Sony UP-D898MD User manual

DIGITAL GRAPHIC PRINTER
UP-D898MD
HYBRID GRAPHIC PRINTER
UP-X898MD
SERVICE MANUAL
1st Edition

UP-D898MD/X898MD
!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.

UP-D898MD/X898MD 1 (P)
CAUTION
Danger of explosion if battery is incorrectly replaced.
Replace only with the same or equivalent type rec-
ommended by the manufacturer.
When you dispose of the battery, you must obey the
law in the relative area or country.
ATTENTION
Il y a danger d’explosion s’il y a remplacement incor-
rect de la batterie. Remplacer uniquement avec
une batterie du même type ou d’un type équivalent
recommandé par le constructeur.
Lorsque vous mettez la batterie au rebut, vous devez
respecter la législation en vigueur dans le pays ou la
région où vous vous trouvez.
VORSICHT
Explosionsgefahr bei Verwendung falscher Batterien.
Batterien nur durch den vom Hersteller empfohlenen
oder einen gleichwertigen Typ ersetzen.
Wenn Sie die Batterie entsorgen, müssen Sie die
Gesetze der jeweiligen Region und des jeweiligen
Landes befolgen.
注意
指定以外の電池に交換すると，破裂する危険があります。
必ず指定の電池に交換してください。
使用済みの電池は，国または地域の法令に従って
処理してください。
FÖRSIKTIGHET!
Fara för explosion vid felaktigt placerat batteri.
Byt endast mot samma eller likvärdig typ av batteri,
enligt tillverkarens rekommendationer.
När du kasserar batteriet ska du följa rådande lagar
för regionen eller landet.
PAS PÅ
Fare for eksplosion, hvis batteriet ikke udskiftes
korrekt.
Udskift kun med et batteri af samme eller tilsvarende
type, som er anbefalet af fabrikanten.
Når du bortskaffer batteriet, skal du følge
lovgivningen i det pågældende område eller land.
HUOMIO
Räjähdysvaara, jos akku vaihdetaan virheellisesti.
Vaihda vain samanlaiseen tai vastaavantyyppiseen,
valmistajan suosittelemaan akkuun.
Noudata akun hävittämisessä oman maasi tai
alueesi lakeja.
FORSIKTIG
Eksplosjonsfare hvis feil type batteri settes i.
Bytt ut kun med samme type eller tilsvarende
anbefalt av produsenten.
Kasser batteriet i henhold til gjeldende avfallsregler.
注意
注意
如果更换的电池不正确，就会有爆炸的危险。
只更换同一类型或制造商推荐的电池型号。
处理电池时，必须遵守相关地区或国家的法律。
[For UP-X898MD]

1 (E)
UP-D898MD/X898MD
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. Top Cover ........................................................1-7 (E)
1-5-2. Front Panel Block Assembly ...........................1-8 (E)
1-5-3. Rear Panel......................................................1-10 (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 ...............................................1-26 (E)
1-10. Lithium Battery (UP-X898MD).............................. 1-27 (E)
1-11. Cleaning ..................................................................1-28 (E)
1-11-1. Cleaning the Cabinet...................................... 1-28 (E)
1-11-2. Cleaning the thermal head .............................1-28 (E)
1-11-3. Cleaning the Platen Roller .............................1-29 (E)
1-12. Periodic Inspection and Periodic
Replacement Parts...................................................1-30 (E)
1-13. Print Size ................................................................. 1-30 (E)
1-13-1. Rough Standard of Print Size.........................1-30 (E)
1-13-2. Interval Between Print Screens......................1-31 (E)
1-13-3. Blank in Horizontal Direction........................1-31 (E)
1-14. Lead-free Solder......................................................1-31 (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
power switch is turned on ................................2-3 (E)
2-2-2. Keys 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. Printing cannot be performed normally from
video signal
(NTSC/PAL) (UP-X898MD Only)..................2-7 (E)
2-2-5. Print image is distorted in the paper feed
direction (irregular feeding).............................2-8 (E)
2-2-6. Print density is too high or too low..................2-9 (E)
2-2-7. Feed operation failure .................................... 2-10 (E)
2-2-8. Thermal head UP/DOWN operation
failure............................................................. 2-11 (E)
2-2-9. Door open/close operation failure..................2-12 (E)
2-2-10. Printing paper presence/absence sensor
failure.............................................................2-13 (E)
2-2-11. Real time clock does not operate normally
(UP-X898MD only).......................................2-14 (E)
2-2-12. Remote terminal does not operate normally
(UP-X898MD only).......................................2-14 (E)
2-2-13. Image is not written in the USB flash memory
after printing (UP-X898MD only).................2-15 (E)
3. Replacement of Board and Main Parts
3-1. MA-195 Board ..........................................................3-2 (E)
3-1-1. Flow Chart .......................................................3-2 (E)
3-1-2. Saving of Setting Value....................................3-3 (E)
3-1-3. Sample (Step) Printing.....................................3-4 (E)
3-1-4. Replacement Procedures of MA-195 Board....3-5 (E)
3-1-5. Setting and Check of Setting Value ................. 3-7 (E)
3-1-6. Density Adjustment (Thermal Head Voltage
Adjustment) and Set Serial Number Setting....3-8 (E)
3-2. KY-711 Board..........................................................3-10 (E)
3-3. SE-1142 Board ........................................................3-12 (E)
3-4. SE-1143 Board ........................................................3-13 (E)

2 (E) UP-D898MD/X898MD
3-5. Switching Regulator................................................3-14 (E)
3-5-1. Replacement of Switching Regulator ............3-14 (E)
3-5-2. Total Power on Time Reset............................3-15 (E)
3-6. MD General Assembly ............................................3-16 (E)
3-7. Thermal Head..........................................................3-17 (E)
3-7-1. Replacement Flow Chart ...............................3-18 (E)
3-7-2. Sample (Gray) Printing..................................3-19 (E)
3-7-3. Replacement of Thermal Head ......................3-20 (E)
3-7-4. Density Adjustment (Thermal Head Voltage
Adjustment) ...................................................3-23 (E)
3-7-5. Input of Thermal Head Information and
Reset of Total Print Count..............................3-24 (E)
3-8. Stepping Motor/DC Motor Assembly .....................3-25 (E)
3-9. Cam Assembly.........................................................3-29 (E)
3-10. Platen Roller............................................................3-31 (E)
3-11. Timing Belt..............................................................3-33 (E)
3-12. Pinch Arm Block Assembly ....................................3-35 (E)
3-13. Check (Self-diagnosis)............................................3-36 (E)
4. Circuit Description
4-1. Outline.......................................................................4-1 (E)
4-2. MA-195 Board ..........................................................4-1 (E)
4-3. KY-711 Board............................................................4-2 (E)
4-4. SE-1142 Board ..........................................................4-2 (E)
4-5. SE-1143 Board ..........................................................4-2 (E)
4-6. SU-167 Board............................................................ 4-2 (E)
5. Spare Parts
5-1. Notes on Repair Parts...................................................... 5-1
5-2. Exploded Views............................................................... 5-2
5-3. Packing Materials & Supplied Accessories...................5-14
6. Diagrams
Overall............................................................................. 6-1
Frame Wiring................................................................... 6-2

3 (E)
UP-D898MD/X898MD
Manual Structure
Purpose of this manual
This manual is the Service Manual of the Hybrid Graphic Printer UP-X898MD and
Digital Graphic Printer UP-D898MD.
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-D898MD/X898MD
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 3-7.
No
Does this unit normally start with
the power turned on?
Refer to “2-2-1. Power does not
turn on even though the power
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-D898MD/X898MD
Yes
Can a defective point be
determined by self-diagnosis?
(Refer to Section 3-13.)
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 3-1-3.)
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 “2-2-5. 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-D898MD/X898MD
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 3-13.)
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 3-1-3.)
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 paper and USB flash memory are removed.

1-4 (E) UP-D898MD/X898MD
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.
n
Keep the packing materials removed during the delivery and installation. Do not discard them.
UP-D898MD UP-X898MD

1-5 (E)
UP-D898MD/X898MD
1-3. Board Location and Main Parts Location
1-3-1. Board Location
1-3-2. Main Parts Location
KY-711 board
SU-167 board
SE-1143 board SE-1142 board
MA-195 board
Thermal head
DC motor
Stepping motor
Switching regulator

1-6 (E) UP-D898MD/X898MD
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
.P3 x4: 0.50 ?0.05 N.m
.PS3 x4: 0.80 ?0.05 N.m
.PS3 x6: 0.80 ?0.05 N.m
.PS4 x8: 1.40 ?0.15 N.m
.PSW3 x8: 0.80 ?0.05 N.m
.LOCK ACE screw (M2): 0.20 ?0.05 N.m
.Tapping screw M1.7: 0.13 ?0.02 N.m
.N6, TYPE2: 1.20 ?0.10 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
Edge sensor
(Light receiving side)
Tray sensor
(Light receiving side)
Head position sensor (Print)
Edge sensor
(Light emitting side) Tray sensor
(Light emitting side)
Door sensor
Head position sensor
(Home)

1-7 (E)
UP-D898MD/X898MD
1-5. Removing/Installing the Cabinet
1-5-1. Top Cover
1. Remove the five screws, then remove the top cover in the direction of the arrow.
2. To install, reverse the removal procedure.
B3 )6
B3 )6
B3 )6
The illustration indicates UP-X898MD.
Top cover

1-8 (E) UP-D898MD/X898MD
1-5-2. Front Panel Block Assembly
1. Remove the top cover. (Refer to Section 1-5-1.)
2. 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.
3. 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.
4. Disconnect the flexible flat cable from the connector (CN1103) on the MA-195 board.
The illustration indicates UP-X898MD.
Hook
B
A
C
C
D
Door panel
Door block assembly
Lock arm
MA-195 board
Mechanical deck portion
CN1103
Flexible flat cable
Hook

1-9 (E)
UP-D898MD/X898MD
5. Close the door block assembly.
6. Remove the FFC guard (KY) from the portion A of the MD top chassis.
7. Remove the three screws and four hooks, then remove the front panel block assembly.
8. Remove the FFC guard (KY) from the flexible flat cable.
9. To install, reverse the removal procedure.
The illustration indicates UP-X898MD.
Hook
Hooks
Hook
BVTT
2.6 ) 4
BVTT
2.6
) 4
BVTT
2.6
) 4
Flexible flat cable
FFC guard (KY)
Portion A
FFC guard (KY)
When attaching the flexible flat cable, route it
through the FFC guard (KY).
Front panel block assembly
MD top chassis
Door block assembly

1-10 (E) UP-D898MD/X898MD
1-5-3. Rear Panel
1. Remove the top cover. (Refer to Section 1-5-1.)
2. Remove the MA-195 board. (Refer to Section 3-1.)
3. Remove the shield plate (MA) and insulating sheet (MA).
4. Remove the screw (PS4 x8), then remove the washer (W4) and earth terminal.
5. Disconnect the harness from the connector (CN101) on the switching regulator.
6. Remove the two screws (P3 x4), then remove the rear panel.
7. Remove the four hooks, then remove the AC inlet.
8. Remove the nut (N6) and washer (LW6), then remove the equipotential terminal.
9. To install, reverse the removal procedure.
PS4 )8
P3 )4
The illustration indicates UP-X898MD.
Shield plate (MA)
Insulating sheet (MA)
Earth terminal
W4
Switching regulator
CN101
Harness
Rear panel
AC inlet
N6
LW6
Equipotential terminal
Hooks
Hooks

1-11 (E)
UP-D898MD/X898MD
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-DX898MD.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-DX898MD.exe).

1-12 (E) UP-D898MD/X898MD
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 (IC507/
MA-195 board) of this unit and displayed.
Information tab
1
2
3
4