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Title: Replace the idle pulley for XLp plotter

Category: XLp plotters

Document Number: 2011-GT-010

Supplied by: John Dai

Last Modified: 28-April-2011

Summary: How to replace the idle pulley and adjust the height

Issue:

Customers have experienced the Y-axis belt breaking. One of the reasons is that the pulley for the
Y-axis belt is not height adjustable, which leads to difficulty of alignment due to the stacked
tolerance.

Solution:

‹ Make the idle pulley of the Y-axis belt height adjustable

This is a quick fix in the field to avoid the customer having to stop production due to the short life
cycle of the Y-axis belt. The idle pulley and the shaft have been modified which allows the height to
be adjusted. The adjusted height is based on the number of the spacers (or washer) added.

Process:

‹ How to replace the idle pulley and adjust the height

1) Material: (Fig.1)
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Fig. 1

a) Items in Green (1,2,3,8,9,11,12,13,15,17) are available on the plotter and can be reused.
b) Items in Yellow (4, 5, 6, 10, 14, 16) should be pre-assembled as a sub-assembly.
c) Item in Blue (7) is used to adjust the height. 7 pieces have been provided in the kit. The
actual quantity used depends on quantity required for height adjustment.

2) Procedure:

— Disconnect the belt from the right side of the ink carriage back plate. So, the belt is not
tensioned. (Fig.2)

Fig. 2 Fig.3

— Unscrew item13 by holding item16. The idle pulley will be disassembled from the plotter.
(Fig. 3)

— Use the pre-assembled parts marked in yellow (4, 5, 6, 10, 14, 16) as the replacement,
Add a number of item7 you estimated for the height adjustment with the smooth side of item 7
towards the pulley. (Fig. 4)
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Fig. 4 Fig. 5

— Install the replacement. (Fig. 5)

— Change the position of item 17 and move item 3 towards the plotter (Fig.6) to ensure the belt
can easily be connected to the ink carriage. (Fig. 7)

Fig. 6 Fig. 7

— Change the position of item 17 and adjust the belt tension. For detail, please refer to the service
note XLp2010-006.

Attention:

— Check the status of the belt during the replacement procedure. Due to some parts quality
issues, some of the inferior belts may have been installed in plotter. If you see following
situation, the belt needs to be replaced as well. (Fig. 8)
Abnormal

Fig.8 wires missing and uneven

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— Check if there is any twist of the belt inside the channel. Sometimes people make such
mistakes and cause the belt to quickly break. (Fig. 9)

Fig. 9

— Move the ink carriage to the idle pulley side (Fig. 10) and ensure the belt is not touching the
upper flange of the idle pulley. Move the ink carriage to the remote side (Fig. 11) and ensure
the belt has no interference with the lower flange of the idle pulley. When the ink carriage
moves to the remote side, the belt may touch slightly with the lower flange without interference
due to the weight of the belt and the way installed. So far, that is not a concern.

Fig. 10 Fig. 11

— Move the ink carriage back and forth to ensure the belt is not hitting the pulley flange and the
edge of the square hole on the side plate. (Fig. 12)

Fig. 12
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— The worst case is that the belt is still touching the edge of the hole on the side plate after
adjustment of item7 by adding enough spacers (or washers). In this situation, it indicates that
the supporting beam or round way or ink carriage might not be well assembled. Otherwise the
customer may see the situation like shown in Fig. 14.

Fig. 13 Fig. 14