Roland TrueVIS SG2-640 Operating and maintenance manual

70591-02
Copyright © 2019 ROLAND DG CORPORATION
Condential
TERMS OF USE
The use of this Service Note constitutes agreement 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 the customers with maintenance
services of SG2-640/540/300.
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
This Service Note may not be copied or modied without permission of Roland DG Corporation.
5. EFFECT OF VIOLATION
Regardless of circumstances, we will vigorously respond to any violation hereof, through legal action.
SERVICE NOTES

T-1 SG2-640/540/300
TABLE OF CONTENTS
Table of Contents
Table of Contents .....................................T-1
Revision History ......................................T-2
Warning Labels .......................................T-3
Special Tools..........................................T-4
Key Combinations ....................................T-5
Chapter 1 Replacement of Main Parts 1-1
Important Points .................................... 1-3
Print Head Replacement ............................. 1-4
Cap Top Replacement ...............................1-18
Tool Carriage Replacement..........................1-24
Scan Motor Replacement............................1-31
Feed Motor Replacement ...........................1-42
Pressure Pump Replacement ........................1-54
Main Board Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61
Servo Board Replacement ...........................1-67
Signal JC Board Replacement........................1-70
SW Power Supply Replacement......................1-72
Pump Drive Board Replacement .....................1-77
Ink System RFID Board Replacement.................1-79
RFID R/W Board Replacement .......................1-81
Carriage Belt Replacement ..........................1-84
Encoder Scale Replacement .........................1-91
Linear Encoder Board Replacement..................1-94
Battery Replacement...............................1-102
Choke Valve Replacement ..........................1-105
Ink Tube Replacement .............................1-109
Chapter 2 Adjustment 2-1
Service Mode........................................ 2-2
History Menu .......................................2-12
Firmware Upgrade ..................................2-15
Firmware Installation ...............................2-18
Limit Position & Cut Down Position Initialization . . . . . 2-24
Linear Encoder Setup ...............................2-27
Flushing Position Adjustment .......................2-29
Crop Mark Sensor Adjustment.......................2-33
Print Head Alignment ...............................2-36
Tool Height Adjustment.............................2-43
Tool Pressure Adjustment ...........................2-46
Belt Tension Adjustment ............................2-50
Belt Position Adjustment............................2-54
Wiper Position Adjustment ..........................2-63
Feed Calibration ....................................2-65
Feed Adjuster Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . .2-67
Chapter 3 Supplement 3-1
Motor Errors.........................................3-2
Service Call Errors....................................3-3
Supplement on Service Call 0400 .....................3-6
Sensor Map. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Wiring Map.........................................3-12
Chapter 4 Service Activities 4-1
Installation Checklist.................................4-2
Maintenance Checklist ..............................4-21

T-2 SG2-640/540/300
TABLE OF CONTENTS
Revision History
Revision Date Description Approver Author
0 July 31, 2019 First edition Nimura Saito
1 September 4, 2019 Chapter 4 Service Activities [Installation Checklist] Nimura Saito
2 October 2, 2019 Chapter 2 Adjustment [Service Mode]
Chapter 4 Service Activities [Installation Checklist] Nimura Saito
3
4
5
6
7
8
9
10
11
12
13
14
15

T-3 SG2-640/540/300
TABLE OF CONTENTS
Warning Labels
Warning Labels
Service parts
For information on service parts required for the replacement of parts or adjustment, refer to
Parts Finder Web.
A.warning.label.is. .to.the.machine.to.make.areas.of.danger.immediately.clear..The.meaning.of.
this.label.is.indicated.below..Be.sure.to.heed.this.warning..Also,.never.remove.the.label.or.allow.it.to.
become.dirty.
The.platen.and.dryer.become.hot..Exercise. .to.avoid. .or.burns.
Be.careful.not.to.allow.the. .to.become.pinched.when.closing.covers.
The.print.heads.inside.the.cover.move.at.high.speed.and.pose.a.hazard..
Never.insert.the.hand.or. .into.the.gap.
If.these. .come.into.contact.with.the.eyes.or.skin,.it.may.be.hazardous.
to.the.health..When.performing.maintenance.work,.for.example.when.dis-
posing.of.discharged. .wear. .eyewear.and. .gloves.
(refer.to.the.safety.data.sheet.[SDS]).
Removing.the.cover.may.result.in.high-voltage.electric.shock.
Flammable
Ink.and.discharged. .are. .Keep.away.from.open.
https://365rolanddg.sharepoint.com/sites/extranet/Work-SitePages/GSV-PartsFinder.aspx

T-4 SG2-640/540/300
TABLE OF CONTENTS
Special Tools
Part No. ST-056
Part Name TORQUE DRIVER N6
Purpose Print head replacement
Print head alignment
Part No. 1000015274
Part Name TOOL, BIT PHILLIPS NO.1 L200MM
Purpose Print head replacement
Print head alignment
Part No. ST-001
Part Name TENSION GAUGE 2000GF/2000CN
Purpose Belt tension adjustment
Part No. ST-002
Part Name TENSION GAUGE 300GF/300CN
Purpose Tool pressure adjustment
Part No. ST-012
Part Name DIAL TENSION METER DTB-50
Purpose Tool pressure adjustment
Part No. 1000003138
Part Name SET,CLEANER STICK TX712A 10PCS.
Purpose Print head cleaning
Part No. 6000004663
Part Name KIT,CLEANING(TR2-CL) SV 500ML
Purpose Print head cleaning
Part No. 6000004662
Part Name KIT,CLEANING(TR2-CL) SV 100ML
Purpose Print head cleaning
*cleaning liquid + cleaning sticks 10 pcs."
Part No. 6000004129
Part Name GREASE,FLOIL G-902 10ML_02
Purpose Grease

T-5 SG2-640/540/300
TABLE OF CONTENTS
For service engineers Panel key combination Description
Service mode +
In order to enter the service mode, you need to
connect Peck2 to the machine.
Press the [MENU] [] keys to enter the service
menu.
Firmware upgrade mode +“UPDATE FIRMWARE?” is displayed.
Press the [ENTER] key to upgrade rmware.
Firmware installation
(When replacing the main board)
+Use this key combination to install rmware
after replacing the main board.
ENTER
In case of a brand-new main board without
rmware installed, [SUM-ERROR] is displayed
when the sub power switch is turned on.
Press the [ENTER] key so that the printer will
become ready to load rmware.
System parameter initialization +
ENTER All parameters will be initialized.
Press the [ENTER] key to start initialization.
Limit position/cut down position initialization +Press the [ENTER] key to initialize limit position.
Then, set up cut down position.
Sensor check mode
When starting the machine in the sensor check
mode, the same menu as [SENSOR CHECK] in
the service mode starts up.
* You cannot exit from this menu. Only sub
power switch can be turned o.
System Switch mode
Only SYSTEM SWITCH menu can be operated.
There is no other menu or function. Only sub
power switch can be turned o.
Without initialization of sub CPU or FPGA, the
menu is started after minimum initialization
is completed. BIT can be changed by entering
the SYSTEM SWITCH menu, even when internal
error occurs in the service mode.
Temporary IP address setting mode
After turning on the main power switch, press
and hold the [FUNCTION] key for about 10
seconds until BEEP sound rings one time. If
the BEEP sound rings three times, try it again.
Set the temporary IP address [192.168.1.99].
This mode is needed to connect Peck2 to the
machine when IP address has not been set
when you replace the main board replacement,
etc.
For users Panel key combination Description
Language/unit selection +
MENU Press the [] [] keys to select language/unit
type.
Key Combinations
+
+
+
FUNCTION

1-1 SG2-640/540/300
Workow..................................1-63
Servo Board Replacement ...................1-67
Information ...............................1-67
Outline Diagram...........................1-67
Cover That Needs to Be Removed ..........1-68
Workow..................................1-68
Signal JC Board Replacement................1-70
Information ...............................1-70
Outline Diagram...........................1-70
Cover That Needs to Be Removed ..........1-71
Workow..................................1-71
SW Power Supply Replacement..............1-72
Information ...............................1-72
Outline Diagram...........................1-72
Cover That Needs to Be Removed ..........1-73
Workow..................................1-73
Pump Drive Board Replacement .............1-77
Information ...............................1-77
Outline Diagram...........................1-77
Cover That Needs to Be Removed ..........1-78
Workow..................................1-78
Ink System RFID Board Replacement.........1-79
Information ...............................1-79
Outline Diagram...........................1-79
Cover That Needs to Be Removed ..........1-80
Workow..................................1-80
RFID R/W Board Replacement ...............1-81
Information ...............................1-81
Outline Diagram...........................1-81
Cover That Needs to Be Removed ..........1-82
Workow..................................1-82
Carriage Belt Replacement ..................1-84
Information ...............................1-84
Outline Diagram...........................1-84
Cover That Needs to Be Removed ..........1-85
Workow..................................1-85
1
REPLACEMENT
Chapter 1 Replacement of
Main Parts
Important Points ............................1-3
Print Head Replacement .....................1-4
Information ................................1-4
Outline Diagram............................1-5
Cover That Needs to Be Removed ...........1-6
Workow...................................1-7
Cap Top Replacement .......................1-18
Information ...............................1-18
Outline Diagram...........................1-18
Cover That Needs to Be Removed ..........1-19
Workow..................................1-19
Tool Carriage Replacement..................1-24
Information ...............................1-24
Outline Diagram...........................1-24
Cover That Needs to Be Removed ..........1-25
Workow..................................1-25
Scan Motor Replacement....................1-31
Information ...............................1-31
Outline Diagram...........................1-31
Cover That Needs to Be Removed ..........1-32
Workow..................................1-34
Feed Motor Replacement ...................1-42
Information ...............................1-42
Outline Diagram...........................1-42
Cover That Needs to Be Removed ..........1-43
Workow..................................1-44
Pressure Pump Replacement ................1-54
Information ...............................1-54
Outline Diagram...........................1-54
Cover That Needs to Be Removed ..........1-55
Workow..................................1-55
Main Board Replacement. . . . . . . . . . . . . . . . . . . .1-61
Information ...............................1-61
Outline Diagram...........................1-62
Cover That Needs to Be Removed ..........1-62

1-2 SG2-640/540/300
Encoder Scale Replacement .................1-91
Information ...............................1-91
Outline Diagram...........................1-91
Workow..................................1-92
Linear Encoder Board Replacement..........1-94
Information ...............................1-94
Outline Diagram...........................1-95
Cover That Needs to Be Removed ..........1-96
Workow..................................1-97
Battery Replacement...................... 1-102
Information .............................1-102
Outline Diagram.........................1-102
Cover That Needs to Be Removed ........1-102
Workow................................1-103
Choke Valve Replacement ................. 1-105
Information .............................1-105
Outline Diagram.........................1-105
Cover That Needs to Be Removed ........1-106
Workow................................1-106
Ink Tube Replacement .................... 1-109
Information .............................1-109
Outline Diagram.........................1-110
Cover That Needs to Be Removed ........1-111
Workow................................1-112
1
REPLACEMENT

1-3 SG2-640/540/300
1
REPLACEMENT
Important Points
Turn off the sub power switch and main power switch, and unplug the power cord of the printer before
performing parts replacement. Performing the parts replacement while the power is on may result in injury due
to the unexpected operation of the printer.
Static electricity can harm some electronic devices. To prevent static damage, discharge static electricity from
your body before you touch any of the electronic parts. You can do so by touching an unpainted metal surface
on the chassis.
We also recommend that you take the following steps to prevent damage from electrostatic discharge (ESD):
zWhen unpacking a static-sensitive device from its shipping carton, do not remove the device from the
antistatic packing material until you are ready to install the part to the printer. Just before removing the
antistatic packaging, be sure to discharge static electricity from your body.
zWhen transporting a static-sensitive part, rst place it in an antistatic container or package.
zHandle all static-sensitive parts in a static-safe area. If possible, use antistatic oor pads and workbench pads.

1-4 SG2-640/540/300
1
REPLACEMENT
Information
Necessary tools
General tools
No. 2 Phillips screwdriver
Gloves (anti-slip)
Waste cloth
Special tools
ST-056 TORQUE DRIVER N6
1000015274 BIT, PHILLIPS NO.2 L200MM
Typical work time
Contents of work Time
Print head replacement (1 piece) 30 min.
Clearing the print head information 1 min.
Print head alignment 25 min.
Print Head Replacement

1-5 SG2-640/540/300
1
REPLACEMENT
Print Head Replacement
Outline Diagram
1
3
21. Print head
2. Print carriage board
3. Panel board

1-6 SG2-640/540/300
1
REPLACEMENT
Print Head Replacement
Cover That Needs to Be Removed
Panel
Carriage cover
CAUTION
Disconnect the cable from the panel board.
NOTE
• The screws are on the right and left side of the carriage cover.

1-7 SG2-640/540/300
1
REPLACEMENT
Print Head Replacement
• When you attach the carriage cover, place the left side of the cover inside the metal plate.
Workow
1. Disconnect all the ribbon cables from the print carriage board.
CAUTION
Open the cover in the direction of the arrow marked "1". Then, disconnect the ribbon cable from the print carriage board.
1
2

1-8 SG2-640/540/300
1
REPLACEMENT
Print Head Replacement
2. Remove the plate that xes the ribbon cables.
3. Place waste cloth under the tube joints so that ink does not spatter around the print head.
4. Remove the print head that you are going to replace from the L-shaped tubes.
CAUTION
Remove the ink tubes slowly to prevent ink from dripping or spattering. Even after the ink tubes are removed from the
L-shaped tubes, ink will not leak from the L-shaped tubes because the choke valves prevent it.
NOTE
Wipe o any ink from the ribbon cables and print heads with waste cloth.

1-9 SG2-640/540/300
1
REPLACEMENT
Print Head Replacement
5. Refer to the following table, remove the tube that corresponds to the print head that you are going to replace.
1
2
Print head
to be replaced
Tube removing
from pump
H1
H2
②
①
6. Connect all the ribbon cables of the print heads to the print carriage board.
CAUTION
Be sure to connect each ribbon cable to the correct connector. The cable with head rank is the upper side.
7. Put the panel back at the original position. You do not need to tighten the screws.
CAUTION
Connect the cable to the panel board.
8. Turn on the power switch. Then connect Peck2 to the machine, and enter the service mode.
CAUTION
The machine may perform automatic cleaning if you do not turn on the sub power for a while and the certain time interval
has passed. To avoid automatic cleaning, be sure to put the machine into service mode within 30 seconds after the main
power is switched on.
9. Go to [SERVICE MENU] > [SUB MENU] > [EMPTY DAMPER] and select the head group being replaced. Then, perform
[EMPTY DAMPER]. Required time for [EMPTY DAMPER]: Approx. 3 min.
CAUTION
Be sure to perform [EMPTY DAMPER]. Otherwise, ink may leak from the dampers while you are removing the print head.
SERVICE MENU
EMPTY DAMPER
10. Remove the panel.
CAUTION
Before removing the panel, make sure to disconnect the ribbon cable from the panel board.

1-10 SG2-640/540/300
1
REPLACEMENT
Print Head Replacement
11. Disconnect the ribbon cables which are connected to the print head you are going to replace from the print carriage
board.
CAUTION
Open the cover in the direction of the arrow marked "1". Then, disconnect the ribbon cable from the print carriage board.
1
2
12. Remove the print head.

1-11 SG2-640/540/300
1
REPLACEMENT
Print Head Replacement
13. Detach the ller guard from the print head, and attach it to the new print head.
NOTE
Pinch the upper part of the ller guard and detach it.
CAUTION
Be careful not to touch the ller.
14. Bend the ribbon cable at the position shown in the gure.
35 mm 35 mm

1-12 SG2-640/540/300
1
REPLACEMENT
Print Head Replacement
15. Attach the new print head to the head base.
CAUTION
Be careful not to touch the ller.
15-1. Hook the spring, which is on the left front side of the print head, to the head base.

1-13 SG2-640/540/300
1
REPLACEMENT
Print Head Replacement
15-2. Then, press the spring against the head base until the spring bends, and then push the rear side of the print head into
the head base.
NOTE
Make sure that the print head is attached to the base rmly.
CAUTION
• If the print head is not attached rmly, it may crack when you secure it with screws.
• Make sure that the aluminum tape you attached to the print head is in contact with the gasket. (static electricity
countermeasures)
GasketGasket
Alminum tape
Alminum tape

1-14 SG2-640/540/300
1
REPLACEMENT
Print Head Replacement
• Make sure that the print head is level to the head base.
16. Tighten two screws with a torque screwdriver in the order shown below to secure the print head (torque value: 0.2 N・m/20
cN・m).
2
1
17. Attach the tubes came with the print head to the L-shaped tubes.
CAUTION
• Be sure to wear gloves (anti-slip).
• Hold the tube about 10 mm from the end and insert it straight so that it does not bend.