F
18
Page 97
Chapter 5: Parts & Drawings
97
2X
4X
REF
64
111
REF
11
10
109
105
REF
2X
17
47
REF
13
REF
21
54
64
111
112
REF
39
25
69
DETAIL A
REF
46
REF
2
REF
34
2X
64
9
2X
8
64
39
DETAIL G
2X
89
64
81
REF
STRIPE
38
REF, 5X
68
REF
7
REF
10
DETAIL J
REF
77
REF
4
3X
SEE DETAIL E
47
REF
18
26
2X
64
REF
10
REF
7
STRIPE
REF
38
DETAIL E
3X, REF
47
REF
59
DETAIL K
REF
82
REF
88
REF
1
DETAIL F
(PEN 1)
DETAIL D
DETAIL N
(FAN CABLE)
REF
38
DETAIL J
REF
90
STRIPE
REF
13
10X
66
REF
38
(CARRIAGE CABLE)
3X
67
REF
41
(FAN CABLE)
REF
38
(POWER)
REF
9
(RS-232 CABLE)
(KEYPAD)
REF
8
(KEYPAD)
REF
8
REF
108
(PAPER SENSOR)
REF
42
REF
39
(MOTOR POWER)
3X REF
59
REF
90
REF
41
REF
39
STRIPE
REF
96
(LEG SENSOR CABLE)
REF
43
REF
11
(Y-MOTOR ENCODER
(FAN CABLE)
REF
103
(PAPER OUT SENSOR)
(FAN CABLE)
VIEW B-B
REF
(MOTOR POWER CABLE)
82
REF
39
(TU/POWER)
REF
36
(X MOTOR ENC)
49
CABLE)
(POWER CABLE)
REF
11
(Y MOTOR ENC)
REF (RS-232 CABLE)
9
15X
68
Ioline FJ Printer (P/N: 108792)
2X
66
VIEW C-C
REF
96
Figure 53. Ioline FJ Printer chassis (exploded view B).
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Ioline FJ Printer & StudioJet Service Manual
2X
24
4X
25
20
5
4X
2X
25
23
2X
2X
26
1
2X
26
39
21
Ioline FJ Printer (P/N: 108790)
REF
1
2X
39
35
37
10
41
2X
15
38
2X
18
9
8
2
14
6
REF
1
2X
12
26
34
30
Figure 54. FJ Printer Packing List.
2X
38
13
2X
19
Page 99
FJ-eX Chassis BOM
( Bill of Materials—108862)
Part
SEQ
Number Description QTY
1 108864 PLATEN ASSY, FJEX, ROHS 1
2 107428 TRAVERSE, 600AEX, ROHS 1
3 107431 DUSTCOVER, 600AEX, ROHS 1
4 106660 SHAFT, CAM, SC98, 24, ROHS 1
5 108867 DRIVE SHAFT ASSY, FJEX, ROHS 1
6 108769 PWHEEL ASSY, DOUBLE WHEEL, 12LB, ROHS 6
7 109335 CARRIAGE ASSY, 600FJ, ROHS 1
8 108718 KEYPAD ASSY, FJ8, ROHS 1
9 109337 REAR PANEL ASSY, 600 FJ, ROHS 1
10 108863 Y-BELT ASSY, FJEX, ROHS 1
11 108758 Y TRANS ASSY, GT, 5080 CPI, ROHS 1
13 106684 LEVER ASSY, PINCHWHEEL, ROHS 1
14 108901 TENSIONER, ASSY, FLANGED BEAR, ROHS 1
15 109178 FAN ASSY, 24-48 V, W/CONN, ROHS 3
16 108847 PCB ASSY, MAIN, FJEX, 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, 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,ROHS 1
46 106649 LABEL, DRIVE AREA, ROHS 6
47 100705 PAD, PEN CAP, 1/4 DIA, ROHS 5
48 106652 RIVET, PLASTIC,.2 GR X .169OD, ROHS 12
49 106695 FERRITE, SPLIT, 100MHZ, .74IDX1.6L, ROHS 1
52 107849 CAP, VINYL, .437”D X 1.5”L, ROHS 2
54 106241 WSHR,#8-32,.190ID,.416OD,.080THK,ROHS 4
58 104180 SCREW,#8,.50 LG,SLF TAP,PHP,SE ROHS 25
59 100026 SCREW #6-32, .5 LG, PHP, SEMS, ROHS 11
61 104590 SCREW #8, .50 LG, ST, FHP, ROHS 14
63 102726 SETSCREW #10-32, .75 LG, STEEL,ROHS 8
64 104013 NUT, #8-32, KEP, ROHS 14
66 100279 CONN, CABLE CLIP, 1 IN, ROHS 13
67 103026 CONN, CABLE CLIP, .18 DIA, ROHS 3
Chapter 5: Parts & Drawings
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Ioline FJ Printer & StudioJet Service Manual
FJ-eX Chassis BOM
(Cont.’d—108862)
Part
SEQ
Number Description QTY
68 103027 TYRAP, .1 IN X 5 3/4 LG, ROHS 20
69 104726 GROMMET STRIP, CONTINUOUS 7/64, ROHS 6
72 108437 TAPE, FOAM, VHB, 5925, .025T, .625W, ROHS 9
74 106786 TAPE, DOUBLE COATED, .25 WIDE, ROHS 94
75 106686 STRIP, CUTTING, SC98, ROHS 94
77 106951 SPRING, TORSN, .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 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 108836 MAGNET, NEO, .50 OD, .25 LG, ROHS 1
106 108796 CHANNEL, RIBBON CABLE, 600FJ, ROHS 1
107 108884 SPACER, DSHAFT, PL, 35.68 LG, ROHS 2
108 108600 CABLE ASSY, PPR OUT, FJ8, ROHS 1
109 100046 SCREW #8-32, 1.25 LG, SHC, ROHS 1
110 103740 TAPE, FOAM, .5 IN, .025 THICK, ROHS 2
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