(2) Remove the customer's Waste Ink Cartridge and replace to a new one. (3) Make sure GT-541 is not in the middle of any operation.

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1 9. Transporting Preparation before transportation Make sure the following SA service kit parts are all available. Part name Qty. Cleaning Cartridge 2 IH Head Carton 4 IH Head Case 8 Cap Tube 4 Tube Joint 1 8 Tube Joint 2 8 Nozzle Protect Film 4 Waste Ink Cartridge 1 Decompress Package 4 Procedure (1) Seal the hole on the Filter Cartridge that the customer possesses with adhesive tape etc. Hole (2) Remove the customer's Waste Ink Cartridge and replace to a new one. (3) Make sure is not in the middle of any operation. 274

2 9. Transporting (4) On the Control Panel, press the Platen Button to eject the Platen if it is not. Up Button Platen Button Stop Button OK Button Down Button (5) Press the OK Button to display the Menu Display. (6) Press the Up/Down Button until Version appears. (7) While holding down both the Up and Down Buttons, press the Stop Button. (8) Press the Up/Down Button to select Tube Cleaning, and then press the OK Button. 275

3 9. Transporting (9) Remove the Ink Cartridge whose ink you will drain, and then insert the Filter Cartridge, whose hole you sealed in step (1), into the same Ink Cartridge Slot. * The following procedure shows the example of removing the Black Print Head. The procedure is the same for other colors. Black Ink Cartridge Filter Cartridge (10) Press the Up/Down Button to select Black, and then press the OK Button. * The following message appears. Wait until the cleaning finishes. (11) When the Tube cleaning is finished, replace the Filter Cartridge with the Cleaning Cartridge. Cleaning Cartridge 276

4 9. Transporting (12) The following message is displayed after the performance of step (10) is finished. Press the OK Button to perform the Tube cleaning. (13) When the Tube cleaning is finished, replace the Cleaning Cartridge with the Filter Cartridge again, and then perform the Tube cleaning. (14) When the Tube cleaning is finished, leave the Filter Cartridge in the Black Ink Cartridge Slot, and then perform the Tube cleaning for other colors by repeating step (9) to (13). * One Cleaning Cartridge can be used for two colors. (15) When the Tube cleaning is finished for all colors, check that the Filter Cartridges are inserted in all the Ink Cartridge Slots. (16) Turn off, and then open the Front Cover. (17) Remove one Filter Cartridge from the Ink Cartridge Slot, then remove the adhesive tape etc. that seals the hole, and then insert the Filter Cartridge into the Ink Cartridge Slot again. * Make this operation for all the Filter Cartridges. 277

5 9. Transporting (18) Replace the current Waste Ink Cartridge and close the opening with a white seal and dispose legally. Put back the Waste Ink Cartridge that had been used by the customer. <Note> To keep the sensors safe and to avoid from spoiling the inside by the waste ink, remove the Waste Cartridge Tray and put the protection material that is originally inserted (left photo in the next page) or some clean cloth (right photo) into the Waste Ink Cartridge mechanism. (19) Remove the four Print Heads. (See Replacing the Print Heads for details.) (20) Fit the Tube Joint 1 and 2 in the end of each of the disconnected Tubes. Tube Tube Joint 1 Tube Joint 2 (21) Attach the Nozzle Protect Film to each of the removed Print Heads. Cover the Nozzle surface of the Print Head with the Nozzle Protect Film. Put either end of the Nozzle Protect Film between the Head Cover and the PCB Cover. Fix the other end of the Nozzle Protect Film onto the Damper Case Support with adhesive tape etc. PCB Cover Damper Case Support Head Cover Nozzle Protect Film 278

6 9. Transporting (22) Attach the Cap Tube to the Print Head, then attach the Tube Joint 1 to the Cap Tube, and then attach the Tube Joint 2 to the Tube Joint 1. Tube Joint 2 Tube Joint 1 Cap Tube (23) Put the Print Head in the IH Head Case, then fix the Case with a rubber band, adhesive tape, etc. IH Head Case (24) Put the Print Head with the IH Head Case in the Decompress Package, and then put it in the IH Head Carton. Decompress Package IH Head Carton (25) Pack the other Print Heads by repeating step (21) to (24). 279

7 9. Transporting (26) Check if the Carriage is over the Maintenance Unit and the Print head Caps are raised (and the detent that moves up and down with the Print Head Caps is raised and the Carriage is locked). If not, move the Carriage to a position over the Print Head Caps by hand, and raise the detent by rotating the Gear. Detent Carriage Gear (27) Close and lock the Front Cover. (28) The work for the service engineer is finished. Inform the customer of the following: * The customer (or the carrier) is responsible for packing and transporting. * You do not have to fix to something when transporting it. However, be careful not to apply force when packing it because the Covers are deformable. After transported Follow the instructions of 2. Setting Up. <Note> Not all instructions in 2. Setting Up will apply to this situation, since the packing configuration differs from the factory default packing. 280

8 2. Setting Up 2-4. Setting Up When the placement of has finished, install parts on by following the procedures below Checking the damage on the Maintenance Unit Before installing the Print Heads, you need to check the shipping damage on the Maintenance Unit. Checking that the Print Head Cap position is correct in the lengthwise direction by using the MNT Check Gauge. (1) Open the Front Cover. (2) Rotate the gear of the CL Drive Cam with your finger to move the Print Head Caps to the lower position. CL Drive Cam Maintenance Unit (3) Move the W Rack Gear Unit to the rearmost position with your finger. W Rack Gear Unit 22

9 2. Setting Up (4) Rotate the gear of the CL Drive Cam with your finger to raise the Print Head Caps. CL Drive Cam (5) Set the MNT Check Gauge as shown below. MNT Check Gauge 23

10 2. Setting Up (6) Attach the MNT Check Gauge s reference side to the upper and lower Carriage Guide Shafts, and then confirm that the Rip of the Print Head Cap Rubber is within the Gauge s concave part that shows the allowable range for the lengthwise position (allowable range: +/-0.65 mm). Concave part Carriage Guide Shaft Rip of the Print Head Cap Rubber Concave part 6 7 Rip of the Print Head Cap Rubber (7) If the Rip is not within the concave part, make the adjustment by following Replacing the Maintenance Unit again. 24

11 2. Setting Up Checking that the Print Head Cap position is correct in the lateral direction (the Print Carriage s scanning direction) by using the MNT Check Gauge. (8) Put the MNT Check Gauge on both the left and right W Guide Shafts, and then set the Gauge at an angle so that the left reference side of the Gauge attaches the Stopper of the Carriage Guide Shaft. Stopper Carriage Guide Shaft W Guide Shaft (9) Confirm that the Rips of the Print Head Cap Rubbers are within the Gauge s concave parts that show the allowable range in the lateral direction (allowable range: +/-1 mm). 1 1 Concave part 6 12 Rip of the Print Head Cap Rubber (10) If the Rips are not within the concave parts, replace the Maintenance Unit (see Replacing the Maintenance Unit ). (11) After completing the above procedure, remove the MNT Check Gauge. (12) Close the Front Cover, and then turn on. If error is occurred during the initialization, check if the CL-Guide R/L behind the Print Head Cap touches the Carriage. If it is, the Maintenance Unit is damaged and needs to be replaced (see Replacing the Maintenance Unit). (13) After Stand By is displayed, turn off and then open the Front Cover. 25

12 2. Setting Up Installing the Print Heads (1) Take out the Print Head from the IH Head Carton and wear the included gloves. IH Head Carton Print Head Glove <Note> For Europe, the Flat Cables must be passed through the Core. Before installing Print Heads, use the accessory hexagonal wrench (1) to loosen the two socket bolts (2), and then remove the core bracket assembly (3). Install the Print Heads following the procedures below. When you reach "step (7)", 3 pages after, go to the instruction "How to pass Flat Cables through the core (for Europe)" at the end of this section and return to "step (8)" to connect the tubes. 26

13 2. Setting Up (2) Rotate the Gear to lower the Print Head Caps. (The Gear can be rotated by pressing it with your finger.) <Note> The Print Heads may be damaged if they are installed with the Print Head Caps raised. Carriage Gear (3) Install the Print Head onto the Carriage by holding the Print Head knob, and holding the Flat Cable with the other hand. Make sure the V-shaped groove of the Print Head hits the pin in the back of Carriage. <Note> The gloves are removed for a better view. V-shaped groove Pin Print Head knob Flat Cable 27

14 2. Setting Up (4) Press down the knob securely. (5) Turn the Lever to the direction of the arrow to lock the Print Head. Leve (6) Remove the Nozzle Protect Film by pulling it up. Nozzle Protect Film 28

15 2. Setting Up (7) Take off the gloves, insert the Flat Cable into the connector, and then turn down the connector tab to lock the Cable. <Note> (1) Make sure the Flat Cable is inserted straight against the connector. If not, reconnect it correctly. Sometimes the warning message "Please Wait... Cooling down" is on the Display of the Control Panel because the mis-sense of overheat occurs with the improper insertion of the Flat Cable. (2) The Flat Cable is very fragile. Be careful handling it. Connector Connector tab (8) Wear the gloves again, and then remove the Tube Fitting from the end of Tube. Tube Fitting 29

16 2. Setting Up (9) Insert the Tube into the Print Head, and then rotate the Tube Connector 90 degrees to the direction of the arrow. Tube How to pass Flat Cables through the core (for Europe) 1. Be sure that the two socket bolts (2) are loosened, and the core bracket assembly (3) is removed with the accessory hexagonal wrench (1) as mentioned in <Note> of the former page. Tube Connector 2. Finish installing the print heads as mentioned in " Installing the Print Heads" above. 3. Return the core bracket assembly (3) to its original position. (Leave the two socket bolts (2) loosened.) 4. Twist the B (black) and M (magenta) flat cables (4) 3/4 of a turn to the left as shown in the illustration pass them through the gap in the core (3) so that the side without the lettering is facing upward, and then connect them to the connectors (5). Refer to the previous page "Step (7)" of this manual for details on connecting to the connectors (5). * Slide the core bracket assembly (3) forward while carrying out this step. 30

17 2. Setting Up 5. Twist the C (cyan) and Y (yellow) flat cables (6) 1/4 of a turn to the right as shown in the illustration, pass them through the gap in the core (3) so that the side without the lettering is facing upward, and then connect them to the connectors (7). Refer to the previous page "Step (7)" of this manual for details on connecting to the connectors (5). 6. Check that the slots (a) in the core bracket assembly (3) are fitted into the bottom of the socket bolts (2), and then securely tighten the two socket bolts (2). 7. Finished installation diagram. Return to "step (8)", 2 pages before, to connect the tubes. 31

18 2. Setting Up Installing the Ink Cartridges Insert the four Ink Cartridges (Black, Magenta, Cyan, and Yellow) into the corresponding Ink Cartridge Slots. (1) Take out the Ink Cartridge from the package. (2) Touch the Sensor Plate pasted on the Ink Pack in the Cartridge with a thin tool like a screwdriver to confirm the Sensor Plate is not caught on something. 32

19 2. Setting Up (3) Confirm that the Ink Cartridge lid is closed securely, and the bottom of the Cartridge is neither broken nor warped. Lid Bottom (4) Insert the Ink Cartridge into the Ink Cartridge Slot of the corresponding color. (The picture below shows the insertion of the Black Ink Cartridge.) 33

20 2. Setting Up Mounting the Rear Cover Mount the Rear Cover by following the procedure below. (1) Remove the four screw binds under the Platen-passing hole on the Back Cover. (2) Remove the screw bind and washer on the right of the Platen-passing hole. Rear Cover Back Cover Screw bind and washer Screw bind (3) Put the four L-shaped projections of the Rear Cover in the grooves of the Back Cover, and then slide the Rear Cover approx. 10 mm in the direction of the Ink Cartridge Slots. Groove L-shaped projection (4) Fix the lower side of the Rear Cover with the four screw binds. (5) Fix the right side of the Rear Cover with the screw bind and washer. 34

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