JS500 Serirs
SignJet
Service Manual
MANUAL NO. JS500-UM-251
JS500-UM-251-01-9370
HISTORY OF REVISIONS
No. Date issued
1
07.12.26 First printing
Description of revision
Page
All
Edition
01
JS500 Service Manual
CONTENTS
1. Introduction ....................................................................................1-1
1.1
Standard Specifications ...................................................................................... 1-1
1.2
Optional Accessories ........................................................................................... 1-2
1.3
Consumables ........................................................................................................ 1-2
1.4
External Dimension .............................................................................................. 1-3
2. Assembling the Printer .................................................................2-1
2.1
Installation Space ................................................................................................. 2-1
2.2
Installation Location............................................................................................. 2-1
2.3
Assembling the printer ........................................................................................ 2-2
3. Parts Name and Functions ...........................................................3-1
3.1
Parts Name and Functions .................................................................................. 3-1
3.2
Standard Accessories .......................................................................................... 3-8
4. Set Up the Printer ..........................................................................4-1
4.1
Installing the Print Heads .................................................................................... 4-2
4.2
Cleaning the Ink Tube .......................................................................................... 4-6
4.3
Removing the Cleaning Solution (or Ink) from the Ink Tubes ........................ 4-14
4.4
Filling the Ink (or ink cleaning solution) to the Tube ...................................... 4-21
4.5
Preparing the Cleaning Roller and the Cap ..................................................... 4-29
4.5.1
Moistening the Cleaning Roller with Cleaning Solution .......................4-29
4.5.2
Moistening the Sponge in the Cap with Cleaning Solution ..................4-32
4.6
Loading the Media .............................................................................................. 4-34
4.6.1
Installing a Media to the Media Supply Shaft ........................................4-34
4.6.2
Load a Media onto the Printer .................................................................4-35
4.6.3
Setting the Take-up Unit ..........................................................................4-38
4.7
Installing the GPU .............................................................................................. 4-42
4.7.1
Installing the GPU ....................................................................................4-42
4.7.2
Start up the GPU .......................................................................................4-44
4.8
Setting the Ink Profile ........................................................................................ 4-45
4.8.1
How to Install the Ink Curve Software ....................................................4-45
4.8.2
How to Set up the Ink Profile ...................................................................4-48
4.9
Setting the EF Value for the Print Heads .......................................................... 4-49
4.10 Adjusting the Print Head Positions .................................................................. 4-51
4.10.1 How to Perform the Jam Test ..................................................................4-51
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JS500 Service Manual
4.10.2 How to Perform the Print Head Cleaning ...............................................4-52
4.10.3 Adjusting the Horizontal Space for Same Color Print Heads ..............4-53
4.10.4 Adjusting the Horizontal Space Between the Color of Each Print Head ......... 4-60
4.10.5 Adjusting the Vertical Space for Each Print Head .................................4-61
4.10.6 Adjusting the Bidirectional Compensation ............................................4-62
4.10.7 Adjusting the Feed Compensation .........................................................4-65
4.10.10 About the Adjustment Value....................................................................4-67
5. Recommended Spare Parts List ..................................................5-1
5.1
Recommended Spare Parts List ......................................................................... 5-1
6. Maintenance ...................................................................................6-1
6.1
Daily Maintenance ................................................................................................ 6-1
6.1.1
Turn on the Power for the Printer .............................................................6-1
6.1.2
Moistening the Sponge in the Cap with Ink Cleaning Solution ............6-1
6.1.3
Checking the Waste Ink Bottles ................................................................6-2
6.1.4
Checking the Cleaning Roller ...................................................................6-3
6.1.5
Check for Interfusion of Air (air bubbles) in the Print head Tubes ........6-4
6.2
Weekly Maintenance ............................................................................................ 6-6
6.2.1
Cleaning of the Capping Unit and the Print Head ...................................6-6
6.3
When the Printer will not be Used for a While ................................................... 6-7
6.4
When the Printer will not be Used for a Long Time .......................................... 6-9
7. Troubleshooting ............................................................................7-1
7.1
When an Error Message is Displayed ................................................................ 7-1
7.2
Printer does not Operate Correctly .................................................................... 7-5
7.3
Printing is not Satisfactory .................................................................................. 7-9
7.4
There are Miss Firing Nozzles after the Head Cleaning is Performed ............7-11
7.5
When the Print Head is Clogged by the Hardened Ink.................................... 7-13
7.6
When the Print Head Touched onto the Media During Printing ..................... 7-15
7.7
When Printing the Long Length the Printing Gradually Becomes Faint ....... 7-16
7.8
How to Replace the Serge Tank ........................................................................ 7-20
7.9
The Media Take-up Shaft Rotates in a Wrong Direction ................................. 7-25
7.10 The Print Head Nozzles Dry up Soon During Standby Mode ......................... 7-26
7.11 The Heater Temperature cannot Control from the Operation Panel .............. 7-27
8. Disassemble and Reassemble .....................................................8-1
8.1
Exterior Parts ........................................................................................................ 8-1
8.1.1
How to Replace the Left Top Cover ..........................................................8-1
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JS500 Service Manual
8.1.2
How to Replace the Left Side Cover .........................................................8-1
8.1.3
How to Replace the Right Top Cover........................................................8-2
8.1.4
How to Open the Control Panel Cover .....................................................8-2
8.1.5
How to Replace the Right Side Cover ......................................................8-3
8.1.6
How to Replace the Left Rear Cover ........................................................8-3
8.1.7
How to Replace the Right Rear Cover ......................................................8-4
8.1.8
How to Replace the Center Rear Cover ....................................................8-4
8.1.9
How to Replace the Carriage Top Cover ..................................................8-5
8.1.10 How to Replace the Carriage Cover .........................................................8-5
8.1.11 How to Replace the Capping Station Cover ............................................8-6
8.2
Mechanical Parts .................................................................................................. 8-7
8.2.1
How to Replace the X Encoder Sensor Assembly ..................................8-7
8.2.2
How to Replace the X Motor Belt ..............................................................8-7
8.2.3
How to Replace the X Motor ......................................................................8-8
8.2.4
How to Replace the X Motor Encoder Disk ..............................................8-9
8.2.5
How to Replace the Y Motor ....................................................................8-10
8.2.6
How to Replace the Y Motor Belt ............................................................8-12
8.2.7
How to Replace the Y Linear Encoder Strip...........................................8-14
8.2.8
How to Replace the Y belt........................................................................8-16
8.2.9
How to Replace the Ink Tubes of the Chain ...........................................8-19
8.2.10 How to Replace the Pinch Roller ............................................................8-22
8.2.11 How to Replace the Pinch Roller Arm ....................................................8-23
8.3
Electrical Parts ................................................................................................... 8-26
8.3.1
How to Replace the Media Detection Sensor ........................................8-26
8.3.2
How to Replace the Home Sensor ..........................................................8-27
8.3.3
How to Replace the Y Encoder Sensor ..................................................8-28
8.3.4
How to Replace the Print Head Drive Board ..........................................8-29
8.3.5
How to Replace the Main Board ..............................................................8-30
8.3.6
How to Replace the USB Hub Board ......................................................8-31
8.3.7
How to Replace the Motor Board ............................................................8-32
8.3.8
How to Replace the Elevator (Capping Station) Board .........................8-33
8.3.9
How to Replace the Power Supply Board 2 ...........................................8-34
8.3.10 How to Replace the Ink Supply (AUX) Board .........................................8-35
8.3.11 How to Replace the Capping Station Position Sensor .........................8-36
8.3.12 How to Replace the Capping Station motor ..........................................8-37
8.3.13 How to Replace the Media Set Lever Sensor .........................................8-38
8.3.14 How to Replace the Internal USB Cable .................................................8-39
8.3.15 How to Replace the Signal Cable of the Chain ......................................8-42
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JS500 Service Manual
8.3.16 How to Replace the Print Head Drive Board Power Cable ...................8-45
8.3.17 How to Replace the Print Head Heater ...................................................8-48
8.3.18 How to Replace the Take Up and Feed Board .......................................8-50
8.3.19 How to Replace the Ink Pump .................................................................8-51
8.3.20 How to Replace the Ink Cartridge Detection Sensor ............................8-52
8.3.21 How to Replace the Ink Cartridge Status Sensor ..................................8-55
9. Upgrading the Firmware ...............................................................9-1
9.1
Upgrading the System Firmware for the main board ........................................ 9-1
10. Wiring Diagrams ..........................................................................10-1
11. Tubing Diagram............................................................................11-1
12. Spare Parts Lists .........................................................................12-1
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JS500 Service Manual
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JS500 Service Manual
1. Introduction
1. Introduction
1.1 Standard Specifications
Item
Nmber of print head
Printing System
Print Head
Ink
Number of print heads
External dimensions
(Including the stand)
Weight (Including the stand)
Printing resolution (dpi) Color
Printing speed
Distance accuracy
Paper source
Media size
Printing size
Media type
Interface
Display panel
Language
Power consumption
Noise level
Rated power supply
Operating environment
(W x D x H)
(approx.)
(approx.)
High quality
Standard
High-speed
Color High quality
Standard
High-speed
Roll
paper
Cut
sheet
Roll
paper
Cut
sheet
Maximum width
Minimum width
Maximum width
Minimum width
Maximum width
Minimum width
Maximum width
Minimum width
During operation
Standby status
Temperature
Humidity
Condition for guaranteed precision Temperature
Humidity
Storage environment
Temperature
Humidity
Safty standards
Electromagnetic standards
Other standards
JS500-UM-251-9370
JS500-18
JS501-18
8
12
Piezo
Xaar 126/300 dpi
Eco Solvent, Solvent (4 colors (BK, C, M, Y))
126 nozzles per each
3076 x 664 x 1110 mm
330 Kg
720 x 1440 dpi
720 x 1080 dpi
720 x 720 dpi
360 x 720 dpi
360 x 360 dpi
6 m2/H (720 x 720 dpi)
9 m2/H (720 x 720 dpi)
12 m2/H (360 x 720 dpi)
18 m2/H (360 x 720 dpi)
2
24 m /H (360 x 360 dpi)
36 m2/H (360 x 360 dpi)
0.3% or less
Roll feed, manual feeding of cut sheets
1823 mm (72 inch)
210 mm
1823 mm (72 inch)
210 mm
1823 mm (72 inch)
210 mm
1823 mm (72 inch)
210 mm
Flex, Vinyl, Windows film, Polyester, etc.
USB 2.0 (High speed)
LCD display with 8 key panel, self-diagnosis available
English
Maximum: 2.7 Kw
Approx. 70 dB or less
Approx. 40 dB or less
AC 200-240 V ±10%, 50/60 Hz
20 to 28 °C (non-condensing)
40 to 70% RH (non-condensing)
20 to 28 °C (non-condensing)
40 to 70% RH (non-condensing)
5 to 35 °C (non-condensing)
10 to 80% RH (non-condensing)
CE Mark and UL
FCC (Class A)
RoHs
1-1
JS500 Service Manual
1. Introduction
1.2 Optional Accessories
No.
Item
1 12 Heads upgrade kit
Model name
Remark
OPH-A07
A kit for upgrading the 8 heads model to the 12 heads model
1.3 Consumables
No.
1
2
3
4
5
6
7
8
9
10
11
Item
Model name
Print head
IH-81000
Ink cartridge Black
IJ-81000BK
Ink cartridge Cyan
IJ-81000C
Ink cartridge Magenta
IJ-81000M
Ink cartridge Yellow
IJ-81000Y
Ink cleaning solution cartridge IJ-81000S
Ink cartridge Black (Eco Solvent ink)
IJ-81050BK
Ink cartridge Cyan (Eco Solvent ink)
IJ-81050C
Ink cartridge Magenta (Eco Solvent ink) IJ-81050M
Ink cartridge Yellow (Eco Solvent ink) IJ-81050Y
Ink cleaning solution cartridge IJ-81050S
(Eco Solvent ink)
12 Cleaning roller
MK-00005
13 Ink cleaning Solution
MK-00006
14 Ink cleaning Solution
JS500-UM-251-9370
MK-00007
Remark
Print heads for replacement
Ink cartridge for the JS500 series (500 ml/ color)
Ink cleaning solution cartridgefor the JS500 series (500 ml)
Ecological solvent ink cartridge for the JS500 series
(500 ml/ color)
Ecological ink cleaning solution cartridge for the
JS500 series (500 ml/ color)
Replacement cleaning roller
Solvent ink cleaning solution for the roller and cap
(250 ml)
Eco solvent ink cleaning solution for the roller and
cap (250 ml)
1-2
JS500 Service Manual
1. Introduction
1.4 External Dimension
1110
3076
664
Units: mm
Dimensional accuracy: ±5 mm
JS500-UM-251-9370
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JS500 Service Manual
2. Assembling the Printer
2. Assembling the Printer
2.1 Installation Space
Sufficient space must be left in front of, behind, and at both sides of the printer not only for normal
operating procedures such as the replacement of consumable, the handling of printed materials, and for
ventilation, but also for the replacement of parts in the event of a malfunction.
Ensure that the space left around the printer is as shown in the following diagram.
Rear
Approx. 2m
Approx. 3m
Approx. 3m
Approx. 2m
Front
2.2 Installation Location
•
Do not use the printer in an unstable location such as on a slope or a location that is subject to a lot of
vibration. Such location may cause the printer to tip over and cause injuries.
•
Avoid using the printer in the following locations.
Excessively humid or dusty locations
Locations exposed to direct sunlight
Locations exposed to high temperatures
Locations near flames or moisture
•
Use at the following places may result in malfunction or failure.
Near equipment which generate a strong magnetic force or magnetic field.
•
Use this printer in places where the ambient temperature is between from 20 to 28˚C and humidity is
between from 40 to 70 RH (non-condensing).
JS500-UM-251-9370
2-1
JS500 Service Manual
2. Assembling the Printer
2.3 Assembling the printer
Preparation
(1)
Spanner
(2)
Philips-head screw driver
(3)
Cutting knife
(4)
Five persons are required to mount the printer on the stand. (One person for the director)
Open the packing boxes
(1)
There are the two packing boxes, which for the main printer unit and the accessory box.
(2)
The left and the right legs for the stand are contained in the accessory box.
(3)
Open the accessory box and then take out the left and the right legs from the accessory box.
Accessory box
Left leg
Right leg
Accessories
(4)
The center bar for the stand, the fan unit, the take-up media shaft and the supply media shaft are
contained in the main printer box.
(5)
Open the main printer box and then take out the center bar for stand and the dryer unit from the
main unit packing box.
Dryer unit
Center bar for stand
Main printer packing box
JS500-UM-251-9370
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JS500 Service Manual
2. Assembling the Printer
Assembling the stand
(1)
Remove the access covers from the left and the right legs.
Access cover
Access cover
(2)
Loosen the four M5 screws on the both ends of the center bar.
Center bar
(3)
Insert the cable of center bar to the access hole of the left leg as shown in the picture below.
(4)
Install the center bar to the left leg.
(5)
Tighten the two M5 screws to hold the center bar.
Take-up motor
The take-up motor and the
media sensor should be
located to the front when
installing the center bar.
Media sensor
(6)
Install the center bar to the right leg and then tighten the two M5 screws to hold the center bar.
JS500-UM-251-9370
2-3
JS500 Service Manual
(7)
2. Assembling the Printer
Attach the access covers to the left and the right legs.
Access cover
Access cover
Mounting the printer unit on the stand
(1)
Take out the take-up shaft and the media stocker shaft from the pallet.
(2)
Loosen the eight nuts holding the printer unit on the pallet. Then slides the nuts to outside of the
bracket.
(3)
Hold the corner of the printer with four persons, and then lift up the printer.
Hold the printer here
(4)
Mount the printer unit on the stand. And position the printer unit by using the positioning plate.
Positioning plate:
Confirm the positioning plate fit to the
right edge of the left stand.
JS500-UM-251-9370
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JS500 Service Manual
2. Assembling the Printer
CAUTION
Take care as shown in the picture below when lifting up the
printer unit by using the forklift truck.
As the barycentric position is located in the
rear side of the printer. Therefore support
the printer from the rear side by the other
person not to fall down.
OK
Forklift arm
Tension bar
Hold here.
Do not hold the tension bar.
NG
Do not hit the tension bar by the forklift arm.
Forklift arm
Tension bar
(5)
Slides the eight nuts to the legs as shown in the picture below.
(6)
And then tighten the eight nuts.
(7)
Connect the take-up motor cables to the printer unit.
(8)
Install the dryer bracket, the dryer unit, the take-up shaft, the media stocker shaft and the two waste
ink bottles as shown in the picture below.
Dryer unt bracket
Media stocker shaft
Waste ink bottle
with holder plate
Take-up shaft
Waste ink bottle
Dryer uint
JS500-UM-251-9370
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JS500 Service Manual
3. Parts Name and Functions
3. Parts Name and Functions
3.1 Parts Name and Functions
Front View
8
10
9
4
3
2
1
5
6
12
7
11
No.
1
2
3
4
5
6
7
8
9
10
11
Name
Top Cover
Front Cover
Front Cover Clear
Rear Cover
Right Upper Cover
Right Bottom Cover
Side Cover (Right)
Left Upper Cover
Left Bottom Cover
Side Cover (Left)
Main Cleaning Position
12 Print Head Maintenance Position
JS500-UM-251-9370
Functions
The upper cover.
The front cover.
The front clear cover.
The upper rear cover.
The right upper cover.
The cover at the cleaning position.
The right side cover.
The upper left cover.
The cover for the maintenance station.
The side cover.
The home position of the print heads.
Capping and Auto Cleaning of the print heads are performed
at this position.
At the initial setup: Installation of the print heads and initial
pouring of ink are performed at this
position.
During normal use: Recovery procedures for nozzles of the
print heads are performed in case that
maintenance is required due to faded
print.
3-1
JS500 Service Manual
3. Parts Name and Functions
Main Part
11
5
4
2
1
3
9
3
7
8
No.
Name
1 LCD Control Panel
2
3
Print Carriage
Waste Ink Tank
4
Heating Panel
5
6
Dryer Unit
Media Take-up Shaft
7
8
Media Supply Shaft
Media Take-up Sensor
9 Left Flange
10 Right Flange
11 Dryer Unit Switch
JS500-UM-251-9370
6
10
Functions
Confirmation of the printer status and various settings can be
performed with this panel.
This part moves the print heads.
These tanks store waste ink which is discharged during the
initial pouring of ink or recovery procedure of the print heads.
One is installed at the main cleaning position, and other one
is installed at the PH Maintenance position.
This panel warms up media to an appropriate temperature
for better printing quality.
This unit is used to accelerate drying of ink after printing.
This shaft takes up the media after printing. It is used for
printing on a long length of the paper.
This shaft is used to set media (Roll media)
This sensor detects the media after printed media reaches
a certain length, the media take-up shaft starts taking up the
media.
This part fixes the media (roll media) onto the shaft.
This part fixes the media (roll media) onto the shaft.
This switch turns the dryer unit on or off.
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JS500 Service Manual
3. Parts Name and Functions
Control Panel
LCD Display
ONLINE Key
FUNC Key
ESC Key
ENTER Key
No.
Name
1 LCD D splay
2 ONLINE key
3
ESC key
4
FUNC key
5
ENTER key
6
POSITION keys
JS500-UM-251-9370
POSITION Key
Functions
The LCD D splay shows various menus.
This key switches Online/Offline.
Press this key to toggle between Online and Offline, and
[Online] or [Offline] is shown on the LCD Display.
When this key is pressed for several seconds during printing,
the printing is paused and the Online menu is displayed.
This key cancels the current job, and returns the menu
display to one position above.
This key is used with the Direct on Key to specify operations.
Press the [FUNC] key +[left arrow] key simultaneously to
execute test print when no printing is performed.
This key confirms the selection of an item or the setting of a
value.
Up/Down Key:
Moves the cursor upward or downward. They are used to
increase or decrease numerical values on the set value input
screen.
Left/Right Key:
They are used to specify the digit when increasing or
decreasing numerical values on the set value input screen.
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JS500 Service Manual
3. Parts Name and Functions
Print Carriage
1
When the head cover is removed
5
7
6
3
2
No.
Name
1 Head cover
2 P.H. Adjustment lever
3
4
5
6
Print head
Print head-carriage
Inlet tube
Outlet tube
7
8
Outlet tube cap
Print head clamp
8
4
Functions
The cover to protect the Print Carriage.
The lever to adjust the height of the print heads.
If the print heads scratch the media, adjust their height by
using this lever.
Print heads.
This part moves the print heads.
These tubes supply ink to the print heads.
These tubes are used for introducing ink to the print heads
or for maintenance.
These caps are for outlet tubes.
These parts are used to fix the print heads and the tubes.
Maintenance Station
1
3
2
No.
Name
1 Cleaning roller
2
3
Capping unit
Media set lever
JS500-UM-251-9370
Functions
This roller cleans the print heads. The cleaning roller is a
replaceable item.
Please replace it with a new one if it becomes dirty.
These parts are used for capping the print heads.
This lever is used to set or remove media.
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JS500 Service Manual
3. Parts Name and Functions
Printing Plat from
1
4
2
3
No.
1 Pinch roller
2
3
4
Name
Functions
These parts are important parts to forward paper. They retain
the paper in place.
This part prevents the paper edges from floating.
This lever is used to set or remove media.
This part is an important part to move the Print head
Carriage.
Printing Platform
Media guide
Y-encoder
Left Side of the Printer
1
2
3
4
5
6
No.
Name
1 Heater Switch
2
3
4
5
6
Media Feeding System switch
Media take-up System switch
Heater power socket
Main power socket
Power switch
JS500-UM-251-9370
Functions
The switch for the Heater (Pre Heater, Front Heater, Plat
form Heater).
The switch for the media feeding system.
The switch for the media take-up system.
The power socket of the heater unit.
The power socket of the main unit.
The power switch of the printer unit.
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JS500 Service Manual
3. Parts Name and Functions
Right Side of the Printer
1
No.
Name
1 USB interface connector
Functions
The connector for a USB interface cable.
Left Rear Side of the Printer
2
Rear view of the printer
2
1
No.
Name
1 Rubber Roller
2
Media Tension Bar
JS500-UM-251-9370
Functions
This part is an important part to stretch the media for better
printing quality.
This part is an important part to stretch the media for better
printing quality.
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JS500 Service Manual
3. Parts Name and Functions
Right Rear Side of the Printer
1
Rear view of the printer
2 (Cyan,Magenta,Yellow,Black)
No.
Name
1 Ink holder C, M, Y, BK
2
Ink cartridge C, M, Y, BK
JS500-UM-251-9370
Functions
This s where ink cartridges are installed. Check the C, M, Y
and BK labels on the ink cartridges, and appropriately install
them in the holders specified for each.
Four ink cartridges, which are Cyan, Magenta, Yellow and
Black.
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JS500 Service Manual
3. Parts Name and Functions
3.2 Standard Accessories
No.
Name
Q’ty
No.
Name
JS500-18 JS501-18
1 Stand
1 Set
Stand R/L, Center bar
2 Dryer unit
1 Set
677663100
3 Print head
677667000
4 Print head clamp
677663110
5 Media Take-up Shaft
677663120
6 Media Feeding Shaft
677663130
7 Rubber Roller
8
9 Waste Ink Tank
2
677663160
10 Flange
4
677663170
11 Plastic Syringe
2
677663180
12 ø3/5 Soft tube
1
12
8
12
1
677663190
13 Outlet tube assembly
12
677663200
14 USB interface cable
1
677663210
15 Power cable (Printer, Heater)
2
1
1 set
677663150
677662700 (CE type)
Installed on the printer
677662720 (UL type)
JS500-UM-251-9370
8
1
677663140
Installed on the printer
8 Media Tension Bar unit
Q’ty
JS500-18 JS501-18
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JS500 Service Manual
No.
3. Parts Name and Functions
Name
Q’ty
No.
Name
JS500-18 JS501-18
16 Power cable (Dryer)
1
677662690 (CE type)
677662710 (UL type)
17 Brush
677663230
18 Non-woven fabric
677663240
19 One-off glove
677663250
20 Software CD-ROM
8
Q’ty
JS500-18 JS501-18
12
24 Screw (Screw for Print head fixation)
16
24
677663310
25 Positioning Pin
18
26
16
24
677663290
26 Plastic block
(For Print head fixation)
1 set
1 set
1
677663320
27 Spoid (5 cc)
3
677663330
28 Solution bottle (250 ml)
2
677663340 (for pure solvent)
677663010
21 User Guide CD-ROM
1
677663000
22 User’s Manual
1
JS500
INKJET PRINTER
677663390 (for eco solvent)
29 Hex-head wrench (5 mm/4 mm)
1
677663350
30 Jig, Print head height adjustment
1
677663360
31 Cleaning roller
2
Set up Guide
677663020
23 Setup Guide
1
JS500
INKJET PRINTER
Set up Guide
677663370
677663040
JS500-UM-251-9370
3-9
JS500 Service Manual
No.
Name
3. Parts Name and Functions
Q’ty
JS500-18 JS501-18
32 Ink Installing Jig
1
677663380
JS500-UM-251-9370
3-10
JS500 Service Manual
4. Set Up the Printer
4. Set Up the Printer
Perform the following procedure when you set up the printer.
4.1 Installing the print heads
4.2 Cleaning the ink tube
4.3 Removing the cleaning solution (or Ink) from the ink tubes
4.4 Filling the ink to the tube
4.5 Preparing the Cleaning Roller and the Cap
4.6 Loading the media
4.7 Installing the GPU
4.8 Setting the Ink Profile
4.9 Setting the EF Value for the Print Heads
4.10 Adjusting the Print Head Positions
JS500-UM-251-9370
4-1
JS500 Service Manual
4.1
4. Set Up the Printer
Installing the Print Heads
(1)
Turn off the power for the JS501/500.
(2)
Remove the carriage fixing screw from the carriage.
Carriage fixing screw
(3)
Remove the four M3 screws holding the carriage cover to remove the carriage cover from the
carriage.
M3 screw
Carriage cover
(4)
Insert the two positioning pins to the carriage as shown in the picture below.
Insert the positioning pins into the
holes on the carriage
Positioning pin
(5)
Take out the print head from the box, and then remove the white caps from the print head.
White caps
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4-2
JS500 Service Manual
(6)
4. Set Up the Printer
Record the installation location and the EF value of the print head before installing the print head.
EF Value
(7)
Install the outlet tube assembly into the outer side of the print head as shown in the picture below.
Outer tube assembly
Be sure to check the direction of the tube connector when installing the outlet tube assembly into the
print head.
Outer tube assembly
(8)
Connect the inlet tube to the print head from the far left side.
Be sure to check the direction of the tube connector when installing the inlet tube assembly into the
print head.
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4-3
JS500 Service Manual
(9)
4. Set Up the Printer
Install the clamper to the print head as shown in the picture below to secure the connection of the
tube connector.
Clamper
Confirm the clamper is
hanging at these locations.
(10) Install the positioning pins into the print head as shown in the picture below.
Insert the positioning pins into the
holes on the print head
Positioning pin
(11) Mount the print head on the carriage plate using the plastic block and the M3 screw as shown in the
picture below.
Plastic block
M3 screw
Put the plastic blocks and the M3 screws onto the print head first.
Tighten the M3 screws to mount
Mount the print head on the carriage plate.
the print head with the plastic
blocks.
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JS500 Service Manual
4. Set Up the Printer
(12) Connect the print head cable to the print head from the K3 cable.
(13) Install the other print heads on the carriage plate by same procedure.
K3
K1
Y1
K2
Y3
M1
Y2 M2
C2
M3
C3
C1
If you have the 8 head model of JS500-18, the installing location of K3, Y3, M3 and C3 are not used
for the print heads.
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JS500 Service Manual
4.2
4. Set Up the Printer
Cleaning the Ink Tube
Clean the ink tubes before you prime the ink.
(1)
Remove the four M3 screws holding the left upper cover, and then remove the left upper cover from
the JS501/500.
Left upper cover
(2)
Turn on the power for the JS501/500.
The beep sounds with the Error 6 after the initialization finished until the ink cleaning solution
cassettes are installed to the ink cassette holder.
(3)
Select the Cleaning Tool using the direction keys from the main menu, and then press the ENTER
key.
Menu
Err.6
Offline
Menu
Err.6
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
Media Detect
Start: 0000 mm
Length: 0000 mm
Offline
If the Media Detect menu is displayed as shown above, press the ESC key to cancel the media
detection.
(4)
Select the PH Maintenance using the direction keys from the sub-menu, then press the ENTER key.
Menu
Err.6
Offline
(5)
1.Firing
2.Jam Test
3.PH Maintenance 4.Home Post.
-
The carriage moves to the maintenance station.
JS500-UM-251-9370
4-6
JS500 Service Manual
(6)
4. Set Up the Printer
Mount the Ink Installing Jig to the carriage as shown in the picture below.
Positioning pin
Fixing lever
(7)
Ink Installing Jig
Fit the three of the positioning pins of the Ink Installing Jig to the edge of the carriage.
And then, fix the Ink Installing Jig to the carriage using the three fixing levers.
Positioning pin
Fixing lever
Note:
Do not touch the operation panel when the Ink Installing Jig is attaching to the carriage.
For avoid moving the carriage from the control panel.
(8)
Gently install the four ink-cleaning solution cassettes to the ink cassette holder.
The beep sounds with the Error 6 will be stopped after the ink cleaning solution cassettes are
installed to the ink cassette holder.
If the beep sounds remained reinstall the ink cleaning solution cassettes.
(9)
Remove the outlet cap from the Cyan-1 outlet tube.
Cap
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4-7
JS500 Service Manual
4. Set Up the Printer
(10) Connect the syringe into the Cyan-1 outlet tube.
(11) Confirm the outlet tube clamper for the Cyan-1 is opened.
Open the outlet tube clamper
(12) Pull the piston of syringe up to the 60 ml mark.
(13) Close the outlet tube clamper when incoming of the ink cleaning solution was stabilized.
Close the outlet tube clamper
(14) Disconnect the syringe from the outlet tube, and then discard the ink cleaning solution from the
syringe to the waste ink receiving area.
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4-8
JS500 Service Manual
4. Set Up the Printer
(15) Close the three clampers of the Cyan surge tank, which is located behind the carriage.
Close the three surge tank
clampers.
(16) Connect the syringe into the Cyan-1 outlet tube.
(17) Open the outlet tube clamper for the Cyan-1 outlet tube.
Open the outlet tube clamper
(18) Pull the piston of syringe up to the 25 ml mark.
(19) Open the three clampers of the Cyan surge tank when incoming of the ink cleaning solution was
stabilized to the syringe.
Open the three surge tank
clampers.
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4-9
JS500 Service Manual
4. Set Up the Printer
(20) Pull the piston of syringe up to the 45 ml mark.
(21) Close the outlet tube clamper when incoming of the ink cleaning solution was stabilized.
Close the outlet tube clamper
(22) Disconnect the syringe from the outlet tube, and then discard the ink cleaning solution from the
syringe to the waste ink receiving area.
(23) Attach the outlet cap to the Cyan-1 outlet tube.
Cap
(24) Open the outlet tube clamper for the Cyan-1 outlet tube.
Open the outlet tube clamper
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JS500 Service Manual
4. Set Up the Printer
(25) Close the outlet tube clamper for the Cyan-2 outlet tube.
Close the outlet tube clamper
(26) Remove the outlet cap from the Cyan-2 outlet tube.
(27) Connect the syringe into the Cyan-2 outlet tube.
(28) Pull the piston of syringe up to the 15 ml mark.
(29) Close the outlet tube clamper when incoming of the ink cleaning solution was stabilized.
Close the outlet tube clamper
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4-11
JS500 Service Manual
4. Set Up the Printer
(30) Disconnect the syringe from the outlet tube, and then discard the ink cleaning solution from the
syringe to the waste ink receiving area.
(31) Attach the outlet cap to the Cyan-2 outlet tube.
(32) Open the outlet tube clamper for the Cyan-2 outlet tube.
Open the outlet tube clamper
(33) Repeat the same procedure from step (25) to (32) for the Cyan-3 print head.
(34) Repeat the same procedure from step (9) to (32) to draw the ink cleaning solution to the outlet tubes
for the Magenta print heads, the Yellow print heads and the Black print heads.
Magenta
Yellow
Black
(35) Remove the Ink Installing jig from the carriage when the ink cleaning solution was drawn to all print
heads.
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JS500 Service Manual
4. Set Up the Printer
(36) Select the Ink Status using the direction keys from the main menu.
Menu
Offline
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
(37) Press the ENTER key to display the menu below.
Menu
Offline
Ink Status
Ch C M Y K
Rn _ M _ _
Al _ _ _ _
The corresponding color is shown in
the second column.
(38) Press the direction keys about 10 seconds, corresponding to each color to perform the positive
pressure cleaning.
(39) Perform the positive pressure cleaning for all print heads.
Cyan
JS500-UM-251-9370
Magenta
Yellow
4-13
Black
JS500 Service Manual
4.3
4. Set Up the Printer
Removing the Cleaning Solution (or Ink) from the Ink Tubes
(1)
Turn off the power for the JS501/500.
(2)
Move the carriage to the Print Head Maintenance Station (Left side of the printer).
(3)
Remove the four M3 screws holding the carriage cover to remove the carriage cover from the
carriage.
M3 screw
Carriage cover
(4)
Remove the four M3 screws holding the left upper cover, and then remove the left upper cover from
the JS501/500.
Left upper cover
(5)
Mount the Ink Installing Jig to the carriage as shown in the picture below.
Positioning pin
Fixing lever
JS500-UM-251-9370
Ink Installing Jig
4-14
JS500 Service Manual
(6)
4. Set Up the Printer
Fit the three of the positioning pins of the Ink Installing Jig to the edge of the carriage.
And then, fix the Ink Installing Jig to the carriage using the three fixing levers.
Positioning pin
Fixing lever
(7)
Remove all ink-cleaning solution cassettes (or Ink cassettes) from the ink cassette holder.
(8)
Close the outlet tube clamper for the Cyan-1 outlet tube.
Close the outlet tube clamper
(9)
Remove the outlet cap from the Cyan-1 outlet tube.
(10) Connect the syringe to the Cyan-1 outlet tube.
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4-15
JS500 Service Manual
4. Set Up the Printer
(11) Open the outlet tube clamper for the Cyan-1 outlet tube.
Open the outlet tube clamper
(12) Pull the piston of syringe up to the 60 ml mark.
(13) Close the outlet tube clamper when incoming of the ink cleaning solution was stabilized.
Close the outlet tube clamper
(14) Disconnect the syringe from the outlet tube, and then discard the ink cleaning solution from the
syringe to the waste ink receiving area.
(15) Close the three clampers of the Cyan surge tank, which is located behind the carriage.
Close the three surge tank
clampers.
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JS500 Service Manual
4. Set Up the Printer
(16) Connect the syringe into the Cyan-1 outlet tube.
(17) Open the outlet tube clamper for the Cyan-1 outlet tube.
Open the outlet tube clamper
(18) Pull the piston of syringe up to the 60 ml mark.
(19) Close the outlet tube clamper for the Cyan-1 outlet tube.
Close the outlet tube clamper
(20) Disconnect the syringe from the outlet tube, and then discard the ink cleaning solution (or Ink) from
the syringe to the waste ink receiving area.
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JS500 Service Manual
4. Set Up the Printer
(21) Attach the outlet cap to the Cyan-1 outlet tube.
Cap
(22) Open the outlet tube clamper for the Cyan-1 outlet tube.
Open the outlet tube clamper
(23) Open the three clampers of the Cyan surge tank when incoming of the ink cleaning solution was
stabilized to the syringe.
Open the three surge tank
clampers.
(24) Close the outlet tube clamper for the Cyan-2 outlet tube.
Close the outlet tube clamper
(25) Remove the outlet cap from the Cyan-2 outlet tube.
JS500-UM-251-9370
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JS500 Service Manual
4. Set Up the Printer
(26) Connect the syringe into the Cyan-2 outlet tube.
(27) Pull the piston of syringe up to the 60 ml mark.
(28) Close the outlet tube clamper for the Cyan-2 outlet tube.
Close the outlet tube clamper
(29) Disconnect the syringe from the outlet tube, and then discard the ink cleaning solution (or Ink) from
the syringe to the waste ink receiving area.
(30) Attach the outlet cap to the Cyan-2 outlet tube.
JS500-UM-251-9370
4-19
JS500 Service Manual
4. Set Up the Printer
(31) Open the outlet tube clamper for the Cyan-2 outlet tube.
Open the outlet tube clamper
(32) Repeat the same procedure from step (23) to (31) for the Cyan-3 print head.
(33) Repeat the same procedure from step (8) to (32) to remove the ink cleaning solution (or Ink) from the
outlet tubes of the Magenta print heads, the Yellow print heads and the Black print heads.
Magenta
Yellow
Black
(34) Remove the Ink Installing jig from the carriage when the ink cleaning solution (or Ink) was removed
from all print heads.
JS500-UM-251-9370
4-20
JS500 Service Manual
4.4
4. Set Up the Printer
Filling the Ink (or ink cleaning solution) to the Tube
(1)
Turn off the power for the JS501/500.
(2)
Remove the four M3 screws holding the left upper cover, and then remove the left upper cover from
the JS501/500.
Left upper cover
(3)
Turn on the power for the JS501/500.
The beep sounds with the Error 6 after the initialization finished until the ink cassettes are installed to
the ink cassette holder.
(4)
Select the Cleaning Tool using the direction keys from the main menu, and then press the ENTER
key.
Menu
Err.6
Offline
Menu
Err.6
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
Media Detect
Start: 0000 mm
Length: 0000 mm
Offline
If the Media Detect menu is displayed as shown above, press the ESC key to cancel the media
detection.
(5)
Select the PH Maintenance using the direction keys from the sub-menu, then press the ENTER key.
Menu
Err.6
Offline
(6)
1.Firing
2.Jam Test
3.PH Maintenance 4.Home Post.
-
The carriage moves to the maintenance station.
JS500-UM-251-9370
4-21
JS500 Service Manual
(7)
4. Set Up the Printer
Mount the Ink Installing Jig to the carriage as shown in the picture below.
Positioning pin
Fixing lever
(8)
Ink Installing Jig
Fit the three of the positioning pins of the Ink Installing Jig to the edge of the carriage.
And then, fix the Ink Installing Jig to the carriage using the three fixing levers.
Positioning pin
Fixing lever
Note:
Do not touch the operation panel when the Ink Installing Jig is attaching to the carriage.
For avoid moving the carriage from the control panel.
(9)
Gently install the four colors of ink (or ink cleaning solution) cassettes to the ink cassette holder.
The beep sounds with the Error 6 will be stopped after the ink cleaning solution (or ink cleaning
solution) cassettes are installed to the ink cassette holder.
If the beep sounds remained reinstall the ink cleaning solution cassettes.
(10) Remove the outlet cap from the Cyan-1 outlet tube.
Cap
JS500-UM-251-9370
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JS500 Service Manual
4. Set Up the Printer
(11) Connect the syringe into the Cyan-1 outlet tube.
(12) Confirm the outlet tube clamper for the Cyan-1 is opened.
Open the outlet tube clamper
(13) Pull the piston of syringe up to the 60 ml mark.
(14) Close the outlet tube clamper when incoming of the ink was stabilized.
Close the outlet tube clamper
(15) Disconnect the syringe from the outlet tube, and then discard the ink from the syringe to the waste
ink receiving area.
JS500-UM-251-9370
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JS500 Service Manual
4. Set Up the Printer
(16) Close the three clampers of the Cyan surge tank, which is located behind the carriage.
Close the three surge tank
clampers.
(17) Connect the syringe into the Cyan-1 outlet tube.
(18) Open the outlet tube clamper for the Cyan-1 outlet tube.
Open the outlet tube clamper
(19) Pull the piston of syringe up to the 25 ml mark.
(20) Open the three clampers of the Cyan surge tank when incoming of the ink was stabilized to the
syringe.
Open the three surge tank
clampers.
JS500-UM-251-9370
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JS500 Service Manual
4. Set Up the Printer
(21) Pull the piston of syringe up to the 45 ml mark.
(22) Close the outlet tube clamper when incoming of the ink was stabilized.
Close the outlet tube clamper
(23) Disconnect the syringe from the outlet tube, and then discard the ink from the syringe to the waste
ink receiving area.
(24) Attach the outlet cap to the Cyan-1 outlet tube.
Cap
(25) Open the outlet tube clamper for the Cyan-1 outlet tube.
Open the outlet tube clamper
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JS500 Service Manual
4. Set Up the Printer
(26) Close the outlet tube clamper for the Cyan-2 outlet tube.
Close the outlet tube clamper
(27) Remove the outlet cap from the Cyan-2 outlet tube.
(28) Connect the syringe into the Cyan-2 outlet tube, and then open the outlet tube clamper for the
Cyan-2 outlet tube.
(29) Pull the piston of syringe up to the 15 ml mark.
(30) Close the outlet tube clamper when incoming of the ink cleaning solution was stabilized.
Close the outlet tube clamper
JS500-UM-251-9370
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JS500 Service Manual
4. Set Up the Printer
(31) Disconnect the syringe from the outlet tube, and then discard the ink cleaning solution from the
syringe to the waste ink receiving area.
(32) Attach the outlet cap to the Cyan-2 outlet tube.
(33) Open the outlet tube clamper for the Cyan-2 outlet tube.
Open the outlet tube clamper
(34) Repeat the same procedure from step (26) to (33) for the Cyan-3 print head.
(35) Repeat the same procedure from step (10) to (32) to draw the ink to the outlet tubes for the Magenta
print heads, the Yellow print heads and the Black print heads.
Magenta
Yellow
Black
(36) Tighten fully all outlet tube caps by using the Long-nose pliers to avoid the air leak from the tubes.
Do not tighten too strongly the cap or the cap may break.
JS500-UM-251-9370
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JS500 Service Manual
4. Set Up the Printer
(37) Remove the Ink Installing jig from the carriage when the ink was drawn to all print heads.
JS500-UM-251-9370
4-28
JS500 Service Manual
4.5
4. Set Up the Printer
Preparing the Cleaning Roller and the Cap
4.5.1
Moistening the Cleaning Roller with Cleaning Solution
(1)
Confirm that the Ink Installing Jig is not installed to the carriage.
(2)
Turn on the power for the JS501/500.
(3)
Select the Cleaning Tool using the direction keys from the main menu, and then press the ENTER
key.
Menu
Offline
Menu
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
Media Detect
Start: 0000 mm
Length: 0000 mm
Offline
If the Media Detect menu is displayed as shown above, press the ESC key to cancel the media
detection.
(4)
Select the Parking using the direction keys, and then press the ENTER key.
Menu
Offline
4.Home Post.
5.Clean
6.Clean(Heavy)
7.Parking
-
(5)
The carriage moves to the Capping position.
(6)
Remove the cleaning roller from the right side of the capping station of the printer.
Cleaning roller
(7)
Remove the cleaning roller shaft from the cleaning roller.
Remove the roller shaft
JS500-UM-251-9370
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JS500 Service Manual
4. Set Up the Printer
(8)
Put the ink cleaning solution in the plate.
(9)
Dip the cleaning roller to the ink cleaning solution.
(10) Reinstall the roller shaft to the cleaning roller and then reinstall the cleaning roller to the capping
station.
Install the roller shaft
(11) Select the Cleaning Tool using the direction keys from the main menu, and then press the ENTER
key.
Menu
Offline
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
(12) Select the Clean (Heavy) using the direction keys, the printer perform the heavy cleaning for the print
head.
Menu
Offline
Caution:
3.PH Maintenance 4.Home Post.
5.Clean
6.Clean(Heavy) Be careful the carriage moves to the home position when performing the heavy
cleaning.
(13) Perform step (12) once more to clean the print head.
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JS500 Service Manual
4. Set Up the Printer
Handing of the Cleaning Roller
When the Cleaning Roller is unused for a while (for more than a week without turning on the printer),
soaked-up ink may be fixed in the Cleaning Roller which may harden the roller.
Using the Cleaning roller under such a condition may deteriorate the cleaning function of the head or
damage the nozzle plate of the head.
Be sure to moisten the Cleaning Roller sufficiently with cleaning solution again before use, or replace with
a new one if cleaning function cannot be recovered by moistening it with cleaning solution.
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JS500 Service Manual
4.5.2
4. Set Up the Printer
Moistening the Sponge in the Cap with Cleaning Solution
The carriage is capped in the Capping Position when the printer is in the standby mode.
To avoid drying of the print head nozzles, the inside of the cap is required to be saturated with an
appropriate amount of moisture from cleaning solution.
Pour cleaning solution by procedure below.
(1)
Confirm that the Ink Installing Jig is not installed to the carriage.
(2)
Turn on the power for the JS501/500.
(3)
Select the Cleaning Tool using the direction keys from the main menu, and then press the ENTER
key.
Menu
Offline
Menu
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
Media Detect
Start: 0000 mm
Length: 0000 mm
Offline
If the Media Detect menu is displayed as shown above, press the ESC key to cancel the media
detection.
(4)
Select the PH Maintenance using the direction keys, and then press the ENTER key.
Menu
Offline
1.Firing
2.Jam Test
3.PH Maintenance 4.Home Post.
-
(5)
The carriage moves to the PH Maintenance position.
(6)
Open the right lower cover to access the capping unit.
Capping unit
Right lower cover
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JS500 Service Manual
(7)
4. Set Up the Printer
Pour cleaning solution into all print head caps.
Keep on pouring it until the fluid level reaches the position the metal plate in the cap.
Spoid
Cleaning solution
Metal plate
Pour cleaning solution until
the fluid level reaches the
position of the metal plate
Cap
(8)
Return the carriage to the Capping position after Cleaning solution was poured for all print head
caps.
(9)
Select the Cleaning Tool using the direction keys from the main menu, and then press the ENTER
key.
Menu
Offline
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
(10) Select the Parking using the direction keys, and then press the ENTER key to move the carriage to
the Capping position.
Menu
Offline
4.Home Post.
5.Clean
6.Clean(Heavy)
7.Parking
-
Maintenance of the print head cap
To maintain stable performance of the printer, moisten the sponge by cleaning solution everyday.
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JS500 Service Manual
4.6
Loading the Media
4.6.1
(1)
4. Set Up the Printer
Installing a Media to the Media Supply Shaft
Install the flange to the media supply shaft.
Media Feeding Shaft
(2)
Flange
Set the position of the flange and then tighten the setscrews.
Setscrew
Roll Media
2
1
3
(3)
Install the media supply shaft to the roll media as shown in the picture above.
(4)
Install the flange of other side to the media supply shaft, and then tighten the setscrews.
Flange
Setscrew
2
1
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JS500 Service Manual
4.6.2
(1)
4. Set Up the Printer
Load a Media onto the Printer
When the power of the printer is on, set the Media Feeding System Switch and Media Take-up
System Switch to the off (“O”) side.
Media feeding
System Switch
Media Feeding
System Switch
Media Feeding System Switch
Continuous reverse rotation
OFF
Automatic
FEEDING
(2)
Remove the two screws holding the right and left media shaft holder covers.
Remove the screws
(3)
Open the right and the left media shaft holder covers.
Open the roll media shaft holder covers
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JS500 Service Manual
(4)
4. Set Up the Printer
Check the direction in which the roll media is wound, and install the media supply shaft with the roll
media on the shaft holder.
(5)
Lower the Media Set Lever to lift up the pinch roller.
Media Set Lever
(6)
Insert the media to printer as shown in the picture below.
Media Feed Roller
Feed roller
Tension roller
Tension Roller
Media
Take-Up
Media
Media Supply
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JS500 Service Manual
(7)
4. Set Up the Printer
Make sure that the left and right sides are pulled out evenly without slack of the media when pulling
the media from the media roll.
And then, set the Media Set Lever to the LOAD position.
Media Set Lever
(8)
Set the left and right media guides to the edge of the media as shown in the picture below.
Media
(9)
Media Guide
The printer is displaying the menu below after the Media Set Lever is set to the LOAD position
Menu
Media Detect
Start: 0000 mm
Length: 0000 mm
Offline
(10) Press the ENTER key to detect the media width.
(11) Set the Media Feeding System Switch to the Automatic (“ ”) side.
Media feeding
System Switch
Media Feeding
System Switch
Media Feeding System Switch
Continuous reverse rotation
OFF
Automatic
FEEDING
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JS500 Service Manual
4.6.3
4. Set Up the Printer
Setting the Take-up Unit
To use the media Take-up unit, pull out the media so that the tip of the roll media reaches media core on
the Media Take-up unit.
How to set the media core
(1)
Install the flange to the media Take-up shaft.
Media Feeding Shaft
(2)
Flange
Tighten the setscrews and set a media core on the media take up shaft.
Setscrew
Core
2
1
3
(3)
Set the left flange to the media core, and tighten the setscrews.
Flange
Setscrew
2
1
(4)
Remove the two screws holding the right and left shaft holder covers.
Remove the screws
JS500-UM-251-9370
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JS500 Service Manual
(5)
4. Set Up the Printer
Open the right and the left media shaft holder covers.
Open the roll media shaft holder covers
(6)
Set the Take-up shaft to the shaft holder.
(7)
Pull the media out until it reaches the media core on the media take-up shaft.
Pull out the media
And then, set the Media Set Lever to the LOAD position.
Media Set Lever
(8)
Fix the media on the media core by using tape.
Fix with tape
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4. Set Up the Printer
How to adjust the Take-up media sensor
(1)
Feed the media to the position of the take-up media sensor to adjust the sensitivity of the sensor.
Pull out the media
(2)
Select “Print Para” form the main menu by using Up or Down arrow keys, and press the ENTER key.
Menu
Offline
(3)
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
Select the Print Post. the Up or the Down arrow keys, and then press the ENTER key.
Menu
Offline
(4)
Slack the media at here
1.Print Post.
2.Bi-dir. Adj
3.Pint Speed
4.Feed Speed
-
Feed the media until the media reaches the height of the media take-up sensor by pressing the
FUNC and the Down arrow keys simultaneously.
(5)
Menu
1.Print Post.
Offline
Start: 0100 mm
Length: 0000 mm
-
Set the media Take-up System Switch to the Automatic (“ ”) side.
Media Take-up
System Switch
Media Take-up
System Switch
Media Take-up System Switch
Continuous reverse rotation
OFF
Automatic
FEEDING
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JS500 Service Manual
(6)
4. Set Up the Printer
Adjust the sensitivity by turning the adjustment trimmer so as the correctly detect the feeding of the
media which allows automatic taking-up the media.
Media Take-up Sensor
Adjustment trimmer
Sensor LED
The sensor LED lights as indicated below.
Media Take-up Sensor
The Sensor LED lights green when the
sensor is not detecting the media.
The Sensor LED lights red or red and green
when the sensor is detecting the media. And
the take-up unit start to wind the media.
When the sensor is correctly adjusted
Front side
Front side
Media Take-UP Sensor
Media Take-UP Sensor
The sensor detects the paper,
and taking-up starts.
The sensor does not detect the paper,
and taking-up stops.
When the sensor is not correctly adjusted
When the sensor output is too weak
When the sensor output is too strong
Front side
Front side
Media Take-UP Sensor
Media Take-UP Sensor
The sensor cannot detect the paper,
and taking-up does not occur.
In this case, turn the adjustment knob
gradually to the right to increase the
sensor output.
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The sensor detects objects other than the
paper, and the roller does not stop after
taking-up of the paper is finished.
In this case, turn the adjustment knob
gradually to the left to decrease the sensor
output.
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4.7
4. Set Up the Printer
Installing the GPU
The GPU (Graphtec Print Utility) adjusts the setting of EF value of print head, the alignment of print head,
the bidirectional printing alignment and the feed distance.
Note:
The adjustment value for the alignment of print head, the bidirectional printing alignment
and the feed distance are written into your computer, so if you replace the computer you
need to adjust or input those values at replaced computer.
4.7.1
Installing the GPU
(1)
Confirm that the USB cable is not connected to the printer.
(2)
Insert the software CD-ROM in your computer’s CD drive.
(3)
Double-click the icon of setup.exe in the “GPU Setup V*.**” folder to run the Setup.
(4)
Specify the destination folder on the following display, and then click the “Next >”.
(5)
Select the “Typical” at the following display, and then click the “Next >”.
(6)
Click the “Next >” to start the installation.
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4. Set Up the Printer
(7)
The Setup Status appears.
(8)
When installation has been completed, the following screen appears.
Before you use the “GPU” utility, you must restart your computer.
Select “Yes, I want to restart my computer now.” and then click “Finish” to restart your computer.
(9)
Connect the printer via the USB cable to your computer, then turn on the power for the printer.
The “USB driver” is installed at this time.
Follow the Windows menu to install the USB driver for the JS501/500.
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4.7.2
(1)
4. Set Up the Printer
Start up the GPU
Double-click the GPU icon on the desktop.
Or start up from the Start menu of Windows -> Programs -> GPU.
(2)
The following screen is displayed.
(3)
Specify the printer you will use.
When using this software for the first time, a printer must be selected.
Select “JS50x-18” from “Printer” on the menu bar.
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4.8
4. Set Up the Printer
Setting the Ink Profile
You can use the following two types of ink cartridges at JS500/JS501.
• IJ-81000 series: Solvent ink cartridge
• IJ-81050 series: Eco solvent ink cartridge
JS500 Ink Curve Software can be used to set up the individual ink profile in order to control a print head
voltage properly to suit the ink cartridge that you use.
Be sure to set up the individual ink profile to meet the ink cartridge that you use.
Be sure to install the JS500 Ink Curve Software after installing “GPU” when you set up the ink profile for
the first time. IJ-81000 of ink profile is set up as default value therefore you need to change the ink profile
setting if you use IJ-81050.
Be sure to set up this software under the condition of plugging a PC into your JS500/501 with USB cable.
4.8.1
How to Install the Ink Curve Software
(1)
Insert the software CD-ROM in your computer’s CD drive.
(2)
Double-click the icon of [Setup.exe] in the “Ink curve setting software Setup V1.0” folder to run the
Setup.
(3)
The following window is displayed then click [Next] button.
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4. Set Up the Printer
(4)
Read “License Agreement” on the display carefully then click [Next] button.
(5)
Click [Next] button.
(6)
Browse and select the location for installation. Click [Next] button after selecting the desired location.
(7)
Select “Typical” then click [Next] button.
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4. Set Up the Printer
(8)
Confirm the folder name that you selected, then click [Next] button.
(9)
The installation is begun after you click [Next].
(10) The installation is done, and then the following window is displayed. Click [Finish] button.
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4.8.2
4. Set Up the Printer
How to Set up the Ink Profile
(1)
Confirm that the USB cable is connected to the printer.
(2)
Start up from “Start - All Programs - InkSelectTool - InkSelectTool”.
(3)
Click [Link] button.
(4)
Current Ink type is displayed in the [ink name]. When your printer is connected properly, “found the
printer” is displayed as blow.
(5)
Select an ink type that you use from the [ink name] pull-down menu.
* 1:Solvent IJ-81000
: Ink profile setting for the IJ-81000series ink cartridges
* 2:ECO IJ-81050
: Ink profile setting for the IJ-81050series ink cartridges
(6)
Click [Set] button, and set up Ink profile to the printer.
(7)
When the “Port reset OK!” is displayed, click
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to finish the Ink Curve Software settings.
JS500 Service Manual
4.9
4. Set Up the Printer
Setting the EF Value for the Print Heads
Set the EF value for the print heads when you had installed the new print heads to the printer.
Prepare the EF values and locations of the print heads, which values were recorded at the section 1.
(1)
Press the ONLINE key on the control panel to put the printer into ONLINE status.
(2)
Double-click the GPU icon on the desktop.
Or start up from the Start menu of Windows -> Programs -> GPU.
(3)
The following screen is displayed.
(4)
Select the Print Setup from the File menu to display the Print Setup menu.
Or Click the Print Setup button from the menu bar to display the Print Setup menu..
Print Setup Button
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4. Set Up the Printer
(5)
Click the EF Setup button to display the Print Head EF Value Control menu.
(6)
Input the EF Values for all print heads.
Print Head 3
Print Head 2
Print Head 1
K
Y
M
C
Print Head 3
Print Head 2
Print Head 1
If you want to have current settings of EF values of the printer, click the GET button.
(7)
Confirm that the EF values are input correctly, and then click the SET button to set the EF values to
the printer.
(8)
Click the Cancel button to exit the Print Head EF Value Control menu.
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4. Set Up the Printer
4.10 Adjusting the Print Head Positions
Adjust the print head positions when you had installed the new print heads to the printer.
There are the five print head position adjustments to have good printing quality.
Before performing any adjustments, print the nozzle check pattern (Jam Test) and check the printing
status of the nozzles.
If there are several non-firing nozzles, perform a print head cleaning operation.
4.10.1 How to Perform the Jam Test
(1)
Press the ONLINE key on the control panel to put the printer into OFFLINE status.
Menu
Offline
(2)
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
Select the Cleaning Tool from the main menu using the Up or the Down Keys, and then press the
ENTER key to display the menu below.
Menu
Offline
(3)
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
Select the Jam Test using the Up or the Down Keys, and then press the ENTER key to perform the
Jam Test.
Menu
Offline
1.Firing
2.Jam Test
3.PH Maintenance 4.Home Post.
-
If there are several non-firing nozzles, perform a print head cleaning operation.
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4. Set Up the Printer
4.10.2 How to Perform the Print Head Cleaning
(1)
Press the ONLINE key on the control panel to put the printer into OFFLINE status.
Menu
Offline
(2)
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
Select the Cleaning Tool from the main menu using the Up or the Down Keys, and then press the
ENTER key to display the menu below.
Menu
Offline
(3)
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
Select the Clean using the Up or the Down Keys, and then press the ENTER key to perform the print
head cleaning.
Menu
Offline
4.Home Post.
5.Clean
6.Clean(Heavy)
7.Parking
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4. Set Up the Printer
4.10.3 Adjusting the Horizontal Space for Same Color Print Heads
This is adjusting horizontal direction for the same color print heads with reference to the first print head.
(1)
Press the ONLINE key on the control panel to put the printer into ONLINE status.
(2)
Double-click the GPU icon on the desktop.
Or start up from the Start menu of Windows -> Programs -> Graphtec -> GPU.
(3)
The following screen is displayed.
(4)
Select the Print Setup from the File menu to display the Print Setup menu.
Or Click the Print Setup button from the menu bar to display the Print Setup menu.
Print Setup Button
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JS500 Service Manual
(5)
4. Set Up the Printer
Set the Print Setup as shown in the display below.
Do not make the check for the Wave Form box and the BiDirection box.
(6)
Click the OK button to display the GPU main menu, and then select the Open file from the file menu.
(7)
The file-browsing menu appeared and then selects the “1_H_Space_1-2_12 HEAD” file from the
GRAPHTEC folder. If your printer is the 8 Heads unit select the “1_H_Space_1-2_8 HEAD” file.
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JS500 Service Manual
(8)
4. Set Up the Printer
Click the Print button to print the adjustment pattern for the 1st and 2nd print heads.
Print Button
(9)
Check the results of printing, select where the lines printed by the 1st and 2nd print heads are
aligned most closely as one line for each color of the print heads.
And then input the compensation values by the Important Setup menu.
(10) Select the Print Setup from the File menu to display the Print Setup menu.
Or Click the Print Setup button from the menu bar to display the Print Setup menu.
Print Setup Button
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4. Set Up the Printer
(11) Click the More button to display the Important Setup menu.
(12) A warning message is displayed. Click OK button.
(13) Input the compensation values from the Important Setup menu, which was selected in the step (9).
Input the compensation values
here for each print head.
(14) Click the OK button to set the values.
(15) Print the adjustment pattern for the 1st and 2nd print heads again to confirm that the printing of lines
of each color is aligned almost as one line where ±0 is indicated.
If your printer is the 8 heads unit, skip to Section 4.10.4.
(16) Select the Open file from the file menu.
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4. Set Up the Printer
(17) The file-browsing menu appeared and then selects the “2_H_Space_12-3_12 HEAD” file from the
GRAPHTEC folder.
(18) Click the Print button to print the adjustment pattern for the 2nd and 3rd print heads.
Print Button
(19) Check the results of printing, select where the lines printed by the 2nd and 3rd print heads are
aligned most closely as one line for each color of the print heads.
And then input the compensation values by the Important Setup menu.
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4. Set Up the Printer
(19) Select the Print Setup from the File menu to display the Print Setup menu.
Or Click the Print Setup button from the menu bar to display the Print Setup menu.
Print Setup Button
(20) Click the More button to display the Important Setup menu.
(21) A warning message is displayed. Click OK button.
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4. Set Up the Printer
(22) Input the compensation values to the Horizontal Space in the Important Setup menu, which values
were selected in the step (9).
Input the compensation values
here for each print head.
(23) Click the OK button to set the values.
(24) Print the adjustment pattern for the 2nd and 3rd print heads again to confirm that the printing of lines
of each color is aligned almost as one line where ±0 is indicated.
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4. Set Up the Printer
4.10.4 Adjusting the Horizontal Space Between the Color of Each Print Head
This is adjusting horizontal direction between each color of print heads with reference to the Cyan print
head.
(1)
Print the adjustment pattern “3_H_Space_Color_12HEAD” file by using the same procedure as
section 4.10.3.
If your printer is the 8 Heads unit select the “2_H_Space_Color_8HEAD” file.
(2)
Check the results of printing, select where the lines printed by between each color of print heads are
aligned most closely as one line.
Cyan to Black
Cyan to Yellow
Cyan to Magenta
Print Head 3
Print Head 2
Print Head 1
(3)
Add the compensation values to the current values by the Important Setup menu.
Add the compensation values to the
current setting value which were set at
Print Head 3
the same color print heads adjustment.
Print Head 2
Print Head 1
K
Y
M
C
If your printer is the 8 Heads unit add the value for Print head 1 and 2.
(4)
Click the OK button to set the values.
(5)
Print the adjustment pattern “3_H_Space_Color_12HEAD” file again to confirm that the printing of
lines of each color is aligned almost as one line where ±0 is indicated.
If your printer is the 8 Heads unit print the “2_H_Space_Color_8HEAD” file.
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4. Set Up the Printer
4.10.5 Adjusting the Vertical Space for Each Print Head
This is adjusting vertical direction for each color of print heads with reference to the Cyan print head.
(1)
Print the adjustment pattern “4_V_Space_12HEAD” file by using the same procedure as section
4.10.3.
If your printer is the 8 Heads unit select the “3_V_Space_8HEAD” file.
Cyan to Black Cyan to Yellow
Cyan to Magenta
Print Head 3
Print Head 2
Print Head 1
(2)
Check the results of printing, select where the lines printed by between each color of print heads are
aligned most closely as one line.
(3)
Average the values for each color print head from 1st to 3rd, and then input the values to the Vertical
Space in the Important Setup menu.
Input the average of compensation
values to here.
(4)
Click the OK button to set the values.
(5)
Print the adjustment pattern “4_V_Space_12HEAD” file again to confirm that the printing of lines of
each color is aligned almost as one line where ±0 is indicated.
If your printer is the 8 Heads unit print the “3_V_Space_8HEAD” file.
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4. Set Up the Printer
4.10.6 Adjusting the Bidirectional Compensation
This is adjusting the bidirectional printing for the print heads.
(1)
Select the BiDirection box to the bidirectional printing in the Print Setup menu.
(2)
Input the -15000 to the Feed Compensation in the Important Setup menu. (Input the -10000 to the 8
print heads unit.)
(4)
Click the OK button to set the values.
(5)
Print the adjustment pattern “5_BiD_123_12HEAD” file by using the same procedure as section
4.10.3.
If your printer is the 8 Heads unit select the “4_BiD_12_8HEAD” file.
(6)
Check the results of printing, select where the lines printed by between each color of print heads are
aligned most closely as one line.
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4. Set Up the Printer
(10) Input the compensation values for the Bidirectional in the Important Setup menu.
Input the compensation values
here for each print head.
(11) Click the OK button to set the values.
(12) Press the ONLINE key on the control panel to put the printer into OFFLINE status.
Menu
Offline
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
(13) Select the Print Para from the main menu using the Up or the Down Keys, and then press the
ENTER key to display the menu below.
Menu
Offline
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
(14) Select the Print Post. the Up or the Down Keys, and then press the ENTER key.
Menu
Offline
1.Print Post.
2.Bi-dir. Adj
3.Pint Speed
4.Feed Speed
-
(15) Feed the media about 6 cm by pressing the FUNC key and the Down Position key simultaneously.
Menu
1.Print Post.
Offline
Start: 0100 mm
Length: 0000 mm
-
(16) Print the adjustment pattern “5_BiD_123_12HEAD” file again to confirm that the printing of lines of
each color is aligned almost as one line where ±0 is indicated.
If your printer is the 8 Heads unit print the “4_BiD_12_8HEAD” file.
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4. Set Up the Printer
(17) Set the Feed Compensation value to 0.
(18) Click the OK button to set the values.
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4. Set Up the Printer
4.10.7 Adjusting the Feed Compensation
This is adjusting the feed compensation for the printing.
If there is a banding in the printing you need to adjust this adjustment.
You need to perform this adjustment when changing media to different thickness.
(1)
Print the adjustment pattern “6_Feed Compensate_12HEAD” file by using the same procedure as
section 4.10.3.
If your printer is the 8 Heads unit select the “5_Feed Compensate_8HEAD” file.
(2)
Check the results of printing that there are the banding in the printing.
If the white stripes are shown, increase the feed compensation value until the white stripes
disappeared.
If the dark stripes are shown, decrease the feed compensation value until the dark stripes
disappeared
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4. Set Up the Printer
(3)
Adjust the feed compensation value in the Important Setup menu.
(4)
Click the OK button to set the values.
(5)
Print the adjustment pattern “6_Feed Compensate_12HEAD” file again to confirm that the printing of
lines of each color is aligned almost as one line where ±0 is indicated.
If your printer is the 8 Heads unit print the “5_Feed Compensate_8HEAD” file.
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4. Set Up the Printer
4.10.10 About the Adjustment Value
You need readjust these compensations values when you replaced the PC, because these compensations
values are stored in your PC.
So take the screen shot of the important setup menu after you adjust all compensations.
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5. Recommended Spare Parts List
5. Recommended Spare Parts List
5.1 Recommended Spare Parts List
No.
Parts No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
677662000
677662010
677662020
677662030
677662040
677662050
677662060
677662070
677662110
677662120
677662130
677662140
677662150
677662160
677662170
677662180
677662190
677662240
677662250
677662340
677662350
677662360
677662430
677662560
677662660
677662670
677662680
677662740
677662750
677662760
JS500-UM-251-9370
Qty/Printer
JS500-18
JS501-18
Main Board
1
1
126 PH Drive Board (12 heads)
1
1
Ink/Heating Control Board
1
1
X,Y Combine Board
1
1
Media Take-up Board Assy 220V 1
1
Stepping Motor Control Board
1
1
Control Panel Assy
1
1
USB HUB
1
1
Home Sensor
1
1
Ink cartridge sensor
4
4
X Encoder Assy
1
1
Media Sensor
1
1
Y Encoder Sensor Board
1
1
Media Take-up Sensor
1
1
Ink Pump(DC24V)
4
4
Y Motor with Encoder
1
1
X Motor (Feed)
1
1
X Encoder
1
1
Y Encoder Strip(180DPI 2830mm) 1
1
USB CABLE
1
1
Igus Cable for 485 series
1
1
Igus Cable for DC power
1
1
Small Filter(PALL 5u)
4
4
DAMPER
8
12
2/3 To 3/5 Joint
8
8
T Model 3/5 Joint
24
24
F Model 3/5 Joint
12
12
3/5 Tube, 4 multi-line
1
1
2/3 Tube, 4 multi-line
1
1
3/5 Tube, 1M
Parts Name
5-1
Remark
Print Cont. Board
Ink Supply Board
JS500 Service Manual
6. Maintenance
6. Maintenance
6.1
Daily Maintenance
To maintain stable performance of the printer, perform the following every day.
6.1.1
Turn on the Power for the Printer
Keep turn on the power for the printer after you install the ink to the printer.
This printer is flashing the ink automatically to maintain the printer head. This avoids drying out
the print head.
6.1.2
Moistening the Sponge in the Cap with Ink Cleaning Solution
The carriage s capped in the Capping Position when the printer is in the standby mode. To avoid drying
of the print head nozzles, the inside of the cap is required to be saturated with an appropriate amount of
moisture from Ink Cleaning Solution. Use the following steps to pour Ink Cleaning Solution into the cap.
(1)
Move the Print head Carriage to the PH Maintenance Position.
Select [3.Cleaning Tool] from the main menu by using Up/Down keys, and press the [ENTER]
key.
Menu
Offline
(2)
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
Select [3.PH Maintenance] from the sub menu by using Up/Down keys, and press the [ENTER]
key.
Menu
Offline
1.Firing
2.Jam Test
3.PH Maintenance 4.Home Post.
-
(3)
The Print head Carriage is moved to the PH Maintenance Position.
(4)
Open the panel on the front lower right side. Opening the panel allows access to the Capping
Unit.
Capping unit
Right lower cover
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JS500 Service Manual
(5)
6. Maintenance
Pour Ink Cleaning Solution into the cap.
Keep on pouring it until the fluid level reaches the position of the metal plate in the cap.
Spoid
Cleaning solution
Metal plate
Pour cleaning solution until
the fluid level reaches the
position of the metal plate
Cap
6.1.3
Checking the Waste Ink Bottles
Check if the waste ink bottles are full. If they are full, transfer the waste fluid into an appropriate
container to empty them.
There are two waste ink bottles, one on the left and the other on the right side of the printer.
Periodically check, and when using the printer, visually check the amount of the waste ink in the
waste ink bottles to avoid an overflow. If the waste ink bottles are full, use the following steps to
dispose of the waste ink.
(1)
Remove the full waste ink bottle carefully from the printer so as not to spill the waste ink.
Turn the waste ink bottle counterclockwise to remove it from the printer body.
(2)
Transfer the waste fluid into an appropriate container to empty the waste ink bottle.
(3)
Install the empty waste ink bottle on the printer body. Turn the waste ink bottle clockwise to install
it on the printer body.
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6.1.4
6. Maintenance
Checking the Cleaning Roller
Check if the cleaning roller is drying, if it is drying apply the ink cleaning solution to the entire
cleaning roller.
Perform the following steps to apply the ink cleaning solution to the cleaning roller.
(1)
Move the Print head Carriage to the Capping Position.
Select [3.Cleaning Tool] from the main menu by using [Up/Down] keys, and press the [ENTER]
key.
Menu
Offline
(2)
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
Select [7.Parking] from the sub menu by using [Up/Down] keys, and press the [ENTER] key.
Menu
Offline
4.Home Post.
5.Clean
6.Clean(Heavy)
7.Parking
-
(3)
The Print head Carriage moves to the Capping Position and is capped.
(4)
Open the panel on the front lower right side. Opening these panels allows access to the Cleaning
Roller.
(5)
Rotate the Cleaning Roller by using the attached brush to apply Ink Cleaning Solution to the
entire roller.
Injector
Ink Cleaning Solution
Rotate
Brush
Cleaning roller
JS500-UM-251-9370
6-3
JS500 Service Manual
6.1.5
6. Maintenance
Check for Interfusion of Air (air bubbles) in the Print head Tubes
After a long-term use, the gradual mixture of air into tubes may occur. If inlet tubes and outlet
tubes connected to the print heads have been interfused with a significant amount of air, printing
under such a condition may lead to a degradation of printing quality or troubles during printing.
Check the inlet tubes and outlet tubes everyday before starting printing, and remove the air if
interfusion is detected according to the following steps.
(1)
Move the Print head Carriage to the PH Maintenance Position.
Select [3.Cleaning Tool] from the main menu by using [Up/Down] keys, and press the [ENTER]
key.
Menu
Offline
(2)
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
Select [3.PH Maintenance] from the sub menu by using Up/Down keys, and press the [ENTER]
key.
Menu
Offline
(3)
1.Firing
2.Jam Test
3.PH Maintenance 4.Home Post.
-
Open the upper and lower panels on the front left side. Opening these panels allows access to
the Print head Carriage.
(4)
Remove the print head cover.
(5)
Install the Ink Install Jig.
(6)
Close the outlet tube clamper of the print head which has interfusion of air, and remove the outlet
tube cap.
(7)
Connect the syringe to the outlet tube, and open the outlet tube clamper.
(8)
When checking the interfusion of air in the tube, slowly remove the air bubbles with the syringe.
(9)
Confirming that the air in the tube has been removed, close the outlet tube clamper, and remove
the syringe.
(10) Install the outlet tube cap, and open the outlet tube clamper.
(11) Remove the Ink Install Jig.
(12) Perform Auto Cleaning.
Select [3.Cleaning Tool] from the main menu by using [Up/Down] keys, and press the [ENTER]
key.
Menu
Offline
JS500-UM-251-9370
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
6-4
JS500 Service Manual
6. Maintenance
(13) Select [6.Cleaning(Heavy)] from the sub menu by using [Up/Down] keys, and press the [ENTER]
key.
Menu
Offline
JS500-UM-251-9370
4.Home Post.
5.Clean
6.Clean(Heavy)
7.Parking
-
6-5
JS500 Service Manual
6.2
6. Maintenance
Weekly Maintenance
To maintain stable performance of the printer, perform the following once a week.
6.2.1
Cleaning of the Capping Unit and the Print Head
Perform the following steps for cleaning of the capping unit and the print head.
(1)
Move the Print head Carriage to the PH Maintenance Position.
Select [3.Cleaning Tool] from the main menu by using [Up/Down] keys, and press the [ENTER]
key.
Menu
Offline
(2)
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
Select [3.PH Maintenance] from the sub menu by using [Up/Down] keys, and press the [ENTER]
key.
Menu
Offline
1.Firing
2.Jam Test
3.PH Maintenance 4.Home Post.
-
(3)
The Print head Carriage is moved to the PH Maintenance Position.
(4)
Open the panel on the front lower right side. Opening the panel allows access to the Capping
Unit.
(5)
Wipe around the edge of the upper side of the cap with the attached brush using Ink Cleaning
Solution.
Then, clean the print head nozzle plate and the lower side of the plate which fixes the print heads.
(6)
Open the upper and lower panels on the front left side. Opening these panels allows access to
the Print head Carriage.
(7)
Cut the attached unwoven fabric into an appropriate size, and apply Ink Cleaning Solution.
(8)
Carefully wipe the nozzle plate of the print head.
(9)
Dip the brush onto the ink cleaning solution, and then clean the print head gently as shown in the
picture below.
Brush
Ink cleaning solution
(10) Carefully wipe the part which has contact with the cap on the lower side of the plate which fixes
the print heads.
Move the Print head Carriage to the Home Position or to the Capping Position after all the work is
complete.
JS500-UM-251-9370
6-6
JS500 Service Manual
6.3
6. Maintenance
When the Printer will not be Used for a While
If the printer will not be used for a while (two weeks to one month), clean the print heads and the
tubes between the print heads and the ink cartridges, and fill them with Ink Cleaning Solution
before storage.
Perform the following steps to store the printer.
(1)
Remove all the ink from the tubes which connect the ink cartridges and print head (see Section
4.3).
(2)
Clean all the ink tubes (see Section 4.2).
(3)
Fill the tubes with the Ink Cleaning Solution (see Section 4.4).
(4)
Leave for 10 - 20 minutes, repeat the above Step (1) to (3).
(5)
Cut the nonwoven cloth in the 1 cm width, and then cut those nonwoven cloth to the half to be the
12 pieces.
(6)
Fold down the nonwoven cloth two times as shown in the picture below. And make the 12 pieces
of folded nonwoven cloth.
(7)
Put these nonwoven cloths onto the print head caps as shown in the picture below.
(8)
Pour the ink cleaning solution to the print head caps as shown in the picture below.
JS500-UM-251-9370
6-7
JS500 Service Manual
(9)
6. Maintenance
Check that the Ink Install Jig is not attached, move the Print head Carriage to the Capping Station
and cap it.
(10) Select the “Cleaning Tool” from the main menu and then select the “Parking” to move the carriage
to the capping position.
Menu
Offline
Menu
Offline
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
4.Home Post.
5.Clean
6.Clean(Heavy)
7.Parking
-
(11) Turn off the power.
JS500-UM-251-9370
6-8
JS500 Service Manual
6.4
6. Maintenance
When the Printer will not be Used for a Long Time
If the printer will not be used for one month or longer, clean the print heads and the tubes
between the print heads and the ink cartridges, and fill the print head with the Ink Cleaning
Solution before storage.
Perform the following steps to store the printer.
(1)
Remove all the ink from the tubes which connect the ink cartridges and print head (see Section
4.3).
(2)
Clean all the ink tubes (see Section 4.2).
(3)
Fill the tubes with the Ink Cleaning Solution (see Section 4.4).
(4)
Leave for 10 - 20 minutes, repeat the above Step (1) to (3).
(5)
Remove all the ink from the tubes which connect the ink cartridges and print head (see Section
4.3).
(6)
Remove all the print heads from the carriage plate.
(7)
Fill the print heads with the ink cleaning solution.
(8)
Cap the print heads by the white caps.
White caps
(9)
Put in the print heads to the plastic bag.
JS500-UM-251-9370
6-9
JS500 Service Manual
7. Troubleshooting
7. Troubleshooting
7.1 When an Error Message is Displayed
Error No.
Cause
Solution
Wrn2
The media set lever is not set to the Set the media and set the Media Set Lever
(Media set lever Warning) LOAD position.
to the LOAD position.
If this error remains when the lever is set to
the LOAD position:
The media set lever sensor is not detecting
the lever position.
Check that the lever is closing the set lever
sensor mechanically.
Check that the connector CN8 on the Ink
Supply Board is securely connecting.
Check that the media set lever sensor is
working correctly.
If the media set lever sensor is not working,
replace the media set lever sensor.
Wrn19
The print head heater is not warmed Wait until the print head heater is warmed.
(Print head heater Warning) yet.
You need to wait a few minutes when the
print head heater temperature setting was
set to high temperature.
If the print head heater is not warmed:
The print head heater is not working.
Or,
The print head heater sensor is not working.
Check that the connector J16 on the Print
Head Drive Board is securely connecting for
the print head heater.
The cyan-1 print head is detecting the print
head heater temperature.
Check that the connector J13 on the Print
Head Drive Board is securely connecting for
the Cyan-1 print head.
Replace the Print head heater.
Or,
Replace the Cyan-1 print head.
Wrn20
This error does not display normally. Install the correct board to the printer.
The incorrect board was installed to
the printer.
JS500-UM-251-9370
7-1
JS500 Service Manual
Error No.
Err5
(Ink end Error)
7. Troubleshooting
Cause
The ink cartridge is empty.
Err6
The ink cartridge is not installed.
(No Ink cartridge Error)
JS500-UM-251-9370
7-2
Solution
Replace the ink cartridge to new one.
If this error remains after you replaced the
ink cartridge:
The ink status sensor is not working
correctly.
Check the ink status sensor.
Check that the connector CN12 on the Ink
Supply board is securely connecting for the
cyan ink status sensor.
Check that the connector CN11 on the Ink
Supply board is securely connecting for the
magenta ink status sensor.
Check that the connector CN14 on the Ink
Supply board is securely connecting for the
yellow ink status sensor.
Check that the connector CN13 on the Ink
Supply board is securely connecting for the
black ink status sensor.
If the ink status sensor is not working,
replace the ink status sensor.
Install the ink cartridge to the ink cartridge
holder.
If this error remains after you installed the ink
cartridge:
The ink cartridge is not installed securely.
Or;
The ink cartridge detection sensor is not
working correctly.
Securely install the ink cartridge to the ink
cartridge holder.
Check the ink cartridge detection sensor.
Check that the connector CN12 on the Ink
Supply board is securely connecting for the
cyan ink cartridge detection sensor.
Check that the connector CN11 on the Ink
Supply board is securely connecting for the
magenta ink cartridge detection sensor.
Check that the connector CN14 on the Ink
Supply board is securely connecting for the
yellow ink cartridge detection sensor.
Check that the connector CN13 on the Ink
Supply board is securely connecting for the
black ink cartridge detection sensor.
If the ink cartridge detection sensor is not
working, replace the ink cartridge detection
sensor.
JS500 Service Manual
Error No.
Err7
(No media Error)
7. Troubleshooting
Cause
Solution
Install the media to the printer.
If this error remains after you installed the
media:
The media detection sensor is dirty.
Or;
The media detection sensor is not working
correctly.
Clean the media detection sensor on the
print head plate.
Check that the connector CN7 on the Ink
Supply board is securely connecting for the
media detection sensor.
If the media detection sensor is not working,
replace the media detection sensor.
No Media.
Err8
The Feed (X) or the Y motors are not Check that there is something blocking to
turn the feed motor.
(Motor servo Error) working correctly.
Check that there is something blocking to
turn the Y motor.
Replace the X or Y motor.
Replace the motor board.
Err9
The error occurred when counting
Check that the Y linear encoder strip.
(Y encoder Error) the Y linear encoder strip.
If the Y linear encoder strip is dirty clean the
Y linear encoder strip.
Check that the Y encoder sensor is not
touching to the Y linear encoder strip.
If so, adjust the position of the Y encoder
sensor.
Check that there is not dust on the Y encoder
sensor.
Or replace the Y linear encoder strip.
Err10
The Y linear encoder sensor is not
Check that the Y encoder sensor on the
(No output from Y working correctly.
carriage unit.
encoder sensor)
Check that the connector CN9 on the Main
board is securely connecting for the Y
encoder sensor.
Check that the Y encoder sensor is not
touching to the Y linear encoder strip.
If so, adjust the position of the Y encoder
sensor.
Replace the Y encoder sensor.
Err11
The error occurs when the X direction Check that the X encoder disk.
(X encoder Error) moves too fast.
If the X encoder disk is dirty clean the X
encoder disk.
Check that the X encoder sensor is not
touching to the X encoder disk.
If so, adjust the position of the X encoder
sensor.
Check that there is not dust on the X encoder
sensor.
Or replace the X encoder sensor or the X
encoder disk.
JS500-UM-251-9370
7-3
JS500 Service Manual
7. Troubleshooting
Error No.
Cause
Err12
The error occurs when counting the
(X encoder counter X encoder disk is not correct.
Error)
Err13
(Main board internal
error)
Err14
(Ink supply board
error)
Err15
(Config ROM error)
The error occurred when initializing
the main board.
This error will not display normally.
The version of the ink supply board
is incorrect.
This error does not display normally.
The error occur when initializing the
main board.
A wrong configuration is written to
the main board.
Err16
The home sensor could not detect
(Home sensor error) the home position.
Err20
Err21
Err22
Err23
JS500-UM-251-9370
Solution
Check that the connector J1 on the Motor
board is securely connecting for the X
encoder sensor.
Check that the X encoder sensor is not
touching to the X encoder disk.
If so, adjust the position of the X encoder
sensor.
Check that there is not dust on the X encoder
sensor.
Or replace the X encoder sensor or the X
encoder disk.
Replace the main board.
Replace it to the correct version of the ink
supply board.
Replace it to the correct main board.
Check the home sensor.
Check that the connector CN11 on the main
board is securely connecting to the home
sensor.
Check that the home sensor is not touching
to the home position dog.
Replace the home sensor when it is
defective sensor.
These errors will not display normally. Replace it to the correct ink supply board.
These errors occur when the wrong
ink supply board was installed to the
JS500.
7-4
JS500 Service Manual
7. Troubleshooting
7.2 Printer does not Operate Correctly
Symptom
Power is not being
supplied.
Printer does not
start printing.
JS500-UM-251-9370
Cause
The power cable is not connected.
The power is not being supplied to
the power outlet.
Solution
Check that the power cable is firmly inserted.
Check that a power voltage conforming to
the power supply specifications is being
supplied.
The power supply unit 1 or 2 are not Check the power supply unit.
supplying the power.
Check that the power supply board 1 is
supplying +24V DC.
Check that the power supply board 2 is
supplying +5V DC.
The power switch is not turned on.
Turn on the power switch.
The USB cable is not connected.
Correctly connect the USB cable between
the printer and a PC.
The printer is not online.
Check whether the printer is online. If it is
not online, press the ONLINE key to put the
printer online.
The USB printer driver is not
Install the USB printer driver to the PC.
installed.
The Wrn19 displayed.
Wait until the print head heater is warmed.
The print head heater is not warmed You need to wait a few minutes when the
yet.
print head heater temperature setting was
set to high temperature.
If the print head heater is not warmed:
The print head heater is not working.
Or,
The print head heater sensor is not working.
Check that the connector J16 on the Print
Head Drive Board is securely connecting for
the print head heater.
The cyan-1 print head is detecting the print
head heater temperature.
Check that the connector J13 on the Print
Head Drive Board is securely connecting for
the Cyan-1 print head.
Replace the Print head heater.
Or,
Replace the Cyan-1 print head.
The printer model setting is not
Specify the printer model at the RIP
specified at the RIP software.
software.
7-5
JS500 Service Manual
7. Troubleshooting
Symptom
The printing stops
suddenly.
Cause
Solution
The USB cable is not matched with Replace the USB cable to USB 2.0 standard
the USB 2.0 standard
cable.
The USB1.0 cable standard is used.
The USB cable is too long.
Use the USB cable which is shorter than 3.0
m.
The USB HUB is not matched to the Replace the USB HUB to USB 2.0 standard
USB 2.0 standard.
HUB.
The USB port of PC is not USB 2.0 Use the PC which has the USB 2.0 port.
standard port.
The disconnection of the internal
Check that the connector on the internal
USB cable in the Y flexible chain.
USB HUB is securely connecting for the
internal USB cable.
And, Check that the connector CN10 on the
main board is securely connecting for the
internal USB cable.
The internal USB is defective.
Replace the internal USB cable.
The disconnection of the Igus Cable Check that the connector CN2 on the main
for 485 in the Y flexible chain.
board is securely connected for the Igus
Cable for 485.
And, Check that the connector CN6 on the
ink supply board is securely connecting for
the Igus Cable for 485.
The main board is defective.
Replace the main board.
The temperature
The power cable for the heater is not Connect the power cable for the heater.
for the front and the connecting to the printer.
rear heater does not The heater temperature setting is too Raise the heater temperature setting.
low.
become high.
The temperature sensor 2 is not
Check the temperature sensor 2.
working.
Check that the connector CN4 on the Ink
Supply Board is securely connecting to the
temperature sensor 2.
Check that the temperature sensor 2 is
working.
If not replace the temperature sensor 2.
The solid relay 2 is not working.
Check the solid relay 2.
Check that the connector CN33 on the Ink
Supply Board is securely connecting to the
solid relay 2.
Check that the solid relay 2 is working.
If not replace the solid relay 2.
The front or the rear heater is
Replace the front or the rear heater.
defective.
JS500-UM-251-9370
7-6
JS500 Service Manual
7. Troubleshooting
Symptom
The temperature for
the bed plate heater
does not become
high.
(Center Heater)
Cause
Solution
The power cable of the heater is not Connect the power cable for the heater.
connecting to the printer.
The heater temperature setting is too Raise the heater temperature setting.
low.
The solid relay 1 is not working.
Check the solid relay 1.
Check that connector CN20 on the Ink
Supply Board is securely connecting to the
solid relay 1.
Check that the solid relay 1 is working.
If not replace the solid relay 1.
The temperature sensor 1 is not
Check the temperature sensor 1.
working.
Check that the connector CN5 on the Ink
Supply Board is securely connecting to the
temperature sensor 1.
Check that the temperature sensor 1 is
working.
If not replace the temperature sensor 1.
The Center heater is defective.
Replace the Center heater.
The dryer unit does The power cable of the dryer unit is Connect the power cable for the dryer unit.
not work.
not connecting for the dryer unit.
If one of the fan is not working, replace it.
The capping system The cable between the elevator
Check that the connector CN5 on the
does not work.
board and the ink supply board is not elevator board and the connector CN3 on
connecting securely.
the main board are securely connecting.
The cable between the elevator
Check that the connector CN6 on the
board and the power supply board is elevator board is securely connected.
not connected securely.
The limit sensor for the capping
Check the limit sensor.
system is not working correctly.
Check that the connector CN7 on the
elevator board is securely connecting to the
limit sensor.
Check that the limit sensor is not touching to
the limit position dog.
Replace the limit sensor when it is defective
sensor.
Or replace the elevator board.
The motor for the capping system is Check the elevator motor.
not working.
Check that the connector CN1 on the
elevator board is securely connecting to the
elevator motor.
Check that the elevator motor is working.
If not replace the elevator motor.
Replace the elevator motor when it is
defective motor.
The elevator board is defective.
Replace the elevator board.
The menu is not
The cable between the LCD board
Check that the connector CN15 on the ink
displaying on the
and the ink supply board is not
supply board is securely connecting to the
connecting securely.
LCD
LCD board.
The LCD board is defective.
Replace the LCD board.
The X motor and
The power is not supplied from the Check that the connector J18 on the Motor
Y motor are not
power supply 1 board.
Board is securely connecting.
The
Motor
Board
is
defective.
Replace the Motor Board.
working.
JS500-UM-251-9370
7-7
JS500 Service Manual
7. Troubleshooting
Symptom
The X motor is not
working.
Cause
The cable for the X Motor is not
connecting securely.
The X Motor is defective.
The Motor Board is defective.
The Y motor is not The cable for the Y Motor is not
working.
connecting securely.
The Y Motor is defective.
The Motor Board is defective.
The internal vacuum The cables for the internal vacuum
fan are not connecting securely.
fans are not
The internal vacuum fan is defective.
working.
The Ink Supply
The cable for the Ink Supply Pump is
not connecting securely.
Pump is not
working.
Solution
Check that the connector J19 on the Motor
Board is securely connecting.
Replace the X Motor.
Replace the Motor Board.
Check that the connector J9 on the Motor
Board is securely connecting.
Replace the Y Motor.
Replace the Motor Board.
Check that the connector CN22 or CN23 on
the Ink Supply Board is securely connecting.
Replace the internal vacuum fan.
Check that the connector CN25 on the Ink
Supply Board is securely connecting for the
Cyan pump.
Check that the connector CN26 on the Ink
Supply Board is securely connecting for the
Magenta pump.
Check that the connector CN27 on the Ink
Supply Board is securely connecting for the
Yellow pump.
Check that the connector CN28 on the Ink
Supply Board is securely connecting for the
Black pump.
The hardened ink clogs the pump.
Replace the pump.
The pump is defective.
Replace the pump.
The Ink supply board is defective.
Replace the Ink supply board.
The Feed Motor is The power cable of the Take-up and Connect the power cable for the Take-up and
not working.
Feed unit is not connected.
Feed unit.
The Feed switch is not setting to the Set the Feed switch to the Auto position.
Auto position.
The cable for the Feed Motor is not Check that the connector CN10 on the Takeconnecting securely.
up and Feed Board is securely connecting.
The Feed Motor is defective.
Replace the Feed Motor.
The Take-up and Feed Board is
Replace the Take-up and Feed Board.
defective.
The Take-up Motor The power cable of the Take-up and Connect the power cable for the Take-up and
is not working.
Feed unit is not connected.
Feed unit.
The Take-up switch is not setting to Set the Take-up switch to the Auto position.
the Auto position.
The cable for the Take-up Motor is
Check that the connector CN9 on the Takenot connecting securely.
up and Feed Board is securely connecting.
The Take-up Motor is defective.
Replace the Take-up Motor.
The Take-up and Feed Board is
Replace the Take-up and Feed Board.
defective.
Correct the wiring.
The Take-up Motor The cable wiring for the Take-up
is turned to the
motor is wrong.
The black wire connect to CN9-1pin.
wrong direction.
The white wire connect to CN9-3pin.
The printed face
The red wire connect to CN9-5pin.
should be outer side
of the core.
JS500-UM-251-9370
7-8
JS500 Service Manual
7. Troubleshooting
7.3 Printing is not Satisfactory
Symptom
Printing quality is
poor.
Cause
Solution
The print settings are not matching to Adjust the temperature settings of the
the media.
heaters.
If the front, rear and center heater
temperature are too high the media wrinkles.
Adjust the temperature settings of the print
head heater.
If the print head heater temperature is too
high much inks stay on surface of the print
head. This ink clogs the print heads nozzles.
If the print head heater temperature is too
low the print head is clogged by hardened
ink easily.
Change the print mode of the RIP software.
Use other type of the media.
The media is not matching to the
Use other type of the media.
Graphtec ink.
Printing is faint and The nozzles of the print heads are
Perform the cleaning for the print head.
is not uniform.
clogging by the ink.
The maintenance station is dirty.
Clean the print head caps and cleaning
roller.
And then put the ink cleaning solution to the
cleaning roller and the print head caps.
The ink cleaning solution is not
Pour the cleaning solution into all print head
contained enough into the print head caps.
caps.
The temperature settings of the
Adjust the temperature settings of the print
print head heater is not matching to head heater.
environment.
If the print head heater temperature is too
high much inks stay on surface of the print
head. This ink clogs the print heads nozzles.
If the print head heater temperature is too
low the print head is clogged by hardened
ink easily.
The EV value of the print heads are Set the EV value of the print heads correctly.
not set correctly.
The air is contained into the tubes. Remove the air from the tubes.
The air is leaking to the outer tubes. Remove the air from the outer tubes, and
then tighten the outer tube caps securely.
The print heads reached duration of Replace the print heads.
life.
The firing volume or flash mode is
Adjust the firing volume or flash mode.
not appropriate.
The color printing bar is not using.
Set the color printing bar by the RIP
software.
The color-printing bar is used for the prefiring of the print head. Therefore the printing
quality of the starting point becomes better.
JS500-UM-251-9370
7-9
JS500 Service Manual
Symptom
The print head
touched on the
surface of the
media.
7. Troubleshooting
Solution
Load the media appropriately.
Adjust the temperature settings of the
heaters.
If the front, rear and center heater
temperature are too high the media wrinkles.
The power of the media vacuum fans Adjust the Fan Velocity settings.
are not sufficiently strong.
The print head height position is low. Set the print height setting lever to the high
position.
The ink is not fired The print head cable is not connected Check that the cable is connected to the
print board and print head securely.
from the print-head. securely.
The nozzles of the print heads are
Perform the cleaning for the print head.
clogging by the ink.
Clean the print head caps and cleaning
The maintenance station is dirty.
roller.
And then put the ink cleaning solution to the
cleaning roller and the print head caps.
The ink cleaning solution is not
Pour the cleaning solution into all print head
contained enough into the print head caps.
caps.
The temperature settings of the
Adjust the temperature settings of the print
print head heater is not matching to head heater.
environment.
If the print head heater temperature is too
high much inks stay on surface of the print
head. This ink clogs the print heads nozzles.
If the print head heater temperature is too
low the print head is clogged by hardened
ink easily.
The EV value of the print heads are Set the EV value of the print heads correctly.
not set correctly.
The air is contained into the tubes. Remove the air from the tubes.
The air is leaking to the outer tubes. Remove the air from the outer tubes, and
then tighten the outer tube caps securely.
The print heads reached duration of Replace the print heads.
life.
The edge of the
The edge guard is not used
Set the edge guard appropriately.
media become dirty. appropriately.
The media is wrinkled or curled.
Set the media after removing wrinkles or
curls.
The platen is dirty.
Clean the platen.
JS500-UM-251-9370
Cause
The media has wrinkles.
The front, rear or center heater
temperature settings are too high.
7-10
JS500 Service Manual
7. Troubleshooting
7.4 There are Miss Firing Nozzles after the Head Cleaning is Performed
There are miss firing nozzles after the head cleaning (Clean or Clean (Heavy)) is performed several
times. And the result of the JAM TEST is no good.
At this time perform the following procedure to solve it.
(1)
Select the “Cleaning Tool” from the main menu and then select the “PH Maintenance” to move the
carriage to the PH Maintenance position.
Menu
Offline
Menu
Offline
(2)
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
1.Firing
2.Jam Test
3.PH Maintenance 4.Home Post.
-
Dip the brush onto the ink cleaning solution, and then clean the print head gently as shown in the
picture below.
Brush
(3)
Ink cleaning solution
Rotate the Cleaning roller by using the brush and then apply the ink cleaning solution to the entire
roller as shown in the figure below.
Injector
Ink Cleaning Solution
Rotate
Brush
Cleaning roller
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JS500 Service Manual
(4)
7. Troubleshooting
Perform the head cleaning again.
Select the “Cleaning Tool” from the main menu, and then select the “Clean (Heavy)”.
Menu
Offline
Menu
Offline
(5)
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
4.Home Post.
5.Clean
6.Clean(Heavy)
7.Parking
-
Confirm the result of printing by the JAM TEST.
When the result of the JAM TEST is still no good, repeat the step (1), (2) and (4).
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JS500 Service Manual
7. Troubleshooting
7.5 When the Print Head is Clogged by the Hardened Ink
If the printer was not used long time without power, that print head is clogged by the hardened ink.
At this time perform the following procedure to solve it.
(1)
Select the “Cleaning Tool” from the main menu and then select the “PH Maintenance” to move the
carriage to the PH Maintenance position.
Menu
Offline
Menu
Offline
(2)
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
1.Firing
2.Jam Test
3.PH Maintenance 4.Home Post.
-
Cut the nonwoven cloth in the 1 cm width, and then cut those nonwoven cloth to the half to be the 12
pieces.
(3)
Fold down the nonwoven cloth two times as shown in the picture below. And make the 12 pieces of
folded nonwoven cloth.
(4)
Put these nonwoven cloths onto the print head caps as shown in the picture below.
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JS500 Service Manual
7. Troubleshooting
(5)
Pour the ink cleaning solution to the print head caps as shown in the picture below.
(6)
Select the “Cleaning Tool” from the main menu and then select the “Parking” to move the carriage to
the capping position.
Menu
Offline
Menu
Offline
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
4.Home Post.
5.Clean
6.Clean(Heavy)
7.Parking
-
(7)
Wait one or two hours until the clogged ink dissolved into the ink cleaning solution.
(8)
Perform the head cleaning.
Select the “Cleaning Tool” from the main menu, and then select the “Clean (Heavy)”.
Menu
Offline
Menu
Offline
(9)
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
4.Home Post.
5.Clean
6.Clean(Heavy)
7.Parking
-
Confirm the result of printing by the JAM TEST.
When the result of the JAM TEST is still no good, repeat the step (5) to (9).
(10) If the result of the JAM TEST is still no good after you repeated this procedure then replace the print
heads.
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JS500 Service Manual
7. Troubleshooting
7.6 When the Print Head Touched onto the Media During Printing
If the heater temperature is too high that cause the wrinkle of media. This depends on the media type too.
And this wrinkle of media is touched to the print head.
When you use thin media the fan velocity setting is related to the wrinkle of media.
If the fan velocity setting is not enough the media lift up from the bedplate.
If you have this kind of problem you need to adjust the heater temperature and the fan velocity.
Recommended settings for the front, bed plate heaters and the fan Velocity
Media Type
Vinyl
Banner
Heater Temperature Setting
35 to 40˚C, Setting Value: 0035 to 0040
40 to 45˚C, Setting Value: 0040 to 0045
Fan Velocity Settings
Setting Value: 0004 to 0006
Setting Value: 0004 to 0008
When you use the thick media, the gap between the surfaces of media and the print head will be shorter.
If the media thickness is over 0.4 mm set the print head height level to high position.
Peint head height lever
Recommended settings for the print head height lever
Media Type
Vinyl
Banner
JS500-UM-251-9370
Position of the print head height lever
Lower position
Upper position
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JS500 Service Manual
7.7
7. Troubleshooting
When Printing the Long Length the Printing Gradually Becomes Faint
When printing the long length the printing gradually becomes faint.
If you have this kind of problem check the following items.
•
The setting of the print head heater temperature
•
The setting of the Flash Mode
•
The setting of the EF value for the print heads
•
The air leak from the serge tank
•
The air leak from the tube and the air contain into the print head
Print head heater temperature setting
Set the print head heater temperature as depends on the printer operating environment.
Temperature of the operating environment
Print head heater temperature setting
20 to 24˚C
35˚C (Setting value:0035) to 38˚C (Setting value:0038)
Set the print head temperature in above range by the result
of the printing.
25 to 28˚C
30˚C (Setting value:0030)
Flash Mode setting
If there are not using colors in the printing that color of the nozzles becomes dry.
Set the Flash Mode to a small value to avoid the dryness of the nozzle.
Recommended setting: 0001 (The firing is performed at each pass.)
EF Value setting
Confirm that the EF values are set correctly to each of the print heads.
Set the EF value that is recorded on the package of the print head to the printer.
Confirm there is not air leak from the serge tank
If there is an air leak from the serge tank replace it to new one.
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JS500 Service Manual
7. Troubleshooting
If the print head or the tube is containing the air
Remove the air from the print head or the tube by the procedure below.
(1)
Turn on the power for the JS501/500.
(2)
Select the Cleaning Tool using the direction keys from the main menu, and then press the ENTER
key.
Menu
Offline
(3)
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
Select the PH Maintenance using the direction keys from the sub-menu, then press the ENTER key.
Menu
Offline
1.Firing
2.Jam Test
3.PH Maintenance 4.Home Post.
-
(4)
The carriage moves to the maintenance station.
(5)
Mount the Ink Installing Jig to the carriage as shown in the picture below.
Positioning pin
Fixing lever
(6)
Ink Installing Jig
Fit the three of the positioning pins of the Ink Installing Jig to the edge of the carriage.
And then, fix the Ink Installing Jig to the carriage using the three fixing levers.
Positioning pin
Fixing lever
(7)
Close the outlet tube clamper for the outlet tube that is containing the air.
Close the outlet tube clamper
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JS500 Service Manual
7. Troubleshooting
(8)
Remove the outlet cap from the outlet tube.
(9)
Connect the syringe into the outlet tube, and then open the outlet tube clamper for the outlet tube.
(10) Pull the piston of syringe to remove the air from the tube.
(11) Close the outlet tube clamper.
Close the outlet tube clamper
(12) Disconnect the syringe from the outlet tube, and then discard the ink from the syringe to the waste
ink receiving area.
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JS500 Service Manual
7. Troubleshooting
(13) Attach the outlet cap to the outlet tube.
(14) Open the outlet tube clamper for the outlet tube.
Open the outlet tube clamper
(15) Remove the Ink Installing jig from the carriage when the ink was drawn to all print heads.
(16) Perform the head cleaning.
Select the “Cleaning Tool” from the main menu, and then select the “Clean (Heavy)”.
Menu
Offline
Menu
Offline
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
4.Home Post.
5.Clean
6.Clean(Heavy)
7.Parking
-
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JS500 Service Manual
7. Troubleshooting
7.8 How to Replace the Serge Tank
If there are the bad film welds at the serge tank the air leaks.
Replace the serge tank according to the following procedures if air leaks from the serge tank.
Leaking area
(1)
Turn on the power for the JS501/500.
(2)
Select the Cleaning Tool using the direction keys from the main menu, and then press the ENTER
key.
Menu
Offline
(3)
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
Select the PH Maintenance using the direction keys from the sub-menu, then press the ENTER key.
Menu
Offline
1.Firing
2.Jam Test
3.PH Maintenance 4.Home Post.
-
(4)
The carriage moves to the maintenance station.
(5)
Turn off the power for the JS501/500.
(6)
Remove the four M3 screws holding the left upper cover, and then remove the left upper cover from
the JS501/500.
Left upper cover
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JS500 Service Manual
7. Troubleshooting
(7)
Remove the leaking serge tank from the serge tank holder.
(8)
Close the clamper of the surge tank.
(9)
Clamp the other side of tube of the surge tank using the paper clip as shown in the picture below.
(10) Puts the vinyl sheet and cloth under the serge tank not to make the printer dirty with the spilled ink.
(11) Cut the tube near the connecting point of the serge tank as shown in the picture below.
Cut the tube near the connecting
point of the serge tank.
(12) Install the new serge tank to tubes.
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JS500 Service Manual
7. Troubleshooting
(13) Open the tube clamper for the surge tank and remove the paper clip.
(14) Reinstall the serge tank to the serge tank holder.
(15) Mount the Ink Installing Jig to the carriage as shown in the picture below.
Positioning pin
Fixing lever
Ink Installing Jig
(16) Fit the three of the positioning pins of the Ink Installing Jig to the edge of the carriage.
And then, fix the Ink Installing Jig to the carriage using the three fixing levers.
Positioning pin
Fixing lever
(17) Close the outlet tube clamper for the outlet tube that is the serge tank replaced.
Close the outlet tube clamper
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JS500 Service Manual
7. Troubleshooting
(18) Remove the outlet cap from the outlet tube.
(19) Connect the syringe into the outlet tube, and then open the outlet tube clamper for the outlet tube.
(20) Pull the piston of syringe up to the 20 ml mark.
(21) Close the outlet tube clamper.
Close the outlet tube clamper
(22) Disconnect the syringe from the outlet tube, and then discard the ink from the syringe to the waste
ink receiving area.
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JS500 Service Manual
7. Troubleshooting
(23) Attach the outlet cap to the outlet tube.
(24) Open the outlet tube clamper for the outlet tube.
Open the outlet tube clamper
(25) Remove the Ink Installing jig from the carriage when the ink was drawn to all print heads.
(26) Turn on the power for the JS501/500.
(27) Perform the head cleaning.
Select the “Cleaning Tool” from the main menu, and then select the “Clean (Heavy)”.
Menu
Offline
Menu
Offline
1.Ink Status
2.Heat Status
3.Cleaning Tool
4.Print Para
+
+
+
+
4.Home Post.
5.Clean
6.Clean(Heavy)
7.Parking
-
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JS500 Service Manual
7. Troubleshooting
7.9 The Media Take-up Shaft Rotates in a Wrong Direction
When the media take-up shaft rotates in a wrong direction that the wiring for the take-up motor is wrong.
Correct the wiring for the take-up motor according to the following procedures
(1)
Turn off the power for the JS500/501.
(2)
Remove the left rear cover as shown in the picture below.
(3)
Confirm the wire color of the connector CN9 on the Take-up and Feed board.
Take-up and Feed motor board
CN9
(4)
Correct the wiring as shown in the picture below
Swap the pin 3 of red wire and the pin 5 of the white wire.
Correct wiring
3. White
Wrong wiring
5. Red
1. Black
3. Red 4. White
1. Black
4. NC
2. NC
4. NC
2. NC
The white wire must be connected to the pin 3.
And the red wire must be connected to the pin 5.
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JS500 Service Manual
7. Troubleshooting
7.10 The Print Head Nozzles Dry up Soon During Standby Mode
When the carriage is staying at home position the printer is flashing the ink at moderate intervals to avoid
the nozzles drying.
If the nozzles are dried soon during the standby mode, adjust the Firing Vol settings to avoid drying
nozzles.
The firing volume for the standby mode
Setting value of the Firing Vol
Firing volume for the standby mode
(ml/min)
0000
0.0050
0010
0.0054
0020
0.0058
0030
0.0063
0040
0.0069
0050
0.0075
0060
0.0084
0070
0.0094
0080
0.0108
0090
0.0126
0100
0.0151
If the nozzles are dried soon adjust the firing volume to large value.
Note that the firing volume is set too large; the nozzles are clogged by extra ink.
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Remark
Default setting
JS500 Service Manual
7. Troubleshooting
7.11 The Heater Temperature cannot Control from the Operation Panel
The solid relay 1 or 2 is defective.
If the front and rear heater temperature cannot control check the solid relay 2.
If the bedplate heater temperature cannot control check the solid relay 1.
How to check the solid relay
(1)
Turn off the main power and the heater for the JS500/501.
(2)
Disconnect the main and the heater AC power cables from the JS500/501.
Caution
Confirm that the AC cables are disconnected.
Replacing the relay is dangerous without disconnecting the AC cables because the relay terminals
are connecting directly from the AC line.
(3)
Remove the left rear cover as shown in the picture below.
Solid relay
JS500-UM-251-9370
Solid relay for the
Solid relay for the front
bedplate heater
and rear heaters
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JS500 Service Manual
(4)
7. Troubleshooting
Check the value of resistance on the LOAD side of the solid relay.
LOAD side
LOAD side
If the value of resistance on the LOAD side is nearly 0 Ohm the solid relay is defective.
(There is 0.8 to 1 M Ohm normally.)
Replace the solid relay.
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JS500 Service Manual
8. Disassemble and Reassemble
8. Disassemble and Reassemble
8.1
8.1.1
Exterior Parts
How to Replace the Left Top Cover
How to detach the left top cover
(1)
Remove the six M4L8 binding head screws holding the left top cover.
Left top cover
(2)
M4L8 binding head screw
Detach the left top cover from the main unit.
How to reinstall the left top cover
(1)
8.1.2
Reattach the left top cover in the reverse order in which it was detached.
How to Replace the Left Side Cover
How to detach the left side cover
(1)
Open the top print head maintenance cover and the bottom print head maintenance cover.
(2)
Detach the left top cover (see Section 8.1.1).
(3)
Remove the four M3.5 self tapping screws and the one M4L8 binding head screw holding the left
side cover.
Left side cover
M3.5L6 self tapping screw
(4)
M4L8 binding head screw
Detach the left side cover from the main unit.
How to reinstall the left side cover
(1)
Reattach the left side cover in the reverse order in which it was detached.
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JS500 Service Manual
8.1.3
8. Disassemble and Reassemble
How to Replace the Right Top Cover
How to detach the right top cover
(1)
Remove the six M4L8 binding head screws holding the right top cover.
Right top cover
M4L8 binding head screw
(2)
Detach the right top cover from the main unit.
How to reinstall the right top cover
(1)
8.1.4
Reattach the right top cover in the reverse order in which it was detached.
How to Open the Control Panel Cover
(1)
Open the right bottom cover.
(2)
Remove the two M3L6 binding head screws holding the control cover.
Control panel cover
M3L6 binding head screw
(3)
Open the control cover.
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JS500 Service Manual
8.1.5
8. Disassemble and Reassemble
How to Replace the Right Side Cover
How to detach the right side cover
(1)
Open the control panel cover (see Section 8.1.4).
(2)
Open the right bottom cover.
(3)
Detach the right top cover (see Section 8.1.3).
(4)
Remove the four M3.5 self tapping screws and the one M4L8 binding head screw holding the
right side cover.
Right side cover
M4L8 binding head screw
M3.5L6 self tapping screw
(5)
Detach the right side cover from the main unit.
How to reinstall the right side cover
(1)
8.1.6
Reattach the right side cover in the reverse order in which it was detached.
How to Replace the Left Rear Cover
How to detach the left rear cover
(1)
Remove the six M4L8 binding head screws holding the left rear cover.
M4L8 binding head screw
Left rear cover
(2)
Detach the left rear cover from the main unit.
How to reinstall the left rear cover
(1)
Reattach the left rear cover in the reverse order in which it was detached.
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JS500 Service Manual
8.1.7
8. Disassemble and Reassemble
How to Replace the Right Rear Cover
How to detach the right rear cover
(1)
Remove the six M4L8 binding head screws holding the right rear cover.
Right rear cover
(2)
M4L8 binding head screw
Detach the right rear cover from the main unit.
How to reinstall the right rear cover
(1)
8.1.8
Reattach the right rear cover in the reverse order in which it was detached.
How to Replace the Center Rear Cover
How to detach the center rear cover
(1)
Remove the six M4L8 binding head screws holding the center rear cover.
M4L8 binding head screw
Center rear cover
(2)
Detach the center rear cover from the main unit.
How to reinstall the center rear cover
(1)
Reattach the center rear cover in the reverse order in which it was detached.
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JS500 Service Manual
8.1.9
8. Disassemble and Reassemble
How to Replace the Carriage Top Cover
How to detach the carriage top cover
(1)
Detach the left top cover (see Section 8.1.1).
(2)
Move the carriage to the far left side.
(3)
Remove the four M3L8 binding head screws holding the carriage top cover.
M3L8 binding head screw
Carriage top cover
(4)
Detach the carriage top cover from the carriage.
How to reinstall the carriage top cover
(1)
Reattach the carriage top cover in the reverse order in which it was detached.
8.1.10 How to Replace the Carriage Cover
How to detach the carriage cover
(1)
Remove the four M3L8 binding head screws holding the carriage cover.
M3L8 binding head screw
Carriage cover
(2)
Detach the carriage cover from the carriage.
How to reinstall the carriage cover
(1)
Reattach the carriage cover in the reverse order in which it was detached.
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JS500 Service Manual
8. Disassemble and Reassemble
8.1.11 How to Replace the Capping Station Cover
How to detach the right side cover
(1)
Open the control panel cover (see Section 8.1.4).
(2)
Open the right bottom cover.
(3)
Remove the three M3L6 binding head screws and the three M4L8 binding head screws holding
the capping station cover.
M4L8 binding head screw
Capping station cover
M3L6 binding head screw
(4)
Detach the capping station cover from the main unit.
How to reinstall the capping station cover
(1)
Reattach the capping station cover in the reverse order in which it was detached.
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JS500 Service Manual
8.2
8.2.1
8. Disassemble and Reassemble
Mechanical Parts
How to Replace the X Encoder Sensor Assembly
How to detach the X encoder sensor
(1)
Detach the left top cover (see Section 8.1.1).
(2)
Detach the left side cover (see Section 8.1.2).
(3)
Disconnect the X encoder sensor cable.
(4)
Remove the two M3L8 binding head screws holding the X encoder sensor assembly.
M3L8 binding head screw
X encoder sensor assembly
(5)
Detach the X encoder sensor assembly form the main unit.
How to reinstall the X encoder sensor assembly
(1)
8.2.2
Reattach the X encoder sensor assembly in the reverse order in which it was detached.
How to Replace the X Motor Belt
How to detach the X motor belt
(1)
Detach the left top cover (see Section 8.1.1).
(2)
Detach the left side cover (see Section 8.1.2).
(3)
Loosen the four M4L12 binding head screws holding the X motor bracket.
X motor bracket
X motor belt
M4L12 binding head screw
(4)
Detach the X motor belt.
How to reinstall the X motor belt
(1)
Reattach the X motor belt in the reverse order in which it was detached.
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JS500 Service Manual
8.2.3
8. Disassemble and Reassemble
How to Replace the X Motor
How to detach the X motor
(1)
Detach the left side cover (see Section 8.1.2).
(2)
Detach the left rear cover (see Section 8.1.6).
(3)
Loosen the four M4L8 binding head screws holding the X motor bracket.
X motor bracket
X motor belt
M4L12 binding head screw
(4)
Detach the X motor belt from the X motor pulley (see Section 8.2.2).
(5)
Disconnect the X motor cable.
X motor cable connector
(6)
Remove the four M3L8 binding head screws holding the X motor.
X motor bracket
M3L8 binding head screw
(7)
Detach the X motor.
How to reinstall the X motor belt
(1)
Reattach the X motor in the reverse order in which it was detached.
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JS500 Service Manual
8.2.4
8. Disassemble and Reassemble
How to Replace the X Motor Encoder Disk
How to detach the X motor encoder disk
(1)
Detach the left top cover (see Section 8.1.1).
(2)
Detach the left side cover (see Section 8.1.2).
(3)
Detach the X motor encoder sensor assembly (see Section 8.2.1).
(4)
Detach the X motor belt (see Section 8.2.2).
(5)
Loosen the two M4L5 set screws holding the X motor encoder disk.
M4L5 set screw
X motor encoder disk
(6)
Detach the X motor encoder disk.
How to reinstall the X motor encoder disk
(1)
Reattach the X motor encoder disk in the reverse order in which it was detached.
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JS500 Service Manual
8.2.5
8. Disassemble and Reassemble
How to Replace the Y Motor
How to detach the Y motor
(1)
Detach the right top cover (see Section 8.1.3).
(2)
Detach the right side cover (see Section 8.1.5).
(3)
Detach the right rear cover (see Section 8.1.7).
(4)
Remove the two M3L8 binding head screws and the one M4L6 binding head screw holding the
shield cover. And then detach the shield cover.
Shield cover
M4L6 binding head screw
M3L8 binding head screw
(5)
Loosen the three M4L8 binding head screws holding the Y motor bracket.
M4L8 binding head screw
Y motor bracket
(6)
Loosen the two set screws holding the Y motor pulley.
Set screw
Y motor pulley
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JS500 Service Manual
(7)
8. Disassemble and Reassemble
Remove the two M3L6 binding head screws holding the Y motor pulley bearing plate.
M3L6 binding head screw
Y motor pulley bearing plate
(8)
Detach the Y motor pulley bearing plate with the Y motor pulley.
(9)
Disconnect the Y motor cables from the motor board.
Motor board
Y motor GND cable
Y motor encoder cable
Y motor power cable
(10) Remove the four M3L6 binding head screws holding the Y motor.
Y motor
M3L6 binding head screw
(11) Detach the Y motor.
How to reinstall the Y motor
(1)
Reattach the Y motor in the reverse order in which it was detached.
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JS500 Service Manual
8.2.6
8. Disassemble and Reassemble
How to Replace the Y Motor Belt
How to detach the Y motor belt
(1)
Detach the right top cover (see Section 8.1.3).
(2)
Detach the right side cover (see Section 8.1.5).
(3)
Loosen the three M4L8 binding head screws holding the Y motor bracket.
M4L8 binding head screw
Y motor bracket
(4)
Loosen the two set screws holding the Y motor pulley.
Set screw
Y motor pulley
(5)
Remove the two M3L6 binding head screws holding the Y motor pulley bearing plate.
M3L6 binding head screw
Y motor pulley bearing plate
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JS500 Service Manual
8. Disassemble and Reassemble
(6)
Detach the Y motor pulley bearing plate with the Y motor pulley.
(7)
Detach the Y motor belt form the Y drive pulley.
Y motor belt
Y drive pulley
How to reinstall the Y motor belt
(1)
Reattach the Y motor belt in the reverse order in which it was detached.
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JS500 Service Manual
8.2.7
8. Disassemble and Reassemble
How to Replace the Y Linear Encoder Strip
How to detach the Y liner encoder strip
(1)
Open the control panel (see Section 8.1.4).
(2)
Open the center front cover.
Center front cover
(3)
Open the maintenance station cover.
(4)
Remove the two M3L6 binding head screws holding the Y linear encoder strip spring bracket at
right end.
M3L6 binding head screw
Y linear encoder strip
(5)
Remove the two M3L6 binding head screws holding the left Y linear encoder strip retainer.
M3L6 binding head screw
Y linear encoder strip
(6)
Detach the Y linear encoder strip.
(7)
Remove the two M3L6 binding head screws holding the left Y linear encoder strip holder.
M3L6 binding head screw
Y linear encoder strip
Y linear encoder strip holder
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8. Disassemble and Reassemble
How to reinstall the Y linear encoder strip
(1)
Reattach the Y linear encoder strip in the reverse order in which it was detached.
(2)
Attach the Y linear encoder as shown below.
Position the notch to left top
(3)
Confirm the Y linear encoder sensor is not touching to the encoder strip.
Encoder Sensor
Encoder strip
Confirm the Y linear encoder
sensor is not touching to the
encoder strip.
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8.2.8
8. Disassemble and Reassemble
How to Replace the Y belt
How to detach the Y belt
(1)
Detach the left top cover (see Section 8.1.1).
(2)
Detach the left side cover (see Section 8.1.2).
(3)
Detach the right top cover (see Section 8.1.3).
(4)
Detach the right side cover (see Section 8.1.5).
(5)
Detach the center rear cover (see Section 8.1.8).
(6)
Detach the carriage cover (see Section 8.1.10).
(7)
Loosen the two M3L45 binding head screws holding the Y idler pulley.
M3L45 binding head screw
Y idler pulley
Y belt
(8)
Detach the media detection sensor (see Section 8.3.1).
(9)
Remove the four M4L10 cap screws holding the print head carriage.
M4L10 cap screw
Print head carriage
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8. Disassemble and Reassemble
(10) Remove the two M3L10 cap screws holding the Y belt holder plates.
Y belt holder plate
M3L8 cap screw
Y belt
(11) Detach the Y belt.
How to reinstall the Y belt
(1)
Reattach the Y belt in the reverse order in which it was detached.
(2)
Set the carriage height lever to the low position.
Carriage height lever
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(3)
8. Disassemble and Reassemble
Put the 2.5 mm carriage height adjustment shim under the carriage plate.
2.5 mm carriage height adjustment plate
(4)
Tighten the four M4L10 cap screws holding the print head carriage.
M4L10 cap screw
Print head carriage
(5)
Tighten the two M3L45 binding head screws holding the Y idler pulley.
M3L45 binding head screw
Y idler pulley
Y belt
(6)
Confirm the Y idler is not tilted.
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8.2.9
8. Disassemble and Reassemble
How to Replace the Ink Tubes of the Chain
How to detach the ink tubes of the chain
(1)
Remove the ink from the tube (see Section 4.3).
(2)
Detach the right top cover (see Section 8.1.3).
(3)
Detach the right rear cover (see Section 8.1.7).
(4)
Detach the carriage top cover (see Section 8.1.9).
(5)
Detach the print head drive board (see Section 8.3.4).
(6)
Detach the main board (see Section 8.3.5)
(7)
Detach the shield plate.
Shield plate
(8)
Remove the two M3L8 binding head screws and the one M4L6 binding head screw holding the
shield cover. And then detach the shield cover.
Shield cover
M4L6 binding head screw
M3L8 binding head screw
(9)
Detach the center rear cover (see Section 8.1.8).
(10) Remove the six M3L20 binding head screws holding the tube & signal cable holders, and then
tube & signal cable holders.
Tube & signal cable holder
M3L20 binding head screw
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8. Disassemble and Reassemble
(11) Remove the two M3L20 binding head screws holding the tube & signal cable holder of the
carriage end.
M3L20 binding head screw
(12) Remove the two M3L8 flat head screws holding the chain of the carriage end.
M3L8 flat head screw
(13) Press down the center of the chain tab to release the notch of the tab, and then open the tab as
shown in the picture below.
(14) Open all chain tabs.
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8. Disassemble and Reassemble
(15) Disconnect (cut the tube) the ink tubes that come from the chain.
(16) Disconnect (cut the tube) the ink tubes that are connecting to the ink cartridges and the pumps.
(17) Detach the ink tubes from the chain.
How to reinstall the ink tubes of the chain
(1)
Reattach the ink tubes in the reverse order in which they were detached.
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8. Disassemble and Reassemble
8.2.10 How to Replace the Pinch Roller
How to detach the pinch roller
(1)
Remove the E-ring from the pinch roller shaft.
Pinch roller
Pinch roller shaft
E-ring
(2)
Detach the pinch roller shaft from the pinch roller holder.
(3)
Detach the pinch roller.
How to reinstall the pinch roller
(1)
Reattach the pinch roller in the reverse order in which it was detached.
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8. Disassemble and Reassemble
8.2.11 How to Replace the Pinch Roller Arm
How to detach the pinch roller arm
(1)
Detach the left top cover (see Section 8.1.1).
(2)
Detach the left rear cover (see Section 8.1.6).
(3)
Detach the right top cover (see Section 8.1.3).
(4)
Detach the center rear cover (see Section 8.1.8).
(5)
Set the media lever to the HOLD position.
(6)
Peel off the tape from the guard cover, and then remove the three M3L6 flat head screws holding
the guard cover.
M3L6 flat head screw
Guard cover
(7)
Remove the eleven M3L6 binding screws and M3L6 flat head screw holding the chain guide.
M3L6 Binding head screw
Chain guide
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(8)
8. Disassemble and Reassemble
Detach the chain guide from the main unit as shown in the picture below.
Chain guide
(9)
Loosen the set screw holding the left side cam shaft collar.
Set screw
Right cam shaft collar
(10) Loosen the set screw holding the right side cam shaft collar and then slide the cam shaft as
shown in the picture below.
Cam shaft
Left cam shaft collar
Set screw
(10) Slide off the cam shaft gear from the cam lever gear and then slide off the cam shaft collar from
the cam shaft collar holder.
Right cam shaft collar
Cam shaft Gear
Cam lever Gear
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8. Disassemble and Reassemble
(11) Detach the cam shaft from the main unit as shown in the picture below.
(12) Remove the pinch roller arm spring bracket from the cam holder as shown in the picture below.
Cam holder
Pinch roller arm spring
Pinch roller arm spring bracket
(13) Detach the pinch roller arm from the front.
Pinch roller arm
How to reinstall the pinch roller arm
(1)
Reattach the pinch roller arm in the reverse order in which it was detached.
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8.3
8.3.1
8. Disassemble and Reassemble
Electrical Parts
How to Replace the Media Detection Sensor
How to detach the media detection sensor
(1)
Detach the left top cover (see Section 8.1.1).
(2)
Detach the carriage top cover (see Section 8.1.9).
(3)
Detach the carriage cover (see Section 8.1.10).
(4)
Disconnect the media detection sensor connector J20 on the print head drive board.
Connector J20
(5)
Remove the two M3L6 binding head screw holding the media detection sensor with the sensor
holder.
M3L10 binding head screw
Media detection sensor
(6)
M3L6 binding head screw
Remove the M3L8 binding head screw and then detach the media detection sensor from the
holder.
How to reinstall the media detection sensor
(1)
Reattach the media detection sensor in the reverse order in which it was detached.
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8.3.2
8. Disassemble and Reassemble
How to Replace the Home Sensor
How to detach the home sensor
(1)
Detach the right top cover (see Section 8.1.3).
(2)
Detach the carriage top cover (see Section 8.1.9).
(3)
Remove the two M3L6 binding head screws holding the home sensor bracket.
M3L6 binding head screw
M3L6 binding head screw
Home sensor
(4)
Disconnect the home sensor from the cable.
(5)
Remove the M3L6 binding head screw holding the home sensor, and then detach the home
sensor from the home sensor bracket.
How to reinstall the home sensor
(1)
Reattach the home sensor in the reverse order in which it was detached.
(2)
Confirm the home sensor dog is not touching to the home sensor.
(3)
If the home sensor is touched to the sensor dog, adjust the sensor position.
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8.3.3
8. Disassemble and Reassemble
How to Replace the Y Encoder Sensor
How to detach the Y encoder sensor
(1)
Detach the right top cover (see Section 8.1.3).
(2)
Detach the carriage top cover (see Section 8.1.9).
(3)
Remove the two M3L6 binding head screws holding the Y encoder sensor bracket.
M3L6 binding head screw
Y encoder sensor bracket
(4)
Disconnect the Y encoder sensor from the main board.
(5)
Remove the M3L6 binding head screw holding the home sensor, and then detach the home
sensor from the home sensor bracket.
How to reinstall the Y encoder sensor
(1)
Reattach the Y encoder sensor in the reverse order in which it was detached.
(2)
Confirm the Y encoder sensor is not touching to the Y encoder strip.
Y encoder sensor
Confirm the Y encoder
sensor is not touching to the
Y encoder strip
(3)
Y encoder strip.
If the Y encoder sensor is touched to the Y encoder strip, adjust the sensor position.
Adjust the Y encoder sensor position and then
tighten the four M3L6 binding head screws
holding the Y encoder bracket.
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8.3.4
8. Disassemble and Reassemble
How to Replace the Print Head Drive Board
How to detach the print head drive board
(1)
Detach the right top cover (see Section 8.1.3).
(2)
Detach the carriage top cover (see Section 8.1.9).
(3)
Disconnect all cables from the print head drive board.
(4)
Remove the four studs holding the print head drive board.
Print head drive board
Stud
(5)
Detach the print head drive board.
How to reinstall the print head drive board
(1)
Reattach the print head drive board in the reverse order in which it was detached.
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8.3.5
8. Disassemble and Reassemble
How to Replace the Main Board
How to detach the main board
(1)
Detach the right top cover (see Section 8.1.3).
(2)
Detach the carriage top cover (see Section 8.1.9).
(3)
Detach the print head drive board (see Section 8.3.4)
(4)
Disconnect all cables from the main board.
(5)
Remove the four studs holding the main board.
Stud
Main board
(6)
Detach the main board.
How to reinstall the main board
(1)
Reattach the main board in the reverse order in which it was detached.
(2)
Set the EF value for the print head using the GPU software when replace the main board to new
one (see Section 4.9).
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8.3.6
8. Disassemble and Reassemble
How to Replace the USB Hub Board
How to detach the USB hub board
(1)
Detach the right top cover (see Section 8.1.3).
(2)
Detach the right rear cover (see Section 8.1.7).
(3)
Remove the two M3L8 binding head screws and the one M4L6 binding head screw holding the
shield cover. And then detach the shield cover.
Shield cover
M4L6 binding head screw
M3L8 binding head screw
(4)
Remove the two M3L6 binding head screws holding the USB board bracket.
M3L6 binding head screw
(5)
Remove the four M3L6 binding head screws holding the USB board.
M3L6 binding head screw
USB hub board
(6)
Disconnect all cables from the USB hub board.
(7)
Detach the USB hub board.
How to reinstall the USB hub board
(1)
Reattach the USB hub board in the reverse order in which it was detached.
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8.3.7
8. Disassemble and Reassemble
How to Replace the Motor Board
How to detach the motor board
(1)
Detach the right top cover (see Section 8.1.3).
(2)
Detach the right rear cover (see Section 8.1.7).
(3)
Remove the two M3L8 binding head screws and the one M4L6 binding head screw holding the
shield cover. And then detach the shield cover.
Shield cover
M4L6 binding head screw
M3L8 binding head screw
(4)
Remove the two M3L6 binding head screws holding the motor board.
M3L6 binding head screw
Motor board
(5)
Disconnect all cables from the ink motor.
(6)
Detach the motor board.
How to reinstall the motor board
(1)
Reattach the motor board in the reverse order in which it was detached.
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8.3.8
8. Disassemble and Reassemble
How to Replace the Elevator (Capping Station) Board
How to detach the elevator board
(1)
Detach the right top cover (see Section 8.1.3).
(2)
Detach the right rear cover (see Section 8.1.7).
(3)
Remove the two M3L8 binding head screws and the one M4L6 binding head screw holding the
shield cover. And then detach the shield cover.
Shield cover
M4L6 binding head screw
M3L8 binding head screw
(4)
Remove the two M3L6 binding head screws holding the elevator board.
M3L6 binding head screw
Elevator board
(5)
Disconnect all cables from the elevator board.
(6)
Detach the elevator board.
How to reinstall the elevator board
(1)
Reattach the elevator board in the reverse order in which it was detached.
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8.3.9
8. Disassemble and Reassemble
How to Replace the Power Supply Board 2
How to detach the power supply board 2
(1)
Detach the right top cover (see Section 8.1.3).
(2)
Detach the right rear cover (see Section 8.1.7).
(3)
Remove the two M3L8 binding head screws and the one M4L6 binding head screw holding the
shield cover. And then detach the shield cover.
Shield cover
M4L6 binding head screw
M3L8 binding head screw
(4)
Remove the four M3L15 binding head screws holding the power supply board 2 from the bottom
chassis.
Power supply board 2
M3L15 binding head screw
(5)
Disconnect all cables from the power supply board 2.
(6)
Detach the power supply board 2.
How to reinstall the power supply board 2
(1)
Reattach the power supply board 2 in the reverse order in which it was detached.
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8. Disassemble and Reassemble
8.3.10 How to Replace the Ink Supply (AUX) Board
How to detach the ink supply board
(1)
Detach the right rear cover (see Section 8.1.7).
(2)
Disconnect all cables from the ink supply board.
(3)
Remove the four M3L8 binding head screws holding the ink supply board.
M3L8 binding head screw
Ink supply board
(4)
Detach the ink supply board.
How to reinstall the ink supply board
(1)
Reattach the ink supply board in the reverse order in which it was detached.
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8. Disassemble and Reassemble
8.3.11 How to Replace the Capping Station Position Sensor
How to detach the capping station position sensor
(1)
Detach the right side cover (see Section 8.1.3).
(2)
Detach the capping station cover (see Section 8.1.11).
(3)
Remove the two M3L8 binding head screws holding the capping station position sensor bracket.
Capping position sensor bracket
Capping position sensor
M3L8 binding head screw
(4)
Disconnect the cable from the capping position sensor.
(5)
Remove the M3L8 binding head screw holding the capping station position sensor.
(6)
Detach the capping station position sensor.
How to reinstall the capping position sensor
(1)
Reattach the capping position sensor in the reverse order in which it was detached.
(2)
Confirm the capping position sensor is not touching to the positioning dog.
Capping station position
Capping station position sensor
Confirm the capping station position
sensor is not touching to the dog.
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8. Disassemble and Reassemble
8.3.12 How to Replace the Capping Station motor
How to detach the capping station motor
(1)
Detach the right top cover (see Section 8.1.3).
(2)
Detach the right rear cover (see Section 8.1.7).
(3)
Remove the two M3L8 binding head screws and the one M4L6 binding head screw holding the
shield cover. And then detach the shield cover.
Shield cover
M4L6 binding head screw
M3L8 binding head screw
(4)
Detach the capping station cover (see Section 8.1.11).
(5)
Remove the four M3L8 binding head screws holding the home position cover, and then slide the
home position cover to right side to remove the home position cover.
Home position cover
M3L8 binding head screw
(6)
Remove the four M5 nuts holding the capping station unit.
(7)
Disconnect the capping station motor cable from the elevator board.
(8)
Disconnect the cable from the capping station position sensor.
(9)
Detach the capping station unit from the main unit.
(10) Remove the four M3L6 binding head screws holding the capping station motor.
(11) Detach the capping station motor from the capping station unit.
How to reinstall the capping station motor
(1)
Reattach the capping station motor in the reverse order in which it was detached.
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8. Disassemble and Reassemble
8.3.13 How to Replace the Media Set Lever Sensor
How to detach the capping station motor
(1)
Detach the right top cover (see Section 8.1.3).
(2)
Detach the right rear cover (see Section 8.1.7).
(3)
Remove the two M3L8 binding head screws and the one M4L6 binding head screw holding the
shield cover. And then detach the shield cover.
Shield cover
M4L6 binding head screw
M3L8 binding head screw
(5)
Remove the two M3L8 binding head screws holding the media set lever sensor bracket, and then
detach the media set lever bracket with sensor.
M3L8 binding head screw
Media set lever sensor bracket
(6)
Disconnect the media set lever sensor cable from the media set lever sensor.
(7)
Remove the M3L10 binding head screws holding the media set lever sensor, and then detach
the media set lever sensor.
How to reinstall the media set lever sensor
(1)
Reattach the media set lever sensor in the reverse order in which it was detached.
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8. Disassemble and Reassemble
8.3.14 How to Replace the Internal USB Cable
How to detach the internal USB cable
(1)
Detach the right top cover (see Section 8.1.3).
(2)
Detach the right rear cover (see Section 8.1.7).
(3)
Detach the carriage top cover (see Section 8.1.9).
(4)
Remove the two M3L8 binding head screws and the one M4L6 binding head screw holding the
shield cover. And then detach the shield cover.
Shield cover
M4L6 binding head screw
M3L8 binding head screw
(5)
Detach the center rear cover (see Section 8.1.8).
(6)
Remove the six M3L20 binding head screws holding the tube & signal cable holders, and then
tube & signal cable holders.
Tube & signal cable holder
M3L20 binding head screw
(7)
Remove the two M3L20 binding head screws holding the tube & signal cable holder of the
carriage end.
M3L20 binding head screw
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(8)
8. Disassemble and Reassemble
Remove the two M3L8 flat head screws holding the chain of the carriage end.
M3L8 flat head screw
(9)
Press down the center of the chain tab to release the notch of the tab, and then open the tab as
shown in the picture below.
(10) Open all chain tabs.
(11) Remove the nylon bands holding the USB cable and then disconnect the internal USB cable from
the main board and the USB board.
Internal USB cable
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8. Disassemble and Reassemble
(12) Detach the USB cable from the chain.
How to reinstall the internal USB cable
(1)
Reattach the internal USB cable in the reverse order in which it was detached.
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8. Disassemble and Reassemble
8.3.15 How to Replace the Signal Cable of the Chain
How to detach the signal cable of the chain
(1)
Detach the right top cover (see Section 8.1.3).
(2)
Detach the right rear cover (see Section 8.1.7).
(3)
Detach the carriage top cover (see Section 8.1.9).
(4)
Remove the two M3L8 binding head screws and the one M4L6 binding head screw holding the
shield cover. And then detach the shield cover.
Shield cover
M4L6 binding head screw
M3L8 binding head screw
(5)
Detach the center rear cover (see Section 8.1.8).
(6)
Remove the six M3L20 binding head screws holding the tube & signal cable holders, and then
tube & signal cable holders.
Tube & signal cable holder
M3L20 binding head screw
(7)
Remove the two M3L20 binding head screws holding the tube & signal cable holder of the
carriage end.
M3L20 binding head screw
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(8)
8. Disassemble and Reassemble
Remove the two M3L8 flat head screws holding the chain of the carriage end.
M3L8 flat head screw
(9)
Press down the center of the chain tab to release the notch of the tab, and then open the tab as
shown in the picture below.
(10) Open all chain tabs.
(11) Disconnect the signal cable from the main board and the ink supply (AUX) board.
Signal cable
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8. Disassemble and Reassemble
(12) Detach the signal from the chain.
How to reinstall the signal cable of the chain
(1)
Reattach the signal cable in the reverse order in which it was detached.
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8. Disassemble and Reassemble
8.3.16 How to Replace the Print Head Drive Board Power Cable
How to detach the print head drive board power cable
(1)
Detach the right top cover (see Section 8.1.3).
(2)
Detach the right rear cover (see Section 8.1.7).
(3)
Detach the carriage top cover (see Section 8.1.9).
(4)
Remove the two M3L8 binding head screws and the one M4L6 binding head screw holding the
shield cover. And then detach the shield cover.
Shield cover
M4L6 binding head screw
M3L8 binding head screw
(5)
Detach the center rear cover (see Section 8.1.8).
(6)
Remove the six M3L20 binding head screws holding the tube & signal cable holders, and then
tube & signal cable holders.
Tube & signal cable holder
M3L20 binding head screw
(7)
Remove the two M3L20 binding head screws holding the tube & signal cable holder of the
carriage end.
M3L20 binding head screw
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(8)
8. Disassemble and Reassemble
Remove the two M3L8 flat head screws holding the chain of the carriage end.
M3L8 flat head screw
(9)
Press down the center of the chain tab to release the notch of the tab, and then open the tab as
shown in the picture below.
(9)
Open all chain tabs.
(10) Disconnect the print head drive board power cable from the print head drive board and the power
relay connector.
Print board drive board power cable
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8. Disassemble and Reassemble
(11) Detach the print head drive board power cable from the chain.
How to reinstall the print head drive board power cable
(1)
Reattach the print head drive board power cable in the reverse order in which it was detached.
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8. Disassemble and Reassemble
8.3.17 How to Replace the Print Head Heater
How to detach the print head heater
(1)
Detach the right top cover (see Section 8.1.3).
(2)
Detach the right rear cover (see Section 8.1.7).
(3)
Detach the carriage top cover (see Section 8.1.9).
(4)
Detach all print heads from the carriage plate.
(5)
Detach the media detection sensor from the carriage plate.
Media detection sensor
(6)
Detach the print head heater cover from the carriage plate.
Print head heater cover
(7)
Remove the eight M3L4 binding head screws holding the print head heater.
Print head heater
M3L4 binding head screw
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(8)
8. Disassemble and Reassemble
Disconnect the print head heater cable from the print head drive board.
Print head heater cable
(9)
Detach the print head heater from the carriage plate.
How to reinstall the print head heater
(1)
Reattach the print head heater in the reverse order in which it was detached.
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8. Disassemble and Reassemble
8.3.18 How to Replace the Take Up and Feed Board
How to detach the print board power cable
(1)
Detach the left top cover (see Section 8.1.1).
(2)
Detach the left rear cover (see Section 8.1.6).
(3)
Remove the four M3L6 binding head screws holding the take-up and feed board.
Take-up and feed board
M3L4 binding head screw
(4)
Disconnect all cables from the take-up and feed board.
(5)
Detach the take-up and feed board.
How to reinstall the take-up and feed board
(1)
Reattach the take-up and feed board in the reverse order in which it was detached.
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8. Disassemble and Reassemble
8.3.19 How to Replace the Ink Pump
How to detach the ink pump
(1)
Remove the ink from the ink tube (see Section 4.3).
(2)
Detach the right top cover (see Section 8.1.3).
(3)
Detach the right rear cover (see Section 8.1.7).
(4)
Remove the three M3L8 self tapping screws holding the ink pump.
M3L8 self tapping screw
(5)
Disconnect (cut the tube) ink tubes that are connecting to the ink pump.
Ink pump
Disconnect cable here
Disconnect the tubes here
(6)
Disconnect ink pump cable from the connector and then detach the ink pump.
How to reinstall the ink pump
(1)
Reattach the ink pump in the reverse order in which it was detached.
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JS500 Service Manual
8. Disassemble and Reassemble
8.3.20 How to Replace the Ink Cartridge Detection Sensor
How to detach the ink cartridge detection sensor
(1)
Detach the right top cover (see Section 8.1.3).
(2)
Detach the right rear cover (see Section 8.1.7).
(3)
Remove the two M3L8 binding head screws and the one M4L6 binding head screw holding the
shield cover. And then detach the shield cover.
Shield cover
M4L6 binding head screw
M3L8 binding head screw
(4)
Remove the four M3L8 binding head screws holding the ink tube holders.
Inky tube holder
M3L10 binding head screw
(5)
Remove the four M3L6 binding head screws holding the ink cartridge holder unit.
M3L6 binding head screw
JS500-UM-251-9370
8-52
JS500 Service Manual
(6)
8. Disassemble and Reassemble
Remove the four M4L6 binding head screws holding the ink supply board bracket.
Ink supply board bracket
M4L6 binding head screw
(7)
Remove the four M3L6 binding head screws holding the ink cartridge holder unit top panel.
Ink cartridge holder unit top panel
(8)
Remove the two M3L6 binding head screws holding the needle unit support bracket.
M3L6 binding head screw
JS500-UM-251-9370
8-53
JS500 Service Manual
(9)
8. Disassemble and Reassemble
Remove the four M3L6 cap screws holding the needle unit support bracket.
M3L15 cap screw
(10) Detach the needle unit support bracket
Needle unit support bracket
(11) Detach the ink cartridge unit separator plate and the remove the M2L6 binding head screw
holding the ink cartridge detection sensor.
Ink cartridge detection sensor
M2L6 binding head screw
Needle unit
Ink cartridge unit separator plate
(12) Detach the ink cartridge unit separator plate and the remove the M2L6 binding head screw
holding the ink cartridge detection sensor.
(13) Detach the ink cartridge detection sensor.
(14) Disconnect the sensor cables using the soldering iron.
How to reinstall the ink cartridge detection sensor
(1)
Reattach the ink cartridge detection sensor in the reverse order in which it was detached.
JS500-UM-251-9370
8-54
JS500 Service Manual
8. Disassemble and Reassemble
8.3.21 How to Replace the Ink Cartridge Status Sensor
How to detach the ink cartridge status sensor
(1)
Detach the right top cover (see Section 8.1.3).
(2)
Detach the right rear cover (see Section 8.1.7).
(3)
Remove the two M3L8 binding head screws and the one M4L6 binding head screw holding the
shield cover. And then detach the shield cover.
Shield cover
M4L6 binding head screw
M3L8 binding head screw
(4)
Remove the four M3L8 binding head screws holding the ink tube holders.
Inky tube holder
M3L10 binding head screw
(5)
Remove the four M3L6 binding head screws holding the ink cartridge holder unit.
M3L6 binding head screw
JS500-UM-251-9370
8-55
JS500 Service Manual
(6)
8. Disassemble and Reassemble
Remove the four M4L6 binding head screws holding the ink supply board bracket.
Ink supply board bracket
M4L6 binding head screw
(7)
Remove the four M3L6 binding head screws holding the ink cartridge holder unit top panel.
Ink cartridge holder unit top panel
(8)
Remove the two M3L6 binding head screws holding the needle unit support bracket.
M3L6 binding head screw
JS500-UM-251-9370
8-56
JS500 Service Manual
(9)
8. Disassemble and Reassemble
Remove the four M3L6 cap screws holding the needle unit support bracket.
M3L15 cap screw
(10) Detach the needle unit support bracket
Needle unit support bracket
(11) Detach the ink cartridge unit separator plate.
Ink cartridge unit separator plate
(12) Disconnect the ink cartridge status sensor cable.
(13) Remove the M3L6 cap screws holding the ink cartridge unit lower rail.
(14) Detach the ink cartridge unit lower rail.
Ink cartridge status sensor
Ink cartridge unit lower rail
M3L6 cap screw
JS500-UM-251-9370
8-57
JS500 Service Manual
8. Disassemble and Reassemble
(15) Remove the M3L10 binding head screw holding the ink cartridge status sensor.
Ink cartridge status sensor
M3L10 binding head screw
How to reinstall the ink cartridge status sensor
(1)
Reattach the ink cartridge status sensor in the reverse order in which it was detached.
JS500-UM-251-9370
8-58
JS500 Service Manual
9. Upgrading the Firmware
9. Upgrading the Firmware
9.1
Upgrading the System Firmware for the main board
To updating the system firmware you need to have the following files. In addition, you need to use a
computer which has the Graphtec Printer Utility “GPU” and USB cable.
• Go.bat
: Batch file for upgrading
• update.exe
: Upgrading file
Preparation
Confirm the USB driver for the JS500/501 is installed.
Copy the “go.bat” and the “update.exe” file to the working directory in the computer. Those files must
be copied in the same directory. If the downloaded file is compressed, please uncompress the file for
getting those files.
How to upgrade the system firmware for the main board
(1)
Connect the computer and the printer via the USB interface
(2)
Turn on the power of the printer.
(3)
Set the printer in the “On Line” mode after the initialization of the printer is completed.
(4)
Browse the “go.bat” file on the computer. Then double click the “go.bat” file to updating the
system firmware. The Command Prompt window is automatically opened.
(5)
The “Done! Press any key please!” message is displayed in the Command Prompt window when
the transferring of the firmware is completed. Press any key on the keyboard.
(6)
Turn off the power of the printer.
JS500-UM-251-9370
9-1
JS500 Service Manual
(7)
9. Upgrading the Firmware
Turn on the power of the printer and then make sure the system firmware version.
JS500-UM-251-9370
9-2
10-1
GND
N
L
Inlet, Dryer Unit
Dryer Unit
GND
N
L
Inlet, Heater
GND
N
L
Solid Relay 1
Dryer Power Switch
Center Heater
20A
Filter
Main Power Switch
Dryer Fan*8
Front and Rear Heater
Solid Relay 2
GND
GND
+5V
+5V
+24V DC2
GND
N
L
Power Supply
Board 2
Power Supply
Board 1
1 2 3 4 5 6
Inlet with filter, Main Power
+V+V-V -V FG N L
JS500-UM-251-9370
1 2 3
Main Printer Unit
GND
GND
+24V DC1
+24V DC1
AC 40V
Transformer
JS500 Service Manual
10. Wiring Diagrams
10. Wiring Diagrams
Temperature Sensor 1
(Front Heater)
2*
Temperature Sensor 2
(Bed Plate Heater)
Core Filter
3*
2*
CN7
1 2 3
CN8
1 2 3
2 1
CN5
CN15
To Main Board CN2
C
CN14
1 2 3 4
1 2 3 4
CN13
1 2 3 4
CN11
CN1
JGAG
NC
K
FAN
FAN
NC
2*
NC
NC
CN17
CN18
APMP- VALVE2 1
2 1
1 2 3
NC
CN33
BHT
2*
CN10
POWER
4 3 2 1
NC
2*
NC
CN35
1 2 3 4 5
(For Bed Plate Heater)
(For Front Heater)
IN
OUT
Solid Relay 2
IN
K
Ink Pump
Y
M
C
OUT
Solid Relay 1
Heater SW
2*
2*
SIGNALSIGNAL+
NC
2*
SIGNALSIGNAL+
NC
CN25
C
2 1
Core Filter
2*
NC
CN26
M
2 1
SIGNALSIGNAL+
NC
CN27
Y
2 1
SIGNALSIGNAL+
NC
CN28
K
2 1
20*
CN29
LC
2 1
CN19
1 2 3
CN20
FHT
2*
NC
CN21
CN16
VALVE+ APMP+
2 1
2 1
M
Y
Ink Status
NC
CN24
FAN
2 1
1 2
1 2
FAN
FAN
CN22 CN23
(Ink Supply Board)
AUX-BOARD
NC
CN2
CN34
VACUUM
1 2 3
CN30
LM
2 1
CN31
CH7
2 1
MOTOR-BOARD
6 5 4 3 2 1
Y-SENSOR
J3
5*
GND
SIGNAL
VCC
5*
2*
CN6
4 3 2 1
GND
+24V DC1
2*
2*
Core Filter
Core Filter
2*
Core Filter
NC
4 3 2 1
CN9
NC
(Capping Station)
+5V
GND
GND
+24VDC1
Elevator Board
From Power Supply 1
Y-Motor
CN4
CN1
X-Motor
MOTOR1
4 3 2 1
4 3 2 1
NC
A+
AB+
B-
4*
Motor
Core Filter
From Power Supply 1
MOTOR2
3 2 1
CN8
Y-Motor Encoder
2*
5 4 3 2 1
X-SENSOR
J1
X-Motor Encoder
CN3
CN5
From Power Supply 2
Core Filter
J18
POWER
4 3 2 1
Core Filter
CN3
BLK(-)
RED(+)
RED(+)
GRY(-)
7*
CN12
1 2 3 4
+24V
GND
SIGNAL
NC
NC
BLK(-)
GRY(+)
BLK(+)
GRY(-)
SIGNAL+
SIGNALSIGNAL+
SIGNAL-
CN6
1 2 3 4 5
CN9
C
M
Y
K
Ink cartridge detection
2*
SIGNAL+
SIGNAL2 1
CN4
SIGNAL+
SIGNAL-
+5V
SIGNAL
GND
BLK(-)
BLU(+)
BLU(+)
GRY(-)
CN20
1 2 3 4 5
NC
NC
SIGNAL
GND
BLK(-)
YEL(+)
YEL(+)
GRY(-)
+5V
GND
GND
+24V DC1
CN32
CH8
2 1
CN21
FLUSH
2 1
Core Filter
3 2 1
CN7
GND
NC
SIGNAL-B
+5V
SIGNAL-A
10*
NC
GND
NC
SIGNAL-B
+5V
SIGNAL-A
40*
Media Load
Lever Sensor
Media End Sensor
+5V
To Media End Sensor
+5v from Power Supply 2
From Power Supply 2
From Power Supply 1
J2
J19
MOTOR-X
4 3 2 1
Operation Panel
GRY(-)
BLU(+)
GRY(-)
RED(+)
GRY(-)
YEL(+)
GRY(-)
BLK(+)
From AUX-BOARD
CN10-4PIN
BLU(+)
BLK(-)
+5V
RED(+)
BLK(-)
+5V
YEL(+)
BLK(-)
+5V
GRY(+)
BLK(-)
+5V
10-2
J9
MOTOR-Y
4 3 2 1
JS500-UM-251-9370
10. Wiring Diagrams
JS500 Service Manual
TAKEUP MOTOR
FEED MOTOR
3*
3*
N(B)
CCW(W)
CW(R)
N
CCW
CW
220V AC
CN10
3*
3*
CN5
CN6
3*
SJSENSOR2
4 3 2 1
FJSENSOR2
4 3 2 1
CN11
SJSENSOR1
4 3 2 1
FJSENSOR1
4 3 2 1
CN3
3*
1 2 3
CN11
NC
NC
1 2
NC
1 2
1 2
NC
NC
CN8 CN7
Y
K
1 2
Connected with 48 pins plug
4*
USB Cable
J12
16*
J11
16*
J10
J9
16*
J8
16*
J7
From Power Supply 2
USB Cable
2*
16*
J6
16*
J5
16*
J4
16*
1 2
NC
1 2
NC
NC
J3
16*
16*
J2
COMPUTER
J15
J14
Print Head Drive Board
16*
Connect to Print Head
To AUX- BOARD (Ink Supply Board) CN6
Raster Sensor
(Y Encoder)
J13
16*
USB-HUB
Core Filter
NC
48*
7*
SIGNAL-B
+5V
SIGNAL-A
NC
GND
From Power Supply 1
CN13 CN12 CN6
C
M
SOV
1 2
Media Switch
From Power Supply 2
JTAG
CN1
2*
2*
2*
Main Board
Home Sensor
3*
NC
CN5
BUS
CN3
GND
+5V
GND
+24V DC1
NC
SIGNAL
GND
NC
2 1
Takeup and Feed Board
1 2 3
SJ-DIR
CN12
Feed Sensor1 Feed Sensor2 Takeup Sensor1
CN8
P-AC
3 2 1
1 2 3
FJ-DIR
CN13
CN15
3*
NC
SIGNAL
GND
NC
2 1
CN16
Feed Switch
1 2 3 4 5
FJ-MOTOR
3*
+5V
GND
SIGNAL
+5V
GND
SIGNAL
CN9
SIGNAL
GND
SIGNAL
+5V
GND
SIGNAL
+5V
GND
SIGNAL
1 2 3 4 5
SJ-MOTOR
L
PE
N
SIGNAL
GND
SIGNAL
3 2 1
CN2
M-DIR
CN1
3 2 1
P-DC
4 3 2 1
CN4
SAFE
CN4
CN9
CN14
J20
1 2 3
Takeup Switch
CN2
CN10
1 2 3 4 5
1 2 3 4
10-3
BLU(+5V)
BLL(GND)
2 1
J21
J17
J19
J16
2 1
6 5 4 3 2 1
1 2 3
JS500-UM-251-9370
RED
YEL
BLK
3*
NC
2*
Print Head Heater
6*
From Power Supply 2
J20
Media Detect Sensor
YEL
BLK
RED
AC
AC
GND
+24V DC2
GND
+5V
Red
Blk
JS500 Service Manual
10. Wiring Diagrams
JS500 Service Manual
11. Tubing Diagrams
11. Tubing Diagram
JS500 Tubing Diagram
C
M
Y
K
Ink Cartridge
3/5 tube 15 mm
3/5 tube 40 mm
3/5 T Joint
3/5 tube 3300 mm
3/5 F Joint
3/5 T Joint
3/5 tube 110 mm
3/5 tube 260 mm
3/5 tube 300 mm
3/5 tube
210 mm
Pump
3/5 tube 60 mm
3/5 tube 110 mm
Filter
Clamper
3/5 T Joint
3/5 tube 180 mm
3/5 tube 110 mm
2/3-3/5 Joint
Intercepting
valve
3/5 6 Joint
Serge Tank
Print Head
2/3 tube 3300 mm
3/5 tube 20 mm
2/3-3/5 Joint
JS500-UM-251-9370
11-1
JS500 Service Manual
12. Spare Parts List
12. Spare Parts Lists
No.
Parts No. & Picture
1
Parts Name
Qty/Printer
Stock
JS501-18
JS500-18
Level
Main Board
1
1
A
126 PH Drive Board (12 heads)
1
1
A
1
1
A
1
1
A
1
1
A
1
1
A
677662000
2
677662010
Ink/Heating Control Board
3
(Ink Supply Board)
677662020
X,Y Combine Board
4
5
(Motor Board)
677662030
677662040
Media Take-up Board Assy 220V
Stepping Motor Control Board
6
(Elevator Board)
677662050
JS500-UM-251-9370
12-1
JS500 Service Manual
No.
Parts No. & Picture
7
12. Spare Parts List
Parts Name
Qty/Printer
Stock
JS501-18
JS500-18
Level
Control Panel Assy
1
1
A
USB HUB
1
1
A
1
1
B
1
1
B
12
8
A
7
7
A
4
4
A
677662060
8
677662070
DC Power Supply (S-150-27)
9
Power Supply Board 1
677662080
DC Power Supply PD-65B
10
(Power Supply Board 2)
677662090
11
PH Board to PH Harness
677662100
Home Sensor x1
Media Set Lever Sensor x1
12
Ink Cartridge Status Sensor x 4
Capping position Sensor x 1
677662110
13
Ink cartridge sensor
677662120
JS500-UM-251-9370
12-2
JS500 Service Manual
No.
Parts No. & Picture
14
12. Spare Parts List
Parts Name
Qty/Printer
Stock
JS501-18
JS500-18
Level
1
1
A
1
1
A
Y Encoder Sensor Board
1
1
A
Media Take-up Sensor
1
1
A
Ink Pump(DC24V)
4
4
A
Y Motor with Encoder
1
1
A
X Motor Encoder Assy
677662130
Media Sensor
15
(Media Detection Sensor)
677662140
16
677662150
17
677662160
18
677662170
19
677662180
JS500-UM-251-9370
12-3
JS500 Service Manual
No.
Parts No. & Picture
20
12. Spare Parts List
Parts Name
Qty/Printer
Stock
JS501-18
JS500-18
Level
X Motor (Feed)
1
1
A
Blower(24V MH1232H24D)
3
3
C
Media take-up Motor(220V)
1
1
B
Media Supply Motor(220V)
1
1
B
Fan for Dryer (220V)
6
6
C
X Motor Encoder Disk
1
1
A
677662190
21
677662200
22
677662210
23
677662220
24
677662230
25
677662240
JS500-UM-251-9370
12-4
JS500 Service Manual
No.
Parts No. & Picture
26
12. Spare Parts List
Parts Name
Qty/Printer
Stock
JS501-18
JS500-18
Level
Encoder Strip(180DPI 2830mm)
1
1
A
Solid relay (TD25-2D)
2
2
C
Main Power Switch
1
1
C
2 way Switch
1
1
C
3 way Switch
2
2
C
677662250
27
677662260
28
677662270
29
677662280
30
677662290
JS500-UM-251-9370
12-5
JS500 Service Manual
No.
Parts No. & Picture
31
12. Spare Parts List
Parts Name
Qty/Printer
Stock
JS501-18
JS500-18
Level
Transformer (220V TO 110V80W)
1
1
C
Socket (15A)
1
1
C
Socket with filter and fuse(10A)
1
1
C
Filter (CW3-20A-T)
1
1
C
1
1
A
1
1
A
677662300
32
677662310
33
677662320
34
677662330
USB CABLE
35
(Internal USB Cable)
677662340
36
Igus Cable for 485 series
677662350
JS500-UM-251-9370
12-6
JS500 Service Manual
No.
Parts No. & Picture
37
12. Spare Parts List
Parts Name
Qty/Printer
Stock
JS501-18
JS500-18
Level
Igus Cable for DC power
1
1
A
P/H Heater
1
1
C
Front & Rear heater
2
2
C
Middle heater
1
1
C
Temperature protector (70 degree)
3
3
C
2
2
C
1
1
C
677662360
38
677662370
39
677662380
40
677662390
41
677662400
Power cord 90 angle
42
677662700 (CE type)
(Printer unit and heater)
677662720 (UL type)
43
Power cord
677662690 (CE type)
677662710 (UL type)
JS500-UM-251-9370
12-7
JS500 Service Manual
No.
Parts No. & Picture
12. Spare Parts List
Parts Name
Stock
JS501-18
JS500-18
Level
4
4
A
Bearing(6900ZZ-NR)
4
4
C
Bearing(699ZZ,20X9X6)
4
4
C
Caster w/Braker-G
2
2
C
Castor w/o Braker-G
2
2
C
Small Filter(PALL 5u)
44
Qty/Printer
(Ink Filter)
677662430
45
677662440
46
677662450
47
677662460
48
677662470
JS500-UM-251-9370
12-8
JS500 Service Manual
No.
Parts No. & Picture
49
12. Spare Parts List
Parts Name
Qty/Printer
Stock
JS501-18
JS500-18
Level
Y Motor Pulley
1
1
C
Y Drive Pulley Assy
1
1
C
Y Idler Pulley Assy
1
1
C
Pinch Roller
23
23
C
X Motor Pulley
1
1
C
X Drive Belt (320-2GT-15)
1
1
C
677662480
50
677662490
51
677662500
52
677662510
53
677662520
54
677662530
JS500-UM-251-9370
12-9
JS500 Service Manual
No.
Parts No. & Picture
55
12. Spare Parts List
Parts Name
Qty/Printer
Stock
JS501-18
JS500-18
Level
Y Belt (10HTD3M6000mm)
1
1
C
Y Drive Belt (400-S2M-15)
1
1
C
DAMPER
12
8
A
Shift Big Gear
1
1
C
Shift Small Gear
1
1
C
Cam
23
23
C
677662540
56
677662550
57
677662560
58
677662570
59
677662580
60
677662590
JS500-UM-251-9370
12-10
JS500 Service Manual
No.
Parts No. & Picture
61
12. Spare Parts List
Parts Name
Qty/Printer
Stock
JS501-18
JS500-18
Level
Damper Holder
3
3
C
Right Side cover-GTC
1
1
C
Left side cover-GTC
1
1
C
Front clear cover
1
1
C
Media Hold Lever
1
1
C
P/H Lifting lever
1
1
C
2/3 To 3/5 Joint
8
8
A
677662600
62
677661010
63
677661000
64
677662630
65
677662640
66
677662650
67
677662660
JS500-UM-251-9370
12-11
JS500 Service Manual
No.
Parts No. & Picture
68
12. Spare Parts List
Parts Name
Qty/Printer
Stock
JS501-18
JS500-18
Level
T Model 3/5 Joint
24
24
A
F Model 3/5 Joint
12
12
A
3/5 Tube, 4 multi-line
2/3 Tube, 4 multi-line
3/5 Tube, 1M
1
1
-
1
1
-
A
A
A
Pinch Roller Arm
23
23
B
677662670
69
70
71
72
677662680
677662740
677662750
677662760
73
677662730
JS500-UM-251-9370
12-12
• The contents of this manual are subject to change with out notice
JS500 Service Manual
26, Dec. 2007
JS500-UM-251-01-9370
1st
Issuer
503-10 Shinano-cho, Totsuka-ku, Yokohama, Japan
GRAPHTEC Corporation