GCC Technologies Jaguar IV Series User manual

V3 Sept., 2012
Jaguar IV Series
Maintenance Manual

- 2 -
Important Safety Information
Safety Instructions
General and Personal Safety Precautions
PERSONAL SAFETY
For personalsafety, observethe followinggeneralprecautions :
Asecond personshouldbe available to disablethe system in an emergency
Wear appropriate protective gear that fits comfortably
Do not wear loose-fitting clothes. If you are wearinga long-sleeved shirt,fold the c uffs up your arm
Never wear glovesclose to movingparts
 Necklaces, ties and scarves should be tucked inside shirts.
Long hair should be covered.
ELECTRICALTOOL SAFETY
When using Electrical Tools make sure :
Use tools that are in good operatingorder. Any tool that appearselectrically or mechanically faulty
must be labeled and sent immediately for repair.
Make sure that you are electrically insulatedwhen using electrical tools. Wear rubber-soled shoes and
stand on a dry surface.
If, duringthe use of electrical equipment,you feel an electrical discharge(e.g. a ticklingsensationon
your skin) immediatelystop using that tool. Label it, and send it for repair.
GENERAL SITE SAFETY REQUIREMENTS
Fire extinguishers must be in workingorder and within easy reach.
The main power supplyswitch must be easily accessible.
The system site must be suitablyilluminated from all sides.
Before operation, carefully read the warning labels on your Cutting plotter unit as w ell as the cautions
and warnings in this manual.
Connectthe Cutting plotter to a properly grounded poweroutlet. Make sure the voltage level of the
Cutting plotter matches that of the power source.
Don’t dissemblethe unit while system power is on since the power supplies inside contain high
voltage.
Never leave the machine unattended duringoperation.
Followthe instructions on maintaining and cleaning your system. Not only will this enable you to utilize
your machine efficiently, but it will also ensure that your machine runs safely.

3
Table of Contents
Important Safety Information 02
1. Introduction and Component Overview 0 5
1.1 Main Unit Assembly Jaguar IV 4 06
1.1.1 Main Unit Assembly Jaguar IV 4 – Price List 07
1.2 Electronic and Electrical Assembly 10
1.2.1 Electronic and Electrical Assembly – Price List 11
1.3 Left End Ass em b l y 12
1.3.1 Left End Assembly – Price List 13
1.4 Tool Carriage Ass em b l y Right EndAssembly 14
1.4.1 Tool Carriage Ass em b l y Right EndAssembly–Price List 15
1.5 X Motor Bracket and Belt Assembly 16
1.5.1 X Motor Bracket and Belt Assembly – Price List 17
1.6 CarriageBelt Idle-Pulley Assembly 18
1.6.1 Carriage Belt Idle-Pulley Assembly – Price List 19
1.7 Pinch Roller Assembly 21
1.7.1 Pinch Roller Assembly – Price List 22
1.8 Grid Drum Assembly 23
1.8.1 Grid Drum Assembly – Price List 24
1.9 Grid Roll Housing Assembly 25
1.9.1 Grid Roll Housing Assembly – Price List 26
1.10 JaguarIV parts used on all size models – Price List 27
2. System Diagram and Componentsof Main Board
2.1 System Diagram 35
2.2 JaguarWiring D ia gr am 36
3. Maintenance
3.1 Components Replacement and Belt Tension Ad j us tm e n t 37
3.1.1 Removing the Front, Back, End and Top Covers 37
3.1.2 Replacing the Pinch Roller Sets 39
3.1.3 Replacing the Tool Carriage 41
3.1.4 Replacing the Y-Motor 44
3.1.5 Replacing the VCM PC Board 46
3.1.6 Main board Connection or Replacement 47
3.1.7 Replacement of Fuses 48
3.1.8 Adjusting the Tool Carriage Transmission Belt 49
3.1.9 Adjusting the X Motor Tension Belt 50
3.1.10 Adjusting The Y Motor Tension Belt 51

4
4. Troubleshooting
4.1 Maintenance Diagnostics
4.1.1 How to Begin Maintenance Diagnostics 53
4.1.2 Diagnostic Test for SRAM and DRAM 55
4.1.3 Diagnostic Test for Lever Sensor 55
4.1.4 Diagnostic Test for Media Sensor 56
4.1.5 Diagnostic Test for Motor Encoder and Tool Holder Encoder 57
4.1.6 X Motor Encoder Test 58
4.1.7 Y Motor Encoder Test 59
4.1.8 Diagnostic Test for Tool Force (VCM) 59
4.1.9 Diagnostic Test for Motor Movement 59
4.1.10 Diagnostic Test for the RS-232 Interface 61
4.2. Problems and Solutions 62
5. Appendix 66
5.1 Recommended Parts & Accessory List 67
5.2. Customer Service Request Form 68

5
1. Introduction and Component Overview
This Maintenance Guide provides step-by-step instructions for replacing and maintaining the
components of the Jaguar Cutting plotter. It also includes a troubleshooting chapter
with some handy hints when problems arise or if the plotter does not operate properly. This
Maintenance Guide provides system diagrams, wiring diagrams and numerous flow charts
detailing the maintenance diagnostics built into the Jaguar Cutting plotter. Finally there is a parts
list and spare parts order form for convenience of ordering replacement parts.
For further Tech Support enquiries and assistance
please contact the following Email address:
Tech.suppo[email protected]
The following diagrams represent all of the maintainable mechanical and electronic components
of the Jaguar Cutting Plotter with corresponding parts lists for convenient identification.

6
1.1 Jaguar IV Main Unit Assembly

7
1.1.1 Jaguar IV Main Unit Assembly – Parts List
A
Most recommend
B
Frequently asked
C
Sometimes needed
D
Barely asked
X
Can not order separately
Y
Screws, Nuts & washer
Z
Cables
ITEM
Part no. Description QTY Remark
1 20600051G Y axis carriage belt (2GT-L3366-W14) 1 C
2 22801068G Square bar 1 C
3 22801149G Top Rail 1 X
4 22801466G White Bush 0604 2 C
5 23400012G Control Panel Sticker 1 A
6 23500005G Nut(M4xt3.2xS7) 11 Y
7 24100230G Front platen extension 1 X
8 24100231G Rear platen extension 1 X
9 24100232G Right cover 1 C
10 24100233G Left cover 1 C
11 24100253G Shift-Lever Cam 1 C
12 24100306G Control panel base 1 D
13 24100311G Lever 1 B
14 24400048G Square bar bracket 1 D
15 24400752G Top cover 1 C
16 24400759G Main beam support 3 X
17 244043700G
Unit Base Box 1 X
18 24900002G E-shape retaining ring.D11*d5*t0.6 3 Y
19 25200003G panhead machine screw(white) M3*8 2 Y
20 25200006G Socket headness set screw.(M3*5L) 1 Y
21 25200115G Truss head machine screw(M3*6L SUS) 36 Y
22 25200122G 90°dish flat head machine screw M3*8 2 Y
23 25200124G Pan head machine screw including spring washer 3 Y

8
1.1.1 Jaguar IV Main Unit Assembly – Parts List
ITEM
Part no. Description QTY Remark
24 25200181G Truss head machine screw(M4*6L) 10 Y
25 25200198G Truss head machine screw(M4*8L) 2 Y
26 25200199G Truss head screw including external tooth washer 4 Y
27 25200237G Socket head set screw.(M4*16L sus + coating) 14 Y
28 25200253G Socket head set screw.(M4*30L) 6 Y
29 25500013G Blocking arm spring 4 Y
30 25500014G Sensor indexer Spring. 4 Y
31 26000006G Spring washer. (d4xD7xt0.8)NI 14 Y
32 26000008G Plastic washer 8 Y
33 26000010G Nylon washer U-7 2 Y
34 26000071G External toothed lock washer (M4-Ni) 2 Y
35 29000388G Carriage stopper Assembly. 1 D
36 29002348G Pinch roller Assembly 4 A
37 29004680G Carriage assembly 1 A
38 29005258G Control Panel Board assembly 1 A
39 29005445G Main Beam Assembly 1 X
S6 20900594G Jaguar II Static to K/B Cable (RI472-20900594G) 1 Z
S7 20900764G Grounding Cable for Main Girder 1 Z
S14 20901675G P/B ground wire 200mm K/3C 1 Z

9
1.1.1 Jaguar IV Main Unit Assembly – Parts List (Cables)
ITEM
Part no. Description QTY
Remark
S1 20900035G Static PCB To C/B Cable Converter 2*5Pin 23cm 1 Z
S2 20900087G M/B to Lever Switch Cable (2.0-2Pin130mm) 1 Z
S3 20900126G Y Motor Driver cable 3.96-2pin 155cm 1 Z
S4 20900128G Cable (from VCM Encoder to tool carriage) 1 Z
S5 20900430G VCM Board to Carriage Board Cable (1.5*3pin soft cable 12cm)
1 Z
S6 20900594G Jaguar II Static to K/B Cable (RI472-20900594G) 1 Z
S7 20900764G Grounding Cable for Main Girder 1 Z
S8 20901334G Wire to Board(2522-02 to 2510-02) 2 Z
S9 20901533G FAN to Wire 600mm Cable 1 Z
S10
20901664G Fuse & ON/OFF SW Cable (black) (K/3C) 1 Z
S11
20901667G Ground wire of Line filter K/3C 1 Z
S12
20901668G EMI Filter to ON/OFF cable white. K/3C 1 Z
S13
20901669G EMI Filter to Fuse cable black. K/3C 1 Z
S14
20901675G P/B ground wire 200mm K/3C 1 Z
S15
20901749G The connector Cable from interface converter Board to M/B
Encoder 1 Z
S16
20901907G ON/OFF SW to Power Board Cable 1150mm/150mm 1 Z
S17
20901911G Power Board to Motor Driver Board Cable 550mm 1 Z
S18
20902023G Y Motor to Interface converter Board Encoder cable 2.54-4PIN
1850mm 1 Z
S19
29004380G 2.54-3Pin M/B to paper sensor Cable 130mm 2 Z
S20
290071420G
Flat cable assembly for 132 model (195cm) 1 Z
S21
290071440G
For Interface converter Board Used Flat Cable Assembly(30cm)
1 Z
S22
20901523G AAS II Sensor PCB to carriage PCB 1 Z

10
1.2 Jaguar IV Electronic and Electrical Assembly

11
1.2.1 Jaguar IV Electronic and Electrical Assembly – Parts List
ITEM
Part no. Description QTY Remark
1 21800034G AC PLUG (including EMI Filter ) (K/3C) 1 B
2 22300021G Fuse Holder Type3A/250V(K/3C) 1 B
X
3 24500083G
250W Isolated Dual Output with PFC(Power Factor Correction)
Function(PID-250C) 1 Power board
4 25700075G ON/OFF Power Switch (K/3C) 1 C
5 29005691G ROHS Main board for Cutter all series assembly (With new
FLASH - SMD Place：U9) 1 A
6 29001804G Motor Assembly 1 A
S2 20900087G M/B to Lever Switch Cable (2.0-2Pin130mm) 1 Z
S3 20900126G Y Motor Driver cable 3.96-2pin 155cm 1 Z
S6 20900594G Jaguar II Static to K/B Cable (RI472-20900594G) 1 Z
S8 20901334G Wire to Board(2522-02 to 2510-02) 2 Z
S10 20901664G Fuse & ON/OFF SW Cable (black) (K/3C) 1 Z
S11 20901667G Ground wire of Line filter K/3C 1 Z
S12 20901668G EMI Filter to ON/OFF cable white. K/3C 1 Z
S13 20901669G EMI Filter to Fuse cable black. K/3C 1 Z
S15 20901749G The connector Cable from interface converter Board to M/B
Encoder 1 Z
S16 20901907G ON/OFF SW to Power Board Cable 1150mm/150mm 1 Z
S17 20901911G Power Board to Motor Driver Board Cable 550mm 1 Z
S19 29004380G 2.54-3Pin M/B to paper sensor Cable 130mm 2 Z
S21 290071440G
For Interface converter Board Used Flat Cable
Assembly(30cm) 1 Z

12
1.3 Jaguar IV Left End Assembly

13
1.3.1 Jaguar IV Left End Assembly – Parts List
ITEM Part no. Description QTY Remark
1 20600007G
Y-axis belt. 2GT-L172-W10 1 D
2 22000149G
P.C.B interval pillar (LCA4-10A) 2 Y
3 22801359G
Y-axis Motor Spacer 3 Y
4 23800032G
Motor board. (12258) 1 B
5 24400039G
Pulley bottom bracket 1 D
6 24400041G
Y-motor bracket 1 D
7 24400526G
Pulley top bracket 1 D
8 24400755G
Side support left 1 X
9 25200052G
Pan head machine screw including spring washer 4 Y
10 25200182G
Truss head screw including external tooth washer 2 Y
11 25200196G
Truss head machine screw including spring washer 3 Y
12 25200228G
Hexagonal Socket Head including spring & flat washer 3 Y
13 25200245G
Truss head machine screw including spring washer 1 Y
14 26000004G
Flat washer. (d4.4xD10xt0.8 NI) 1 Y
15 29000936G
Active Gear Assembly 1 C
16 29001804G
Motor Assembly 1 A
S3 20900126G
Y Motor Driver cable 3.96-2pin 155cm 1 Z
S18 20902023G
Y Motor to Interface converter Board Encoder cable
2.54-4PIN 1850mm 1 Z

14
1.4 Jaguar IV Right End Assembly

15
1.4.1 Jaguar IV Right End Assembly – Parts List
ITEM
Part no. Description QTY
Remark
1 20600009G
X-axis belt. 2GT-L220-W10 1 D
2 22000149G
P.C.B interval pillar (LCA4-10A) 2 Y
3 24400038G
X-motor adjusting bracket 1 D
4 24400066G
Cable basket 1 D
5 24400304G
Ideal pulley ass y bracket 1 D
6 24400715G
Ideal pulley Assembly adjusting bracket 1 D
7 24400757G
Right Side Plate 1 X
8 24400761G
X-motor bracket 1 D
9 25200017G
Truss head machine screw(M3*15L).black 2 Y
10 25200052G
Pan head machine screw including spring washer 4 Y
11 25200117G
Hexagonal Socket Head including spring & flat washer(M3*8L) 2 Y
12 25200157G
Hexagonal Socket Head including spring & flat washer(M3*16L) 1 Y
13 25200181G
Truss head machine screw(M4*6L) 2 Y
14 25200182G
Truss head screw including external tooth washer 4 Y
15 25200208G
Truss head screw including spring & flat washer(M4*10) 6 Y
16 25200245G
Truss head machine screw including spring washer 1 Y
17 25700002G
Lever Switch (VM3-04N-80S-U3 (390)) 1 A
18 29000560G
Y ideal pulley assembly 1 D
19 29001804G
Motor Assembly 1 A
20 29005256G
Watch dog-Interface converter board Assembly 1 A
S1 20900035G
Static PCB To C/B Cable Converter 2*5Pin 23cm 1 Z
S2 20900087G
M/B to Lever Switch Cable (2.0-2Pin130mm) 1 Z
S6 20900594G
Jaguar II Static to K/B Cable (RI472-20900594G) 1 Z
S15 20901749G
The connector Cable from interface converter Board to M/B Encoder 1 Z
S18 20902023G
Y Motor to Interface converter Board Encoder cable 2.54-4PIN 1850mm
1 Z
S20
290071420G
Flat cable assembly for 132 model (195cm) 1 Z
S21
290071440G
For Interface converter Board Used Flat Cable Assembly(30cm) 1 Z

16
1.5 Jaguar IV X Motor Bracket and Belt Assembly

17
Number Part no. Description Qty Remark
6
29001804G Motor assembly,Jaguar.
1
A
6.1.1 23100014G Motor MS090600,Jaguar. 1
X
6.1.2 21700009G Motor pulley, 2GT-P18,Jaguar. 1
X
6.1.3 25200169G HeadlessScrew, M4x3.5. 1
Y
6.1.4 22000107G CableTie, YJ-160. 1
Y
6.2
24400761G X-motorbracket,Jaguar.
1
D
6.3
24400038G X-motoradjustingbracket,Jaguar.
1
D
6.4
25200245G Truss head screw & spring washer, M4x20.
1
Y
6.5
25200208G Truss head screw& spring & flat washer,
6
Y
6.6
25200052G Pan head screw & spring washer, #6x8.
4
Y
1.5.1 Jaguar IV X Motor Bracket and Belt Assembly – Parts List

18
1.6 Jaguar IV Carriage Assembly

19
1.6.1 Jaguar IV Carriage Assembly – Parts List
ITEM
Part no. Description QTY Remark
1 20200071G
Blade holder slide bracket assembly 1 X
2 20700029G
Bearing 4 C
3 21700034G
Y-axis belt bracket 1 D
4 22000105G
Cable saddle 1 Y
5 22800410G
Carrier guide roller(DU type) 4 X(29005702G)
6 22800411G
Spacer for carrier guide roller(DU type) 2 X(29005702G)
7 22800765G
Slide shaft in tool carriage 1 X(Carriage assy)
8 22800767G
Carrier guide roller(DU type)shaft 2 X(29005702G)
9 22800769G
Right-Slide shaft in tool carriage 1 X(Carriage assy)
10 22800838G
Blade holder bracket screw 1 C
11 22801464G
White spring bracket for carrier guide roller 4 X(29005702G)
12 22802197G
carriage base finishing 1 X(Carriage assy)
13 23300824G
Cable Fix 1 Y
14 23500005G
Nut(M4xt3.2xS7) 2 Y
15 24100307G
Carriage plastic cover 1 B
16 24400400G
Encoder grid bracket 1 X(Carriage assy)
17 24700022G
Oil ring 2 X(Carriage assy)
18 24700044G
O-Ring(d2.0*r1.5) 1 C
19 25200004G
Pan head machine screw(M2.6*6L) 2 Z
20 25200008G
Socket head set screw.(M3*6L) 2 Z
21 25200017G
Truss head machine screw(M3*15L).black 2 Z
22 25200048G
Pan head machine screw.M3*5 2 Z
23 25200049G
Pan head machine screw.M3*6 2 Z
24 25200059G
Pan head machine screw(M2*4L) 2 Z

20
1.6.1 Jaguar IV Carriage Assembly – Parts List
ITEM
Part no. Description QTY Remark
25 25200065G
Pan head machine screw including flat
washer.(2*6) 6 Z
26 25200093G
Pan head machine screw(M3*4L black) 2 Z
27 25200107G
Pan head machine screw including spring
washer. 1 Z
28 25200112G
Truss head screw including flat washer 2 Z
29 25500041G
Spring for carrier guide roller 2 X(29005702G)
30 25500043G
Tool carriage spring 2 X(Carriage assy)
31 25600019G
VCM Encoder grid 1 X(Carriage assy)
32 26000003G
Flat washer. (d2xD4xt0.4 NI) 2 Y
33 26000009G
Spring washer.(d3xD5.3x0.7 Ni) 2 Y
34 29000568G
A roller Assembly 2 A
35 29000940G
VCM Assembly. 1 X(Carriage assy)
36 29001802G
Encoder PCB Assembly. 1 X(Carriage assy)
37 29004369G
AASII carriage board assembly 1 A
38 29005382G
AAS II sensor assembly with bracket 1 X(Carriage assy)
S4 20900128G
Cable (from VCM Encoder to tool carriage) 1 Z
S5 20900430G
VCM Board to Carriage Board Cable (1.5*3pin
soft cable 12cm) 1 Z
S20
290071420G
Flat cable assembly for 132 model (195cm) 1 Z
S22
20901523G
AAS II Sensor PCB to carriage PCB 1 Z