Roland VersaCamm VP-540 Operating and maintenance manual

SERVICE NOTES
70046-06
TERMS OF USE
Users of this Service Note shall be deemed to agree with the following Terms of Use.
1. USERS
This Service Note is only for authorized persons with user ID and password issued by Roland DG Corporation.
2. PURPOSE
Authorized persons can use this Service Note only for the purposes of selling and providing to the customers
maintenance service of VP-540/VP-300.
3. REUSE
Authorized persons shall not disclose, transfer, rent or distribute this Service Note to, or allow this Service Note
to be used in any manner by, any third party other than authorized persons.
4. REPRODUCTION
Authorized persons shall not copy, change or alter this Service Note without permission of Roland DG
Corporation.
5. EFFECT OF VIOLATION
Regardless of circumstances, we will vigorously respond to any violation hereof, through legal action.
Confidential
Copyright © 2008 ROLAND DG CORPORATION

Windows and MS-DOS are registered trademark or trademark of Microsoft Corporation in the United States and/or other countries.
Contents
1 Structure & Spare Parts
1-1 COVERS ............................................................................................................................................................. 1-1
1-2 FRAME .............................................................................................................................................................. 1-4
1-3 DRIVE UNIT ....................................................................................................................................................... 1-8
1-4 HEAD CARRIAGE (VP-540).............................................................................................................................. 1-12
1-5 HEAD CARRIAGE (VP-300).............................................................................................................................. 1-14
1-6 BASE FRAME.................................................................................................................................................... 1-16
1-7 CHASSIS .......................................................................................................................................................... 1-18
1-8 PINCH ROLLER ............................................................................................................................................... 1-19
1-9 STAND .............................................................................................................................................................. 1-20
1-10 TOOL CARRIAGE ............................................................................................................................................. 1-21
1-11 WIPER SYSTEM .............................................................................................................................................. 1-22
1-12 PUMP SYSTEM ................................................................................................................................................ 1-23
1-13 INK SYSTEM .................................................................................................................................................... 1-25
1-14 ACCESSORIES.................................................................................................................................................. 1-26
2 Electrical Section
2-1 WIRING MAP ...................................................................................................................................................... 2-1
2-2 MAIN BOARD ..................................................................................................................................................... 2-3
2-3 SERVO BOARD ............................................................................................................................................... 2-14
2-4 CARRAGE BOARD .......................................................................................................................................... 2-20
2-5 SUB BOARD...................................................................................................................................................... 2-23
2-6 MAINTENANCE PARTS LIST .......................................................................................................................... 2-28
3 Replacement of Main Parts
3-1 HEAD REPLACEMENT ...................................................................................................................................... 3-3
3-2 WIPER REPLACEMENT .................................................................................................................................... 3-9
3-3 CAP TOP REPLACEMENT ...............................................................................................................................3-11
3-4 TOOL CARRIAGE REPLACEMENT ................................................................................................................ 3-14
3-5 CARRIAGE MOTOR REPLACEMENT ............................................................................................................. 3-18
3-6 FEED MOTOR REPLACEMENT ...................................................................................................................... 3-22
3-7 PUMP REPLACEMENT ................................................................................................................................... 3-30
3-8 INK TUBE REPLACEMENT ............................................................................................................................. 3-37
3-9 BOARD REPLACEMENT (MAIN BOARD SW POWER SUPPLY).................................................................... 3-43
3-10 BATTERY REPLACEMENT .............................................................................................................................. 3-54
3-11 CARRIAGE BELT REPLACEMENT ................................................................................................................ 3-57
3-12 ENCODER SCALE REPLACEMENT ............................................................................................................... 3-62
3-13 GRIT ENCODER REPLACEMENT ................................................................................................................. 3-64
3-14 PINCH ROLLER REPLACEMENT ................................................................................................................... 3-67
3-15 CUTTER PROTECTION REPLACEMENT ....................................................................................................... 3-68
4 Adjustment
4-1 SERVICE MODE ................................................................................................................................................ 4-1
4-2 HOW TO UPGRADE FIRMWARE/INSTALL FIRMWARE ................................................................................. 4-15
4-3 HOW TO UPGRADE FIRMWARE OF THE NETWORK CONTROLLER.......................................................... 4-22
4-4 HEAD ALIGNMENT........................................................................................................................................... 4-24
4-5 LIMIT POSITION & CUT DOWN POSITION INITIALIZE ................................................................................. 4-32
4-6 LINEAR ENCODER SETUP ............................................................................................................................. 4-34
4-7 FLUSHING POSITION ADJUSTMENT ............................................................................................................ 4-36
4-8 CROP MARK SENSOR ADJUSTMENT .......................................................................................................... 4-38
4-9 CROP-CUT ADJUSTMENT .............................................................................................................................. 4-40
4-10 PRINT/CUT POSITION ADJUSTMENT ............................................................................................................ 4-43
4-11 CALIBRATION(FEEDING DIRECTION) ........................................................................................................... 4-46
4-12 TOOL HEIGHT ADJUSTMENT ......................................................................................................................... 4-48
4-13 TOOL PRESSURE ADJUSTMENT .................................................................................................................. 4-50
4-14 BELT TENSION ADJUSTMENT ....................................................................................................................... 4-53
4-15 BELT POSITION ADJUSTMENT ...................................................................................................................... 4-56
4-16 TAKE-UP UNIT OPERATION CHECK .............................................................................................................. 4-62
5 Supplemental Information
5-1 SPECIAL TOOLS................................................................................................................................................. 5-1
5-2 SENSOR MAP..................................................................................................................................................... 5-
2
6 Troubleshooting
6-1 DEFECT OF PRINT QUALITY (BANDING/SCRATCHY PRINTING/BLURRED PRINTING).............................. 6-1
6-2 PARTICULAR COLOR IS NOT PRINTED AT ALL .............................................................................................. 6-2
6-3 SHIFTING IN PRINTING / COLOR SHIFTING.................................................................................................... 6-2
6-4 INK DROPS ON THE MEDIA.............................................................................................................................. 6-3
6-5 VERTICAL BANDING.......................................................................................................................................... 6-3
6-6
MISSING DOT OR DEFLECTED-FIRED DOT APPEARS WHEN PERFORMING PRINTING WITH LONG DELAY .......... 6-3
6-7 PRINT & CUT MISALIGHMENT.......................................................................................................................... 6-4
6-8 POOR CUTTING QUALITY(STITCH CUT, DISTORTED CUT, MISMATCHED START AND END POINTS) ..... 6-7
6-9 MEDIA SKEW...................................................................................................................................................... 6-7
6-10 MOTOR ERROR ................................................................................................................................................. 6-8
6-11 HEATER/DRYER TEMPERATURE DOES NOT GO UP..................................................................................... 6-9
6-12 PROBLEM IN NETWORK(RIP DOES NOT RECOGNIZE THE PRINTER)........................................................ 6-9
6-13 ERROR MESSAGE........................................................................................................................................... 6-10
6-14 SERVICE CALL ................................................................................................................................................. 6-10
7 Service Activities
7-1 INSTALLATION CHECK LIST ............................................................................................................................. 7-1
7-2 MAINTENANCE CHECK LIST .......................................................................................................................... 7-12
7-3 SPACIFICATION................................................................................................................................................ 7-13

Revision Record
Revision
NO.
Date Description of Changes Approval Issued
0 2007.3.9 First Edition Kato Uchiyama
1 2007.4.25
Sect1 : Parts have been revised.
Sect3 : Procedures have been revised.
Sect4 : Procedures have been revised.
Sect7 : Installation Check List has been revised.
Kato Mabuchi
2 2007.6.15
Sect1 : Parts have been revised.
Sect3 : Procedures have been added.
Kato Mabuchi
3 2007.8.24
Sect3 : Procedures have been revised. Kato Mabuchi
4 2007.10.12
Sect3 : Procedures have been revised.
Sect4 : Service Mode has been revised. Kato Misako
5 2007.11.20
Sect1 : Parts have been revised.
Sect7 : Procedures have been revised.
Kato Yuki
6 2008.1.29
Sect1 : Parts have been revised.
2-1 : Wiring Map Cable has been added.
Sect4 : Service Mode has been revised.
Kato Yuki

To Ensure Safe Work
About and Notices.
Used for instructions intended to alert the operator to the risk of death
or severe injury should the unit be used improperly.
Used for instructions intended to alert the operator to the risk of injury
or material damage should the unit be used improperly.
* material damage refers to damage or other adverse effects caused
with respect to the home and all its furnishings, as well to domestic
animals or pets.
About the Symbols
The symbol alerts the user to items that must never be carried out (are
forbidden). The speci c thing that must not be done is indicated by the design
contained within the circle.
The symbol at left means not to touch.
The symbol alerts the user to things that must be carried out. The speci c
thing that must be done is indicated by the design contained within the circle. The
symbol at left means the power-cord plug must be unplugged from the outlet.
The symbol alerts the user to important instructions or warnings. The speci c
meaning of the symbol is determined by the design contained within the triangle.
The symbol at left means “danger of electrocution”.
In addition to the and symbols, the symbols shown below are also used.
: Tips and advise before the adjustment.

About the Labels Affixed to the Unit
These labels are af xed to the body of this product.
The following gure describes the location.
Caution : Moving Print Heads
The print heads move at high speed and
pose a hazard.
Caution : Pinching Hazard
Contact during operation may cause the
hand or ngers to become pinched, rsult-
ing in injury.
Caution : High Temperature
The platen and dryer become hot. Exer-
cise caution to avoid re or burns.
Flammable
Ink and discharged uid are ammable.
Keep away from open ame.
Ink Is Toxic
Ink and discharged uid are toxic. Avoid
contact with the body. Use only in a well-
ventilated area.
Flammable
Ink and discharged uid are ammable.
Keep away from open ame.
Ink Is Toxic
Ink and discharged uid are toxic. Avoid
contact with the body. Use only in a well-
ventilated area.

HIGH VOLTAGE,
HANDLING ATTENTION
• Do not touch during power on
Electric shock, Compornents damage
• Do not repair. Replace power unit.
• Do not replace fuse. Can not be recovered.
WARNING - FOR CONTINUED
PROTECTION AGAINST RISK OF FIRE,
REPLACE ONLY WITH FUSE OF THE
SPECIFIED TYPE AND CURRENT RATING.
F80L HS
Electric charge.
Do not touch when power is on.
The wiring terminal untended for connec-
tion of the protective earthing conductor
associated with the supply wiring.
Do not disconnect the cable of this termi-
nal except the time of replacement.

1 Structure & Spare Parts
PARTS LIST -Main Parts-
Parts No. Parts Name Parts No. Parts Name
1 W700461210 ASSY,PANEL BOARD VP-540 17 1000002637 SHEET,PANEL VP-540
2 23505834 CABLE-ASSY MAINT-COVER SW FJ-540 18 1000002625 STAY,PANEL VP-540
3 1000002608 COVER,INK CARTRIDGE VP-540 19 1000003029 SHEET,LCD VP-540
4 1000002633 COVER,CHASSIS VP-540 20 22535347 LABEL,CAUTION PINCH-2 #LA423
5 1000002550 COVER,MAINTENANCE INKHEAD VP-540 21 1000001099 LABEL,HARMFUL FIRE #LA915
6 1000002620 COVER,MAINTENANCE VP-540 22 22535441 LABEL,SET INK SP-300 #LA634
1000002676 COVER,RAIL B VP-300 23 22535442 LABEL,USE ONLY ECO-SOL #LA635
1000002624 COVER,RAIL B VP-540 24 22535444 LABEL,READ MANUAL #LA637
8 1000002651 COVER,RAIL B-RIGHT VP-540 25 23475212 CABLE-CARD,24P1 600L BB
1000002150 COVER,RAIL F VP-300 PARTS LIST -Supplemental Parts-
1000002146 COVER,RAIL F VP-540 Parts No. Parts Name
10 1000002619 COVER,SIDE L VP-540 S1 31289111AS CUPSCREW SET, M4*6 NI 100 PCS.
11 1000002621 COVER,SIDE R VP-540 S2 31289109AS CUPSCREW SET,M3*4 NI 100 PCS.
12 1000002627 COVER,UNDER L VP-540 S3 31139103 PLAPOINT,FE4*6 WH
13 1000002628 COVER,UNDER R VP-540 S4 31149601 RING SET,PUSH-ON CS CSTW-3 100 PCS
14 22495102 KEY TOP,CLEAR GX-24 S5 31019149 SCREW SET,BINDING M2.3*8 3CBC 100PCS
15 22495101 KEY TOP,WHITE GX-24 S6 31019703 SCREW,BINDING P-TIGHT M3*8 3C 100P
16 1000002626 LABEL,EMBLEM LOGO VERSACAMM S7 31139104 SCREW,PLAPOINT M4*6 BK FE
7
9
1-1 COVER ( VP-540：Below ZW65382, VP-300：Below ZW61509 )
1-1
13
4
8
9
3
7
10
5
6
12
16
11
17
18
1
2
14
1514
19
22
20
20
21
23
21
24
25
S2
S2
S2
S1
S2
S2
S2
S2 S2
S2
S1
S2
S2
S2 S5
S3
S1
S1
S1 S7
S7
S1
S1
S1
S1
S6
S4
Revised 1
Revised 1

1-2
1-1 COVER ( VP-540：Above ZW65383, VP-300：Above ZW61510)
13
4
8
9
3
7
10
5
6
12
16
11
17
18
1
2
14
1514
19
22
20
20
21
23
21
24
25
35
S12
S8
S2
S2
S2
S1
S2
S2
S2
S2 S2
S2
S1
S2
S2
S2 S5
S3
S1
S1
S1 S7
S7
S1
S1
S1
S1
S6
S4
26
27
28
29
30 31
32
33
34
36
37 31
38
32 S5
S9
S10
S10
S11
Revised 1
Revised 6
Revised 6

PARTS LIST -Supplemental Parts-
Parts No. Parts Name Parts No. Parts Name
1 W700461210 ASSY,PANEL BOARD VP-540 S1 31289111AS CUPSCREW SET, M4*6 NI 100 PCS.
2 23505834 CABLE-ASSY MAINT-COVER SW FJ-540 S2 31289109AS CUPSCREW SET,M3*4 NI 100 PCS.
3 1000002608 COVER,INK CARTRIDGE VP-540 S3 31139103 PLAPOINT,FE4*6 WH
4 1000002633 COVER,CHASSIS VP-540 S4 31149601 RING SET,PUSH-ON CS CSTW-3 100 PCS
5 1000002550 COVER,MAINTENANCE INKHEAD VP-540 S5 31019149 SCREW SET,BINDING M2.3*8 3CBC 100PCS
6 1000002620 COVER,MAINTENANCE VP-540 S6 31019703 SCREW,BINDING P-TIGHT M3*8 3C 100P
1000002624 COVER,RAIL B VP-540 S7 31139104 SCREW,PLAPOINT M4*6 BK FE
1000002676 COVER,RAIL B VP-300 S8 31049106AS SCREW SET,CAP M3*8 3CBC 20 PCS
8 1000002651 COVER,RAIL B-RIGHT VP-540 S9 31049169AS SCREW SET,CAP M4*8 3CBC+PW 20PCS
1000004207 COVER,RAIL F TYPE2 VP-540 S10 31289102AS CUPSCREW SET,M3*6 NI 50 PCS.
1000004208 COVER,RAIL F TYPE2 VP-300 S11 31289112AS CUPSCREW SET,M3*10 NI 100 PCS.
10 1000002619 COVER,SIDE L VP-540 S12 31029816AS BUSH SET,ROLL 3*4 100 3C PCS.
11 1000002621 COVER,SIDE R VP-540
12 1000002627 COVER,UNDER L VP-540
13 1000002628 COVER,UNDER R VP-540
14 22495102 KEY TOP,CLEAR GX-24
15 22495101 KEY TOP,WHITE GX-24
16 1000002626 LABEL,EMBLEM LOGO VERSACAMM
17 1000002637 SHEET,PANEL VP-540
18 1000002625 STAY,PANEL VP-540
19 1000003029 SHEET,LCD VP-540
20 22535347 LABEL,CAUTION PINCH-2 #LA423
21 1000001099 LABEL,HARMFUL FIRE #LA915
22 22535441 LABEL,SET INK SP-300 #LA634
23 22535442 LABEL,USE ONLY ECO-SOL #LA635
24 22535444 LABEL,READ MANUAL #LA637
25 23475212 CABLE-CARD,24P1 600L BB
1000004197 PLATE,COVER F VP-540
1000004204 PLATE,COVER F VP-300
27 22535390 LABEL,EMERGENCY STOP #LA496
28 22535286 LABEL,CAUTION COVER #LA265
1000004196 PLATE,NUT COVER F VP-540
1000004203 PLATE,NUT COVER F VP-300
30 21425110 WASHER,COVER FJ-50
31 1000004199 PAD, STOPPER VP-540
32 1000004198 SHAFT,COVER F VP-540
1000004195 FRAME,COVER F VP-540
1000004202 FRAME,COVER F VP-300
34 1000004361 COVER,INT SW VP-540
35 11879107 ABSORBER TK-12
36 13169102 COVER SW R (AVT32344)
37 1000004200 HOOK,INT SW VP-540
38 22535287 LABEL,CAUTION CARRIAGE #LA266
1-3
PARTS LIST -Main Parts-
1-1 COVER ( VP-540：Above ZW65383, VP-300：
A
bove ZW61510 )
7
9
33
29
26
Revised 1
Revised 6
Revised 6

1-4
1-2 FRAME ( VP-540：Below ZW65382, VP-300：Below ZW61509 )
28
8
22
13
9
26
33
32
8
31
25
18
7
24
29
20
19
16
34
4
3
9
21
6
2
23
17
30
35
1
27
1
14
8
11
11
10
5
5
15
12
36
37
38
37
S6 S11
S16
S20
S10
S12
S17
S14
S8
S17
S4
S4
S13
S17 S14 S17
S17
S16
S20
S7
S20 S10
S10
S3
S9
S4
S10
S4
S10
S17
S10 S17
S17
S10
S18
S17
S20
S1
S2
S19
S17
S8
S5
S14
S5
S14
S1
S8
S6
S11
S6S11
S10