Advisor y Bulletin

Subject Purpose 5330 new carriage drive motor/gearbox assembly replacement procedure. Installation of new carriage drive motor/gearbox assembly, mounting bracket and update of servo controller parameter file. 5330, all serial numbers 4: For information only 45071266 Rev D July 2008

Applies to Priority Number Date

Summary
Upgrade kit part number 45071076 Tools required: Socket set, box wrench set, allen wrench set, electric drill, large C-clamp Square Parameter file for carriage servo controller update Alignment Coupling, part number 45071077 Not part of upgrade kit Loctite 242 (Blue) 0.060 Shim Power Tools FM Rev. 4.1 The current carriage drive motor/gearbox assembly is being discontinued by the manufacturer. All replacement carriage drive motors will require this upgrade kit 45071076. If this upgrade was previously installed, please order the new motor/gearbox assembly 45071049.

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Parts in this kit:

45071076 45063736 45070935 45071049 45071054 45071077 45071266 AA70507 H1406-A H1507-A H1531-A H1994-A H2156-A H2200-A H2369-A P9801-A W1022 45071049 45071055 P3608-A P9853-A AA70507 H2008-A H2026-A P1687-A P7412-A P5173-A P5081-A H1922-A P7325-A H1757-A A50487-A 45071078 A50482-A A50481-A A50480-A A50479-A P7257-A 5330 X-DRIVE UPGRADE KIT DRILL BIT 27/64 MNT, C-CHANNEL, X-DRIVE ASSY, CARRIAGE DRIVE, APEX GB COUPLING, BELLOWS, KEYLESS 16MM FIXTURE, 5330 X-DRIVE ALIGNMENT, APEX GB DOCUMENT, OPTION, 5330 X-DRIVE ASM, PULLEY DRIVE END 5330 K-NUT 1/4-20 SS WASHER 1/4 FLAT SS WASHER 3/8 LOCK SS NUT 3/8-16 LOCK SCREW 1/4-20 X 1 SOC SS WASHER 3/8 ID .125 THK ZNC SCREW 3/8-16 x 1-1/2 HEX HD G8 SCREW SET 1/4-20 X 3/4L KNRL C DRILL BIT #21 ASSY, CARRIAGE DRIVE, APEX GB GEARBOX, PLANETARY, APEX, 15:1 STRIAGHT SERVO MOTOR EMERSON SCREW M6 X M12 ALLOY ASM, PULLEY DRIVE END 5330 LOCTITE 680 GREEN SCREW 1/4-20 X 1-1/4 SHCS SST COLLAR 3/4 IN LOCKING HYDRAULIC SHOCK ABSORBER PULLEY TIMING HTD5 COUPLING 3/4 ID EXPANSION LOCTITE 242 BLUE BEARING 3/4IDX1.75OD SCREW 1/4-20X1 SO CAP BLK AL CARRIAGE STOP BLOCK SHAFT, DRIVE PULLEY PULLEY BRKT SPACER PULLEY SIDE PLATE LEFT PULLEY SIDE PLATE RIGHT PULLEY SPACER SCREW 1/4-20X1/2 FLAT SOC SS 1 1 1 1 1 1 1 4 4 2 2 4 4 2 4 1 1 1 1 0.001 4 2 1 1 1 0.001 2 12 1 1 1 1 1 1 2

This procedure should only be performed by a qualified EFI-VUTEk Service Engineer.

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Procedure
Before you start
Please review this document and all its steps before beginning. Installing this upgrade should take about two-three hours. During this time you will not be able to use the printer. 1. Verify that you have all of the parts in the upgrade kit and tools required before starting this procedure. 2. Power Tools FM Rev 4.1 may be down loaded from the Support WEB site. Search for the word power. 3. Without the special Alignment Coupling you cannot start this procedure. This Alignment Coupling IS NOT part of the upgrade kit. This side connects to gearbox shaft Bolts are on this side only

Sliding Coupler

Locking bolt Locking bolt Alignment coupling, part number 45071077 4. Upgrade the carriage drive servo controller with the new parameter file (5330X_03202008.Ei). This document (45071266) is posted on the support WEB site and the parameter file is linked to this document. An overview of the upgrade procedure is provided at the end of this document.

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THIS PARAMETER FILE (5330X_03202008.Ei) WILL ONLY WORK WITH THE NEW 5330 MOTOR GEARBOX ASSEMBLY. 5. Power down the printer. Do not perform any carriage movements. 6. Remove top and bottom right side end panels. 7. Remove the carriage drive belt from the right side of the carriage. 8. Measure the distance from points A to B of the pulley hold down bolts. This will be your reference point when installing the replacement pulley.

9. Remove the carriage drive pulley. 10. Install the replacement pulley. Use the measurements recorded in step #8 to position the replacement pulley. 11. Use a square to insure the pulley block is square with the carriage rails and tighten the pulley hold down bolts. 12. Remove the old motor/gearbox and motor mounting bracket. 13. Install the four set screws into the new motor mounting bracket. All four set screws should not protrude beyond the surface of the motor mounting bracket.

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Set screws top, flush with surface Surface of motor mounting bracket These set screws are not flush

Right end horizontal C-Channel Frame

Set screws bottom, flush with surface These set screws are not flush

Bottom of motor/gearbox mounting bracket 14. Install the new motor/gearbox assembly onto the new motor mounting bracket, reference pictures on page 10. Tighten all four bolts; do not apply loctite at this time. 15. Install the Alignment Coupling onto the gearbox output shaft. The end of the alignment coupling with the bolts must be installed on the gearbox output shaft. 16. VERY IMPORTANT: Push the sliding coupling onto the shaft as far as possible. You should not see the gap on the sliding coupling (see below pictures). Tighten the locking bolt on the motor/gearbox side only. IF THIS IS NOT DONE CORRECTLY, YOU WILL DAMAGE THE ALIGNMENT COUPLING.

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Should not see this gap

Should not see this gap

Incorrect position of sliding couplings

No gap between sliding coupling and fixture

No gap between sliding coupling and fixture

Correct position of sliding couplings

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17. VERY IMPORTANT: Place the other end of the Alignment Coupling onto the shaft of the carriage drive pulley. This will push the sliding coupling back into the Alignment Coupling. Use a flat bladed screw drive to move the sliding coupler onto the pulley shaft until the sliding coupler is against the pulley and you cannot see the gap between the sliding coupling and alignment fixture (see previous pictures). IF THIS IS NOT DONE CORRECTLY, YOU WILL DAMAGE THE ALIGNMENT COUPLING. . If installed correctly you should not see this gap on the sliding coupling

If installed correctly you should not see this gap on the sliding coupling

Sliding coupler

Sliding coupler

This side connects to gearbox shaft

Alignment coupling 18. Support the back of the motor and tighten the locking bolt on the sliding coupler. 19. Rotate the motor mounting bracket so that it is flush against the horizontal frame member of the printer. Use the C-clamp to hold the motor mounting bracket against the frame member. 20. Scribe the location of the holes in the motor mounting bracket onto the frame of the printer.

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21. Move the motor mounting bracket away from the frame member. Using a center punch mark the center of the scribed holes. 22. Place a piece of scrap vinyl over the servo controllers so that the metal shavings do not drop inside these components. 23. Using the smaller of the two drill bits, drill a pilot hole at the indent created by the center punch. 24. From the end of the printer use the larger of the two drill bits and enlarge the pilot hole.

Right end horizontal frame member Install bottom bolt

Printer frame with both holes drilled 25. Loctite all four set screws on the motor mounting bracket. 26. Position the bottom two set screws out approximately 0.060, leaving the top two set screw flush on the motor mounting bracket. 27. Position the motor mounting bracket against the frame and install and tighten the bottom bolt only. 28. Tighten the top two set screws against the frame of the printer. 29. Install and tighten the top bolt through the frame member and the motor mounting bracket.

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30. Loosen the bolt on the alignment coupling that is holding the coupling to the shaft of the pulley.

Alignment coupling 31. Remove the motor/gearbox assembly from the mounting bracket. 32. Remove the alignment coupling from the gearbox shaft. 33. Please return the alignment coupling to EFI-VUTEk at your earliest convenience. Inside the box add a note that indicates Part Number 45071077, RETURN TO STOCK. 34. Install the new coupling onto the shaft of the motor gearbox. Push the coupling onto the shaft as far as possible and tighten the coupling locking bolt. 35. Install the motor/gearbox/coupling onto the motor mounting bracket and the coupling onto the pulley shaft. Use loctite on the motor/gearbox bolts. Position the two cables at the bottom of the motor.

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Motor mounting bracket 36. Tighten the bolt on the coupling at the pulley shaft. 37. Clean up the metal shavings. 38. Connect the two cables to the Carriage Servo controller. 39. Reinstall the two end panels. 40. Reinstall the carriage drive belt and adjust the belt tension. 41. Power up the printer and print a test image at the three different carriage speeds; Quality, Standard and Maximum. If possible, use 5 meter wide material.

Please return the alignment coupling to EFI-VUTEk at your earliest convenience. Inside the box add a note that indicates Part number 45071077, return to stock.

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New motor/gearbox mounting bracket New motor/gearbox mounting bracket

New coupling

Installed motor/gearbox assembly

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Upgrading Carriage Servo Parameter file

This section is an overview on downloading the servo parameter file (5330X_03202008.Ei). This parameter file is ONLY applicable for this motor/gearbox assembly. 1. Remove the X servo communications cable from the printer side COM port and install it into one of the COM ports on the workstation side.

2. Remove the T2 jumper on the servo transition board. The servo transition board is located in the cabinet with the servo controllers. Servo Transition Board

Servo Controllers

Servo Cabinet

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T2 Jumper remove

Servo transition board 3. Open Power Tools FM Rev. 4.1 on the workstation computer. 4. On the Options menu choose Preferences, Communications, Configure serial port and set the baud rate to 19200 and choose the COM port. 5. From the File menu, click Open. 6. Open the carriage parameter file 5330X_03202008.Ei. This is the parameter file that you downloaded from the WEB site. 7. After the file opens, click Download, the Target Drive Address(es) is 1.

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8. When the download is completes, choose Yes to reboot the drive, as the motor type has changed.

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9. Click Disconnect and then close any open drive windows.

10. When prompted to Save changes to 5330X_01022008.Ei?, select No.

11. Close the Power Tools program. 12. Replace the COM cable from the Windows computer to the printer computer. 13. Replace the T2 jumper on the servo transition board. End
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