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MAINTENANCEMANUAL

Eco-Solvent Inkjet Printer

Rockhopper 46/62

Rockhopper: AP-74016, Rev:1.0

C O N 1 0 0 0Model Name: Rockhopper-46/62

C O N 1 0 0 0Model Name:Rockhopper-46/62

Introduction

Introduction

This equipment is Class 1 communications equipment (communications equipmentto be used in commercial and industrial areas) and conforms to VoluntaryCommunications Control Institute (VCCI) standards for data processing and otherequipment for the prevention of radio wave interference in commercial and industrialareas. Therefore, if it is used in or near a residential area, it may cause interference withradio and television reception. It should be used correctly in accordance with the operation manual.

� Concerning interference with receptionSince this product emits weak radio waves, if it is not installed and used correctlyand is thought to be causing interference with radio and television reception, thismay be prevented by trying a combination of the following measures:• Try changing the orientation of the receiving antenna and feeder.• Try changing the orientation of this product.• Change the distance between the receiver and this product.• Try using different power supply systems for the receiver and this product.

� Trademarks included in this manual • MUTOH, Model Name:Rockhopper-46/62, MH-GL, MH-GL/2, MH-RTL

are trademarks or trade names of Mutoh Industries Ltd.• HP, HP-GL, HP-GL/2, HP-RTL, HP759X, HP758X, C2848 are trademarks or

trade names of the Hewlett Packard Company.• Centronics and Bitronics are trademarks or trade names of the Centronics Data

Computer Company.• Windows 3.1, Windows 95, Windows NT 3.51, Windows NT 4.0, MS-DOS are

trademarks or trade names of the Microsoft Corporation • Other names of products and companies are the trademarks or trade names of

each relevant company.

This manual contains basic technical details necessary for marketplace servicing tomaintain product quality and performance of Model Name:Rockhopper-46/62 printer.Model Name:Rockhopper-46/62 printer is equipped with a self-diagnostic program that will be of service for adjusting and checking whenever a fault is detected or during maintenance.

This manual contains all the basic items but actual maintenance work should beundertaken only after a thorough understanding of the functions, operations andmovements has been gained from the operation manual and by other means.

Please note that there may be occasions where the name of a part used in theexplanation in this manual differs from the name of that same part that is used in theoperation manual or in the parts list.

Published by Mutoh Europe, Archimedesstraat 13, 8400 Oostende Belgium

Copyright February 2002, Mutoh Europe All rights reserved.

CAUTION:

• The details of this product and the contents of this manual are protected by copyright held by this Company and, except for legitimate use by individuals, unauthorized copying, reproduction or distribution in whole or part is forbidden.

• Details contained in this manual may be subject to future alteration without notice.

• Details contained in this manual are believed to be correct but please contact this Company or a dealer if an error is suspected or a point is not clear.

• In no event will this Company be responsible for the consequences of using this product or this manual.



Some Thoughts on Maintenance Work

Some Thoughts on Maintenance Work

1. Algunas ideas sobre el trabajo de MantenciónnLa mantencion cae en dos categorias, Full mantencion y mantencion preventiva, both of which are aimed at stable operation of the equipment that has been deliv-ered to the user. Las posibilidades de mantencion deben considerar.• In principle, fault maintenance and protective maintenance are both carried out by the

one person. • Both fault maintenance and protective maintenance involve the bringing of maintenance

parts.• The cooperation of the user/operator is used effectively.

2. Protective maintenance workLa mantencion periodica esta designed to provide the user con mas estabilidad operation of theequipment and involves the periodic cleaning and replacement of replacement parts. Basicideas on protective maintenance include:• Adhere strictly to preventive maintenance periods.• In a case of carrying out preventive maintenance, gain the approval of the user before-

hand. • Don’t press preventive maintenance on the user.

3. Fault maintenance workA fault will hold up the user’s work and must be remedied quickly. The following are somebasic ideas on fault maintenance:

3-1 If it is not solved by the primary consultation, take the necessary maintenance itemsand make an on-site visit. • Assemble the necessary maintenance parts from the matrix map • At the user’s premises, first check the symptoms.• Proceed with maintenance work in accordance with the fault tracing procedure.• After the repair work is finished, be sure to check again by testing in accordance

with the test procedure.

3-2 If repair is not possible even though all the work has been done in accordance withthe fault tracing procedure:• Contact the Sales Support Groups in your local distributor.

4. The need for user/operator cooperation

! CAUTION: The user cannot be compelled to do the following!

Asking the user/operator to cooperate is not a matter of having the user do the mainte-nance for you but it is necessary in order to have the equipment working more efficientlyand for having faults rectified quickly.Actually, even when you do ask for the user’s cooperation, instead of a simple acknowl-edgement you will usually get doubts and quibbles such as “I’m paying for maintenance”,“I’m not familiar with the equipment” and “it only benefits the manufacturer.”However, you must try to persuade the user/operator to cooperate by explaining that doingdaily inspections will give better printing quality and giving you all the fine details of a faultmeans that the fault will be rectified quickly.

The following explains the items you need in order to understand fault conditions in detail:• Check error messages• Check user’s usage conditions• Output from diagnostic pattern• Output from setup lists• Retest after changing settings• Probability of recovery by implementing daily inspections.



Precautions For Maintaining This Printer

Precautions For Maintaining This Printer

PRECAUTION 1 Head Cleaning

Head cleaning (see REP1620) must be carried out when this printer is to be trans-ported by truck (see CON6000) and when the following parts are to be replaced.< Replacement parts > Head, Damper, Head Cable, Cartridge Frame Assembly,

Ink Tubes

PRECAUTION 2 Head Cleaning Jig

When the head cleaning jig is to be used, fill the jig’s 100 cc bottle with at least 50cc of cleaning fluid and use it with the cap loosened.If head cleaning is done with the cap tightened, ink will flow back into the 100 ccbottle.When you have finished head cleaning, return the remaining cleaning fluid from the100 cc bottle to the 500 cc cleaning fluid bottle (JD-42054).

PRECAUTION 3 Printing After Initial Filling

On rare occasions, printing quality may be unstable if printing is carried out immedi-ately after initial filling.If this occurs, switch off the power and wait for at least 30 minutes before trying toprint again.

PRECAUTION 4 Thorough Waste Fluid Bottle Replacement

When the following tasks have been carried out,drain the waste fluid bottle.

1. After head cleaning and initial filling.2. When it was not possible to capture main board assembly backup parameters.

PRECAUTION 6 Take Care When Inserting Head Cable and Y Cable

PRECAUTION 7 Ink and Cleaning Fluid Conduct Electricity

When the print head assembly, head board assembly and main board assemblyhave been replaced, be careful to insert the head cable and Y cable straight to theback and don’t forget to lock the connectors. (The connectors fitted with locks are J207 and J208 on the head board.)If the cables are inserted obliquely or power is applied without locking the connec-tors, there is a risk that the main board assembly may be damaged and it will beimpossible for ink to be ejected.

Ink and cleaning fluid will conduct electricity.If there is ink or cleaning fluid on the connectors of the head or head cables whenpower is applied, there will be a short circuit which may lead to all sorts of damage. If there is ink on the contacts of the connector, wipe it off with alcohol or ethanol andallow to dry thoroughly before reconnecting.

PRECAUTION 5 Maintenance Unit Tubes

If you can not lower the maintenance unit cap assembly and the cap assembly andpump assembly have been replaced:• When the two tubes from the pump assembly are being connected to the cap

assembly, turn them clockwise through 45 to 90 degrees as you insert them.



Contents

Contents

Rockhopper-463 Rockhopper-62

Introduction CON 1000 CON 1000

Some Thoughts on Maintenance Work CON 1010 CON 1010

Precautions For Maintaining This Printer CON 2000 CON 2000

Contents CON 3001 ~ 3 CON 3007 ~ 9

How to use the Maintenance Manual CON 4000 CON 4000

Trouble-Shooting Lists TRB 0000 TRB 0000-3

Matrix Map MAP 0000 MAP 0000-3

Fault-Tracing Procedure EXA 0000 EXA 0000-3

Replacement and Adjustment Procedures REP 0000 REP 0000-3

Fundamental Knowledge GID 0000 GI D 0000-3

Stored Test Patterns PAT 0000 PAT 0000-3

Self-Diagnosis Functions BAC 0000 BAC 0000-3

Maintenance Parts CAT 0000 CAT 0000-3

C O N 3 0 0 1Model Name: Rockhopper-46

Model Name: Rockhopper-46Rockhopper-463 Contents 1

Rockhopper 46 inch

Trouble-Shooting Lists TRB0000• When Message is Displayed TRB1000

- How to Use LEDs to Check CPU System and Mechanical System Faults TRB1001

• When Message is not Displayed- Initialization, Media Feed, Printing TRB2000- Noise, Media Cutting, Online, Others TRB2001

Matrix Map MAP0000• When Message is Displayed

- Printer Status Messages MAP1000- Data Errors MAP1200- Command Errors MAP1250- CPU System Faults MAP1500- Mechanical System Faults MAP1700

• When Message is not Displayed- Trouble with Initialization MAP2000- Trouble with Media Feed MAP3000- Trouble with Printing MAP4000- Problem Involving Noise MAP5000- Trouble with Media Cutting MAP6000- Online/Function Problems MAP7000- Other MAP8000

Fault-Tracing Procedure EXA0000 • When Message is Displayed

- Printer Status Messages EXA1000~- Data Errors EXA1200~- Command Errors EXA1250~- CPU System Faults EXA1500~- Mechanical System Faults EXA1700~

• When Message is not Displayed- Trouble with Initialization EXA2000~- Trouble with Media Feed EXA3000~- Trouble with Printing EXA4000~- Problem Involving Noise EXA5000~- Trouble with Media Cutting EXA6000~- Online/Function Problems EXA7000~- Others EXA8000~

Heater System MAP9000

Heater System EXA9000

Heater System Faults EXA1800

C O N 3 0 0 2

C O N 3 0 0 2

Rockhopper-463 Contents 2


Replacement and Adjustment Procedures

Right and Left Covers REP 1010Front Cover REP 1020Panel Cover, Y Rail Cover REP 1030Front Paper Guide and Rear Paper Guide REP 1040Left Side Cap and Right Side Cap REP 1041Control Box REP 1050Head Cover REP 1060X Motor Assembly REP 1070Fan Assembly and Fan Cable REP 1080X Speed Reduction Belt REP 1090Lever Sensor Assembly REP 1100Cover Switch Assembly REP 1110Waste Fluid Box Sensor Assembly REP 1120Switch Cable Assembly, DC Cable Assembly REP 1130Main Board Assembly REP 1140Power Supply Board Assembly REP 1150Panel Board Assembly and Heater anel Board Assembly REP 1160Panel Cable REP 1170Extension Board Assembly REP 1180

XR Cable Assembly (Rear Paper Sensor) REP 1200Pressure Assembly, Pressure Roller and Blade REP 1220Pump Motor Assembly REP 1230Cap Assembly REP 1240Wiper REP 1250Pump Assembly REP 1260Maintenance Station Assembly REP 1270Y Motor Assembly REP 1280Steel Belt REP 1290T Fence Assembly REP 1300

Cursor Plate Spring, Steel Flexible Guide Assembly REP 1310Y Return Pulley Assembly REP 1320Cartridge Frame Assembly REP 1330Ink ID Sensor Assembly REP 1340Detector Assembly REP 1350Y Cable REP 1360Ink Tubes REP 1370Cutter Solenoid Assembly REP 1380Print Head Assembly, Head Cable REP 1390

Edge Sensor Assembly REP 1410Head Board Assembly REP 1420Dampers REP 1430Cursor Assembly REP 1440Origin Sensor Assembly, Y Encoder REP 1450

Junction Board Assembly REP 1470

How to Adjust the Platen Height REP 1520

Tubes Guides Assemblies REP 1540How to Adjust Steel Belt Tension REP 1550How to Adjust X Speed Reduction Belt Tension REP 1560How to Adjust the Tilt of the Print Head REP 1570

How to Capture and Install Backup Parameters REP 1590How to Install a Program (Software Upgrade) REP 1600

Head Cleaning Procedure REP 1620How to Clean the Head Nozzle Face REP 1660

Speed Reduction Pulley Assembly REP 1680Grid Roller Assembly REP 1690

F Absorbent Assembly REP 1700

Front / Rear Heater (or heater sensors) (refer to)REP 1040





Fundamental Knowledge GID0000• Basic Specifications GID1000• System Block Diagram GID3000• Operating Sequence

- Power On Sequence GID4010- Power Off Sequence GID4020- Media Detection Sequence GID4030- Normal Standby Sequence GID4040- Encoder Disconnected Check Sequence GID4050- Origin Detection Sequence GID4060- Media Cutting Sequence GID4070- Printing Sequence (Including Flushing) GID4080

Stored Test Patterns PAT0000• Presentation Pattern PAT1000• Print quality adjustment pattern PAT3000• Setup List PAT4000

Self-Diagnosis Functions BAC0000

• Examination BAC1000- Memory (RAM) Capacity BAC1010- Version BAC1020- Panel BAC1030- Sensors BAC1040- Encoders BAC1050- Fans BAC1060- Ethernet Board BAC1065- History: Last error message BAC1070- History: Head nozzle ejection count check BAC1070- Head Waveform BAC1080

• Adjustment BAC2000- Capping Position Adjustment BAC2010- Skew Verification BAC2030

- Head Rank Input (Include Initial filling) BAC2040- Head Nozzle Verification BAC2050- Left Head Tilt Verification BAC2060- Right Head Tilt Verification BAC2070- Repeatability Printing Positioning BAC2080- CW Adjustment BAC2090- Flush Pointer Adjustment BAC2110- Media Feed Distance Compensation BAC2120- Margin Adjustment BAC2130- Rear Sensor Position Adjustment BAC2140- Test Print BAC2150- Head Wash BAC2160

• Cleaning BAC3000- Normal BAC3000- Powerful BAC3000

• Test Printing BAC4000- Head Printing Verification BAC4000- Adjustment Parameters BAC4000

• Parameters BAC5000- Initialize BAC5010- Update BAC5020

• Aging BAC6000- Carriage Motor BAC6010- Media Feed Motor BAC6020- Cutter BAC6030- Maintenance Unit BAC6040- Head BAC6050

Maintenance Parts CAT0000Maintenance Parts List CAT1000Maintenance Tool List CAT2000Lubrication Points CAT4000Exploded View Drawing CAT5000





Rockhopper 62 inch

Trouble-Shooting Lists TRB0000-3• When Message is Displayed TRB1000

- How to Use LEDs to Check CPU System and Mechanical System Faults TRB1001

• When Message is not Displayed- Initialization, Media Feed, Printing TRB2000- Noise, Media Cutting, Online, Others TRB2001

Matrix Map MAP0000-3• When Message is Displayed

- Printer Status Messages MAP1000- Data Errors MAP1200- Command Errors MAP1250- CPU System Faults MAP1500- Mechanical System Faults MAP1700-2

• When Message is not Displayed- Trouble with Initialization MAP2000-2- Trouble with Media Feed MAP3000-2- Trouble with Printing MAP4000-2- Problem Involving Noise MAP5000- Trouble with Media Cutting MAP6000- Online/Function Problems MAP7000- Other MAP8000

Fault-Tracing Procedure EXA0000-3• When Message is Displayed

- Printer Status Messages EXA1000~(1020-2)

- Data Errors EXA1200~- Command Errors EXA1250~- CPU System Faults EXA1500~- Mechanical System Faults EXA1700~

• When Message is not Displayed- Trouble with Initialization EXA2000~

(2070-2)- Trouble with Media Feed EXA3000~

(3000-2)- Trouble with Printing EXA4000~

(4050-2)(4100-2)(4130-2)

- Problem Involving Noise EXA5000~- Trouble with Media Cutting EXA6000~- Online/Function Problems EXA7000~- Others EXA8000~

(8050-2)


Heater System EXA9000-2

Heater System Faults EXA1800-2





Replacement and Adjustment Procedures R E P 0 0 0 0 - 2

Right and Left Covers REP 1010Front Cover REP 1020Panel Cover, Y Rail Cover REP 1030Front Paper Guide and Rear Paper Guide REP 1040-2Left Side Cap and Right Side Cap REP 1041Control Box REP 1050Head Cover REP 1060X Motor Assembly REP 1070Fan Assembly and Fan Cable REP 1080-2X Speed Reduction Belt REP 1090Lever Sensor Assembly REP 1100Cover Switch Assembly REP 1110Waste Fluid Box Sensor Assembly REP 1120Switch Cable Assembly, DC Cable Assembly REP 1130Main Board Assembly REP 1140Power Supply Board Assembly REP 1150Panel Board Assembly REP 1160Panel Cable REP 1170Extension Board Assembly REP 1180


Cursor Plate Spring, Steel Flexible Guide Assembly REP 1310-2Y Return Pulley Assembly REP 1320Cartridge Frame Assembly REP 1330Ink ID Sensor Assembly REP 1340Detector Assembly REP 1350Y Cable REP 1360-2Ink Tubes REP 1370-2Cutter Solenoid Assembly REP 1380Print Head Assembly, Head Cable REP 1390

Edge Sensor Assembly REP 1410Head Board Assembly REP 1420Dampers REP 1430Cursor Assembly REP 1440Origin Sensor Assembly, Y Encoder REP 1450

Junction Board Assembly REP 1470

How to Adjust the Platen Height REP 1520

Tubes Guides Assemblies REP 1540-2How to Adjust Steel Belt Tension REP 1550How to Adjust X Speed Reduction Belt Tension REP 1560How to Adjust the Tilt of the Print Head REP 1570


Head Cleaning Procedure REP 1620How to Clean the Head Nozzle Face REP 1660

Speed Reduction Pulley Assembly REP 1680Grid Roller Assembly REP 1690

F Absorbent Assembly REP 1700Waste Fluid Bottle Assembly REP 1710

Front / Rear Heater (or heater sensors) (refer to)REP 1040-2





Fundamental Knowledge GID0000-3• Basic Specifications GID1000-3• System Block Diagram GID3000• Operating Sequence

- Power On Sequence GID4010- Power Off Sequence GID4020- Media Detection Sequence GID4030- Normal Standby Sequence GID4040- Encoder Disconnected Check Sequence GID4050- Origin Detection Sequence GID4060- Media Cutting Sequence GID4070- Printing Sequence (Including Flushing) GID4080

Stored Test Patterns PAT0000-3• Presentation Pattern PAT1000• Print quality adjustment pattern PAT3000• Setup List PAT4000

Self-Diagnosis Functions BAC0000-3

• Examination BAC1000- Memory (RAM) Capacity BAC1010- Version BAC1020- Panel BAC1030- Sensors BAC1040- Encoders BAC1050- Fans BAC1060- Ethernet Board BAC1065- History: Last error message BAC1070- History: Head nozzle ejection count check BAC1070- Head Waveform BAC1080

• Adjustment BAC2000- Capping Position Adjustment BAC2010- Skew Verification BAC2030

- Head Rank Input (Include Initial filling) BAC2040- Head Nozzle Verification BAC2050- Left Head Tilt Verification BAC2060- Right Head Tilt Verification BAC2070- Repeatability Printing Positioning BAC2080- CW Adjustment BAC2090- Flush Pointer Adjustment BAC2110- Media Feed Distance Compensation BAC2120- Margin Adjustment BAC2130- Rear Sensor Position Adjustment BAC2140- Test Print BAC2150- Head Wash BAC2160

• Cleaning BAC3000- Normal BAC3000- Powerful BAC3000

• Test Printing BAC4000- Head Printing Verification BAC4000- Adjustment Parameters BAC4000

• Parameters BAC5000- Initialize BAC5010- Update BAC5020

• Aging BAC6000- Carriage Motor BAC6010- Media Feed Motor BAC6020- Cutter BAC6030- Maintenance Unit BAC6040- Head BAC6050

Maintenance Parts CAT0000-3Maintenance Parts List CAT1000-3Maintenance Tool List CAT2000Lubrication Points CAT4000Exploded View Drawing CAT5000

C O N 4 0 0 0


How to use the Maintenance Manual



Como usar el Manual de Mantenimientol CON4010

How to use the Trouble-Shooting Lists (TRB) CON4020

How to use the Matrix Map (MAP) CON4040

How to use the Fault-Tracing Procedure (EXA) CON4050

Procedimiento de Reemplazo y Ajustes (REP) CON4060

Model Name: Rockhopper-46/62





� Fault maintenance work procedures and how to use the Maintenance ManualWhen a user reports an equipment fault, use the following procedure to carry out fault recovery tasks.

A fault occurs

Task Page Details Reference Materials

Check fault circumstances, select fault details from Trouble-Shooting Lists

Trouble-Shooting List TRB❉❉❉❉

Check circumstances by “fax” or “telephone”. Check error messages, check user usage conditions, retry after changing settings, output diagnostic pattern, etc. Select fault symptoms produced by user from the Trouble-Shooting List.

Conduct a consultation by “fax” or “telephone”. Check possibility of user error or recovery by daily inspection. Check error messages, check user usage conditions, output diagnostic pattern, output setup list. Retry after changing settings, etc.

Manual de Operaciones, Conocimiento báasico, Cuidados diarios, Mantencion periodica/inspeccion/Limpieza

Task Page Details Reference Materials

Gather the necessary maintenance parts

Matrix Map MAP❉❉❉❉

Gather the necessary maintenance parts Maintenance Parts list, Maintenance Tools list, Exploded views

Conduct a tracing inquiry Fault Tracing Procedures EXA❉❉❉❉

Conduct an inquiry to trace the cause of the fault Basic knowledge

Replace parts and adjust Replacement and Adjustment Procedures REP❉❉❉❉

Replace or readjust parts suspected to be faulty. Carry out adjustments after replacing parts.

Basic knowledge

Final check Separate causes of faults and check operation after faults have been rectified.

Conduct a primary consultation with the user

• If you are unable to resolve the fault at this point, take the necessary maintenance parts and make an on-site visit.



How to use the Trouble-Shooting Lists (TRB)

How to use the Trouble-Shooting Lists (TRB)

1. How to look up trouble-shooting tables� When a user has reported a fault, first select the applicable details from the trouble-shooting lists (TRB) and jump to the specified primary consultation (ENT). • Faults are broadly classified as those which cause a message to appear in the printer LCD and those which do not. • For troubles that cause a message to be displayed, select the message as it is.• Troubles with no message display are classified into the 10 blocks shown below. First select the block then select the appropriate fault details from that block.

2. Definitions of groupings in the case of faults that produce no message display

When Message is Displayed TRB1000

• Printer Status Messages, Data Errors, Command Errors

• CPU System Faults, Mechanical System Faults

When Message is Not Displayed TRB2000 to TRB2001

• Trouble with Initialization: Troubles that occur when unpacking immediately after delivery are grouped here.Check this group for a similar trouble occurring other than immediately after delivery. Troubles concerning the series of operations up to the enabling of printing are grouped here.

• Trouble with Printing: This group concerns printing quality problems.

• Trouble with Media Feed: This group concerns problems with the media path.

• Trouble with Media Cutting: Cutter section problems are grouped here.

Printing precision problems are grouped here.

• Problem Involving Noise: Troubles that produce abnormal noise from the driving section.

• Online/Function Problems: Online printing function problems.

Troubles involving driver software, consumable items, peripheral devices are grouped here.• Other: Troubles concerning the series of operations up to the enabling of printing are grouped here.



How to use the Matrix Map (MAP)

How to use the Matrix Map (MAP)

� When the primary consultation (ENT) has not revealed any anomaly, gather the necessary maintenance parts according to the matrix map (MAP) shown below and visitthe user.

Major classification of fault detailsWhether an error message is displayed

Major classification of fault details and range of EXA numbers

Fault details

Replacement and adjustment procedure page

Names and drawing numbers of required parts

When Message is Not Displayed Trouble with Initialization

Trouble with Initializatio Model Name: 463 M A P 2 0 0 0When Message is Not Displayed

When Message is Not Displayed[Trouble with Initialization]

EXA2000 to EXA2070

Problem

- Power supply does not come on - LCD faulty (no display/erratic display)- Initial filling of inks failed - Initial filling is completed but no ink comes out- After power is switched on, nothing works- When power is applied, “Initializing” appears and then a reset is executed. - After mounting media, initial operation fails- Printer does not work even with the cover closed- Printer does not stop even with the cover opened- Ink cartridges are installed but not recognized- Can not make entries from the operating panel- Data is received but not plotted- Media is not suction

Replacement and Adjustment Procedure REP. No.

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2000200020102020203020302030203020302040205020602070

Fault-Tracing Procedure EXA No.



How to use the Fault-Tracing Procedure (EXA)

How to use the Fault-Tracing Procedure (EXA)

� Gather the parts specified by the matrix map (MAP), visit the user and carry out the task of recovery in accordance with the fault-tracing procedure (EXA) shown below.• First, check again on-site that there was no mistake about the primary consultation. (EXA and ENT page numbers are the same) • Carry out the checking tasks in order, beginning with 1-1, and move to the next task if there is nothing abnormal. If an abnormality is revealed, carry out the task indi-

cated by the arrow [→].

E X A 2 0 2 1Model Name: Rockhopper-46/62


Trouble with Initialization

When No Error is Displayed on the Printer's Liquid Crystal Display

1 • Initial filling is completed but no inkcomes out

(Initial filling means to fill the headwith ink to enable it to print.)

1-10

1-11

1-12

1-13

1-14

1-15

1-16

1-17

• Are there any breaks, cuts or air leaks in the ink tubes?→ Change each ink tube, cleaning each time and checking that ink flows during cleaning.

• Check that connectors J207 (HEAD C1) and J208 (HEAD C2) on the head board assembly, andhead cables on the print head are not inserted obliquely, and they are locked securely.→ Insert the connectors again.

• Is there a broken lead in head cables?→ Replace head cables.

• Is the print head assembly damaged?→ Replace the print head assembly.

• Is the head board assembly damaged?→ Replace it.

• Check that the Y cable connector is connected securely and not inserted obliquely.→ Reconnect head board assembly connectors J201 (MAIN1) and J202 (MAIN2) and main board

assembly connectors J111 (HEAD1) and J112 (HEAD 2).

• Is there a broken lead in Y cables?→ Replace Y cables.

• The main board assembly may be damaged.→ Replace it.

No. SymptomSequence

Items to be Confirmed



1370

1400

1390

1420

1360

1140

R E P B A C

G O T O R e f . P a g e s

CAUTION: Power must be off when connectors are being disconnected or reconnect-ed, otherwise you may be injured or a board may be damaged.The main board assembly will certainly be damaged if power is appliedwith main board assembly connectors J111 (HEAD) and J112 (HEAD2) andhead board connectors J201 (MAIN1) and J202 (MAIN2) inserted withoblique FFP.

Whether an error message is displayed

Fault details

Fault-tracing sequence

Major classification of fault detailsPage specified by matrix map (MAP)

Page specified by matrix map (MAP)

Replacement and adjustment procedure (REP) page reference

Hidden diagnostic procedure page reference



How to use Replacement and Adjustment Procedure (REP)

How to use Replacement and Adjustment Procedure (REP)

� If the fault-tracing procedure (EXA) has produced a replacement task, carry out the work of replacement and adjustment in accordance with the replacement and adjust-ment procedure (REP) shown below.• If you don’t know how to go about the removal of covers involved in replacing a part, refer to REP1010 to REP1060.

Screws

Y motor cable terminal

Y motor assembly

R E P 1 2 8 0Model Name: Rockhopper-46/62


How to replace the Y Motor Assembly


Item Replacement and Adjustment Procedure

1. ReplacementProcedure

2. AdjustmentandExaminationProcedure

« REFERENCE » If there is to be no replacement thatincludes the Y motor assembly, steps 2, 4and 5 are not necessary.

Replace the Y Motor Assembly

1. Remove the Left and Right Covers.2. Remove the Rear Paper Guide.3. Remove the Steel Belt.4. Open the Control Box.5. Disconnect connector J120 (YMOT) from the Main Board

Assembly.6. Remove the Y Motor Assembly. (3 fastening screws)7. Assembling is the reverse of the removal procedure.

« REFERENCE » Since the Y Motor Assembly Cable pass-es below the Cartridge Unit, the work willbe easier if you remove the two CartridgeBase screws and push it back.

1. Carry out the Steel Belt Tensioning Adjustment.

Replacement and adjustment item

Replacement procedure

Adjustment procedure and items to be checked

Page specified by the fault-tracing procedure (EXA)

Page specified by the fault-tracing procedure (EXA)

DDV

DDV

T R B 0 0 0 0Model Name: Rockhopper-46

T R B 0 0 0 0Model Name: Rockhopper-46

Rockhopper-463 Trouble-Shooting Lists


Trouble-Shooting Lists

When Message is Displayed

Printer Status Messages TRB1000Data Errors TRB1000Command Errors TRB1000CPU System Faults TRB1000Mechanical System Faults TRB1000

When Message is Not Displayed

Trouble with Initialization TRB2000

Trouble with Printing TRB2000Trouble with Media Feed TRB2000

Trouble with Media Cutting TRB2001Problem Involving Noise TRB2001

Online/Function Problems TRB2001Others TRB2001Heater System TRB2001

How to Use LEDs to Check CPU System TRB1001 and Mechanical System Faults

Heaters System Faults TRB1000

T R B 0 0 0 0 - 3Model Name: Rockhopper-62

T R B 0 0 0 0 - 3Model Name: Rockhopper-62



Trouble-Shooting Lists


Printer Status Messages TRB1000Data Errors TRB1000Command Errors TRB1000CPU System Faults TRB1000Mechanical System Faults TRB1000


Trouble with Initialization TRB2000

Trouble with Printing TRB2000Trouble with Media Feed TRB2000

Trouble with Media Cutting TRB2001Problem Involving Noise TRB2001

Online/Function Problems TRB2001Others TRB2001Heater System TRB2001

How to Use LEDs to Check CPU System TRB1001 and Mechanical System Faults

Heaters System Faults TRB1000


When Message is Displayed T R B 1 0 0 0Model Name: Rockhopper-46/62

T R B 1 0 0 0Model Name: Rockhopper-46/62

Trouble-Shooting 1/3 (List of Faults)


Cases where an error message is displayed on the liquid crystal display of the main printer unit

GO TO EXA No.Minor Faults CPU System/Mechanical System Faults GO TO EXA No.

Pri

nte

r S

tatu

s M

ess

ag

es

CP

U S

yste

m F

au

lts

• Cover Open• Lever Up• Cover and Lever• Undefined Media• Media Skew Error• [User 1] Media End• Remove Media • Roll Media End• Media Cut Error• Not enough memory SIMM 12 MB• Insert Special Cartridge• [ ∗ ] Ink Low• [ ∗ ] No Ink• [ ∗ ] No Cartridge• Capping position not specified• Not Filled• No Waste Fluid Box• Wrong Ink Type

EXA1000EXA1000EXA1000EXA1010EXA1020EXA1030EXA1040EXA1050EXA1060EXA1070EXA1080EXA1090EXA1090EXA1100EXA1110EXA1120EXA1130EXA1150

• E001 Error DRAM (Standard DRAM error)• E002 Error Opt.DRAM (Optional DRAM error) • E 0 1 6 C P U E r r [ 0 0 ] (Interrupt exception error)• E 0 1 6 C P U E r r [ 0 2 ] (Command boundary exception error)• E 0 1 6 C P U E r r [ 0 3 ] (Data boundary exception error)• E 0 1 6 C P U E r r [ 0 4 ] (Address error exception)

(Load or command fetch) • E 0 1 6 C P U E r r [ 0 5 ] (Address error exception) (Store)• E 0 1 6 C P U E r r [ 0 6 ] (Bus error exception) (Command fetch)• E 0 1 6 C P U E r r [ 0 7 ] (Bus error exception) (Data load)• E 0 1 6 C P U E r r [ 0 8 ] (System call exception error)• E 0 1 6 C P U E r r [ 0 9 ] (Break point exception error)• E 0 1 6 C P U E r r [ 1 0 ] (Reserved command exception error)• E 0 1 6 C P U E r r [ 1 1 ] (Unable to use coprocessor exception error)• E 0 1 6 C P U E r r [ 1 2 ] (Operation overflow exception error)• E 0 1 6 C P U E r r [ 1 3 ] (Trap exception error)• E 0 1 6 C P U E r r [ 1 5 ] (Floating point exception error)• E 0 1 6 C P U E r r [ 2 2 ] (Watch exception error)• E 0 1 6 C P U E r r [ 3 2 ] (Watchdog timeout exception error)• E 0 1 6 C P U E r r [ 3 3 ] (Abort error)• Error E237 Transfer memory (Transfer memory error/Transfer memory

access error)• Error E129 NVRAM

EXA1500EXA1500EXA1510EXA1510EXA1510EXA1510

EXA1510EXA1510EXA1510EXA1510EXA1510EXA1520EXA1520EXA1520EXA1520EXA1520EXA1520EXA1520EXA1520EXA1520

EXA1530

Me

cha

nic

al

Sys

tem

Fa

ult

s

• E065 Error X Motor• E069 Error X Encoder• E071 Error X Timeout• E073 Error X Overcurrent• E066 Error Y Motor• E070 Error Y Encoder• E072 Error Y Timeout• E074 Error Y Overcurrent• E075 Error Sensor Fault

EXA1700EXA1700EXA1700EXA1700EXA1710EXA1710EXA1710EXA1710EXA1720

Da

ta E

rro

rs • Network Detection Error• Network Initialization Error

EXA1230EXA1230

Co

mm

an

d E

rro

rs

• MH01 Error (Undefined Command)• MH02 Error (Parameter Error)• MH03 Error (Numerical Error)• MH04 Error (Undefined Character Set)• MH07 Error (Buffer Overflow)

EXA1250EXA1250EXA1250EXA1250EXA1250

Heater System Faults EXA1800

DDV



How to Use LEDs to Check CPU System and Mechanical System Faults

How to Use LEDs to Check CPU System and Mechanical System Faults

• When the printer stops working and nothing appears on the liquid crystal display (LCD), a fault has probably occurred in the CPU system or the mechanical system.In that case, open the control box and check the error by the LEDs on the main board assembly. is on, is off.

LED display1 2 3 4 5 6 7 8

• E001 Error DRAMFallas Sistema CPU

Details of Error

• E002 Error Opt.DRAM• E002 Error Opt.DRAM• E 0 1 6 C P U E r r [ 0 0 ]• E 0 1 6 C P U E r r [ 0 2 ]• E 0 1 6 C P U E r r [ 0 3 ]• E 0 1 6 C P U E r r [ 0 4 ]• E 0 1 6 C P U E r r [ 0 5 ]• E 0 1 6 C P U E r r [ 0 6 ]• E 0 1 6 C P U E r r [ 0 7 ]• E 0 1 6 C P U E r r [ 0 8 ]• E 0 1 6 C P U E r r [ 0 9 ]• E 0 1 6 C P U E r r [ 1 0 ]• E 0 1 6 C P U E r r [ 1 1 ]• E 0 1 6 C P U E r r [ 1 2 ]• E 0 1 6 C P U E r r [ 1 3 ]• E 0 1 6 C P U E r r [ 1 5 ]• E 0 1 6 C P U E r r [ 2 2 ]• E 0 1 6 C P U E r r [ 3 2 ]• E 0 1 6 C P U E r r [ 3 3 ]• E237 Error Transfer memory• E129 Error NVRAM

(Standard DRAM error)(Optional DRAM 1 error)(Optional DRAM 2 error)(Interrupt exception error)(Command boundary exception error)(Data boundary exception error)(Address error exception) (Load or command fetch)(Address error exception) (Store)(Bus error exception) (Command fetch)(Bus error exception) (Data load)(System call exception error)(Break point exception error)(Reserved command exception error)(Unable to use coprocessor exception error)(Operation overflow exception error)(Trap exception error)(Floating point exception error)(Watch exception error)(Watchdog timeout exception error)(Abort error)(Transfer memory error/Transfer memory access error)

EXA1500

Fault-Tracing ProcedureEXA page

EXA1500EXA1500EXA1510EXA1510EXA1510EXA1510EXA1510EXA1510EXA1510EXA1510EXA1510EXA1520EXA1520EXA1520EXA1520EXA1520EXA1520EXA1520EXA1520EXA1520EXA1530

• E065 Error X Motor

• E066 Error Y Motor

• E069 Error X Encoder

• E070 Error Y Encoder

• E071 Error X Timeout

• E072 Error Y Timeout

• E073 Error X Overcurrent

• E074 Error Y Overcurrent• E075 Error Sensor Fault

EXA1700EXA1700EXA1700EXA1700EXA1710EXA1710EXA1710EXA1710EXA1720

FALLAS SISTEMA MECANICO







GO TO EXA No.

Cases where no error message is displayed on the liquid crystal display of the main printer unit

GO TO EXA No.


Tro

uble

with

Initi

aliz

atio

n

Tro

uble

with

Prin

ting

• No power • Faulty liquid crystal display (no display/unstable display)• Initial filling of inks failed • Initial filling is completed but no ink comes out• After power is switched on, nothing works • When power is applied, “Initializing” appears and then a reset is executed.• Media is mounted but the initialization operation is not done• Printer does not work even with the cover closed• Printer does not stop even with the cover opened• Ink cartridges are installed but not recognized• No se puede entrar al Panel de Operaciones• Data is received but not printed• Media is not suction

EXA2000EXA2000EXA2010EXA2020EXA2030EXA2030EXA2030EXA2030EXA2030EXA2040EXA2050EXA2060EXA2070

EXA3000EXA3000EXA3000EXA3000EXA3000EXA3010EXA3010

• No imprime en forma continua• There is an extra feed after printing is finished• Dots are missing from the printing• Cleaning does not cure blockage• No imprime nada• No imprime un color especifico • La superficie entera se imprime en negro• Printing becomes shaded• The image contains blurs• Transverse lines appear to be split• AParecen lineas blancas y negras en la impresion• Orillas de la impresion aparecen borrosas • Many satellites (unwanted dots)• The printing has whiskers• Printed lines appear blurred (printing is dirty)• Mixed colour lines do not overlap• Black and colour positions are offset• Inaccurate line length in the direction of head movement (Main scanning direction)• Inaccurate straight line in the direction of head movement (straightness) • Inaccurate line distance in the direction of media feed (Subsidiary scanning distance)• Inaccurate straight line in the direction of media feed (joining precision Y)• Bad right angle precision

EXA4000EXA4010EXA4020EXA4020EXA4030EXA4030EXA4040EXA4050EXA4050EXA4050EXA4050EXA4060EXA4070EXA4070EXA4070EXA4080EXA4080EXA4090EXA4100EXA4110EXA4120EXA4130

Tro

uble

with

Med

ia F

eed

• The media comes off when it is initialized or during printing• The media is skewed or meanders when it is initialized or during printing• The media becomes wrinkled when it is initialized or during printing• The media jams when it is initialized or during printing• The media tears when it is initialized or during printing• The media size is different after media mounting and initialization• Tracing paper and thin media cannot be detected







GO TO EXA No.


GO TO EXA No.


Pro

blem

Invo

lvin

g N

oise

Onl

ine/

Fun

ctio

n P

robl

ems

Oth

ers

• Abnormal noise when media is sucked down• Abnormal noise when standing by ready to print• Abnormal noise when head is moving left and right• Abnormal noise when media is fed• Abnormal noise when cutting

EXA5000EXA5010EXA5020EXA5030EXA5040

EXA6000EXA6010EXA6020EXA6020EXA6030EXA6040EXA6050EXA6050

EXA7000EXA7000EXA7020EXA7020EXA7020EXA7020EXA7030EXA7040EXA7050EXA7060

• The printer hangs up• Power shutdown during printing • The ink cartridges will not go in• Ink has overflowed from the waste fluid box • Ink overflows from flushing box• Ink is split around the X-rail

• Cannot connect normally with Centronics• Cannot connect normally with Network• The scale function does not work correctly • The rotate function does not work correctly• The mirror function does not work correctly• Other functions are not working correctly• Printing position is offset• Some data are not printed (omitted)• Text and printing data are garbled (extra lines appear) • There is an extra feed after printing is finished

EXA8000EXA8010EXA8020EXA8050EXA8050EXA8050

Tro

uble

with

Med

ia C

uttin

g

• Does not cut normally• Cutting occurs during printing• The cutting operation is normal but the media is not cut• The cutting is bad and the media jams• The cutting operation is normal but the media does not fall out• Inaccurate media cutting• Cutting is delayed for some time after printing has ended• White paper is cut (Blank print) Sistema Calefactores EXA9000

M A P 0 0 0 0

M A P 0 0 0 0Rockhopper-463 Matrix Map

Rockhopper-463 Matrix Map

Matrix Map


Printer Status Messages MAP1000Data Errors MAP1200Command Errors MAP1200CPU System Faults MAP1500Mechanical System Faults MAP1700


Trouble with Initialization MAP2000

Trouble with Printing MAP4000Trouble with Media Feed MAP3000

Trouble with Media Cutting MAP6000Problem Involving Noise MAP5000

Online/Function Problems MAP7000Other MAP8000

Model Name: Rockhopper-46



Heaters Fault MAP1800

M A P 0 0 0 0 - 3

M A P 0 0 0 0 - 3Rockhopper-62 Matrix Map

Rockhopper-62 Matrix Map

Matrix Map


Printer Status Messages MAP1000-3Data Errors MAP1200Command Errors MAP1200CPU System Faults MAP1500Mechanical System Faults MAP1700-2


Trouble with Initialization MAP2000-2

Trouble with Printing MAP4000-2, 4001-3Trouble with Media Feed MAP3000-3

Trouble with Media Cutting MAP6000-2Problem Involving Noise MAP5000-3

Online/Function Problems MAP7000-2Other MAP8000-2



Heater System MAP9000-2

Heaters Fault MAP1800-2

When Message is Displayed Printer Status Messages Model Name: Rockhopper463 M A P 1 0 0 0

Printer Status Messages Model Name: Rockhopper463 M A P 1 0 0 0

100010001000101010201030104010501060107010801090109011001110112011301150

1140

1160

1110

1170

1100

1410

1420

1200

1360

1380

1350

1350

1350

1350

1350

1350

1120

1220

1220

1330

1340

1340

1340

1340

1340

1340

1470

1470

1690


When Message is Displayed[Printer Status Display]

EXA1000 to EXA1150

Problem

- Cover open- Lever up- Cover & Lever- Undefined Media- Media Skew Error- [User 1] Media End- Remove Media- Roll Media End- Media Cut Error- Not enough memory SIMM12MB- Insert Special Cartridge- [✼✼] Ink Low- [✼✼] No Ink- [✼✼] No Cartridge- Capping position not specified- Not Filled- No Waste Fluid Box- Wrong Ink Type


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When Message is Displayed Printer Status Messages Model Name: Rockhopper62 M A P 1 0 0 0 - 3

Printer Status Messages Model Name: Rockhopper62 M A P 1 0 0 0 - 3

1000100010001010

1020-21030104010501060107010801090109011001110112011301150

1140

1160

1110

1170

1100

1410

1420

1200

1360

-213

8013

5013

5013

5013

5013

5013

5011

2012

2012

2013

3013

40

1340

1340

1340

1340

1340

1470

1470

1690

1690


When Message is Displayed[Printer Status Display]

EXA1000 to EXA1150

Problem

- Cover open- Lever up- Cover & Lever- Undefined Media- Media Skew Error- [User 1] Media End- Remove Media- Roll Media End- Media Cut Error- Not enough memory SIMM12MB- Insert Special Cartridge- [✼✼] Ink Low- [✼✼] No Ink- [✼✼] No Cartridge- Capping position not specified- Not Filled- No Waste Fluid Box- Wrong Ink Type


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When Message is Displayed Data Errors, Command Errors M A P 1 2 0 0

Data Errors, Command Errors Model Name: Rockhopper-46/62


M A P 1 2 0 0

1230123012501250125012501250

1140


When Message is Displayed[Data Errors, Command Errors]

EXA1230 to EXA1250

Problem

- Network Detection Error- Network Initialization Error- MH01 Error (Undefined Command)- MH02 Error (Parameter Error)- MH03 Error (Numerical Error)- MH04 Error (Undefined Character Set)- MH07 Error (Buffer Overflow)


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When Message is Displayed CPU System Faults M A P 1 5 0 0

CPU System Faults Model Name: Rockhopper-46/62


M A P 1 5 0 0

150015001510151015101510151015101510151015101520152015201520152015201520152015201530

1140


When Message is Displayed[CPU System Faults]

EXA1500 to EXA1530

Problem

- E001 Error DRAM (Standard DRAM error)- E002 Error Opt.DRAM (Optional DRAM error)- E016 CPUErr[00] (Interrupt exception error)- E016 CPUErr[02] (Command boundary exception error)- E016 CPUErr[03] (Data boundary exception error)- E016 CPUErr[04] (Address error exception load) - E016 CPUErr[05] (Address error exception store)- E016 CPUErr[06] (Bus error exception check)- E016 CPUErr[07] (Bus error exception load)- E016 CPUErr[08] (System call exception)- E016 CPUErr[09] (Break point exception)- E016 CPUErr[10] (Reserved command exception)- E016 CPUErr[11] (Processor usage denial exception)- E016 CPUErr[12] (Operation overflow exception)- E016 CPUErr[13] (Trap exception)- E016 CPUErr[15] (Floating point exception)- E016 CPUErr[22] (Watch exception)- E016 CPUErr[32] (Watchdog timeout error)- E016 CPUErr[33] (Abort error)- E237 Error Transfer memory (Transfer memory error/access error)- Error E129 NVRAM (Backup memory error)


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When Message is Displayed Mechanical System Faults Model N.:Rockhopper-463 M A P 1 7 0 0

Mechanical System Faults Model N.: Rockhopper-463 M A P 1 7 0 0

1140

1070

1280

1290

1450

1150

1080

1080

1080

1080


When Message is Displayed[Mechanical System Faults]

EXA1700 to EXA1720

Problem

- Error E065 X Motor- Error E069 X Encoder- Error E071 X Timeout- Error E073 X Overcurrent- Error E066 Y Motor- Error E070 Y Encoder- Error E072 Y Timeout- Error E074 Y Overcurrent- Error E075 Sensor Abnormal


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bly

DF

-415

98 C

R M

otor

Ass

embl

y (Y

Mot

or)

DF

-416

07 T

Fen

ceD

F-4

0109

Orig

in S

enso

r A

ssem

bly

DF

-415

87 P

ower

Boa

rd A

ssem

bly

DF

-401

73 V

acuu

m F

an A

ssem

bly

DF

-416

20 F

an E

xten

sion

Cab

le 1

Ass

embl

yD

F-4

1621

Fan

Ext

ensi

on C

able

2 A

ssem

bly

DF

-416

22 F

an E

xten

sion

Cab

le 3

Ass

embl

y

170017001700170017101710171017101720


When Message is Displayed Mechanical System Faults Model Name: Rockhopper 62 M A P 1 7 0 0 - 2

Mechanical System Faults Model Name: Rockhopper 62 M A P 1 7 0 0 - 2

1140

1070

1280

1290

1450

1150

1080

-210

80-2

1080

-2

1080

-210

80-2


When Message is Displayed[Mechanical System Faults]

EXA1700 to EXA1720

Problem

- Error E065 X Motor- Error E069 X Encoder- Error E071 X Timeout- Error E073 X Overcurrent- Error E066 Y Motor- Error E070 Y Encoder- Error E072 Y Timeout- Error E074 Y Overcurrent- Error E075 Sensor Abnormal


Nam

e an

d D

iagr

am N

umbe

r of

R

epla

cem

ent P

art

DF

-415

86 M

ain

Boa

rd A

ssem

bly

DF

-415

97 X

Mot

or A

ssem

bly

DF

-415

98 C

R M

otor

Ass

embl

y (Y

Mot

or)

DF

-416

07 T

Fen

ceD

F-4

0109

Orig

in S

enso

r A

ssem

bly

DF

-415

87 P

ower

Boa

rd A

ssem

bly

DF

-401

73 V

acuu

m F

an A

ssem

bly

DF

-416

20 F

an E

xten

sion

Cab

le 1

Ass

embl

yD

F-4

1621

Fan

Ext

ensi

on C

able

2 A

ssem

bly

DF

-416

22 F

an E

xten

sion

Cab

le 3

Ass

embl

yD

F-4

1993

Fan

Ext

ensi

on C

able

4 A

ssem

bly

170017001700170017101710171017101720


When Message is Displayed d Heater System Faultsr Model N:Rockhopper46 3 M A P 1 8 0 0

Heater System Faultsr Model N:Rockhopper46 3 M A P 1 8 0 0When Message is Displayed

When Message is Displayed[Heater system]

EXA1800

Problem

- Err : F.R.T. Sensor


Nam

e an

d D

iagr

am N

umbe

r of

R

epla

cem

ent P

art

Fro

nt R

ight

Hea

ter

Sen

sor

Fro

nt L

eft H

eate

r S

enso

rR

ear

Rig

ht H

eate

r S

enso

rR

ear

Left

Hea

ter

Sen

sor

1040

10

40

1040

10

40

1800


- Err : F.L.T. Sensor1800- Err : R.L.T. Sensor1800- Err : R.R.T. Sensor1800- Err : FRFLT Sensor1800- Err : FRRLT Sensor1800- Err : FRRRT Sensor1800- Err : FLRLT Sensor1800- Err : FLRRT Sensor1800- Err : RRRLT Sensor1800- Err : 2FRLT Sensor1800- Err : 2FRRT Sensor1800- Err : FR2RT Sensor1800- Err : FL2RT Sensor1800- Err : All T. Sensor1800- Err : Heater Stop1800

Hea

ter

Sys

tem

1040

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

d

DDV

3

DDV

3

When Message is Displayed d Heater System Faultsr Model N:Rockhopper62 3 M A P 1 8 0 0 - 2

Heater System Faultsr Model N:Rockhopper62 3 M A P 1 8 0 0 - 2When Message is Displayed

When Message is Displayed[Heater system]

EXA1800

Problem

- Err : F.R.T. Sensor


Nam

e an

d D

iagr

am N

umbe

r of

R

epla

cem

ent P

art

Fro

nt R

ight

Hea

ter

Sen

sor

Fro

nt L

eft H

eate

r S

enso

rR

ear

Rig

ht H

eate

r S

enso

rR

ear

Left

Hea

ter

Sen

sor

1040

-2

1040

-2

1040

-2

1040

-2

1800


- Err : F.L.T. Sensor1800- Err : R.L.T. Sensor1800- Err : R.R.T. Sensor1800- Err : FRFLT Sensor1800- Err : FRRLT Sensor1800- Err : FRRRT Sensor1800- Err : FLRLT Sensor1800- Err : FLRRT Sensor1800- Err : RRRLT Sensor1800- Err : 2FRLT Sensor1800- Err : 2FRRT Sensor1800- Err : FR2RT Sensor1800- Err : FL2RT Sensor1800- Err : All T. Sensor1800- Err : Heater Stop1800

Hea

ter

Sys

tem

1040

-2

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

3

DDV

3

DDV

d

When Message is Not Displayed Trouble with Initialization Model N. :Rockhopper463 M A P 2 0 0 0

Trouble with Initialization Model N. : Rockhopper463 M A P 2 0 0 0When Message is Not Displayed


EXA2000 to EXA2070

Problem



Nam

e an

d D

iagr

am N

umbe

r of

R

epla

cem

ent P

art

DF

-415

86 M

ain

Boa

rd A

ssem

bly

DF

-400

97 P

anel

Boa

rd A

ssem

bly

DF

-416

17 P

anel

Cab

leD

F-4

1590

Cov

er S

witc

h A

ssem

bly

DF

-415

89 L

ever

Sen

sor

Ass

embl

yD

F-4

1595

Edg

e S

enso

r A

ssem

bly

DF

-415

88 H

ead

Boa

rd A

ssem

bly

DF

-415

92 X

R C

able

Ass

embl

y (P

aper

Sen

sor

R)

DF

-416

00 Y

Cab

leD

F-4

1619

Sw

itch

Cab

le A

ssem

bly

DF

-415

87 P

ower

Boa

rd A

ssem

bly

DF

-414

68 D

C C

able

Ass

embl

yD

F-4

1593

Det

ecto

r 1

Ass

embl

yD

F-4

1594

Det

ecto

r 2

Ass

embl

yD

F-4

0106

Det

ecto

r A

ssem

bly

(Bla

ck)

DF

-401

07 D

etec

tor

Ass

embl

y (Y

)D

F-4

0146

Det

ecto

r A

ssem

bly

(M)

DF

-401

47 D

etec

tor

Ass

embl

y (C

)D

F-4

1602

Cap

Ass

embl

yD

F-4

1603

Pum

p A

ssem

bly

DF

-416

04 M

aint

enan

ce S

tatio

n A

ssem

bly

DF

-406

90 P

rint H

ead

Ass

embl

y (C

olou

r)D

F-4

1601

Hea

d C

able

DF

-415

91 W

aste

Flu

id B

ottle

Sen

sor

DF

-401

73 V

acuu

m F

an A

ssem

bly

DF

-416

20 F

an E

xten

sion

Cab

le 1

Ass

embl

yD

F-4

1621

Fan

Ext

ensi

on C

able

2 A

ssem

bly

DF

-416

22 F

an E

xten

sion

Cab

le 3

Ass

embl

yD

F-4

1609

INK

ID S

enso

r 1

Ass

embl

yD

F-4

1610

INK

ID S

enso

r 2

Ass

embl

yD

F-4

1611

INK

ID S

enso

r 3

Ass

embl

yD

F-4

1612

INK

ID S

enso

r 4

Ass

embl

yD

F-4

1613

INK

ID S

enso

r 5

Ass

embl

yD

F-4

1614

INK

ID S

enso

r 6

Ass

embl

yD

F-4

1615

INK

ID S

enso

r C

able

DF

-415

36 J

unct

ion

Boa

rd A

ssem

bly

1140

1160

1170

1110

1100

1410

1420

1200

1360

1130

1150

1130

1350

1350

1350

1350

1350

1350

1240

1260

1270

1390

1390

1120

1080

1080

1080

1080

1340

1340

1340

1340

1340

1340

1470

1470

2000200020102020203020302030203020302040205020602070


When Message is Not Displayed Trouble with Initialization Model Name: Rockhopper 62 M A P 2 0 0 0 - 2

Trouble with Initialization Model Name: Rockhopper 62 M A P 2 0 0 0 - 2When Message is Not Displayed


EXA2000 to EXA2070-2

Problem



Nam

e an

d D

iagr

am N

umbe

r of

R

epla

cem

ent P

art

DF

-415

86 M

ain

Boa

rd A

ssem

bly

DF

-400

97 P

anel

Boa

rd A

ssem

bly

DF

-416

17 P

anel

Cab

leD

F-4

1590

Cov

er S

witc

h A

ssem

bly

DF

-415

89 L

ever

Sen

sor

Ass

embl

yD

F-4

1595

Edg

e S

enso

r A

ssem

bly

DF

-415

88 H

ead

Boa

rd A

ssem

bly

DF

-415

92 X

R C

able

Ass

embl

y (P

aper

Sen

sor

R)

DF

-416

00 Y

Cab

leD

F-4

1619

Sw

itch

Cab

le A

ssem

bly

DF

-415

87 P

ower

Boa

rd A

ssem

bly

DF

-414

68 D

C C

able

Ass

embl

yD

F-4

1593

Det

ecto

r 1

Ass

embl

yD

F-4

1594

Det

ecto

r 2

Ass

embl

yD

F-4

0106

Det

ecto

r A

ssem

bly

(Bla

ck)

DF

-401

07 D

etec

tor

Ass

embl

y (Y

)D

F-4

0146

Det

ecto

r A

ssem

bly

(M)

DF

-401

47 D

etec

tor

Ass

embl

y (C

)D

F-4

1602

Cap

Ass

embl

yD

F-4

1603

Pum

p A

ssem

bly

DF

-416

04 M

aint

enan

ce S

tatio

n A

ssem

bly

DF

-406

90 P

rint H

ead

Ass

embl

y (C

olou

r)D

F-4

1601

Hea

d C

able

DF

-415

91 W

aste

Flu

id B

ottle

Sen

sor

DF

-401

73 V

acuu

m F

an A

ssem

bly

DF

-416

20 F

an E

xten

sion

Cab

le 1

Ass

embl

yD

F-4

1621

Fan

Ext

ensi

on C

able

2 A

ssem

bly

DF

-416

22 F

an E

xten

sion

Cab

le 3

Ass

embl

yD

F-4

1993

Fan

Ext

ensi

on C

able

4 A

ssem

bly

DF

-416

09 IN

K ID

Sen

sor

1 A

ssem

bly

DF

-416

10 IN

K ID

Sen

sor

2 A

ssem

bly

DF

-416

11 IN

K ID

Sen

sor

3 A

ssem

bly

DF

-416

12 IN

K ID

Sen

sor

4 A

ssem

bly

DF

-416

13 IN

K ID

Sen

sor

5 A

ssem

bly

DF

-416

14 IN

K ID

Sen

sor

6 A

ssem

bly

DF

-416

15 IN

K ID

Sen

sor

Cab

leD

F-4

1536

Jun

ctio

n B

oard

Ass

embl

y

1140

1160

1170

1110

1100

1410

1420

1200

1360

-211

3011

5011

3013

5013

5013

5013

5013

5013

5012

4012

6012

7013

9013

9011

2010

80-2

1080

-210

80-2

1080

-210

80-2

1340

1340

1340

1340

1340

1340

1470

1470

200020002010202020302030203020302030204020502060

2070-2


When Message is Not Displayed Trouble with Media Feed Model N. :Rockhopper463 M A P 3 0 0 0

Trouble with Media Feed Model N. :Rockhopper463 M A P 3 0 0 0When Message is Not Displayed

When Message is Not Displayed[Trouble with Media Feed]

EXA3000 to EXA3010


Problem

- The media comes off when it is initialized or during printing- The media is skewed or meanders when it is initialized or during printing- The media becomes wrinkled when it is initialized or during printing- The media jams when it is initialized or during printing- The media tears when it is initialized or during printing- The media size is different after media mounting and initialization- Tracing paper and thin media cannot be detected


Nam

e an

d D

iagr

am N

umbe

r of

R

epla

cem

ent P

art

DF

-415

86 M

ain

Boa

rd A

ssem

bly

DF

-401

73 V

acuu

m F

an A

ssem

bly

DF

-416

20 F

an E

xten

sion

Cab

le 1

Ass

embl

yD

F-4

1621

Fan

Ext

ensi

on C

able

2 A

ssem

bly

DF

-416

22 F

an E

xten

sion

Cab

le 3

Ass

embl

yD

F-4

1529

Pre

ssur

e A

ssem

bly

DF

-415

95 E

dge

Sen

sor

Ass

embl

yD

F-4

1592

XR

Cab

le A

ssem

bly

(Pap

er S

enso

r R

)D

F-4

1600

Y C

able

DF

-418

40 G

rid R

olle

r A

ssem

bly

1140

1080

1080

1080

1080

1110

1410

1200

1360

1690

3000300030003000300030103010

When Message is Not Displayed Trouble with Media Feed Model N. : Rockhopper-62 M A P 3 0 0 0 - 3

Trouble with Media Feed Model N. : Rockhopper-62 M A P 3 0 0 0 - 3When Message is Not Displayed

When Message is Not Displayed[Trouble with Media Feed]

EXA3000-2 to EXA3010


Problem

- The media comes off when it is initialized or during printing- The media is skewed or meanders when it is initialized or during printing- The media becomes wrinkled when it is initialized or during printing- The media jams when it is initialized or during printing- The media tears when it is initialized or during printing- The media size is different after media mounting and initialization- Tracing paper and thin media cannot be detected


Nam

e an

d D

iagr

am N

umbe

r of

R

epla

cem

ent P

art

DF

-415

86 M

ain

Boa

rd A

ssem

bly

DF

-401

73 V

acuu

m F

an A

ssem

bly

DF

-416

20 F

an E

xten

sion

Cab

le 1

Ass

embl

yD

F-4

1621

Fan

Ext

ensi

on C

able

2 A

ssem

bly

DF

-416

22 F

an E

xten

sion

Cab

le 3

Ass

embl

yD

F-4

1993

Fan

Ext

ensi

on C

able

4 A

ssem

bly

DF

-415

29 P

ress

ure

Ass

embl

yD

F-4

1595

Edg

e S

enso

r A

ssem

bly

DF

-415

92 X

R C

able

Ass

embl

y (P

aper

Sen

sor

R)

DF

-416

00 Y

Cab

leD

F-4

1840

Grid

Rol

ler

Ass

embl

y

1140

1080

-210

80-2

1080

-210

80-2

1080

-211

1014

1012

0013

60-2

1690

3000-23000-23000-23000-23000-2

30103010

When Message is Not Displayed Trouble with Printing Model N. : Rockhopper-463 M A P 4 0 0 0

Trouble with Printing Model N. : Rockhopper-463 M A P 4 0 0 0When Message is Not Displayed

When Message is Not Displayed[Trouble with Printing]

EXA4000 to EXA4130(EXA4110 to EXA4130 → See MAP4001)

Problem

- Does not print continuously- There is an extra feed after printing is finished- Dots are missing from the printing- Cleaning does not cure blockage- Does not print at all or does not print a specific colour- The entire surface is printed black- Printing becomes shaded- The image contains blurs- Transverse lines appear to be split- Black and white lines appear in the printed image- Edges of printing are blurred - Many satellites (unwanted dots)- The printing has whiskers- Printed lines appear blurred- Mixed colour lines do not overlap- Black and colour positions are offset- Inaccurate line length in the direction of head movement (Main scanning direction)- Inaccurate straight line in the direction of head movement (straightness)


Nam

e an

d D

iagr

am N

umbe

r of

R

epla

cem

ent P

art

DF

-415

86 M

ain

Boa

rd A

ssem

bly

DF

-401

73 V

acuu

m F

an A

ssem

bly

DF

-416

20 F

an E

xten

sion

Cab

le 1

Ass

embl

yD

F-4

1621

Fan

Ext

ensi

on C

able

2 A

ssem

bly

DF

-416

22 F

an E

xten

sion

Cab

le 3

Ass

embl

yD

F-4

1605

Ink

Tub

eD

F-4

1601

Hea

d C

able

DF

-416

00 Y

Cab

leD

F-4

1607

T F

ence

DF

-416

02 C

ap A

ssem

bly

DF

-416

03 P

ump

Ass

embl

yD

F-4

1599

Pum

p M

otor

Ass

embl

yD

F-4

0125

Wip

erD

F-4

1604

Mai

nten

ance

Sta

tion

Ass

embl

yD

F-4

0690

Prin

t Hea

d A

ssem

bly

(Col

our)

DF

-415

88 H

ead

Boa

rd A

ssem

bly

DF

-415

93 D

etec

tor

1 A

ssem

bly

DF

-415

94 D

etec

tor

2 A

ssem

bly

DF

-401

06 D

etec

tor

Ass

embl

y (B

lack

)D

F-4

0107

Det

ecto

r A

ssem

bly

(Y)

DF

-401

46 D

etec

tor

Ass

embl

y (M

)D

F-4

0147

Det

ecto

r A

ssem

bly

(C)

DF

-415

92 X

R C

able

Ass

embl

y (P

aper

Sen

sor

R)

DF

-415

87 P

ower

Boa

rd A

ssem

bly

1140

1080

1080

1080

1080

1370

1390

1360

1290

1240

1260

1230

1250

1270

1390

1420

1350

1350

1350

1350

1350

1350

1200

1150

400040104020402040304040405040504050405040604070407040704080408040904100


When Message is Not Displayed Trouble with Printing Model Name: Rockhopper 62 M A P 4 0 0 0 - 2

Trouble with Printing Model Name: Rockhopper 62 M A P 4 0 0 0 - 2When Message is Not Displayed


EXA4000 to EXA4130-2(EXA4110 to EXA4130-2 → See MAP4001-2)

Problem

- Does not print continuously- There is an extra feed after printing is finished- Dots are missing from the printing- Cleaning does not cure blockage- Does not print at all or does not print a specific colour- The entire surface is printed black- Printing becomes shaded- The image contains blurs- Transverse lines appear to be split- Black and white lines appear in the printed image- Edges of printing are blurred - Many satellites (unwanted dots)- The printing has whiskers- Printed lines appear blurred- Mixed colour lines do not overlap- Black and colour positions are offset- Inaccurate line length in the direction of head movement (Main scanning direction)- Inaccurate straight line in the direction of head movement (straightness)


Nam

e an

d D

iagr

am N

umbe

r of

R

epla

cem

ent P

art

DF

-415

86 M

ain

Boa

rd A

ssem

bly

DF

-401

73 V

acuu

m F

an A

ssem

bly

DF

-416

20 F

an E

xten

sion

Cab

le 1

Ass

embl

yD

F-4

1621

Fan

Ext

ensi

on C

able

2 A

ssem

bly

DF

-416

22 F

an E

xten

sion

Cab

le 3

Ass

embl

yD

F-4

1993

Fan

Ext

ensi

on C

able

4 A

ssem

bly

DF

-416

05 In

k T

ube

DF

-416

01 H

ead

Cab

leD

F-4

1600

Y C

able

DF

-416

07 T

Fen

ceD

F-4

1602

Cap

Ass

embl

yD

F-4

1603

Pum

p A

ssem

bly

DF

-415

99 P

ump

Mot

or A

ssem

bly

DF

-401

25 W

iper

DF

-416

04 M

aint

enan

ce S

tatio

n A

ssem

bly

DF

-406

90 P

rint H

ead

Ass

embl

y (C

olou

r)D

F-4

1588

Hea

d B

oard

Ass

embl

yD

F-4

1593

Det

ecto

r 1

Ass

embl

yD

F-4

1594

Det

ecto

r 2

Ass

embl

yD

F-4

0106

Det

ecto

r A

ssem

bly

(Bla

ck)

DF

-401

07 D

etec

tor

Ass

embl

y (Y

)D

F-4

0146

Det

ecto

r A

ssem

bly

(M)

DF

-401

47 D

etec

tor

Ass

embl

y (C

)D

F-4

1592

XR

Cab

le A

ssem

bly

(Pap

er S

enso

r R

)D

F-4

1587

Pow

er B

oard

Ass

embl

y

1140

1080

-210

80-2

1080

-210

80-2

1080

-213

7013

9013

60-2

1290

1240

1260

1230

1250

1270

1390

1420

1350

1350

1350

1350

1350

1350

1200

1150

400040104020402040304040

4050-24050-24050-24050-2

4060407040704070408040804090

4100-2


When Message is Not Displayed Trouble with Printing Model N. : Rockhopper-463 M A P 4 0 0 1

Trouble with Printing Model N. : Rockhopper-463 M A P 4 0 0 1When Message is Not Displayed

Problem

- Inaccurate line distance in the direction of media feed (Subsidiary scanning distance)

- Inaccurate straight line in the direction of media feed (joining precision Y)

- Bad right angle precision


Nam

e an

d D

iagr

am N

umbe

r of

R

epla

cem

ent P

art

DF

-415

86 M

ain

Boa

rd A

ssem

bly

DF

-401

73 V

acuu

m F

an A

ssem

bly

DF

-416

20 F

an E

xten

sion

Cab

le 1

Ass

embl

yD

F-4

1621

Fan

Ext

ensi

on C

able

2 A

ssem

bly

DF

-416

22 F

an E

xten

sion

Cab

le 3

Ass

embl

yD

F-4

1529

Pre

ssur

e A

ssem

bly

DF

-408

54 C

urso

r P

late

Spr

ing

DF

-416

16 S

teel

Fle

xibl

e C

able

Ass

embl

yD

F-4

1840

Grid

Rol

ler

Ass

embl

yD

F-4

1841

Spe

ed R

educ

tion

Pul

ley

Ass

embl

y

1140

1080

1080

1080

1080

1220

1310

1310

1690

1680

411041204130



EXA4000 to EXA4130(EXA4000 to EXA4100 → See MAP4000)

When Message is Not Displayed Trouble with Printing Model N. : Rockhopper-62 M A P 4 0 0 1 - 3

Trouble with Printing Model N. : Rockhopper-62 M A P 4 0 0 1 - 3When Message is Not Displayed

Problem

- Inaccurate line distance in the direction of media feed (Subsidiary scanning distance)

- Inaccurate straight line in the direction of media feed (joining precision Y)

- Bad right angle precision


Nam

e an

d D

iagr

am N

umbe

r of

R

epla

cem

ent P

art

DF

-415

86 M

ain

Boa

rd A

ssem

bly

DF

-401

73 V

acuu

m F

an A

ssem

bly

DF

-416

20 F

an E

xten

sion

Cab

le 1

Ass

embl

yD

F-4

1621

Fan

Ext

ensi

on C

able

2 A

ssem

bly

DF

-416

22 F

an E

xten

sion

Cab

le 3

Ass

embl

yD

F-4

1993

Fan

Ext

ensi

on C

able

4 A

ssem

bly

DF

-415

29 P

ress

ure

Ass

embl

yD

F-4

0854

Cur

sor

Pla

te S

prin

gD

F-4

1616

Ste

el F

lexi

ble

Cab

le A

ssem

bly

DF

-418

40 G

rid R

olle

r A

ssem

bly

DF

-419

88 S

peed

Red

uctio

n P

ulle

y A

ssem

bly

1140

1080

-210

80-2

1080

-210

80-2

1080

-212

2013

10-2

1310

-216

9016

80

41104120

4130-2



EXA4000 to EXA4130-2(EXA4000 to EXA4100-2 → See MAP4000-2)

When Message is Not Displayed Problem Involving Noise Model N.: Rockhpopper-46/62 M A P 5 0 0 0

Problem Involving Noise Model N.: Rockhopper-46/62 M A P 5 0 0 0When Message is Not Displayed

When Message is Not Displayed[Problem Involving Noise]

EXA5000 to EXA5040

Problem

- Abnormal noise when media is sucked down- Abnormal noise when standing by ready to print- Abnormal noise when head is moving left and right- Abnormal noise when media is fed- Abnormal noise when cutting


Nam

e an

d D

iagr

am N

umbe

r of

R

epla

cem

ent P

art

DF

-415

86 M

ain

Boa

rd A

ssem

bly

DF

-401

73 V

acuu

m F

an A

ssem

bly

DF

-415

87 P

ower

Boa

rd A

ssem

bly

DF

-406

90 P

rint H

ead

Ass

embl

y (C

olou

r)D

F-4

1588

Hea

d B

oard

DF

-401

44 Y

Ret

urn

Pul

ley

Ass

embl

yD

F-4

1598

Cur

sor

Mot

or A

ssem

bly

(Y M

otor

)D

F-4

1529

Pre

ssur

e A

ssem

bly

DF

-401

37 X

Spe

ed R

educ

tion

Bel

tD

F-4

1597

X M

otor

Ass

embl

yD

F-4

1600

Y C

able

DF

-416

77 T

ube

Gui

de A

ssem

bly

DF

-418

40 G

rid R

olle

r A

ssem

bly

1140

1080

1150

1390

1420

1320

1280

1220

1090

1070

1360

1540

1690

50005010502050305040


When Message is Not Displayed Problem Involving Noise Model N. : Rockhopper-62 M A P 5 0 0 0 - 3

Problem Involving Noise Model N. : Rockhopper-62 M A P 5 0 0 0 - 3When Message is Not Displayed

When Message is Not Displayed[Problem Involving Noise]

EXA5000 to EXA5040

Problem

- Abnormal noise when media is sucked down- Abnormal noise when standing by ready to print- Abnormal noise when head is moving left and right- Abnormal noise when media is fed- Abnormal noise when cutting


Nam

e an

d D

iagr

am N

umbe

r of

R

epla

cem

ent P

art

DF

-415

86 M

ain

Boa

rd A

ssem

bly

DF

-401

73 V

acuu

m F

an A

ssem

bly

DF

-415

87 P

ower

Boa

rd A

ssem

bly

DF

-406

90 P

rint H

ead

Ass

embl

y (C

olou

r)D

F-4

1588

Hea

d B

oard

DF

-401

44 Y

Ret

urn

Pul

ley

Ass

embl

yD

F-4

1598

Cur

sor

Mot

or A

ssem

bly

(Y M

otor

)D

F-4

1529

Pre

ssur

e A

ssem

bly

DF

-401

37 X

Spe

ed R

educ

tion

Bel

tD

F-4

1597

X M

otor

Ass

embl

yD

F-4

1600

Y C

able

DF

-416

77 T

ube

Gui

de A

ssem

bly

DF

-418

40 G

rid R

olle

r A

ssem

bly

1140

1080

-211

5013

9014

2013

2012

8012

2010

9010

7013

60-2

1540

-216

90

50005010502050305040


When Message is Not Displayed Trouble with Media Cutting Model N. :Rockhopper-463 M A P 6 0 0 0

Trouble with Media Cutting Model N. :Rockhopper-463 M A P 6 0 0 0When Message is Not Displayed

When Message is Not Displayed[Trouble with Media Cutting]

EXA6000 to EXA6050

Problem

- Does not cut normally- Cutting occurs during printing- The cutting operation is normal but the media is not cut- The cutting is bad and the media jams- The cutting operation is normal but the media does not fall out- Inaccurate media cutting- Cutting is delayed for some time after printing has ended- White paper is cut


Nam

e an

d D

iagr

am N

umbe

r of

R

epla

cem

ent P

art

DF

-415

86 M

ain

Boa

rd A

ssem

bly

DF

-401

13 C

utte

r S

olen

oid

Ass

embl

yD

F-4

1600

Y C

able

DF

-415

88 H

ead

Boa

rd A

ssem

bly

1140

1380

1360

1420

60006010602060206030604060506050


When Message is Not Displayed Trouble with Media Cutting Model Name: Rockhopper 62 M A P 6 0 0 0 - 2

Trouble with Media Cutting Model Name: Rockhopper 62 M A P 6 0 0 0 - 2When Message is Not Displayed

When Message is Not Displayed[Trouble with Media Cutting]

EXA6000 to EXA6050

Problem

- Does not cut normally- Cutting occurs during printing- The cutting operation is normal but the media is not cut- The cutting is bad and the media jams- The cutting operation is normal but the media does not fall out- Inaccurate media cutting- Cutting is delayed for some time after printing has ended- White paper is cut


Nam

e an

d D

iagr

am N

umbe

r of

R

epla

cem

ent P

art

DF

-415

86 M

ain

Boa

rd A

ssem

bly

DF

-401

13 C

utte

r S

olen

oid

Ass

embl

yD

F-4

1600

Y C

able

DF

-415

88 H

ead

Boa

rd A

ssem

bly

1140

1380

1360

-214

20

60006010602060206030604060506050


When Message is Not Displayed Online/Function Problems Model N.: Rockhopper-463 M A P 7 0 0 0

Online/Function Problems Model N.: Rockhopper-463 M A P 7 0 0 0When Message is Not Displayed

When Message is Not Displayed[Online/Function Problems]

EXA7000 to EXA7060

Problem

- Cannot connect normally with RS-232C - Cannot connect normally with Centronics- Cannot connect normally with Network- The scale function does not work correctly - The rotate function does not work correctly- The mirror function does not work correctly- Other functions are not working correctly- Printing position is offset- Some data are not printed (omitted)- Text and printing data are garbled (extra lines appear) - There is an extra feed after printing is finished


Nam

e an

d D

iagr

am N

umbe

r of

R

epla

cem

ent P

art

DF

-415

86 M

ain

Boa

rd A

ssem

bly m

)

DF

-416

00 Y

Cab

leD

F-4

1588

Hea

d B

oard

Ass

embl

yD

F-4

1607

T F

ence

1140

1360

1420

1290

70007000700070207020702070207030704070507060


When Message is Not Displayed Online/Function Problems Model Name: Rockhopper 62 M A P 7 0 0 0 - 2

Online/Function Problems Model Name: Rockhopper 62 M A P 7 0 0 0 - 2When Message is Not Displayed

When Message is Not Displayed[Online/Function Problems]

EXA7000 to EXA7060

Problem

- Cannot connect normally with RS-232C - Cannot connect normally with Centronics- Cannot connect normally with Network- The scale function does not work correctly - The rotate function does not work correctly- The mirror function does not work correctly- Other functions are not working correctly- Printing position is offset- Some data are not printed (omitted)- Text and printing data are garbled (extra lines appear) - There is an extra feed after printing is finished


Nam

e an

d D

iagr

am N

umbe

r of

R

epla

cem

ent P

art

DF

-415

86 M

ain

Boa

rd A

ssem

bly m

)

DF

-416

00 Y

Cab

leD

F-4

1588

Hea

d B

oard

Ass

embl

yD

F-4

1607

T F

ence

1140

1360

-214

2012

90

70007000700070207020702070207030704070507060


When Message is Not Displayed Other Model N.: Rockhopper-463 M A P 8 0 0 0

Other Model N.: Rockhopper-463 M A P 8 0 0 0When Message is Not Displayed

When Message is Not Displayed[Other]

EXA8000 to EXA8050

Problem

- The printer hangs up- Power shutdown during printing- The ink cartridges will not go in- Ink has overflowed from the waste fluid bottle- Ink overflows from flushing box- Ink is split around the X-rail


Nam

e an

d D

iagr

am N

umbe

r of

R

epla

cem

ent P

art

DF

-415

86 M

ain

Boa

rd A

ssem

bly

DF

-401

27 C

artr

idge

Fra

me

Ass

embl

yD

F-4

1593

Det

ecto

r 1

Ass

embl

yD

F-4

1594

Det

ecto

r 2

Ass

embl

yD

F-4

0106

Det

ecto

r A

ssem

bly

(Bla

ck)

DF

-401

07 D

etec

tor

Ass

embl

y (Y

)D

F-4

0146

Det

ecto

r A

ssem

bly

(M)

DF

-401

47 D

etec

tor

Ass

embl

y (C

)D

F-4

1587

Pow

er B

oard

Ass

embl

yD

F-4

1591

Was

te F

luid

Bot

tle S

enso

r A

ssem

bly

DF

-420

07 F

Abs

orbe

nt M

ater

ial A

ssem

bly

1140

1330

1350

1350

1350

1350

1350

1350

1150

1120

1700

800080108020803080408050


When Message is Not Displayed Other Model Name: Rockhopper 62 M A P 8 0 0 0 - 2

Other Model Name: Rockhopper 62 M A P 8 0 0 0 - 2When Message is Not Displayed

When Message is Not Displayed[Other]

EXA8000 to EXA8050-2

Problem

- The printer hangs up- Power shutdown during printing- The ink cartridges will not go in- Ink has overflowed from the waste fluid bottle- Ink overflows from flushing box- Ink is split around the X-rail- Ink has overflowed from the waste fluid bottle


Nam

e an

d D

iagr

am N

umbe

r of

R

epla

cem

ent P

art

DF

-415

86 M

ain

Boa

rd A

ssem

bly

DF

-401

27 C

artr

idge

Fra

me

Ass

embl

yD

F-4

1593

Det

ecto

r 1

Ass

embl

yD

F-4

1594

Det

ecto

r 2

Ass

embl

yD

F-4

0106

Det

ecto

r A

ssem

bly

(Bla

ck)

DF

-401

07 D

etec

tor

Ass

embl

y (Y

)D

F-4

0146

Det

ecto

r A

ssem

bly

(M)

DF

-401

47 D

etec

tor

Ass

embl

y (C

)D

F-4

1587

Pow

er B

oard

Ass

embl

yD

F-4

1591

Was

te F

luid

Bot

tle S

enso

r A

ssem

bly

DF

-420

07 F

Abs

orbe

nt M

ater

ial A

ssem

bly

DF

-420

08 W

aste

Flu

id B

ottle

Ass

embl

y

1140

1330

1350

1350

1350

1350

1350

1350

1150

1120

1700

1710

800080108020

8050805080508050


When Message is Not Displayed Heater Systemr Model N:Rockhopper46 3 M A P 9 0 0 0

Heater Systemr Model N:Rockhopper46 3 M A P 9 0 0 0When Message is Not Displayed

When Message is Not Displayed[Heater system]

EXA9000

Problem

- Heater does not stop warming up or is broken


Nam

e an

d D

iagr

am N

umbe

r of

R

epla

cem

ent P

art

Fro

nt H

eate

rR

ear

Hea

ter

Fro

nt H

eate

r S

enso

rR

ear

Hea

ter

Sen

sor

1040

1040

10

40

1040

9000


DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

3

DDV

3

When Message is Not Displayed Heater Systemr Model N:Rockhopper62 3 M A P 9 0 0 0 - 2

Heater Systemr Model N:Rockhopper62 3 M A P 9 0 0 0 - 2When Message is Not Displayed

When Message is Not Displayed[Heater system]

EXA9000

Problem

- Heater does not stop warming up or is broken


Nam

e an

d D

iagr

am N

umbe

r of

R

epla

cem

ent P

art

Fro

nt H

eate

rR

ear

Hea

ter

Fro

nt H

eate

r S

enso

rR

ear

Hea

ter

Sen

sor

1040

-2

1040

-2

1040

-2

1040

-2

9000


DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

3

DDV

3

E X A 0 0 0 0Model Name: Rockhopper-46

E X A 0 0 0 0Model Name: Rockhopper-46Rockhopper-463 Fault-Tracing Procedure

Rockhopper-463 Fault-Tracing Procedure


Printer Status Messages EXA1000Data Errors EXA1200Command Errors EXA1250CPU System Faults EXA1500Mechanical System Faults EXA1700


Trouble with Initialization EXA2000

Trouble with Printing EXA4000Trouble with Media Feed EXA3000

Trouble with Media Cutting EXA6000Problem Involving Noise EXA5000

Online/Function Problems EXA7000Other EXA8000

Fault-Tracing Procedure

Heater System EXA 9000

Heaters System Faults EXA1800

E X A 0 0 0 0 - 3Model Name: Rockhopper-62

E X A 0 0 0 0 - 3Model Name: Rockhopper-62Rockhopper-62 Fault-Tracing Procedure

Rockhopper-62 Fault-Tracing Procedure


Printer Status Messages EXA1000 ( 1020-2 )Data Errors EXA1200Command Errors EXA1250CPU System Faults EXA1500Mechanical System Faults EXA1700


Trouble with Initialization EXA2000 ( 2070-2 )

Trouble with Printing EXA4000 ( 4050-2, 4100-2, 4130-2 )Trouble with Media Feed EXA3000 ( 3000-2 )

Trouble with Media Cutting EXA6000Problem Involving Noise EXA5000

Online/Function Problems EXA7000Other EXA8000

(Difference between Rockhopper-46 and 62)

Fault-Tracing Procedure

Heater System EXA9000-2

Heaters System Faults EXA1800-2



Printer Status Messages


1

2

3

• Cover OpenThis message means that the FrontCover is open

• Lever UpThis message means that thePressure Lever is up.

• Cover and LeverThis message means that the FrontCover and Pressure Lever are up.

1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

1-9

1-10

1-11

1-12

• Is the cover sensor arm loose? (Related to opening and closing the front cover)→ Tighten the cover sensor arm screw.

• When the front cover is opened and closed, does the cover switch go on and off normally?→ Adjust the height of the cover switch assembly.→ Adjust the relative positions of the cover shaft R and front cover fulcrum.

• Is the cover switch cable connected securely? (Related to opening and closing the front cover)→ Connect the sensor cable securely to connector J106 (COVER) on the main board assembly.

• Does the pressure lever move smoothly? (Related to raising and lowering the pressure lever)→ Adjust the position of the pressure relay plate.→ Apply grease G-501 to the elongated round hole in the pressure relay plate. (Refer to CAT4000)

• Is the lever sensor assembly fitted securely? (Related to raising and lowering the pressure lever)→ Adjust the lever sensor assembly fitting position.

• Is the sensor unit in the lever sensor assembly dirty? (Related to raising and lowering the pressure lever)→ Clean the sensor unit with cotton swabs.

• Is the lever sensor assembly cable fitted securely? (Related to raising and lowering the pressure lever)→ Connect the lever sensor cable securely to connector J102 (LEVER) on the main board assembly.

• The panel board assembly may be damaged. (Related to opening and closing the front cover)→ Replace it.

• The panel cable may be damaged. (Related to opening and closing the front cover)→ Replace it.

• Is the cover limit switch working on "Sensor: Cover" in the printer self-diagnostics?→ Replace the cover switch assembly

• Is the lever sensor working on "Sensor: Lever" in the printer self-diagnostics?→ Replace the lever sensor assembly.

• The main board assembly may be damaged. (Related to both)→ Replace it.

No. SymptomSequence




1110

1110

1110

1100

1100

1100

1160

1170

1110

1100

1140

1040

1040

R E P B A C






1 • Undefined MediaThis message means that whenmedia was mounted, it was not ableto be recognized.

1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

• Is the edge sensor assembly cable that is attached to the head unit securely connected?→ Connect it securely to connector J204 (P EDGE) on the head board assembly.

• Is the XR cable assembly (paper sensor R) cable that is attached below paper guide Rsecurely connected?→ Connect it securely to connector J107 (XR) on the main board assembly.

• Use the printer's self-diagnostic “Sensor: Edge” to confirm the amount of sensor reflec-tion. Using thick coated paper, check whether the paper detection value is within 0090 to00a4. → Replace edge sensor assembly.→ Adjust with the head board assembly variable resistor (VR1).

• Check Y cable contacts. Check that they are not inserted obliquely.→ Reconnect main board assembly connector J111 (HEAD1) and head board assembly

connector J201 (MAIN1).

• The head board assembly may be damaged.→ Replace it.

• Check with the self-diagnostic “Sensor: X Rear” whether the sensor is operating.→ Replace paper sensor R if “Paper End” is displayed when media is mounted.


• The Y cable assembly may be damaged→ Replace it.

No. SymptomSequence




1410

1200

1410

1420

1200

1140

1360

1040

1040

R E P B A C


E X A 1 0 2 0Model Name: Rockhopper 46/62



1 • Media Skew Error 1-1

1-2

1-3

1-4

1-5

1-6

1-7

2-1

• Reload the media and confirm its current status.→ If the problem is simply due to poor loading, explain to the user how to load the media properly.

• Are the fans working normally according to the self-diagnostic “Examination: Fans”? → Check the connectors between fan assembly, fan extension cable assembly and main board

assembly.Fan extension cable 1 assembly is J115 (FAN1) on the main board assemblyFan extension cable 2 assembly is J116 (FAN2) on the main board assemblyFan extension cable 3 assembly is J117 (FAN3) on the main board assemblyFan extension cable 4 assembly is J118 (FAN4) on the main board assembly

→ Replace fan assembly.→ Replace Fan extension cable 1 assembly, Fan extension cable 2 assembly, Fan extension cable

3 assembly and Fan extension cable 4 assembly.

• Is the shielding material securely attached in the proper positions?Shield material GA-A, shield GA-B, shield GA-C→ Re-attach in the proper positions.

• Is there a problem with the movement of the pressure lever?→ Apply grease (G501) and adjust the pressure transfer plate.

• With the pressure lever lowered, do all pressure rollers make contact with the grid roller?(Are any of the pressure rollers idling?)→ Replace the pressure rollers or the pressure assembly.

• Is there a uniform gap between head and platen?→ Use the rail height jig (JD-30395) to adjust the position of the platen.

• Is there distortion or damage to the grid roller?→ Replace grid roller.

• After carrying out the adjustments according to the procedure above, run the self-diagnostic “SkewVerification”.

No. SymptomSequence



1080

1220

1520

1690

1060

2030

R E P B A C


[ Rated Value ] Rated ValueCondition

7m

50m

Within 2.5 mm

Within 1.5 mm

Within 10 mm

Cut media

Roll media

CAUTION:

Since this task will establish thereference position for determin-ing skew, it should be adjustedcarefully.





1 • [User 1] Media EndThis message is displayed when nomedia is mounted or printing in cutmedia mode has been completed.

1-1

1-2

1-3

1-4

1-5

1-6

1-7

• Is the edge sensor assembly cable that is attached to the head unit securely connected? → Connect it securely to connector J204 (P EDGE) on the head board assembly.

• Is the XR cable assembly (paper sensor R) cable that is attached below the rear paperguide securely connected?→ Connect it securely to connector J107 (XR) on the main board assembly.

• Use the printer's self-diagnostic “Sensor: Edge” to confirm the amount of sensor reflec-tion.Using thick coated paper, check whether the paper detection value is within 0090 to00a4. → Replace edge sensor assembly.


• Check with the printer's self-diagnostic "Sensor: X Rear" whether the sensor is operating.→ Replace paper sensor R if “Paper End” is displayed when media is mounted.


• The Y cable assembly may be damaged.→ Replace it.

No. SymptomSequence




1410

1200

1410

1420

1200

1140

1360

1040

1040

R E P B A C






1 • Remove MediaThis message is displayed if, afterraising the lever during printing andcutting the media, the lever is loweredwithout the media having beenremoved.

1-1

1-2

1-3

1-4

1-5

1-6

• Switch off the printer temporarily and check that the message is displayed when youswitch on again.

• Use the printer's self-diagnostic "Sensor: Lever" to make sure that the pressure lever isworking normally.→ Check that the liquid crystal display unit does not show that the up and down move-

ment of the pressure lever appears to be chattering when the lever is moved slowly upand down.

• Check the lever sensor assembly contact.→ Reconnect main board assembly connector J104 (LEVER).

If there seems to be chattering, the sensor may be faulty.Replace the lever sensor assembly.

• Is the cable of the XR cable assembly (rear paper sensor) that is attached below the rearpaper guide connected securely?→ Connect it securely to connector J107 (XR) on the main board.

• Use the self-diagnostic “Sensor: X Rear” to check whether there is media.→ If media is loaded but “No Media” is displayed, replace the rear paper sensor.


No. SymptomSequence




1100

1200

1200

1140

1040

R E P B A C






1 • Roll Media EndThis message is displayed when rollmedia is being used and the trailingedge of the media is detected. It willbe cancelled by raising the lever.

1-1

1-2

1-3

1-4


• Use the printer's self-diagnostic "Sensor: X Rear" to make sure that the media end detec-tion is working normally.→ Cover the paper sensor R (XR cable assembly) with media and confirm that "SENS: Xr

Paper On" is displayed.

• Check the paper sensor R contact.→ Reconnect main board assembly connector J107 (XR).

If "Media Present" does not appear, the sensor may be faulty.Replace the paper sensor R assembly.


No. SymptomSequence




1200

1140

1040

R E P B A C






1 • Media Cut ErrorThis message is displayed when themedia is not cut and does not fall outdespite the cutting operation havingbeen performed.

1-1

1-2

1-3

1-4

1-5

• Is there an accumulation of paper dust in the cutter groove?→ Remove accumulated paper dust along the paper groove.

• Check how the cutter cap is fitted.→ Fit the cutter cap securely.

• Check the up and down movement of the cutter. With the cutter installed, push it down to the bot-tom with your finger and check that the power of the spring alone brings it back to the top.→ If it rises, go to 1-5→ If it does not rise, got to 1-4

• Remove the cutter and take out the cutter spring. Fit the cutter and check that in this condition, thecutter will fall to the bottom under its own weight.→ If it falls the cutter spring may be faulty. Refer to the exploded drawings and replace the cutter

spring.→ If it does not fall, the cutter may be faulty. Replace the cutter.

• Use the printer's self-diagnostic “Aging: Cutter” to confirm the up-and-down movement of the sole-noid.

No. SymptomSequence




Refer to theOperationManual(BasicManual)

Refer to theOperationManual(BasicManual)

R E P B A C


Moves up/down → Check the down position of the cutter blade relative to the cutter groove.

[OK] → Cutter blade is damaged or worn out. Replace with a new blade.[NG] → Refer to REP 1380 position adjustment and adjust the position of the cutter

holder.No up/down movement → Connection may be faulty. Check the following connectors.

• Head board assembly connector J206 (SOL) • Head board assembly connector J201 (MAIN1) • Main board assembly connector J206 (HEAD1)

CAUTION: Power must be off when connectors are being disconnected or reconnected, otherwise you may be injured or a board may be damaged. The main board assembly will certainly be damaged if power is applied with main board assembly connectors J111 (HEAD) and J112 (HEAD2) and head board connectors J201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP.

→ Continued on next page





1 • Media Cut ErrorThis message is displayed when themedia is not cut and does not fall outdespite the cutting operation havingbeen performed.

1-6 • There may be a broken Y cable lead, faulty solenoid assembly or a faulty board assembly.

a. Try fitting a new Y cable. (Check for continuity between connectors)→ If there is up/down movement, replace Y cable.

b. Try fitting a new solenoid assembly. (Check for continuity between connectors)→ If there is up/down movement, replace solenoid assembly.

c. Try replacing the head board assembly.(Reference) after replacement, use the printer's “EXAM: Sensor” self-diagnostic "Edge" to

adjust the amount of sensor reflection. (The adjustment volume is on the headboard.)

d. Try replacing the main board assembly.(Reference) Back up the parameters before replacing the main board and check the operation

after executing Recovery with the new main board assembly.

No. SymptomSequence




R E P B A C


E X A 1 0 7 0Model Name: Rockhoppper-46/62




1 • Not enough memory SIMM✼✼MB(Intermediate code buffer overflow)

When this printer has insufficientmemory for the amount of data sentby the personal computer, this mes-sage indicates the required memorysize.

1-1

1-2

1-3

• Check RAM capacity with the printer's self-diagnostic “Examination: RAM Capacity”.→ The capacity without optional extended memory is 8 MB. If SIMM has been extended,

the value “Standard memory 8 MB + Extended memory” will be displayed.(If two 36 MB SIMMs have been installed, “80 MB” is displayed.)(With Iris 46 WIDE, since a 16 MB SIMM has been added in Slot 1, the display is nor-mally "24 MB")

• “Optional Memory = ∗∗ MB” shown in the “Setup List” is the amount of extended memoryonly. If there is a difference between the actual memory capacity and the memory capac-ity shown on the panel or the memory capacity shown in the setup list, the SIMM may bedamaged. Replace the SIMM.


No. SymptomSequence




1140

1140

1010

R E P B A C






1 • Insert Special CartridgeThis message is displayed when acartridge other than a genuine Mutohcartridge has been installed.

1-1

1-2

1-3

1-4

1-5

1-6

1-7

• Switch off the printer temporarily and check that the message is displayed when you switch onagain.

• Check whether you are using the specified ink cartridge.

• Use the printer’s self-diagnostic “Sensor: Cartridge” to make sure that the ink cartridge statusdetection is working correctly.If normal detection fails, the ink ID sensor assembly, junction board assembly, ink ID cable, or mainboard assembly may be at fault.

• Check the ink ID sensor assembly connector contacts. → Reconnect junction board assembly connectors J406 (Ink ID Sensor 1 BK), J407 (Ink ID Sensor

2 C), J408 (Ink ID Sensor 3 M), J409 (Ink ID Sensor 4 Y), J412 (Ink ID Sensor 5), J413 (Ink IDSensor 6).If there is no change, move to the next step.

• Using the printer’s self-diagnostic “Sensor: Cartridge”, exchange the position of the connector of theink ID sensor assembly that is shown as being faulty with the position of any one of J406 to J409,J412 and J413 on the junction board assembly that appears to be normal. → If after re-inserting the connectors a different ink cartridge unit now appears to be faulty, it means

that the ink ID sensor assembly that was shown as being faulty is damaged. → Replace the faulty ink ID sensor assembly. → If after re-inserting the connectors there is no change in the part that was shown as being faulty,

or all units are shown as being faulty, the damage may be between the junction board assemblyand the main board assembly.

• Check the ink ID cable contacts. → Reconnect junction board assembly connector J401 (INK ID Cable) and main board assembly

connector J109 (INK ID).

• Replace the ink ID cable and repeat procedures 1-3 and 1-4.(a) If the fault display is cleared, it means that the ID cable may be faulty.→ Replace the ink ID cable.(b) If there is no change at all in the symptoms, it means that the junction board assembly or the

main board assembly may be faulty.→ Replace the junction board assembly. → Replace the main board assembly.

No. SymptomSequence




1340

1340

1470

14701140

1040

R E P B A C






1

2

• [65YMCK] Ink LowThis message is displayed when theamount of ink shown on the operatingpanel is low.Printing can continue.(Refer to GID2010 for details)

• [65YMCK] No InkThis message is displayed when theink shown on the operating panel hasbeen used up.If this message appears while animage is being printed, stop printingimmediately.(Refer to GID2010 for details)

1-1

1-2

1-3

1-4

1-5

• Check the no ink cartridge with the printer's self-diagnostic "Sensor: No Ink".→ Remove all cartridges and gently switch the detector assemblies (BK, C, M and Y)

(black plastic levers) on and off to confirm that the displays “Sensor: No Ink K (black)”,“Sensor: No Ink C (cyan)”, “Sensor: No Ink M (magenta)” and “Sensor: No Ink Y (yel-low)” change.

• Check the detector assembly connector contacts. → Reconnect junction board assembly connector J402 (Detector Assembly BK), J403

(Detector Assembly C), J404 (Detector Assembly M), J410 (Detector1 Assembly [O/5]),J411 (Detector2 Assembly [G/6]).If there is no change, move to the next step.

• Exchange the position of the connector of the ink detector assembly for the ink for which“Ink Low” or “No Ink” is indicated with the position of any one of J402 to J405, J410 andJ411 on the junction board assembly that appears to be normal. → If after re-inserting the connectors a different ink now appears to be “No Ink”, it means

that the detector assembly is damaged.→ Replace the detector assembly. → If after re-inserting the connectors there is no change in the “No Ink” display, or “No

Ink” is shown for all inks, the damage may be between the junction board assemblyand the main board assembly.

• Check the ink ID cable contacts. J401 (ink ID cable) on the junction board assembly and J109 (INK ID) on the main boardassembly.→ Disconnect and reconnect them.

• Replace the ink ID cable and repeat procedure 1-3.(a) If the fault display is cleared, it means that the ID cable may be faulty.→ Replace the ink ID cable.(b) If there is no change at all in the symptoms, it means that the junction board assem-

bly or the main board assembly may be faulty.→ Replace the junction board assembly. → Replace the main board assembly.

No. SymptomSequence




1350

1350

1470

14701140

1040

R E P B A C






1 • [65YMCK] No CartridgeThis message indicates that the inkcartridge that is shown on the operat-ing panel is missing.

1-1

1-2


• Check the no ink cartridge with the printer's self-diagnostic "Sensor: No Ink".→ Remove all the cartridges and, using an object with a flat tip such as a ball pen, press

the switch that detects the presence of the cartridge that is to be checked (theseswitches are inside the cartridge frame assembly.)

No. SymptomSequence




1330 1040

R E P B A C


With “Sensor: No Cartridge”, the following is displayed when all cartridges are removed:

and the following is displayed when the switch that detects whether the black cartridge is present is pressed:

Sensor: No Cartridge KCMYOG

CAUTION: Take care. You can be hurt by the ink filling needle when you operate the switch showing whether there is ink in the cartridge frame assembly. For safety, work with the cartridge cover removed.

Sensor: No Cartridge CMYOG

The same applies to the other cartridges C, M and Y.

(Reference) The differences between error messages shown to the user and messages shown by "Test" and "Sensor" diagnostic modes are as follows.

Display to user Diagnostic mode display Cartridge position

5 O No. 5

6 G No. 6

• Check the cartridge frame assembly connector contacts. → Reconnect junction board assembly connector J402 (Detector Assembly BK), J403

(Detector Assembly C), J404 (Detector Assembly M), J410 (Detector1 Assembly [O/5]),J411 (Detector2 Assembly [G/6]).If there is no change, move to the next step.


1-3

1350





1 • [65YMCK] No CartridgeThis message indicates that the inkcartridge that is shown on the operat-ing panel is missing.

1-4

1-5

1-6

1-7

• Exchange the position of the connector of the cartridge detector assembly for the car-tridge for which “No Cartridge” is indicated with the position of any one of J402 to J405,J410 and J411 on the junction board assembly that appears to be normal. → If after re-inserting the connectors a different ink now appears to have “No Cartridge”, it

means that the detector assembly is damaged.→ Replace the detector assembly. → If after re-inserting the connectors “No Cartridge” appears, or “No Cartridge” is shown

for all cartridges, the damage may be between the junction board assembly and themain board assembly.

Reference: Take care when you are replacing the detector assembly that senseswhether there is a cartridge present. It can become damaged by over-tightening the attaching screw.

• Check the ink ID cable contacts. → Reconnect junction board assembly connector J401 (INK ID Cable) and main board

assembly connector J109 (INK ID).

• Replace the ink ID cable and repeat procedure 1-4.If the “No Cartridge” display is cleared, it means that the Ink ID may be faulty.→ Replace it.

• If there is no change in the symptoms, it means that the junction board assembly or themain board assembly may be faulty.→ Replace the junction board assembly. → Replace the main board assembly.

No. SymptomSequence




1350

14701140

R E P B A C






1 • Capping position not specifiedThe capping position was not dis-played at the time of initialization.

1-1

1-2

1-3

• Adjust the capping position by running the printer's self-diagnostic "Adjust: Capping posi-tion".→ If the capping position parameter is changed for some reason you will not be able to

shift to the next adjustment task so the capping position adjustment should be donefirst.

• Check whether the parameters are set to the initial values by running the printer's self-diagnostic "Adjust: Test print" to output the parameters that have been set.Refer to the functions and operations manual for the initial values of parameters.→ If the parameters have been restored to their initial values, please contact the "Inquiry

desk" and quote your printer serial number to obtain a setup list for the time your print-er was shipped from the factory.Enter all parameters in accordance with the setup list. (See PAT4000)


No. SymptomSequence




1140

2010

2150

R E P B A C






1 • Not FilledThis message means "Initial filling hasnot been done".

1-1

1-2

• With the specified cartridge inserted securely, use the printer's self-diagnostic mode"Sensor: No Ink" or "Sensor: No Cartridge" to check whether the presence of ink and car-tridge are being detected normally.→ For checking, use the [65YMCK] “No Ink” procedure shown in EXA1090.→ After adjustment and replacement, carry out initial filling with the printer’s self-diagnos-

tic “Adjust: Enter Rank”.

• With the specified cartridge inserted securely, use the printer's self-diagnostic mode"Sensor: Cartridge" to check whether the status of the special cartridge is operating nor-mally.→ For checking, use the “Insert Special Cartridge” procedure shown in EXA1080.→ After adjustment and replacement, carry out initial filling with the printer’s self-diagnos-

tic “Adjust: Enter Rank”.

No. SymptomSequence




1040

2040

1040

2040

R E P B A C


CAUTION: Wait at least 30 minutes after initial filling before printing. Printingquality can not be assured unless ink filling has been stabilized.





1 • No Waste Fluid BoxThis message means that the wastefluid bottle is not installed.

1-1

1-2

1-3

1-4

1-5


• Use the printer's self-diagnostic "Sensor: Tank Exist/Tank is not" to make sure that thewaste fluid bottle detection is working normally.→ Slowly remove and replace the waste fluid bottle to confirm that the present/absent dis-

play appears.If the display is not normal, the sensor position may be faulty.Adjust the position of the waste fluid bottle detection switch assembly.

• Make sure the waste liquid bottle is making contact.→ Reconnect main board assembly connector J105 (INK TANK).

• The waste fluid bottle detection switch assembly may be faulty.→ Replace it.


No. SymptomSequence




1120

1120

1140

1040

R E P B A C






1 • Check Waste Fluid Box 1-1

1-2

1-3

1-4

1-5


• Use the printer's self-diagnostic "Sensor: Tank Exist/Tank is not" to make sure that thewaste fluid bottle detection is working normally.→ Slowly remove and replace the waste fluid bottle to confirm that the present/absent dis-

play appears.If the display is not normal, the sensor mounting position may be at fault.Adjust the mounting position of the waste fluid bottle detectionswitch assembly.

• Make sure the waste liquid bottle is making contact.→ Reconnect main board assembly connector J105 (INK TANK).

• The waste fluid bottle detection switch assembly may be faulty.→ Replace it.


No. SymptomSequence




1120

1120

1140

1040

R E P B A C






1 • Ink Type ErrorThis message is displayed when thewrong type of ink cartridge has beeninstalled.

1-1 • Use the printer's self-diagnostic "Sensor: Cartridge" to check the ink type.→ Install all cartridges and check that all six colours have the same type of ink.

No. SymptomSequence




1470

14701140

1040

R E P B A C


Sensor: K C M Y O G

Depending on the ink type, the following symbols will be displayed at locations _.

D : Dye type ink cartridge installedP : Pigment or Eco-solvent type ink cartridge installedW : Wash fluid cartridge installedN : Other ink cartridge installed

• Make sure the detector assembly connector is making contact.→ Reconnect junction board assembly connectors J406 (INK ID Sensor1 BK), J407 (INK

ID Sensor2 C), J408 (INK ID Sensor3 M), J409 (INK ID Sensor4 Y), J412 (INK IDSensor5), J413 (INK ID Sensor6).If there is no change, move to the next step.

• Check the ink ID cable contacts. J401 (ink ID cable) on the junction board assembly and J109 (INK ID) on the main boardassembly.→ Disconnect and reconnect them.

• Replace the ink ID cable and repeat procedure 1-2.(a) If the fault display is cleared, it means that the ID cable may be faulty.

→ Replace the ink ID cable.(b) If there is no change at all in the symptoms, it means that the junction board assem-

bly or the main board assembly may be faulty.→ Replace the junction board assembly. → Replace the main board assembly.

1-2

1-3

1-4



Data Errors


1

2

• Network Detection ErrorThe optional network board can notbe detected

• Network Initialization ErrorAn error has occurred during theoptional network board initializationoperation

1-1

1-2


• The Ethernet board assembly may be damaged.→ Replace it.

Go to MAP1200

No. SymptomSequence



Data Errors

1140

R E P B A C




Command Errors


1

2

3

4

5

• MH01 Error (Undefined Command)A command that is not defined in anycommand mode has been analysed

• MH02 Error (Parameter Error)Wrong number of parameters follow-ing the command

• MH03 Error (Numerical Error)Wrong number of parameters follow-ing the command

• MH04 Error (Undefined CharacterSet)A nonexistent character set is present

• MH07 Error (Buffer Overflow)The polygon buffer or the download-able character buffer has overflowed

1-1

1-2

1-3

1-4

• Try communicating with the available computer and cable.→ Contact your Mutoh distributor.

• Is there any record of an error in the printing data?→ Try changing the type of application driver.

• If the symptoms persist despite various application driver changes→ Obtain the printing data (Report to the your distributor after you have obtained it).


No. SymptomSequence



Command Errors

1140

R E P B A C




CPU System Faults


1

2

• E001 Error DRAM (Standard DRAMerror)

This error display means that a faulthas occurred in the standard memoryof the Main Board that controls theprinter.

• E002 Error Opt. DRAM (OptionalDRAM error)

This error display means that a faulthas occurred in the optional memoryof the Main Board that controls theprinter.

1-1

2-1

2-2

2-3


• This error may occur when there is dust, etc. in extended memory slot 1 or slot 2.→ Use an air duster to remove the dust and reinstall.

• Install reliable memory of the same capacity and check with the self-diagnostic“Examination: Memory Capacity”.→ Replace optional memory.


No. SymptomSequence



CPU System Faults

1140

1140

1010

R E P B A C


CAUTION: If only one extended memory is added, it must be installed in Slot 1. (Rockhopper-46 has an extra 16 MB SIMM in Slot 1)(Rockhopper-62 has an extra 32 MB SIMM in Slot 1)



CPU System Faults


1

2

3

4

5

6

7

8

9

• E016 CPU Err [00] (Interrupt exceptionerror)Indicates that handling an interrupt hasgenerated an error.

• E016 CPU Err [02] (Command boundaryexception error)Indicates that the boundary of a commandhas caused an error.

• E016 CPU Err [03] (Data boundary excep-tion error)Indicates that the boundary of a commandhas caused an error.

• E016 CPU Err [04] (Address error excep-tion) (Load or command check)Indicates that an address error hasoccurred when checking a load or com-mand.

• E016 CPU Err [05] (Address error excep-tion) (Store)Indicates that an address error hasoccurred when saving.

• E016 CPU Err [06] (Bus error exception)(Command check)Indicates that a bus error has occurredwhen loading or storing a command.

• E016 CPU Err [07] (Bus error exception)(Data load)Indicates that a bus error has occurredwhen loading or storing a command.

• E016 CPU Err [08] (System call exceptionerror)Indicates that a system call has caused anerror.

• E016 CPU Err [09] (Break point exceptionerror)Indicates that a break point has caused anerror.

1-1

1-2

1-3

1-4

• Check AC power supply and printer peripheral devices.→ Contact your Mutoh distributor.

• Check whether the problem recurs. Even if there is no problem, switch on several times.(Use the same conditions as the customer's)→ Contact your Mutoh distributor.

• Check the serial number.→ Contact your Mutoh distributor.


No. SymptomSequence



CPU System Faults

1140

R E P B A C




CPU System Faults


1

2

3

4

5

6

7

8

9

• E016 CPU Err [10] (Reserved commandexception error)Indicates that a reserved command hascaused an error.

• E016 CPU Err [11] (Unable to usecoprocessor exception error)Indicates that the coprocessor has causedan error.

• E016 CPU Err [12] (Operation overflowexception error)Indicates that an overflow has occurred.

• E016 CPU Err [13] (Trap exception error)Indicates that a trap has occurred.

• E016 CPU Err [15] (Floating point excep-tion error)Indicates that a floating point error hasoccurred.

• E016 CPU Err [22] (Watchdog timeoutexception error)Indicates that the watch has caused anerror.

• E016 CPU Err [32] (Watchdog timeoutexception error)Indicates that a watchdog timeout hasoccurred.

• E016 CPU Err [33] (Abort error)Indicates that an abort has occurred.

• E237 Err Transfer Memory (Transfermemory error/Transfer memory accesserror)Indicates that a fault has occurred intransferring printing data that has beenanalysed.

1-1

1-2

1-3

1-4

• Check AC power supply and printer peripheral devices.→ Contact your Mutoh distributor.

• Check whether the problem recurs. Even if there is no problem, switch on several times.(Use the same conditions as the customer's)→ Contact your Mutoh distributor.

• Check the serial number.→ Contact your Mutoh distributor.


No. SymptomSequence



CPU System Faults

1140

R E P B A C




CPU System Faults


1 • E129 Error NVRAMThis message indicates that a faulthas occurred in the NVRAM on theMain board that records printer set-tings.

1-1 • The main board assembly may be damaged.→ Replace it.

No. SymptomSequence



CPU System Faults

1140

R E P B A C




Mechanical System Faults


1

2

3

4

• E065 Error X MotorThis message indicates that a faulthas occurred in the media feed motor(X axis) while the printer was working.This occurs when there is a large dif-ference between the motor commandvalue and encoder feedback value.

• E069 Error X EncoderThis message indicates that a faulthas occurred in the amount of mediamovement (X axis) while the printerwas working.This occurs when there is no encoderfeedback.

• E071 Error X TimeoutThis message indicates that a timeouthas occurred in the amount of mediamovement (X axis) while the printerwas working.This occurs when the pressure doesnot reach its designated position.

• E073 Error X OvercurrentThis message indicates that a faulthas occurred due to an overload ofthe media feed (X-axis) motor whilethe printer was working.

1-1

1-2

1-3

1-4

1-5

1-6

• Use the self-diagnostic “Examination: History” to check the history of faults.

• Use the self-diagnostic “Aging: Media Feed Motor” with a setting of 50 times to checkwhether the X Motor error occurs.→ Check connectors J119 (X MOT) and J121 (X ENC) on the main board.

• Use the self-diagnostic “Examination: Encoder” to check Encoder X.→ If it is no good, check the J121 (X ENC) cable connector.

• Check “Power Supply Voltage Check 24 DC”

• The X Motor assembly may be damaged.→ Replace it.


No. SymptomSequence




1070

1140

1070

6020

1050

R E P B A C


CAUTION: If the Power supply board assembly and Main board assembly arereplaced without checking “24 V DC” on those, there is a risk thatthe new boards may also be damaged.





1

2

3

4

• E066 Error Y MotorThis message indicates that a faulthas occurred in the head movementmotor (Y axis) while the printer wasworking.This occurs when there is a large dif-ference between the motor commandvalue and encoder feedback value.

• E070 Error Y EncoderThis message indicates that a faulthas occurred in the amount of headmovement (Y axis) while the printerwas working.This occurs when there is no encoderfeedback.

• E072 Error Y TimeoutThis message indicates that a timeouthas occurred in the amount of headmovement (Y axis) while the printerwas working.This occurs when the carriage has notreached its designated position.

• E074 Error Y OvercurrentThis message indicates that a faulthas occurred due to an overload ofthe head movement (Y axis) motorwhile the printer was working.

1-1

1-2

1-3

1-4

1-5

1-6

• Use the self-diagnostic “Examination: History” to check the history of faults.

• With power off, move the carriage to left and right. Is the movement restricted? → Clean and lubricate the Y rail rollers.

• Use the self-diagnostic “Aging: Carriage Motor” with a setting of 50 times to checkwhether the Y Motor error occurs.→ Check cable connector J120 (Y MOT) on the main board.

• Check whether the timing fence (T fence) is dirty or twisted.→ If there is grease or dirt on the fence, wipe it away with a dry cloth.→ If there is ink on the fence, wet a cloth with neutral cleaner and wipe lightly. → If the T fence is severely soiled and can not be cleaned, it should be replaced → Replace the T fence.

• Use the self-diagnostic “Examination: Encoder” to check Encoder Y.→ If it is no good, check cable connections J112 (HEAD2) on the main board assembly

and J202 (MAIN2) on the head board assembly.→ Replace the T fence.→ Replace the Y motor assembly.→ Replace the head board assembly.→ Replace the Y cable (between J112 (HEAD2) on the main board and J202 (MAIN2) on

the head board)


No. SymptomSequence




1300

1300128014201360

1140

1070

6010

R E P B A C


CAUTION: Power must be off when connectors are being disconnected orreconnected, otherwise you may be injured or a board may bedamaged.The main board assembly will certainly be damaged if power isapplied with main board assembly connectors J111 (HEAD) andJ112 (HEAD2) and head board connectors J201 (MAIN1) and J202(MAIN2) inserted with oblique FFP.





1 • E075 Error Sensor Fault This message indicates that conditionhas occurred in which the origin can-not be detected.

1-1

1-2

1-3

1-4

1-5

• Use the self-diagnostic “Sensor: Origin” and carry out the origin sensor test.

• Check the origin sensor assembly connection.J205 (H ORIGN) on the head board assembly.→ Reconnect properly.

• Check Y cable connections.Check that they are not inserted obliquely.J111 (HEAD1) on the main board assembly and J201 (MAIN1) on the head board assem-bly.→ Insert them properly.→ Replace the Y cable between J111 (HEAD1) and J201 (MAIN1).

• The origin sensor assembly may be faulty.→ Replace it.


No. SymptomSequence




1360

1450

1140

1040

R E P B A C





Heater System Faults


1 • Err : F.R.T. Sensor • Is Front Right Temperature Sensor not connected / broken?→ Reconnect sensor / replace the Front Paper Guide

• Is Front Left Temperature Sensor not connected / broken?→ Reconnect sensor / replace the Front Paper Guide

• Is Rear Right Temperature Sensor not connected / broken?→ Reconnect sensor / replace the Rear Paper Guide

• Is Rear Left Temperature Sensor not connected / broken?→ Reconnect sensor / replace the Rear Paper Guide

• Are 2 Front Temperature Sensors not connected / broken?→ Reconnect sensors / replace the Front Paper Guide

• I

No. SymptomSequence


When Message is Displayed (on LCD heater)


1040

1040

1040

1040

1040

1040

R E P B A C


• Err : F.L.T. Sensor

• Err : R.R.T. Sensor

• Err : R.L.T. Sensor

• Err : FRFLT Sensor

• Are Front Right and Rear Left Temperature Sensor not connected / broken?→ Reconnect sensors / replace the Front/Rear Paper Guide

• Are Front Right and Rear Right Temperature Sensor not connected / broken→ Reconnect sensors / replace the Front/Rear Paper Guide

• Are Front Left and Rear Left Temperature Sensor not connected / broken?→ Reconnect sensors / replace the Front/Rear Paper Guide

• Are Front Left and Rear Right Temperature Sensor not connected / broken?→ Reconnect sensors / replace the Front/Rear Paper Guide

• Are two Rear Temperature Sensor not connected / broken?→ Reconnect sensors / replace the Rear Paper Guide

• I

• Err : FRRLT Sensor

• Err : FRRRT Sensor

• Err : FLRLT Sensor

• Err : FLRRT Sensor

• Err : RRRLT Sensor

1040

1040

1040

10401040

1040





1 • Err : 2FRLT Sensor • Are two Front and Rear LeftTemperature Sensors not connected / broken?→ Reconnect sensors / replace the Front Paper Guide

• Are two Front and Rear Right Temperature Sensors not connected / broken?→ Reconnect sensors / replace the Front Paper Guide

• Are two Rear and Front Right Temperature Sensors not connected / broken?→ Reconnect sensors / replace the Rear Paper Guide

• Are two Rear and Front Left Temperature Sensors not connected / broken?→ Reconnect sensors / replace the Rear Paper Guide

• Are all Temperature Sensors not connected / broken?→ Reconnect sensors / replace the Front Paper Guide

• I

No. SymptomSequence


When Message is Displayed (on LCD Heater)


1040

1040

1040

1040

1040

1040

R E P B A C


• Err : 2FRRT Sensor

• Err : FR2RT Sensor

• Err : FL2RT Sensor

• Err : All T Sensor

• After the heater start for 10 minutes andREAL temperature could not reach.→ Replace the Front/Rear Paper Guide

•→

•→

•→

•→

• I

• Err : Heaters Stop 1040

DDV

• → • → • → • → • I





1 • Err : F.R.T. Sensor • Is Front Right Temperature Sensor not connected / broken?→ Reconnect sensor / replace the Front Paper Guide

• Is Front Left Temperature Sensor not connected / broken?→ Reconnect sensor / replace the Front Paper Guide

• Is Rear Right Temperature Sensor not connected / broken?→ Reconnect sensor / replace the Rear Paper Guide

• Is Rear Left Temperature Sensor not connected / broken?→ Reconnect sensor / replace the Rear Paper Guide

• Are 2 Front Temperature Sensors not connected / broken?→ Reconnect sensors / replace the Front Paper Guide

• I

No. SymptomSequence


When Message is Displayed (on LCD heater)


1040 -2

1040 -2

1040 -2

1040 -2

1040 -2

1040

R E P B A C


• Err : F.L.T. Sensor

• Err : R.R.T. Sensor

• Err : R.L.T. Sensor

• Err : FRFLT Sensor

• Are Front Right and Rear Left Temperature Sensor not connected / broken?→ Reconnect sensors / replace the Front/Rear Paper Guide

• Are Front Right and Rear Right Temperature Sensor not connected / broken→ Reconnect sensors / replace the Front/Rear Paper Guide

• Are Front Left and Rear Left Temperature Sensor not connected / broken?→ Reconnect sensors / replace the Front/Rear Paper Guide

• Are Front Left and Rear Right Temperature Sensor not connected / broken?→ Reconnect sensors / replace the Front/Rear Paper Guide

• Are two Rear Temperature Sensor not connected / broken?→ Reconnect sensors / replace the Rear Paper Guide

• I

• Err : FRRLT Sensor

• Err : FRRRT Sensor

• Err : FLRLT Sensor

• Err : FLRRT Sensor

• Err : RRRLT Sensor

1040 -2

1040 -2

1040 -2

1040 -21040

1040 -2





1 • Err : 2FRLT Sensor • Are two Front and Rear LeftTemperature Sensors not connected / broken?→ Reconnect sensors / replace the Front Paper Guide

• Are two Front and Rear Right Temperature Sensors not connected / broken?→ Reconnect sensors / replace the Front Paper Guide

• Are two Rear and Front Right Temperature Sensors not connected / broken?→ Reconnect sensors / replace the Rear Paper Guide

• Are two Rear and Front Left Temperature Sensors not connected / broken?→ Reconnect sensors / replace the Rear Paper Guide

• Are all Temperature Sensors not connected / broken?→ Reconnect sensors / replace the Front Paper Guide

• I

No. SymptomSequence


When Message is Displayed (on LCD Heater)


1040 -2

1040 -2

1040 -2

1040 -2

1040 -2

1040

R E P B A C


• Err : 2FRRT Sensor

• Err : FR2RT Sensor

• Err : FL2RT Sensor

• Err : All T Sensor

• After the heater start for 10 minutes andREAL temperature could not reach.→ Replace the Front/Rear Paper Guide

•→

•→

•→

•→

• I

• Err : Heaters Stop 1040 -2

DDV

• → • → • → • → • I





1

2

• No power

• Faulty liquid crystal display (nodisplay/unstable display)

1-1

1-2

1-3

2-1

2-2

2-3

2-4

2-5

2-6

2-7

• Is there a broken or shorted lead in the switch cable assembly (between the switch and main boradassembly)? Use a tester to check for broken or shorted leads.→ Replace the switch cable assembly.

• The inlet assembly may be faulty.→ Replace it.

• The power board assembly may be faulty.→ Replace it.

• Check the power supply check 120V AC or 240V AC.(Differs according to sales region.)

• Check the power supply voltage 5 V DC.

• Check the power supply voltage 24, 42 V DC.

• Check the connections of the panel cable connectors on the panel board assembly and main boardassembly.Check that they are not inserted obliquely and that they are securely locked.→ Reconnect main board assembly connector J110 (PANEL) and panel board assembly connector

J301 (MAIN).

• The panel cable may be faulty.→ Replace it.

• Is there a fault in the panel board assembly liquid crystal display?→ Replace the panel board assembly.


No. SymptomSequence




1130

1150

1170

1160

1140

R E P B A C







1

2

• Initial filling of inks failed❈ This symptom means that when new

cartridges are first installed, or when anew cartridge is fitted as a result of a"no ink" message, the initial fillingoperation is not performed.

• Initial filling begins but the ink doesnot reach the head or it reaches thehead but is not ejected.

Go to EXA2020

1-1

1-2

1-3

1-4

1-5

1-6

1-7

• With the printer cover closed, is the liquid crystal display showing cover open?→ Adjust cover switch height.→ Check cover switch assembly connector.

J106 (COVER) on the panel board assembly→ Replace cover switch assembly.

• Check panel cable connectors.→ Reconnect main board assembly connector J110 (PANEL) and panel board assembly connector

J301 (MAIN).→ Replace them.

• With the hold lever down, is the liquid crystal display showing lever up?→ Adjust the lever sensor.

• Check J104 (LEVER) cable connection on the main board. → Re-insert it.→ Replace the lever sensor assembly.

• With the specified cartridge inserted securely, use the printer's self-diagnostic mode "Sensor: NoInk" or "Sensor: No Cartridge" to check whether the presence of ink and cartridge are being detect-ed normally.→ Check using EXA1100 “[65YMCK] No Cartridge” procedure.→ After adjustment or replacement, implement initial filling with the printer's self-diagnostic "Adjust:

Head Rank".

• With the specified cartridge inserted securely, use the printer's self-diagnostic mode "Sensor:Cartridge" to check whether the status of the special cartridge is operating normally.→ Check using EXA1080 "Insert special cartridge" procedure.→ After adjustment or replacement, implement initial filling with the printer's self-diagnostic "Adjust:

Head Rank".

• The main board assembly may be damaged.→ Replace it.→ After replacement, start self-diagnostic mode and carry out initial filling from “Head Rank” menu.

No. SymptomSequence




1110

1170

1100

1140

1040

2040

1040

2040

2040

R E P B A C


CAUTION: Wait at least 30 minutes before printing after initial filling. Printing qualitycan not be assured unless the ink filling is stabilized.







1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

1-9

• Is the cap assembly spring fallen out or broken? → If it has fallen out, refit it.→ If it is broken, replace the cap assembly.

• Is the capping position correct?→ Adjust the capping position and check that the ink flows during cleaning.→ If ink flows, carry out initial filling.

• Are the pump assembly tubes connected to the cap assembly tubes?→ Insert the pump assembly tubes into the cap assembly tubes.

• Is there any looseness in the head unit, the flexible cable keeper unit under the head board, the inktubes behind the cartridge unit, or the SUS pipe connectors (Bk, Y, M, C, Lm, Lc)? Check that theO-rings are fitted properly.→ Remove the head cover and check the damper assemblies at the base of the tubes for all four

black and colour ink tubes.→ Remove the Y Rail cover and cartridge cover and check the flexible cable keeper unit under the

head board assembly and the sides of the cartridge.

• Is there an air leak in the damper assembly shield unit? → Replace the damper assembly and check that ink flows during the cleaning action. → If ink flows, carry out initial filling.

• Are the ink tubes damaged inside the pump assembly?→ Replace the pump assembly and check that ink flows during the cleaning action. → If ink flows, carry out initial filling.

• Is the pump motor turning during the cleaning action?→ Check the pump motor cable connector J102 (PUMP MOT) on the main board and try again.→ Replace the pump motor.→ If the pump motor does not turn after performing the above tasks, replace the main board

assembly.

• Was there any mismatching of gears during the cleaning operation?→ Replace the maintenance station assembly.

• Was the transfer gear shaft damaged during cleaning?→ Replace the maintenance station assembly.


No. SymptomSequence




1240

1430

1260

12301140

1270

1270

2040

2040

R E P B A C








1-10

1-11

1-12

1-13

1-14

1-15

1-16

1-17

• Are there any breaks, cuts or air leaks in the ink tubes?→ Change each ink tube, cleaning each time and checking that ink flows during cleaning.

• Check that connectors J207 (HEAD C1) and J208 (HEAD C2) on the head board assembly, andhead cables on the print head are not inserted obliquely, and they are locked securely.→ Insert the connectors again.

• Is there a broken lead in head cables?→ Replace head cables.



• Check that the Y cable connector is connected securely and not inserted obliquely.→ Reconnect head board assembly connectors J201 (MAIN1) and J202 (MAIN2) and main board

assembly connectors J111 (HEAD1) and J112 (HEAD 2).

• Is there a broken lead in Y cables?→ Replace Y cables.


No. SymptomSequence




1370

1400

1390

1420

1360

1140

R E P B A C







1

2

3

4

5

• After power is switched on, nothingworks

If nothing is displayed on the panelliquid crystal display unit.

Go to EXA2000

• When power is applied, “Initializing”appears and then a reset is executed.

• Media is mounted but the initializationoperation is not done

• Printer does not work even with thecover closed

• Printer does not stop even with thecover opened.

1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

• With the printer cover closed, is the liquid crystal display showing cover open?Does the cover switch assembly function work normally with the self-diagnostic“Examination/Sensors”?→ Adjust cover switch assembly height.→ Check cover switch assembly connector and J106 (COVER) on the panel board assembly.→ Replace cover switch assembly.

• Check panel cable connectors.Check that they are not inserted obliquely and they are securely locked.→ Reconnect the main board assembly connector J110 (PANEL) and the panel board assembly

J301 (MAIN).→ Replace them.

• With the hold lever down, is the liquid crystal display showing lever up?→ Check the lever sensor connector J104 (LEVER) on the main board assembly.→ Replace the lever sensor assembly.

• Check J104 (LEVER) cable connection on the main board assembly. → Re-insert it.→ Replace the lever sensor assembly.

• Does the XR cable assembly (rear paper sensor) detect normally with the self-diagnostic“Examination/Sensors”?→ Check the connections of the paper sensor connectors J107 (XR) on the main board assembly. → Replace the XR cable assembly (rear paper sensor).

• Carry out “5 V DC Power Supply Check” and “24, 42 V DC Power Supply Check”→ Replace the power board assembly.

• Is the cable of the switch cable assembly connected properly to J100 (MAIN SW) on the mainboard assembly? (Refer to EXA2000)→ Reconnect it.

• The switch cable board assembly may be faulty.→ Replace it.


No. SymptomSequence




1110

1170

1110

1100

11901200

1150

1130

1040

R E P B A C






1

2

3

4

5

• After power is switched on, nothingworks

If nothing is displayed on the panelliquid crystal display unit.

Go to EXA2000

• When power is applied, “Initializing”appears and then a reset is executed.

• Media is mounted but the initializationoperation is not done

• Printer does not work even with thecover closed

• Printer does not stop even with thecover opened.

1-9

1-10

• Is the DC cable assembly connected properly to J001 on the power board assembly andJ101 (MAIN POWER) on the main board assembly? (See EXA2000)→ Reconnect it.→ Replace it.


No. SymptomSequence




1130

1140

R E P B A C


E X A 2 0 4 0Model Name: Rockhoppper-46/62




1 • Ink cartridges are installed but notrecognized

1-1

1-2

• With the specified cartridge inserted securely, use the printer's self-diagnostic mode"Sensor: No Ink" or "Sensor: No Cartridge" to check whether the presence of ink and car-tridge are being detected normally.→ Check using EXA1100 “[65YMCK] No Ink” procedure.→ After adjustment or replacement, implement initial filling with the printer's self-diagnos-

tic "Adjust: Head Rank".

• With the specified cartridge inserted securely, use the printer's self-diagnostic mode"Sensor: Cartridge" to check whether the status of the special cartridge is operating nor-mally.→ Check using EXA1080 "Insert special cartridge" procedure.→ After adjustment or replacement, implement initial filling with the printer's self-diagnos-

tic "Adjust: Head Rank".

No. SymptomSequence




1350 1040

2040

1040

2040

R E P B A C


CAUTION: Wait at least 30 minutes after initial filling before printing. Printingquality can not be assured unless ink filling has been stabilized.





1 • Can not make entries from the operat-ing panel

1-1

1-2

1-3

1-4

• Is the panel cover key input unit broken?→ Replace the panel cover.

• Check the panel cable connectors.Check that they are inserted obliquely and securely locked.→ Reconnect main board assembly connector J110 (PANEL) and panel board assembly

connector J301 (MAIN).→ Replace the panel cable.

• The panel board assembly may be damaged.→ Replace the panel board assembly.

• The main board assembly may be damaged.→ Replace the main board assembly.

No. SymptomSequence




1170

1160

1140

R E P B A C






1 • Data is received but not printed 1-1 • For checking, use “Cannot connect normally with Centronics or Ethernet Board” proce-dures shown in EXA7000.

No. SymptomSequence




R E P B A C






1 • Media is not suction 1-1

1-2

1-3

1-4

1-5

1-6

1-7

• Are the media suction fans turning?→ If they are not turning, go to consultation 1-4.

• Are XR cable assembly (rear paper sensor) and edge sensor detecting normally accord-ing to the self-diagnostic sensor test?→ Check the connections of XR cable assembly and edge sensor.

XR cable assembly is the main board assembly J107 (XR).Edge sensor is the head board assembly J204 (P EDGE).

→ Replace XR cable assembly and edge sensor.

• Are the fans working normally according to the self-diagnostic test?→ Check the connectors between fan assembly, fan extension cable assembly and main

board assembly.Fan extension cable 1 assembly is J115 (FAN1) on the main boardFan extension cable 2 assembly is J116 (FAN2) on the main boardFan extension cable 3 assembly is J117 (FAN3) on the main board

→ Replace fan assembly.→ Replace fan extension cable 1 ~ 3.

• Is shielding material fixed securely in the specified places?Shield GA-A, Shield GA-B, Shield GA-C→ Refit shielding securely.

• Is +24 V being output between Pin 11 (GND) and Pin 10 (+24V) of connector J001 on thepower board assembly?

• Carry out the "24 V and 42 V power voltage check".


No. SymptomSequence




11901200

1080

1140

1040

1060

R E P B A C


E X A 2 0 7 0 - 2Model Name: Rockhopper-46/62




1 • Media is not suction 1-1

1-2

1-3

1-4

1-5

1-6

1-7

• Are the media suction fans turning?→ If they are not turning, go to consultation 1-4.




• Are the fans working normally according to the self-diagnostic test?→ Check the connectors between fan assembly, fan extension cable assembly and main

board assembly.Fan extension cable 1 assembly is J115 (FAN1) on the main boardFan extension cable 2 assembly is J116 (FAN2) on the main boardFan extension cable 3 assembly is J117 (FAN3) on the main boardFan extension cable 4 assembly is J118 (FAN4) on the main board



• Is +24 V being output between Pin 11 (GND) and Pin 10 (+24V) of connector J001 on thepower board assembly?

• Carry out the "24 V and 42 V power voltage check".


No. SymptomSequence




11901200

1080

1140

1040

1060

R E P B A C




Trouble with Media Feed


1

2

3

4

5

• The media comes off when it is initial-ized or during printing

• The media is skewed or meanderswhen it is initialized or during printing

• The media becomes wrinkled when itis initialized or during printing

• The media jams when it is initializedor during printing

• The media tears when it is initializedor during printing

1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

• Are XR cable assembly (rear paper sensor) and edge sensor detecting normally according to theself-diagnostic sensor test?→ Check the connections of XR cable assembly and edge sensor.



• Are the fans working normally according to the self-diagnostic test?→ Check the connectors between fan assembly, fan extension cable assembly and main board

assembly.Fan extension cable 1 assembly is J115 (FAN1) on the main boardFan extension cable 2 assembly is J116 (FAN2) on the main boardFan extension cable 3 assembly is J117 (FAN3) on the main board



• When the pressure lever is raised and lowered, does the pressure unit move up and down smooth-ly at the same time?→ Apply grease (G-501) if it does not move smoothly.

• Is the pressure roller pressing on the media over its entire length?• With the pressure lever up, does the pressure rollers seem reluctant to turn?• With the pressure lever down, does the pressure rollers idle or contact the platen on one side?• With the pressure lever down, is the blade pressing firmly on the media?

→ If there are paper dust or scraps near the pressure roller, wipe with soft damp cloth.→ If necessary, replace pressure assembly, pressure rollers and blade. → If the gap between platen and plate is less than 0.2 mm, adjust platen height.

• Is there major distortion, damage or foreign matter on the front and rear paper guides?→ Replace front and rear paper guides.

• Are the adjustment of scroller position and fitting of flanges correct? → Adjust scroller position correctly.→ Fit flanges correctly into the core of the roll media.

• Is there major distortion or damage to the grid roller?→ Replace the grid roller.

No. SymptomSequence




12001410

1080

1220

12201520

1040

1690

1040

1060

R E P B A C


1040-2





1

2

3

4

5

• The media comes off when it is initial-ized or during printing

• The media is skewed or meanderswhen it is initialized or during printing

• The media becomes wrinkled when itis initialized or during printing

• The media jams when it is initializedor during printing

• The media tears when it is initializedor during printing

1-1

1-2

1-3

1-4

1-5

1-6

1-7

• Are XR cable assembly (rear paper sensor) and edge sensor detecting normally according to theself-diagnostic sensor test?→ Check the connections of XR cable assembly and edge sensor.



• Are the fans working normally according to the self-diagnostic test?→ Check the connectors between fan assembly, fan extension cable assembly and main board

assembly.Fan extension cable 1 assembly is J115 (FAN1) on the main boardFan extension cable 2 assembly is J116 (FAN2) on the main boardFan extension cable 3 assembly is J117 (FAN3) on the main boardFan extension cable 4 assembly is J117 (FAN4) on the main board



• When the pressure lever is raised and lowered, does the pressure unit move up and down smooth-ly at the same time?→ Apply grease (G-501) if it does not move smoothly.




• Are the adjustment of scroller position and fitting of flanges correct? → Adjust scroller position correctly.→ Fit flanges correctly into the core of the roll media.

No. SymptomSequence




12001410

1080

1220

12201520

1040

1040

1060

R E P B A C


1040-2





1

2

• The media size is different aftermedia mounting and initialization

• Tracing paper and thin media cannotbe detected

1-1

1-2

1-3

1-4

1-5

• Is the media mounted recommended by Mutoh? If it is not media recommended by Mutoh (especially thin tracing paper, etc.), the papersensors may read incorrectly and be unable to recognize the media. → Mount recommended media and try again.




• Use the printer's self-diagnostic “Sensor: Edge” to confirm the amount of sensor reflec-tion. Using thick coated paper, check whether the paper detection value is within 0090 to00a4. → Check edge sensor connector and head board assembly connector J204 (PEDGE).→ Adjust the detection value with the head board assembly variable resistor. → Replace edge sensor assembly.

• Check the Y cable connectors.Check that they are not inserted obliquely.→ Reconnect main board assembly connector J111 (HEAD1) and head board assembly

connector J201 (MAIN1).→ Replace the Y cable.

• The main board assembly may be damaged.→Replace it.

No. SymptomSequence




1200

1410

1410

1360

1140

1040

1040

R E P B A C





Trouble with Printing


1 • Does not print continuously 1-1

1-2

1-3

• Is there a problem with the printer driver software?→ Upgrade the printer driver version.

• Is there a problem with the program ROM?→ Upgrade the version.


No. SymptomSequence




1140

R E P B A C






1 • There is an extra feed after printing isfinished

1-1

1-2

1-3

1-4

• Is XR cable assembly (rear paper sensor) detecting normally according to the self-diag-nostic sensor test?→ Check the connections of XR cable assembly and main board assembly J107 (XR).→ Replace XR cable assembly.




No. SymptomSequence




12001200

1140

1040

R E P B A C






1 • Dots are missing from the printing 1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

1-9

1-10

• Clean twice in succession.

• Are the ink tubes filled with ink? → Carry out initial filling.

CAUTION: Wait at least 30 minutes after initial filling before printing. Printing quality cannot be assured unless ink filling has been stabilized.

• Print the self-diagnostic “Printing: Nozzle Check Pattern” and the “Test Printing”.→ If the nozzle check pattern is printed normally, go to EXA4060.

• Does the pump motor turn during the cleaning operation?→ Check the connection of pump motor assembly connector and J102 (PUMP) on the main board

assembly.→ Replace the pump motor assembly.→ If the pump motor still does not turn, replace the main board assembly.

• Are the gears and transfer gear shaft broken or badly meshed during the cleaning operation?→ Replace the maintenance station assembly.

• Is the cap assembly spring fallen out or broken? → If it has fallen out, refit it.→ If it is broken, replace the cap assembly of the maintenance station assembly.

• Is the capping position correct?→ Adjust the capping position, carry out strong cleaning and try again.

• What is the condition of the wiper section?→ Dampen the accessory cleaning cloth slightly with clean water and use it to wipe the surface of

the cleaning wiper. After the wiper has been cleaned, carry out two successive cleanings.→ If it is wet with ink, replace it.

• Are the nozzle surfaces being wiped and rubbed?→ Check how the wiper is fitted and fasten it correctly.

• Does the head that is fitted have a rank that is different from the recorded rank?→ Re-enter the rank of the head correctly.


No. SymptomSequence




12301140

1270

12401270

1250

1250

1390

2050or

PAT1000

2040

R E P B A C


Bad example

Good example

• Cleaning does not cure clogging ordeflection

Clogging: There is a discontinuity in line G of the “Test Print”.

Deflection: There is a deflection or offset in the step pattern in line G of the “Test Print”.

2





1-11

1-12

1-13

1-14

1-15

• Has ink dried on the surface of the print head and inside the nozzles?→ Use the self-diagnostic “Adjustment: Head Cleaning” to clean the print head, carry out initial fill-

ing with “Adjustment: Head Rank” and try again.→ Clean the head nozzle face.


• Check that the T-fence and Encoder behind the head board assembly are not touching.→ If they are touching, adjust them. → If adjustment is not effective, replace both the head board assembly and the T-fence.

• Are the tubes crushed inside the pump assembly?→ Replace the pump assembly and check the ink flow. If it is good, carry out initial filling.

• Is the print head assembly damaged?→ Replace the obstructed print head assembly.


No. SymptomSequence




1620

1660

14201300

1260

13901400

1140

R E P B A C


1 • Dots are missing from the printingBad example

Good example

• Cleaning does not cure clogging ordeflection

Clogging: There is a discontinuity in line G of the “Test Print”.

Deflection: There is a deflection or offset in the step pattern in line G of the “Test Print”.

2





1

2

• No imprime nada

• Does not print a specific colour

1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

• Check 24, 42 V DC Power Supply Check.

• Is the cap assembly spring fallen out or broken? → If it has fallen out, refit it.→ If it is broken, replace the cap assembly.

• Is the capping position correct?→ Adjust the capping position and use the cleaning operation to check ink flow.→ If ink flow is confirmed, carry out initial filling.

• Check the Y cable connections.Check that they are not inserted incorrectly.J201 (MAIN1) and J202 (MAIN2) on the head board J114 (HEAD1) and J115 (HEAD2) on the main board→ Reconnect main board assembly connector J111 (HEAD1) and head board assembly connectors

J201 (MAIN1) and J202 (MAIN2).→ Replace both Y cables.

• Is there any looseness in the head unit, the flexible cable keeper unit under the head board assem-bly, the ink tubes behind the cartridge unit, or the SUS pipe connectors (Bk, Y, M, C, Lm and Lc)?Check that the O-rings are fitted properly.→ Remove the head cover and check the damper.→ Remove the Y Rail cover and cartridge cover and check the flexible cable keeper unit under the

head board assembly and the sides of the cartridge.

• Is there an air leak in the damper assembly shield unit? → Replace the damper assembly and check that ink flows during the cleaning action. → If ink flow is confirmed, carry out initial filling.

• Are the ink tubes damaged inside the pump assembly?→ Replace the pump assembly and check that ink flows during the cleaning action. → If ink flow is confirmed, carry out initial filling.

• Is there an air leak in the ink tubes?→ Replace each ink tube, cleaning each time to check for ink flow. → If ink flow is confirmed, carry out initial filling.



No SINTOMA Sequence




1240

1360

1430

1260

1370

R E P B A C


Bad example

Good example





1-9

1-10

1-11

1-12

1-13

1-14

1-15

1-16


Head Rank".

• Check the connections of head cables 1 and 2.Check that they are not inserted obliquely and they are securely locked. J207 (HEAD BK), J208 (HEAD COL) on the head board assenmbly→ Reconnect head board assembly connectors J207 (HEAD C1) and J208 (HEAD C2).→ Replace head cables 1 and 2.


• Is the main board assembly damaged?→ Replace it.


• Is the pump motor turning during the cleaning action?→ Check the pump motor cable connector J102 on the main board.→ Replace the pump motor.→ If the pump motor does not turn after performing the above tasks, replace the main board

assembly.

• Was there any gear damage or mismatching of gears during the cleaning operation?→ Replace the pump assembly.

• Was the transfer gear shaft damaged during cleaning?→ Replace the maintenance station assembly.

No. SymptomSequence




1390

1420

1140

1390

1230

1260

1270

1040

2040

R E P B A C


1

2

• NO IMPRIME NADA

• Does not print a specific colour

Bad example

Good example

CAUTION: Power must be off when connectors are being disconnected or reconnected,otherwise you may be injured or a board may be damaged.The main board assembly will certainly be damaged if power is applied withmain board assembly connectors J111 (HEAD) and J112 (HEAD2) and headboard connectors J201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP.





1 • The entire surface is printed black 1-1

1-2

1-3

1-4

1-5

• Check the connections for head cables 1 and 2. Check that they are not inserted obliquely and they are locked securely.→ Reconnect the head board assembly connectors J207 (HEAD C1) and J208 (HEAD

C2).→ Replace the connectors.

• Check the Y cable connectionsCheck that they are not inserted obliquely.→ Reconnect main board assembly connectors J111 (HEAD1) and J112 (HEAD2), and

head board assembly connectors J201 (MAIN1) and J202 (MAIN@).→ Replace both Y cables.


• The head head assembly may be damaged.→ Replace the print head assembly.


No. SymptomSequence




1390

1360

1420

1390

1140

R E P B A C


Bad example

Good example

CAUTION: Power must be off when connectors are being disconnected or recon-nected, otherwise you may be injured or a board may be damaged.The main board assembly will certainly be damaged if power isapplied with main board assembly connectors J111 (HEAD) and J112(HEAD2) and head board connectors J201 (MAIN1) and J202 (MAIN2)inserted with oblique FFP.





1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

1-9

• Is the usage site environment in accordance with the operating environment?→ Use the printer in a proper operating environment.

• Was the printing done immediately after initial filling?→ Wait at least 30 minutes after initial filling before printing. Printing quality can not be assured

unless ink filling has been stabilized.


• Are the fans working normally according to the self-diagnostic “Examination: Fan”? → Check the connectors between fan assembly, fan extension cable assembly and main board


→ Replace fan assembly.→ Replace Fan extension cables 1 ~ 3.

• Is the shielding material securely attached in the proper positions?Shield material GA-A, shield material GA-B, shield material GA-C→ Re-attach in the proper positions.

• If the media in question is roll media, does the scroller rotate smoothly?→ Adjust the position of the scroller support rollers.→ Replace any roller that is damaged or that moves badly.

• Is the X speed reduction belt tension adjusted to the prescribed value?41.2 N (4.2 kg ± 0.2 Kg).



• Are the nozzle surfaces being wiped and rubbed?→ Carry out repairs.→ Replace the wiper.

→ Continued on next page (EXA4051)

No. SymptomSequence




10801080

1560

1250

1250

1060

R E P B A C


1

2

3

• Printing becomes shaded.

• The image contains blurs.

• Transverse lines appear to be split.Split line

Dire

ctio

n of

m

edia

feed

Shading and blurring

• Black and white lines appear in theprinted image(Not including gaps in the step pat-terns in locations 1G to 7G of the testpattern)If dots are missing, go to EXA4020

Dire

ctio

n of

m

edia

feed

Good example

Bad example

4

E X A 4 0 5 0 - 2Model Name: Rockhopper 62




1

2

3



• Transverse lines appear to be split.

1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

1-9


• Was the printing done immediately after initial filling?→ Wait at least 30 minutes after initial filling before printing. Printing quality can not be assured





→ Replace fan assembly.→ Replace Fan extension cables 1 ~ 4.



• Is the X speed reduction belt tension adjusted to the prescribed value?41.2 N (4.2 kg ± 0.2 Kg).



• Are the nozzle surfaces being wiped and rubbed?→ Carry out repairs.→ Replace the wiper.


No. SymptomSequence




10801080

1560

1250

1250

1060

R E P B A C


Split line

Dire

ctio

n of

m

edia

feed



Dire

ctio

n of

m

edia

feed

Good example

Bad example

4





1-10

1-11

1-12

1-13

1-14

1-15

1-16

1-17

• Is the T-fence dirty?→ Clean it.→ If the T fence is severely soiled and can not be cleaned, replace it.



• Is the pump motor turning during the cleaning action?→ Check the pump motor assembly connector J102 (PUMP) on the main board assembly and try

again.→ Replace the pump motor assembly.→ If the pump motor does not turn after performing the above tasks, replace the main board

assembly.

• Was there any mismatching of gears during the cleaning operation?→ Replace the maintenance station assembly.

• Is the cap assembly spring fallen out or broken? → If the part has fallen out, refit it.→ Replace the cap assembly or the maintenance station assembly.

• Are the tubes crushed inside the pump assembly?→ Replace the pump assembly and check the ink flow. If it is good, carry out initial filling.


• Does the head that is fitted have a rank that is different from the recorded rank?→ Re-insert print head rank correctly.

• The print head assembly may be damaged.→ Replace the obstructed print head assembly.


No. SymptomSequence




1300

12201520

1230

1270

12401270

1390

2040

R E P B A C


1

2

3




Dire

ctio

n of

m

edia

feed



Dire

ctio

n of

m

edia

feed

Good example

Bad example

4





1-18

1-19

1-20

1-21




Head Rank".




No. SymptomSequence




1140

1420

1040

2040

R E P B A C


1

2

3




Dire

ctio

n of

m

edia

feed



Dire

ctio

n of

m

edia

feed

Good example

Bad example

4





1 • Edges of printing are blurred 1-1

1-2

1-3

1-4

1-5

• Does cleaning restore normal operation?→ Carry out three successive cleanings.

• Is media recommended by Mutoh being used?→ If the media is causing the symptoms, and it is not recommended media, the results

cannot be guaranteed. Please use recommended media.

• Does the head that is fitted have a rank that is different from the recorded rank?→ Re-enter the rank of the print head correctly.

• Check that the T-fence and Encoder behind the head board assembly are not touching.→ If they are touching, adjust them. → If adjustment is not effective, replace both the head board assembly and the T-fence.


No. SymptomSequence




1390

14201300

1140

2040

R E P B A C


Bad example

Good example





1

2

3

• Many satellites (unwanted dots)

• The printing has whiskers

• Printed lines appear blurred (printingis dirty)

1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

1-9

1-10


• Is there sufficient ink remaining?→ Replace with a new cartridge.

• Do three cleanings in succession.

• Have the Test Print printed. (Refer to PAT1000)→ If the nozzle check pattern is printed normally, return to EXA4020.

• Is the printing less than 30 minutes after initial filling?→ Wait at least 30 minutes after initial filling before printing. Printing quality can not be assured


• Is the steel belt tension adjusted properly?0.98 N (100 g ±20 g)

• Make sure the encoder and T-fence mounted on the back of the head board assembly are nottouching.→ If they are touching, adjust them.→ If adjustment does not solve the problem, replace both the head board assembly and the fence.

• Is there a loose set screw on the Y drive pulley?→ Re-tighten the set screw.

• Is the capping position correct?→ Adjust the capping position and try again after strong cleaning.




No. SymptomSequence




1550

14201300

1250

2050or

PAT1000

R E P B A C


[ Bad example ]

[ Good example ]

1. Satellites

2. Whiskers

3. Blurring





1-11

1-12

1-13

1-14

1-15

1-16

1-17

1-18

1-19

• Is it able to wipe/rub the nozzle face normally?→ Check how the wiper is fitted and fasten it correctly.

• Does the head that is fitted have a rank that is different from the recorded rank?→ Re-enter the rank of the print head correctly.

• Are the ink tubes damaged inside the pump assembly?→ Replace the pump assembly and check that ink flows during the cleaning action. If ink flows,

carry out initial filling.

• Is the pump motor turning during the cleaning action?→ Check the pump motor assembly connector J102 (PUMP) on the main board assembly and try

again.→ Replace the pump motor assembly.→ If the pump motor does not turn after performing the above tasks, replace the main board

assembly.

• During the cleaning operation, was there any mismatching or damage to the gears or transfer gearshaft?→ Replace the maintenance station assembly.

• Has the cap assembly spring fallen out or been broken? → If a part has fallen out, refit it.→ Replace the cap assembly or maintenance station assembly.




• Is the print head assembly damaged?→ Replace the obstructed print head assembly.


No. SymptomSequence




1250

1390

1260

1230

1270

12401270

1620

1660

1390

1140

2040

2040

2040

R E P B A C


1

2

3

• Many satellites (unwanted dots)

• The printing has whiskers

• Printed lines appear blurred (printingis dirty)

[ Bad example ]

[ Good example ]

1. Satellites

2. Whiskers

3. Blurring





1 • Mixed colour lines do not overlap 1-1

1-2

1-3

1-4

1-5

1-6

1-7

• Is the steel belt tension adjusted properly?0.98 N (100 g ± 20 g)

→ Readjust steel belt tension.

• Is the Y drive pulley set screw loose?→ Re-tighten the set screw securely.

• Is there any mistake in the rank of the head that is actually installed and the rank that isrecorded?→ Re-enter the rank of the print head correctly.

• Is the problem with the head tilt adjustment?→ Adjust it.

• Is there a problem with the reciprocal printing position alignment?→ Adjust it.

• Is there a problem with the CW adjustment?→ Adjust it.

• Make sure the encoder and fence mounted on the back of the head board assembly arenot touching.→ If they are touching, adjust them.→ If adjustment does not solve the problem, replace the T fence.

No. SymptomSequence




1550

1310

1390

1300

2040

2060

2080

2090

R E P B A C


Bad example

Good example

2 • Black and colour positions are offsetBad example

Good example





1 • Inaccurate line length in the directionof head movement (Main scanningdirection)

1-1

1-2

1-3

1-4

1-5



→ Re-adjust steel belt tension.

• Is the timing fence dirty or has foreign matter stuck to it?→ Clean it.→ Replace if soiling is not removed by washing or if there is damage.

• Is the Y drive pulley set screw loose?→ Re-tighten the set screw securely.

• The internal processing operation of the main board may be faulty.→ Initialize, re-enter or re-adjust the parameters and try again.

No. SymptomSequence




1550

1300

1280

50102000

R E P B A C


Direction of media feed





1 • Inaccurate straight line in the directionof head movement (straightness)

1-1

1-2

1-3

1-4

1-5

1-6

1-7



→ Replace fan assembly.→ Replace fan extension cables 1 to 3.

• Are the front paper guide and platen securely screwed?→ Tighten it.


• Is the X drive pulley set screw loose?→ Replace the X motor assembly.

• Is the X speed reduction belt tension adjusted to the prescribed value?41.2 N (4.2 kg ±0.2 kg)→ Readjust the X speed reduction belt tension.



→ If there are paper dust or scraps near the pressure roller, wipe with soft damp cloth.→ If necessary, replace pressure assembly, pressure rollers and blade. → If the gap between platen and blade is less than 0.2 mm, adjust platen height.

No. SymptomSequence




10801080

1070

1560

12201520

1060

R E P B A C







1 • Inaccurate straight line in the directionof head movement (straightness)

1-1

1-2

1-3

1-4

1-5

1-6

1-7




• Are the front paper guide and platen securely screwed?→ Tighten it.


• Is the X drive pulley set screw loose?→ Replace the X motor assembly.

• Is the X speed reduction belt tension adjusted to the prescribed value?41.2 N (4.2 kg ±0.2 kg)→ Readjust the X speed reduction belt tension.




No. SymptomSequence




10801080

1070

1560

12201520

1060

R E P B A C







1 • Inaccurate line distance in the direc-tion of media feed(Subsidiary scanning distance)

1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

1-9


• Are you using adjusting the distance with the media that is being used?→ Carry out distance adjustment.→ Even if the distance adjustment is being done with the media that is in use, do it for the sake of

confirmation.

• Is the X drive pulley loose?→ Replace the X motor assembly.

• Is the X speed reduction belt tension adjusted to the specified value?41.2 N (4.2 kg ±0.2 kg)→ Readjust X speed reduction belt tension.

• Is there major distortion in the X speed reduction pulley?→ Replace the X speed reduction pulley.



• Is the rough surface of the grid roller worn in some places?• Is the grid roller heavy to turn? Or does it not turn smoothly?

→ Use a nylon brush to clean away any paper dust or paper scraps from the grid roller.→ Adjust platen height or refit the rear paper guide.→ Replace grid roller.


• If roll media is being used, does the scroller rotate smoothly?→ Replace the scroller shaft.→ Change the media that is being used.

No. SymptomSequence




1070

1560

1680

12201520

1520, 10401690

1040

2120

R E P B A C



[Standard value]500 mm ±0.1%Since the adjustment here is 300 mm,the measured value, x is such that299.7 mm ≤ x ≥ 300.3 mm

1040-2

1040-2





1 • Inaccurate straight line in the directionof media feed (joining precision Y)

1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

1-9

• Is there any mistake in the rank of the head that is actually installed and the rank that isrecorded?→ Enter the rank of the print head correctly.

• Is the problem with the head tilt adjustment?→ Adjust it.

• Is the steel belt tension adjusted to the specified value?0.98 N (100 g ±20 g)

→ Readjust steel belt tension.

• Is the Y drive pulley set screw loose?→ Replace it.

• Is there a problem with the reciprocal printing position alignment?→ Adjust it.


• Is the T fence dirty?→ Clean it.→ Replace if soiling is not removed by washing or if there is damage.

• Although the step pattern of the self-diagnostic "Head Nozzle Check" is well adjusted, ifthe vertical lines of the "Black Head Tilt Check" do not join, carry out the following tasks.→ Replace the steel flexible belt assembly.

• Is there play in the cursor?→ Replace the CR flat spring or the cursor assembly.

No. SymptomSequence




1390

1390

1550

1280

1300

1310

1310

2040

2060

2080

2090

R E P B A C







1 • Bad right angle precision 1-1

1-2

1-3

1-4

• Are the fans working normally according to the self-diagnostic “Examination: Fan”? → Check the connectors between fan assembly, fan extension cable assembly and main

board assembly.Fan extension cable 1 assembly is J115 (FAN1) on the main boardFan extension cable 2 assembly is J116 (FAN2) on the main boardFan extension cable 3 assembly is J117 (FAN3) on the main board



• Is the pressure roller pressing on the media over its entire length?• With the pressure lever up, does the pressure rollers seem reluctant to turn?• With the pressure lever down, does the pressure rollers idle or contact the platen on one

side?• With the pressure lever down, is the blade pressing firmly on the media?




No. SymptomSequence




10801080

12201520

1520, 10401690

1060

R E P B A C







1 • Bad right angle precision 1-1

1-2

1-3

1-4

• Are the fans working normally according to the self-diagnostic “Examination: Fan”? → Check the connectors between fan assembly, fan extension cable assembly and main

board assembly.Fan extension cable 1 assembly is J115 (FAN1) on the main boardFan extension cable 2 assembly is J116 (FAN2) on the main boardFan extension cable 3 assembly is J117 (FAN3) on the main boardFan extension cable 4 assembly is J118 (FAN4) on the main board



• Is the pressure roller pressing on the media over its entire length?• With the pressure lever up, does the pressure rollers seem reluctant to turn?• With the pressure lever down, does the pressure rollers idle or contact the platen on one

side?• With the pressure lever down, is the blade pressing firmly on the media?



→ Use a nylon brush to clean away any paper dust or paper scraps from the grid roller.→ Adjust platen height or refit the rear paper guide.

No. SymptomSequence




10801080

12201520

15201040-2(-2)

1060

R E P B A C





Problem Involving Noise


1 • Abnormal noise when media issucked down

1-1

1-2

1-3

1-4

1-5

1-6


• Are the rotating fins of the suctions fans touching the cable or are there paper scraps andforeign matter?→ Remove obstructions and foreign matter.

• Check for a broken cable and connections.→ Replace any parts that are broken.

• The fan itself may be faulty.→ Replace it.

• The main board assembly may be faulty.→ Replace it.

• The power board assembly may be faulty.→ Replace it.

No. SymptomSequence




1080

1140

1150

R E P B A C






1 • Abnormal noise when standing byready to print

1-1

1-2

• Is there something touching or some foreign matter at the place producing the abnormalnoise?→ Remove the obstruction or foreign matter.

• It a board producing the noise?→ Replace the board assembly in question.

• Power board assembly• Main board assembly• Head board assembly• Print head assembly

No. SymptomSequence




1150114014201390

R E P B A C






1 • Abnormal noise when head is movingleft and right

1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

1-9

1-10

• The abnormal noise could be squirting noise when printing.→ Explain specifications.

• Is the abnormal noise caused by a loose screw on the cover?→ Tighten the screws.

• Is it a rattle when the cursor moves left and right?→ Remove dirt from the carriage bearings and roller tracks.→ Be sure to apply a light Sumi-grease spray to the roller tracks when you clean them.

• Is the noise coming from the Y flexible plate?→ Repair it by taking out warping.→ If the noise is coming from between the steel flexible belt and the tube guide, replace

the tube guide assembly.

• Check whether the cable connected to the head board on the carriage is touching thecover. Also, check whether is it touching the encoder and fence mounted at the back ofthe head board.→ If adjusting the position does not solve the problem, replace it.

• Is the noise coming from the Y pulley box assembly bearing?→ Replace the Y Motor assembly.

• Is the noise coming from the Y return pulley bearing?→ Replace it.


→ Re-adjust steel belt tension.

• Is the Y drive pulley screw loose?→ it securely.

• Is the noise coming from the Y motor assembly?→ Replace it.

No. SymptomSequence




1540

1280

1320

1550

1280

1280

R E P B A C






1 • Abnormal noise when media is fed 1-1

1-2

1-3

1-4

• Is the abnormal noise due to pressure roller deformation?→ Replace them. Also, explain the need to raise the lever, as shown in the caution label,

when the printer is not printing.

• Is the X speed reduction belt out of tooth with the X speed reduction pulley?→ Replace the X speed reduction belt.

• Is the noise coming from the X motor?→ Replace it.



No. SymptomSequence




1220

1090

1070

1520, 10401690

R E P B A C


1040-2





1 • Abnormal noise when cutting 1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

• Has the cutter cap been fixed securely on the top of the cutter as a result of checking inthe primary consultation?→ Refit it.

• Does the cutter move up and down smoothly?→ Refit the spring and remove any foreign matter.

• Is there foreign matter in the cutter groove and front surface of the printing board section?→ Remove the foreign matter.

• Is the cutter blade parallel with the printing board cutter groove? → Adjust it.

• The cutter itself may be no good.→ Replace it.


• The Y cable may be damaged.→ Replace it.

• The power assembly board may be faulty.→ Replace it.

No. SymptomSequence




1420

1360

1150

R E P B A C




Trouble with Media Cutting


1 • Does not cut normally

(Since there is no cutting of cut sheetmedia, this item applies only to rollmedia)

1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

1-9

• Is the tip of the cutter blade chipped or worn?→ Replace the cutter.

• Is the cutter cap set securely on the top of the cutter?→ Refit it.


• Is there foreign matter in the cutter groove and front surface of the printing board section?→ Remove foreign matter.→ Remove paper dust from the cutter groove.


• Use self-diagnostic "Aging:Cutter" to confirm up and down movement. → Check the connections on cutter solenoid assembly connector and head board assembly con-

nector J206 (SOL). → If there is no up and down movement, the solenoid may be damaged.

Replace the cutter solenoid assembly.

• Check the Y cable connectorsCheck that they are not inserted obliquely.→ Re-insert the main board assembly connector J111 (HEAD1) and the head board assembly con-

nector J201 (MAIN1).→ Replace them.



No. SymptomSequence




1380

1360

1420

1140

6030

R E P B A C


CAUTION: Power must be off when connectors are being disconnected or reconnected,otherwise you may be injured or a board may be damaged.The main board assembly will certainly be damaged if power is applied withmain board assembly connectors J111 (HEAD) and J112 (HEAD2) and headboard connectors J201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP.





1 • Cutting occurs during printing


1-1

1-2

1-3

1-4

1-5

1-6



• Check the Y cable connectors.Check that they are not inserted obliquely.→ Insert the main board assembly connector J111 (HEAD1) and the head board assem-

bly J201 (MAIN1).→ Replace them.



No. SymptomSequence




1360

1420

1140

R E P B A C



Cut






1

2

• The cutting operation is normal butthe media is not cut

• The cutting is bad and the media jams


1-1

1-2

1-3

1-4

1-5

• Is the cutter blade chipped or deteriorated as checked in the primary consultation?→ Replace the cutter.



• Is there foreign matter in the cutter groove and on the surface of front paper guide?→ Remove the foreign matter.→ Remove paper dust from the cutter groove.

• Is the cutter blade parallel with the front of the paper guide?→Adjust it.

No. SymptomSequence




R E P B A C






1 • The cutting operation is normal butthe media does not fall out


1-1

1-2

• Are paper guide surfaces being cleaned daily?→ Clean the surfaces.

• There may be a static charge on the front paper guide or media. → Make a proper earth connection.→ Check the humidity of the usage environment and bring it within usage environment

specifications.

No. SymptomSequence




R E P B A C






1 • Inaccurate media cutting 1-1

1-2

1-3

1-4

1-5

1-6




• Is there foreign matter in the cutter groove and front surface of the printing board section?→ Remove the foreign matter.→ Remove paper dust from the cutter groove.


• The cutter itself may be no good.→ Replace it.

No. SymptomSequence




R E P B A C



X

The media cutting precision of thismachine is x ≤ 0.3 mm





1

2

• Cutting is delayed for some time afterprinting has ended

• White paper is cut

1-1

1-2

1-3

1-4

• Are internal sample prints output without trouble?→ Refer to EXA4030 "Does not print at all"




No. SymptomSequence




1140

PAT1000

R E P B A C




Online/Function Problems


1

2

• Cannot connect normally withCentronics

• Cannot connect normally withNetwork

1-1

1-2

1-3

1-4

1-5

1-6

• Try communicating with the available computer and cable.→ Contact your Mutoh distributor.

• Does the error occur after the interface cable has been changed?→ There may be a broken lead in the interface cable or the cable itself may be too long for good

communication. Advise the use of a cable that conforms to specifications.



• For network connections, make sure of the type of cable that is to be used for the connection envi-ronment.For direct connection of one host and one printer → Use a cross cable (100/10Base-T) For connection of several hosts and one printer through a hub → Use a straight cable (100/10Base-T)

❈ To check connections to the network board, use the board accessory setup utilities or connectdirectly to the computer (using a crossed cable in the case of 10BASE-T) and use the PINGcommand.

Example of use of PING commandPING (ping) is run from the MS-DOS prompt under Windows 95/NT.Example: C:\WINDOWS>PING 192.168.41.34 [Enter]

PING may be upper or lower case. Connection is indicated by a response such as:Reply from 192.168.41.15: bytes=32 time=4ms TTL32(This address is the default value.)


No. SymptomSequence




1140

R E P B A C






1

2

3

• The scale function does not work cor-rectly

• The mirror function does not work cor-rectly

• Other functions are not working cor-rectly

1-1

1-2

1-3




No. SymptomSequence




1140

R E P B A C






1 • Printing position is offset 1-1

1-2

1-3

1-4

1-5


• Is the front-sensor-to-head distance or the cutter-to-head distance causing a problem fortop and bottom margin distance adjustments?→ Adjust them.




No. SymptomSequence




1140

2090

2130

R E P B A C






1 • Some data are not printed (omitted) 1-1

1-2

1-3

1-4

1-5



• Check whether the timing fence is dirty or twisted.→ If it is greasy or dusty, wipe it clean.→ If it is ink stained wipe it lightly with a cloth damped in a neutral detergent.→ If it is severely soiled and can not be cleaned, replace the T fence.

• Check Encoder: Y that is in the self-diagnostics examinations. (Examination: Encoder)→ If it is no good, check the cable connections of J112 (HEAD2) on the main board

assembly and J202 (MAIN2) on the head board assembly.→ Replace the T fence.→ Replace the Y motor assembly.→ Replace the head board assembly.→ Replace the Y cable (between J112 (HEAD2) on the main board assembly and J202

(MAIN2) on the head board assembly).


No. SymptomSequence




1300

130012801420

1360

1140

R E P B A C







1 • Text and printing data are garbled(extra lines appear)

1-1

1-2

1-3

1-4

1-5



• Check whether the timing fence is dirty or twisted.→ If it is greasy or dusty, wipe it clean.→ If it is ink stained wipe it lightly with a cloth damped in a neutral detergent.→ If it is severely soiled and can not be cleaned, replace the T fence.

• Check Encoder: Y that is in the self-diagnostics examinations. (Examination: Encoder)→ If it is no good, check the cable connections of J112 (HEAD2) on the main board

assembly and J202 (MAIN2) on the head board assembly.→ Replace the T fence.→ Replace the Y motor assembly.→ Replace the head board assembly.→ Replace the Y cable (between J112 (HEAD2) on the main board assembly and J202

(MAIN2) on the head board assembly).


No. SymptomSequence




1300

130012801420

1360

1140

R E P B A C







1 • There is an extra feed after printing isfinished

1-1

1-2

1-3

1-4

• Are the printing position and location method settings suitable?→ Set them to suitable values.




No. SymptomSequence




1140

R E P B A C




Others


1 • The printer hangs up 1-1

1-2

• Bad internal processing in the main board?→ Initialize parameters after switching the printer off and on temporarily, enter settings

manually and the check the operation. → Install the program and try again.


No. SymptomSequence



Others

1600

1140

R E P B A C




Others


1 • Power shutdown during printing 1-1

1-2

1-3

1-4

• Is there a short in the power cable.→ Check it with a tester.

• Is there a power leak?→ Check for contact with the frame due to frayed covering.

• Check power voltagesPower supply voltage check ∗∗∗ V AC (∗∗∗: 100, 120 or 240)Power supply voltage check 5 V DCPower supply voltage check 24, 42 V DC


No. SymptomSequence



Others

1150

R E P B A C




Others


1 • The ink cartridges will not go in 1-1

1-2

• Is the cartridge holder assembly needle deformed or broken?→ Replace the cartridge frame assembly.

• Is the ink present/absent sensor (a black plastic lever switch) on the detector assemblydamaged?→ Replace it.

No. SymptomSequence



Others

1330

1350

R E P B A C




Others


1

2

3

4

• Ink has overflowed from the waste fluid bottle

• Ink overflows from flushing box

• Ink is spilt around the X rail

• Ink has overflowed from the waste fluid bottle

1-1

1-2

1-3

1-4

1-5

2-1

2-2

2-3

3-1

3-2

3-3

4-1

• Check inside the waste fluid bottle. If it is full of ink, explain to the customer as you replace the waste fluid bottle.

• Use the self-diagnostic "Sensor: No Ink" to check the cartridge that has no ink.→ Remove all cartridges and check that the "No Ink" display changes when you gently press the black plastic

switches of all the detector assemblies On and Off.

• Use the printer's self-diagnostic "Sensor: Tank Exist/Tank is not" to make sure that the waste fluid bottle detectionis working normally.→ Slowly remove and replace the waste fluid bottle to confirm that the present/absent display appears.→ If the display is not normal, the sensor mounting position may be at fault.

Adjust the mounting position of the waste fluid bottle detection switch assembly.

• Check the waste fluid bottle detection switch contact.J109 (INK TANK) on the main board→ Insert it correctly.→ Replace it.

• Is the waste fluid tube from the flushing bottle kinked?→ Fix it and attach it again.

• Is the flushing box choked with trash?→ Remove the trash.→ Replace it.

• Is the waste fluid tube from the flushing box kinked?→ Fix it and attach it again.

• Is the absorbent material for flushing box full of ink?→ Replace it.

• The extension tube under the pump assembly may have come away.→ Remove the maintenance station assembly and check whether the extension tube has come away.→ Replace the pump assembly.→ Replace the pump motor assembly.→ Replace the cap assembly.

• The ink tube may be cut.→ Replace the ink tube.

• Print head, main board assembly and head board assembly may be damaged.→ Remove ink cartridges and check that each board is normal.

• Is the waste liquid bottle full of ink?→ Replace it.

No. SymptomSequence



Others

1350

1120

1700

1270126012301240

1370

1710

1040

1040

R E P B A C




Heater System

When Message is not Displayed

1 • Heater does not stop warming up. 1-1

1-2

1-3

1-4

1-5

• Is Sensor Rear Heater broken?→ Replace the Rear Paper Guide

• Is Sensor Front Heater broken?→ Replace the Front Paper Guide

• Is cable damaged/broken of Rear or Front Heater?→ Replace Rear or Front Paper Guide

• Is Front Heater broken?→ Replace the Front Paper Guide

• Is Rear Heater broken?→ Replace the Rear Paper Guide

• I

No. SymptomSequence



Heater System

1040

1040

1040

1040

1040

1040

R E P B A C


• Heater does not work.

DDV

• I



Heater System


1 • Heater does not stop warming up. 1-1

1-2

1-3

1-4

1-5

• Is Sensor Rear Heater broken?→ Replace the Rear Paper Guide

• Is Sensor Front Heater broken?→ Replace the Front Paper Guide

• Is cable damaged/broken of Rear or Front Heater?→ Replace Rear or Front Paper Guide

• Is Front Heater broken?→ Replace the Front Paper Guide

• Is Rear Heater broken?→ Replace the Rear Paper Guide

• I

No. SymptomSequence



Heater System

1040-2

1040-2

1040-2

1040-2

1040-2

1040

R E P B A C


• Heater does not work.

DDV

• I

R E P 0 0 0 0Model Name: Rockhopper-46


Rockhopper-463 Replacement and Adjustment Procedures


Procesos de Ajuste y Recambio

R E P 0 0 0 0 - 3Model Name: Rockhopper-62




Procedimiento de Ajustes y Recambio





Replacement and Adjustment Procedure

Right and Left Covers REP 1010Front Cover REP 1020Panel Cover and Y Rail Cover REP 1030Front Paper Guide and Rear Paper Guide REP 1040Right Side Cap and Left Side Cap REP 1041Control Box REP 1050Head Cover REP 1060X Motor Assembly REP 1070Fan Assembly and Fan Cable REP 1080X Speed Reduction Belt REP 1090Lever Sensor Assembly REP 1100Cover Switch Assembly REP 1110Waste Fluid Box Sensor Assembly REP 1120Switch Cable Assembly and DC Cable Assembly REP 1130Main Board Assembly REP 1140Power Supply Board Assembly REP 1150Panel Board Assembly and Heater Panel Board Assembly REP 1160lyy Panel Cable REP 1170Extension Board Assembly REP 1180


Cursor Plate Spring and Steel Flexible Guide Assembly REP 1310Y Return Pulley Assembly REP 1320Cartridge Frame Assembly REP 1330Ink ID Sensor Assembly REP 1340Detector Assembly REP 1350Y Cable REP 1360Ink Tubes REP 1370Cutter Solenoid Assembly REP 1380Print Head Assembly and Head Cable REP 1390

Y Paper Sensor Assembly REP 1410Head Board Assembly REP 1420Dampers REP 1430Cursor Assembly REP 1440Origin Sensor and Y Encoder REP 1450Junction Board Assembly REP 1470

Platen Height Adjustment REP 1520Tube Guide Assembly REP 1540How to Adjust Steel Belt Tension REP 1550How to Adjust X Speed Reduction Belt Tension REP 1560How to Adjust Print Head REP 1570


Head Cleaning Procedure REP 1620How to Clean the Head Nozzle Face REP 1660X Speed Reduction Pulley Assembly REP 1680Grid Roller Assembly REP 1690F Absorbent Material Assembly REP 1700

Front / Rear Heater (or sensors) (refer to)REP 1040





Replacement and Adjustment Procedure

Right and Left Covers REP 1010Front Cover REP 1020Panel Cover and Y Rail Cover REP 1030Front Paper Guide and Rear Paper Guide REP 1040-2Right Side Cap and Left Side Cap REP 1041Control Box REP 1050Head Cover REP 1060X Motor Assembly REP 1070Fan Assembly and Fan Cable REP 1080-2X Speed Reduction Belt REP 1090Lever Sensor Assembly REP 1100Cover Switch Assembly REP 1110Waste Fluid Box Sensor Assembly REP 1120Switch Cable Assembly and DC Cable Assembly REP 1130Main Board Assembly REP 1140Power Supply Board Assembly REP 1150Panel Board Assembly REP 1160Panel Cable REP 1170Extension Board Assembly REP 1180


Cursor Plate Spring and Steel Flexible Guide Assembly REP 1310-2Y Return Pulley Assembly REP 1320Cartridge Frame Assembly REP 1330Ink ID Sensor Assembly REP 1340Detector Assembly REP 1350Y Cable REP 1360-2Ink Tubes REP 1370-2Cutter Solenoid Assembly REP 1380Print Head and Head Cable REP 1390

Y Paper Sensor Assembly REP 1410Head Board Assembly REP 1420Dampers REP 1430Cursor Assembly REP 1440Origin Sensor and Y Encoder REP 1450Junction Board Assembly REP 1470

Platen Height Adjustment REP 1520Tube Guide Assembly REP 1540-2How to Adjust Steel Belt Tension REP 1550How to Adjust X Speed Reduction Belt Tension REP 1560How to Adjust Print Head REP 1570


Head Cleaning Procedure REP 1620How to Clean the Head Nozzle Face REP 1660X Speed Reduction Pulley Assembly REP 1680Grid Roller Assembly REP 1690F Absorbent Material Assembly REP 1700Waste Fluid Bottle Assembly REP 1700Front / Rear Heater (or sensors) (refer to)REP 1040-2



How to remove and replace the Right and Left Covers

How to remove and replace the Right and Left Covers


1. Removal andReplacementProcedure

❈ Before carrying out this operation, switch off the power supply and removethe power plug.

❈ Before removing the covers, remove roll media with scroller from scrollerreceiver.

Right Cover

1. Remove four screws.2. The cover is caught at the place shown by arrow A. Remove the cover while

lifting in the direction of arrow B.3. Assembling is the reverse of the removal procedure.

Left Cover

1. Remove in the same way as for the Right Cover.

A

B

ScrewScrew

Right cover

Right cover

Screws



How to remove and replace the Front Cover

How to remove and replace the Front Cover



Front Cover

1. Remove the Right Cover.2. Loosen the two fastening screws on the right side of the Front

Cover. (Refer to the diagram on the right)3. Loosen the Panel Cover Screw and remove the Panel Cover by

sliding it about 3 mm to the left. 4. Slide the right side Front Cover Shaft to the right. 5. Remove the Front Cover by sliding it to the right.6. Replacement is the reverse of the removal procedure but before

replacing the Right Cover, open and close the Front Cover tocheck that the Cover Switch is being pressed correctly.

Cover shaft R2 fastening screws

Slide the cover shaft

Pull out

Front cover

DDV

DDV

DDV



How to remove and replace the Panel Cover and Y Rail Cover

How to remove and replace the Panel Cover and Y Rail Cover



Panel Cover

1. Loosen the two screws on the Front Cover Right Cover Shaft andpush the Front Cover to the left.

2. Loosen the Panel Cover Screw (1 screw) by 3 mm or remove it.3. Slide the Panel Cover to the left (in the direction of arrow A) and

remove it towards you (in the direction of arrow B). 4. Assembling is the reverse of the removal procedure.

Y Rail Cover

1. Remove the Panel Cover.2. Remove the Front Cover.3. Remove the Cartridge Cover. (5 screws)4. Remove the Y Rail Cover Screws (3 front/4 rear).5. Remove the Y Rail Cover by lifting it upwards. 6. Assembling is the reverse of the removal procedure.

Panel cover

Screws

B

A

Screw

Screw

Screws

DDV

DDV

DDV



How to remove and replace the Front Paper Guide and Rear Paper Guide



Rear Paper Guide

6. Remove the Ink Carriage Cover. (3 top/2 bottom screws)7. Remove the Small Rear Guide at the left rear side of . the printer.

1. Remove the Right Cover.2. Remove the Left Cover.3. Remove the Key Panel.4. Remove the Front Cover.5. Remove the Y-rail Cover.

.9. Loosen the cables from their cable clamps.. ...

.

.8 Remove the protection board at the left bottom side of the printer (6 screws).

.

.11. Carefully pull out the cables. Do not damage the cables

CAUTION: When replacing the Rear Paper Guide, please be sure not to damage the cables.Be carefully otherwise you may suffer an electrical shock.Do not forget to lock the cables in their cable clamps.

. or connectors.12. Remove the rear paper guide (with front heater).13. Assembling is the reverse of the removal procedure.. .

Rear side

Small Rear Guide

.10. Carefully loosen the connectors . Be sure not to damage

. .. the cables or connectors..

DDV

.

DDV

.

DDV

7. . .

DDV

DDV

DDV

DDV



How to remove and replace the Front Paper Guide and Rear Paper Guide (bis)



.

.

.

.

.

.

.

.

.

.

Front Paper Guide

1. Remove the protection board at the left bottom side of the printer (6 screws).2. Loosen the cables from their cable clamps.3. Carefully loosen the connectors . Be sure not to damage the cables or connectors.4. Carefully pull out the cables. Do not damage the cables or connectors. .

.CAUTION: When replacing the Rear Paper Guide, please be sure not to damage the cables.

Be carefully otherwise you may suffer an electrical shock.Do not forget to lock the cables in their cable clamps.

.6. Assembling is the reverse of the removal procedure....

Front paper guide

Screws

ScrewsFront side

.

.

.

. Remove the Front Paper Guide. Be sure not to damage any cables.

. Pull the Front Paper Guide carefully forward.

.

.5....

DDV

.

DDV

.

DDV

. .





Front paper guide

Screws

ScrewsFront side


Front Paper Guide

6. Remove the Ink Carriage Cover. (3 top/2 bottom screws)7. Remove the Heater Panel Cover. (2 top screws). Loosen connectors J12 & J15

1. Remove the Right Cover.2. Remove the Left Cover.3. Remove the Key Panel.4. Remove the Front Cover.5. Remove the Y-rail Cover.

. (Remove 6 top/5 bottom screws)9. Remove the connectors & sensors. (2 yellow, 2 red, 1 brown ; use. Tool TL-24000) (connector 240 VAC)..

10. Remove Front Paper Guide (with Front Heater).

.

.8 Remove screws from Front Paper Guide (with Front Heater).

Heater Panel screws

Front Heaters Connectors

.

.11. Assembling is the reverse of the removal procedure.

CAUTION: When replacing the Front Paper Guide,please be sure not to damage the cables.Also keep the cables away from the fans and grid rollers.

DDV

.

DDV

.

DDV

.

DDV

7. . .





Rear side

Rear paper guide


8. To remove the Rear Paper Guide, be sure you do not . damage any cables. Pull the Rear Paper Guide. carefully backwards.

.

.

.

.

.

6. Remove the first three Platen Fitting Boards starting from the righ.Mark their place, reinstallation must be on the same place.

7 Loosen the screws of the Rear Paper Guide. (6 top / 5 bottom screws) .

Rear Paper Guide

1. Remove the Front Paper Guide.2. Remove the Support Brackets.3. Loosen cables and connectors from the rear heater.4. Open the PCB box.5. Loosen the connectors from the rear hater to the heater panel.

Pull them to the top front side of the printer body.

.

Support Brackets

Platen Fitting Board

DDV

.

DDV

.

DDV

. .






Connectors Rear Heater

A

Platen Fitting Board

. Reinstallation of the Rear Paper Guide.1. Place the Rear Paper Guide on the printer body.2. Place the connectors and cables to the front of the machine.3. When reinstalling the Rear Paper Guide be sure not to damage. or block a cable or connector.

4. Place and lock the cables so that they can not touch the . Grid Rollers.

5. Fix the Rear Paper Guide.6. Reinstall the Platen Fitting Boards. (exact same place as before). Push downwards on the front (arrow A) so the boards can not. touch the Grid Rollers.

7. Reconnect cables and connectors of the Rear Paper Guide.8. Reinstall the Support Brackets. Be sure not to damage the cables.9. Reinstall the Front Paper Guide.

CAUTION: When replacing the Rear Paper Guide,please be sure not to damage the cables.Also keep the cables away from the fans and grid rollers.

DDV

.

DDV

.

DDV

.

DDV

. .

DDV

.

Front box

Right side cap

Left side cap



How to remove and replace the Right Side Cap and Left Side Cap

How to remove and replace the Right Side Cap and Left Side Cap



Right Side Cap

1. Remove the Front Paper Guide.2. Remove Panel Bottom Cover. (4 screws)3. Bring the Head to the middle.4. Hold up the Front Box.5. Remove two screws from the Front Side Cap.6. Turn the Right Side Cap clockwise and remove it.7. Refitting is the reverse of the removal procedure.

Left Side Cap

1. Remove the Front Paper Guide.2. Remove X Motor Cover. (4 screws)3. Hold up the Front Box.4. Remove two screws from the Left Side Cap.5. Remove the Left Side Cap upwards.6. Refitting is the reverse of the removal procedure.

DDV

DDV

DDV

DDV

DDV

DDV



How to open and close the Control Box

How to open and close the Control Box



❈ Before working, be sure to switch off power and remove thepower cable from the inlet.

❈ Since the Control Box will hit the roll media when it isopened and can not be opened completely, the scrollermust be removed.

Opening and closing the Control Box

1. Remove three hexagonal socket head bolts from the front ofthe Control Box so that the Control Box Cover can beremoved.

2. Remove the three screws holding the Control Box.❈ Since the Control Box will fall open when the three fastening

screws are removed, support it with your hand as youremove the screws.

3. Slide the Control Box Cover to the rear and lift it out.

4. Assembling is the reverse of the removal procedure.

(Side)

(Front)

Hexagonal socket head boltsScrews holding Control box

Control box

Control box cover

1

2



How to remove and replace the Head Cover

How to remove and replace the Head Cover



Head Cover

1. Open the Front Cover.2. Slide the Head out from the Maintenance Station.

3. Remove the Head Cover. (2 fastening screws)4. Assembling is the reverse of the removal procedure.

Head

Screw

Screw

Caution: When you pull the Head, don’t press the cut-ter cap, otherwise the cutter blade will bedamaged.



How to replace the X Motor Assembly






1. Remove the Front Paper Guide.2. Remove the Left Cover.3. Remove the Control Box.4. Remove the X Motor Cover.5. Disconnect connectors J120 and J121 from the Main Board

Assembly.6. Remove one cable clamp (black) from the bottom surface of

the Rear Frame X Reinforcement and cut the cable tie thatholds the cables together.

7. Remove two cable clamps (metal) from the top surface of theFront Frame X Reinforcement and withdraw the cables fromthe hole in the Front X Reinforcement.

8. Loosen four screws holding the X Motor Assembly so that itdoes not apply tension to the Speed Reduction Belt.

9. Remove the two screws that hold the X Motor to the X Motormounting plate and pull out the motor.


Adjust X Motor tension.

X Motor Assembly fastening screws

Pull out

Slide

X Motor fastening screws


Front X Reinforcement

Cable clamp

Fan Assembly

Fan duct fastening screws

Fan duct

Fan connector

Fastening screw

Fan connectorJ117, J116 and J115



How to replace the Fan Assembly and Fan Cable




Replace the Fan Assembly

1. Remove the Front Paper Guide.2. Remove the Fan Duct. (3 fastening screws)3. Remove the Fan Cable Connector.4. Remove the Fan. (1 fastening screw)5. Assembling is the reverse of the removal procedure.

Replace Fan Extension Cables 1, 2 and 3

1. Remove the Front Paper Guide.2. Remove the Rear Paper Guide.3. Remove each Fan Cable Connector.4. Remove each cable clamp.5. Open the Control Box.6. Remove the two cable clamps on the Front Frame X

Reinforcement.7. Remove one cable clamp on the Rear Frame X Reinforcement

and cut the cable tie that holds the cables together.8. Disconnect connectors (J115, J116 and J117) from the Main

Board Assembly and remove the cables.9. Assembling is the reverse of the removal procedure.

R E P 1 0 8 0 - 2Model Name: Rockhopper 62






Replace the Fan Assembly

1. Remove the Front Paper Guide.2. Remove the Fan Duct. (3 fastening screws)3. Remove the Fan Cable Connector.4. Remove the Fan. (1 fastening screw)5. Assembling is the reverse of the removal procedure.

Replace Fan Extension Cables 1, 2, 3 and 4

1. Remove the Front Paper Guide.2. Remove the Rear Paper Guide.3. Remove each Fan Cable Connector.4. Remove each cable clamp.5. Open the Control Box.6. Remove one cable clamp on the Rear Frame X Reinforcement

and cut the cable tie that holds the cables together.7. Disconnect connectors (J115, J116, J117 and J118) from the

Main Board Assembly and remove the cables.8. Assembling is the reverse of the removal procedure.

Cable clamp

Fan Assembly

Fan duct fastening screws

Fan duct

Fan connector

Fastening screw

Fan connectorJ118, J117, J116 and J115



X Motor fastening screws

X speed reduction belt

Speed reduction pulley support



How to replace the Speed Reduction Belt

How to replace the Speed Reduction Belt




Replace the X Speed Reduction Belt

1. Loosen the four screws that fasten the X Motor Assembly toloosen the belt tension.

2. Remove the X Motor (2 fastening screws) from the X MotorMounting Plate and take off the X Motor.

3. Undo the four screws holding the Speed Reduction PulleySupport and remove the Speed Reduction Pulley Support.

4. Remove the X Speed Reduction Belt from the X SpeedReduction Pulley.


Adjust X Motor tension.



How to replace the Lever Sensor Assembly

How to replace the Lever Sensor Assembly



2. Adjustment andExaminationProcedure

Replace the Lever Sensor Assembly

1. Remove the Front Paper Guide.2. Remove the Panel Cover.3. Remove the Panel Bottom Cover.4. Remove the Right Cover.5. Open the Control Box.6. Disconnect the Main Board connector J104 (LEVER) and

cut the cable tie that holds the cables together.7. Remove the Panel Cable connector and Tube Holder (one

fastening screw) and pull out connector J301 and thePanel Cable (FFC).

8. Remove the Panel Mounting Plate. (3 fasteningscrews)

9. Remove the two black cable clamps attached to the FrontX Reinforcement and pull out the Lever Sensor Assemblycable from the hole.

10. Remove the Lever Sensor Mounting Plate. (1 fasteningscrew)

11. Remove the Lever Sensor. (2 fastening screws)12. Assembling is the reverse of the removal procedure.

Open the Lever and confirm that “Lever Up” is displayed.

Dowel

Push up

Lever sensor mounting plate

Lever sensor Assembly

+

Cable clampSensor fastening screws

Sensor mounting plate

Two fastening screwsof switch

Fastening screws

Cover switch

Cover sensor arm

CAUTION: If the Cover Sensor Arm does not pressthe Cover Switch when the Front Coveris opened and closed, carry out the "Sensor Mounting Plate Position Adjustment".

+

++

+

Adjust timingby sliding

Tighten after adjustment



How to replace the Cover Switch Assembly

How to replace the Cover Switch Assembly




Replace the Cover Switch Assembly

1. Remove the Panel Cover, Front Cover and Rail Coverin that order then undo the two screws holding the YRail Cover Support and remove the Y Rail CoverSupport. Then remove the Rear Paper Guide.

2. Remove the Right Cover.3. Undo the two screws holding the Ink Cartridge Unit

then lift it up a little and slide it so that you can see thecable that passes beneath it.

4. Open the Control Box and pull out connector J106 fromthe Main Board.

5. Remove the black cable clamp and cut the cable tiethat holds the cables together.

6. Remove the Cover Switch (2 fastening screws).7. Assembling is the reverse of the removal procedure.

Open the Front Cover and confirm that “Cover Open” isdisplayed.



How to replace the Waste Fluid Bottle Sensor Assembly

How to replace the Waste Fluid Box Sensor Assembly



Replace the Cover Switch Assembly

1. Remove the Waste Fluid Bottle.

2. Disconnect connector

3. Remove the Waste Fluid Bottle Sensor Assembly. (2 fasteningscrews)


CAUTION: Be careful not to over-tighten when mount-ing the Waste Fluid Bottle Sensor Assembly.

Power board assembly

Main board assembly

Switch cableassembly

Connector J001

Connector J001 (POWER)

ConnectorJ100 (SW)

ConnectorJ100 (SW)



How to replace the Switch Cable Assembly/CD Cable Assembly

How to replace the Switch Cable Assembly/CD Cable Assembly



CAUTION: The power cable connector must be discon-nected before this operation.

Switch Cable Assembly Replacement

1. Open the Control Box.2. Disconnect connector J100 (SW) from the Main Board

Assembly.3. Press the Switch Lock and remove it by pushing it out.4. Remove the cable from the white Cable Clamp.5. Assembling is the reverse of the removal procedure.

❈ After fitting, check that the switch cable is not touchingpower supply board.

DC Cable Replacement

1. Open the Control Box.2. Disconnect connector J001 from the Power Board Assembly.3. Disconnect connector J101 (POWER) from the Main Board

Assembly and remove the cable.4. Assembling is the reverse of the removal procedure.

DDV

DDV

Memory cardslot



How to replace the Main Board Assembly



1. Capture back-up parame-ters

For main board replacement, in addition to the new main board you must arrange for (1) a memory card for firmware installation and (2) a memory cardfor backup parameters (Fujitsu 4 MB card is recommended).

❈ Some memory cards do not always work.

This main board assembly is constructed to accept backup parameters (user parameters and adjustment parameters) in a flash memory card.

Caution: Be sure to capture these backup parametersbefore the board is replaced.

1. Be sure to take up backup parameters before the Main Boardis replaced.

Caution: If you are unable to do this operation, ask tosee the user setup list.For adjustment parameters, you can alsocontact the Inquiry Desk with the serial num-ber of your plotter and receive adjustmentparameters.


DDV

DDV







3. Install latestprogram

4. Install backupparameters

2. Replace the Main Board1) Disconnect all communications connectors.2) If the Optional Interface is connected with the two Centronics

Interface connector screws, remove it now.3) Open the Control Box.4) Disconnect all Main Board Assembly connectors.5) Remove the Extension Board Assembly (4 screws) and SIMM. 6) Remove the Main Board Assembly. (5 fastening screws)7) Assembling is the reverse of the removal procedure.

« REFERENCE » SIMM must be inserted from Slot 1.

« REFERENCE » Main board assembly DIP switches are for test-ing and have no settings.

CAUTION: Firmware installation and parameter recovery will becarried out after this but these tasks must be doneafter the connections have been checked and with theControl Box closed.Otherwise you may suffer an electric shock or compo-nents may be damaged.

3. Install the latest program.

4. Install the backup parameters that were taken up in Step 1 in the newMain Board Assembly.

CAUTION: If backup parameters were not taken up in Step 1, enter them manually.For the user setup list, refer to the section on “How to set parameters” in the Users Guide and Functional Operation Edition.Also, for adjustment parameters, refer to BAC5020 (parameter update).

CAUTION: Replace the “Waste Fluid Box” if backup parameters were not taken up in Step 1.The message “Change Tank?:” will appear on the panel display. You should confirm by answering “Yes”.

Five main boardassembly fasteningscrews

Four extension board assemblyfastening screws

Main boardassembly

Extension boardassembly

Connector J000Connector J001



How to replace the Power Supply Board Assembly

How to replace the Power Supply Board Assembly



Replace the Power Supply Board Assembly

1. Open the Control Box.2. Disconnect Power Supply Board Assembly connectors J000

and J001.3. Remove the Power Supply Board Assembly. (5 fastening

screws)4. Assembling is the reverse of the removal procedure.

CAUTION: The power cable connector must be disconnected before this operation.

CAUTION: Since the power supply remains hot after the power is switched off, wait until it has cooled before performing this operation.

ScrewsScrews

Panel board assembly



How to replace the Panel Board Assembly and Heater Panel Board Assembly

How to replace the Panel Board Assembly and Heater Panel Board Assembly



Replace the Panel Board Assembly

1. Remove the Panel Cover.2. Disconnect connector J301 from the Panel Board Assembly.3. Remove the Panel Board Assembly. (4 fastening screws)4. Assembling is the reverse of the removal procedure.

❈ Do not forget to peel the LCD protection film off.


Replace the Heater Panel Board Assembly

1. Remove the Panel Cover.2. Remove the Heater Panel Cover (2 screws top/ 2 screws front)3. Open the PCB box and remove the PCB cover plate.4. Loosen connector J105. Carefully pull out the heater panel cable to the heater panel board.6. Remove theHeater Panel Board.7. Assembling is the reverse of the removal procedure..

CAUTION:5 . For replacing the Heater Panel board on a Rockhopper 62" . please refer to REP 1040-2...

Cable ofHeater PanelBoard

DDV

DDV

DDV

7.

DDV

7.

DDV

7.

DDV

DDV

Connector J110



How to replace the Panel Cable

How to replace the Panel Cable



Replace the Panel Cable

1. Open the Control Box.2. Remove the Panel Bottom Cover. (4 screws)3. Remove the Panel Cover.4. Disconnect connector J301 from the Panel Board Assembly.5. Remove the Tube Guide. (1 screw)6. Disconnect connector J110 (PANEL) from the Main Board

Assembly and remove the cable.7. Assembling is the reverse of the removal procedure.

❈ When re-laying a new Panel Cable, refer to the positions ofthe bends in the previous cable and proceed after first mak-ing the bends in the new cable.

❈ Use double-sided tape to stick the cable to the underside ofthe X Rail.

Four extension board assemblyfastening screws

Extension board assembly



How to replace the Extension Board Assembly

How to replace the Extension Board Assembly



Replace the Extension Board Assembly

1. Disconnect all communications connectors.2. Open the Control Box.3. Remove the Extension Board Assembly. (4 fastening screws)4. Assembling is the reverse of the removal procedure.

Five holes for removal of rear paper guide

XR cable assembly(Rear paper sensor)

Sensor fastening screws

Two holes for removal of sensor



How to replace the XR Cable Assembly (Rear Paper Sensor)

How to replace the XR Cable Assembly (Rear Paper Sensor)




Replace the XR Cable Assembly (Rear Paper Sensor)

1. Open the Control Box.2. Remove connector J107 (XR) from the Main Board Assembly.3. Remove the Panel Cover.4. Remove the Front Cover.5. Remove the Y Rail Cover.6. Remove the Rear Paper Guide.7. Remove the two screws holding the Sensor Mounting Plate

through the hole in the Flexible Support Cable Guide.

CAUTION: Be careful not to damage the Y Cable cover-ing.

8. Remove the sensor from the sensor mounting plate (2 screws)on the Rear Frame X Reinforcement.


1. Adjust the bundle of Y cable, N belt and ink tubes.(Make sure the pressure arm is lowered then move the headleft and right so that there is no twisting.)

2. Carry out "Rear sensor position" with the printer's self-diagnos-tics under the adjustments menu.

Tension screws

Steel belt

Y motor assembly

Steel belt fastening screw

Three Y motorfastening screws



How to replace the Pressure Assembly, Pressure Roller and Blade




Replacing the Pressure Assembly

1. Remove right and left covers.2. Remove panel cover.3. Remove front cover.4. Remove Y rail cover.5. Remove front paper guide6. Remove rear paper guide7. Loosen two steel belt tensioning screws.

8. Remove one steel belt fastening screw.9. Remove the steel belt.

CAUTION: Be careful not to cut your finger on the edgeof the steel belt.

10. Remove the Y motor assembly. (3 fastening screws)


DDV

Ball screw driver

Link

Fastening spacer

X rail

E-ring







11. With the pressure roller down, loosen the set screw on thepressure axle fastening spacer.

12. Operate the pressure lever and with the pressure roller up,remove the E-ring holding the link.

13. The pressure axle that is stuck into the hexagonal hole in thelink should be pushed a little way in.At this time, the stepped collar will come off so be careful notto lost it.


DDV

DDV

Ratchet screwdriver

Y rail reinforcement plate

Pressure assembly

Four hexagonal nuts

Four screws

Pressure shaft

Pull out

Hex. screw







14. Pull out the pressure shaft from the right side of the frame.

CAUTION: Be careful. If the pressure axle is taken outcompletely, the pressure axle fastening spac-er and the media keeper will fall into the bodyof the printer.

15. Remove the four hexagonal nuts holding tube bracket and liftthe entire Y cable tube bracket while you undo the four nutsholding the Y cable guide.

16. Remove the screws (5 at the back and 4 below) holding theY rail reinforcement plate and pull the entire pressureassembly to the back while you slide it towards the X motorand remove it.

« REFERENCE » A special ratchet tool is required for thebottom screw holding the Y rail reinforce-ment plate (hex. 4 × 10 mm double SEMS).

17. Remove the pressure assemblies from the Y rail reinforce-ment plate. (2 screws for each assembly)

18. Refitting is the reverse of the removal precedure.


Pressure arm

Open

OpenPressure roller

Pressure arm

Blade







Blade Replacement

1. Open the front cover.2. Use a fine straight screwdriver to slightly prize apart the blade

attachment and remove the blade.

CAUTION: When removing the blade, don’t use exces-sive force to part it as there is a risk of dam-aging the blade.

3. To refit, insert the blade on the pressure arm.

Pressure Roller Replacement

1. Follow the blade replacement procedure to remove the blade.2. Use a fine straight screwdriver to slightly prize apart the pres-

sure roller attachment and remove the pressure roller.

CAUTION: When removing the blade, don’t use exces-sive force to part the blade and pressure armas there is a risk of damaging the pressurearm and the blade.

3. To refit, insert the pressure roller and then the blade on thepressure arm.



How to replace the Pump Motor Assembly

How to replace the Pump Motor Assembly



Replace the Pump Motor Assembly

1. Remove the Panel Cover.2. Remove the Front Cover.3. Remove the Panel Bottom Cover.4. Remove the Right Cover.5. Remove the Y Rail Cover.6. Remove the Panel Cable connector and Tube Fixer (1 fastening

screw) and disconnect connector J301.7. Remove the Panel Mounting Plate. (3 fastening screws)8. Open the Control Box.9. Disconnect connector J102 (PUMP) from the Main Board

Assembly.10. Remove the cable clamp fastened to the Front X Reinforcement.11. Slide the head to the left (in the center section) and remove the

entire Maintenance Assembly. (2 top screws/2 front screws)12. Remove the two screws holding the Pump Motor Plate and lift out

the Pump Unit.13. Remove the four screws holding the Pump Motor Assembly.14. Assembling is the reverse of the removal procedure.

1. Carry out the Capping Position Adjustment.2. Adjustment andExaminationProcedure

CAUTION: Apply silicone grease to motor gears.

CAUTION: Pass the motor cable through the round hole inthe pump motor plate.

Screw

Draw out the tube(2 places)



How to replace the Cap Assembly

How to replace the Cap Assembly




Replace the Cap Assembly

1. Remove the Panel Cover.2. Remove the Front Cover.3. Remove the Y Rail Cover.4. Remove the Panel Bottom Cover.5. Remove the Panel Mounting Plate.6. Remove the Maintenance Assembly.7. Draw out the tube on the panel side.8. Remove one screw holding the Cap Assembly.9. Slide the Cap Assembly towards the gear and lift it out.

CAUTION: Be careful not to touch the cap surface andthe wiper with your hand while you are work-ing.


CAUTION: When you insert the tubes into the capassembly refer to the picture on the right sothat the tubes do not exert any load.Otherwise the cap assembly will not movesmoothly.

CAUTION: When screwing the cap assembly to the main-tenance frame, push it right back before fas-tening.

1. Carry out the Capping Position Adjustment.



How to replace the Wiper

How to replace the Wiper



Replace the Wiper

1. Remove the Panel Mounting Plate.2. Move the Wiper back and, with the Wiper rack disconnected,

pull the Wiper up and remove it.3. Assembling is the reverse of the removal procedure.

CAUTION: When refitting the Wiper, be careful not todamage the Head contact surface by touchingit with your hand or with forceps.

2 AdjustmentandInspectionProcedure

1. Initialize the wiper count.

Pull up

Wiper Rack section

[ Cap side ][ Printing roller side ]

Rubber surfaceFelt surface



How to replace the Pump Assembly

How to replace the Pump Assembly




« REFERENCE » When the pump assembly is replaced, the wipershould also be replaced at the same time so besure to have a spare wiper ready.

Replace the Pump Assembly

1. Remove the Panel Cover.2. Remove the Front Cover.3. Remove the Y Rail Cover.4. Remove the Panel Bottom Cover.5. Remove the Panel Mounting Plate.6. Take out the Maintenance Station Assembly.7. Disconnect and remove the tubes between the Pump Assembly and the

Cap Assembly.8. Remove the waste liquid tube that is clamped to the outside of the

Right Frame.9. Remove the metal plate to which the gear is attached together with two

screws.10. Remove the pump assembly (1 screw), slide it towards the wiper and

lift it out.11. Assembling is the reverse of the removal procedure.

« REFERENCE » Before assembly, check that the wiper is installedon the pump assembly.

1. Carry out the Capping Position Adjustment.2. Initialize the wiper count.

CAUTION: Be sure to clamp the waste liquid tube in the proper position on the outside of the right frame.Otherwise the ink will spill and soil the floor and clothing.

CAUTION: When you insert the tubes into the cap assembly refer to the picture on the right so that the tubes do not exert any load.Otherwise the cap assembly will not move smoothly.

Screw

Screws



How to replace the Maintenance Station Assembly

How to replace the Maintenance Station



Replace the Maintenance Station Assembly

1. Remove the Panel Cover.2. Remove the Front Cover.3. Remove the Y Rail Cover.4. Remove the Panel Bottom Cover.5. Remove the Panel Mounting Plate.6. Open the Control Box.7. Disconnect the pump motor connector J102.8. Undo the bundle of cables.9. Remove the waste liquid tube from the clamp.10. Remove the Maintenance Station. (2 top screws/2 front

screws)11. Assembling is the reverse of the removal procedure.

1. Carry out the Capping Position Adjustment.2. Initialize the wiper count.

CAUTION: Be sure to clamp the waste liquid tube in theproper position on the outside of the rightframe.Otherwise the ink will spill and soil the floorand clothing.


Screws

Y motor cable terminal

Y motor assembly








« REFERENCE » If there is to be no replacement thatincludes the Y motor assembly, steps 2, 4and 5 are not necessary.

Replace the Y Motor Assembly

1. Remove the Left and Right Covers.2. Remove the Rear Paper Guide.3. Remove the Steel Belt.4. Open the Control Box.5. Disconnect connector J120 (YMOT) from the Main Board

Assembly.6. Remove the Y Motor Assembly. (3 fastening screws)7. Assembling is the reverse of the removal procedure.

« REFERENCE » Since the Y Motor Assembly Cable pass-es below the Cartridge Unit, the work willbe easier if you remove the two CartridgeBase screws and push it back.


DDV

Fastening screws

Tension adjustment screws

Steel belt



How to replace the Steel Belt

How to replace the Steel Belt



Replace the Steel Belt

1. Remove left and right covers.2. Move the head to near the center.3. Remove the head cover. (2 fastening screws)4. Loosen the two steel belt tensioning screws.5. Remove the belt fastening screw and take off half the steel belt

towards the Y motor side 6. overlap the end of the steel belt removed in 5. with the end of a new

steel belt and attach it with tape.7. Pass the taped part around the drive pulley, press it into the Y rail

and pull it from the return pulley side and fit the new belt into the Yrail.

CAUTION: Do this work with the pressure roller down.

Up to here Press in

Old steel belt

New steel belt

Tape to old belt using the fitting on the front of the new belt

CAUTION: Check that there is no foreign matter or dust onthe new steel belt, drive pulley or return pulley asthis may cause abnormal printing or belt damage.

CAUTION: Be careful not to cut your finger with the end ofthe steel belt.

8. Remove the tape and fasten the new steel tape to the head with thetwo fastening screws.

CAUTION: Be careful that the belt is not twisted in the Y rail.

1. Adjust the steel belt tension.2. Adjustment andExaminationProcedure

T Fence

Twelve fastening screws



How to replace the T Fence

How to replace the T Fence



Replace the T Fence

1. Remove the Panel Cover.2. Remove the Front Cover.3. Remove the Y Rail Cover.4. Loosen the 12 screws holding the T Fence keeper plate

(11 on 62-inch model), slide theplate towards the Y Cable side, then remove the T Fence.

How to clean the T Fence

1. Gently wipe the T Fence with a lint-free cloth which has beenwet with water or ethanol. (Lint-free cloth is closely woven fromextremely fine threads and has no nap and produces no dust.)

CAUTION: Mind the Head Board and take out the TFence on the X Motor side.


« REFERENCE » The T Fence has a front and a back.Assemble it so that the round hole is atthe top on the X motor side or on the bot-tom on the maintenance unit side.

CAUTION: When wiping the T Fence, be careful not torub it vigorously.

or

or

Correct

WrongX m

oto

r

2. CleaningProcedure

Ink tube

Steel flexible guide

Tube guide assembly

Steel flexible guide

Tube guide assembly

Cable keeper

(1) Press and remove (2) Press

Cursor plate spring

(3) Remove to left

Tube keeper

Screw

Tube bracket

Hexagonal nut

Cartridge pipe



How to Replace the Steel Flexible Guide Assembly and Cursor Plate Spring




Removal

Assembling


Replace the Steel Flexible Guide Assembly

1. Remove the Panel Cover.(H for fitting flexible cable support is included.)

2. Remove the Front Cover.3. Remove the Y Rail Cover.4. Remove 2 screws holding the Steel Flexible Cable Support to the H Board Fitting Plate.5. Move the head towards the X Motor side.6. Remove the Cable Keeper on the Tube Keeper. (2 screws)7. Undo the four places where the Tube Guide is clamping the Steel Flexible Cable Support and

remove the Steel Flexible Cable Support.

1. Screw the steel bare to the H Board Fitting Plate.2. Clamp the Steel Flexible Cable Support to the Tube Guide.3. Fully tighten the screws holding the Steel Flexible Cable Support to the H Board Fitting Plate.4. Temporarily fasten the CableKeeper to hold the Steel Flexible Cable Support to the Tube

Guide.5. Move the head inside the maintenance assembly then tighten the cable keeper.

Replace the Cursor Plate Spring

1. Remove the Panel Cover.2. Remove the Front Cover.3. Remove the Y Rail Cover.4. Bring the head to center of the printer,

press down the left and right ends of the cursor plate spring and pull it out to the right.








Removal

Assembling


[ 62 inch ]

Clamping part

Ribbon cable guide

Steel flexible cable



H board mounting plate

Cable keeper

(1) Press and remove (2) Press

Cursor plate spring

(3) Remove to left

Tube keeper

Flexible cable support keeper

Replace the Steel Flexible Guide Assembly

1. Remove the Panel Cover.2. Remove the Front Cover.3. Remove the Y Rail Cover.4. Undo the two screws holding the steel bare to the H board mounting

plate (flexible cable support keeper on 62-inch models).5. Move the head towards the X Motor side.6. Remove the Cable Keeper on the Tube Keeper. (2 screws)7. Undo the part that is clamping the steel bare for the ribbon cable

guide and remove the steel bare.

1. Screw the steel bare to the H Board Fitting Plate.2. Clamp the Steel Flexible Cable Support to the Tube Guide.3. Fully tighten the screws holding the Steel Flexible Cable Support to

the H Board Fitting Plate.4. Temporarily fasten the CableKeeper to hold the Steel Flexible Cable

Support to the Tube Guide.5. Move the head inside the maintenance assembly then tighten

the cable keeper.

Replace the Cursor Plate Spring

1. Remove the Panel Cover.2. Remove the Front Cover.3. Remove the Y Rail Cover.4. Bring the head to center of the printer, press down

the left and right ends of the cursor plate spring and pull it out to the right.


Tension screw

Belt fastening screwBelt fastening screw

Return pulley

Steel belt



How to replace the Y Return Pulley Assembly

How to replace the Y Return Pulley Assembly




Replace the Y Return Pulley Assembly

1. Remove the Panel Cover.2. Remove the Front Cover.3. Remove the Y Rail Cover.4. Remove the Left and Right Covers.5. Move the Head to the left (X Motor side).6. Loosen the Steel Belt tension (loosen two tensioning screws).7. Remove the Steel Belt fastening screws on the left side and

slide it out to the Return Pulley.8. Remove the Y Return Pulley.9. Assembling is the reverse of the removal procedure.


Ink ID sensor connector

Detector assembly connector

Fastening screw

Fastening screw



How to replace the Cartridge Frame Assembly




Replace the Cartridge Frame Assembly

1. Carry out Head Cleaning.2. Remove the Right Paper Guide.3. Disconnect all connectors J402 to J413 from the

junction board assembly leaving only J401(FFC) connected.

4. Remove the connectors of the cartridge pipesand ink tubes on the cable guide.

5. Remove the Y Rail Cover Support. (2 fasteningscrews)


CAUTION: If there is wash liquid remain-ing in the ink tubes and headdampers, it may flow out fromthe head nozzles and spillaround the maintenanceassembly. Use cotton waste towipe up any spilt wash liquid.

CAUTION: When pipes and tubes arebeing removed, mark thetubes so that they will not beconfused when they are re-assembled.

J401 MAIN FFC 16-core

J402 Detector K Black 4-core

J403 Detector C Cyan 4-core

J404 Detector M Magenta 4-core

J405 Detector Y Yellow 4-core

J406 Ink ID K Black 5-core

J407 Ink ID C Cyan 5-core

J408 Ink ID M Magenta 5-core

J409 Ink ID Y Yellow 5-core

J410 Detector 5 Black 6-core

J411 Detector 6 White 6-core

J412 Ink ID 5 Black 6-core

J413 Ink ID 5 White 6-core

❈ On panel display, 5 = O (Orange)6 = G (Green)

❈ J413 has twisted lines

Connector Table

Two screws

Slide

Lift

Two screws

Cartridge slide 2








6. Remove two screws holding the cartridge base.Slide the cartridge base towards (1) then lift as in (2) to sepa-rate it from the rear X reinforcement.

1

2

7. Cut the cable tie holding the cables.

8. Remove the cartridge pipes from the cartridge frame.

« REFERENCE » Be careful not to lose the nuts and O-rings on the disconnected cartridgepipes.

9. Undo the two screws holding cartridge slide 2.


Cartridge base

Cartridge slide

Cartridge side plate

Frame assembly and needles

Cartridge frameI/C guide basea

1

2







10. Remove 2 screws holding the cartridge frame to the cartridge base,slide the cartridge frame in the direction of arrow a and lift to sepa-rate it from the cartridge base.

11. To dismantle the cartridge frame, open the upper claw of the frameassembly and needles as in (1) then slide it down (arrow (2)). Next, slide the cartridge in the direction of arrow (3) to remove it.

CAUTION: Please work carefully as there is a risk of injuryfrom the sharp needles on the frame assembly.

« REFERENCE » Replacements related to the sensorsattached to the cartridge frame can be car-ried out with "cartridge side plates" afterthis work.

12. The I/C guide base attached to the cartridge base can be disman-tled when the four claws are disconnected from the back.At the same time, the plates for preventing incorrect insertion andthe cushioning spring and felt can be removed.

CAUTION: Take care not to mistake the positioning of theplates for preventing incorrect insertion otherwiseit will be impossible to insert the cartridges cor-rectly.










1. Carry out the initial filling.

CAUTION: Don’t use a tool to tighten the couplingscrews but get them as tight as possible withyour fingers. If you use a tool, there is a riskof breaking the plastic taps.

CAUTION: About 100 cc of waste fluid will be expelledinto the Waste Fluid Box from head cleaningand initial filling. Fit a new Waste Fluid Box.The message “Change Tank?:” will appear onthe panel display. You should confirm byanswering “Yes”.

CAUTION: Wait at least 30 minutes after the initial fillingbefore printing. Otherwise the printing quali-ty can not be assured.

2. Carry out a test print.3. Fit a new Waste Fluid Box.

Ink ID sensor assembly

Two fastening screws

Ink ID sensor connector



How to replace the Ink ID Sensor Assembly





1. Carry out replacement steps 1 to 10 of the previous item"Cartridge Frame Assembly Replacement" (REP1330-1332).

2. Remove two screws holding the ink ID sensor.

3. Assembly is the reverse of dismantling.

CAUTION: The ink ID sensor must be installed in thesame place as the previous sensor.The printer will not work if the ID is unsuit-able.

Fastening screw

Fastening screw

Detector assemblyInk detection switch

Cartridge frame assembly

Cartridge detection switch



How to replace the Detector Assembly

How to replace the Detector Assembly



Replace the Detector Assembly

1. Carry out replacement steps 1 to 11 of the previous item"Cartridge Frame Assembly Replacement" (REP1330-1332).

2. The no ink detection sensor and cartridge detection sensor ofthe detector assembly are each held to the cartridge side plateby one screw. Remove the screws and carry out the replace-ment.


CAUTION: Be careful not to over-tighten when refittingthe cartridge sensor.If it is over-tightened the detection section ofthe sensor will not slide. Tightening torque is29.4 N•cm (3 kg•cm).

CAUTION: Detector assemblies have different cablelengths and connectors depending on whichslot they are fitted to. Be careful not to con-fuse them.

Screw

Y cableX reinforcement R


Fastening screw

Cartridge pipe

Hexagonal nut

Tube bracket

Cable keeper (2)

Cable keeper

Tube keeper

Y cable

Junction board assembly



How to replace the Y Cable




Replace the Y Cable

1. Remove the Panel Cover.2. Remove the Front Cover.3. Remove the Y Rail Cover.4. Open the Control Box.5. Remove the Rear Paper Guide.6. Disconnect connectors J111 (HEAD1) and J112 (HEAD2) from the Main

Board Assembly.« REFERENCE » The flat core will come away at the same time. Be

careful not to drop it.7. Remove the cable keeper from the Head Board Assembly. (2 fastening

screws)8. Disconnect connectors J201 (MAIN1) and J202 (MAIN2) from the Main Board

Assembly.9. Remove 4 hex. nuts holding the tube bracket.10. Withdraw the Y Cable that passes through the Right X Reinforcement into the

Control Box, straighten out the bends and pass it through the hole in the leftFlexible Cable Guide Support.« REFERENCE » This work will be easier if you remove the screw

holding the ink cartridge base and move the base.11. Lift the tube bracket up and remove Y Cable together with the N Belt.12. Assembling is the reverse of the removal procedure.

« REFERENCE » The new Y cable has no fold crease. Make a foldcrease in the new cable to match the old cable.

CAUTION: Power must be off when connectors are being disconnect-ed or reconnected, otherwise you may be injured or aboard may be damaged.The main board assembly will certainly be damaged ifpower is applied with main board assembly connectorsJ111 (HEAD) and J112 (HEAD2) and head board connectorsJ201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP.

1. When the Y Cable has been laid, first fit the Y Rail Cover only then move thehead by hand to confirm does not produce any hindrance, noise or jamming. Ifthere is a fault, adjust by moving the part of the Y Cable on the Head BoardAssembly Cable keeper.

2. Adjustment







Replace the Y Cable

1. Remove the Panel Cover.2. Remove the Front Cover.3. Remove the Y Rail Cover.4. Open the Control Box.5. Remove the Rear Paper Guide.6. Disconnect connectors J111 (HEAD1) and J112 (HEAD2) from the Main

Board Assembly.« REFERENCE » The flat core will come away at the same time. Be

careful not to drop it.7. Remove the cable keeper from the Head Board Assembly. (2 fastening

screws)8. Disconnect connectors J201 (MAIN1) and J202 (MAIN2) from the Main Board

Assembly.9. Remove the ribbon cable guide clamp parts.10. Remove 4 hex. nuts holding the tube bracket.11. Withdraw the Y Cable that passes through the Right X Reinforcement into the

Control Box, straighten out the bends and pass it through the hole in the leftFlexible Cable Guide Support.« REFERENCE » This work will be easier if you remove the screw

holding the ink cartridge base and move the base.12. Lift the tube bracket up and remove Y Cable together with the N Belt.13. Assembling is the reverse of the removal procedure.

« REFERENCE » The new Y cable has no fold crease. Make a foldcrease in the new cable to match the old cable.

CAUTION: Power must be off when connectors are being disconnect-ed or reconnected, otherwise you may be injured or aboard may be damaged.The main board assembly will certainly be damaged ifpower is applied with main board assembly connectorsJ111 (HEAD) and J112 (HEAD2) and head board connectorsJ201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP.

1. When the Y Cable has been laid, first fit the Y Rail Cover only then move thehead by hand to confirm does not produce any hindrance, noise or jamming. Ifthere is a fault, adjust by moving the part of the Y Cable on the Head BoardAssembly Cable keeper.

2. Adjustment Y cable

X reinforcement RTube keeperHexagonal nut

Tube bracket

Cable keeper

Cable keeper

Ribbon cable guideClamping partY cable

Junction board assemb

Ink tube

Flexible cable guide

Open the clamp here

Tube fastening screw (small)

Joining screwJoining screw

Joining screw (large)



How to replace the Ink Tubes




Replace the Ink Tubes

1. Carry out Head Cleaning and empty the ink inside the tubes.2. Remove the Panel Cover.3. Remove the Front Cover.4. Remove the Y Rail Cover.5. Remove the Head Board Assembly Cable keeper and disconnect

the Y Cable from the connector.6. Remove the ten tube guide clamps.7. Undo the two screws holding the tube keeper.8. Remove the four joining screws and O-rings on the Flexible Cable

Guide.9. Remove the four joining screws and O-rings below the cursor.10. Assembling is the reverse of the removal procedure.

→ Continued on next page (REP1371)

CAUTION: Be careful not to lose the O-rings. Initial fillingand printing can not be done if the O-rings aremissing.

CAUTION: Don’t use a tool to tighten the coupling screwsbut get them as tight as possible with your fin-gers. If you use a tool, there is a risk of breakingthe plastic taps.

« REFERENCE » Ink tubes have a tendency to bend. Layingthe tubes in the direction of that tendencyprevents the tubes from behaving badlyand jamming.

« REFERENCE » Couplings have a definite orientation. (Seediagram below)

Car

trid

ge s

ide

Hea

d si

de







Replace the Ink Tubes

1. Carry out Head Cleaning and empty the ink inside the tubes.2. Remove the Panel Cover.3. Remove the Front Cover.4. Remove the Y Rail Cover.5. Remove the head board assembly cable keeper and disconnect the

Y cable from the connector.6. Remove the ribbon cable guide and tube guide clamps.7. Undo the two screws holding the tube keeper.8. Remove the tube bracket cable keeper.9. Remove the four joining screws and O-rings on the Flexible Cable

Guide.10. Remove the four joining screws and O-rings below the cursor.11. Assembling is the reverse of the removal procedure.


CAUTION: Be careful not to lose the O-rings. Initial fillingand printing can not be done if the O-rings aremissing.

CAUTION: Don’t use a tool to tighten the coupling screwsbut get them as tight as possible with your fin-gers. If you use a tool, there is a risk of breakingthe plastic taps.

« REFERENCE » Ink tubes have a tendency to bend. Layingthe tubes in the direction of that tendencyprevents the tubes from behaving badlyand jamming.

« REFERENCE » Couplings have a definite orientation. (Seediagram below)

Car

trid

ge s

ide

Hea

d si

de

Flexible cable guide

Joining screw

I Ink tube

Ribbon cable guide

Clamping partsTube guide

Tube keeper

Cable keeper

Joining screw (large)Joining screw (small)







1. Carry out the initial filling.

Joint nut (large)DE-49778

O-ring (large)DE-49777

Coupling (black)DE-49992


Joint nut (large)DE-49778

(Cartridge side)

(Head side)


Coupling (white)DE-49993

Tube stop screw (small)DE-48950

Ink tube

Head pipe

Cartridge pipe

Ink tube

Coupling screw (large)DE-49778

Tube fastening O-ring (small)DE-48949

Diagram showing construction of joiners

2. Carry out a test print.3. Fit a new Waste Fluid Box.

CAUTION: Wait at least 30 minutes after the initial filling before printing. Otherwise the printing quality can not be assured.

CAUTION: If possible, ink cartridges used for initial filling should be cartridges that have not been used previously. Since a large amount of ink is required for filling, filling may fail if there is insufficient ink remaining.

CAUTION: About 100 cc of waste fluid will be expelled into the Waste Fluid Box from head cleaning and initial filling. Fit a new Waste Fluid Box. Themessage “Change Tank?:” will appear on the panel display. You should confirm by answering “Yes”.




Plate nut

Cutter springCutter solenoidassembly

Solenoidassembly

Cutter cap



How to replace the Cutter Solenoid Assembly

How to replace the Cutter Solenoid Assembly



Replace the Cutter Solenoid Assembly

1. Remove the Panel Cover.2. Remove the Front Cover.3. Remove the Y Rail Cover.4. Disconnect connector J206 (SOL) from the Head Board Assembly.5. Remove the Head Cover.6. Move the Head 20 to 30 cm to the left.7. Undo the two screws on the left edge of the head and remove the

cutter unit. 8. Remove the screw holding the cutter cap. 9. Undo the two screws holding the solenoid to the cutter box and

take the solenoid from the box. 10. Assembling is the reverse of the removal procedure.

CAUTION: When removing the cutter blade, the headmust first be moved to a position over thecutter mat. If the tip of the cutter blade hitsagainst the front paper guide, the tip will bechipped and will no longer be able to cut.

« REFERENCE » There are two types of springs inside the cut-ter unit, the solenoid spring and the cutterspring. Be careful not to lose them when youare dismantling.

1. When the cutter unit is being assembled its position relative to thecutter mat must be adjusted. Refer to Figure A and fasten it in thecorrect position.

[Diagram A]

Platen Cutter mat

Cutter blade Fix so that the front corner of the cutter mat groove and the flat part of the cutter blade are aligned.

« REFERENCE »This rib should cover at least half the flat part of the cutter mat. Move the head to make sure that both left and right edges cover at least one-third.



How to replace the Head and Head Cable




Head, Head Cable Replacement

❈ Do head washing. ❈ If HEAD1 (left) only is to be replaced, change "6 places" to "3 places".

1. Remove panel cover.2. Remove front cover.3. Remove Y rail cover.4. Remove head cover.5. Unlock and disconnect FFC entering the head board assembly connectors J207 (HEAD C1) and J208 (HEAD C2) 6. Cut the cable tie holding the head pipes.7. Undo the tube stop screws holding the head pipes on the damper (6 places) and disconnect the head pipes.

« REFERENCE »When the tube stop screws are removed, there will be O-rings on the head pipes. Be careful not to lose them. 8. Remove the damper positioning materials. (1 screw)9. Disconnect the dampers from the print head. (6 places)

CAUTION: The damper will not function if the film part of the damper is gripped strongly and print-ing may not work.

10. With a small straight-bladed screwdriver remove the compression spring from where it is attached on thealuminum die-cast side of the head fastening material. (2 places)

11. Remove the screw holding the print head together with H spacer.12. Slide the left print head, Head 1, towards arrow (1) and after disconnecting the insertion section, lift it out. 13. Remove Head 2 in the same manner.

« REFERENCE »When print heads and head cables are to be replaced:For dismantling, remove Head 1 (left)then Head 2 (right)For assembly, refit Head 2 (right) then Head 1 (left) Cabling makes it impossible to work in the opposite order.

14. Disconnect head cables from the print head connectors.


Insertion section

1






2. Assembling 1. For bending, refer to the head cable that was previously used.

CAUTION: The bend on the print head side of the head cable used with Head 1(left) should be made such that the protrusion from the connector isminimal. Otherwise the range for adjusting head inclination becomestoo small and adjustment is impossible.

2. Print the head rank of the print head that is to be used on the head cable. If the previoushead rank is inscribed, this should be cancelled with two lines before the print.


CAUTION: The parts inside the print head that are shown in diagram A must notbe touched. Otherwise oil and dirt may make it impossible for them tobe used properly.

[Diagram A] Damper connection

Nozzle face


Correct

Example of head cable bending for Head 1 (left)

Wrong







2. Load roll media in the printer.3. Do a "Nozzle check" to confirm whether there is incomplete filling or abnormal ejection.

If there is a fault, try again after "Cleaning".

« REFERENCE » At rare intervals a dirty wiper may cause faulty ejection and the wiper should be rubbed with a wiper cleaning cloth.

4. Do “Left Tilt” adjustment.

5. Do “Right Tilt” adjustment.

6. Do “Repeatability (Normal)” adjustment.

7. Do “Repeatability (Microdot)” adjustment.

8. Do "Unidirectional" adjustment.

9. Do "Unidirectional (Microdot)" adjustment.

10. Do "Test print" to confirm results of adjustments.

« REFERENCE » If a head has been replaced, the nozzle ejection count value should be reset.

1. Carry out initial filling with ink.

« REFERENCE » Head washing and initial filling consumes a large quantity of waste liquid.The waste liquid box should be replaced when initial filling is finished.

CAUTION: After initial filling, wait for at least 30 minutes before printing.Otherwise the printing quality cannot be assumed.



How to replace the Edge Sensor Assembly

How to replace the Edge Sensor Assembly



Edge Sensor Replacement

1. Remove front cover.2. Remove panel cover.3. Remove Y rail cover.4. Remove head board assembly connector J204 (P EDGE).5. Remove head cover.6. Remove edge sensor. (1 fastening screw)

Use straight blade screwdriver No. 1.


CAUTION: Fastening screws are self-tapping screws. Becareful not to over-tighten.Tightening torque is 29.4 N.cm (3 kg.cm).

Screw (self-tapping)

Edge sensor a

Screws

Screws

Connector J201 (MAIN1) J202 (MAIN2)



How to replace the Head Board Assembly

How to replace the Head Board Assembly



Replace the Head Board Assembly

1. Remove the Front Cover.2. Remove the Panel Cover.3. Remove the Y Rail Cover.4. Disconnect all connectors from the Head Board.5. Remove the Head Board. (4 fastening screws)6. Assembling is the reverse of the removal procedure.

CAUTION: Be sure to switch off the power wheneverconnectors are disconnected or inserted.Incorrect operation will lead to injury andcomponent damage.The main board assembly will certainly bedamaged if power is applied with main boardassembly connectors J111 (HEAD) and J112(HEAD2) and head board connectors J201(MAIN1) and J202 (MAIN2) inserted withoblique FFP.

Damper fixer

Tube fixer

Head cable

Head board assembly



How to replace the Dampers

How to replace the Dampers



2. Carry out a test print.3. Fit a new Waste Fluid Bottle.

Dampers Replacement

1. Carry out Head Cleaning.2. Remove the Panel Cover.3. Remove the Front Cover.4. Remove the Y Rail Cover.5. Remove the Head Cover.6. Cut the cable tie holding the head pipes.7. Remove the damper fixer (2 fastening screws).8. Remove joint screws and move the head pipes up out of the way.9. Remove the colour dampers.

CAUTION: When removing the colour dampers, be careful notto grip the transparent film surface of the damper.Rough handling of the transparent film surfacemay cause an air leak and prevent printing.


1. Carry out initial filling.

CAUTION: Wait at least 30 minutes after the initial fillingbefore printing. Otherwise the printing quality cannot be assured.

CAUTION: About 150 cc of waste fluid will be expelled intothe Waste Fluid Bottle from head cleaning and initialfilling.Fit a new Waste Fluid Bottle. The message “Change Tank?” will appear on thepanel display. You should confirm by answering“Yes”.




How to replace the Cursor Assembly




Cursor Assembly Replacement

1. Wash the head to remove the ink.2. Remove the Panel Cover.3 Remove the Panel Bottom Cover.4. Remove the Front Cover.5. Remove the Y Rail Cover.6. Remove the Right and Left Covers.7. Remove the Head Cover.8. Disconnect connectors J204 (P EDGE), J206 (SOL), J207 (HEAD C1), J208 (HEAD C2) from the head board assembly.9. Cut the cable tie holding the head pipes.10. Remove tube stop screws and disconnect head pipes from dampers.11. Remove two screws from each outer side of the upper part of the cursor and separate the cursor unit from the head board unit.

Reverse the disconnected head board unit so as to extend the steel bare and place it on top of the X motor side of the flexible cable guide.

CAUTION: Be careful not to damage the T fence when taking out the head board unit.Scarring may cause abnormal print quality.

12. Loosen the steel belt tension with the Y return pulley.13. Undo the screws that fasten the belt at both ends of the cursor unit and separate the steel belt. 14. Move the cursor unit between the drive roller on the right and the cap unit. 15. Bend the CR flat spring and remove it.16. To remove the cursor unit from the Y rail, after undoing one side of the cursor axle E-ring, take out the cursor axle together with both roller bearings.

The cursor unit will drop down and can be taken from the Y rail.

Be careful not to touch or damage the nozzle face of the head when removing the cursor unit from the Y rail.








2. Assemblingand fitting

3. Adjustmentand confirma-tion

17. Remove the head sub-plate that is on the cursor roller side.(2 screws)

18. Remove three fastening screws on the print head side andseparate the hear unit and cursor assembly. The belt attach-ment plate will come away at the same time.

1. Align the cursor assembly with the head unit, bring the headunit in the direction of the arrow (up) and hold it temporarilywith three fastening screws.

2. Temporarily attach the head sub-plate. 3. Following the reverse procedure, fit the cursor assembly to

the Y rail and continue until just before attaching the headcover.

4. Move the cursor assembly over the right end of platen on thecap side.

5. Place the head height jig under the nozzle face of the printhead, press the flat part of the upper edge of the print headand, while the metal part surrounding the nozzles is in closeeven contact with the head height jig, firmly tighten thescrews that had been held temporarily.

6. Withdraw the jig without touching the nozzle face and, usingthe pressure bracket gap at the back of the printer, firmlyfasten the head sub-plate that had been held temporarily.

7. After fitting the Y rail cover, do the initial filling and proceedwith item 3. Adjustment and Checking. Fit the remaining cov-ers after adjustment and checking.

1. Execute the "Cap position" adjustment.2. Execute a "Test print" to see whether any printing adjust-

ments are needed. Depending on the result, carry out anynecessary adjustments.

3. Apply the "Margin" adjustment.

CAUTION: As shown below, make sure nozzle face does not touch jig.

All screws shown here are temporarily tightened

This will touch nozzle face.

Fastening screws (3)

Belt attachment plate

Cursor assembly

Head sub-plate

Head unit

M3 × 5 (double SEMS round)

M3 × 16 (cap screw)

M4 × 10(double SEMS)

Press places shown by arrows

Right edge platen

Wrong

Head height jig



How to replace the Origin Sensor, Y Encoder

How to replace the Origin Sensor, Y Encoder



Origin Sensor and Y Encoder Replacement

1. Remove panel cover.2. Remove front cover.3. Remove Y rail cover.4. Disconnect all connectors plugged into the head board.5. Remove head board from the H board mounting plate. (4

screws) 6. Remove Y cable together with the cable keeper.7. Remove tube guide keeper. (2 screws)8. Remove steel belt. (2 screws)9. Remove pipe fittings with head pipes still connected. (2

screws)10. Remove two screws holding the H board mounting plate.11. Remove origin sensor or Y encoder from the H board mount-

ing plate. (2 screws each) 12. Assembly is the reverse of dismantling.

CAUTION: Encoder cable connection errors will damagethe encoder.

1. Execute the "Cap position" adjustment.2. Adjustment

Origin sensor fitting direction

Y encoder and encoder cable fitting direction

Sensor Cable

Cable from origin sensor board in on the cap side

Connector mark to left as seen from front of printer

Encoder terminal comes to H board mounting plate attachment section.

Junction cable connection J109 (INK ID) behind here

Ink ID sensorconnector

Four fastening screws

Detector assemblyconnector

Junction cableconnector J401

Junction cable(FFP)



How to replace the Junction Board Assembly, Ink ID Cable

How to replace the Junction Board Assembly, Ink ID Cable



Junction Board Assembly Ink ID CableReplacement

1. Remove the Front Cover.2. Remove the Panel Cover.3. Remove the Y Rail Cover.4. Remove the Rear Paper Guide.5. Open the Control Box.6. Disconnect junction cable connector J109 (INK ID).7. Disconnect all junction board assembly connectors.8. Remove the junction board assembly. (4 fastening

screws) 9. Assembly is the reverse of the removal procedure.

CAUTION: Power must be off when connectorsare being disconnected or recon-nected, otherwise you may beinjured or a board may be damaged.The main board assembly will cer-tainly be damaged if power isapplied with main board assemblyconnectors J111 (HEAD) and J112(HEAD2) and head board connec-tors J201 (MAIN1) and J202 (MAIN2)inserted with oblique FFP.

Standard base

Slide

Platen

Adjusting screw

Measuring position (rib)

Standard value : 0(2.00 mm)

Rail height jig



How to Adjust the Platen Height

How to Adjust the Platen Height


1. AdjustmentandInspectionProcedure

Platen Height Adjustment

1. Adjust using rail height jig (JD-30395).Mount the rail height jig on a standard base and set the dialgauge to "0" (2.00 mm).

Mount the rail height gauge over the ribs at both ends of theplaten, loosen the platen retaining screws and adjust theplaten up and down until the dial gauge reads 2.10 to 2.20mm.

Standard value2.10 to 2.20 mm by dial gauge

Ink tube

Steel bare

Tube guide assembly

Steel bare

Tube guide assembly

Cable keeperTube keeper

Screw

Tube bracket

Hexagonal nut

Cartridge pipe



How to replace the Tube Guide Assembly




Tube Guide Assembly Replacement

1. Disconnect all connectors from head board.2. Remove head board. (4 screws)3. Remove tube guide keeper. (2 screws)4. Remove two tube guide fastening screws.5. Undo all parts clamping tube guide ink tubes and steel bares

and remove the tube guide.6. Assembling is the reverse of the removal procedure.






Tube Guide Assembly Replacement

1. Remove panel cover, IC slot cover and Y rail cover 2. Remove H mounting plate cable keeper.3. Remove all ribbon cable guide clamping parts.4. Remove the cable keeper on the tube keeper and remove the

steel bare.5. Remove all tube guide clamping parts.6. Remove tube keeper.7. Undo tube bracket nut.8. Lift the tube bracket gently and remove the tube guide assem-

bly.9. Assembling is the reverse of the removal procedure.

Ribbon cable guide

Tube guide

Clamping parts

Cable keeper

Tube keeper

Tube bracket

Belt tension attachmentJD-42050

Steel belt

Adjustingscrews



How to Adjust Steel Belt Tension

How to Adjust Steel Belt Tension


1. AdjustmentandVerification

CAUTION: Steel belt are highly susceptible to breakageand end damage and must be handled care-fully.

CAUTION: Be careful not to cut your hands when han-dling the steel belt.

Steel Belt Tension Adjustment

1. Set the steel belt in the middle of the return pulley and motorpulley. (Center of Y rail)

2. While moving the cursor left and right, turn the return pulleyadjusting screw until the steel belt does not tend to come offthe pulley or move across the pulley.

3. When the belt adjustment is completed, use a belt tensioningjig to adjust the tension. Move the cursor to the capping posi-tion and measure the deflection of the belt at the center of theY rail.

4. Finally, move the cursor left and right to check for belt skew.

Specification values: 0.98 N(100 g ± 20 g)

DDV

DDV

DDV

DDV

DDV

DDV

41.16 N ± 1.96 N (4.2 kg ± 0.2 kg)



How to Adjust X Speed Reduction Belt Tension

How to Adjust X Speed Reduction Belt Tension



CAUTION: When the Speed Reduction Belt has beenreplaced, apply grease to the belt evenly.(Silicone Grease G501)

X Speed Reduction Belt Tension Adjustment

1. Hook a 5 kgf Bar Tension Gauge to the X motor mountingplate, tension the belt and fasten the mounting plate.

Specification value: 41.16 N ± 1.96 N (4.2 kg ± 0.2 kg)

DDV

DDV

DDV



How to Adjust the Print Head




Print Head Adjustment

When the Print Head and the Head Cable are removed, make the follow-ing adjustments in Diagnostic Mode.

“Capping Position Adjustment”“Head Rank Input” (Initial filling function is available.)“Head Nozzle Verification”“Left Head Tilt Verification”“Right Head Tilt Verification”“Repeatability Printing Positioning”, “Repeatability Printing Positioning(Microdot)”“Unidirectional”, “Unidirectional (Microdot)’“Margin”

1. Run Diagnostic Mode.2. Lower the Pressure Lever and select “Adjustment”.3. After initialization, load media on the printer.

❈ If the Print Head is not replaced or removed, go to Step 7.


Head rank(5-digit)

12

34

5

CAUTION: Avoid touching, knocking or rubbing the nozzleface of the Print Head Assembly.

CAUTION: Cada Print Head Assembly tiene un “rank” that has amajor effect on the ejection of ink. Entering awrong rank will adversely affect the life of thehead and the emission of inks. “Rank” isinscribed on the print head assembly (see dia-gram on right). The value to be input is a 5-digitnumber.

[Fig. 1]

[Fig. 2]

[Fig. 3]

Media ejectdirection

Here is lined up. Test pattern

In this case, adjust towards (a). In this case, adjust towards (b).

123213131212

Press gently

Head adjustment plate A

(b) (a)






1. Adjustment andVerification

4. Execute "Capping position adjustment".5. Apply "Head rank entry".

Initial filling can now be done.6. Enter Head 1 rank.

If Head 1 has not been replaced, rank will be recorded as is.7. Execute "Ink filling".

After ink filling, return to the previous level.8. Mount media.9. Execute "Head nozzle check".

Check whether ejection is normal from all nozzles and proceed tothe next item.

10. Execute “Left Head Tilt”.Adjust with head adjustment material A so that printing with allHead 1 colours forms a straight line.

11. Loosen the screw holding Head 1 and move the head adjustmentmaterial A towards (b) if the offset rises to the right, or towards (a) ifthe offset rises to the left.After gently pressing with a straight-bladed watchmaker's screwdriv-er or similar in the same direction as the compression spring hold-ing the print head, tighten the screw.(One click changes head adjustment place A by about 0.005 mm)

« REFERENCE » Sometimes simply moving the head adjust-ment material does not alter the inclination.)

12. Execute “Left Tilt”.Repeat steps 10 and 11 until the test pattern is properly aligned.

13. When the inclination adjustment is finished, proceed to the nextitem.


a

c

c

dd

b

Fastening screwPress gently

14631643525

Media eject direction

HEAD1

[Display when looking at the print head from above]

HEAD2

Test pattern

654321

(K) (C) (G) (M) (Y) (O)






1. Adjustment andVerification

14. Execute “Right Head Tilt”.With Head 1 as a standard, adjust the inclination and depth of Head2 with head adjustment material A (mainly for inclination) and headadjustment material B (mainly for depth) so that the printed band isa straight line.

15. Loosen the screw holding Head 2 and, if the parts printed by Head2 (4 to 6) rise to the right relative to the parts printed by Head 1 (1to 3), move the head adjustment material towards (b), or towards(a) if the offset rises to the left. Also, if the offset is to the front orback, move the head adjustment material towards (c) or (d).After gently pressing with a straight-bladed watchmaker's screwdriv-er or similar in the same direction as the compression spring hold-ing the print head, tighten the screw.

16. Execute “Right Head Tilt”.Repeat steps 14 and 15 until the test pattern is properly aligned.

17. When the right head tilt is properly adjusted, proceed to the nextitem.


Media eject direction

Plus Minus

Third line

Second line

First line

Distance to edge of media (5 mm)







18. Execute "Repeatability"This makes three 1-pass bi-directional scans and compensates forthe offset of the second scan (CCW printing) relative to the first andthird scans (CW printing).

19. Check the printing, first for black then for colour, and record a posi-tive increment if the second scan (CCW printing) is offset towardsthe cap side, or a negative decrement for the opposite direction.(Repeat the printing after the registration.)Repeat until both directions are aligned.

20. When repeatability printing position alignment has been achieved,proceed with the “Repeatability (Microdot)” adjustment in the samemanner.

21. Execute "Unidirectional".This corrects the initial printing position (5 mm from media edge)and compensates for the position of Head 2 relative to Head 1(head pitch).

22. With a steel ruler, measure from the edge of the media to the posi-tion of the black printing and enter the measured value.








23. Next, check the printing and record a positive increment if Head 2 isto be moved towards the cap side relative to Head 1, or a negativedecrement for the opposite direction.

Repeat items 20 to 23 until the starting position and the printingpositions of Head 1 and Head 2 are aligned.

24. When "Unidirectional" is finished, execute the "Unidirectional(Microdot)" adjustment in the same manner.

25. Execute "Margin".This corrects the printer's media detection position and the actualprinting position.

26. Use a steel ruler and a loupe to measure from the edge of themedia to the printing position and make the correction by enteringthe actual measured value.

27. Complete the adjustments by switching off the power.

Bottom distance (20 mm)

Top distance (25 mm)

Left side margin (5 mm)

Right side margin (5 mm)

Pitch between heads

CAUTION: Failure to switch off the power before mounting and unmounting flash memory card may cause damage to the Main Board andmake it impossible to install data properly.

1. Switch off power to the printer.

2. Mount a backup-only flash memory card in the slot at the back of the printer.

3. Turn on the power. All LEDs light up instantly and “PLOTTER” → CARD” appears in the printer’s LCD display unit.

4. When “ENTER” is pressed, “P → C Started” appears in the printer’s LCD display unit and parameters start to be absorbed.

5. When parameters have been completely absorbed, “P → C Completed” appears in the printer’s LCD display unit to indicate that the comparison ofabsorbed parameters has ended normally.

6. Switch off and remove the flash memory.

1. Switch off power to the printer.

2. Mount a backup-only flash memory card in the same slot at the back of the printer.

3. Turn on the power. All LEDs light up instantly and “PLOTTER” → CARD” appears in the printer’s LCD display unit. “Menu Up” or “Menu Down” will change this to “CARD → PLOTTER”.

4. When “ENTER” is pressed, “C → P Started” appears in the printer’s LCD display unit and parameters start to be installed.

5. When parameters have been completely installed, “C → P Completed” appears in the printer’s LCD display unit to indicate that the comparison ofinstalled parameters has ended normally.

6. Switch off and remove the flash memory card.

1. Switch on power to the printer and verify that it is working normally.



How to Capture and Install Backup Parameters

How to Capture and Install Backup Parameters


1. CaptureBackupParameters

2. Install

3. Verify

CAUTION: Failure to switch off the power before mounting and unmounting flash memory may cause damage to the Main Board andmake it impossible to install data properly.

1. Switch off power to the printer.2. Mount the latest program flash memory card in the slot at the back of the printer.3. Switch on the power.4. The following message will appear in the liquid crystal display:



How to Install a Program (Software Upgrade)

How to Install a Program (Software Upgrade)


1. Install

Erase

Copy

Compare

End

The buzzer will sound. (It will end after about 60 seconds)

5. Switch off power to the printer.6. Remove the flash memory card.

1. Switch on power to the printer and verify from the initialization and panel display that the version has been upgraded. 2. Verify

REFERENCE:

The following flash memory card is used for program installation:SDMP Vx.xx 4 MB

�



Head Cleaning Procedure 1

Head Cleaning Procedure 1

CAUTION 1: When to Clean the Head

“Head Wash” must be carried out whenever this printer is moved by truck, befoe usingEco-Solvent ink or when the parts shown below are replaced. When this operation is performed, there is a risk that the inks remaining in the headand ink tubes may be spilt and soil the printer.< Replacement Parts > Head, Damper, Cursor Assembly, Cartridge Frame

Assembly, Ink Tubes

CAUTION 2: Head Cleaning Jig

When you are using the Head Cleaning Jig, the 100 cc jig bottle should contain atleast 50 cc of cleaning fluid and its cap should be loosened.If the cap of the jig bottle is tightly closed, the ink will flow back into the bottle.Also, when you have finished using the Head Cleaning Jig, return the cleaning fluidfrom the 100 cc bottle to the 500 cc cleaning fluid bottle (JD-42054).

CAUTION 3: What to do After the Initial Filling

Wait for at least 30 minutes after the initial filling before you use the printer for print-ing. Otherwise picture quality can not be assured.

� Head Cleaning is a self-diagnostic function not available to the user.

« REFERENCE » Head washing includes all six colours at the same time.Therefore, you should prepare six sets of head washingjigs.

❈ Single colour or separate head washing is not possible.

Panel diagnostic functions (when implemented from panel only)

1. To start panel diagnosis, switch on while pressing [Cleaning], [Menu Display] and [Shift] at the same time.

2. Select "Adjustment" menu → "Head Wash" self-diagnosis.

3. Rm All Cartridge

When this display appears, take out the specified cartridge.(Alternatively, the ink cartridges may be removed beforehand.)

4. Set Wash Jig

When this display appears, mount the cleaning jig.

5. Ink Absorb

When this display appears, cleaning fluid is being sucked from within the headand tubes.

6. Rm Wash Jig

When this display appears, remove the cleaning jig.

7. Washing

When this display appears, cleaning fluid remaining inside the head and tubes isbeing ejected.

8. AJST: Home

When this display appears, it is the end.CAUTION: Before using Eco-Solvent ink, perform a head wash.

Use the special Eco-Solvent Transition Liquid.Once you have worked with Eco-Solvent inks, it is forbitten to changeto another ink type.



How to Clean the Head Nozzle Face

How to Clean the Head Nozzle Face

If the nozzles are clogged by paper dust or foreign matter clinging to the HeadNozzle Face, use the following procedure to remove it.

CAUTION: Be careful not to touch the nozzle face directly with your fin-gers otherwise normal ejection may not be possible.

1. Turn off the Power Switch and return the Head to the home position.(The Power Cable may remain connected)

2. Open the front cover and remove "Panel bottom cover" and "Panel bottom coversupport"

3. Move the head to the place where the "Panel bottom cover" was removed.

4. Soak a lint-free cloth in water or distiled water and gently wipe the Head NozzleFace. (Lint-free cloth is closely woven from extremely fine threads and has nonap and produces no dust.)

CAUTION: Don’t wipe with fluffy cloth or tissue paper as these tend tomake the clogging worse.

CAUTION: Be careful not to rub the nozzle face too hard.

5. Move the head to the maintenance assembly.

6. Refit the "Panel bottom cover" and "Panel bottom cover support"

7. Turn on the Power Switch and print out a diagnostic pattern. If there are no dotsmissing from the G-line step pattern, the task is completed.If some dots are missing, repeat Steps 1 to 7.

Bearing stopper Bearing

Speed reduction pulley support

Speed reduction pulley assembly

Speed reduction pulley assembly

X motor mounting plate

Stopper

Coupling



How to replace Speed Reduction Pulley Assembly

How to replace Speed Reduction Pulley Assembly



2. AdjustmentandInspectionProcedure

Speed Reduction Pulley Replacement

1. Remove the left cover.2. Remove the X motor cover.3. Loosen the four screws on the X motor mounting plate and

relieve the belt tension.4. Loosen the bearing stopper screw and remove it.5. Remove the speed reduction pulley support and bearing. 6. Loosen the two coupling screws.7. Loosen the stopper screw.8. Remove the X speed reduction belt from the speed reduction

pulley.9. Withdraw the speed reduction pulley assembly towards the

right side.10. Assembly is the reverse of dismantling.

1. Adjust the X speed reduction belt tension.



How to replace Grid Roller Assembly

How to replace Grid Roller Assembly



Grid Roller Assembly Replacement

1. Remove left cover.2. Remove front paper guide.3. Remove rear paper guide.4. Remove X motor cover.5. Remove right and left side caps.6. Remove speed reduction pulley assembly.7. Remove platen mounting plate (with platen attached).8. Raise pressure lever.9. Remove all bearing box screws.10. Move all bearing boxes to a position where the grid roller can be

taken out upwards.

CAUTION: In order to install bearing boxes and adjustmentspacers in the positions prior to replacement,check their distribution. Take care not to lose anyadjustment spacers.

11. Remove the bearing keepers from both sides of the grid roller to bereplaced.

12. Loosen the coupling screws, slide the bearing boxes to the side andtake out the grid roller assembly.


CAUTION: • Install bearing boxes and spacers in the samepositions as before the replacement.

• Install bearing boxes by pushing them far backand moving them to the left.

• Apply lock-tight to the screw threads wheninstalling bearing boxes.

• Be careful not to damage the grid roller.

1. Adjust the platen height.2. Adjust X speed reduction belt tension.

1. Adjustment andInspectionProcedure

[62 inch][46 inch]

Adjusting spacer

Platen mounting plate

Bearing Box

Bearing keeper CouplingGrid roller assembly



How to replace F Absorbent Assembly

How to replace F Absorbent Assembly



F Absorbent Assembly Replacement

1. Remove the absorbent material from the F box.2. Insert the absorbent material assembly in the F box.

Absorbent materialF box

R E P 1 7 1 0Model Name: Rockhopper 62

R E P 1 7 1 0Model Name: Rockhopper 62

How to replace Waste Liquid Tank Assembly

How to replace Waste Liquid Tank Assembly



Waste Liquid Tank Assembly Replacement

1. Remote X motor cover.2. Take out the waste liquid tube from the left waste liquid bottle.

CAUTION: Be careful not to scatter the ink.

3. Remove the left waste liquid bottle mounting plate.4. Undo the waste liquid bottle cap and remove the left waste liq-

uid bottle. 5. Assembly is the reverse of dismantling.

Waste fluid bottle mounting plate

Waste fluid bottle L

Waste fluid tube

G I D 0 0 0 0Model Name: Rockhopper-46


Rockhopper-463 Fundamental Knowledge


Fundamental Knowledge

Basic Specifications GID1000

System Block Diagram GID3000

Operating Sequence• Power On Sequence GID4010• Power Off Sequence GID4020• Media Detection Sequence GID4030• Normal Standby Sequence GID4040• Encoder Disconnected Check Sequence GID4050• Origin Detection Sequence GID4060• Media Cutting Sequence GID4070• Printing Sequence (Including Flushing) GID4080

G I D 0 0 0 0 - 3Model Name: Rockhopper-62




Fundamental Knowledge

Basic Specifications GID1000-3

System Block Diagram GID3000

Operating Sequence• Power On Sequence GID4010• Power Off Sequence GID4020• Media Detection Sequence GID4030• Normal Standby Sequence GID4040• Encoder Disconnected Check Sequence GID4050• Origin Detection Sequence GID4060• Media Cutting Sequence GID4070• Printing Sequence (Including Flushing) GID4080



Rockhopper-463 Basic Specifications


System

Printing System

Printing Direction

Resolution

Media Transport

Media Supply and Eject

CPU

Input Buffer

Commands

Linear Precision

Drop-on-demand piezo driving system(Large capacity, 6-colour, independently removable ink cartridges: 220 cc ± 5 cc)Eco-solvent nk

Shortest distance printing (bidirectional or unidirectional)

360 dpi x 360 dpi 720 dpi x 720 dpi 1440 dpi x 720 dpi

Multi-point pressure grid roller system

Cut Media: Front supply/front eject Roll Media: Rear supply/front eject

64 bit RISC CPU

Standard: 8 MB (main) + 4 MB (plain)Extended: 16 MB, 32 MBExpansion slots: 2 slots (16 MB installed in one slot as standard) Maximum: 72 MB (main) + 1 MB (plain)

Printer commands: MH-GL, MH-GL/2, (MH-RTL), RTL-PASS

The larger of ±0.1% of movement distance or ±0.5 mmMedia: Thick coated paper (roll media)

Working temperature: 20°C, Humidity: 60%, Printing mode: High quality/720 dpi

Within ±0.5 mm/500.0 mmAngular PrecisionMedia: Thick coated paper (roll media)Working temperature: 20°C, Humidity: 60%, Printing mode: High quality/720 dpi

High quality paper, coated paper, thick coated paper, art paper, glossy paper, glossy photographic paper, glossy film, Yupo film, Yupo tac film, cloth, fire-resistant cloth, glossy PVC tac film (Media other than the above and new media are based on OEM assessment.)

Media Types

Standard 2-inch & 3-inchh Roll Media Tube Diameter

1089.6 mm (42.9 inch)Maximum Media Width

1069.6 mm (42.1 inch)Media Sizes

50 m (maximum size roll that can be mounted)Maximum Roll Media Length

1300 mm

Media longer than this can be loaded but media size cannot be detected and it is handled as roll media.

Maximum Cutting Media Length

46 inch System

Area Available for Printing (Margins)❉ Printing quality is assured

within standard margins❉ If media wider than 1361.6 mm is used, the left and right margins will be different from those shown on the left.

Roll mediaStandard: Cut media

Compatible: Cut mediaRoll media

Media Holding System

Media Cutting System

Ink Cartridges

Kanji

Interfaces StandardOption

Head Life

Environmental Conditions

Rate of change

Operating environment

Storage environment

Power Supply

Power Supply

Front Back Right Left25mm 20mm 10mm 10mm25mm 20mm 10mm 10mm25mm 20mm 5mm 5mm25mm 20mm 5mm 5mm

Pressure roller lowered by manually operated lever

Transverse auto-cut system

Black, cyan, magenta, yellow , light cyan, light magenta: each 220 cc ± 5 cc After using Eco-solvent ink, only use Eco-solvent ink in future

Conforms to JIS1, JIS2 (1990 edition stroke font built-in)(Font has some independent codes unspecified by JIS)

Bidirectional Centronics: IEEE 1284 (compatible, nibble, ECP modes)Ethernet: WindowsNT, Windows95, TCP/IP, NetWare, EtherTalk support

Temperature: 10°C to 35°C, humidity 20% to 80% (no condensation)

Temperature: 2°C/h, Humidity: 5%/h

Temperature: -10°C to 60°C, humidity 20% to 90% (no condensation)

AC100 ~ 120 V ±10%, AC200 ~ 240 V ±10% Auto Change

50 Hz ±1 Hz / 60 Hz ±1 Hz Auto Change

60 W or less

75 W or less

75 W or less

1264 mm

1656 mm

580 mm

49.0 kg (480.2 N)

15.5 kg (151.9 N)

Power Consumption

External Dimensions

Weight

(Voltage)

(Frequency)

Printing

Standby

Cleaning

Height

Width

Depth

Body

Legs

46 inch





System

Printing System

Printing Direction

Resolution

Media Transport

Media Supply and Eject

CPU

Input Buffer

Commands

Linear Precision

Drop-on-demand piezo driving system(Large capacity, 6-colour, independently removable ink cartridges: 220 cc ± 5 cc)Eco solvent ink

Shortest distance printing (bidirectional or unidirectional)

360 dpi x 360 dpi 720 dpi x 720 dpi 1440 dpi x 720 dpi

Multi-point pressure grid roller system

Cut Media: Front supply/front eject Roll Media: Rear supply/front eject

64 bit RISC CPU

Standard: 8 MB (main) + 4 MB (plain)Extended: 16 MB, 32 MBExpansion slots: 2 slots (32 MB installed in one slot as standard) Maximum: 72 MB (main) + 8 MB (plain)

Printer commands: MH-GL, MH-GL/2, (MH-RTL), RTL-PASS

The larger of ±0.1% of movement distance or ±0.5 mmMedia: Thick coated paper (roll media)

Working temperature: 20°C, Humidity: 60%, Printing mode: High quality/720 dpi

Within ±0.5 mm/500.0 mmAngular PrecisionMedia: Thick coated paper (roll media)Working temperature: 20°C, Humidity: 60%, Printing mode: High quality/720 dpi

High quality paper, coated paper, thick coated paper, art paper, glossy paper, glossy photographic paper, glossy film, Yupo film, Yupo tac film, cloth, fire-resistant cloth, glossy PVC tac film (Media other than the above and new media are based on OEM assessment.)

Media Types

Standard 2-inch & 3- inchRoll Media Tube Diameter

1574.8 mm (62 inch)Maximum Media Width

1554.8 mm (61.2 inch)Media Sizes

50 m (maximum size roll that can be mounted)Maximum Roll Media Length

1300 mm

Media longer than this can be loaded but media size cannot be detected and it is handled as roll media.

Maximum Cutting Media Length

62 inch System

Area Available for Printing (Margins)❉ Printing quality is assured

within standard margins❉ If media wider than 1361.6 mm is used, the left and right margins will be different from those shown on the left.

Roll mediaStandard: Cut media

Compatible: Cut mediaRoll media

Media Holding System

Media Cutting System

Kanji

Interfaces StandardOption

Head Life

Environmental Conditions

Rate of change

Operating environment

Storage environment

Power Supply

Power Supply

Front Back Right Left25mm 20mm 10mm 10mm25mm 20mm 10mm 10mm25mm 20mm 5mm 5mm25mm 20mm 5mm 5mm

Pressure roller lowered by manually operated lever

Transverse auto-cut system

Conforms to JIS1, JIS2 (1990 edition stroke font built-in)(Font has some independent codes unspecified by JIS)

Bidirectional Centronics: IEEE 1284 (compatible, nibble, ECP modes)Ethernet: WindowsNT, Windows95, TCP/IP, NetWare, EtherTalk support

Temperature: 10°C to 35°C, humidity 20% to 80% (no condensation)

Temperature: 2°C/h, Humidity: 5%/h

Temperature: -10°C to 60°C, humidity 20% to 90% (no condensation)

AC100 ~ 120 V ±10%, AC200 ~ 240 V ±10% Auto Change

50 Hz ±1 Hz / 60 Hz ±1 Hz Auto Change

60 W or less

110 W or less

75 W or less

1163.5 mm

2350 mm

650 mm (680 mm)

85 kg (833 N)

17.5 kg (171.5 N)

Power Consumption

External Dimensions

Weight

(Voltage)

(Frequency)

Printing

Standby

Cleaning

Height

Width

Depth

Body

Legs

62 inch

Ink Cartridges Black, cyan, magenta, yellow, light cyan, light magenta: each 220 cc ± 5 cc After using Eco-solvent ink, only use Eco-solvent ink in future

G I D 1 1 0 0Model Name: Rockhopper-46/62


Names of Parts

Names of Parts

1. Exterior parts of the Main Unit (Front)

Left Cover

Front Paper Guide

Front Cover Y-rail Cover Operating Panel Right Cover

Heater Panel

Pressure Lever

Waste Bottle

Control Box Take-up System



Names of Parts

Names of Parts

1. Exterior parts of the Main Unit (Rear)

Cartridge Cover 6 Ink Slots

Rear Paper Guide

Scroller

Waste Bottle

Scroller Adjusting Screw Scroller Slip Ring

DDV



Names of Parts

Names of Parts

2. Parts of the Main Unit media transport system and left and right frames

Grid Roller

Pressure Arm

Pressure Bracket

Pressure Roller

Y Rail

Blade

Suction Fan Assembly Platen Y rail Flushing Box

Protector board coverwith connectors .

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV

DDV



Names of Parts

Names of Parts

3. Main Unit Y Drive Section

Y Return Pulley Shaft

T Fence

Y Cable

Belt Fastening Screws (2) Cover Switch

Drive Pulley

Y Motor Assembly

Right Frame

Waste Fluid Bottle

Lever sensor Assembly Pressure Relay Plate Pressure Lever

Lever Lock

Front Paper Guide

Cutter Groove

Cutter Guide

Steel Belt

Left Frame



Names of Parts

Names of Parts

4. Head Section

Origin Sensor

Head Mount

Cutter Cap

Cutter Blade (s)

Cutter Holder

H Adjustor A (2)

H Adjustor B (1)

Damper Fixer

Cursor

Head Board Assembly

Paper Sensor Assembly

Linear Encoder

Printer Head Assembly (Colour)Cable Tie

Tube Stop Screws (6) Dampers (6)

Head cables (2)

Head pipes (6)

Head Section



Names of Parts

Names of Parts

5. Maintenance Station Parts

Cap Assembly

Wiper

Pump AssemblyInk Tube

Extension Tube

Maintenance Base

P Motor Flange

CR Damper Axle

Pump Motor Plate

Damper CR

Flat Washer

Pump Speed Reduction Gear 1

Pump Speed Reduction Gear 2

Pump Gear

Pump Idler Gear

Pump Motor Assembly

Pump Motor Gear

Speed Reduction Gear BearerMaintenance Unit



Names of Parts

Names of Parts

6. Cartridge Holder Section

Cartridge Sensor

Ink Tubes

Coupling Screws

Coupling BK

Coupling Screws

Cartridge Side Plate (6)

Insertion Error Prevention Plates (4)

IC Guide Bases (6)

Cartridge Base

Remaining Ink Sensor

Waste Bottle

Cartridge Pipe (6)

Ink Cartridge Needle

Ink ID Sensor (6 types)



System Block Diagram

System Block Diagram



System Block Diagram - Heater System


MK-41314

MK-24204

MK-24205

MK-41461

MK-21000

MK-24209

MK-24210

MK-24201

MK-24200

DDV

DDV

DDV



Power On Sequence

Power On Sequence

Power Switch ON [Checks Standard DRAM]error occurs

[Checks Optional DRAM]error occurs

[Checks NVRAM]error occurs

[Read NVRAM]error occurs

[Initialize Tasks]

< Enter Self-diagnostic Key >

[Cover & Lever monitoring begins]

[Encoder diagnostic check]error occurs

[Motor excitation on]

[Origin detection]error occurs

< Is capping position registered? >Origin position not set

< Carriage not at capping position on startup >No

[Write initial values to NVRAM]

Serious Error (StdDRAM)

Serious Error (OptDRAM)

Serious Error (NVRAM)

Self-diagnostic Standby

Serious Error (Encoder)

Serious Error (Sensor)

Error Display

Strong Cleaning

Normal Standby



Power Off Sequence

Power Off Sequence

Power Switch Off < Origin detection in progress > [Servo slows and stops]

< Media initialization in progress > [Servo slows and stops]

[Servo slows and stops]

[Servo slows and stops]

< Media cutting in progress >

< Open Cover >

< Lever up and location other than capping position >

< Cleaning in progress >

< Printing in progress >

< Lever down and location other than capping position > [Move to capping position]

[Write settings to NVRAM]

< Is Power Switch on ? > [Reset software]

[Power off]



Media Detection Sequence


< Panel setting: cut sheet >

[Media trailing edge detection]

[Media width detection at trailing edge detection position]

[Media width detection]Media feed

[Media leading edge detection]

[End]

YESNo

Media rewind






[Base value χ = ad2]

[Base value χ = ad1]

< Reflection sensor reading <= 0 x 56 ? > Yes[Sets media edge gain to normal]

[Waits 2 ms]

No

(1) Media Edge Base Value Detection

[Moves the carriage to a position where the reflection sensor has no media]

[Sets media edge gain to half, waits 2 ms]

[ad1 = reads reflection sensor]

[Sets media edge gain to normal, waits 2 ms]

[ad2 = reads reflection sensor]

[Sets media edge gain to half]

[Moves the carriage to a position where the reflection sensor is over media]





[Moves carriage to a position where the reflection sensor comes over the media, a = reflection sensor reading]

[Moves 10 mm towards B, b = reflection sensor reading]

[Moves 5 mm towards A, c = reflection sensor reading]

[Media edge Z = { (a + b + c) + c x 3} ÷6 = { c + (a + b + c)÷3}÷2]

[Moves media slowly back to a position where reflective sensor value becomes Z]

[Moves forward 7 mm]

[Moves media slowly back to a position where reflective sensor value becomes Z]

(2) Media Leading Edge Detection HeadB directionA direction

Rear Sensor (XR)

< Media moved 10 mm >

< Reflective sensor value became Z >

Yes

Yes

[Media detection error]

[End]

No

No

Yes

Yes

[Media detection error]No

No

< Cut media moved 200 mm >< Roll media moved 3010 mm >< Reflective sensor value became Z >





(3) Media width detection

Media width detection

Right edge detection

Left edge detection

[Quick detection]144.875mm

[Slow detection]50.0mm

[Quick detection]46 inch: 1098.125mm

62 inch: 1555.425mm

[Slow detection]50.0mm

< Moved 144.875 mm > [Media detection error]

[Media edge base value detection]

< Is the carriage over the maintenance unit? > [Move carriage to maintenance unit]

Switch gain and read again, then select the more suitable of the two values to determine gain.

No

Yes

Maintenance unit

Carriage

A direction B direction

[Moves the carriage to a position where the reflection sensor is over media, a = reflection sensor reading]

[Moves 5 mm towards A, b = reflection sensor reading]

[Moves 10 mm towards B, c = reflection sensor reading]

[Media edge (Z) = (χ + (a+b+c)÷ 3) ÷2]

[Move the carriage to a position where the reflection sensor is over media][Move the carriage slowly towards A to a position where the reflection sensor becomes equal to the Z value]

[Moves the carriage slowly towards B to a position where the reflection sensor becomes equal to the Z value]

[Media width = e2-e1 : move carriage to the position of e1]

YesNo

< Reflection sensor reached Z >

[e1 = encoder count]

NoYes

< 46 inch: Moved 1098.125 mm >

< 62 inch: Moved 1555.425 mm >

YesNo

< Reflection sensor reached Z >

[e2 = encoder count]

NoYes





Head

Rear sensor(XR)

[Move media forward until XR sensor goes "off" status]

[Move forward 7 mm]

[Move media slowly back until XR sensor goes "off" status]



< XR sensor becomes "off" status >

< XR sensor becomes "off" status >

[Media detection error]

[Recognizes that roll media is loaded]

[End]

Yes

Yes

Yes

Yes

No

No

No

No



Normal Standby Sequence

Normal Standby Sequence

Normal Standby Condition < Receive online data >

< Analyse received data >

< Mount media > [Initializes media] [Media is mounted when either XF or XR sensor is on]

[Printing is forcibly ended]

[Data already received/analysed is ignored]

[If roll media is mounted, it is cut]

< Printing in progress >

< Reception/Analysis in progress >

< Standby >

[Begins printing]

< Enter the Cancel key >

< End data analysis >



Encoder Disconnected Check Sequence

Encoder Disconnected Check Sequence

Compete check for disconnected encoder

Check each axis in each direction for disconnection

[Initializes PWM gate array]

[Checks X-axis + direction]

< Origin sensor ? >

[PWM output on]

[PWM torque output]

< Move 5 pulses ? >

[END]

ONOFF

[Check Y-axis + direction]

[Check X-axis - direction]

[Check Y-axis - direction]

[Checks Y-axis - direction]

[Checks X-axis - direction]

[Checks Y-axis + direction]

< 20 msec elapsed ? >

< 20 msec elapsed ? >

[Encoder error][End]

No

No

No

No

Yes

Yes

Yes

[Increases PWM torque]

< Moves 5 pulses ? >

Yes



Origin Detection Sequence


Origin Detection

A direction B direction Machine Origin Flag

Origin

Origin Detection

< Inside origin flag ? > Yes

No[Move (200 mm) towards A while monitoring Origin sensor off]

< Moved 200 mm ? >Yes

[Moves 1 mm towards A and set origin sensor off]

No[Faulty sensor error]

Yes

[Moves (46 inch: 1410 mm, 62 inch 1890 mm) towards B while monitoring Origin sensor off]

< Origin sensor off ? >

[Moves 2 mm towards A and set origin sensor off]

No

Yes< Origin sensor off ? >

[Moves carriage 10 mm towards A]

< Origin sensor on ? >

Yes

[Moves 20 mm towards B and set origin sensor on]No

[Moves carriage 25 mm towards B]

< Origin sensor on ? >

Yes

(Go to next page)





[Moves 10 mm towards B]

[Moves (50 mm) towards A until origin sensor goes off]

No< Moved 50 mm without sensor going off ? >

Yes[Faulty sensor error]

[Let current position be "a"]

[Moves 5 mm towards A]

[Moves (35 mm) towards B until origin sensor goes off]

< Moved 35 mm without sensor going off ? >Yes

No

[Let current position be "b"]

[Set the origin between points "a" and "b"]

[Moves to origin]

[End]



Media Cutting Sequence

Media Cutting Sequence

[Moves to a point 1/3 of media from right edge]

[Moves to a point 1/3 of media from left edge]

[Moves to a point 1/3 of media from left edge]

Media Cutting

Detects trailing edge of media

< Printing in progress ? >

If media has just been initialized, feed 10 mm< Manual cutting requested ? >

< Manual cutting requested ? >

< XR sensor is "off" status ? >Yes

YesNo

No

Maintenance Unit

No[Wait ink drying period]

[Moves forward 186 mm]

< Is ink drying period finished ? >

[Cut towards (1)]

[Cut towards (2)]

[Cut towards (3)]

[ End ]

(2) (3) (1)

< Manual cut finished key entry occurred >

[ End ] [Waiting for key entry]

Yes

Yes

[Try to shake out the media]

Retry once if media can not be shaken out

< There is media at the position detected by the edge sensor >

[Media cutting error]

[Moves 20 mm forward] (45 mm in the case of a retry)

[Moves 20 mm back] (45 mm in the case of a retry)

< Tried 3 times ? >

[Moves 5 mm forward]

[Moves 5 mm back]

< Tried 3 times ? >Yes

Yes

No

No

Yes

No



Printing Sequence (Including Flushing)

Printing Sequence (Including Flushing)

< Did you wait for 20 minutes after initialization ? >

Colour Printing Sequence

[Pull media 300 mm forward]< Are you printing with media already mounted when power was switched on ?>

[Move to position for starting to plot]

< Printing Mode ?>

[Moves media 4.3 mm forward]

360dpi High Speed360 × 360: 2-pass bidirectional[Moves carriage and prints]

< Printing finished ? >

Yes

No

No

[Pull media 250 mm forward]

[Pull media 150 mm forward]

Yes

No

Yes

[End]


360dpi Standard360 × 360: 4-pass bidirectional[Moves carriage and prints]

< Printing finished ? >No

Yes

[End]


360dpi High Quality360 × 360: 4-pass unidirectional[Moves carriage and prints]


Yes

[End]

< Printing Mode ?>




Yes

[End]


720dpi Standard720 × 720: 4-pass unidirectional[Moves carriage and prints]


Yes

[End]




Yes

[End]

Note: Flushing occurs each time. • 46-inch: Flushes on right side

• 62-inch: Flushes on right side (for bidirectional printing with pigment inks, flush left & right)

< Printing Mode ?>




Yes

[End]

[Moves media1.13 mm forward]

1440dpi Standard1440 × 720: 8-pass unidirectional[Moves carriage and prints]


Yes

[End]




Yes

[End]

PAT 0 0 0 0Model Name: Rockhopper-46

PAT 0 0 0 0Model Name: Rockhopper-46

Rockhopper-463 Stored Test Patterns


Stored Test Patterns

< Stored Test Patterns >These are patterns that are stored in the printer and can be output by the user or the serviceman when required without using a host computer.The printer contains the following three stored test patterns, any of which can be output directly by keys.

No. Name of Stored Test Pattern Name of Direct Keys Purpose and Details Reference Page

PAT1000

PAT3000

PAT4000

1. Test Pattern [Shift]+[PRINT LAYOUT] When trouble related to printing (such as picture quality or printing precision) has occurred, having this pattern output in the field can become the basis for identifying the cause of the problem from the maintenance manual. In A3 size, it is a 7-colour pattern showing picture quality and printing precision. When printing with A0 media mounted, in addition to the A3 size pattern, the J line pattern will be printed over the entire width in the Y direction. • Printing will be in accordance with the printing mode set on the panel.

2.

3. Print Quality Adjustment Pattern [Shift]+[CLEANING] Print quality adjustment pattern for obtaining the best printing quality.Mount A3 or bigger cut media or roll media.Pattern A is for adjusting the Repeatability printing position of the left head.Pattern B is for adjusting the Repeatability printing position of the right head.Pattern C is for aligning the printing positions of the left and right heads.• The printing mode set on the panel will be ignored.

4. Setup List [Shift]+[MEDIA] Outputs the user information currently set in the printerA4 size, settings are output as test.• The printing mode set on the panel will be ignored.

PAT 0 0 0 0 - 3Model Name: Rockhopper-62

PAT 0 0 0 0 - 3Model Name: Rockhopper-62



Stored Test Patterns

< Stored Test Patterns >These are patterns that are stored in the printer and can be output by the user or the serviceman when required without using a host computer.The printer contains the following three stored test patterns, any of which can be output directly by keys.

No. Name of Stored Test Pattern Name of Direct Keys Purpose and Details Reference Page

PAT1000

PAT3000

PAT4000

1. Test Pattern [Shift]+[PRINT LAYOUT] When trouble related to printing (such as picture quality or printing precision) has occurred, having this pattern output in the field can become the basis for identifying the cause of the problem from the maintenance manual. In A3 size, it is a 7-colour pattern showing picture quality and printing precision. When printing with A0 media mounted, in addition to the A3 size pattern, the J line pattern will be printed over the entire width in the Y direction. • Printing will be in accordance with the printing mode set on the panel.

2.

3. Print Quality Adjustment Pattern [Shift]+[CLEANING] Print quality adjustment pattern for obtaining the best printing quality.Mount A3 or bigger cut media or roll media.Pattern A is for adjusting the Repeatability printing position of the left head.Pattern B is for adjusting the Repeatability printing position of the right head.Pattern C is for aligning the printing positions of the left and right heads.• The printing mode set on the panel will be ignored.

4. Setup List [Shift]+[MEDIA] Outputs the user information currently set in the printerA4 size, settings are output as test.• The printing mode set on the panel will be ignored.

PAT 1 0 0 0Model Name: Rockhopper-46/62


Stored Test Patterns/Test Pattern

Stored Test Patterns/Test Pattern

Test Pattern

When trouble related to printing (such as picture quality or printing precision) hasoccurred, having this pattern output in the field can become the basis for identifyingthe cause of the problem from the maintenance manual. In A3 size, it is a 7-colour pattern showing picture quality and printing precision.When plotting with A0 media mounted, in addition to the A3 size pattern, the J linepattern will be printed over the entire width in the Y direction.

1. Make sure no data are being received then mount an A3 or larger sheet of cutmedia or roll media in the printer.

2. Start printing by pressing [Shift]+[PLOT LAYOUT] at the same time.During printing, [Printing ] will appear in the liquid crystal display unit.

When the image quality faults shown below have occurred, you can investigatethe type of problem by consultation based on reports using the location numberson the consultation pattern.

Image Quality Fault Location for Confirmation• Printed result differs from other machines Whole• No printing at all Whole• Entire surface printed black Whole• Printing density varies Rows C, D, E, H• Black and white stripes appear in the printing Rows C, D, E, H, J• Edges of printing are blurred Rows C, D, E, G• Dots missing from printing Row Row G• Many satellites (unwanted dots) Whole• Whiskers on the printing Rows A, B, I• Lines are blurred Frame and Frame, Row I • Mixed colour lines do not overlap Rows A, B, I• Black and colour positions are offset Row I• Printed length is abnormal Frame

Plotted over the entire width of the mediathat is loaded



Stored Test Patterns/Print quality adjustment pattern

Stored Test Patterns/Print quality adjustment pattern

Print quality adjustment pattern

This prints patterns shown in the diagram on the right for making fine adjustments of printingquality.• Pattern A is for adjusting the Repeatability printing position of the left head. • Pattern B is for adjusting the Repeatability printing position of the right head. • Pattern C is for aligning the printing positions of the left and right heads.

1. Make sure no data are being received then mount an A3 or larger sheet of cut media orroll media in the printer.

2. Start printing by pressing [Shift]+[CLEANING] at the same time.During printing, [Accur. Adj Plot] will appear in the liquid crystal display unit.

3. Choose the best precision from lines 1) to 7) in patterns A, B and C and make adjust-ments using the following procedures.

4. [Pattern A: 4] is displayed.Use the setting Value + and - keys to enter the number of the best image and press[ENTER].

5. [Pattern B: 4] is displayed.Use the setting Value + and - keys to enter the number of the best image and press[ENTER].

6. [Pattern C: 4] is displayed.Use the setting Value + and - keys to enter the number of the best image and press[ENTER].

7. [[User 1] Plot OK] is displayed.The specified values are now stored in the printer.

Good and bad examples of Patterns A and B

Bad Good Bad

Good and bad examples of Patterns C

Bad Good Bad

A l i g n m e n t P r i n t



Stored Test Patterns/Setup List

Stored Test Patterns/Setup List

Setup List

This prints out a list of user data currently set in the printer.

1. Make sure no data are being received then mount an A4 or larger sheet of cut media or roll media in the printer.2. Start printing by pressing [Shift]+[Print Settings] at the same time.

During printing, [Printing ] will appear in the liquid crystal display unit.

B A C 0 0 0 0Model Name: Rockhopper-46

B A C 0 0 0 0Model Name: Rockhopper-46

Rockhopper-463 Self-Diagnostic Functions


Self-Diagnostic FunctionsThis chapter explains about self-diagnostic functions that are not available to the user.These functions are intended for use during manufacture, adjustment and maintenance andinclude “Panel Diagnosis” operated from the panel.For the Rockhopper-46, since post-adjustment parameters (settings and mechanical constants)are saved in non-volatile memory, due care is needed in using them.

Self-Diagnosis Tree -------------------------------------------------------------------------BAC0010How to Start Self-Diagnosis---------------------------------------------------------------BAC0020

1. Examination ----------------------------------------------------------------------------------BAC1000Memory Capacity-----------------------------------------------------------------------BAC1010Version ------------------------------------------------------------------------------------BAC1020Panel --------------------------------------------------------------------------------------BAC1030Sensors -----------------------------------------------------------------------------------BAC1040Encoders ---------------------------------------------------------------------------------BAC1050Fans ---------------------------------------------------------------------------------------BAC1060Ethernet Board--------------------------------------------------------------------------BAC1065History: Last error message ---------------------------------------------------------BAC1070History: Head nozzle ejection count check --------------------------------------BAC1070Head Drive Waveform ----------------------------------------------------------------BAC1080

2. Adjustment -----------------------------------------------------------------------------------BAC2000Capping Position Adjustment -------------------------------------------------------BAC2010Skew Verification -----------------------------------------------------------------------BAC2030Head Rank Input (Initial Filling)-----------------------------------------------------BAC2040Head Nozzle Verification -------------------------------------------------------------BAC2050Left Head Tilt Verification ------------------------------------------------------------BAC2060Right Head Tilt Verification ----------------------------------------------------------BAC2070Repeatability Printing Positioning (Normal dot, Micro dot) ------------------BAC2080CW Adjustment (Normal dot, Micro dot) -----------------------------------------BAC2090

Flush Pointer Adjustment ------------------------------------------------------------BAC2110Media Feed Distance Compensation ---------------------------------------------BAC2120Margin Adjustment ---------------------------------------------------------------------BAC2130Rear Sensor Position Adjustment--------------------------------------------------BAC2140Test Print ---------------------------------------------------------------------------------BAC2150Head Wash ------------------------------------------------------------------------------BAC2160

3. Cleaning ---------------------------------------------------------------------------------------BAC3000Normal, Powerful

4. Test Printing ---------------------------------------------------------------------------------BAC4000Head Printing VerificationCheck Black In-fillingAdjustment Parameters

5. Parameters -----------------------------------------------------------------------------------BAC5000Initialize -----------------------------------------------------------------------------------BAC5010Update ------------------------------------------------------------------------------------BAC5020

6. Aging -------------------------------------------------------------------------------------------BAC6000Carriage Motor --------------------------------------------------------------------------BAC6010Media Feed Motor----------------------------------------------------------------------BAC6020Cutter --------------------------------------------------------------------------------------BAC6030Maintenance Unit-----------------------------------------------------------------------BAC6040Head ---------------------------------------------------------------------------------------BAC6050

B A C 0 0 0 0 - 3Model Name: Rockhopper-62

B A C 0 0 0 0 - 3Model Name: Rockhopper-62



Self-Diagnostic FunctionsThis chapter explains about self-diagnostic functions that are not available to the user.These functions are intended for use during manufacture, adjustment and maintenance andinclude “Panel Diagnosis” operated from the panel.For the Rockhopper-62, since post-adjustment parameters (settings and mechanical constants)are saved in non-volatile memory, due care is needed in using them.

Self-Diagnosis Tree -------------------------------------------------------------------------BAC0010How to Start Self-Diagnosis---------------------------------------------------------------BAC0020

1. Examination ----------------------------------------------------------------------------------BAC1000Memory Capacity-----------------------------------------------------------------------BAC1010Version ------------------------------------------------------------------------------------BAC1020Panel --------------------------------------------------------------------------------------BAC1030Sensors -----------------------------------------------------------------------------------BAC1040Encoders ---------------------------------------------------------------------------------BAC1050Fans ---------------------------------------------------------------------------------------BAC1060Ethernet Board--------------------------------------------------------------------------BAC1065History: Last error message ---------------------------------------------------------BAC1070History: Head nozzle ejection count check --------------------------------------BAC1070Head Drive Waveform ----------------------------------------------------------------BAC1080

2. Adjustment -----------------------------------------------------------------------------------BAC2000Capping Position Adjustment -------------------------------------------------------BAC2010Skew Verification -----------------------------------------------------------------------BAC2030Head Rank Input (Initial Filling)-----------------------------------------------------BAC2040Head Nozzle Verification -------------------------------------------------------------BAC2050Left Head Tilt Verification ------------------------------------------------------------BAC2060Right Head Tilt Verification ----------------------------------------------------------BAC2070Repeatability Printing Positioning (Normal dot, Micro dot) ------------------BAC2080CW Adjustment (Normal dot, Micro dot) -----------------------------------------BAC2090

Flush Pointer Adjustment ------------------------------------------------------------BAC2110Media Feed Distance Compensation ---------------------------------------------BAC2120Margin Adjustment ---------------------------------------------------------------------BAC2130Rear Sensor Position Adjustment--------------------------------------------------BAC2140Test Print ---------------------------------------------------------------------------------BAC2150Head Wash ------------------------------------------------------------------------------BAC2160

3. Cleaning ---------------------------------------------------------------------------------------BAC3000Normal, Powerful

4. Test Printing ---------------------------------------------------------------------------------BAC4000Head Printing VerificationCheck Black In-fillingAdjustment Parameters

5. Parameters -----------------------------------------------------------------------------------BAC5000Initialize -----------------------------------------------------------------------------------BAC5010Update ------------------------------------------------------------------------------------BAC5020

6. Aging -------------------------------------------------------------------------------------------BAC6000Carriage Motor --------------------------------------------------------------------------BAC6010Media Feed Motor----------------------------------------------------------------------BAC6020Cutter --------------------------------------------------------------------------------------BAC6030Maintenance Unit-----------------------------------------------------------------------BAC6040Head ---------------------------------------------------------------------------------------BAC6050

B A C 0 0 1 0Model Name: Rockhopper-46/62


Self-Diagnosis Tree 1


1. Examination BAC1000

1.1 Memory Capacity Memory Capacity BAC10101.2 Versions Firmware BAC1020

ParametersDIP Switches

1.3 Panel Keys BAC1030 LCD LEDs and Buzzer

1.4 Sensors X Front, X Rear, Cover, Lever BAC1040Origin, No Ink, No Cartridge, Ink ID, Media Edge Temperature, Waste Fluid Tank

1.5 Encoder Encoder X BAC1050 Encoder Y

1.6 Fan Fan Check On BAC1060Fan Check Off

1.7 Ethernet Board BAC10651.8 History Maintenance L Head Ejections: ❉❉mdot BAC1070

(Head Nozzle Ejection Count) L Wiping Count: ❉❉ L Rubbing Count: ❉❉ R Head Ejections: ❉❉mdot R Wiping Count: ❉❉

R Rubbing Count: ❉❉ W Wiping Count: ❉❉ W Rubbing Count: ❉❉ Quantity of Ink in Waste Fluid Tank Black Ink Remaining Cyan Ink Remaining Magenta Ink Remaining Yellow Ink Remaining

G Ink RemainingO Ink Remaining

CPU System and Mechanical System Errors Failure Error 1 ~ 7 BAC1070 (Last error message display) 1.9 Head Drive Waveform Head Waveform VK BAC1080

KC1CHGND2ND1TR1FLUSH





2.1 BAC2010Capping Position Adjustment2.2 Skew Verification BAC20302.3 Head Rank Input (including Initial Filling) Left Rank: ❉❉❉ BAC2040

Right Rank: ❉❉❉Filling

2.4 Head Nozzle Verification Printing BAC2050Normal CleaningPowerful Cleaning

2.5 Left Head Tilt Verification Printing BAC20602.6 Right Head Tilt Verification Printing BAC20702.7 Repeatability Printing Positioning (Normal dot) BAC2080

2.9 CW Adjustment (Normal dot) BAC2090

2.11 Flush Pointer Adjustment Left Pointer BAC2110Right Pointer

2.12 Media Feed Distance Compensation BAC2120

2.13 Front-to-Head, Cutter-to-Head Distance Adjustment Top Distance BAC2130Bottom Distance

2.14 Rear Sensor Position Adjustment BAC21402.15 Test Print Head Printing Verification BAC2150

Black in-filling

2.16 Head Wash BAC2160

Distance Distance

Adjustment Parameters

Left Pointer (left flushing)Right Pointer (right flushing)

Left DifferentialRight Differential

2.8 Repeatability Printing Positioning (Micro dot) BAC2080Left DifferentialRight Differential

Gap adjustment

2.10 CW Adjustment (Micro dot) BAC2090Gap adjustment

2. Adjustments





3. Cleaning BAC30003.1 Normal3.2 Powerful

4. Test Printing BAC40004.1 Head Printing Verification4.2 Black infill printing4.3 Adjustment Parameters

5. Parameters BAC50005.1 Initialization Capping Position BAC5010

X Encoder ResolutionMaintenance History

Serial NumberComplete

5.2 Updating Capping Position BAC5020Head Rank Left

RightPrint Positioning L Delay

R DelayGap

6. Aging6.1 Carriage Motor6.2 Media Feed Motor

BAC6000

6.3 CutterBAC6010

6.4 Maintenance UnitBAC6020

6.5 Head LeftBAC6030

RightBAC6040BAC6050

Error HistoryLeft HeadRight HeadWiper

Print Positioning (Micro dot) L DelayR DelayGap

Media Transport DistanceMechanical Parameters Head-to-Edge Sensor

X Front-to-HeadHead-to-CutterX Front-to-X RearMedia Edge(Black) Left Flash Pointer(Colour) RIght Flash PointerLeft Flashing Left Flash PointerRIght Flashing RIght Flash PointerPaperWidAdj



How to Start Self-Diagnosis

How to Start Self-Diagnosis

These pages deal with the hidden diagnostic functions of the Rockhopper-46/62Inkjet Printer. These hidden diagnostics are mainly intended for examining boardsand determining mechanical and firmware adjustment parameters. These functionsare incorporated into the printer firmware but they are not disclosed to end users.They are enabled by applying power to the printer while holding down several spe-cial panel keys. It is not possible to access the hidden diagnostic functions from thenormal printer mode. Updated firmware adjustment parameters can be registeredby exiting diagnostic mode or by switching off the power. Firmware adjustmentparameters are also registered when there is a serious MOE failure error on adjust-ment. The printer will be reset on exiting diagnostic mode. Diagnostic functions areas follows.

1. Power supply to the printer is off.2. Switch on the power with the [Head Cleaning] + [Menu Display] + [Shift] keys

held down.3. The panel LCD will display “DIAG: EXAM”. X and Y excitation remains off.

Note 1: The system will not revert to normal mode even if there is no key entry for three minutes.Note 2: Roll media mode is set automatically.Note 3: Panel keys that can be operated are [CANCEL] and the keys for menu display (Menu Up

and Down, Back, Value + and –, ENTER) Note 4: To terminate self-diagnostics, switch off the power.Note 5: To feed media, press [MENU] while holding down the [Shift] key when the Diagnostics Menu

is displayed.

Table 1: Hidden diagnostic functionsItem Details

Examination Verification of RAM capacity, version, panel, sensors, encoders, fans, network board, history and waveform

Adjustment Manufacturing processes, adjustments on head replacement and adjustments to media feed system

Cleaning Mode specified head cleaningTest printing Head nozzle verification printing, black in-filling and adjustment parametersParameters Initialization, updatingAging Carriage motor, media feed, cutter, maintenance unit, head

Menu Up

Menu Up

Menu Up

Menu Up

Menu Up

Menu UpMenu Down

Menu Down

Menu Down

Menu Down

Menu Down

Menu Down

DIAG: Exam

DIAG: Exam

Examination MenuENTER

Back

DIAG: Adjustment Adjustment Menu

DIAG: Cleaning Cleaning Menu

DIAG: Test Print Test Print Menu

DIAG: Parameter Parameter Menu

DIAG: Aging Aging Menu

ENTER

Back

ENTER

Back

ENTER

Back

ENTER

Back

ENTER

Back

❈ To terminate self-diagnostics, switch off the power.

Operations for selecting Diagnostics items are shown below.



Examination

Examination

This is intended for board checking. X and Y excitation is not turned on by selecting“Examination” from the Diagnostics Menu. The X and Y excitation condition will be preserved as it is at the time you select anitem to be examined. Items to be examined are as follows.

To return to the Diagnostics Menu from the Examination Menu, press [Back].

Table 1-1: Board examination itemsItem Details

Memory Capacity Check memory capacityVersions Programs, Backup parameters, DIP SwitchesPanel Keys, LCD, LEDs, BuzzerSensors XF, XR, Covers, Levers, Origin, Ink out, No cartridge, Ink ID,

Media edge, Thermistor, Waste fluid tankEncoders X-axis (media feed), Y-axis (carriage)Fans Check on/offNetwork Initializing, None, Error, Initialization Error, Initialization OK History Maintenance, Major failureHead Waveform Check head drive waveform

Menu Up

Menu Up

Menu Up

Menu Up

Menu Up

Menu UpMenu Down

Menu Down

Menu Down

Menu Down

Menu Down

Menu Down

EXAM: Ram Capacity Memory Capacity DisplayENTER

Back

EXAM: Version Version Display

EXAM: Panel Panel Check

EXAM: Encoder Encoder Check

EXAM: Fan Fan Check

EXAM: Record History Display

ENTER

Back

ENTER

Back

ENTER

Back

Menu UpMenu Down

EXAM: Sensor Sensor Check

Back

ENTER

ENTER

BackMenu UpMenu Down

EXAM: Option Board Initialize Data DisplayENTER

Back

ENTER

Back

Waveform CheckENTER

Back

Menu Up

Menu Down

EXAM: Head Drive

EXAM:



Examination: Memory Capacity

Examination: Memory Capacity

This procedure is used to check the capacity of the memory on a board. When thisitem is selected, the memory capacity is displayed on the panel or terminal.

Press [ENTER] to shift to “EXAM: Version” or [Back] to shift to “EXAM: MemoryCapacity”.

Ram Capacity: 40 MB

EXAM: Memory Capacity



Examination: Version

Examination: Version

This confirms firmware version (program, backup parameters) and DIP switches(On:0, Off:1, switch No. 1 is the least significant byte, 8 is the most significant byte).Each is displayed on the panel when this item is selected.

Press [ENTER] to shift to “EXAM: Panel” or [Back] to shift to “EXAM: Version”.

Menu Up

V E R : F i r m 1 . 0 0

V E R : P a r a m 1 . 0 0

V E R : D i p S W 0 x F F

Program version display

Backup parameter version display

Verify DIP switches

Menu Down

Menu Down

Menu Down

Menu Up

Menu Up

« Reference »DIP switch

1 Off 2 Off : 0 X 031 On 2 Off : 0 X 021 Off 2 On : 0 X 011 On 2 On : 0 X 00

EXAM: Version



Examination: Panel

Examination: Panel

This procedure is used to check panel keys, LCD, LEDs and buzzer.

Press [ENTER] to shift to “EXAM: Sensor” or [Back] to shift to “EXAM: Panel”.

Menu Up

Menu Up Menu Down

Menu Down

ENTER

PANEL: Key Panel key check

PANEL: L c d � � � � � � Panel LCD check

PANEL: L e d • B u z z e r Panel LED and buzzer check

EXAM: Panel

Under key check, when each key is pressed that key is shown on the LCD. Press the [ENTER] key to shift to LCD check after 2 seconds.

Under LCD check, the screen is repeatedly filled with black from the right edge.

Under LED and buzzer check, LEDs are lit in sequence from Data, Error, Standard, Thin, High Quality, Normal, High Speed, Low, HighRoll Media, Cut Sheet and finally the sounding of the buzzer is checked.



Examination: Sensors

Examination: Sensors

Menu Up

Menu Up

Menu Up

Menu Down

SENS: Xf Paper Off X Front sensor check

No Cart. means No Cartridge. Colour is expressed by an alphabetical letter. Cartridge indicates the Special Cartridge sensor.

Press [ENTER] to shift to [EXAM: Encoder] or [Back] to shift to [EXAM: Sensor].

SENS: Xr Paper Off X Rear sensor check

SENS: Cover Open Cover sensor check

Menu Up

SENS: K D C D G D M P Y W O N Ink type check

Menu Up

SENS: Edge 004e Media edge sensor check

Menu Up

SENS: TEMP 25, 25°C Temperature sensor check

Menu Down

Menu Down

Menu Down

Menu Down

SENS: Tank Exist Waste fluid tank sensor check

Menu Up

SENS: Lever Down Lever sensor check

Menu Up

SENS: Origin On Origin sensor check

Menu Up

SENS: No Ink KCGMYO No Ink sensor check

Menu Up

SENS: No Car KCGMYO Cartridge sensor check

Menu Down

Menu Down

Menu Down

Menu Down

Menu Down

Menu Down

Menu Up

EXAM: Sensor

This procedure is used for checking, from displays on panel or terminal, the status of sensors for XF (the X Front Sensor), XR (the X Rear Sensor), cover, lever, origin, no ink (K, C, G, M, Y, O), cartridge (K, C, G, M, Y, O), ink ID, media edge sensor level, head thermistor value and whether or not the waste fluid tank is present.

KCGMYO ink ID display D = dye, P = pigment, W = cleaning liquid, N = other brand, = no cartridge



Examination: Encoders

Examination: Encoders

This procedure is used to verify the values of X-axis (media feed) and Y-axis (car-riage) from displays on the panel or the terminal.

Press [ENTER] to shift to “EXAM: Fan” or [Back] to shift to “EXAM: Encoder”.

Menu Up

Menu Up

Menu Down

Menu Down

ENCODER : X 0000

ENCODER : Y FFFF

X encoder check

Y encoder check

EXAM: Encoder



Examination: Fans

Examination: Fans

This procedure is used to verify that the fans are working by turning them on andoff.

Panel keys are ignored during fan on/off display. 5 seconds after displaying Fan Off,the display will shift to “EXAM: Fan”.

Fan: On Fan goes off 10 seconds after starting

Fan: Off Displayed for 5 seconds after fan has gone off

EXAM: Fan



Examination: Ethernet Board

Examination: Ethernet Board

This procedure is used to verify the initialization of Ethernet board data.

After confirming the status of initialization of the Ethernet Board from the messagesshown above, press [ENTER] to move to “EXAM: Record”.

OptBoard: Initialize

OptBoard: No

OptBoard: Wrong

OptBoard: Error

OptBoard: OK

Ethernet board initialization is in progress. Wait until the next message is displayed.

There is no Ethernet board.

The Ethernet board is wrong.

An error has occured during initialization of the Ethernet board.

Ethernet board has been initialized.

EXAM: Option Board



Examination: History


This procedure is used to verify the history of maintenance (head ejection count andnumbers of wipings and rubbings, the numbers of wipings and rubbings with thewiper, volume of waste fluid, and the amount of ink remaining) and serious failures(MOE type). Operations for the selection of history items are shown below.

If [Back] is pressed while the History menu is displayed, the display will shift to“EXAM: Record”.

Menu Up

Menu Up

Menu Down

Menu Down

RECORD: Mainte Verify maintenance history

RECORD: Error Verify error history

EXAM: Record





Menu Up

Menu Up

Menu UpMenu Down

Menu Down

Menu Down

L Head Count: 0MNumber of Black head ejections (Unit 1 Mdot)

L Wiping: 2 Number of times Black head wipings

L Rubbing: 2 Number of times Black head rubbings

Menu UpMenu Down

Waste-Ink: 120 cc Volume of ink waste fluid

Menu UpMenu Down

KRemainder: Full Number of ejections remaining to end of black ink

Menu UpMenu Down

CRemainder: Full

MRemainder: Full

Number of ejections remaining to end of cyan ink

Number of ejections remaining to end of magenta ink

Menu UpMenu Down

YRemainder: Full Number of ejections remaining to end of yellow ink

Menu UpMenu Down

R Head Count: 0MNumber of Colour head ejections (Unit 1 Mdot)

Menu UpMenu Down

R Wiping: 2 Number of times Colour head wipings

Menu UpMenu Down

R Rubbing: 2

W Wiping: 4

Number of times Colour head rubbings

Number of times Wiper wipings

Menu UpMenu Down

W Rubbing: 4 Number of times Wiper rubbings

Menu UpMenu Down

Quit from Maintenance History by entering the [ENTER] or [Back] key. Press the [ENTER] key to shift to "RECORD: Error" or the [Back] key to shift to “RECORD: Mainte”.

Menu UpMenu Down

GRemainder: Full Number of ejections remaining to end of G ink

Menu UpMenu Down

Menu Down

ORemainder: Full Number of ejections remaining to end of O ink

Menu Up

EXAM: Mainte

Maintenance History

Panel and Terminal displays are shown below.





Serious Failure History

This procedure is used to verify the history of serious failures. CPU errors are not included in the serious failure history. Error 0 is the latest error, up to 7 previous errors are displayed. Panel displaysare shown below.

Menu Up

Menu Up

Menu Down

Menu Down

Err0 : Y CURRENT

Err1 : X MOTOR

Y over-current error

X motor error

Menu UpMenu Down

Err2 : X ENCODER X encoder error

RECORD: Error

Quit from Maintenance History by entering the [ENTER] or [Back] key. Press the[ENTER] key to shift to “RECORD: Mainte” or the [Back] key to shift to “RECORD:Error”.



Examination: Head Waveform

Examination: Head Waveform

Menu Up

Menu Up

Menu Down

Menu Down ENTER

ENTER

Menu Up

Menu Up

Menu Down

Menu Down

Menu Up

Menu Up

Menu Down Menu Up

Menu Down

Menu Down

Head Driver: VK

Head Driver: KC1

Head Driver: CHG

Head Driver: ND2

Head Driver: ND1

Head Driver: TRI

Head Driver: FLUSH

PullOut Head Cable

ENTER KEY to END

CAUTION: When this item is selected, it will try to force the head nozzles to eject. Therefore the cables connected to the head board should be disconnected.

EXAM: Head Drive

[Terminal]Left Head VK voltage TP17Left Head COM Q5ERight Head VK voltage TP15Right Head COM Q3E

Press [ENTER] for "Test: Memory", [PREV] for "Test: Head Driver"

This confirms the ejection action waveform for both heads.



Adjustment

Adjustment

This procedure is used for correcting media feed and printing position. This is doneby mechanical adjustments (head tilt) and firmware parameter adjustments. If thisitem is selected when X and Y excitations are off, the X and Y excitations will beturned on and the initialization sequence will be carried out. Items for adjustmentare listed in Table 2-1. All these procedures are implemented during production.When the head is replaced, head cleaning (followed by switching off and replacingthe head), head rank input, ink filling and print positioning are implemented. CWadjustment, reciprocal printing positioning and zone delay compensation are carriedout when the printing position is to be corrected after a change of media type. Ifmedia feed is off, the media feed distance is compensated.

Table 2-1 Adjustment itemsItem Details

Capping Position Adjustment To adjust capping position parameters in the firmwareSkew Verification To use sensor results to check for media skewHead Rank Input To enter a specific value for a specific head and fill inksHead Nozzle Verification After filling inks, to check head nozzle ejection by print resultsBlack Head Tilt Verification To check left head tilt by printing (mechanical adjustment)Colour Head Tilt Verification To check right head tilt by printing (mechanical adjustment)Repeatability Printing Positioning To align reciprocal printing position by printingCW Adjustment To align the shafts of the two heads by printing and adjust left

margin Flush Pointer Adjustment To adjust the position for flushing into the flushing boxMedia Feed Distance Compensation To print a line in the X direction and enter its distance (X resolu-

tion adjustment) XF-XR Sensor Distance To measure the distance XF and XR sensors with cut mediaXF, Cutter-to-Head Distance To adjust top, bottom, left and right marginsTest Print To check head nozzles and adjust parameters (enter serial num-

bers)Head Wash Done after manufacturing and before head replacement



Adjustment

Adjustment

Menu UpENTER

BackMenu Up

Menu UpMenu Down

Menu Down

AJST: Home Capping Position Adjustment

AJST: Chk Paper Mov

Menu UpMenu Down

AJST: UniDir Print

Menu UpMenu Down

Menu UpMenu Down

AJST: Flash Point

AJST: X Length

Menu UpMenu Down

AJST: Head Wash

Menu UpMenu Down

Menu UpMenu Down

AJST: Margin

AJST: Rear Sns Posi

AJST: Test Print

Menu UpMenu Down

AJST: Head Rank

Menu UpMenu Down

AJST: ChkNozzles

Menu UpMenu Down

AJST: Left Tilt

AJST: BiDir Print

Menu UpMenu Down

AJST: UniDir Print

Menu Down

AJST: UniDir (MD)

Menu Up

AJST: Right Tilt

Menu UpMenu Down

Menu Up

Press [Back] to return to the self-diagnostics Menu from the Adjustment Menu.

DIAG: Adjustment

Note: MD = Microdot



Adjustment: Capping Position

Adjustment: Capping Position

This procedure is used for aligning the capping position correctly by adjusting thecapping position parameters in the firmware.When this item is selected, the printer carries out the home position detectionsequence and then automatically pushes the carriage against the maintenance unitto detect the carriage position at that time. The position displayed is the distancefrom the home position flag.

H o m e D e t e c t

After the carriage has moved to the capping position, that position is displayed

H o m e : - 7 4 . 0 0 0

O r i g i n D e t e c t

After the origin has been detected, the capping position will be detected

AJST: Home

Press [ENTER] to update the capping positions and move to “AJST: Measure High”, press [Back] to move to “AJST: Home” without updating the capping position.



Adjustment: Media Skew

Adjustment: Media Skew

This procedure will feed a specific amount of paper (a single pass band feed) and the sen-sors will read the position of the edge of the media before and after feeding and check forany discrepancy. If no media is loaded when this item is selected, you will be asked to loadthe media. After media initialization, when the amount of media feed is entered, the edgesensors will detect the left and right edges of the media and media feed will begin. Afterfeeding the specified amount, the edge sensors will again detect the left and right edges ofthe media and any difference from the readings before media was fed will be checked anddisplayed. A media recognition error before and after feeding, or detection by the rear sensorof no paper during feeding, will cause a media error to be displayed and this procedure maybe terminated by pressing any key. To terminate the procedure when processing is not inprogress, press [Back] on the panel. To escape from this item, press [Back] while no pro-cessing is in progress.

Set Paper If no media is loaded

After media has been loaded

Paper Initial

After media initialization has been completed

Paper Feed 1.0 m

ENTER

Paper Edge Detect

Paper Feed

Media feed ends normally

Paper Edge Detect

Media edge detection ends normally

>0.100 mm> +0.100 mm + for cap side, - for opposite side

Non-origin side Capping position side

Setting can be specified in units of 0.1 m using the VALUE + and - keys

AJST: Chk Paper Mov

Standard values

Condition A0

Cut Sheet ±1.5 mm or less

7 mRoll Media

±2.5 mm or less

50 m ±10 mm or less

Media

Thick

coated

paper

Press [ENTER] to move to “Adjustment: Rank Input” or [Back] to move to “AJST: ChkPaperMov”. Other panel keys are ignored during processing.

The first time this adjustment is made, the reference position for media skew will be deter-mined by detecting the right edge (origin side). If the adjustment is made with a bad medialoading position, that position will become the reference position and “Media skew error” willoccur frequently.

CAUTION: Make sure media is properly loaded.



Adjustment: Head Rank

Adjustment: Head Rank

R i g h t R a n k : 2 6 � � �

Press [ENTER] to move to the following item

F I L L S T A R T

Press [ENTER] to move to the following item

S e t C a r t r i d g e

I n k f i l l * m i n

L e f t R a n k : 2 1 1 1 7

Menu UpMenu Down

AJST: Head Rank

This is to enter the rank for the left or right head. This is used to determine the head operating voltage and for temperature correction. The panel holds rank setting ranges. A rank outside the range that is entered from the terminal is invalid. When the right rank is set, pressing the [ENTER] key will switch to the ink filling menu.

Settings are changed by + and -, from the left normal rank, frequency ID, micro-rank are all displayed when everything is confirmed. Parameters are updated by setting the entire right rank.

Update head rank with [ENTER]. Shift to ink filling menu by entering right rank and pressing [ENTER]. Under the ink filling menu, [ENTER] starts ink filling and [Back] shifts to "Adjust: Nozzle check".

CAUTION:

The following operations must not be performed during ink filling.Printing will not work properly if ink filling is stopped or interrupted.

• Switching off the power• Opening the front cover• Raising the pressure lever• Removing an ink cartridge

CAUTION:

The ink filling operation will not proceed unless all six ink cartridges are of the same kind.



Adjustment: Head Nozzles

Adjustment: Head Nozzles

After filling the inks, this procedure uses printing results to check whether the headnozzles are ejecting the ink properly. If the nozzles are ejecting ink badly, imple-ment the cleaning treatment in this procedure. If there is no media, the printer willrequest media. If it is out of ink, it will ask for an ink cartridge. If there is media andink, the Head Nozzle Check Pattern will be printed.

This and subsequent items that require printing for adjustment or checking includerequests for media and inks. If the [CANCEL] key is pressed during printing, theprinter will stop printing.

If [ENTER] is pressed while “Nozzle check completed” is displayed, the “AJST:BlackTilt” menu will be appear. If [Back] is pressed while no processing is inprogress, “AJST: ChkNozzles” will be restored.

Paper InitialMedia initialization in progress

After installing a cyan ink cartridge

Printing is finished

Select cleaning [Enter] to move to the following

[C] no ink

If media is not loaded

If there is no cyan ink for instance

Adjustment print is displayed

Menu Up is output

[Menu Down] completed

Set PaperAfter media has been loaded

Adjustment Print

START: ChkNozzles

END: ChkNozzlesMenu UpMenu Down

CLEAN: NormalMenu UpMenu Down

CLEAN: PowerfulMenu UpMenu Down

Cleaning

After cleaning is finished, the menu will return to the start

AJST: ChkNozzles

5

25

m

k

y

c

o

g

G KM YY C OO G KCMG KM YY C OO G KCG KC M

Head Nozzle Check Pattern

Lettering is not printed in the Head Nozzle Check Pattern.

Head Nozzle Check Pattern (6 colours)

Check Items Nozzle ink eject check (missing, discontinuous, meandering)SatelliteTiming fence

Printing method Single-pass, bidirectionalX 180 dpi Y 360 dpi



Adjustment: Left Head Tilt

Adjustment: Left Head Tilt

This procedure uses printing results to check whether the left head is tilted. If it istilted, it needs to be adjusted mechanically.

Left Head Tilt Check Pattern

Check Items Left head tilt

Print Method Single-pass, uni-directionX 180 dpi, Y 720 dpi

Adjustment Print Displayed during printing

[Menu Down] is output

Press [ENTER] to print again, next menu is end

END: Check Tilt

Printing finished

START: Check Tilt

Menu UpMenu Down

Press [ENTER] while “END: Check Tilt” is displayed to move to “AJST: Right Tilt”.

AJST: Left Tilt

30 µm or less

30 µm or less

5Width 4.5

25

Paint Vertical width 6

Right side (g side) is too far back.

Right side (g side) is too far forward.

ccc k kk c k g cck kk gk g kk gk gk g

kk kkgg



Adjustment: Right Head Tilt

Adjustment: Right Head Tilt

This procedure uses printing results to check whether the right head is tilted. If it istilted, it needs to be adjusted mechanically.

Right Head Tilt Check Pattern

Check Items Right head tilt (based on Left head)

Print Method Single-pass, uni-directionalX 180 dpi, Y 360 dpi


[Menu Down] is output

Press [ENTER] to print again, next menu is end

END: Check Tilt

Printing finished

START: Check Tilt

Menu UpMenu Down

AJST: Right Tilt

Press [ENTER] while “END: Check Tilt” is displayed to move to “AJST: BiDirPrint”.

5

25

The center of the left head

The center of the right head

Paint Vertical width 6

Width 9

30 µm or less

Standard values

30 µm or less

kk mm oo ggc yy

ccyy

yy

k



Adjustment: Repeatability Printing Position


This procedure is used to align left and right Normal-Dot and Micro-Dot repeatability printing positions. This involves making a bidirectional test print and from the resultsadjusting the CCW printing delay (position and timing) by entering into the firware the differences between the CW printing position and the CCW printing position. There areseparate differences for both black and colour normal dots and micro dots.

KCG Err: -250 µm

Menu Up

MYO Err: -250 µm

Adjustment Print

AJST: BiDirPrint

DIAG: Adjustment

Bidirectional position adjustment for Normal-Dot

Displayed during printing

Setting can be specified in units of 10 µm using the VALUE + and - keysPress [ENTER] to update reciprocal difference

Setting can be specified in units of 10 µm using the VALUE + and - keysPress [ENTER] to update the reciprocal difference

Print Start?

Press [ENTER] without correction

Menu Down

ENTER

ENTER

Press [ENTER] after correction

ENTER

If [ENTER] is pressed at “MYO Err:” and the parameter has been changed, the left and right CCW printing delays (position and timing) will each be updated in the firmware and another adjustment print will be made. If the parameter was not changed, “Print Start?” will be displayed.If [ENTER] is pressed, another adjustment print will be made.If [Back] is pressed, the display will move to “AJST: BiDir (MD)”.

KCG Err: -250 µm

Menu Up

ENTER

ENTER

MYO Err: -250 µm

Adjustment Print

AJST: BiDir (MD)

DIAG: Adjustment

Bidirectional position adjustment for Micro -Dot


Setting can be specified in units of 10 µm using the VALUE + and - keysPress [ENTER] to update reciprocal difference

Setting can be specified in units of 10 µm using the VALUE + and - keysPress [ENTER] to update the reciprocal difference

Print Start?

Press [ENTER] without correction

Menu Down


ENTER

If [ENTER] is pressed at “MYO Err:” and the parameter has been changed, the left and right CCW printing delays (position and timing) will each be updated in the firmware and another adjustment print will be made. If the parameter was not changed, “Print Start?” will be displayed.If [ENTER] is pressed, another print will be made.If [Back] is pressed, the display will move to “AJST: UniDirPrint”. (BAC2090)

→ Continued next page





Repeatability printing position alignment pattern (6 colours)

Adjustment items Left and right repeatability printing position alignment

Printing method Single-pass, bidirectionalX 180 dpi, Y 720 dpi

CW printing

CCW printingCW printing

+–

50 µm or less 70 µm or less

Standard values



Adjustment: CW

Adjustment: CW

Left and right head axial adjustment for normal dots and microdots.Have the printer print unidirectionally and from the results enter the position error for CW printing (separately for Normal-Dot and Micro-Dot) to adjust the right head CWprinting delay (position and time) and the left head CCW printing delay (position and time) in the firmware.

AJST: UniDirPrint

Head Gap: -34765µm


Setting can be specified in units of 5 µmPress [ENTER] to update gap

ENTER

ENTER


DIAG: AdjustmentPanel

CW Adjustment for Normal-Dot

Set values are updated by [ENTER]. In the case where [ENTER] was pressedunder "Head Gap:", if the parameter change is changed another adjustment printwill be made.If [ENTER] is pressed without the parameter being changed, control shifts to"Adjust: CW (MD)".

AJST: UniDir (MD)

Head Gap: -34765 µm


Setting can be specified in units of ±5 µmPress [ENTER] to update gap

Adjustment Print

ENTER

ENTER


DIAG: AJSTPanel

CW Adjustment for Micro-Dot

Set values are updated by [ENTER]. In the case where [ENTER] was pressedunder "Head Gap:", if the parameter change is changed another adjustment printwill be made.If [ENTER] is pressed without the parameter being changed, control shifts to "FlushPointer adjustment".




Adjustment: CW

Adjustment: CW

CW Adjustment Pattern (6 colours)

Adjustment Items Left and right head axial alignment

Printing method Single-pass, uni-directionalX 180 dpi, Y 360 dpi

5

0.7

25

9

kcg

m

k

yomyoyo m

+-

Enter this distance50 µm or less

Standard value



Adjustment: Flush Pointer

Adjustment: Flush Pointer

This procedure is for adjusting the position for flushing over the flushing boxes onboth sides of the left and right heads. The adjustment causes flushing into theflushing box and from the results the flushing positions for both left and right headsare entered in 720 dpi units. Enter a positive value to shift the flushing positiontowards the cap unit side, or a negative value for the opposite direction.

AJST: FlushPoint

Press [ENTER] to update the settings. If a change has been made, flushing will be repeated. If [ENTER] was pressed with no change having been made, the display will move to the “AJST: XLength” menu.

Flushing

Left Point: 2424

Right Point: 3699

Flushing

Left Point: 38700

Cap unit side flushing box ejection finished

[ENTER] causes flushing to the flushing box on the opposite side

ENTER

ENTER

Opposite side flushing box ejection finished

Setting can be specified in 1 pulse units using the VALUE + and - keys (- for cap unit side, + for opposite side)

Right Point: 40000



Adjustment: Media Feed Distance

Adjustment: Media Feed Distance

This procedure is used to adjust the distance for media transport. The adjustmentdetermines the resolution in the firmware for the X encoder by causing lines to beprinted in the direction of media feed and entering their distance.

Adjustment Print

XLine Len: 300.0 mm

Printing finished

Print Start?

AJST: X Length

Press [ENTER] to update the settings. If settings have been changed, another adjustment printwill be made. If there was no change, the display will move to the “AJST: Margin” menu.

Displayed during adjustment printing

Setting can be specified in 0.1 mm units using the VALUE + and - keys

When parameter is changed and [ENTER] is pressed

Press [ENTER] for another adjustment print, [Back] to move to next menu

Media feed distance adjustment pattern

Adjustment items Adjust the distance for media transportPrinting method Four-pass, bidirectional 360 dpi

Standard valuesUp to 500 mm ±0.1%Here, the adjustment is 300 mm so the actual value, x, will be 299.7 ≤ x ≥ 300.3 mm

k m c y

300

70

150

k r g y b m c

100 %

k

k

Output direction



Adjustment: Top and Bottom, Left and Right Margins

Adjustment: Top and Bottom, Left and Right Margins

This procedure involves cutting the media, printing and cutting the media again,then entering the distances between front sensor and head, cutter and head, andthe media edge sensors and head. Moreover, in order to know the media widthexactly, it determines the correction value of the media edge detecting position.

Adjustment Print

T Margin: 25.0 mm

B Margin: 20.0 mm

> Margin: 5.0 mm

< Margin: 5.0 mm

Menu UpMenu Down

Menu UpMenu Down

Menu UpMenu Down

AJST: Margin

An adjustment print is made after the leading edge of the media is cut.

Displayed during adjustment printing



After print finished and the media was cut

Press [ENTER] to update settings. Press [ENTER] at Bottom Distance to move to “AJST: Rear Sns Posi”.

Front/Cutter to Head Distance Adjustment Pattern

Adjustment Items Top and bottom margins, left and right marginsPrinting Method Black, single-pass, uni-directional 360 dpi

Top distance 25

Bottom distance 20

55

Black paint, vertical width 9

Output direction



Adjustment: Rear Sensor Position

Adjustment: Rear Sensor Position

This procedure is used to ensure the proper detection of the length of cut sheetmedia. It adjusts the position of the rear sensor in the firmware by entering themedia length after cut media has been loaded and detected.

This item is essential in the production process but it is no longer necessary oncemedia feed distance compensation has been carried out.

When this item is selected, whether media is loaded or not, it will ask for cut sheetmedia. If panel diagnosis decides that media is loaded, this will be assumed to becut sheet media and media initialization will begin. Therefore roll media should notbe loaded. After the media has been initialized, it will be ejected.

To terminate this program without updating the setting, press the [Back] while noprocessing is in progress.

AJST: Rear Sns Posi

Press [ENTER] to update the setting, and move to “AJST: Test Print”.

Set CuttingPaper

After loading media

Paper Initial

After initializing media

Paper X: 594.0 mm

Enter

Paper Y: 840.0 mm Setting can be specified in ±0.1 mm units using the VALUE + and - keys



Adjustment: Test Print

Adjustment: Test Print

This procedure is used to check adjustments by printing a test pattern. it also printsadjustment parameters and if no serial number has been entered at that time, serialnumber input will be requested. Online data signal reception is always enabled butany data should not be transmitted during the processing of a self-diagnosticsequence.

ENTER

Back

Adjustment parameter printing begins

Parameter is printed but serial number is not printed.

Register Serial Number

Digits to be entered will blink from the left. Use the VALUE + and - keys to change the settings Use [ENTER], [Menu Up] and [Menu Down] to move between digits

On [ENTER], if no serial number is registered

BZ400001

AJST: TestPrint ENTER

Printing finished

Printing finished

ENTERPrint

PrintPRINT: ChkNozzles

PRINT: Black Fill

Menu Up Menu Down

Printing finished

ENTERPrintPRINT: Parameters

Menu Up Menu Down

Press [Back] after adjustment parameter printing has finished to move to “AJST: HeadWash”. At other times, press [Back] to move to “AJST: TestPrint”.

1 Display varies according to type of printer.

1



Adjustment: Head Wash

Adjustment: Head Wash

This procedure is used at the end of the production process or before prior to headreplacement.

Note: If you suspect the cartridge sensor to be faulty, you can carry out the follow-ing procedure by pressing the [ENTER] key.

AJST: Head Wash

Rm All Cartridge

After all cartridges are removed

Set Wash Jig

After withdrawing a specified amount of ink

Ink Absorb

After all cleaning jigs are installed

Washing

After cleaning fluid has been extracted

Rm Wash Jig

After cleaning jig has been removed

Washing

After head cleaning has been completed, the display will move to “AJST: Home”.



Cleaning: Normal, Powerful

Cleaning: Normal, Powerful

This procedure is used for head nozzle cleaning. The items are as follows. NormalNormal cleaning (wiping). It moves to next menu, “CLEAN: Powerful” whenNormal cleaning is finished.

PowerfulThis procedure carries out powerful cleaning (wiping and rubbing). The operationis the same as for normal cleaning.

Item DetailsNormal Normal cleaning (wiping)Powerful Powerful cleaning (wiping and rubbing)

Cleaning selection operation is shown below.Press [Back] to return to the Diagnostics Menu

ENTERPrinting finished To next menu

when Normal cleaning is finished

CLEAN: Normal

CLEAN: Powerful

Menu Down

Menu Down Menu Up



Test Printing: Head Printing, Black in-filling, Parameters

Test Printing: Head Printing, Black in-filling, Parameters

This procedure is used for test printing. The items are as shown below. For adjust-ment parameter prints, if no serial number has been entered, a serial number willbe requested. Online data signal reception is always enabled but no signals aretransmitted during the processing of a diagnostic sequence.

Procedures for the selection of items from panel are shown below.Press [Back] to return to the Diagnostics Menu.

1. Head Printing VerificationTo check that the head prints and print an adjustment pattern.

Item DetailsHead Printing Verification Adjustment pattern printingCheck in-filling Black in-fillingAdjustment Parameters Display firmware adjustment parameters

Menu Up

Menu Up

Menu Down

Menu Down

PRINT: ChkNozzles End Print

ENTER

PRINT: Parameters

Menu UpMenu Down

PRINT: Black Fill End

ENTER

DIAG: Test Print

Black infill printing

3. Adjustment ParametersThis procedure is used to print firmware adjustment parameters.

Press [ENTER] to print firmware adjustment parameters but if no serial number hasbeen registered, registration will be requested.

Adjustment Print

Panel

Adjustment Print

Panel

After the adjustment pattern printing has been finished, “PRINT: ChkNozzles” willappear.

2. Check black in-fillingTo print by filling an area with black colour.

Adjustment Print

Panel

After the adjustment pattern printing has finished, "Print: black in-fill" appears.



Parameters

Parameters

This procedure concerns changing adjustment parameters. Details are as shownbelow. A special purpose memory card is used to back up backup parameters tothe memory card and to update the backup parameters from the memory card.

Item DetailsInitialize Initalize adjustment parametersUpdate Input adjustment parameter values

Menu Up

Menu UpBack

Menu Down

Menu Down

PARAM: Initial

ENTER

PARAM: Update

DIAG: Parameter

Parameter initialization

Press [Back] to return to the Diagnostics Menu.



Parameters: Initialize

Parameters: Initialize

Initialization

ENTERINIT: Left Head

INIT: Right Head

INIT: Wiper

INIT: Home

Menu Down Menu Up

INIT: X Length

Menu Down Menu Up

INIT: Maintenance

Menu Down Menu Up

INIT: ErrorRecord

Menu Down Menu Up

INIT: Serial No.

Menu Down Menu Up

INIT: All

Menu Down Menu Up

Press [ENTER] to display “Param Initial?”. Press [ENTER] again to initialize. After initialization, “INIT: Parameter” is restored.

Press the [BACK] key to restore “PARM: Initial” without initializing.

This procedure is used to initialize adjustment parameters. Items are: Capping Position, X Resolution, Zone Delay, Head Height, Maintenance History (Left Head, Right Head, Wiper), Serial Number and Complete Initialization.

INIT: Parameter



Parameters: Update

Parameters: Update

Update

This procedure will update adjustment parameters. Note: The actual writing to flash memory is done when diagnostics are com-

pleted or power is switched off.

UPDATE: Home Previou menu is "UPDATE: Mech Param"

Menu Down Menu Up

UPDATE: Head Rank

Menu Down Menu Up

UPDATE: Print Posi

Menu Down Menu Up

UPDATE: Microdot

Menu Down Menu Up

UPDATE: X Length

Menu Down Menu Up

UPDATE: Mech Param Next menu is "UPDATE: Home"

PARAM: Update

Press [ENTER] to input the adjustment parameter.

Press [BACK] to return to “PARM: Update”.



Update: Capping Position Parameter

Update: Capping Position Parameter

This procedure will update the capping position parameter.

UPDATE: Home

If [Back] is pressed instead of the second [ENTER], a message that the parameter is not updated will appear and the display will move to “UPDATE: Home”

Home: -2162

Param Update?

Update Parameter

Use the VALUE + and - keys to change the setting

After this display, [Menu Down] will appear

If there is a change, a confirmation message will appear when you press [ENTER]

The update message will appear when you press [ENTER]



Update: Head Rank Parameter

Update: Head Rank Parameter

This procedure will update the head rank parameter.

UPDATE: Head Rank

If [Back] was pressed, a message that the parameter is not updated will appear and the display will move to “UPDATE: Head Rank”.

Left Rank: 21117

Right Rank: 21117

Param Update?

Update Parameter

Use the VALUE + and - keys to change the setting and press [ENTER] to confirm the change.



If there is a change, a confirmation message will appear when you press [ENTER].


Menu UpMenu Down



Update: Print Positioning Parameter

Update: Print Positioning Parameter

This procedure will update the print positioning parameter.

UPDATE: PrintPosi (and Micro-Dot)

If [Back] was pressed, a message that the parameter is not updated will appear and the display will move to “UPDATE: PrintPosi”.

D e l a y L : - 0 . 2 5 0 m m

D e l a y R : - 0 . 2 5 0 m m

L - R G a p : - 3 4 . 2 9 0 m m

P a r a m U p d a t e ?

U p d a t e P a r a m e t e r


Use the Setting + and - keys to change the setting and press [ENTER] to confirm the change.

Use the Setting + and - keys to change the setting and press [ENTER] to confirm the change.




Menu UpMenu Down

Menu UpMenu Down



Update: Media Transport Distance Parameter

Update: Media Transport Distance Parameter

This procedure will update the media transport distance parameter.

UPDATE: X Length

If [Back] was pressed, a message that the parameter is not updated will appear and the display will move to “UPDATE: X Length”.

X l e n g t h : 3 0 0 . 0 m m


U p d a t e P a r a m







Update: Mechanical Parameters

Update: Mechanical Parameters

This procedure will update the mechanical parameters.

Menu Up

Menu Up

Menu UpMenu Down

Menu Down

Menu Down

H t o E d g e : 2 5 . 1 8 0 m m

X F t o H : 3 0 . 8 9 0 m m

H t o C u t : 1 5 . 3 9 0 m m

X F t o X R : 1 2 3 . 7 0 0 m m

P a p e r E d g e : 2 8 0 9

R i g h t F l u s h P : 3 6 9 9

L e f t F l u s h P : 2 4 2 4

U p d a t e P a r a m








A n o t h e r L F P : 3 8 7 0 0


P a p e r W i d A d j : - 5

A n o t h e r R F P : 4 0 0 0 0







UPDATE: Mech Param

If [Back] was pressed, a message that the parameter is not updated will appear and the display will move to “UPDATE: Mech Param”.

Menu UpMenu Down

Menu UpMenu Down

Menu UpMenu Down

Menu UpMenu Down

Menu UpMenu Down

Menu UpMenu Down



Aging

Aging

This procedure concerns the aging of the mechanism and head. Details of the itemsare as follows.

Selection of items from the panel is shown below.

Item DetailsCarriage Motor Reciprocal carriage scanning Media Feed Motor Media feed roller driveCutter Media cuttingMaintenance CappingHead In-fill printing

Menu Up

Menu Up

Menu Up

Menu Up

Menu UpMenu Down

Menu Down

Menu Down

Menu Down

AGING: Y Motor Carriage motor agingENTER

BackEnd

AGING: X Motor

AGING: Cutter

AGING: Mainte Unit

AGING: Head

Menu Down

DIAG: Aging

Press [Back] to return to the Diagnostics Menu.



Aging: Carriage Motor

Aging: Carriage Motor

This procedure is used for aging the carriage motor. Select uni-directional printscanning mode or bidirectional print scanning mode and specify a number of timesfor repeatability scanning of the carriage. If the specified number is -1, aging willcontinue until a key is entered.

Press [ENTER] to begin aging

End

AGING Y: UniDir Prn

AGING Y: BiDirPrn

AGING COUNT: 50

AGING: 10

AGING END: 50

AGING: Y Motor

Press [ENTER] to move to number of agings


Menu Up Menu Down

[ENTER]

Escape with [ENTER] or [Back]

Terminate endurance with [ENTER], [Back] or[CANCEL]



Aging: Media Feed

Aging: Media Feed

This procedure is used for aging the media feed motor. Repeatability operation iscarried out for a specified number of times.


End

AGING COUNT: 50

AGING: 10

AGING END: 50

AGING: X MotorUse the VALUE + and - keys to change the setting

Press [ENTER], [Back] or [CANCEL] to end aging.



Aging: Cutter

Aging: Cutter

This procedure is used for aging the cutter. Media is cut a specified number oftimes.


End

AGING COUNT: 50

AGING: 10

AGING END: 50

AGING: CutterUse the VALUE + and - keys to change the setting

Press [ENTER], [Back] or [CANCEL] to end aging



Aging: Maintenance Unit

Aging: Maintenance Unit

This procedure is used for aging the capping. Capping is carried out a specifiednumber of times.


End

AGING COUNT: 50

AGING: 10

AGING END: 50

AGING: Mainte UnitUse the VALUE + and - keys to change the setting

Press [ENTER], [Back] or [CANCEL] to end aging.



Aging: Head

Aging: Head

This procedure is used for aging the print head. Select left or right and carry out in-fill printing a specified number of times.

Menu UpMenu Down

ENTER


End

AGING HEAD: Left

AGING HEAD: Right

AGING COUNT: 50

AGING: 10

AGING END: 50

AGING: Head

Press [ENTER] to specify a number of times to carry out aging in the same way as the carriage motor and return to “AGING: Head” when finished.

C AT 0 0 0 0Model Name: Rockhopper-46


Rockhopper-463 Maintenance Parts


Maintenance Parts Still Under Construction

Maintenance Parts List CAT1000Maintenance Tool List CAT2000Lubrication Points CAT4000Exploded Drawings CAT5000Periodical Maintenances CA T7000

C AT 0 0 0 0 - 3Model Name: Rockhopper-62




Maintenance Parts Still Under Construction

Maintenance Parts List CAT1000-3Maintenance Tool List CAT2000Lubrication Points CAT4000Exploded Drawings CAT6000(Not yet available)Periodical Maintenances CA T8000

C AT 1 0 0 0Model Name: Rrockhopper-46


Rockhopper-463 Maintenance Parts List


Description Technical Preferred Reference Order N°

Main Board Assy DF-41586 DE-34498 Power Supply Board Assy DF-41587 DE-34535 Head Board Assy DF-41588 DE-34456 Panel Board Assy DF-40097 DE-33585 Mother Board Assy DF-40098 DE-48667 Lever Sensor Assy DF-41589 DF-41469 Cover Sw. R. Assy DF-41590 DF-41478 Paper Sensor XR cable Assy DF-41592 DF-41468 Detection Unit Assy (Black) DF-40106 DF-40011 Detection Unit Assy (Yellow) DF-40107 DF-40012 Detection Unit Assy (Magenta) DF-40146 DF-40013 Detection Unit Assy (Cyan) DF-40147 DF-40014 Detection Unit Assy (LC/Orange) DF-41593 DF-41480 Detection Unit Assy (LM/Green) DF-41594 DF-41481 Paper Sensor Y Assy DF-41595 DF-41470 Origin Sensor Assy DF-40109 DE-49921 X Motor Assy DF-41597 MY-34558 Y Motor Assy DF-41598 MY-34087

Pump Motor Assy PE DF-41599 DE-34187 + DF-41060

Cutter Solenoid Assy DF-40113 DE-33659 Vacuum Fan Assy DF-40173 DE-33353 Fan extension cable RH 46” MK-24210 Fan extension cable 2 assy DF-41621 DF-41483 Fan extension cable 3 assy DF-41622 DF-41484

Description Technical Reference

Panel Cable Assy DF-41617 DF-41461 SW Cable Assy DE-41619 DF-41477 DC Cable Assy DF-41468 DF-41464 Y Cable Assy (46") DF-41600 DF-41460 Head Cable (Colour) DF-41601 DF-41462 Print Head (Colour) DF-40690 DE-49732 Cap Assy DF-41602 DF-41406 Pump Assy DF-41603 DF-41603 Wiper DF-40125 DE-49771 Maintenance Station Assy DF-41604 MY-21474 Cartridge Frame Assy MY-44051 MY-44051 Damper (Colour) DF-40129 DE-49734 Ink Tube (2.0 BK) 46" DF-42726 DF-42726 Grid Roller Assy DF-41840 DE-34525 Pressure Assy DF-42727 MY-33987P Pressure Roller Assy DF-41530 DF-40982 Blade DF-42728 DE-21612 X Speed Reduction Belt DF-40137 DE-49802 Steel Belt 46" DF-41606 DE-49764C T Fence (46") DF-41607 DE-34516 Cursor Assy DF-42729 MY-34986 Y Return Pulley Assy DF-40144 MY-49761 Fuse DF-40345 DF-40317 Flange(2") DF-40446 DE-33602 Flange(3") DF-40447 DE-21303 2” Core flange set MY-33602 MY-33602

C AT 1 0 0 0Model Name: Rrockhopper-46





3” Core flange set MY-40447 MY-40447 O Ring (Small) 100 pcs. DF-40487 DF-40487 O Ring (Large) 100 pcs. DF-40488 DF-40488 Tube Guide 46" DF-41677 MY-34517

Cursor Plate Spring DF-40854 DF-40854 Steel Bare (46") DF-41616 DE-33943C Junction Board Assy DE-34540 DE-34540 Ink ID Sensor 1 Assy (Blk) DF-41609 DF-41471 Ink ID Sensor 2 Assy (Cy) DF-41610 DF-41472 Ink ID Sensor 3 Assy (Mg) DF-41611 DF-41473 Ink ID Sensor 4 Assy (Ye) DF-41612 DF-41474 Ink ID Sensor 5 Assy (Lcy) DF-41613 DF-41475 Ink ID Sensor 6 Assy (Lmg) DF-41614 DF-41476 Ink ID Cable DF-41615 DF-41463 Spring Cutting blade DF-40936 DE-49743 Spring Plunger Magnet DE-49194 DE-49194 Bearing Grid Roller DE-48846 DE-48846 Encoder reader (incl. Cable) DF-41626 DF-41465 Media Distance Pieces (10 pcs) MY-40650 MY-40650 X motor extension cable assy DF-41623 DF-41485 X ENC extension cable assy DF-41624 DF-41486 Switch Head Height DF-42733 DF-42340 N Belt 46" DF-42735 DE-34522 Scroller Lock receiver roller DF-41634 DE-49811 Scroller Roller assy DF-41633 DF-41633 Y-motor cable assy DF-41625 DF-41466


Cartridge Pipe slot 1 DE-34514A DE-34514A Cartridge Pipe slot 2 DE-34514B DE-34514B Cartridge Pipe slot 3 DE-34514C DE-34514C Cartridge Pipe slot 4 DE-34515A DE-34515A Cartridge Pipe slot 5 DE-34515B DE-34515B Cartridge Pipe slot 6 DE-34515C DE-34515C Waste tank sensor plate ME-24124 Waste tank sensor Cable MK-24208 Waste connection tube small ME-24115 Flush box spare part MY-24115 Paper guide assy F 46" SDMP MY-24159 Heating strip for SDMP 46” Assy MY-24218 Paper guide rear assy 46” MY-24206 Heating strip rear SDMP 46” assy MY-24217 Power AC-inlet schutter 10A MC-7001 External waste bottle system SDMP V2 MY-24146 Cleaning bottle 500ml JD-42054 Keyboard assy for SDMP 46” EY-24502 Panel cable DF-41461 Keyboard sheet SDMP V2 LB-242000 Heater PCB for SDMP 46” EY-24501






Main Board Assy DF-42010 DE-34719 Power Supply Board Assy DF-41587 DE-34535 Head Board Assy DF-41588 DE-34456 Panel Board Assy DF-40097 DE-33585 Mother Board Assy DF-40098 DE-48667 Lever Sensor Assy DF-41589 DF-41469 Cover Sw. R. Assy DF-41590 DF-41478 Paper Sensor XR cable Assy DF-41592 DF-41468 Detection Unit Assy (Black) DF-40106 DF-40011 Detection Unit Assy (Yellow) DF-40107 DF-40012 Detection Unit Assy (Magenta) DF-40146 DF-40013 Detection Unit Assy (Cyan) DF-40147 DF-40014 Detection Unit Assy (LC/Orange) DF-41593 DF-41480 Detection Unit Assy (LM/Green) DF-41594 DF-41481 Paper Sensor Y Assy DF-41595 DF-41470 Origin Sensor Assy DF-40109 DE-49921 X Motor Assy DF-41597 MY-34558 Y Motor Assy DF-41598 MY-34087

Pump Motor Assy PE DF-41599 DE-34187 + DF-41060

Cutter Solenoid Assy DF-40113 DE-33659 Vacuum Fan Assy DF-40173 DE-33353 Fan extension cable 1/3 assy DF-41620 DF-41482 Fan extension cable 2/3 assy MK-42403 MK-42403 Fan extension cable 3/3 assy MK-42401 MK-42401 Fan extension cable 2 assy DF-41621 DF-41483


Fan extension cable 3 assy DF-41622 DF-41484

Fan extension cable 4 assy DF-41993 DF-41773

Panel Cable Assy DF-41617 DF-41461 SW Cable Assy DE-41619 DF-41477 DC Cable Assy DF-41468 DF-41464 Y Cable Assy (62") DF-41998 DF-41775 Head Cable (Colour) DF-41601 DF-41462 Print Head (Colour) DF-40690 DE-49732 Cap Assy DF-41602 DF-41406 Pump Assy DF-41603 DF-41603 Wiper DF-40125 DE-49771 Maintenance Station Assy DF-41604 MY-21474 Cartridge Frame Assy MY-44051 MY-44051 Damper (Colour) DF-40129 DE-49734 Ink Tube (2.0 BK) 62" DF-41999 DF-41999 Grid Roller Assy DF-41840 DE-34525 Coupling assy DE-34776 DE-34776 Pressure Assy DF-42727 MY-33987P Pressure Roller Assy DF-41530 DF-40982 Blade DF-42728 DE-21612 X Speed Reduction Belt DF-40137 DE-49802 Steel Belt 62" DF-42001 DE-41754 T Fence (62") DF-42002 DE-34698 Cursor Assy DF-42729 MY-34986 Y Return Pulley Assy DF-40144 MY-49761 Fuse DF-40345 DF-40317






Flange(2") DF-40446 DE-33602 Flange(3") DF-40447 DE-21303 2” Core flange set MY-33602 MY-33602

3” Core flange set MY-40447 MY-40447 O Ring (Small) 100 pcs. DF-40487 DF-40487 O Ring (Large) 100 pcs. DF-40488 DF-40488 Tube Guide 62" DF-42732 MY-34983

Cursor Plate Spring DF-40854 DF-40854 Steel Bare (62") DF42004 DF-41738 Junction Board Assy DE-34540 DE-34540 Ink ID Sensor 1 Assy (Blk) DF-41609 DF-41471 Ink ID Sensor 2 Assy (Cy) DF-41610 DF-41472 Ink ID Sensor 3 Assy (Mg) DF-41611 DF-41473 Ink ID Sensor 4 Assy (Ye) DF-41612 DF-41474 Ink ID Sensor 5 Assy (Lcy) DF-41613 DF-41475 Ink ID Sensor 6 Assy (Lmg) DF-41614 DF-41476 Ink ID Cable DF-41615 DF-41463 Spring Cutting blade DF-40936 DE-49743 Spring Plunger Magnet DE-49194 DE-49194 Bearing Grid Roller DE-48846 DE-48846 Encoder reader (incl. Cable) DF-41626 DF-41465 Media Distance Pieces (10 pcs) MY-40650 MY-40650 Flange set roll tubs ZMY-46040 ZMY-46040

Linear encoder 180 LPI E-HEDS-9200#Q00

E-HEDS-9200#Q00

X motor extension cable assy DF-41994 DF-41771 X ENC extension cable assy DF-41995 DF-41772


Switch Head Height DF-42733 DF-42340 N Belt 62" DF-42737 DE-34700 Head fixing assy DF-42734 DE-34987 +

DF-42345 + DF-42344 + DF-40836

Scroller Lock receiver roller DF-41634 DE-49811 Scroller Roller assy DF-41633 DF-41633 Absorbent assy set DF-42007 MY-41326 (2x) X pulley assy RJ54&62 DF-41988 MY-41739 Y-motor cable assy DF-41625 DF-41466 Waste ink bottle RJ-6100 54 & 62 DF-42008 DF-42008

Coupling assy DF-40693 DE-34776 +

3x NS-21040031

Cartridge Pipe slot 1 DE-34702 DE-34702 Cartridge Pipe slot 2 DE-34703 DE-34703 Cartridge Pipe slot 3 DE-34704 DE-34704 Cartridge Pipe slot 4 DE-34705 DE-34705 Cartridge Pipe slot 5 DE-34706 DE-34706 Cartridge Pipe slot 6 DE-34707 DE-34707 Hooked screw driver Rockhopper TL-24000 Waste tank sensor plate ME-24124 Waste tank sensor MS-24000 Waste tank sensor Cable MK-24208 Waste connection tube small ME-24115 Flush box spare part MY-24115 Paper guide assy F 62" SDMP MY-11249






Temp sensor long SDMP 62” front MS-24004 Temp sensor short SDMP 62” short MS-24005 Keyboard sheet SDMP LB-24100 PCBA heater system Falcon EY-24500 Paper guide assy R 62” SDMP MY-11250 Temp sensor long SDMP 62” rear MS-24001 Temp sensor short SDMP 62” rear MS-24002 Inlet assy : DF-40775 + MC-5131 EY-27775 Power supply 5V/24V – 0.5A/2.5A EY-25580 Relais solid state realy MM-1003

Wago connection blok A-1701620 MC-5136

External waste bottle system MY-24100

Cleaning bottle 500 ml JD-42054

Silicone glue for rockhopper AG-91240

C AT 2 0 0 0Model Name: Rockhopper-46/62


Maintenance Tool List


No.

1

2

2.1

2.2

3

4

Drawing No.

JD-30410

JD-42052

JD-42053

JD-42050

Name Appearance

Personal Computer

Head cleaning jig assembly (6 sets required)

Rubber bushing ❉ Replace after

using 20 times

Mini-fitting (made by Inaiseieido)

Belt tension attachment

Bar tension gauge 4.9 N (500 gf) (made by Ooba S/S)

Remarks

Commercial item

Special item, includes rubber bush and mini-fitting

Special item (consumable)

Special item (commercial item)

Special item

Commercial item

No.

5

6

7

8

9

10

Drawing No.

JD-30395

JD-30432

Name Appearance

Bar tension gauge 49 N (5 kgf) (made by Ooba S/S)

Rail height jig assembly

Rail height reference base assembly

Phillips screwdriver No. 1

Commercial item

Remarks

Commercial item

Special item

Special item

Phillips screwdriver No. 2

Commercial item

Hex nut driver 5.5 mm Commercial item





No. Drawing No. Name Appearance Remarks

11

12

Standard screwdriver Commercial item

13

Allen key 1.5 mm Commercial item

14

Allen key 2 mm Commercial item

15

Allen key 2.5 mm Commercial item

16

Allen key 3 mm Commercial item

17

Spanner 5.5 mm Commercial item

18

19

Spanner 17 mm Commercial item

20 Multimeter Commercial item

21 Cleaning fluid A-29 (18-liter)

Special item

22

JD-41844

JD-42054 Cleaning fluid bottle, 500 ml

Special item(Commercial item)

24 Ball driver 2.5 mm Commercial item

25 Hexagon ratchet spanner

Commercial item

23 Ball driver 1.5 mm Commercial item


Tweezers Commercial item

Jeweller's screwdriver Commercial item





No.

26

Drawing No. Name Appearance

M-block (Height: 20)

27 JD-42145 Head height jig

28 Pocket microscope (Magnification: 25x to 50x)

Remarks

Commercial item

Special item

Commercial item


Hooked screwdriver Commercial item

TL-2400029For Rockhopper 62"



Lubrication Points

Lubrication Points

No.

1

2

3

4

5

6

7

Name of Unit

Pressurization Unit

Maintenance Unit

R Frame

X Drive

Y Rail

Y Rail

Covers

Lubrication Point

Pressure cam

Transfer gear bearings

Sliding parts around pressurizing relay plate

X speed reduction belt parts

Back of roller track

Cursor track

Cover pins and frame holes

Brand, Product Number

Shin-Etsu Chemical Co., Ltd., Silicone Grease G501





Sumiko Lubricants Co., Ltd Sumi Grease Spray


Application

To improve sliding

To improve durability

To improve sliding

To improve durability

For inserting roller, reducing cursor noise

To prevent burning

For cover opening/closing action and noise

Remarks

or similar

or similar

or similar

or similar

or similar

Soak a cloth and apply lightly

ROCKHOPPER 46

NS-51040101

DF-40521C

DF-40411C

DE-31567

NS-11030061

NS-11030061

DF-41490(A/E)

DF-41388

NS-05030081

NS-11040081

DF-41386

NS-05030081

NS-11040081

DE-10873

NS-11030061

DE-21467

DF-40650

DE-10973

NS-11030061

NS-05030081

NS-05030081

DF-41376

DE-11159

DF-41429

NS-11030061

NS-05030081

NS-11030061

DF-41375

NS-05030081

NS-05030081

ME-24206

LB-10250

ME-24124

NS-11040081

NS-11040081

DE-21469

DE-21469

DR-4014-43315

DF-41387

NS-05030081

NS-05030081

NS-05030081

NS-21030031

DE-47066

NS-51040101

NS-05030081

NS-05040081

NS-11040081

NS-05030081

DE-21470

LB-10082DE-33950C

DE-34501

DE-11174

DE-10872

DE-10972

DF-40027

MY-24218= ME-24227+AP-52128+ME-24218

MY-24217

ME-24233

NS-11030061

LB-10031

LB-10080(2x)

UNIT-SDMP46 CAT5001-00 REV. /

ME-24205

ME-24232

EY-24502

LB-24200

ME-24237(2x)

DR-4001-43993(2x)

DF-41461

ME-24236

NS-06030061(4x)

DR-4001-43993(4x)

MY-24205

NS-05030081

DE-49796

DF-41378

DF-40981

DE-33991DE-49801

NS-21030031

NS-05040081 NS-11040041

DF-41384

NS-04040101

NS-05040081NS-35040201

NS-05040101

DE-11170

DE-49796

NS-05040101

DE-49804

DE-46562DE-49803

N-40202C

DE-49802

DF-41484

DF-41622

NS-05030101NS-05030101

NS-05030101 NS-05030061

NS-05030061

NS-05030061

E-NAD-06

NS-05040081

DE-47866F

E-NAD-06

E-P-25

DE-33992

E-P-20

E-P-20

DF-40091

DE-49651

DE-49651

NS-05030401

NS-05040081

NS-05030401

NS-05030401

ME-24211

DE-33608

DE-33608

DE-33608

DF-40173

NS-21030031 DF-41428

DF-40520

DE-49810

DF-40470

DE-46552

DE-46552

DE-46552

DE-40321

DE-49904

DE-49813

DE-49812

DE-49812

DE-46552

DF-40469

DF-40469

DE-49811

DF-49828DP-3022-40153

DS-1074-41211KDE-49814

DE-49815

DE-33609

DF-40470

DE-49811

DF-40137

DE-41597

DE-34558

DF-41486DF-41623DF-41485

DF-41624

DF-41621

DF-41483

MK-24210

DF-40173

DE-33353

DE-33353DE-33353

DF-40173

DE-40615

ME-24231

ME-23046(5x)

DE-47866X(1,5x)

NS-05040081(3x)

NS-06040061(3x)

DF-41793

MY-41793

UNIT-SDMP46 CAT5002-00 REV. /

ROCKHOPPER 46ROCKHOPPER 46

DR-4010-41280

NS-05040121

NS-05040401

JD-42054

BM-1301-003006NS-05040101

DE-45115

NS-05030061

NS-05030081

DE-49812

DF-40469

DF-40470

DE-46552

MY-40469 (3x)

DE-46552

DP-3022-40153

NS-04040101

E-P-25

NS-51030051

NS-01020081DF-42341

DF-42342

NS-04030061

DR-4010-41280

DF-40561 DE-49827

NS-51030051

DF-41463

DF-41615DE-45115

E-P-25

DE-47046

DF-41433DF-41468

DF-41592

DF-40562

DE-10868

DF-42340DF-42733

DF-41374

DF-40564

DF-41931

NS-05040081

DE-49948

DE-33999

DE-32692 NS-06030061

NS-05040121

NS-05040101

NS-06020051

DE-48931

NS-01020081

DF-41478

NS-11040041

NS-11040041

DE-49142

NS-05040101

ME-24239

DE-49782

DE-49781

DE-49947

DE-49826

DF-41590

DF-41329

DR-4014-43892

DE-47071DF-40553

NS-35040201

DF-40081

DF-41329DE-49950

DF-40556

DE-49949

DF-41425

NS-05040101

DE-49651(3x)

DE-47866E

E-NAD-06

E-NAD-06

DE-47866H

NS-06020051

DF-41581

ME-24234

DE-34540DF-41536

DF-41469

DF-41589

DF-41792

MY-41792

NS-06030061

ME-24240

MK-24207

MY-24146

ME-24128(0,7 m)

MK-24208

ME-24104

NS-04030061 (4x)

NS-04030061 (2x)

NS-04030061 (4x)

AE-91025 (3x)

DE-44113

ME-24101

ME-24103

ME-24102

NS-04030061 (4x)

DE-49738(2x0,44 m) DE-49891(8x0,02 m)

DE-48958 (2x)

ME-24100

ROCKHOPPER 46UNIT-SDMP46 CAT5003-00 REV. /REV. /

DDV

DDV

DDV

DDV

DDV

DF-40693

ME-24118

ME-24118

ME-24118

NS-05030061

NS-05030061

DE-11158

NS-05030081

E-P-25

(t=0.1) DF-41578A(t=0.2) 〃 B(t=0.3) 〃 C

DF-41382

NS-35030061

NS-35030061

NS-35030061

DE-48846

DE-34525

DE-34525

DF-44183

DE-34525

DE-21465

DE-21465

DE-21465

NS-35030101

NS-35030101

NS-35030101 NS-35030101

ME-24128

DF-42007

DF-41326

DF-41327

ME-24138

ME-24138

ME-24138

NS-41030061

NS-41030061

NS-41030061

NS-05030061

DF-40523

DF-40522

DF-40522

DF-40522

DF-40522

DE-21394

DE-21394

DE-21394

DE-21394

NS-35030101

DE-49771

DF-41603

DF-41405

DF-41582

DE-48918C

DF-41406

NS-11030061

NS-05030061

NS-05030121 DP-3022-40153

DE-34068

NS-05030061

DE-34999

NS-05030061DE-21608

DF-40681

DF-40682

DE-34069

DF-41401

DE-40176DF-41403

DF-41400

DE-34508

DF-41602

DF-41599

DF-41060

DE-34187

NS-05030061

DF-42725

DF-40125

ME-24138

NS-41030061

DF-40523

DF-40523

DF-40523

DE-48846

DE-48846

DE-48846

DE-48846

DE-48846

DF-40514

DF-40514

DF-40514

NS-21030031

NS-21030031

NS-21030031

DE-34521

DE-34521 DF-41840

ROCKHOPPER 46ROCKHOPPER 46UNIT-SDMP 46 CAT5004-00 REV. /

NS-05030081

NS-05030081

NS-04030061

DF-40982

DE-33987

DF-40510

DF-40551

DF-40555

DE-35084

DF-42735

DF-40559

DE-34520

NS-05030061

DE-21395

DR-7032-41990

DR-7032-41990 DF-41625

DF-41466

DF-40552C

DR-7032-41990

DF-40550

DF-40550

DF-41518

DF-40551

DF-40360

DE-49753C

DE-49753C

DE-49752C

DE-42544

DE-21479

NS-05030081

NS-05030061

NS-04030061

DE-33602

DP-3022-40153

DF-40641

DF-40558

NS-05040081

DE-33598

NS-51040101

DF-41422

DF-41424

N-40202C

DE-34087

DF-41598

DP-3022-40153

DF-41435

DF-40447 (3") DF-40446 (2")

DE-21303 (3")DE-33602 (2")

DE-34519

DF-41427

NS-05030081

DE-11172

DE-34500

NS-05030061

NS-01030301

NS-21030061

DE-49763

DE-47091

DE-47040

DE-44181

DF-41259

DE-44181

DS-4104-40904

DE-11171

DF-40555

NS-04030061

DR-7032-41990

DF-40510

MY-33987P

DE-49883

DF-41606

DE-49764C

DE-21612DF-41530

DF-40982

DE-33987

DF-42728

DF-40144

NS-05030061

DE-34516

DF-41607

DE-49780

DF-41600

DF-41460

DR-4010-43353

DR-4010-43353

DE-34499

NS-35040201

NS-05030081

DE-49760

DE-47092

DE-21612

NS-05040081NS-05040101

DE-21395

DE-11173

NS-23040041NS-35040101

NS-35040101

NS-05040101

DE-34521

DE-34521

ME-27065


NS-41020081

DE-21300

DF-44051

DE-34514A(SLOT1)

DE-34513

DE-49777

DE-49992

DE-49778

DF-40488

DF-41410

DE-21477D

DE-21477E

DE-21477F

DE-21477A

DE-48950

DE-48949

DE-49777

DE-49777

DF-40488

DF-40487

DE-49993

DE-49778

DE-49738G

DE-33943C

DE-35084

DF-41460

DF-41460

DE-34978

DE-34979

DF-41616

DF-42726

DE-21477B

DE-21477C

DE-34514B(SLOT2)

DE-34514C(SLOT3)

DE-34515A (SLOT4)

DE-34515B(SLOT5)

DE-34515C (SLOT6)

～ﾌﾚｰﾑｱｾﾝﾌﾞﾘ,針

+DE-49892

DE-49778

DF-41476

DF-41614

NS-05030081NS-05030081

DE-33600

NS-41030061

DF-40488

NS-41030121

DF-41481

DF-41594

DF-41475

DF-41613

DF-41480

DF-41593

DF-41474

DF-41612

DF-40012

吸収材DE-34746

ｶｰﾄﾘｯｼﾞﾍﾞｰｽDE-11166

ﾅﾍﾞ小ﾈｼﾞM3×8(W)NS-05030081

ﾅﾍﾞ小ﾈｼﾞM3×8(W)NS-05030081

誤挿入防止板YDF-41395 誤挿入防止板LC

DF-41398

誤挿入防止板LMDF-41399

誤挿入防止板MDF-41394

DF-41393DF-41392

I/Cｽﾗｲﾄﾞ2DE-21537

ｶﾞﾀ取りﾊﾞﾈDF-40978

I/CｶﾞｲﾄﾞﾍﾞｰｽDE-21473

DE-49772

DF-40107

DF-41473

DF-41611

DF-40013

DF-40146

DF-41472

DF-41610

DF-40014

DF-40147

DF-41471

DF-41609

DF-40011

DF-40106

DF-42731


DF-42734

DE-49194

DF-40853

DF-40936

DF-41404

DF-41404

DF-42332

DF-42344

DF-42343

DF-42345

DR-4010-43353

DF-41470

DF-41595

DF-40113

NS-11030061

NS-11030061

NS-11030061

DF-40934NS-11030061

DF-40934

DF-40820

DE-48949

NS-11030061

DE-33659

NS-05030061

NS-05030061

NS-41020041

DF-41411

DE-34065

DF-40685

NS-11030061

NS-11030061

DE-11167

DF-40718NS-11030061

DE-42051

DE-34986

DF-42339

DE-42051

DF-41444

NS-41030051

NS-41030061

DF-41444

DE-42051

DE-42051

DE-49879

DF-42333 DE-49746

DF-40951

DF-41445

DF-41445

DE-44197

DF-42729

DF-41443

NS-05030081

NS-05030081

NS-05030081

NS-05030081

DF-41409

DF-40854

DF-41462DF-40690

DF-41601

DF-41462DE-48950

DF-40613

DF-41601 DE-49921

E-HEDS-9200#Q00180LPI

DE-40109

NS-06020121

DF-41430

DF-41426

DE-34456

DE-41588

DF-41626

DF-41465

NS-05030101

DE-33943C

NS-05030081

DF-41416

DF-41439ADE-21478

DE-34513

DF-41669

Rev.1

DE-49744

DR-7032-41990

NS-06020051

DF-42331

DF-42334

DF-42330

DF-42330

DE-42051

DE-44197

DE-44197

DE-44197

DE-44197

DF-41432

DF-42335

DF-42337

DF-42336DE-44197

DE-44197

DE-47014

DE-47014DF-42338

DE-47014

DE-49744

DE-49746

DF-40683

DF-40683

DP-3022-40153DP-3022-40153

DP-3022-40153

DR-7032-41990

DR-7032-41990

DR-7032-41990

DR-7032-41990

DR-7032-41990

DE-49879

DE-34066

DP-5005-40189

NS-05040081

DE-34987

DF-40836

DE-34067

DE-21476

DF-40690

DF-40613

DE-49734

DF-40129

DE-48950DE-49734

DF-40129

DF-40487

DE-48949

DF-40487


UNIT-SDMP 46 CAT5008-00 REV. /

ROCKHOPPER 46ROCKHOPPER 46

PCB Layout + cables refer to drawing AP-76128

J11

J09

12

21

J2

J07

J1

J000

J02

MK-24209

MK-21000

NS-06030061

NS-06030061

DE-33641

DE-49832

NS-11030061

NS-11030061

NS-11040041

AE-91025 (3x)

NS-35030061

E-SL10K2-5

DF-41619

ME-24200

MC-7001

NS-05040081

DF-41439B

E-SSC-58-12-FE-MTFC231114

DF-41494

DF-41464

(DF-41618)

DE-34505

DF-41439C (7x)

NS-05030081

DE-49749

DF-41461

DF-41617

DE-33585(DF-40097)

NS-05030081

NS-05030081

DE-10871

NS-51030061

NS-05030081

DE-11165

NS-06030041

DE-34535(DF-41587)

DF-41477

SIMM(16MB)DF-41340B

DF-41439A

MAIN PCB DE-34498

(DF-41586)

E-MSFC-6KEX

DF-41391

DE-48667

DF-41437DF-41439A

DF-41439B

DF-41439C (3x)

ME-24230

DE-46951 NS-05040081

NS-11040041

DE-48958

(DF-40098) ME-24238

DR-4001-43993 (3x)

SENSORS MK-24200

POWER MK-24201

EY-24501

MK-

2420

4

MK-

2420

4

MK-41314

C A T 7 0 0 0Model Name: Rockhopper-46

C A T 7 0 0 0Model Name: Rockhopper-46



You have to change some parts of the Rockhopper printer to obtain a good quality. Please refer to the tables for an overview of periodical maintenance. You will notice that the X-marks indicate a renewal of the mentioned part(s) after this many months. You have to change the absorbents every week.

IMPORTANT : Note that the x-marks in month 6 and month 12 are only to be done by authorised Mutoh technicians.

Maintenance cycle on Rockhopper 46 “

Monthly Description Qty 1 2 3 4 5 6 7 8 9 10 11 12 Print Head 2 X Flush Box Spare Part 1 X X Wiper 1 X X Sensor on ext. Waste Bottle syst. 1 X Maint. Station GA Assy RJ-6100 1 X X Waste Connection tube small 2 X X Dust removal in fan area - X Cleaning maintenance Station - X X Cleaning bottle 1 X X Blade on press roller 4100/6100P 18 X F-absorbent 1 RJ-4100 4 WEEKLY





You have to change some parts of the Rockhopper printer to obtain a good quality. Please refer to the tables for an overview of periodical maintenance. You will notice that the X-marks indicate a renewal of the mentioned part(s) after this many months. You have to change the absorbents every week.

IMPORTANT : Note that the x-marks in month 6 and month 12 are only to be done by authorised Mutoh technicians.

Maintenance cycle on Rockhopper 62 “

Monthly Description Qty 1 2 3 4 5 6 7 8 9 10 11 12 Print Head 2 X Flush Box Spare Part 1 X X Wiper 1 X X Sensor on ext. Waste Bottle syst. 1 X Maint. Station GA Assy RJ-6100 1 X X Waste Connection tube small 2 X X Dust removal in fan area - X Cleaning maintenance Station - X X Cleaning bottle 1 X X Blade on press roller 4100/6100P 24 X F-absorbent 1 RJ-4100 4 WEEKLY

Download - Falcon Outdoor Maint Man

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