Sony UP-D898DC User manual

DIGITAL GRAPHIC PRINTER
UP-D898DC
SERVICE MANUAL
1st Edition

UP-D898DC
!警告
このマニュアルは，サービス専用です。
お客様が，このマニュアルに記載された設置や保守，点検，修理などを行うと感電や火災，
人身事故につながることがあります。
危険をさけるため，サービストレーニングを受けた技術者のみご使用ください。
!WARNING
This manual is intended for qualified service personnel only.
To reduce the risk of electric shock, fire or injury, do not perform any servicing other than that
contained in the operating instructions unless you are qualified to do so. Refer all servicing to
qualified service personnel.
!WARNUNG
Die Anleitung ist nur für qualifiziertes Fachpersonal bestimmt.
Alle Wartungsarbeiten dürfen nur von qualifiziertem Fachpersonal ausgeführt werden. Um die
Gefahr eines elektrischen Schlages, Feuergefahr und Verletzungen zu vermeiden, sind bei
Wartungsarbeiten strikt die Angaben in der Anleitung zu befolgen. Andere als die angegeben
Wartungsarbeiten dürfen nur von Personen ausgeführt werden, die eine spezielle Befähigung
dazu besitzen.
!AVERTISSEMENT
Ce manual est destiné uniquement aux personnes compétentes en charge de l’entretien. Afin
de réduire les risques de décharge électrique, d’incendie ou de blessure n’effectuer que les
réparations indiquées dans le mode d’emploi à moins d’être qualifié pour en effectuer d’autres.
Pour toute réparation faire appel à une personne compétente uniquement.

1 (E)
UP-D898DC
Table of Contents
Manual Structure
Purpose of this manual............................................................ 3 (E)
Related manuals...................................................................... 3 (E)
Trademarks.............................................................................. 3 (E)
1. Service Overview
1-1. Service Flow Chart....................................................1-1 (E)
1-1-1. Flow Chart before Service ............................... 1-1 (E)
1-1-2. Flow Chart after Service..................................1-3 (E)
1-2. Precaution for Transporting.......................................1-4 (E)
1-3. Board Location and Main Parts Location .................1-5 (E)
1-3-1. Board Location ................................................1-5 (E)
1-3-2. Main Parts Location.........................................1-5 (E)
1-3-3. Sensor Location ...............................................1-6 (E)
1-4. Tightening Torque ..................................................... 1-6 (E)
1-5. Removing/Installing the Cabinet............................... 1-7 (E)
1-5-1. Rear Cover (DC)..............................................1-7 (E)
1-5-2. Top Cover (DC) ...............................................1-8 (E)
1-5-3. Front Panel Block (DC) Assembly ..................1-9 (E)
1-6. General Information of Utility Software................. 1-11 (E)
1-6-1. Required Equipment/Tools ............................ 1-11 (E)
1-6-2. Preparation..................................................... 1-11 (E)
1-6-3. Function Description......................................1-12 (E)
1-7. Firmware Version Upgrade ..................................... 1-21 (E)
1-8. Service Mode...........................................................1-22 (E)
1-8-1. Startup Procedure........................................... 1-22 (E)
1-8-2. Service Mode Menu.......................................1-22 (E)
1-9. Menu Lock Function ...............................................1-25 (E)
1-10. Speed Lock Function...............................................1-26 (E)
1-11. Cleaning ..................................................................1-26 (E)
1-11-1. Cleaning the Cabinet...................................... 1-26 (E)
1-11-2. Cleaning the Thermal Head ........................... 1-26 (E)
1-11-3. Cleaning the Platen Roller .............................1-27 (E)
1-12. Print Size ................................................................. 1-28 (E)
1-12-1. Rough Standard of Print Size.........................1-28 (E)
1-12-2. Interval Between Print Screens......................1-28 (E)
1-12-3. Blank in Horizontal Direction........................1-28 (E)
1-13. Lead-free Solder......................................................1-29 (E)
2. Troubleshooting
2-1. Error Log Acquisition Procedure ..............................2-1 (E)
2-1-1. Error Code Table..............................................2-1 (E)
2-2. Trouble Flow Chart ...................................................2-3 (E)
2-2-1. Power does not turn on even though the
ON/STANDBY switch is turned on.................2-3 (E)
2-2-2. Buttons and LEDs on the front panel cannot be
controlled normally..........................................2-4 (E)
2-2-3. Printing cannot be performed normally from
PC or no image is output .................................. 2-5 (E)
2-2-4. Print image is distorted in the paper feed direction
(irregular feeding)............................................2-7 (E)
2-2-5. Print density is too high or too low..................2-8 (E)
2-2-6. Feed operation failure ...................................... 2-9 (E)
2-2-7. Thermal head UP/DOWN operation failure...2-10 (E)
2-2-8. Door open/close operation failure..................2-12 (E)
2-2-9. Printing paper presence/
absence sensor failure .................................... 2-13 (E)
3. Replacement of Board and Main Parts
3-1. Guide of Removal .....................................................3-1 (E)
3-2. MD General Assembly (DC).....................................3-2 (E)
3-3. SE-1142 Board ..........................................................3-3 (E)
3-4. SE-1143 Board ..........................................................3-4 (E)
3-5. KY-763 Board ...........................................................3-5 (E)
3-6. DC-182 Board ...........................................................3-7 (E)
3-6-1. Replacement Procedure of DC-182 Board ......3-7 (E)
3-6-2. Total Power on Time Reset..............................3-9 (E)
3-7. SW-1703 Board.......................................................3-10 (E)
3-8. MA-201 Board ........................................................ 3-11 (E)
3-8-1. Replacement Flow Chart ............................... 3-11 (E)
3-8-2. Saving of Setting Value..................................3-12 (E)
3-8-3. Sample (Step) Printing...................................3-13 (E)
3-8-4. Replacement Procedures of MA-201 Board ...3-14 (E)
3-8-5. Setting and Check of Setting Value ............... 3-15 (E)
3-8-6. Density Adjustment (Thermal Head Voltage
Adjustment) and Set Serial Number Setting ...3-16 (E)
3-9. Thermal Head..........................................................3-18 (E)
3-9-1. Replacement Flow Chart ...............................3-19 (E)
3-9-2. Sample (Gray) Printing..................................3-20 (E)
3-9-3. Replacement of Thermal Head ......................3-20 (E)

2 (E) UP-D898DC
3-9-4. Density Adjustment (Thermal Head Voltage
Adjustment) ...................................................3-23 (E)
3-9-5. Input of Thermal Head Information and
Reset of Total Print Count..............................3-24 (E)
3-10. Stepping Motor/DC Motor Assembly .....................3-25 (E)
3-11. Cam Assembly.........................................................3-28 (E)
3-12. Platen Roller............................................................3-30 (E)
3-13. Timing Belt.............................................................. 3-32 (E)
3-14. Pinch Arm Block Assembly ....................................3-34 (E)
3-15. Check (Self-diagnosis)............................................3-35 (E)
4. Circuit Description
4-1. Outline.......................................................................4-1 (E)
4-2. MA-201 Board ..........................................................4-1 (E)
4-3. DC-182 Board ...........................................................4-1 (E)
4-4. KY-763 Board ...........................................................4-1 (E)
4-5. SW-1703 Board.........................................................4-2 (E)
4-6. SE-1142 Board ..........................................................4-2 (E)
4-7. SE-1143 Board ..........................................................4-2 (E)
4-8. SU-167 Board............................................................ 4-2 (E)
5. Spare Parts
5-1. Notes on Repair Parts...................................................... 5-1
5-2. Exploded Views............................................................... 5-2
Cover and Chassis Block................................................. 5-2
Front Panel Block............................................................5-4
Mecha Deck Block 1....................................................... 5-6
Mecha Deck Block 2....................................................... 5-8
Mecha Deck Block 3..................................................... 5-10
5-3. Packing Materials & Supplied Accessories...................5-12
6. Diagrams
Overall............................................................................. 6-1
Frame Wiring................................................................... 6-2
Revision History

3 (E)
UP-D898DC
Manual Structure
Purpose of this manual
This manual is the Service Manual of the Digital Graphic Printer UP-D898DC.
This manual describes the information items that premise the service based on the
board replacement assuming use of service engineers.
Therefore, the schematic diagram, board layout and electrical parts list are not
contained.
Related manuals
In addition to this Service Manual the following manual is provided.
.Instructions for Use CD-ROM (Supplied with this unit)
This manual contains information required to operate and use the unit.
Trademarks
Trademarks and registered trademarks used in this manual are as follows.
.Windows and Windows Vista are the registered trademarks of Microsoft Corpora-
tion in the United States and Other countries.
Other system names, product names, and company names appearing in this manual
are trademarks or registered trademarks of their respective holders.

1-1 (E)
UP-D898DC
Section 1
Service Overview
1-1. Service Flow Chart
1-1-1. Flow Chart before Service
Before providing services, check symptoms according to the flow chart below.
Start
Check the information from a user.
 Serial number of this unit
 Information of connection equipment (Modality name, application, etc.)
 Occurrence date and its status
 Frequency of occurrence (Did defects occur for the first time, irregularly
several times, or in a specific case?)
 Which operation did you perform after occurrence of defects?
$
The items above are used as an information source for analyzing defects.
Therefore, collect detailed information as far as possible.
$
Communication with this unit cannot be performed using utility software
when menu “DIGITAL” - “DRIVER” is set to “DRV: 897” .
In this case, start this unit in a service mode (refer to Section 1-8) and
use utility software.
Stripes or flaws
Is the cause of defects streaks
(white or black) or scratches in
a print direction or a failure or
trouble?
Failure or trouble
Check the symptoms, clean the
thermal head or replace it.
&

Cleaning: Refer to Section 1-11-2.
 Replacement: Refer to Section 3-9.
No
Does this unit normally start with
the power turned on?
Refer to “2-2-1. Power does not
turn on even though the
ON/STANDBY switch is turned on” .
Yes
No
Is USB connection recognized?
Refer to “2-2-3. Printing cannot be
performed normally from PC or no
image is output” .
Yes
Acquire the information of this unit
using utility software. (Refer to step
3of “1. Information tab” in
Section 1-6-3.)
Yes
Could the defects be determined
from user information and error
history? (Refer to steps 1and
2of “1. Information tab” in
Section 1-6-3.)
Check the determined point or
replace the relevant parts.
No
Go to next page.

1-2 (E) UP-D898DC
Yes
Can a defective point be
determined by self-diagnosis?
(Refer to Section 3-15.)
Check the determined point or
replace the relevant parts.
(Refer to Section 2-1.)
No
From the previous page
Yes
Can a 17-step test pattern be
normally printed?
(Refer to Section 3-8-3.)
Normal
Refer to “2-2-3. Printing cannot be
performed normally from PC or no
image is output” .
No
Yes
Cannot paper be printed at all or
is paper printed in white?
No
Refer to “2-2-4. Print image is
distorted in the paper feed direction
(irregular feeding)” .
Yes
Is the image in a test pattern
disturbed?
No
Check the contents of a trouble.

1-3 (E)
UP-D898DC
1-1-2. Flow Chart after Service
After terminating services, check symptoms according to the flow chart below.
Start
Yes
No
Perform self-diagnosis and check
that no problem exists in
assembling. (Refer to Section 3-15.)
Yes
Is upgrading of firmware required? Upgrade the firmware.
(Refer to Section 1-7.)
No
Install a UPP-110HG.
Print a 17-step test pattern.
(Refer to Section 3-8-3.)
Check the external view and
clean it. (Refer to Section 1-11-1.)
Clean the thermal head and platen
roller. (Refer to Section 1-11.)
Was this unit disassembled?
Return this unit to a user.
&

Thermal head: Refer to Section 1-11-2.
Platen roller: Refer to Section 1-11-3.
$
Check that the paper is removed.

1-4 (E) UP-D898DC
1-2. Precaution for Transporting
Perform the operation below so as to prevent the damage due to vibration and shock when transporting
this unit.
.Remove the printer paper and transport with closing the door.
.When you lift up the printer, do not hold the opened door. Otherwise, it may cause a failure due to an
excessive force applied to the door mechanism. Also, your hand might accidentally get caught between
the door and main unit resulting in injury.
.Use the packaging materials supplied for this unit.
t
Keep the packing materials removed during the delivery and installation. Do not discard them.

1-5 (E)
UP-D898DC
1-3. Board Location and Main Parts Location
1-3-1. Board Location
1-3-2. Main Parts Location
KY-763 board
SU-167 board
SW-1703 board
DC-182 board
SE-1143 board SE-1142 board
MA-201 board
Thermal head
DC motor
Stepping motor

1-6 (E) UP-D898DC
1-3-3. Sensor Location
1-4. Tightening Torque
Tighten the following screws to the tightening torques as described below.
n
The screw (BVTT2.6 x5) of this unit has two types of the tighten torque. Be careful not to confuse.
.B3 x6: 0.80 ?0.05 N.m
.BVTT2.6 x4: 0.80 ?0.05 N.m
.BVTT2.6 x5 (for excluding paper holder): 0.80 ?0.05 N.m
.BVTT2.6 x5 (for paper holder): 0.50 ?0.05 N.m
.P2.6 x5: 0.50 ?0.05 N.m
.P3 x4: 0.50 ?0.05 N.m
.PS3 x6: 0.80 ?0.05 N.m
.PSW3 x8: 0.80 ?0.05 N.m
.Newtru-star screw M2: 0.10 ?0.02 N.m
.Tapping screw M1.7: 0.13 ?0.02 N.m
When using the torque driver with the unit representation of cN.m, calculate the value as follows.
Example: 0.8 N.m = 80 cN.m
Paper front sensor
(Light receiving side)
Paper tray sensor
(Light receiving side)
Head position sensor 1
Paper front sensor
(Light emitting side) Paper tray sensor
Door sensor
Head position sensor 0

1-7 (E)
UP-D898DC
1-5. Removing/Installing the Cabinet
1-5-1. Rear Cover (DC)
1. Remove the two screws, then remove the rear cover (DC) in the direction of the arrow.
2. To install, reverse the removal procedure.
t
When attaching the rear cover (DC), be careful not to catch the flexible flat cable.
B3 )6
Flexible flat cable
Rear cover (DC)

1-8 (E) UP-D898DC
1-5-2. Top Cover (DC)
1. Remove the rear cover (DC). (Refer to Section 1-5-1.)
2. Remove the five screws, then remove the top cover (DC) in the direction of the arrow.
3. To install, reverse the removal procedure.
B3 )6
B3 )6
B3 )6
Top cover (DC)

1-9 (E)
UP-D898DC
1-5-3. Front Panel Block (DC) Assembly
t
The following part cannot be reused. Prepare the new part.
.Print media label
1. Remove the rear cover (DC). (Refer to Section 1-5-1.)
2. Remove the top cover (DC). (Refer to Section 1-5-2.)
3. Release the lock arm on the mechanical deck portion (bottom) in the direction of the arrow A, then
open the door block assembly in the direction of the arrow B.
4. Remove the two hooks in the right and left directions of the arrows C, then remove the door panel in
the direction of the arrow D.
n
When replacing the door panel, peel off the UDI label and print media label.
The UDI label is reused. Therefore, peel it off slowly.
Hook
Hook
A
C
C
D
Door panel
Door panel
Door block assembly
Lock arm
UDI label
Print media label
B

1-10 (E) UP-D898DC
5. Disconnect the flexible flat cable from the connector (CN1002) on the MA-201 board.
6. Close the door block assembly.
7. Remove the FFC guard (DC-KY) from the portion A of the MD top chassis.
8. Remove the three screws and four hooks, then remove the front panel block (DC) assembly.
9. Remove the FFC guard (DC-KY) from the flexible flat cable.
10. To install, reverse the removal procedure.
CN1002
Hooks
Hook
Hook
BVTT
2.6
) 4
BVTT
2.6
) 4
BVTT
2.6 ) 4
Flexible flat cable
Flexible flat cable
Portion A
FFC guard (DC-KY)
FFC guard (DC-KY)
When attaching the flexible flat cable, route it
through the FFC guard (DC-KY).
Front panel block (DC) assembly
MD top chassis
MA-201 board

1-11 (E)
UP-D898DC
1-6. General Information of Utility Software
1-6-1. Required Equipment/Tools
.Personal computer (PC) having the USB interface
.OS: Windows Vista/7/8
.Utility software: Utility Tool for UP-D898DC.exe
t
For obtaining the utility software, contact your local Sony Sales Office/Service Center.
.USB cable
n
Use the USB 2.0 certified USB cable having a length of 2 m or less. Use of cables other than specified
may cause unstable operation of this unit.
.Thermal Print Media: UPP-110HG (Part number: 1-772-473-13)
1-6-2. Preparation
1. Connect this unit and PC using the USB cable.
t
The installation of printer driver may be requested when this unit and PC are connected. However, it
is not required to install the printer driver when using this utility software.
2. Turn on the power of PC.
3. Press the power switch of this unit to turn on the power.
4. Start the utility software (Utility Tool for UP-D898DC.exe).

1-12 (E) UP-D898DC
1-6-3. Function Description
1. Information tab
1Printer Information
When you click the [OPEN] button, the information of this unit is obtained from EEPROM (IC404/
MA-201 board) of this unit and displayed.
Information tab
1
2
3
4

1-13 (E)
UP-D898DC
.Firmware Ver.: Version of firmware
.Set Serial No.: Serial number of this unit
.Head Serial No.: Serial number of thermal head
.Head Resistance: Resistance value (Z) of thermal head
.Head Voltage: Voltage setting value (D/A value) of thermal head
.Total Prints:
Set: Total print count of this unit
S: Total print count of paper (UPP-110S)
HD: Total print count of paper (UPP-110HD)
HG: Total print count of paper (UPT-110HG)
Video: Not used
Digital: Total print count of digital image transmitted from PC
Head: Total print count of thermal head
After Cleaning: Total print count after cleaning of thermal head
.Total Store Images: Not used
.Power On Time
Set: Total power on time of this unit (h)
Power Unit: Total power of time of power unit (h)
.Max Temperature
Head: Maximum temperature of thermal head (dC)
Room: Maximum room temperature (dC)
.Power ON Count: Number of power ON times
.Cleaning Count: Number of thermal head cleaning times
.Paper Tray Sensor: Information of paper tray sensor (Luminance side: D201/SE-1142 board, light
receiving side: Q301/SE-1143 board)
DA Value: Amount of luminescence (D/A value)
High Level: Light receiving portion High level
Low Level: Light receiving portion Low level
Threshold: Light receiving portion threshold level
.Paper Front Sensor: Information of paper tray sensor (Luminance side: D301/SE-1143 board, light
receiving side: Q551/KY-763 board)
DA Value: Amount of luminescence (D/A value)
High Level: Light receiving portion High level
Low Level: Light receiving portion Low level
Threshold: Light receiving portion threshold level
.[OK] button: Closes the Printer Information screen.

1-14 (E) UP-D898DC
2Error Log
When you click the [OPEN] button, the 20 errors that have occurred in the past are displayed. When the
number of error exceeds 20, the error is overwritten by the latest error beginning with the chronologically
oldest error (No. 20). However, when the same errors are overlapped (the errors of the same error code
occurred continuously), only the Count number of the latest error (No. 1) is overwritten (increased) and
the error No. 20 is not deleted.
t
For the error code ID, refer to Section 2-1.
.ID: Error code ID information
.Count: Number of overlapping errors
.Clock (F): Date and time when the first error is detected (In this unit, always displayed as 2000/0/0
00:00:00.)
.Clock (L): Date and time when the last error is detected (In this unit, always displayed as 2000/0/0
00:00:00.)
.T.Prints (F): Total print count of this unit when the first error is detected
.T.Prints (L): Total print count of this unit when the last error is detected (This is displayed only when
the errors are overlapped.)
.H.Temp (F): Thermal head temperature (dC) when the first error is detected
.H.Temp (L): Thermal head temperature (dC) when the last error is detected (This is displayed only
when the errors are overlapped.)
.R.Temp (F): Room temperature (dC) when the first error is detected
.R.Temp (L): Room temperature (dC) when the last error is detected (This is displayed only when the
errors are overlapped.)
.[OK] button: Closes the Error Log screen.
3Save Log Data
When you click the [Save] button, the menu setting and operation log information of this unit as well as
the information displayed in Printer Information and Error Log are saved as CSV format file on PC.
The saved file can be displayed by using the spreadsheet software such as Excel.
The information in this file is important when the person in charge of design performs a failure analysis.
4GetDeviceID
Not used