GRAPHTEC FC8600-60 User manual

CUTTING PLOTTER
SERVICE MANUAL
FC8600-60/75/100/130/160
FC8600-UM-251-07-9370

FC8600-UM-251-9370 I
HISTORY OF REVISIONS
No. Date issued Description of revision Page Edition
113.2.22 First Printing All 01
214.6.18
The rank of items 10 and 15, 16 were changed to A rank. 9-8 02
314.6.18 Parts name was corrected for item number 35. 9 -11 02
414.6.18 The rank of Pinch Roller Base was changed to B rank. 9-10 02
514.6.18 Parts number of Drive Pulley Assy was corrected. 9 -11 02
614.6.18 The rank of I/F Panel LAN was changed to D rank. 9-1 02
714.6.18 Parts number of End Cap was added. 9-15 02
814.6.18 The rank of Cam Shaft was changed to C rank. 9-10 02
914.7. 23 Parts number of Drive Pulley Assy was corrected. 9-10 03
10 14.8.27 Parts number of Center Covers were corrected. 9-1 04
11 14.8.27
Quantity of Push Roller Positioning Label S for the FC8600-60 and FC8600-75 were corrected. 9-14 04
12 14.8.27
The rank of labels were changed to C rank except I/F labels. 9-14 04
13 14.11.18 Parts number for LED Base was added. 9-4 05
14 14.11.18
The construction of Pen Block Assembly was corrected. 9-5 05
15 15.02.24 Parts number for Fan was
corrected. 9-1 05
16 15.04.28
Item number of Paper Hold down A and B were corrected. 9-6 05
17 15.05.21 The procedure of distance adjustment was corrected. 7-22 to 7-24 05
18 15.08.04 The procedure of distance adjustment was corrected. 7-23 to 7-24 06
19 15.10.2 0
The procedure of the Tool 2 and the Cross Cutter Threshold adjustment was added. 7-40 to 7-41 07

FC8600-UM-251-9370 II

FC8600-UM-251-9370 III
CONTENTS
1 INTRODUCTION .........................................................................1-1
1.1 Main Specifications ...............................................................................................................1-1
1.2 External Dimensions ............................................................................................................ 1-2
2 PARTS NAMES and FUNCTIONS ............................................ 2-1
2.1 Parts Names and Functions..................................................................................................2-1
2.2 Assembling............................................................................................................................ 2-3
2.3 Attaching a Tool .................................................................................................................... 2-8
2.4 Replacing the Cross-Cutter Unit ........................................................................................2-11
3 OPER ATIONS ............................................................................ 3-1
3.1 Control Panel......................................................................................................................... 3-1
3.2 Reading the Screen (LCD) .................................................................................................... 3-3
4 RECOMMENDED PARTS LIST................................................. 4-1
5 LIST OF TOOLS ........................................................................ 5-1
5.1 Tools....................................................................................................................................... 5-1
5.2 Greasing And Gluing Points ................................................................................................ 5-1
6 DISASSEMBLY AND REASSEMBLY ....................................... 6-1
6.1 Exterior Parts ........................................................................................................................ 6-1
6.1.1 How to Replace the Right Side Cover.................................................................................................. 6-1
6.1.2 How to Replace the Left Side Cover .................................................................................................... 6-2
6.1.3 How to Replace the Control Panel Assembly ..................................................................................... 6-3
6.1.4 How to Replace the Center Cover ........................................................................................................ 6-4
6.1.5 How to Replace the Front Guide .......................................................................................................... 6-5
6.1.6 How to Replace the Rear Guide ........................................................................................................... 6-6
6.1.7 How to Replace the Rear Writing Panel............................................................................................... 6-7
6.1.8 How to Replace the Front Writing Panel Assembly............................................................................ 6-8
6.2 Mechanical Parts................................................................................................................... 6-9
6.2.1 How to Replace the Rear Media Sensor .............................................................................................. 6-9
6.2.2 How to Replace the Front Media Sensor ............................................................................................6-10
6.2.3 How to Replace the Pinch Roller.........................................................................................................6-11

FC8600-UM-251-9370 IV
6.2.4 How to Replace the Control Panel Board and the LCD.....................................................................6-12
6.2.5 How to Replace the Pen Block ............................................................................................................6-13
6.2.6 How to Replace the Y-belt....................................................................................................................6-15
6.2.7 How to Replace the Pinch Roller Sensor............................................................................................6-17
6.2.8 How to Replace the Y-relay Board.......................................................................................................6-19
6.2.9 How to Replace the Cam Sensor........................................................................................................ 6-20
6.2.10 How to Replace the Y-motor ............................................................................................................... 6-21
6.2.11 How to Replace the X-motor............................................................................................................... 6-22
6.2.12 How to Replace the Main Board ......................................................................................................... 6-23
6.2.13 How to Replace the Vacuum Fan........................................................................................................ 6-24
6.2.14 How to Replace the Drive Roller......................................................................................................... 6-25
6.2.15 How to Replace the Cutting Mat......................................................................................................... 6-27
6.2.16 Home Dog Position.............................................................................................................................. 6-28
6.2.17 Cross Cutter Dog Position.................................................................................................................. 6-28
7 ADJUSTMENTS..........................................................................7-1
7.1 List of Items Requiring Readjustment .................................................................................7-1
7.2 Mechanical Adjustments.......................................................................................................7-2
7.2.1 Y-Belt Tension Adjustment ....................................................................................................................7-2
7.2.2 Y-Drive Belt Tension Adjustment ..........................................................................................................7-3
7.2.3 X-Drive Belt Tension Adjustment ..........................................................................................................7- 4
7.2.4 Pinch Roller Pressure Adjustment........................................................................................................7-5
7.3 Electrical Adjustments ........................................................................................................7-13
7.3.1 DIP Switch Settings..............................................................................................................................7-13
7.3.2 Explanation of the Values of the Main Board Settings ..................................................................... 7-15
7.3.3 Clearing the Non-Volatile RAM............................................................................................................7-16
7.3.4 How to Enter the Adjustment Menu ....................................................................................................7-18
7.3.5 Adjusting the Pen Force.......................................................................................................................7-20
7.3.6 Adjusting the Distance Accuracy........................................................................................................7-22
7.3.7 Adjusting the Registration Mark Sensor Sensitivity .........................................................................7-25
7.3.8 Adjusting the Offset of the Auto-Registration Mark Sensor ............................................................7-26
7.3.9 Adjusting the Cross Cutter Home Position........................................................................................7-28
7.3.10 Adjusting the Offset of the Light Pointer Position ............................................................................7-30
7.3.11 Confirming the 2-Pen Model (2-pen model) .......................................................................................7-32
7.3.12 Adjusting the Pen Exchange Y Direction Value (2-pen model) ........................................................7-34

FC8600-UM-251-9370 V
7.3.13 Adjusting the Spacing Between Pen 1 and Pen 2 (2-pen model).....................................................7- 36
7.3.14 Adjusting the Tool 2 and the Cross Cutter Threshold (2-pen model) ............................................. 7- 40
7.4 Upgrading the System Firmware ....................................................................................... 7- 42
8 TROUBLESHOOTING ............................................................... 8-1
8.1 The Plotter is Turned On But Doesn’t Operate................................................................... 8-1
8.2 Media Loading Operations................................................................................................... 8-1
8.3 Cutting Operations ............................................................................................................... 8-2
8.4 Error Messages ..................................................................................................................... 8-3
8.4.1 Hardware Error Messages .................................................................................................................... 8-3
8.4.2 Error Messages in GP-GL Command Mode ........................................................................................ 8-6
8.4.3 Error Messages in HP-GL Emulation Mode ........................................................................................ 8-7
8.4.4 Error Messages on ARMS..................................................................................................................... 8-9
8.4.5 Other Error Messages ..........................................................................................................................8-12
8.4.6 Warning Messages ...............................................................................................................................8-13
8.5 Service mode........................................................................................................................8-14
8.5.1 Sensor Test Mode & Panel Switch Test Mode....................................................................................8-14
8.5.2 Printing the Setting of the Plotter ..........................................................................................................16
8.5.3 Printing the Test Pattern .........................................................................................................................17
8.5.4 Confirm the Cutting Data ........................................................................................................................18
8.5.5 Self Diagnostic Test.................................................................................................................................19
9 PARTS LIST............................................................................... 9-1
9.1 Outer Casing.......................................................................................................................... 9-1
9.2 Control Panel......................................................................................................................... 9-3
9.3 Pen Block............................................................................................................................... 9-4
9.4 Registration Mark Sensor Assy........................................................................................... 9-6
9.5 Cross Cutter .......................................................................................................................... 9-7
9.6 Main Frame ............................................................................................................................ 9-8
9.7 Y Rail .....................................................................................................................................9-10
9.8 Y Slider..................................................................................................................................9-12
9.9 Wiring Harness.....................................................................................................................9-13
9.10 La bels ....................................................................................................................................9-14

9.11 Media Stocker, Stand ...............................................................................9-15
9.12 Basket ...................................................................................................................................9-16
9.13 Other Parts ...........................................................................................................................9-16
10 BLOCK DIAGRAMS AND CIRCUIT DIAGRAMS ................... 10-1
10.1 Block Diagrams....................................................................................................................10-1
10.2 Circuit Diagrams ................................................................................................................. 10-2
10.2.1 Main Board (CPU)..................................................................................................................................10-2
10.2.2 Main Board (CONNECTOR) ................................................................................................................. 10-3
10.2.3 Main Board (MOTOR DRIVER)............................................................................................................ 10-4
10.2.4 Main Board (FPGA) .............................................................................................................................. 10-5
10.2.5 Main Board (I/F).................................................................................................................................... 10-6
10.2.6 Main Board (MEMORY).........................................................................................................................10-7
10.2.7 Main Board (Power) ............................................................................................................................. 10-8
10.2.8 LAN Board ............................................................................................................................................ 10-9
10.2.9 Light Pointer........................................................................................................................................10-10
10.2.10 Pen Relay Board .................................................................................................................................10-11
10.2.11 Pinch Roller Sensor Board ................................................................................................................10-12
10.2.12 RMS Board ..........................................................................................................................................10-12
10.2.13 Control Panel Board ...........................................................................................................................10-13
10.2.14 Cam Sensor Board .............................................................................................................................10-14

FC8600-UM-251-9370 1-1
1 INTRODUCTION
1 INTRODUCTION
1.1 Main Specications
FC8600-60 FC8600-75 FC8600-100 FC8600-130 FC8600-160
CPU 32-bit
Configuration Grit-rolling plotter
Drive Digital servo
Max. cutting area
(expanded mode)
50 m x 610 mm 50 m x 762 mm
50 m x 1067 mm 50 m x 1372 mm 50 m x 1626 mm
Max. cutting area when 2-pen
(option) isused.
50 m x 601 mm 50 m x 753 mm 50 m x 1053 mm 50 m x 1352 mm 50 m x 1613 mm
Guaranteed precision cutting area*1 15 m x 590 mm 15 m x 742 mm 10 m x 1047 mm
15 m x 894 mm
10 m x 1352 mm
15 m x 894 mm
10 m x 1606 mm
15 m x 894 mm
Mountable media width Max. 730 mm,
Min. 50 mm
Max. 901 mm,
Min. 50 mm
Max. 1206 mm,
Min. 50 mm
Max. 1511 mm,
Min. 50 mm
Max. 1765 mm,
Min. 50 mm
Max. cutting speed (Axial) 148.5cm/sec (45 degree direction)
Specifiable speeds
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 70, 80, 90, 100, 105 cm/sec
Cutting pressure 48 steps, 0.196 to 5.88N (20 to 600gf)
Min. character size 3 mm (0.125 in.) alphanumeric Helvetica med. Font
Mechanical resolution 0.005mm
Programmable resolution GP-GL: 0.01/0.05/0.025/0.01 mm, HP-GL*2: 0.025 mm
Repeatable accuracy *1 Max. 0.1 mm/2-m unit (excluding media shrinkage)
Number of cutters/pens 1 (2 for 2-pen model (option))
Pen types Water-based fiber-tip, oil-based ballpoint and disposable ink pens
Pouncing tool type Pouncing tool: PPA33-TP12, 1.2-mm pin diameter) *3
Compatible media Mono-vinyl chloride media, fluorescent media, and reflective media up to 0.25
mm thick, high reflective media.*4
Compatible paper for pouncing Regular paper from 0.06 to 0.13 mm thick
Interfaces USB2.0 (Full Speed)/Network (Ethernet 10BASE-T/100BASE-TX)/RS-232C
(Auto switching)
Buffer memory 2 MB
Resident command sets GP-GL/HP-GL*2(Control panel switching)
LCD Panel Graphic type (Yellow backlight)
Power supply 100-240VAC/50-60 Hz (Auto switching)
Power consumption 160VA max.
Operating environment Temperature: +10˚C to +35˚C
Humidity: 35% to 75% (non-condensing)
Guaranteed accuracy environment Temperature: +16 ˚C to +32 ˚C
Humidity: 35% to 70%(non-condensing)
External dimensions
(W x H x D)
1120 x 1219 x
715 mm
1270 x 1219 x
715 mm
1570 x1219 x
715 mm
1870 x 1219 x
715 mm
2130 x 1219x
715 mm
Weight 38 kg 42 kg 46 kg 54 kg 59 kg
*1 When the optional basket and Graphtec-specied media are used.
*2 HP-GL is a registered trademark of Hewlett-Packard Company.
*3 The PPA32-TP12 pouncing pen cannot be used.
*4 The CB15UA cutter blade and a reinforced backing sheet must be used when cutting high-intensity reective lm.

FC8600-UM-251-9370 1-2
1 INTRODUCTION
1.2 External Dimensions
FC8600-60: 1128
FC8600-75: 1278
FC8600-100: 1578
FC8600-130: 1878
FC8600-160: 2138
715
1219
1162
Units: mm
Dimensional accuracy: ±5 mm

FC8600-UM-251-9370 2-1
2 PARTS NAMES and FUNCTIONS
2 PARTS NAMES and FUNCTIONS
2.1 Parts Names and Functions
Front View
Power switch
Cutting groove
Cutting mat
Grit roller position guide
Push roller
Grit roller
Media sensor
Cross cutter unit
Tool carriage
Tool holder
Push roller
Control panel
Stand
Pen station
(Optional)
Rail
Power switch: ����������������� Used to turn the plotter on and off�
Control panel: ����������������� Used to access various plotter functions�
Pinch rollers:������������������� Rollers that push the media against the grit rollers�
Grit rollers:���������������������� Metallic rollers with a file-like surface that feed the media back and forth�
Media sensors: ��������������� The front sensor is used to sense the leading edge of the media� The rear sensor is
used to sense the trailing edge of the media�
Tool carriage: ������������������ Moves the cutter-pen or plotting pen across the media during cutting or plotting�
Tool holder: ��������������������� Holds the cutter-pen or plotting pen and moves it up or down�
Pen station (installed on 2-pen models only):
The second pen is mounted here� (Factory-installed option)
Stand: ����������������������������� Used to make the plotter more portable and to free up counter space�
Grit roller position guide:
Stickers on the front of the Y rail and the rear side of the top cover that show the
position of each grit roller� Use these alignment marks as an aid in locating the
pinch rollers�
Cutting mat: �������������������� Cutter blade moved on this mat, preventing wears of the blade�
Cutting groove: ��������������� Used when cross-cutting is performed�
Cross-cutter unit: ������������ Used to perform cross-cutting of media so that the cut length can be removed from
the roll�

FC8600-UM-251-9370 2-2
2 PARTS NAMES and FUNCTIONS
Rear View
Push roller hold-down force switching lever
Media set lever
Stock rollers
Media stocker
AC line inlet
USB interface
Media lock
RS-232C interface
Network interface (Factory-installed option)
Media set lever: �������������� Used to raise or lower the pinch rollers during the loading or unloading of media�
Pinch roller hold-down force switching lever:
���������������������������������������� Used to switch between the three pinch roller forces (outside push rollers only has
2 forces of strong and medium)�
AC line inlet: ������������������� Inlet where the power cord is connected�
Media stocker: ���������������� Used to carry roll media and ensure its proper rotation�
Stock rollers:������������������� A media roll is placed on these rollers�
Media lock: ��������������������� Used to prevent the stock rollers from rotating when the media roll has been placed
on top of them� The media lock ensures that the media is pulled straight out from
the roll�
USB interface connector:
���������������������������������������� Used to connect the plotter to the computer with a USB interface cable�
Network interface connector:
���������������������������������������� Used to connect the plotter to the computer with a network interface cable�
(Factory-installed option)
RS-232C interface connector:
���������������������������������������� Used to connect the plotter to the computer with an RS-232 serial interface cable�

FC8600-UM-251-9370 2-3
2 PARTS NAMES and FUNCTIONS
2.2 Assembling
Assemble the stand�
Stand side bar x 2 Base assembly x 2 Center bar x 1 Allen wrench
(for M5 screws) x 1
Socket head cap screw
(M5) x 20
Media stocker x 2
Stock roller x 2
Front Loading and Rear Loading
It is necessary to set the loading settings from the plotter control panel depending on the attachment
direction�
Default factory setup is set as rear loading�
It is recommended to use as rear loading�
If you desire to load the material from the front, it is also possible to use the front loading�
Use the plotter with enough space behind in this case�
Also, be aware that continuous cutting with cross cut is not possible�
Assembling the Stand
The mounting direction is different for the front loading and the rear loading models�
<Front loading>
<Rear loading>

FC8600-UM-251-9370 2-4
2 PARTS NAMES and FUNCTIONS
Assembly
(1) Assemble the left and right stand sides� Fasten a base assembly to each of the stand side bars with
four socket head cap screws using the Allen wrench�
Socket head
cap screw
Stand side bar
Base
assembly
Stand side bar
(2) Loosely fasten the center bar to the left and right stand sides with four socket head cap screws (two on
each side), using the Allen wrench�
Center bar
Stand sides
Socket head
cap screw
Socket head
cap screw
(3) Attach a media stocker to each of the left and right stand sides with two socket head cap screws, using
the Allen wrench� Mount the media stockers so that each one protrudes directly above the longer of the
two base assembly lengths�
Media stocker
Media stocker
Socket head cap screw
Base assembly
Stand sides
Short Long

FC8600-UM-251-9370 2-5
2 PARTS NAMES and FUNCTIONS
(4) Mount the plotter on the stand by inserting the positioning pins on the stand into the positioning holes
on the underside of the plotter� Fasten with four socket head cap screws (two on each side), using the
Allen wrench� The cutting plotter mounting direction is different for the front loading and the rear loading
models�
Socket head
cap screw
Positioning pin hole
Caster stoppers
Socket head
cap screw
Positioning pin
<Front loading>
<Rear loading>
(5) Tighten the socket head cap screws loosely fastened in Step 2�
Mounting the stock rollers
Insert the stock rollers into the slots on the media stocker brackets�
<Front loading>
Stock rollers
<Rear loading>
Stock rollers
Front

FC8600-UM-251-9370 2-6
2 PARTS NAMES and FUNCTIONS
Attaching the Basket
The basket is attached directly to the plotter�
The basket is made up of the following parts�
Basket x 1, basket tubes (long) x 3, basket tubes (short) x 4, joints x 4, mounts x 2, socket cap head screws
x 4, use Allen wrench to assemble the basket�
Be sure to use the basket when cutting long-axis media of more than 1 meter is to be produced�
Cloth basket Basket tube (long) x 3
Socket head cap
screw
(M5) x 4
Mount x 2
Basket tube (short) x 4
Joint x 4
Assembly
(1) Insert the basket tubes (long) into both ends and center of the basket� Attach the joints to the end of the
2 outside basket tubes�
Cloth basket
Basket tube (long)
Joint
Joint
Joint

FC8600-UM-251-9370 2-7
2 PARTS NAMES and FUNCTIONS
(2) Insert 2 basket tubes (short) into the mount from the side without the cap� Assemble 2 sets as shown
below�
Cap
Mount
Basket tube (short)
(3) Connect the basket tubes (short) to the joints inserted on the basket tubes (long) at the end of the
basket attached in step 1�
Mounting position of the center basket pipe (long) depends on the loading direction�
Basket tube (long)
Cloth basket
Joint
For front
loading
For rear
loading
(4) Fix the part assembled in 3 to the stand using the socket head cap screws� Assembly is completed by
separating basket to front and back of the center bar�
Socket head
cap screw
Socke thead
cap screw
Center bar
Stand

FC8600-UM-251-9370 2-8
2 PARTS NAMES and FUNCTIONS
2.3 Attaching a Tool
Attach a tool (cutter pen, plotter pen) to the plotter�
Attaching a Tool
When mounting the tool in the tool holder, push the tool all the way into the holder until its ange contacts
the upper part of the holder and then tighten the screw rmly. To prevent injury, avoid touching the tool
immediately after the cutting plotter is turned on or whenever the tool is moving� It is explained here using
cutter pen as anexample�
(1) Loosen the pen holder screw�
(2) While pushing the tool holder in the upward direction, push the tool all the way into the holder until its
ange contacts the upper part of the holder.
• When pushing the tool holder with your ngers, the blade tip may be protruding.
Take care not to cut your ngers.
For half cutting
(backward)
For cutting out
(forward)
Upper part of
tool holder
Flange
(3) Make sure that the tool bracket is engaged on the tool’s ange, and then tighten the screw.
Bracket to hold tool
Flange

FC8600-UM-251-9370 2-9
2 PARTS NAMES and FUNCTIONS
Attaching a Pen to the Two-Pen Holder (Option)
The two-pen holder is a factory-installed option, and cannot be retrotted.
(1) Loosen the pen holder screw�
(2) While pushing the pen holder in the upward direction, push the pen all the way into the holder until its
ange contacts the upper part of the holder.
• When you push the pen holder with your ngers, the blade tip may be protruding.
Take care not to cut your ngers.
Flange
Upper part of pen holder
(3) Make sure that the pen bracket is engaged on the pen’s ange, and then tighten the screw.
Bracket to hold pen
Flange

FC8600-UM-251-9370 2-10
2 PARTS NAMES and FUNCTIONS
Attaching a Plotting Pen to the Pen Station
(1) Open the pen-hold mechanism on the pen station, and then attach a pen�
(2) Make sure that the bracket of the pen station is engaged in the upper groove of the pen�
(3) Close the pen-hold mechanism on the pen station to hold the pen in place�
• Do not leave a pen attached to the pen station for a long period of time, as the
pen tip will dry up and make it unusable�
• To store the pen, remove it from the pen station and replace its protective cap�