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MUTOH Rockhopper 38, Maintenance Manual

The MUTOH Rockhopper 38 is a high-performance printer ideal for professional printing applications. Need guidance to maximize its potential? Look no further! Access the comprehensive User Manual and breathe life into your prints. Download it for free from our website and unlock endless possibilities for your creativity.

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Rockhopper 38 – Maintenance Manual

 

 

 

 

 

 

 

8

 

AP-74038, Rev. 1.1, 25/01/05 

 

 
 
 

4.4. Replacement of PF Driving Section Components................................................................ 51 

4.4.1 Replacing the X Motor Assembly................................................................................................... 51 
4.4.2 Replacing the Fan Assembly and Fan Cables............................................................................... 52 
4.4.3 Replacing the Speed Reduction Belt ............................................................................................. 54 
4.4.4. Replacing the Lever Sensor Assembly......................................................................................... 55 
4.4.5 Replacing the Cover Switch Assembly .......................................................................................... 57 
4.4.6 Replacing the Waste Bottle Fluid Sensor Assembly ..................................................................... 58 
4.4.7 Replacing the Front Paper Sensor Assembly................................................................................ 59 
4.4.8 Replacing the Rear Paper Sensor Assembly ................................................................................ 60 
4.4.9 Replacing the Grid Roller Assembly and Coupling Assembly ....................................................... 62 
4.4.10 Replacing the Pressure Assembly............................................................................................... 63 
4.4.11 Replacing the Blade..................................................................................................................... 66 
4.4.12 Replacing the Pressure Rollers ................................................................................................... 66 
4.4.13 Platen Height Adjustment ............................................................................................................ 67 

4.5 Replacement of CR Driving Section Components ................................................................ 68 

4.5.1 Replacing the Y Motor Assembly................................................................................................... 68 
4.5.2 Replacing the Steel Belt................................................................................................................. 69 
4.5.3 Replacing the T fence .................................................................................................................... 69 
4.5.4 Replacing the Steel Flexible Guide Assembly............................................................................... 71 
4.5.5 Replacing the Cursor Plate Spring ................................................................................................ 72 
4.5.6 Replacing the Y Return Pulley Assembly ...................................................................................... 73 

4.6 Replacing the Maintenance Area.......................................................................................... 74 

4.6.1 Replacing the Pump Motor Assembly............................................................................................ 74 
4.6.2 Replacing the Cap Assembly......................................................................................................... 75 
4.6.3 Replacing the Wiper....................................................................................................................... 76 
4.6.4 Replacing the Pump Assembly...................................................................................................... 77 
4.6.5 Replacing the Maintenance Station Assembly .............................................................................. 79 

4.7 Replacement of Ink Supply Section Components................................................................. 80 

4.7.1 Replacing the Cartridge Frame Assembly..................................................................................... 80 
4.7.2 Replacing the Ink ID assembly (Black, Yellow, Magenta, Cyan)................................................... 84 
4.7.3 Replacing the Detector Assembly (Black, Yellow, Magenta and Cyan) ........................................ 85 
4.7.4 Replacing the Y Cable ................................................................................................................... 85 
4.7.5 Replacing the Ink Tubes ................................................................................................................ 88 
4.7.6 Replacing the O-rings (Small) and (Large).................................................................................... 89 
4.7.7 Replacing the Tube Guide Assembly ............................................................................................ 91 

4.8 Replacement of Cartridge Area............................................................................................. 92 

4.8.1 Replacing the Cutter Solenoid Assembly ...................................................................................... 92 
4.8.2 Replacing the Print Head Assembly and Head Cable (Black)....................................................... 93 
4.8.3 Replacing the Print Head Assembly and Head Cable (color)........................................................ 96 
4.8.4 Replacing the Y Paper Sensor Assembly...................................................................................... 98 
4.8.5 Replacing the Head Board Assembly ............................................................................................ 99 
4.8.6 Replacing the Dampers (Black and Colour) ................................................................................ 100 
4.8.7 Replacing the Cursor Assembly .................................................................................................. 102 
4.8.8 Replacing the Origin Sensor Assembly ....................................................................................... 103 
4.8.9 Removing the Scroller from the printer ........................................................................................ 104 
4.8.10 Replacing the cutter blade ......................................................................................................... 104 

4.9 Replacement of Support and Scrollers ............................................................................... 106 

4.9.1 Replacing the head height sensor. .............................................................................................. 106 
4.9.2 Replacing the Junction Board Assembly ..................................................................................... 107 
4.9.3 Replacing the Network Interface Board (Optional Item) .............................................................. 108 

4.10 Replacement of heater system ......................................................................................... 109 

4.10.1 Replacing the fixer heater strip .................................................................................................. 109 
4.10.2 Replacing the dryer heater strip................................................................................................. 111

 

 

Summary of Contents for Rockhopper 38

Page 1: ...Maintenance Manual MUTOH EUROPE N V AP 74038 Rev 1 1 25 01 2005 ...

Page 2: ...Rockhopper 38 Maintenance Manual 2 AP 74038 Rev 1 1 25 01 05 ...

Page 3: ...on contained in this document the party to whom it is given assumes its custody and control and agrees to the following The information herein contained is given in confidence and any part thereof shall not be copied or reproduced without written consent of Mutoh Europe N V This document or the contents herein under no circumstances shall be used in the manufacture or reproduction of the article s...

Page 4: ...Rockhopper 38 Maintenance Manual 4 AP 74038 Rev 1 1 25 01 05 ...

Page 5: ...stance between them Be sure the product and the receiving antenna are on separate power lines 2 Trademark mentioned in this manual MUTOH Rockhopper 38 Eco Solvent Plus MH GL MH GL2 MH RTL are registered trademarks or product names of MUTOH INDUSTRIES LTD Centronics and Bitronics are registered trademarks or product names of Centronics Data Computer Corporation Windows 95 Windows 98 Windows Me Wind...

Page 6: ...Rockhopper 38 Maintenance Manual 6 AP 74038 Rev 1 1 25 01 05 ...

Page 7: ...cover 35 4 2 2 Removing the left cover 35 4 2 3 Removing the Front Cover 35 4 2 4 Removing the Unit Panel Cover 36 4 2 5 Removing the Heater Panel Cover 36 4 2 6 Removing the Y Rail Cover 36 4 2 7 Removing the Front Paper Guide 37 4 2 8 Removing the Rear Paper Guide 37 4 2 9 Removing the Right Side Cap 37 4 2 10 Removing the Left Side Cap 38 4 2 11 Opening and closing the Control Box 38 4 2 12 Rem...

Page 8: ...ng the Wiper 76 4 6 4 Replacing the Pump Assembly 77 4 6 5 Replacing the Maintenance Station Assembly 79 4 7 Replacement of Ink Supply Section Components 80 4 7 1 Replacing the Cartridge Frame Assembly 80 4 7 2 Replacing the Ink ID assembly Black Yellow Magenta Cyan 84 4 7 3 Replacing the Detector Assembly Black Yellow Magenta and Cyan 85 4 7 4 Replacing the Y Cable 85 4 7 5 Replacing the Ink Tube...

Page 9: ...tances 133 5 4 12 How to Adjust the Rear Sensor Position 134 5 4 13 How to make a Test Print 135 5 4 14 Head Cleaning 136 5 5 Cleaning 137 5 5 1 Normal 137 5 5 2 Powerful 137 5 6 Test Printing 138 5 6 1 Head Printing Verification 138 5 6 2 Adjustment Parameters 138 5 7 Parameters 139 5 7 1 How to Initialize Parameters 139 5 7 2 How to Update Parameters 140 5 7 3 How to Update the Capping Position ...

Page 10: ...oor 175 8 1 2 How to move to a different building by vehicle 176 8 2 Daily maintenance 177 8 2 1 How to clean the printer unit 177 8 2 2 Replacing the ink Cassettes 179 8 2 3 Replacing the cutting blade 180 8 2 4 Emptying the waste bottle 182 8 2 5 Replacing the blades 183 8 3 Periodical Services 184 8 3 1 Service by end user 184 8 3 2 Service by authorised Mutoh technician 184 9 Troubleshooting 1...

Page 11: ...rately or lightly or damage to your equipment Notes Contains important information and useful tips on the operation of your printer 1 3 IMPORTANT SAFETY INSTRUCTIONS General safety instructions that must be observed to use the equipment safely are explained below Do not place the printer in the following areas Doing so may result in the printer tipping or falling over and causing injury o Unstable...

Page 12: ...o Wipe away dust and any other residue before inserting the plug o Ensure that the plug is firmly inserted as far as it will go When handling ink cassettes be careful that ink does not get in your eyes or on your skin However if this happens flush immediately with water Otherwise your eyes may become congested or inflamed slightly If you feel discomfort consult a doctor immediately Do not disassem...

Page 13: ...printer Lifting the printer with the vinyl cover on may cause your hands to slip and drop or damage the printer Have two or more people transport the printer Ensure that the plug has been disconnected from the power socket when it is not to be used for a long time Earth wires must be connected to wires or terminals that fulfil the conditions below o Earth terminals of power sockets o Earth wires w...

Page 14: ...tached to the internal and external area of the printer to alert you to potentially hazardous situations or conditions The following safety labels are used in and on the printer La partie externe et interne de l imprimante porte des symboles de sécurité destinés à attirer votre attention sur des sources potentielles de danger ou des conditions pouvant être dangereuses Les symboles de sécurité suiv...

Page 15: ...Rockhopper 38 Maintenance Manual 15 AP 74038 Rev 1 1 25 01 05 1 2 3 4 ...

Page 16: ...Rockhopper 38 Maintenance Manual 16 AP 74038 Rev 1 1 25 01 05 5 6 7 8 9 ...

Page 17: ...Rockhopper 38 Maintenance Manual 17 AP 74038 Rev 1 1 25 01 05 2 PRODUCT OVERVIEW 2 1 GETTING TO KNOW THE PRINTER PARTS AND COMPONENTS ...

Page 18: ...printhead and dryer 9 heater element 10 Slip Ring Prevent that Scroller to slip 11 Eco Solvent Plus ink cassette slots Hold detect the Eco Solvent Plus ink cassettes that are in use 12 Scroller Feeds through the roll media core to hold the media 13 Scroller receiver Set of 4 wheels which keep the scroller into place 14 Paper Basket Media collecting basket prevents finished prints to fall on the fl...

Page 19: ...ED The ERROR LED is ON after an ERROR has occurred to indicate a possible hazardous situation The LED will go out if the error is corrected or after pressing the CANCEL key 3 Cancel Key The CANCEL key is a special key controlling both the CANCEL FUNCTION as well as the ROLL MEDIA sheet off function Printer Condition Result by pressing CANCEL Idle Status Roll media is cut at the current position Re...

Page 20: ... only be changed in idle status When pressed together with SHIFT key 9 outputs the Test Print Go to the Next menu option or increase a parameter value when in menu mode operation The LED indication is also influenced by data coming from the RIP driver software 6 Resolution Pressing RESOLUTION will change the output resolution between 360 DPI 720 DPI or 1440 DPI The set up can only be changed in id...

Page 21: ...closed in the yellow area 9 Shift button Shift button to activate Head Adjustment manual roll feed forward or reverse Nozzle check print Test print or Set Up List Back out of menu levels or switch back to ONLINE level from top level Menu mode operation 10 Menu The Menu Mode Operation is used to change printer settings and parameters Press the MENU key to switch from ONLINE status to menu mode oper...

Page 22: ...n adjustment parameter plot Note When the data light is ON receiving or blinking processing all the keys are disabled except the head cleaning key The keys will be operational in case of receiving data while you are in the setup menu The setting changes however will then only be valid for the next printing job Panel set up from the printer is only possible when no printing data or processing data ...

Page 23: ...hold lever is down 1 Menu Press the Menu Key to switch from ONLINE status to menu mode operation 2 Menu Down Press the Menu Key to go to the NEXT menu 3 Menu Up Press the Cleaning Key to go to the Previous menu 4 Back Press the Shift Key to back out of menu levels or to switch back to online when in top menu level 5 Value Press the Quality Speed Key to select the next menu option or to increase a ...

Page 24: ...ge size Command or by plot data Cut Position Data Standard Specify cutting position on roll media following data or standard media size MediaCut Auto Off Manual Automatic sheet off set up Copy 1 to 99 Set up number of copies InkDensity Normal Micro Select Normal or Micro dot drop size in function of media ink type Dist Adj No Clear Change Confirm Plot distance adjustment Function StepAdj Change Cl...

Page 25: ... direct heater fixer Real RT and set ST temperature are displayed on the LCD screen The maximum temperature is 70 C By pushing the buttons you can select an appropriate temperature Controls Post Heater Dryer Set temperature for the post heater dryer Real RT and set ST temperature are displayed on the LCD screen The maximum temperature is 50 C By pushing the buttons you can select an appropriate te...

Page 26: ...Rockhopper 38 Maintenance Manual 26 AP 74038 Rev 1 1 25 01 05 ...

Page 27: ...s x 20 characters Heater Backlight LED 4 lines x 16 characters Take up System Automated optional Roll Media Core 3 2 optional Interface Centronics IEEE 1284 compatible Network High Speed Interface standard high speed interface card 4 Mb s optional Graphics Command Language RTL PASS MH GL MH GL 2 Power Consumption 930 VA External Dimensions in mm W x D x H Weight 1520 x 580 x 1264 57 kg Noise Level...

Page 28: ...SG 2 DATA1 To and from printer 20 SG 3 DATA2 To and from printer 21 SG 4 DATA3 To and from printer 22 SG 5 DATA4 To and from printer 23 SG 6 DATA5 To and from printer 24 SG 7 DATA6 To and from printer 25 SG 8 DATA7 To and from printer 26 SG 9 DATA8 To and from printer 27 SG 10 ACK From printer 28 SG 11 BUSY From printer 29 SG 12 P ERROR From printer 30 SG 13 SELECTED From printer 31 INIT To printe...

Page 29: ...pecifications Item Specifications Network Type Ethernet IEEE802 3 Network I F 10 Base T 100 Base TX RJ 45 connector twisted pair cable Automatic switching Protocol TCP IP Mode ftp lpr socket Functions Automatic protocol recognition Transmission speed up to 4 MB s Network environment setting by Web ...

Page 30: ...n the table below Area 3 m larger Floor loading capability 2490Pa 300kg m or over Voltage AC100V 120V or AC220V 240V Frequency 50 60Hz 1Hz Electrical Capacity AC100V 120V 3A or more AC220V 240V 1 5A or more Recommended working environment Temperature 22 C to 30 C Humidity 40 to 60 without condensation Operational conditions Temperature 10 C to 35 C Humidity 20 to 60 without condensation Rate of ch...

Page 31: ...P 74038 Rev 1 1 25 01 05 2 Installation space Install on a horizontal place that satisfies following conditions The floor has the sufficient strength to sustain the weight of the printer and the stand Notes Refer to product specifications ...

Page 32: ...Rockhopper 38 Maintenance Manual 32 AP 74038 Rev 1 1 25 01 05 ...

Page 33: ...y be damaged Disconnect all cables from the machine Not doing so could cause damage to the printer Caution Assembling and disassembling the printer are possible only for the parts for which disassembling procedures are shown in the operation manual Do not disassemble any frame parts or parts for which disassembling procedures are not shown in the manual Doing so may cause trouble that cannot be re...

Page 34: ...ide the printer it is necessary to remove all covers The procedures for removing the covers are given below Nr Description 1 Right Cover 2 Left Cover 3 Front Cover 4 Unit Panel Cover 5 Y Rail Cover 6 Front Paper Guide 7 Rear Paper Guide 8 Right Side Cap 9 Left Side Cap 10 Control Box 11 Head Cover 12 Heater Panel Cover ...

Page 35: ...right Cover 4 2 3 Removing the Front Cover Step 1 Remove the Right cover Step 2 Loosen the two fastening screws on the right side of the Front Cover Step 3 Loosen the Unit Panel Cover Screw and remove the Panel Cover by sliding it about 3 mm to the left Step 4 Slide the right side Front Cover Shaft to the right Step 5 Remove the Front Cover by sliding it to the right Step 6 Reinstall all parts in ...

Page 36: ...Step 6 Reinstall all parts in the opposite order of the removal procedure Step 1 Loosen the two screws on the Front Cover Right Cover Shaft and push the Front Cover to the left Step 2 Loosen the Unit Panel Cover Screw by 3 mm or remove it Step 3 Slide the Unit Panel Cover to the left in the direction of arrow A and remove it towards you in the direction of arrow B Step 4 Reinstall all parts in the...

Page 37: ...the Front Cover Step 3 Remove the Y Rail Cover Refer to Removing the Y Rail Cover Step 4 Remove the eight screws of the Rear Paper Guide Step 5 Lift the Rear Paper Guide from the back of the unit as you pull it out towards you Step 6 Reinstall all parts in the opposite order of the removal procedure Rear Paper Guide 4 2 9 Removing the Right Side Cap Step 1 Remove the Front Paper Guide Refer to Rem...

Page 38: ... parts in the opposite order of the removal procedure 4 2 11 Opening and closing the Control Box Since the Control Box will hit the roll media when it is opened and can not be opened completely the scroller must be removed Follow the steps below to open the control box Step 1 Remove the three screws holding the Control Box Notes Since the Control Box will fall open when the three fastening screws ...

Page 39: ...over Step 1 Open the Front Cover Step 2 Slide the Head out from the Maintenance Station Caution When pull the Head don t press the cutter cap or the cutter blade will be damaged Step 3 Remove the Head Cover 2 screws Step 4 Reinstall all parts in the opposite order of the removal procedure ...

Page 40: ... before this operation 4 3 1 1 Replacing the Switch Cable Assembly Step 1 Open the Control Box Refer to Opening and Closing Control Box No Description 1 Switch cable assembly Step 2 Disconnect connector J101 from the Main Board Assembly Step 3 Remove the power supply cover 2 screws Step 4 Press the Switch Lock and remove it by pushing it out Step 5 To install the removed components reverse the rem...

Page 41: ...losing Control Box Step 2 Remove the power supply cover 2 screws Step 3 Disconnect connector J001 from the Power Board Step 4 Disconnect connector J101 MAIN from the Main Board and remove the cable Step 5 To install the removed components reverse the removal procedure No Description 1 Main board assy 2 Power board assy 3 Connector J101 4 Connector J001 ...

Page 42: ... backup parameters Be sure to take up backup parameters before the Main Board is replaced Refer to Replacing the Main Board If you are enable to do this operation ask to see the user setup list Caution If you are unable to do this operation ask to see the user setup list 2 Replacement procedure Step 1 Disconnect all communications connectors No Description 1 Slot for network card 2 Communication c...

Page 43: ...ll the latest driver Refer to Installing a program 5 Install the backup parameters that were taken up in 1 in the new Main Board 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 Parameter Update Replace the Was...

Page 44: ...rforming this operation Step 1 Remove the two inlet holding screws Step 2 Open the Control Box Refer to Opening and Closing Control Box Step 3 Remove the power supply cover 2 screws Step 4 Remove the earth wire from the rear X reinforcements Step 5 Disconnect the 100 V AC connectors J000 and J001 from the Power Supply Board Step 6 Remove the Power Supply board 5 fastening screws No Description 1 5...

Page 45: ...embly Step 1 Remove the Unit Panel Cover Refer to Removing the Panel Cover Step 2 Disconnect connectors J301 from the Panel Board Step 3 Remove the Panel Board Assembly 4 fastening screws Nr Part Description 1 4 screws 2 Connector J301 Step 4 To install the removed components reverse the removal procedure ...

Page 46: ...uide Step 3 Remove the Unit Panel Cover Refer to Removing Unit Panel Cover Step 4 Disconnect connector J301 from the Panel Board Nr Part Description 1 Connector J301 2 Panel Cable 3 Screw 4 Fastening screw Step 5 Remove the Tube Guide 1 fastening screw Step 6 Disconnect connector J110 PANEL from the Main Board and remove the cable Nr Part Description 1 Connector J110 Step 7 To install the removed ...

Page 47: ...er Refer to Removing the Unit Panel Cover Step 3 Remove the Heater Panel Cover Refer to Removing the Heater Panel Cover Step 4 Disconnect the flat cable connected to the mainboard Step 5 Remove the four screws of the Heater Panel Assembly Step 6 Remove the Heater Panel Board after removing the two screws holding the flat cable Step 7 To install removed components please reverse removal procedure ...

Page 48: ...e Front Paper Guide Refer to Removing Front Paper Guide Step 3 Remove the Unit Panel Cover Refer to Removing Unit Panel Cover Step 4 Disconnect connector J301 from the Heater Panel Unit Board Step 5 Disconnect connector J10 PANEL from the Heater Board and remove the cable Nr Description 1 Flat Cable 2 Connecter J10 Step 6 To install the removed components reverse the removal procedure ...

Page 49: ... Disconnect all communication connectors Step 2 Open the Control Box Refer to Opening and Closing Control Box Step 3 Remove the Mother Board Assembly 7 fastening screws Nr Description 1 Main board assembly 2 Mother board assembly 3 Fastening screws To install the removed components reverse the removal procedure ...

Page 50: ...eft and right push the SIMM over towards the rear and remove it from the slot Step 3 To install removed components reverse removal procedure Adjustments Use self diagnostic Examination to confirm memory capacity Please refer to Memory Capacity Standard memory capacity is 8 Mb When to 32 MB extended memory boards are added to Slot 1 and Slot 2 memory capacity will be shows as 72 MB 8 32 32 MB on th...

Page 51: ...ing the Rear Paper Guide Step 5 Disconnect connectors J119 and J121 from the Main Board Step 6 Remove the cable clamp on the Rear Frame X Reinforcements Step 7 Remove the two cable clamps on the Front Frame X Reinforcements and pull out the cable from the holes in the Front X Reinforcements Step 8 Remove the X Motor Assembly 4 fastening screws Step 9 Remove the two screws that hold the X motor to ...

Page 52: ...the Fan 1 fastening screw Step 5 Reinstall all parts in the opposite order of the removal procedure 4 4 2 1 Replacing the Fan Cables 1 2 and 3 Step 1 Remove the Front Paper Guide Step 2 Remove the Rear Paper Guide Refer to Removing Rear Paper Guide Step 3 Remove each Fan Cable Connectors Step 4 Remove each Cable Clamp Step 5 Open the Control Box Removing Control Box Step 6 Remove the two cable cla...

Page 53: ...intenance Manual 53 AP 74038 Rev 1 1 25 01 05 Step 8 Disconnect connectors J115 J116 and J117 from the Main Board Assembly and remove the cables Step 9 Reinstall all parts in the opposite order of the removal procedure ...

Page 54: ...astening screws from the X Motor Mounting Plate and take off the X Speed Reduction Belt Step 3 Loosen the one bearing stopper hexagon set screw and remove the four screws that hold the Speed Reduction Pulley Support Step 4 Remove the X Speed Reduction Belt from the X Speed Reduction Pulley Step 5 Reinstall all parts in the opposite order of the removal procedure To adjust X Motor tension please re...

Page 55: ...ver Refer to Removing Right Cover Step 4 Open the Control Box Refer to Opening and Closing Control Box Step 5 Disconnect connectors J104 lever from the Main Board Step 6 Remove the Panel Cable Connector and Tube Guide 1 fastening screw and disconnect connector J301 Nr Description 1 Connector J301 3 Tube guide Step 7 Remove the Panel Mounting Plate 2 fastening screws Step 8 Open the two cable clamp...

Page 56: ... 05 Step 9 Remove the Lever Sensor Mounting Plate 1 fastening screw Step 10 Remove the Lever Sensor 2 fastening screws Step 11 Reinstall all parts in the opposite order of the removal procedure Adjustments Open the Lever and confirm that Lever Up is displayed ...

Page 57: ...embly Step 1 Remove the Right Cover Refer to Removing Right Cover Step 2 Disconnect connector J106 from the Main Board Step 3 Remove the Sensor Mounting Plate 1 fastening screw Step 4 Remove the Cover Switch 2 fastening screws Step 5 Reinstall all parts in the opposite order of the removal procedure ...

Page 58: ...Sensor Assembly Step 1 Remove the waste fluid bottle Step 2 Disconnect connector Step 3 Remove the Waste Fluid Bottle Sensor Assembly 2 fastening screws Step 4 Assembling is the reverse of the removal procedure Caution Be careful not to over tighten when mounting the Waste Fluid Bottle Sensor Assembly ...

Page 59: ...o the Cable Clamp attached to the front X Reinforcement Step 4 Remove the connector J103 XF from the Main Board Step 5 Remove the Front Paper Sensor 2 fastening screws Step 6 To install the removed components reverse the removal procedure Adjustments Carry out Front Head and Cutter Head distance adjustment This adjusts the distance from the leading edge of the media to the printing position Please...

Page 60: ...l Cover Refer to Removing Y Rail Cover Step 6 Remove the Rear Paper Guide Refer to Removing Rear Paper Guide Step 7 Remove the Media Keeper while pressing the tabs to the inside Caution If you press to hard an on the tabs they will break Step 8 Remove the flexible cable keeper four fastening screws Step 9 Through the Steel Flexible Guide hole remove the two fastenings screws holding the sensor mou...

Page 61: ...and right and fasten flexible cable fitting C so that there is no twisting Carry out Front Head and Cutter Head distance adjustment This adjust the distance from the leading edge of the media to the printing position Please refer to How to adjust Front to Head Cutter to Head Distances Carry out the Linear Sensor Position adjustment Please refer to How to Adjust the Rear Sensor Position ...

Page 62: ...towards the back and remove it Step 4 Use an Allen Key to loosen the set screws on the coupling Nr Description 1 Grid roller 2 Coupling 3 Screw 4 Bearing Step 5 Lift the grid roller and remove it Step 6 To install the removed components reverse the removal procedure Caution Never loosen the platen fastening screw If it is loosened it will be necessary to adjust the platen position with the height ...

Page 63: ...e Y rail cover Refer to Removing Y Rail Cover Step 5 Remove Front paper guide Refer to Removing Front Paper Guide Step 6 Remove Rear paper guide Refer to Removing Rear Paper Guide Step 7 Loosen the two steel belt tensioning screws Step 8 Remove one steel belt fastening screw Step 9 Remove the steel belt Caution Be careful not to cut your finger on the end of the steel belt Step 10 Remove the Y mot...

Page 64: ...s on the pressured transfer plate Step 13 Raise the pressure lever as you remove the pressure transfer plate and pressure link Step 14 Pull out the pressure shaft from the right side of the frame Caution When the pressure shaft is pulled completely out the pressure shaft fastening spacer will fall into the printer main unit ...

Page 65: ...plate and take out the pressure assemblies Caution You will need a special tool such as a ratchet for the fastening screw on the bottom of the Y rail reinforcement plate a 4 x 10 mm hexagonal double SEMS Step 17 Remove the pressure assemblies 15 from the Y rail reinforcement plate 2 screws for each assembly Step 18 To install the removed components reverse the removal procedure ...

Page 66: ... the blade Step 3 Reinstall all parts in opposite order of the removal procedure 4 4 12 Replacing the Pressure Rollers Step 1 Follow the blade replacement procedure to remove the blade Step 2 Use a fine straight screwdriver to slightly prize apart the pressure roller attachment and remove the pressure roller Nr Description 1 Pressure arm 2 Pressure roller 3 Screwdriver Caution When removing the bl...

Page 67: ...il Fitting Precision Mount the rail height jig on the standard base and set the dial gauge to 0 Mount the rail height gauge over the ribs at both ends of the platen loosen the platen retaining screws and adjust the platen up and down until the dial gauge reads 2 6 to 2 7 mm STANDARD VALUE 2 6 to 2 7 by dial gauge Nr Description 1 Adjusting screws 2 Platen ...

Page 68: ... Paper Guide Step 3 Remove the Steel Belt Refer to Replacing Steel Belt Step 4 Open the Control Box Refer to Opening and Closing Control Box Step 5 Disconnect connector J120 YMOT from the Main Board Assembly Step 6 Remove the Y Motor Assembly 3 fastening screws Step 7 To install the removed components reverse the removal procedure Tip Since the Y Motor Assembly Cable passes below the Cartridge Uni...

Page 69: ...Refer to Removing Left and Right Covers Step 5 Remove the Head Cover 2 fastening screws Step 6 Loosen the 2 Steel Belt Tensioning Screws Nr Description 1 Tension adjustment screws Step 7 Remove the Steel Belt 2 fastening screws Nr Description 1 Fastening screws 2 Steel belt Step 8 Take off the steel belt from the Y Motor or Y Drive Pulley side Step 9 To install the removed components reverse the r...

Page 70: ...he 10 screws holding the T Fence Pressure and remove the T fence Caution Mind the Head Board and take out the T Fence on the X Motor side Step 5 To install removed components reverse the removal procedure Adjustments 1 Gently wipe the T Fence with a lint free cloth which has been wet with water or ethanol Lint free cloth is closely woven from extremely fine threads and has no nap and produces no d...

Page 71: ... to Removing Front Cover Step 3 Remove the Y Rail Cover Refer to Removing Y Rail Cover Step 4 Remove the Flexible Guide Fixer C 2 fastening screws Step 5 Remove the Tube guide Assembly Remove the Steel Flexible Guide which is clipped to the ink tubes Step 6 Remove the Steel Flexible Guide Assy 2 fastening screws including the flexible cable fitting H Step 7 To install removed components reverse th...

Page 72: ...over Step 2 Remove the Front Cover Refer to Removing Front Cover Step 3 Remove the Y Rail Cover Refer to Removing Y Rail Cover Step 4 Bring the head to the centre of the printer press down the left and right ends of the cursor plate spring and pull it out to the right Nr Description 1 Cursor plate spring Step 5 To install removed components reverse removal procedure ...

Page 73: ...Left and Right Covers Refer to Removing Left and Right Covers Step 5 Move the head to the left X Motor Side Step 6 Loosen the Steel Belt tension loosen two tensioning screws Nr Description 1 Tension adjustment screws Step 7 Remove the Steel Belt fastening screws on the left side and slide it out to the Return Pulley Step 8 Remove the Y Return Pulley Step 9 To install removed components reverse rem...

Page 74: ...4 Remove the Right cover Refer to Removing Right Cover Step 5 Remove the Panel Cable Connector and Tube Fixer 1 fastening screw and disconnect connectors J301 Step 6 Remove the Panel Mounting Plate 2 fastening screws Step 7 Open the Control Box Step 8 Disconnect connector J102 pump from the Main Board Step 9 Remove the cable clamp fastened tot the front X reinforcement Step 10 Slide the Head to th...

Page 75: ... Pump Motor Assembly 1 6 Step 6 Remove the Cap Assembly Spring Step 7 Disconnect the two tubes from the Cap Assembly Step 8 Grasp the plug on the right side of the Cap Assembly lift it up and remove the right side of the Cap Step 9 Grasp the centre section of the Cap Assembly lift it up and take out the Cap Caution Be careful not to touch the surfaces of the Cap or the Cleaner ASP Step 10 To insta...

Page 76: ... Plate Refer to Replacing Pump Motor Assembly 1 6 Step 2 Move the Wiper back and with the wiper rack disconnected pull the Wiper up and remove it Step 3 To install the removed components reverse the removal procedure Caution When refitting the Wiper be careful not to damage the Head contact surface by touching it with your hand or with forceps Adjustments Initialize the wiper count Refer to How to...

Page 77: ... Guide Step 5 Remove the Panel Mounting Plate Refer to Replacing Pump Motor Assembly 1 6 Step 6 Take out the Maintenance Station Assembly Refer to Replacing Cap Assembly Step 7 Disconnect and remove the tubes between the Pump Assembly and the Cap Assembly Step 8 Remove the Cap Assembly Step 9 Pick out the Transfer Gear Shaft with your finger Caution Be careful not to break the claw on the Transfer...

Page 78: ...ition Adjustment Please refer to How to Adjust the Capping Station 2 Initialize the wiper count Please refer to How To Initialize Parameters Caution When inserting tubes on the Cap Assembly turn the tubes clockwise trough 45 to 90 degrees If not you may be unable to lower the Cap Assembly to the bottom ...

Page 79: ...er Guide Refer to Removing Front Paper Guide Step 5 Remove the Panel Mounting Plate Refer to Replacing Pump Motor Assembly 1 6 Step 6 Take out the Maintenance Station Assembly 3 fastening screws Caution Be careful not to disconnect the Waste Fluid Tube which is connected to the bottom Step 7 To install removed components reverse the removal procedure Adjustments 1 Carry out the Capping Position Ad...

Page 80: ...Paper Guide Step 4 Disconnect junction board connectors J402 Detector BK J403 Detector C J404 Detector M J405 Detector Y and J406 Ink ID BK J407 Ink ID C J408 Ink ID M J409 Ink ID Y J410 head height switch Step 5 Remove the Unit Panel Cover Refer to Removing Unit Panel Cover Step 6 Remove the Front Cover Refer to Removing Front Cover Step 7 Remove the Y Rail Cover Refer to Removing Y Rail Cover St...

Page 81: ...way in the direction of Arrow A then hold it there while you remove it from the cartridge base by lifting it out in the direction of Arrow B Step 12 Remove the cartridge mounting plate from the cartridge base 2 fastening screws on the side Step 13 Remove the cartridge mounting plate Grasp the part that is caught in the groove Step 14 Cut the cable tie holding the ink ID sensor cable and detector a...

Page 82: ...rame assembly Step 16 Remove the cartridge unit by pulling it forward Step 17 Remove the cartridge frame assembly for each ink Two fastening screws x four colours Caution Be careful that the ink needles on the Cartridge Frame Assembly do not prick your finger Step 18 Slide the Cartridge Frame Assembly in the direction shown by Arrow A ...

Page 83: ...tic taps Adjustments 1 Carry out the initial filling Please refer to How to enter Head Rank CAUTION Wait at lease 30 minutes after the initial filling before printing Otherwise the printing quality can not be assured 2 Carry out a test print Please refer to Test procedures test 8 3 Fit a new Waste Fluid Box Please refer to How to enter Head Rank CAUTION About 100 cc of waste fluid will be expelled...

Page 84: ...rt Refer to Replacing Cartridge Frame Assembly Step 9 Remove the Cartridge Mounting Plate from X Reinforcement R Refer to Removing Step 10 Slide the Cartridge Unit a little way forward and lift it up Refer to Replacing Cartridge Frame Assembly Step 11 Remove Ink ID Sensor 1 Assembly BK one fastening screw Ink ID Sensor Assemblies 2 to 4 are handled as follows Step 12 Remove the Cartridge Mounting ...

Page 85: ...nk ID C J408 Ink ID M J409 Ink ID Y Refer to Replacing Ink ID Assembly BYMC Step 4 Remove the Ink Detector Switch on the Detector Assembly One fastening screw Step 5 Remove the switch that determines whether the Cartridge Frame Assembly is present One fastening screw Step 6 To install removed components reverse removal procedure Caution Be careful not to over tighten when refitting the Waste Fluid...

Page 86: ...n the Control Box Refer to Opening and Closing Control Box Step 5 Remove the Rear Paper Guide Refer to Removing Rear Paper Guide Step 6 Disconnect connectors J111 HEAD1 and J112 HEAD2 from the Main Board Step 7 Remove the Head Board Cable keeper 2 fastening screws Step 8 Disconnect connectors J201 MAIN1 and J202 MAIN2 rom the Head Board Step 9 Remove Flexible Guide Fixer C 2 fastening screws Step ...

Page 87: ...d components reverse the removal procedure Caution The new Y cable has no fold crease Make a fold crease in the new cable to match the old cable Head Board assembly connectors J201 MAIN1 and J202 MAIN2 should be plugged in securely The Main Board may be damaged if power is applied when they are not properly connected ...

Page 88: ...to Removing Y Rail Cover Step 5 Remove Flexible Guide Fixer H 2 fastening screws Step 6 Remove Flexible Guide Fixer C 2 fastening screws Step 7 Remove ht four jointing screws and O rings on the Flexible Cable Guide Step 8 Remove the four jointing screws and O rings below the cursor Caution Be careful not to lose the O rings Initial filling and printing can not be done if the O rings are missing Do...

Page 89: ...nk 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 Please refer to Replacing Waste Fluid Box The message Change Tank will appear on the panel display You should confirm by answering YES 4 7 6 Replacing the O rings Small and Large Caution 16 O rings small and large are used Be careful not to mistake them ...

Page 90: ...or replacement of Cartridge Frame Unit O Rings refer to Caution Be careful not to lose the O rings Initial filling and printing can not be done if the O rings are missing Caution Don t use a tool to tighten the coupling screws but get them as tight as possible with your fingers If you use a tool there is a risk of breaking the plastic taps ...

Page 91: ...nt Cover Refer to Removing Front Cover Step 3 Remove the Y Rail Cover Refer to Removing Y Rail Cover Step 4 Remove the Flexible Guide Fixer H 2 fastening screws Step 5 Remove the Flexible Guide Fixer C 2 fastening screws Step 6 Remove the Tube Guide Assembly Since it is clipped to the Ink Tubes and Steel Flexible Guide remove them Step 7 To install removed components reverse removal procedure ...

Page 92: ...Head Board Step 5 Remove the Head Cover Refer to Removing Head Cover Step 6 Move the Head 20 to 30 cm to the left Step 7 From the back remove the two fastening screws holding the solenoid Step 8 Remove the cutter cap remove the solenoid Step 9 To install removed components reverse the removal procedure Caution Be careful not to lose the O rings Initial filling and printing can not be done if the O...

Page 93: ...r Step 5 Disconnect connectors J207 Head BK and J208 HEAD COL from the Head Board Nr Description 1 Connectors J207 and J208 2 Head Board 3 Tube fixer 4 Head cable Step 6 Remove the Tube Fixer Step 7 Remove the coupling screw and shift the ink tube up out of the way Step 8 Remove the damper fixer 2 fastening screws Step 9 Remove the black damper Caution When removing the black damper be careful not...

Page 94: ...number on the side of the head are the rank and write the number with a marker pen on the black head cable Delete the old head rank by drawing two lines trough the number When fitting the head into the head mount put the black head cable on top Adjustments 1 Reset the head nozzle ejector count Please refer to How to Initialize Parameters 2 Carry out initial filling Please refer to How to enter Hea...

Page 95: ...ow to enter Head Rank 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 Please refer to Replacing Waste Fluid Box The message Change Tank will appear on the panel display You should confirm by answering YES CAUTION Head board assembly connectors J201 MAIN1 and J202 MAIN2 should be plugged in securely The m...

Page 96: ...Cover Step 5 Disconnect connectors J207 Head BK and J208 HEAD COL from the Head Board Step 6 Remove the Tube Fixer Step 7 Remove the coupling screw and shift the ink tube up out of the way Step 8 Remove the damper fixer 2 fastening screws Step 9 Remove the colour damper 3 pieces Caution When removing the black damper be careful not to grip the transparent film surface of the damper Rough handling ...

Page 97: ...ling Please refer to How to enter Head Rank CAUTION Wait at lease 30 minutes after the initial filling before printing Otherwise the printing quality can not be assured 3 Carry out the Print Head Colour Tilt Adjustment Please refer to Adjusting the Tilt of the Print Head Colour 4 Carry out a test print Please refer to Test Procedures Test 2 5 Fit a new Waste Fluid Box Pleas refer to How to enter H...

Page 98: ...emoving Unit Panel Cover Step 3 Remove the Y Rail Cover Refer to Removing Y Rail Cover Step 4 Disconnect connector J204 PEDGE from the Head Board Step 5 Remove the Head Cable keeper Step 6 Remove the Paper Sensor Step 7 To install removed components reverse removal procedure Caution Be careful not to over tighten when refitting the Waste Fluid Box Detector Switch Assembly Tightening torque is 29 4...

Page 99: ... Panel Cover Step 3 Remove the Y Rail Cover Refer to Removing Y Rail Cover Step 4 Disconnect all connectors from the Head Board Step 5 Remove the Head Board 4 fastening screws Step 6 To install removed components reverse removal procedure Caution Head board assembly connectors J201 MAIN1 and J202 MAIN2 should be plugged in securely The main board may be damaged if power is applied when they are no...

Page 100: ...ing Y Rail Cover Step 5 Disconnect connectors J207 Head BK and J208 HEAD COL from the Head Board Step 6 Remove the Tube Fixer Step 7 Remove the coupling screw and shift the ink tube up out of the way Step 8 Remove the damper fixer 2 fastening screws Step 9 Remove the black damper and colour dampers Caution When removing the black damper be careful not to grip the transparent film surface of the da...

Page 101: ...ting quality can not be assured 2 Carry out a test print Please refer to Test procedures test 2 3 Fit a new Waste Fluid Box Please refer to How to enter Head Rank 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 Please refer to Replacing Waste Fluid Box The message Change Tank will appear on the panel dis...

Page 102: ...e Head Board Assembly Step 7 Remove the Y cable Refer to Replacing Y Cable Step 8 Remove the ink tubes Refer to Replacing Ink Tubes Step 9 Remove the Head Cover Refer to Removing Head Cover Step 10 Remove the two Steel Belt fastening screws from the Cursor Unit Refer to Replacing Steel Belt Step 11 Remove the setscrew and remove each damper tube Refer to Replacing damper Step 12 Remove the Cursor ...

Page 103: ...r to Removing Front Cover Step 2 Remove the Unit Panel Cover Refer to Removing Unit Panel Cover Step 3 Remove the Y Rail Cover Refer to Removing Y Rail Cover Step 4 Disconnect connector J205 HORIGIN from the Head Board Assembly Step 5 Remove the Origin Sensor 2 fastening screws Step 6 To install removed components reverse removal procedure ...

Page 104: ...roller and slide the Scroller to the right to remove it Caution Loosen the scroller adjustment screws completely 4 2 58 2 Mount the scroller in the printer Step 1 Fit the Scroller with media loaded to the Scroller Support Hold the fixed flange end with your left hand and insert the left side into the Scroller Support from the inside then insert the right end from the top Caution Loosen the scrolle...

Page 105: ...o the left Step 2 Lift the Cutter Cap and slide it towards you Step 3 Lift out the Cutter Blade Step 4 To install the removed components reverse removal procedure Caution When the cutter blade is to be removed the head must first be moved to a position over the cutter mat The tip of the cutter blade will be chipped and no longer able to cut if it touches paper guide F ...

Page 106: ...fer to Removing Y Rail Cover Step 4 Remove the Rear Cover Refer to Removing the Rear Cover Step 5 Disconnect connector J410 on the Junction Board Nr Description 1 Connector J410 Step 6 Loosen the two screws of the head height sensor Nr Description 1 Screws 2 Lip Step 7 To install removed components reverse removal procedure Caution When reinstalling the head height sensor be sure that the lip on t...

Page 107: ...er Step 3 Remove the Y Rail Cover Refer to Removing Y Rail Cover Step 4 Remove the Rear Paper Guide Refer to Removing Rear Paper Guide Step 5 Open the board box Refer to Opening and Closing Board Box Step 6 Disconnect junction cable connector J109 INK ID Step 7 Disconnect all junction board assembly connectors Step 8 Remove the junction board assembly 4 fastening screws Step 9 To install removed c...

Page 108: ...rd Optional Item Caution Before starting work be sure to disconnect the power supply cable connector Step 1 Disconnect all Ethernet communications cables Step 2 Remove the 2 screws holding the Ethernet board and pull out the board towards you Step 3 To install removed components reverse removal procedure ...

Page 109: ...AP 74038 Rev 1 1 25 01 05 4 10 REPLACEMENT OF HEATER SYSTEM 4 10 1 Replacing the fixer heater strip Step 1 Remove the power cable Step 2 Remove the heater cable cover Step 3 Disconnect the fixer power cable Step 4 Remove the two partitions ...

Page 110: ...r 38 Maintenance Manual 110 AP 74038 Rev 1 1 25 01 05 Step 5 Remove the 4 screws Step 6 Remove the heater strip Step 7 Degrease the platform Step 8 To install removed components please reverse removal procedure ...

Page 111: ... four screws of the front paper guide Step 3 Disconnect the dryer power cable grounding and sensor cable Nr Description 1 Dryer power cable 2 Sensor cable 3 Grounding Step 4 Remove the eight screws of the brackets Step 5 Remove the heater strip and degrease the platform afterwards Step 6 To install removed components please reverse removal procedure ...

Page 112: ...Rockhopper 38 Maintenance Manual 112 AP 74038 Rev 1 1 25 01 05 ...

Page 113: ...ormal printer mode Updated firmware adjustment parameters can be registered by exiting diagnostic mode or by switching off the power Firmware adjustment parameters are also registered when there is a serious MOE failure error on adjustment The printer will be reset on exiting diagnostic mode Diagnostic functions are as follows Table1 Hidden diagnostic functions Item Details Examination Verificatio...

Page 114: ... when the Diagnostics Menu is displayed 2 Connecting power cable Connect the power cable to the machine s inlet assembly and insert the plug into the outlet Notes Do not connect three or more power plugs to the outlet 5 2 2 Starting up To use the self diagnosis function you should first display the self diagnosis menu on the operation panel The self diagnosis menu is completely independent of the ...

Page 115: ...Fans Check on off Network Initializing None Error Initialization Error Initialization OK History Maintenance Major failure Head Waveform Check head drive waveform No function 5 3 1 Memory Capacity This procedure s used to check the capacity of the memory on board When this item is selected the memory capacity is displayed on the panel or terminal EXAM Memory Capacity Press ENTER to shift to Exam V...

Page 116: ...n panel or terminal the status of sensors for XF the X Front Sensor XR the X Rear Sensor cover lever origin no ink K M C Y cartridge K M C Y special cartridge media edge sensor level head thermistor value and whether or not the waste fluid tank is present No Cart means No Cartridge and applies to No Ink or No Cartridge Color is expressed by an alphabetical letter Cartridge indicates the Special Ca...

Page 117: ...o EXAM Encoder 5 3 6 Fans This procedure is used to verify that the fans are working by turning them on and off Panel keys are ignored during fan on off display 5 seconds after displaying Fan Off the display will shift to EXAM Fan 5 3 7 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 ...

Page 118: ...me 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 Maintenance History Panel and Terminal displays are shown below Quit from Maintenance History by entering the ENTER or Back key Press the ENTER key to shift to RECOR...

Page 119: ...serious failures CPU Errors are not included in thee serious failure history The history displays a maximum of seven events Panel displays are shown below 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 5 3 9 Head Waveform No function ...

Page 120: ...ack Head Tilt Verification To check head tilt by printing mechanical adjustment Colour Head Tilt Verification To check head tilt by printing mechanical adjustment Repeatability Printing Positioning To align reciprocal printing position by printing CW 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 ...

Page 121: ... displayed A media recognition error before and after feeding or detection by the rear sensor of no paper during feeding will cause a media error to be displayed and this procedure may be terminated by pressing any key To terminate the procedure when processing is not in progress press Back on the panel or ESC on the terminal Caution Make sure media is properly loaded The first time this adjustmen...

Page 122: ...in colour rank entry to return to Ink Fill Menu Press ENTER in the Ink Fill Menu to fill inks or Back to move to AJST ChkNozzles Caution The following operations must not be performed during ink filling Plotting will not work properly if ink filling is stopped or interrupted Switching off the power Opening the front cover Raising the pressure level Removing an ink cassette Caution The ink filling ...

Page 123: ... Note If there are cartridges but the ink has not been filled the printer will still start printing This and subsequent items that require printing for adjustment or checking include requests for media and inks If the CANCEL key is pressed during printing the printer will stop printing If ENTER is pressed while Nozzle check completed is displayed the AJST BlackTilt menu will be appear If Back is p...

Page 124: ...Rockhopper 38 Maintenance Manual 124 AP 74038 Rev 1 1 25 01 05 Lettering is not printed in the Head Nozzle Check Pattern ...

Page 125: ... to check whether the black head is tilted If it is tilted it needs to be adjusted mechanically Press ENTER while End Check Tilt is displayed to move to AJST Colour Tilt Black Head Tilt Check Pattern Check Items Black Head Tilt Print Method Single pass two scans in CW direction and two scans in CCW direction Black X 360 dpi Y 720 dpi ...

Page 126: ...s to check whether the black head is tilted If it is tilted it needs to be adjusted mechanically Press ENTER while END Check Tilt is displayed to move to AJST CW Colour Head Tilt Check Pattern Check Items Colour Head Tilt based on Black Head Print Method Single pass uni directional Black X 180 dpi Y 360 dpi Colour X 180 dpi Y 360 dpi ...

Page 127: ... Cmy err and the parameter has been changed the black and color 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 Bidirectional MD If ENTER is pressed at Cmy err and the pa...

Page 128: ... 74038 Rev 1 1 25 01 05 Repeatability printing position alignment pattern Adjustment items Black and colour reciprocal printing position alignment Printing method Single pass bidirectional Black X 180 dpi Y 360 dpi Colour X 180 dpi Y 360 dpi ...

Page 129: ...time is made by entering the value positional difference resulting from a unidirectional adjustment print Zone delay is not required for this adjustment print Press ENTER to update the setting If ENTER is pressed at HeadGap and either of the two parameters has been changed another adjustment print will be made If there has been no change the display will move to AJST CW MD Press ENTER to update th...

Page 130: ...1 1 25 01 05 CW Adjustment Pattern Adjustment Items Adjust position of left edge of plot on the capping position side Black and colour head axial alignment Printing method Single pass uni directional Black X 180 dpi Y 360 dpi Colour X 180 dpi Y 360 dpi ...

Page 131: ...ing into the flushing box and from the results the position for black or color flushing will be entered in 720 dpi units Enter a positive value to shift the flushing position towards the capping side or a negative value for the opposite direction Press ENTER to update settings If a change has been made flushing will be repeated If ENTER was pressed with no change has been made the display will mov...

Page 132: ...er a positive value to shift the flushing position towards the capping side or a negative value for the opposite direction Press ENTER to update the settings If settings have been changed another adjustment print will be made If there was no change the display will move to the AJST Top Bottom menu Media feed distance adjustment pattern Adjustment items Adjust the distance for media transport Print...

Page 133: ...argins Press ENTER to update settings Press ENTER at Bottom Distance to move to AJST TestPrint Enter the distance from the bottom of the media to the printing position Current bottom margin is 25 0 mm Real length mm The distance from the bottom of the media to the printing position is 25 0 mm Return to Adjustment Menu Press the Return key to update the setting Front Cutter to Head Distance Adjustm...

Page 134: ...ut it is no longer necessary once media feed distance compensation has been carried out When this item is selected whether media is loaded or not it will ask for cut sheet media If panel diagnosis decides that media is loaded this will be assumed to be cut sheet media and media initialization will begin Therefore roll media should not be loaded After the media has been initialized it will be eject...

Page 135: ...f no serial number has been entered at that time serial number input will be requested Online data signal reception is always enabled but any data should not be transmitted during the processing of a self diagnostic sequence Press Back after adjustment parameter printing has finished to move to AJST HeadWash At other times press Back to move to AJST TestPrint 1 The display is as shown below MUTOH ...

Page 136: ...prior to head replacement Note For color head cleaning you will be asked to confirm that all color cartridges have been removed and to install the cleaning jig Also if you suspect the cartridge sensor to be faulty you can carry out the following procedure by pressing the ENTER key After head cleaning has been completed the display will move to AJST Home ...

Page 137: ... for selecting cleaning by panel and terminal are shown below Press Back to return to the Diagnostics Menu 5 5 1 Normal Normal Cleaning wiping Select from Both black and colour Black only and colour only When cleaning is finished Cleaning Menu will appear 5 5 2 Powerful This procedure carries out strong cleaning wiping and rubbing There are three items Both Black and Color Black only and Color onl...

Page 138: ...Normal Cleaning wiping Powerful Powerful Cleaning wiping and rubbing Procedures from the selection of items from panel and terminal are shown below 5 6 1 Head Printing Verification This procedure is used to print the head nozzle verification pattern and adjustment parameters Panel After the adjustment pattern printing has been finished END ChkNozzles will appear 5 6 2 Adjustment Parameters This pr...

Page 139: ...meters Update Input adjustment parameter values Procedures for the selection of items from panel and terminal are shown below 5 7 1 How to Initialize Parameters This procedure is used to initialize adjustment parameters Items are Capping Position X Resolution Zone Delay Head Height Maintenance History Black Head Color Head Wiper Serial Number and Complete Initialization Press ENTER to display Para...

Page 140: ... when diagnostics are completed or power is switched off Press ENTER to input the adjustment parameter Press BACK to return to Param Update 5 7 3 How to Update the Capping Position Parameter This procedure will update the capping position parameter 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 ...

Page 141: ...er If Back was pressed a message that the parameter is not updated will appear and the display will move to UPDATE Head Rank 5 7 5 How to Update the Print Positioning Parameter This procedure will update the print positioning parameter If Back was pressed a message that the parameter is not updated will appear and the display will move to UPDATE PrintPosi ...

Page 142: ...ack was pressed a message that the parameter is not updated will appear and the display will move to UPDATE X Length 5 7 7 How to Update the Mechanical Parameters This procedure will update the mechanical parameters If Back was pressed a message that the parameter is not updated will appear and the display will move to UPDATE Mech Param B l a c k F l u s h P 1 3 4 C o l o r F l u s h P 1 3 4 ...

Page 143: ...er Media Cutting Maintenance Capping Head In fill printing Selection of items from the panel or a terminal is shown below Press BACK to return to the Diagnostic Menu 5 8 1 Carriage motor This procedure is used for aging the carriage motor Select uni directional print scanning mode or bidirectional print scanning mode and specify a number of times for repeatability scanning of the carriage If the s...

Page 144: ...ing the media feed motor Repeatability operation is carried out for a specified number of times 5 8 3 Cutter This procedure is used for aging the cutter Media is cut a specified number of times 5 8 4 Maintenance Unit This procedure is used for aging the cutter Capping is carried out a specified number of times ...

Page 145: ...5 Head This procedure is used for aging the cutter Select black or color and carry out in fill printing a specified number of times 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 finishing ...

Page 146: ...Rockhopper 38 Maintenance Manual 146 AP 74038 Rev 1 1 25 01 05 ...

Page 147: ...e maintenance mode and provides the list of available diagnosis items 6 2 1 Starting Up Maintenance Mode To use the maintenance mode you should first call up the maintenance menu on the operation panel The maintenance menu is completely independent of the normal operation mode and setup menu display mode To call up the maintenance menu follow the steps below Step 1 If the system is in the operatio...

Page 148: ...nsumption counter 6 Rest ink 7 Displays ink consumption counter 7 Rest ink 8 Displays ink consumption counter 8 Cutter service life Displays the cutter service life counter Number of prints Displays the counter for the total number of prints Waste ink Displays the service life counter for the waste liquid tank right Cleaner Displays the cleaning unit life counter CR motor Displays the CR motor ser...

Page 149: ...emain 7 00000000 Ink remain 8 00000000 4 11 Counter Display CutterLife 00000000 PrintNumber 00000000 5 11 Counter Display WasteInk 00000000 Cleaner 00000000 6 11 Counter Display CR Motor 00000000Mdot PF Motor 00000000Mdot 7 11 Counter Display Head 1A 00000000Mdot Head 1B 00000000Mdot 8 11 Counter Display Head 2A 00000000Mdot Head 2B 00000000Mdot 9 11 Counter Display Head 3A 00000000Mdot Head 3B 00...

Page 150: ...r service life counter Head unit 1 initialization Initializes the head 1 nozzle service life counter Head unit 2 initialization Initializes the head 2 nozzle service life counter Head unit 3 initialization Initializes the head 3 nozzle service life counter Head unit 4 initialization Initializes the head 4 nozzle service life counter Initialize PrintNumber Ink ID WasteInk Head error 1 4 Initialize ...

Page 151: ...nto the printer Step 1 Power on the unit in a special mode Press the POWER key to power ON the unit while simultaneously holding the F1 F3 and Menu key Step 2 The unit will start up in special mode Following message will appear on the display Counter Indication InitMenu F3 MACaddress Step 3 Press the F3 key to select the option MAC Address Following message will appear on the display MAC address I...

Page 152: ...Rockhopper 38 Maintenance Manual 152 AP 74038 Rev 1 1 25 01 05 ...

Page 153: ...2 1 Steel Belt Tension Adjustment Caution Steel belt are highly susceptible to breakage and end damage must e handled carefully Caution Be careful not to cut your hands when handling the steel belt Step 1 Set the steel belt in the middle of the return pulley and motor pulley Step 2 While moving the cursor left and right turn the return pulley adjustment screw until the steel belt does not tend to ...

Page 154: ...tre of the Y rail SPECIFICATION VALUES 150 g 20 g 1 47 N Step 4 Finally move the cursor left and right to check for belt skew 7 2 2 How to Adjust X Speed Reduction Belt Tension Caution When the Speed Reduction Belt has been replaced apply grease to the belt evenly Silicone Grease G501 Step 1 Hook a 5kgf Bar Tension Gauge to the X motor mounting plate tension the belt and fasten the mounting plate ...

Page 155: ...nscribed on the print head assembly see diagram on right The value to be input is a 5 digit number When the Print Head Black and the Head Cable Black are removed make the following adjustments in Diagnostic Mode Capping Position Adjustment Head Rank Input Head Nozzle Verification Black Head Tilt Verification Color Head Tilt Verification Repeatability Printing Positioning CW Adjustment Flush Pointe...

Page 156: ...d Adjuster B to bring the first and second lines and the third and fourth lines to approximately straight lines Step 11 Check the printing and move the carriage to the centre If the first line is offset to right relative to the second line slide Head Adjuster B down and fasten it If the first line is offset to left relative to the second line slide Head Adjuster B up and fasten it When fastening t...

Page 157: ... A and B represent a change of about 0 1 mm per graduation Step 16 Implement the Color Head Tilt Verification Repeat Steps 13 and 14 until the positioning matches that of the Black Head Step 17 After completing the Black Head and Color Head positioning adjustment return to the previous menu level Step 18 Implement Repeatability Printing Positioning Refer to Aligning Repeatability Printing Position...

Page 158: ... move in the opposite direction Register this value Repeat Steps 20 and 21 until the printing start position and the Black and Color positions are aligned Step 24 When the compensating numbers have been entered press BACK to return to the previous menu Step 25 Implement the Flush Pointer Adjustment Refer to Adjust the Flush Pointer Step 26 Implement the Front and Cutter to Head Distance Adjustment...

Page 159: ...f the head and the emission of inks Rank is inscribed on the print head assembly see diagram on right The value to be input is a 5 digit number When the Print Head Black and the Head Cable Black are removed make the following adjustments in Diagnostic Mode Capping Position Adjustment Head Rank Input Head Nozzle Verification Black Head Tilt Verification Color Head Tilt Verification Repeatability Pr...

Page 160: ...usted by Head Adjuster A Step 11 Check the printing and move the carriage to the centre If the cyan or yellow printing appears more forward than the black printing slide Head Adjuster A up and fasten it If the cyan or yellow printing is behind the black printing slide Head Adjuster A down and fasten it When fastening the Print Head push it towards the taper of the Head Adjuster A for depth and tow...

Page 161: ...s will compensate for any difference between the printing start position 5 mm from the edge of the media and the Color printing position relative to Black pitch between heads Step 18 Next check the printing and enter a positive value to move the Color towards the Cap with respect to the Black or a negative value to move in the opposite direction Register this value Repeat Steps 20 and 21 until the...

Page 162: ... C Completed appears in the printer s LCD display unit to indicate that the comparison of absorbed parameters has ended normally Step 6 Switch off and remove the flash memory 7 2 5 2 Install Step 1 Switch off power to the printer Step 2 Mount a backup only flash memory card in the slot at the back of the printer Step 3 Turn on the power All LEDs light up instantly and PLOTTER CARD appears in the p...

Page 163: ...ower to the printer Step 2 Mount the latest program flash memory card in the slot at the back of the printer Step 3 Switch on the power Step 4 The following message will appear in the liquid crystal display Erase Copy Compare End The buzzer will sound It will end after about 70 seconds Step 5 Switch off power to the printer Step 6 Remove the flash memory card Step 7 To Verify Switch on power to th...

Page 164: ...If Y Rail parallelism L2 has altered this will affect rectangular precision XF sensor and cutter head distance capping precision etc Y Rail height measurement can be measured with the covers fitted but the jig must be fitted in a place where there is no pressure unit Fit the Jig Assembly to the Y Rail and read the measurements with slight pressure For Y Rail parallel precision the position of the ...

Page 165: ...height is fixed by pressing on frame guide pins left and right in each of two places and parallelism is fixed by the inserting the Y Rail fitting control jig JD 42051 between the Y Rail and the Frame At this time it doesn t matter whether you use the capping side as the reference and the opposite side becomes the contact point where there are guide pins ...

Page 166: ...ead Cleaning Jig return the cleaning fluid from the 100 cc bottle to the 500 cc cleaning fluid bottle What to do After the Initial Filling Wait for at least 30 minutes after the initial filling before you use the printer for printing Otherwise picture quality can not be assured Head Cleaning is a self diagnostic function not available to the user The following two methods can be used Refer to BAC2...

Page 167: ...fied cartridge Alternatively the ink cartridges may be removed beforehand Step 5 Fit Cleaning Jig When this display appears mount the cleaning jig Step 6 Head Cleaning in Progress When this display appears cleaning fluid is being sucked from within the head and tubes Step 7 Remove Cleaning Jig When this display appears remove the cleaning jig Step 8 Head Cleaning in Progress When this display appe...

Page 168: ...s being output between pins 2 and 3 of connector J001 on the Power Board If not take the following steps to identify the cause Is the power outlet providing 100 to 120 V AC or 200 to 240 V AC Replace the Power Cable Replace the Power Board Assembly Step 3 Turn on the Power Switch and check that 100 to 120 V AC or 200 to 240 V AC is being output between pins 4 and 6 of connector J002 on the Power B...

Page 169: ... the power supply momentarily to take out the Extended Memory SIMM and check again If this is successful the Extended Memory SIMM is faulty Turn off the power supply momentarily to take out the Option Interface Board and check again If this is successful the Extended Memory SIMM is faulty Turn off the power supply momentarily to disconnect J109 INK ID from the Main Board and check again If this is...

Page 170: ...e Main Board and check again If this is successful either the Head Board or the Print Head Assembly or the Y Cable Assembly or the Head Cable Assembly or the Origin Sensor Assembly or the Paper Sensor Assembly is faulty Turn off the power supply momentarily to disconnect J120 from the Main Board and check again If this is successful the Y Motor Assembly is faulty Turn off the power supply momentar...

Page 171: ...e following steps to identify the cause Turn off the power supply momentarily to disconnect J102 PUMP from the Main Board and check again If this is successful the Pump Assembly is faulty Turn off the power supply momentarily to disconnect J207 Head Black from the HeadBoard and check again If this is successful either the Print Head Black Assembly or the Head Cable Black Assembly is faulty Turn of...

Page 172: ...uide You will need a short Phillips screwdriver to remove the Plotting board Step 3 Bring the Head to the printing area Step 4 Soak a lint free cloth in water or distilled water and gently wipe the Head Nozzle Face Lint free cloth is closely woven from extremely fine threads and has no nap and produces no dust Caution Don t wipe with fluffy cloth or tissue paper as these tend to make the clogging ...

Page 173: ... Step 2 Remove the front cover Step 3 Remove the Y rail cover Step 4 Remove the Front Plate Step 5 Loosen the four screws holding the X motor assembly and loosen the belt tension Step 6 Remove the bearing stopper 1 hexagon set screw Step 7 Remove the speed reduction pulley support Four fastening screws Step 8 Loosen two B stopper hexagon set screws ...

Page 174: ...Rockhopper 38 Maintenance Manual 174 AP 74038 Rev 1 1 25 01 05 Step 9 Slide and remove the X speed reduction pulley assembly Step 10 Assembly is the reverse of the removal procedure ...

Page 175: ...plained to the user Caution Two people are required to move the printer Cleaning is not necessary Cartridges cutter waste fluid box may remain installed Be careful to keep the printer level If it is tilted waste may spill from the fluid box Step 1 With power off bring the head to the home position and attach head fastening fittings with wing screws Step 2 Remove the power cable and interface cable...

Page 176: ...t 30 minutes before printing otherwise printing quality can not be assured Step 1 Remove the four cartridges Step 2 Carry out head cleaning Refer to REP1620 Step 3 With power off bring the head to the home position and attach the head fastening plate with the wing bolt Step 4 Remove the power cable and interface cable Step 5 Remove the waste fluid box and install a new one Step 6 Install the cable...

Page 177: ...xed with screws contain electrical components and must not be opened during cleaning Paper dust which is produced when the printer is working should be removed periodically Make sure that it does not get blown around Stubborn dirt that is difficult to remove may be removed with a lint free cloth dampened with alcohol Use a soft damp cloth to wipe away any paper dust adhering to the printing board ...

Page 178: ...ia and produce a Skew check error They must be cleaned periodically Use a cotton bud to wipe away any dust and paper dust from the front and back paper sensor covers in two places Important Progressive soiling will affect the sensitivity of the sensor and faulty detection of the media in the initial operation may cause a Skew Check Error They must be cleaned periodically ...

Page 179: ... back of the printer YMCK cartridge Note Each sign Y M C K indicates Y Yellow M Magenta C Cyan K Black Colors for No ink are expressed as colors from 1 to 4 Step 2 Unpack a new ink cartridge packet Note Only use original Mutoh ink cassettes For each cassette there is a correct place and a correct inserting direction Open the ink cassette just before inserting it into the slot Use ink cassettes wit...

Page 180: ...tch off the printer and pull the printing head to the center of the printer Step 2 Take out the cutting blade by pushing the cutter head down and rotating the cutter arm towards you Either clean the cutting blade with a dry cloth or replace it Caution There is a spring fitted in the hole of the cutter head Be careful not to loose it while replacing the cutting blade Step 3 Insert a new cutting bla...

Page 181: ...sed environment We recommend purchasing a spare cutting blade so that you always have a spare blade at hand Important If you don t have a new sheet off blade available to replace your blade you can temporarily switch off the automatic sheet off o Press menu until you see Function o Press Enter Function Ink Dry Time o Press menu until you see Media Cut ON o Press value or value Media Cut OFF o Pres...

Page 182: ... after printing about 2000 A0 pages Step 2 Remove the waste ink bottle by turning it to the left Using absorbent sheet and forceps soak up the waste liquid in the bottle and discard the waste liquid absorbent sheet into the open vinyl bag Step 3 The waste ink bottle fitted with new waste liquid absorbent sheet is installed in the printer by turning it to the right Caution The used waste liquid abs...

Page 183: ...one by an authorised Mutoh technician Step 1 Put the lever up Step 2 Remove all the blades as shown in the picture below Remove previous blade wing Two pins on each side of the pressure roller Step 3 Install the new blades Make sure that the 4 pins of the pressure roller match with the holes in the blade 2 holes in blade at both sides Installed blade pins in the holes Step 4 Installation of the ne...

Page 184: ...Change wiper 2 DF 41326 DF 41327 1 1 Change absorbents in spitting box Month Maintenance Cycle 1 2 3 4 5 6 7 8 9 10 11 12 1 X X X 2 4x 4x 4x 4x 4x 4x 4x 4x 4x 4x 4x 4x 8 3 2 Service by authorised Mutoh technician Perform periodical inspections according to the table below N Part number Quantity Action 1 DE 49732 DF 49733 1 1 Change printheads black colour 2 MY 24115 1 Change flush box spare parts ...

Page 185: ...en the product indicates a failure and an error message is also displayed on the control panel refer to Troubleshooting procedures when a message has been displayed and implement treatment When the product indicates failure but an error message has not been displayed refer to Troubleshooting procedures when an error message has not been displayed and implement treatment ...

Page 186: ...he pressure move smoothly Adjust the position of the pressure relay plate Apply grease G 501 to the elongated round hole in the pressure relay plate 1 6 Is the lever sensor assy fitted securely Adjust the lever sensor assy fitting position 1 7 Is the sensor unit in the lever sensor assy dirty Clean the sensor unit with cotton swabs 1 8 Is the lever sensor assy cable fitted securely Connect the lev...

Page 187: ... Sensor Edge Using thick coated paper confirm that the difference in the amount of sensor reflection with and without media is a change of at least 10 Replace paper sensor Y assy 1 5 Check Y cable contacts Are they inserted obliquely Check Mainboard J111 HEAD1 Head board J201 MAIN1 Insert them correctly 1 6 The head board assy may be damaged Replace it 1 7 Check with self diagnostic Sensor X Front...

Page 188: ... securely attached in the proper positions Shield material GA A shield GA B shield 1 4 Is there a problem with the movement of the pressure lever Apply grease G501 and adjust the pressure transfer plate 1 5 With the pressure lever lowered do all pressure make contact with the grid roller Replace the pressure rollers or pressure assy 1 6 Is there a uniform gap between head and platen Use the rail h...

Page 189: ... sensor reflection with the printer s self diagnostic Sensor Edge Using thick coated paper confirm that the difference in the amount of sensor reflection with and without media is a change of at least 10 Replace paper sensor Y assy 1 5 The head board assy may be damaged Replace it 1 6 Check with self diagnostic Sensor X Front whether the sensor is operating Replace paper sensor F if Paper End is d...

Page 190: ...r X Front whether the sensor is operating Replace paper sensor F if Paper End is displayed when media is mounted 1 7 Check with self diagnostic Sensor X Rear whether the sensor is operating Replace paper sensor R if Paper End is displayed when media is mounted 1 Remove Media This message is displayed if after raising the lever during printing and cutting the media the lever is lowered without the ...

Page 191: ...ntact of the cutter solenoid assy Head board J206 SOL Insert it correctly 1 5 Check the up and down movement with the printer s self diagnostic Aging Cutter If it does not move up and down the solenoid may be damaged Replace the cutter solenoid assy 1 6 The head board assy may be damaged Replace it 1 7 Check the Y cable contacts Is it inserted obliquely Check Main board J111 HEAD1 Head Board J201 ...

Page 192: ...n been installed 80Mb is displayed Optional Memory MB shown in the Setup List is the amount of extended memory only If there is a difference between the actual memory capacity and the memory capacity shown on the panel or the memory capacity shown in the setup list the SIMM may be damaged Replace the SIMM 1 Not enough memory SIMM MB Intermediate code buffer overflow When this printer has insuffici...

Page 193: ...to J409 on the junction board assy 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 assy that was shown as being faulty is damaged Replace the faulty ink ID sensor assy 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 bein...

Page 194: ... means that the detector assy is damaged Replace the detector assy 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 assy and the main board assy 1 4 Check the ink ID cable contacts J401 ink ID cable on the junction board assy and J109 on the main board assy Disconnect and reconnect them 1 2 KC...

Page 195: ...on board assy Disconnect and reconnect them If there is no change move to the next step 1 4 Exchange the position of the connector of the ink detector assy 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 assy is damaged Replace the detector assy If after re inserting the connectors there is no change in the No Ink d...

Page 196: ...ot been done 1 2 Caution Wait at least 30 minutes after initial filling before printing Printing quality can not be assured unless ink filling has been stabilized No Message Explanation N Checkpoint Action 1 1 Switch off the printer temporarily and check that the message is displayed when you switch on again 1 2 Use the printer s self diagnostic Sensor Box Exist Box is not to make sure that the wa...

Page 197: ... 1 K J407 Ink ID Sensor 2 C J408 Ink ID Sensor 3 M and J409 Ink ID Sensor 4 Y on the junction board assy Disconnect and reconnect them If there is no change move to the next step 1 3 Check the ink ID cable contacts J401 ink ID cable on the junction board assy and J109 on the main board assy Disconnect and reconnect them 1 Ink type error This message is displayed when the wrong type of ink cartridg...

Page 198: ... Checkpoint Action 1 1 The main board assy may be damaged Replace it 1 2 Network Detection Error Network Initialization Error The optional network board can not be detected An error has occurred during the optional network board initialization operation 1 2 The Ethernet Board assy may be damaged Replace it ...

Page 199: ...the printing data Try changing the type of application driver 1 3 If the symptoms persist despite various application driver changes Obtain the printing data Report to your local Mutoh dealer after you have obtained it 1 MH01 Error undefined command MH02 Error Parameter Error MH03 Error Numerical Error MH04 Error Undefined Character Set MH07 Error Buffer Overflow A command that is not defined in a...

Page 200: ... the same capacity and check with the self diagnostic Examination Memory Capacity Replace Optional Memory 1 2 E001 Error DRAM Standard DRAM Error E002 Error Opt DRAM Optional DRAM Error This error display means that a fault has occurred in the standard memory of the Main Board that controls the printer This error display means that a fault has occurred in the optional memory of the Main Board that...

Page 201: ...U Err 05 Interrupt exception error E016 CPU Err 06 Interrupt exception error E016 CPU Err 07 Interrupt exception error E016 CPU Err 08 Interrupt exception error E016 CPU Err 09 Interrupt exception error Indicates that handling an interrupt has been generated an error Indicates that the boundary of a command has caused an error Indicates that the boundary of a command has caused an error Indicates ...

Page 202: ... CPU Err 15 Floating point exception error E016 CPU Err 22 Watchdog timeout exception error E016 CPU Err 32 Watchdog timeout exception error E016 CPU Err 33 Abort Error E237 Err Transfer Memory Transfer memory error access error E129 Error NVRAM Indicates that a reserved command has caused an error Indicates that the coprocessor has caused an error Indicates that a floating point error has occurre...

Page 203: ...dicates that a fault has occurred in the media feed motor X axis while the printer was working This occurs when there is a large difference between the motor command value and encoder feedback value This message indicates that a fault has occurred in the amount of media movement X axis while the printer was working This occurs when there is no encoder feedback This message indicates that a timeout...

Page 204: ...lace the Y motor assy Replace the head board Replace the Y cable between J112 HEAD2 on the main board and J202 MAIN2 on the head board 1 2 3 4 E066 Error Y Motor E070 Error Y Encoder E072 Error Y Timeout E074 Error Y Over current This message indicates that a fault has occurred in the head movement motor Y axis while the printer was working This occurs when there is a large difference between the ...

Page 205: ...d and J201 MAIN1 on the head board Insert them properly Replace the Y cable between J111 HEAD1 on the main board and J201 MAIN1 on the head board 1 4 The origin sensor assy may be faulty Replace it 1 5 The main board assy may be damaged Replace it 1 E075 Error Sensor Fault This message indicates that condition has occurred in which the origin cannot be detected Caution Main board assy connector J1...

Page 206: ...bove 35 C then this test cannot be run and the user will be asked to wait until the heaters cool down The following message will be shown Safety Cool Down Please wait If the temperature has dropped below 35 C the following message will be shown Cool Down Done Please Restart 3 Sensor connected test All sensors are tested to see if they are properly connected to the heater mainboard 4 Heater capabil...

Page 207: ...r group D error 20 C difference between sensors D1 and D2 Group Fixer Err sensor group A error 20 C difference between sensors A1 and A2 Front strip err heater strip D has connection problem please check the fuse Fixer strip err heater strip A has connection problem please check the fuse Front Fail Heat heater strip D failed to reach target temperature within 10 min Fixer Fail Heat heater strip A ...

Page 208: ...the Power supply voltage check 100 V AC 1 3 Do the Power supply voltage check 5 V DC 1 4 Do the Power supply voltage check 24 42 V DC 1 5 Check the panel cable connectors on the panel board and main board Are they inserted obliquely Are they securely locked Check Main board J110 PANEL panel board J301 MAIN Reconnect the connectors 1 6 The panel cable may be faulty Replace it 1 7 Is there a fault i...

Page 209: ... No Cartridge procedure for checking After adjustment and replacement carry out initial filling with the printer s self diagnostic Adjust Enter Rank 1 6 With genuine Mutoh cartridges properly inserted use the printer s start self diagnostic Sensor Cartridge to check that the status and operation of the cartridges is normal For checking use the Insert Special Cartridge After adjustment and replacem...

Page 210: ... Y Rail cover and cartridge cover and check the flexible cable keeper unit under the head board and the sides of the cartridge 1 5 Is there an air leak in the damper assy shield unit Replace the damper assy and check that ink flows during the cleaning action If ink flows carry out initial filling 1 6 Are the ink tubes damaged inside the pump assy Replace the pump assy and check that ink flows duri...

Page 211: ...maged Replace the print head assy black Replace the print head assy color 1 14 Is the head board assy damaged Replace it 1 15 Check the Y cable connections Is it inserted obliquely Check J201 MAIN1 and J202 MAIN2 on the head board assy J111 HEAD1 and J112 Head2 on the main board assy Insert the connectors again 1 16 Is there a broken lead in Y cables 1 and 2 Replace Y cables 1 and 2 1 17 The main ...

Page 212: ...Replace the lever sensor assy 1 5 Do the front and rear paper sensors detect normally with the self diagnostic Examination Sensors Check the connections of the paper sensor connectors J103 XF and J107 XR on the main board Replace the front and rear paper sensor assemblies 1 6 Carry out 5 V DC Power Supply Check and 24 42 V DC Power Supply Check Replace the power board assy 1 7 Is the cable of the ...

Page 213: ...eplacement carry out initial filling with the printer s self diagnostic Adjust Enter Rank 1 Ink cartridges are installed but not recognized 1 2 Caution Wait at least 30 minutes before printing after initial filling Printing quality can not be assured unless the ink filling is stabilized No Message N Checkpoint Action 1 1 Is the panel cover key input unit broken Replace the panel cover 1 2 Check th...

Page 214: ... between fan assy fan cable assy and main board assy Fan cable A assy is J115 FAN1 on the main board Fan cable B assy is J116 FAN2 on the main board Fan cable C assy is J11 FAN3 on the main board Replace fan assy Replace Fan cable A assy Fan cable B assy Fan cable C assy 1 4 Is shielding fixed securely in the specified places Shield GA A Shield GA B Shield GA C Refit shielding securely 1 5 Is the ...

Page 215: ...same time Apply grease G 501 if it does not move smoothly 1 5 Are all the pressure rollers 15 pressurizing the media With the pressure lever raised do any pressure rollers seem reluctant to turn With the pressure lever lowered are any of the pressure rollers idling With the pressure lever lowered is the plate pressing strongly on the media If there is paper dust or scraps near the pressure rollers...

Page 216: ...e amount of sensor reflection with the printer s self diagnostic Sensor Edge Check that the difference with and without media is a change of at least 10 Check using thick coated paper Check the edge sensor connector J204 PEDGE on the head board Replace paper sensors F and R 1 4 Check the Y cable connectors Are they inserted obliquely Check J201 MAIN1 on the head board J111 HEAD1 on the main board ...

Page 217: ...it No Message N Checkpoint Action 1 1 Are paper sensors XF XR working normally according to the diagnostic sensor test Check the connections of paper sensor F and paper sensor R connectors Paper sensor F is the main board connector J103 XF and paper sensor R is J107 XR Replace paper sensors F and R 1 2 Is there a problem with the printer driver software Upgrade the printer driver version 1 3 Is th...

Page 218: ...eanings If it is wet with ink replace it 1 9 Are the nozzle surfaces being wiped and rubbed Carry out repairs Replace the wiper 1 10 Does the head that is fitted have a rank that is different from the recorded rank Re enter the rank of the black head correctly Re enter the rank of the color head correctly 1 11 Has ink dried on the surface of the print head and inside the nozzles CAUTION Wait at le...

Page 219: ...s are fitted properly Remove the head cover and check the damper assemblies at the base of the tubes for all four black and color ink tubes Remove the Y Rail cover and cartridge cover and check the flexible cable keeper unit under the head board and the sides of the cartridge 1 6 Is there an air leak in the damper assy shield unit Replace the damper assy and check that ink flows during the cleanin...

Page 220: ...ard assy damaged Replace it 1 12 Is the main board assy damaged Replace it 1 13 Is the print head assy damaged Replace the black print head assy Replace the color print head assy 1 14 Is the pump motor turning during the cleaning action Check the pump motor cable connector J103 PUMP MOT on the main board Replace the pump motor If the pump motor does not turn after performing the above tasks replac...

Page 221: ...MAIN2 on the head board assy J111 HEAD1 and J112 HEAD2 on the main board assy Insert the connectors again Replace both Y cables 1 and 2 1 3 The head board may be damaged Replace it 1 4 The head may be damaged Replace the black print head Replace the color print head The main board may be damaged Replace it 1 The entire surface is printed black Bad example Good example 1 5 CAUTION Main board connec...

Page 222: ...ttach in the proper positions 1 5 If the media in question is roll paper does the scroller turn freely Adjust the position of the scroller bearing so that it turns freely 1 6 Is the X speed reduction belt tension adjusted to the prescribed value Adjust the X belt tension prescribed value is 4 2 kg 1 7 Is the X speed reduction pulley set screw loose Tighten it securely 1 8 What is the condition of ...

Page 223: ...ain board and try again Replace the pump motor If the pump motor does not turn after performing the above tasks replace the main board assy 1 14 Was there any mismatching of gears during the cleaning operation Replace the maintenance station GA assy 1 15 Is the cap assy spring fallen out or broken If the part has fallen out refit it Replace the cap assy or the maintenance station GA assy 1 16 Are ...

Page 224: ...maged Replace it 1 21 The head board assy may be damaged Replace it 1 2 3 4 Printing becomes shaded The image contains blurs Transverse lines appear to be split Black and white lines appear in the printed image Not including gaps in the step patterns in locations 1G to 7G of the test pattern If dots are missing go to page 208 1 22 With genuine Mutoh cartridges properly inserted use the printer s s...

Page 225: ...ith compound printing such as Panel User setup Overprint etc last print priority For details refer to Parameter Settings in the Operation Manual 1 4 Does the head that is fitted have a rank that is different from the recorded rank Re enter the rank of the black head correctly Re enter the rank of the color head correctly 1 5 Check that the T fence and Encoder behind the head board assy are not tou...

Page 226: ...ey Re tighten the set screw 1 7 Are the fans working normally according to the self diagnostic Examination Fans Check the connectors between fan assy fan cable assy and main board assy Fan cable A assy is J115 FAN1 on the main board Fan cable B assy is J116 FAN2 on the main board Fan cable C assy is J117 FAN3 on the main board Replace fan assy Replace Fan cable A assy Fan cable B assy Fan cable C ...

Page 227: ...tion was there any mismatching or damage to the gears or transfer gear shaft Replace the maintenance station GA assy 1 15 Has the cap assy spring fallen out or been broken If a part has fallen out refit it Replace the cap assy or maintenance station 1 16 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 ca...

Page 228: ...sy Fan cable B assy Fan cable C assy 1 4 Is there any mistake in the rank of the head that is actually installed and the rank that is recorded Re enter the rank of the black head correctly Re enter the rank of the color head correctly 1 5 Is the problem with the black head tilt adjustment Adjust it 1 6 Is the problem with the color head tilt adjustment Adjust it 1 7 Is there a problem with the rec...

Page 229: ...nts in detail 1 2 Is the steel belt tension adjusted properly 150 g 20 g Re adjust steel belt tension 1 3 Is the timing fence dirty or has foreign matter stuck to it Clean it 1 4 Is the timing fence scared or damaged Replace it 1 5 Is the Y drive pulley set screw loose Re tighten the set screw securely 1 Inaccurate line length in the direction of head movement Main scanning direction 1 6 The inter...

Page 230: ...the prescribed value 4 2 kg 0 2 kg Readjust it 1 7 If the media in question is roll paper does the scroller turn freely Adjust the position of the scroller bearing so that it turns freely 1 8 Are all the pressure rollers 15 pressurizing the media With the pressure lever raised do any pressure rollers seem reluctant to turn With the pressure lever lowered are any of the pressure rollers idling With...

Page 231: ...djusted to the prescribed value 4 2 kg 0 2 kg Readjust it 1 6 Are all the pressure rollers 15 pressurizing the media With the pressure lever raised do any pressure rollers seem reluctant to turn With the pressure lever lowered are any of the pressure rollers idling With the pressure lever lowered is the plate pressing strongly on the media If there is paper dust or scraps near the pressure rollers...

Page 232: ...ey set screw loose Re tighten the set screw securely 1 6 Is there a problem with the reciprocal printing position alignment Adjust it 1 7 Is there a problem with the CW adjustment Adjust it 1 8 Is the T fence dirty Clean it If it is still dirty or scarred after cleaning replace it 1 9 Although the step pattern of the self diagnostic Head Nozzle Check is well adjusted if the vertical lines of the B...

Page 233: ...r scraps near the pressure rollers wipe with a soft damp cloth If necessary replace pressure assy pressure rollers and plate If the gap between platen and plate is less than 0 8 mm adjust platen height 1 Bad right angle precision 1 4 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 If there is paper dust or scraps sticking to...

Page 234: ...riage bearings and roller tracks Be sure to apply a light Sumi grease spray to the roller tracks when you clean them 1 4 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 A1 A0 tube guide assy 1 5 Check whether the cable connected to the head board on the carriage is touching the ...

Page 235: ...s the grid roller heavy to turn Or does it not turn smoothly If there is paper dust or scraps sticking to the grid roller clean it with a nylon brush If necessary replace the grid roller assy and coupling assy No Message N Checkpoint Action 1 1 Has the cutter cap been fixed securely on the top of the cutter as a result of checking in the primary consultation Refit it 1 2 Does the cutter move up an...

Page 236: ...cutter groove Adjust it 1 6 Use self diagnostic Aging Cutter to confirm up and down movement Check the cutter solenoid connector J206 SOL on the head board If there is no up and down movement the solenoid may be damaged Replace the cutter solenoid assy 1 7 Check the Y cable connectors Are they inserted obliquely Check J111 HEAD1 on the main board assy and J201 MAIN1 on the head board assy Insert t...

Page 237: ... assy connector J111 HEAD1 and head board assy connector J201 MAIN1 should be plugged in securely The main board may be damaged if power is applied when they are not properly connected No Message N Checkpoint Action 1 1 Is the cutter blade chipped or deteriorated as checked in the primary consultation Replace the cutter 1 2 Is the cutter blade chipped or deteriorated as checked in the primary cons...

Page 238: ...r deteriorated as checked in the primary consultation Replace the cutter 1 2 Has the cutter cap been fixed securely on the top of the cutter as a result of checking in the primary consultation Refit it 1 3 Does the cutter move up and down smoothly Refit the spring and remove any foreign matter 1 4 Is there foreign matter in the cutter groove and front surface of the printing board section Remove t...

Page 239: ...Use a straight cable 10Base T Reference This does not apply when 10Base 2 is used To check connections to the network board use the board accessory setup utilities or connect directly to the computer using a crossed cable in the case of 10BASE T and use the PING command Example of use of PING PING ping is run from the MS DOS prompt under Windows 95 NT Example C WINDOWS PING 192 168 41 34 Enter PIN...

Page 240: ...tility RPU Upgrade the RPU version 1 3 Is there a problem with the program ROM Upgrade the version 1 4 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 1 5 Check Encoder Y that is in the self diagnostics examina...

Page 241: ...ff and on temporarily enter settings manually and the check the operation Install the program and try again 1 The printer hangs up 1 2 The main board assy may be damaged Replace it No Message N Checkpoint Action 1 1 Is there a short in the power cable Check it with a tester 1 2 Is there a power leak Check for contact with the frame due to frayed covering 1 3 Check power voltages Power supply volta...

Page 242: ...ns working normally according to the self diagnostic tests Check the connectors between fan assy fan cable assy and main board assy Fan cable A assy is J115 on the main board Fan cable B assy is J116 on the main board Fan cable C assy is J117 on the main board Replace fan assy Replace Fan cable A assy Fan cable B assy Fan cable C assy 1 Mounting the media is difficult 1 5 Is shielding fixed secure...

Page 243: ... that the present absent display appears If the display is not normal the sensor mounting position may be at fault Remove the R Cover and adjust the mounting position of the waste fluid box detection switch assembly 1 4 Check the waste fluid box detection switch contact J105 INK TANK on the main board Insert it correctly Replace it 1 5 Is the waste fluid tube from the flushing box kinked Fix it an...

Page 244: ...rn it to the dealer and request that it be checked No Message N Checkpoint Action 1 1 The extended memory optional item may be damaged Return it to the dealer and request that it be checked 2 1 The mother board assembly that is connected to the main board assembly by a connector may be damaged Replace it 2 2 The Ethernet board optional item may be faulty Return the Ethernet board optional item to ...

Page 245: ... above 35 C then this test cannot be run and the user will be asked to wait until the heaters cool down The following message will be shown Safety Cool Down Please wait If the temperature has dropped below 35 C the following message will be shown Cool Down Done Please Restart 3 Sensor connected test All sensors are tested to see if they are properly connected to the heater mainboard 4 Heater capab...

Page 246: ...or 20 C difference between sensors D1 and D2 Group Fixer Err sensor group A error 20 C difference between sensors A1 and A2 Front strip err heater strip D has connection problem please check the fuse Fixer strip err heater strip A has connection problem please check the fuse Front Fail Heat heater strip D failed to reach target temperature within 10 min Fixer Fail Heat heater strip A failed to rea...

Page 247: ...opper 38 Maintenance Manual 247 AP 74038 Rev 1 1 25 01 05 10 APPENDIX 10 1 INTRODUCTION This chapter provides referential information such as service data and exploded views 10 2 WIRING DIAGRAM ROCKHOPPER 38 ...

Page 248: ...AMS This section includes the service parts list exploded views of respective units and configuration diagrams Notes For the latest exploded views and part description please refer to the spare part lists of the printer For spare parts please refer to the latest spare part list Specifications are liable to changes without prior notice ...

Page 249: ...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 11040081 NS 11040061 NS 11030061 LB 45171 DE 21472 LB 10080 DE 33950B DE 34503 DE 21308B DE 10872 ME 24614 ME 24605 DE 10973 LB 10082 LB 45170 ME 24609 EY 24603 NS 11030061 NS 05030041 ME 60050 ME 24615 NS 11030061 MY 24612 ME 24612 EY 24502 LB 24600 DF 43737 DF 414...

Page 250: ...47866F DE 40615 E NAD 06 E P 25 E P 20 DF 40091 DE 49651 NS 05030401 NS 05040081 NS 05030401 NS 05030401 ME 24606 DE 33608 DE 33608 DE 33608 NS 21030031 DF 40519 ME 24618 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 DE 49828 DP 3022 40153 DS 1074 41211K DE 49814 DE 49815 DE 33609 DF 40470 DE 49811 DE 34558 DF 41725 DF...

Page 251: ...E 49142 DE 49947 DP 3022 40153 E P 25 E P 25 DF 42105 DF 42104 DF 42103 DE 49827 NS 51030061 NS 51030051 NS 05030081 DE 34540 NS 06020051 DF 41468 DE 47046 DF 41446 DF 40561 DE 49826 DE 49782 DE 49781 DF 41469 DF 41478 NS 35040201 DE 49948 DE 33999 DE 32692 NS 06030061 DF 41463 DF 41581 NS 05030061 DE 49812 DF 40469 DF 40470 DE 46552 MY 40469 3x DE 46552 DF 41792 MY 41792 JD 42054 BM 1301 003006 M...

Page 252: ... NS 21040031 4x DF 40523 NS 05030061 DF 40523 DF 40522 DE 34776 NS 21040031 4x DE 48846 DE 21394 DE 48846 DE 34190 DE 34190 DE 21397 NS 35030061 NS 05030081 NS 05030081 NS 41030061 NS 41030061 NS 41030061 NS 41030061 NS 05030081 NS 06020051 DF 41467 DF 40522 DE 21394 DE 21394 DE 48846 NS 35030061 NS 35030061 NS 35030061 DE 21397 DE 48846 DE 34776 NS 21040031 4x DE 33599 MY 24114 ME 24138 ME 24138 ...

Page 253: ...Rockhopper 38 Maintenance Manual 253 AP 74038 Rev 1 1 25 01 05 DE 21303 3 DP 3022 40153 DP 3022 40153 DF 40980 DE 21303 3 DE 49780 ME 27065 LB 45000 RJ41 SR03 ...

Page 254: ...396 DF 40394 DE 33825F DE 33825G DE 33825H DE 49777 DE 49777 DF 40397 DF 40395B NS 05030081 NS 04030061 DF 44766 DE 49772 DE 21471 NS 05030081 NS 41030121 NS 41030061 DF 40012 DF 40013 DF 40014 DF 40011 DE 33600 NS 41020081 DE 21300 DF 40978 DE 48982C DE 48982C DE 33945B DF 40398B DE 33943B DE 49778 DE 49777 DF 40991 DE 49992 NS 11030061 DE 21595 DE 49993 DE 49993 DE 49992 DE 49778 DE 48949 DE 489...

Page 255: ...9746 DE 42051 DE 47014 DE 47014 DE 34834 DR 7032 41990 DR 7032 41990 DR 7032 41990 DR 7032 41990 DR 7032 41990 DS 4014 40904 DE 49879 DE 49879 DE 49879 DR 4010 43361 DP 1012 40093 DE 49879 DF 42047 DE 33594 NS 05030081 NS 05030081 NS 05030081 NS 05030081 NS 05030081 DE 34207 NS 05030081 DE 47866G DE 34209 DE 49750 DF 41301 DF 41301 DF 40397 NS 05030081 DE 49734 DE 49736 NS 11030061 DR 4010 43361 D...

Page 256: ...DE 10871 NS 51030061 NS 05030081 DE 11165 NS 06030041 DE 34535 DF 41477 DF 41340A DE 34972 E MSFC 6KEX DF 41391 EY 24320 DF 41437 DF 41439A DF 41439B DF 41439C ME 24610 DE 46951 NS 05040081 NS 11040041 DE 48958 NS 11040041 EY 24600 DR 4001 43293 3x ME 24238 AE 91025 3x J2 J0 7 J1 J000 J02 MK 24209P MK 21000 MK 2 4204 MK 2 4205 PCB Layout cables refer to drawing AP 76130 AP 76131 RJ8 ETH14 UNIT SDM...

Page 257: ...Rockhopper 38 Maintenance Manual 257 AP 74038 Rev 1 1 25 01 05 DE 10875B UNIT SDMP38 CAT5009 00 REV ...

Page 258: ...Rockhopper 38 Maintenance Manual 258 AP 74038 Rev 1 1 25 01 05 ...

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