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MUTOH Rockhopper II 2H, Maintenance Manual

The MUTOH Rockhopper II 2H is a powerful printing machine designed to deliver exceptional quality and speed. For easy maintenance and troubleshooting, a comprehensive Maintenance Manual is available for download, completely free of charge, from {Website}. Obtain the manual, ensure optimal performance, and maximize the potential of your printing operations.

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Maintenance Manual 

 

 

MUTOH EUROPE N.V. 

AP-74065, Rev 1.2: , 27/09/2004 

 

Summary of Contents for Rockhopper II 2H

Page 1: ...Maintenance Manual MUTOH EUROPE N V AP 74065 Rev 1 2 27 09 2004 ...

Page 2: ...67163 E mail ibd mutoh co jp http www mutoh co jp MUTOH EUROPE N V Tel 32 0 59 561400 Fax 32 0 59 807117 E mail mutoh mutoh be http www mutoh be MUTOH DEUTSCHLAND GmbH Tel 49 0 2159 913430 Fax 49 0 2159 913456 E mail Mutoh Sales t online de MUTOH AMERICA INC Tel 480 968 7772 Fax 480 968 7990 E mail Sales mutoh com http www mutoh com ...

Page 3: ...Rockhopper II series printers Maintenance Manual 4 AP 74065 Rev 1 2 27 09 04 ...

Page 4: ...e information 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 th...

Page 5: ...Rockhopper II series printers Maintenance Manual 6 AP 74065 Rev 1 2 27 09 04 ...

Page 6: ... more distance between them Be sure the product and the receiving antenna are on separate power lines 2 Trademark mentioned in this manual MUTOH Rockhopper II 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...

Page 7: ...Rockhopper II series printers Maintenance Manual 8 AP 74065 Rev 1 2 27 09 04 ...

Page 8: ...Language 27 2 5 Position and function of the heating elements 28 2 5 1 Rockhopper II 2 heater printers 28 2 5 2 Rockhopper II 4 heater printers 28 2 5 3 2 or 4 heater 29 3 Specifications 31 3 1 Introduction 31 3 2 Product Specifications 31 3 3 Interface Specifications 33 3 3 1 Centronics Bidirection Parallel Interface IEEE1284 33 3 3 2 Network Interface Optional Specifications 34 3 4 Installation ...

Page 9: ... and the CR deceleration belt 92 4 6 7 Replacing the steel bearer tube guide CR tape power cable and ink tube 93 4 6 8 Replace the cover R sensor assembly and the cover L sensor assembly 95 4 7 Replacing the Cursor 96 4 7 1 Replacing the cutter holder cutter spring cutter cap solenoid assembly and solenoid spring 96 4 7 2 Replacing the print head assembly and head tape power cable 98 4 7 3 Replaci...

Page 10: ...68 5 5 9 P_REAR sensor position adjustment menu 169 5 5 10 Test print menu 170 5 5 11 Head wash menu 171 5 5 12 Software Counter Initialization Menu 173 5 5 13 Feed Pitch Check Menu 174 5 5 14 Fill printing menu 174 5 6 Purge Menu 175 5 7 Sample Printing Menu 176 5 8 Parameter Menu 177 5 8 1 Parameter Initialization Menu 177 5 8 2 Parameter Update Menu 178 5 9 Endurance Running Menu 185 5 9 1 CR M...

Page 11: ... belt tension adjustment 220 7 6 1 Tools required for work 220 7 6 2 Adjustment Procedure 220 7 7 Head precision adjustment slant 221 7 7 1 Head slant adjustment 221 7 7 2 Front and back of head adjustment 225 7 8 Repeatability Adjustment Bi Directional 230 7 9 CW adjustments Uni Directional 231 7 10 CR deceleration belt tension adjustment 232 7 10 1 Tools required for work 232 7 10 2 Adjustment P...

Page 12: ...y 268 9 2 2 Message type errors 270 9 2 3 Heating system error 277 9 2 4 Data error 278 9 2 5 Command errors 279 9 2 6 Errors requiring restart 280 9 3 Troubleshooting procedures when errors are not displayed 291 9 3 1 Problems relating to initial operation 291 9 3 2 Problems relating to paper feed 296 9 3 3 Problems relating to the printing operation 297 9 3 4 Problems relating to noise 309 9 3 5...

Page 13: ...Rockhopper II series printers Maintenance Manual 14 AP 74065 Rev 1 2 27 09 04 ...

Page 14: ... to your equipment Note 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 1 3 1 Warning Do not place the printer in following areas Doing so may result in the printer falling over and causing injury Angled place Areas subject to vibration...

Page 15: ...k When connecting or disconnecting the FFC type cable from the connector of the main substrate assembly be sure to connect or disconnect the cable straight out from the connector Connecting or disconnecting at a slant angle may damage break or short circuit the inner terminal of the connector That may damage the elements on the substrate When connecting or disconnecting the FFC type cable from the...

Page 16: ... and contents thoroughly 1 4 1 Handling the operation procedure labels Notes Make sure that all labels can be recognized If text or illustrations are invisible clean or replace the label When cleaning labels use a cloth with water or neutral detergent Do not use a solvent or gasoline If a warning label has been damaged lost or cannot be recognized replace the label 1 4 2 Locations and types of ope...

Page 17: ...zerknittern und demzufolge erzielen Sie keine gute Druckergebnisse mehr N ouvrez pas le couvercle quand l imprimante est en train d imprimer Ne touchez pas non plus le papier afin d éviter que la qualité s aggrave Si vous ne comptez pas imprimer pendant un certain temps retirez le papier et mettez le levier en position levée Sinon le support risque de se soulever et de se froisser et vous n obtien...

Page 18: ...printers Maintenance Manual 19 AP 74065 Rev 1 2 27 09 04 2 Back Part No Type 3 CAUTION THIS UNIT HAS TWO POWER SUPPLY CORDS STANDARD TO REDUCE THE RISK OF ELECTRICAL SHOCK DISCONNECT ALL POWER SUPPLY CORDS BEFORE SERVICING ...

Page 19: ...t Number of Ink Cartridge 1 2 3 4 5 6 7 8 Number of the Colours 4 6 Eco Solvent 2x4 colours Eco Solvent 1x6 colours Black Transition Liquid Cyan Æ Refer to the User s Guide Installing ink cartridges Please note that ink cassettes order is different for 87 printers versus 50 and 64 printers Label 50 and 64 printer 6 Yellow Black Magenta Cyan Black Transition Magenta Liquid Light Magenta Light Cyan ...

Page 20: ...riety of compatible media Adjustable head height can adapt to various media thickness from 0 08 up to 1 1 mm 3 Vibrant Colour Reproduction To reproduce sharp and vivid colour 4 6 and 8 ink colours are used for printing The 220ml large capacity ink tank is equipped with an IC chip This unit can automatically detect the ink quantity significantly improving productivity 4 Effective usage of media A J...

Page 21: ...nce cover This protects users from electric shocks caused by touching the internal electrical parts The cover is opened when expansion memory optional has to be installed and is closed for normal use 6 Stand This stand is used to install the printer on a surface flat floor The following options are available for installation Take up system scroller receiver Motorized roll off roll up system 7 Medi...

Page 22: ...ot switch cable is attached 4 Insertion slot This is the slot for inserting media when loading it 5 Interface slot 1 The network interface board attaches here 6 Interface slot 2 7 Interface slot 3 This is not used for this printer Close it with the cover 8 Hard disk slot The hard disk attaches here When not using a hard disk keep the cover closed 9 Nameplate rating The type name serial number rati...

Page 23: ...assigned to F2 4 F3 key Executes the function assigned to F3 Executes the function assigned to F3 5 F4 key Executes the function assigned to F4 Executes the function assigned to F4 6 MENU key Changes the LCD monitor display to setup menu status Changes the menu in reverse order 7 MENU key Changes the LCD monitor display to setup menu status Changes the menu in forward order 8 ENTER key Displays th...

Page 24: ...3 DATA lamp Orange OFF The printer is waiting to receive print data ON The pressure rollers are in the release position Media is not set 14 MEDIA SET lamp Orange OFF The pressure rollers are in secured position The media is set ON The media type is set to roll media 15 ROLL lamp Orange OFF The media type is set to sheet media ON The media type is set to sheet media 16 SHEET lamp Orange OFF The med...

Page 25: ... can be conducted with the operation panel Notes Refer to the User s Guide 2 4 3 Self diagnosis Function Display Indicates that you can make settings concerning adjusting the printer using the operation panel Keys of the operation panel have the same names and functions as the display status of the setup menu Notes Refer to the chapter Self Diagnosis function 2 4 4 Maintenance Mode Display Indicat...

Page 26: ... display Japanese or English is selectable for the display language of the printer Follow the steps below to select the display language Step 1 Press the POWER key while pressing the CANCEL key on the operation panel Step 2 Press the F1 key or F2 key on the operation panel to change the parameter Step 3 Press the POWER key and then press the POWER key again ...

Page 27: ... dry before it reaches the automatic take up system 2 5 2 Rockhopper II 4 heater printers Heater element Temperature Function Pre heater Heater A 20 50 C Open the pores to make the media more receptive for eco solvent or eco solvent plus ink Fixer Heater B 20 70 C To establish optimum fixation onto the media coated and uncoated Optimizes the dot gain control Post Fixer Heater C 20 70 C The post fi...

Page 28: ...Maintenance Manual 29 AP 74065 Rev 1 2 27 09 04 2 5 3 2 or 4 heater To verify if your printer is equipped with 2 or 4 heaters please refer to the photo s mentioned below Rockhopper II 2 heater printer Rockhopper II 4 heater printer ...

Page 29: ...Rockhopper II series printers Maintenance Manual 30 AP 74065 Rev 1 2 27 09 04 ...

Page 30: ...rectional output Interweaving Mirror Output Multi Copy Ink Status Origin Control Speed Overview Table 914mm 36 wide output 50 64 87 Ink Set Up 2 x 4 Colours 6 Colours 2 x 4 Colours 6 Colours 360 x 360 5 7 37 7 2 9 19 6 5 7 37 7 3 9 27 7 720 x 360 5 8 22 8 2 9 11 5 5 9 23 1 5 3 20 6 720 x 720 2 9 11 4 1 4 5 6 2 9 11 5 2 6 10 2 1440 x 720 2 9 5 9 1 4 2 8 3 0 6 0 2 6 5 2 1440 x 1440 1 4 2 9 0 7 1 5 1...

Page 31: ...tage of 4 3 m or greater 64 model 12 7 m or larger Frontage of 4 7 m or greater Area 87 model 14 3 m or larger Frontage of 5 3 m or greater 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 25 C Humidity 40 to 60 without condensation...

Page 32: ...nd from printer Å Æ 20 SG 3 DATA2 To and from printer Å Æ 21 SG 4 DATA3 To and from printer Å Æ 22 SG 5 DATA4 To and from printer Å Æ 23 SG 6 DATA5 To and from printer Å Æ 24 SG 7 DATA6 To and from printer Å Æ 25 SG 8 DATA7 To and from printer Å Æ 26 SG 9 DATA8 To and from printer Å Æ 27 SG 10 ACK From printer Æ 28 SG 11 BUSY From printer Æ 29 SG 12 P ERROR From printer Æ 30 SG 13 SELECTED From pr...

Page 33: ...tional Specifications 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 34: ...so may result in electrical shock or fire 1 Conditions of the installation environment Select the place to install this unit according to the environmental condition in the table below 50 model 11 7 m or larger Frontage of 4 3 m or greater 64 model 12 7 m or larger Frontage of 4 7 m or greater Area 87 model 14 3 m or larger Frontage of 5 3 m or greater Floor loading capability 2490Pa 300kg m or ov...

Page 35: ...laces where there is direct sunlight or strong light Places where there is direct air from the air conditioner It is recommended to install the printer in an environment where the air conditioning is adjustable for temperature and humidity 2 Installation space Install on a horizontal place that satisfies following conditions The floor has the sufficient strength to sustain the weight of the printe...

Page 36: ...rcuits may be damaged Disconnect all cables from the machine Not doing so could cause damage to the printer Caution Assembling and disassembling the printer is only allowed 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 canno...

Page 37: ...ING THE COVER When replacing any of the parts inside the printer it is necessary to remove all covers The procedures for removing the covers are given below 1 I H cover 5 Panel unit assembly 2 Side cover R 6 Y rail cover 3 side Cover L 7 Front paper guide 4 Front cover 8 Rear paper guide ...

Page 38: ...the 4 screws fixing the I H cover Step 4 Remove the I H cover and I H cover lid 1 Screws M3x12 fixing the I H cover Step 5 Remove the 2 screws fixing the ink cover sensor Step 6 Remove the ink cover sensor 1 Ink cover sensor 2 Screws M2x10 fixing the ink cover sensor Step 7 Replace the parts inside the printer Step 8 Reinstall all parts in the opposite order of the removal procedure ...

Page 39: ...om the upper part of the side cover R 1 Screws M4x12 on the upper part of the side cover R Step 2 Remove the 2 screws from the bottom of side cover R 1 Screws M4x16 on the side of the bottom of side cover R Step 3 Remove the 3 screws from the back of the bottom of side cover R 1 Screws M4x16 on the back of the bottom of side cover R ...

Page 40: ...ottom of side cover R and the front cover nut 1 Hexagon socket head cap screws M4x16 2 Cover nut Step 6 Remove the 6 bolts from the front and back of the bottom surface on the bottom of the side cover R Step 7 Remove the bottom of side cover R 1 Hexagon socket head cap screws M5x18 Step 8 Replace the parts inside the printer Step 9 Reinstall all parts in the opposite order of the removal procedure...

Page 41: ...per part of side cover L 1 Screws M4x12 on the side of the upper part of the side cover L Step 2 Remove the 2 screws from the front of the bottom of side cover L 1 Screws 4x16 on the back of the bottom of side cover L Step 3 Remove the 3 screws from the back of the bottom of side cover L 1 Screws M4x16 on the rear of the bottom part of the side cover L ...

Page 42: ...ottom of side cover L 1 Hexagon socket head cap screws M4x16 2 Cover nut Step 5 Remove the 6 bolts from the front and back of the bottom surface on the bottom of side cover L 1 Hexagon socket head cap screws M5x18 Step 6 Remove the bottom of side cover L Step 7 Replace the parts inside the printer Step 8 Reinstall all parts in the opposite order of the removal procedure ...

Page 43: ...p 1 Open the front cover Step 2 Remove the E ring on the left side Step 3 Remove the 4 screws on the left and right cover spindles 1 E ring 2 Screws M3x8 on the left and right cover spindles Step 4 If the machine is a 50 inch model remove cover spindle L and then slide and remove the front cover 1 Cover spindle L ...

Page 44: ...tep 5 If the machine is 64 or 87 inch model remove the E ring and the sensor cam push the cover spindle L to the origin side and then slide and remove the front cover 1 Cover spindle L 2 Sensor cam 3 E ring Step 6 Reinstall all parts in the opposite order of the removal procedure ...

Page 45: ... Rockhopper II 2 heaters printer Step 1 Remove the I H cover Step 2 Remove side cover R Step 3 Remove side cover L Step 4 Remove the front cover Step 5 Remove the 4 screws fixing the carriage cover Step 6 Remove the carriage cover 1 Carriage cover 2 Screws M3x6 fixing the carriage cover Step 7 Reinstall all parts in the opposite order of the removal procedure ...

Page 46: ...6 fixing the panel unit assembly 3 Tape wire Step 4 Remove the panel unit assembly Step 5 Remove the 6 screws fixing the panel board assembly and the panel cover 1 Screws M3x8 fixing the panel cover Step 6 Remove the panel cover Step 7 Remove the 4 screws fixing the panel bracket and the panel board assembly 1 Screws M3x8 fixing the panel board assembly Step 8 Replace the panel board assembly Step...

Page 47: ...side cover R Step 2 Remove side cover L Step 3 Remove the front cover Step 4 Remove the carriage cover Caution Please note that this cover is only on a Rockhopper II 2 heaters printer Step 5 Remove the 3 screws fixing the Y rail cover and the Y rail cover FG 1 Y rail cover FG 2 Screws M3x6 fixing the Y rail cover and the Y rail cover FG Step 6 Remove the 6 screws from the front of the Y rail cover...

Page 48: ...rom the rear of the Y rail cover If the machine is an 87 inch model there are 8 screws on the rear Y rail cover 1 Screws M4x8 on the rear of the Y rail cover Step 8 Remove the Y rail cover Step 9 Replace the parts inside the printer Step 10 Reinstall all parts in the opposite order of the removal procedure ...

Page 49: ...r Step 4 Remove the carriage cover Caution Please note that this cover is only on a Rockhopper II 2 heaters printer Step 5 Remove the Y rail cover Step 6 Remove the screws from the top of front media guide Notes Please note that the amount of screws is size dependent Rockhopper II 2 heater 1 Screws on the top of front media guide Rockhopper II 4 heater 1 Screws on the top of front media guide ...

Page 50: ...ront media guide Rockhopper II 4 heater 1 Screws on the front of front media guide Step 8 Standing before the unit move the front paper guide towards you Step 9 Loosen the cables from their cable clamps Step 10 Carefully loosen the connectors Notes Be sure not to damage the cables or connectors Step 11 Remove the front paper guide Step 12 Replace the parts inside the printer Step 13 Reinstall all ...

Page 51: ... dependent 1 Screws on the rear paper guide Step 6 Remove the screws from the rear of rear paper guide Notes Please note that the amount of screws is size dependent Step 7 Standing at the rear of the unit move the rear paper guide towards you Step 8 Loosen the cables from their cable clamps Step 9 Carefully loosen the connectors Notes Be sure not to damage the cables or connectors Step 10 Remove t...

Page 52: ...I 2 heaters printer Step 6 Remove the Y rail cover Step 7 Unlock the head Notes Please refer to the Head lock menu Step 8 Pull the head out to the left of the maintenance station Caution When pulling the head out do not press on the cutter cap Doing so could damage the cutter blade Step 9 Remove the 2 screws fixing the head cover 1 Screws M3x8 fixing the head cover Step 10 Remove the head cover St...

Page 53: ...the front cover Step 5 Remove the carriage cover Caution Please note that this cover is only on a Rockhopper II 2 heaters printer Step 6 Remove the 6 screws fixing the maintenance cover Rockhopper II 2 heater Rockhopper II 4 heater 1 Screws M3x8 1 Screws M3x8 Step 7 Remove the maintenance cover Step 8 Replace the parts inside the printer Step 9 Reinstall all parts in the opposite order of the remo...

Page 54: ...s to be done in a special production environment Important Before replacing parts be sure to perform the following operations Turn the machine power OFF Remove the product s electrical plug from the socket Otherwise you may suffer electric shock or the machine s electric circuits may be damaged Disconnect all cables from the machine Not doing so could cause damage to the printer 4 3 1 Rockhopper I...

Page 55: ...ure that the strips connect properly Please make sure that the sensor blue blocks are positioned on the flat surface of the front paper guide Notes Please make sure that there are no air bubbles under the heater strip Air bubbles below the heater strip could cause overheating of the heater strip Step 10 Stick onto the sensor an isolation strip Step 11 Reinstall all parts in the opposite order of t...

Page 56: ...ckhopper II printer please follow the instructions mentioned below Step 1 Remove side cover L Step 2 Remove side cover R Step 3 Remove the front cover Step 4 Remove the Y rail cover Step 5 Remove the rear paper guide Step 6 Remove the rear heater strip Step 7 Degrease the plate Notes Make sure the plate is cleaned properly Dust glue and other parts must be removed Step 8 Stick the rear heater stri...

Page 57: ...ance Manual 58 AP 74065 Rev 1 2 27 09 04 Notes It will take 1 hour to let the glue dry Step 10 Reinstall all parts in the opposite order of the removal procedure Notes During reinstallation of the plate make sure there are no cables stuck ...

Page 58: ... cover Step 4 Remove the Y rail cover Step 5 Remove the front paper guide Step 6 Remove the dryer strip s Step 7 Degrease the plate Notes Make sure the plate is cleaned properly Dust glue and other parts must be removed Step 8 Stick the dryer strip s onto the plate Notes Make sure that the strips connect properly Please make sure that the sensor blue blocks are positioned on the flat surface of th...

Page 59: ...4H printer please follow the instructions mentioned below Step 1 Remove side cover L Step 2 Remove side cover R Step 3 Remove the front cover Step 4 Remove the Y rail cover Step 5 Remove the front paper guide Step 6 Remove the post fixer strip Step 7 Degrease the plate Notes Make sure the plate is cleaned properly Dust glue and other parts must be removed Step 8 Stick the post fixer strip onto the...

Page 60: ...printer Before replacing the fixer make sure to have following items 50 model Fixer B1 50 and Fixer B2 50 64 model Fixer B1 64 and Fixer B2 64 87 model Fixer B1 87 and Fixer B2 87 Isolation tape Plot platform calibre To replace the fixer on a Rockhopper II 4H printer please follow the instructions mentioned below Step 1 Remove side cover L Step 2 Remove side cover R Step 3 Remove the front cover S...

Page 61: ...f the plot platform 1 screws plot platform Step 9 Pull upwards the plot platform calibre and so remove the plot platform with fixer Step 10 Remove the fixer Step 11 Degrease the plot platform Notes Make sure the plate is cleaned properly Dust glue and other parts must be removed Step 12 Stick the two fixer strips onto the plot platform Notes Please make sure that there are no air bubbles under the...

Page 62: ...n a Rockhopper II 4H printer Before replacing the post fixer make sure to have following items 50 model Heater A 50 64 model Heater A 64 87 model Heater A 87 2 x press plate Silicone glue To replace the heater on a Rockhopper II 4H printer please follow the instructions mentioned below Step 1 Remove side cover L Step 2 Remove side cover R Step 3 Remove the front cover Step 4 Remove the Y rail cove...

Page 63: ... the heater strip could cause overheating of the heater strip Step 9 Stick with silicone glue the two press plates onto the heater strip 50 model X 380 mm 64 model X 380 mm Y 1060 mm 87 model X 660 mm Y 1200 mm Z 1750 mm Notes It will take 1 hour to let the glue dry Step 10 Reinstall all parts in the opposite order of the removal procedure Notes During reinstallation of the plate make sure there a...

Page 64: ...t the FFC type cable you should leave the plug disconnected from the power socket for a while Otherwise over current could be generated and damage the board When changing the main substrate assembly follow Parameter backup to backup the parameter Failure to do so could cause the life span counters for the waste fluid tank and tube not to reset resulting in an overflow of ink inside the printer See...

Page 65: ...sembly Step 6 Replace the cooling fan assembly Step 7 Remove the 15 screws fixing the Mainboard cover 1 Panel unit assembly 2 Cooling fan assembly 3 Screws M3x25 fixing the cooling fan assembly 4 Screws M3x20 fixing the cooling fan assembly 5 Mainboard cover 6 Screws M3x6 fixing the Mainboard cover Step 8 Remove the 4 screws fixing the HEAD_DRV board assembly 1 HEAD_DRV board assembly 2 Screws M3x...

Page 66: ...1 4 White Ink cover sensor 22 J122 5 White Lever foot SW cable 23 J123 4 Black Lever up sensor Transmission photosensor 24 J124 4 Yellow Lever down sensor Transmission photosensor 25 J125 6 White Maintenance origin sensor cable Transmission photosensor 26 J126 No preparation 27 J127 5 Red Head slide sensor 28 J128 5 Yellow P_REAR_L sensor 29 J129 4 Blue P_REAR_R sensor 30 J130 4 CR origin sensor T...

Page 67: ...156 3 Black Cover L sensor 57 J157 2 White PF motor Lock type 58 J158 3 White CR motor Lock type 59 J159 4 White Lever motor Lock type 60 J160 4 White Pump 1 motor 61 J161 5 White Pump 2 motor 62 J162 6 White HEAD U D motor 63 J163 7 White Maintenance U D motor 64 J164 4 White Wiper motor 65 J165 66 J167 7 White Interf Cable Db9 Jst 1 PCI_Linux board assembly 2 Screws fixing the PCI_Linux board as...

Page 68: ...agon spacer 4 Screws M3x6 5 Cooling fan assembly 6 Screws M3x20 fixing the cooling fan assembly 7 I F guide 8 Screws M3x8 fixing the I F guide Step 19 Replace the HDD_Extension board assembly Step 20 Replace the Mainboard assembly Step 21 Reinstall all parts in the opposite order of the removal procedure Step 22 Perform media sensor sensitivity adjustment following the Media sensor sensitivity adj...

Page 69: ...tructions in Replacing the Mainboard assembly HDD_Extension board assembly HEAD_DRV board assembly PCI_Linux board assembly and cooling fan assembly to remove the Mainboard assembly Step 2 Remove the 2 screws fixing the PS board cover 1 PS board cover 2 Screws M3x6 fixing the PS board cover Step 3 Remove the 5 screws fixing the Mainboard base 1 Screws M3x8 fixing the Mainboard base 2 Mainboard bas...

Page 70: ... the power board assembly 4 Power source 5 Screws M3x6 fixing the power source Step 7 Replace the power source Step 8 Remove the 2 screws and 2 hexagon nuts fixing the power source board assembly Step 9 Remove the power source board assembly Step 10 Reinstall all parts in the opposite order of the removal procedure Notes When installing the mainboard assembly be careful not to pinch the foot SW ca...

Page 71: ... Remove the connector between the inlet board assembly and the inlet assembly Step 4 Remove the 4 screws fixing the inlet board assembly 1 Inlet board assembly 2 Screws M3x6 fixing the inlet board assembly 3 Inlet assembly 4 Screws M3x6 fixing the inlet assembly and lever foot SW cable assembly 5 Screw M4x8 fixing the inlet assembly 6 Lever foot SW cable assembly Step 5 Replace the inlet board ass...

Page 72: ... Plug in 3 J403 4 White Ink sensor K Cartridge 1 4 J404 4 Black Ink sensor C Cartridge 2 5 J405 4 Red Ink sensor M Cartridge 3 6 J406 4 Yellow Ink sensor Y Cartridge 4 7 J407 4 Blue Ink sensor LC Cartridge 5 8 J408 5 White Ink sensor LM Cartridge 6 9 J409 5 Black Ink sensor O Cartridge 7 10 J410 5 Red Ink sensor G Cartridge 8 11 J411 5 Yellow SC cable K Cartridge 1 12 J412 5 Blue SC cable C Cartri...

Page 73: ... assembly connector from the PF motor cable assembly Step 2 Remove the 2 screws fixing the X motor installation board to the side of the L side frame 1 Screws M4x10 fixing the X motor installation board to the side of the L side frame 2 Screws M4x10 fixing the PF motor assembly to the X motor installation board 3 PF deceleration belt Step 3 Remove the 2 screws fixing the PF motor assembly to the X...

Page 74: ...Bearing 2 Screws M3x6 fixing the PF scale installation board 3 PF scale 4 Screws M4x10 fixing the PF encoder installation board Step 3 Remove the PF encoder installation board Step 4 Remove the bearing Step 5 Remove the 4 screws fixing the PF scale installation board Step 6 Remove the PF scale installation board Step 7 Replace the PF scale assembly Step 8 Remove the screws fixing the PF_ENC assemb...

Page 75: ...side cover R Side cover L refer to Removing side cover L Front cover refer to Removing the front cover Carriage cover refer to Removing the carriage cover Y rail cover refer to Removing the Y rail cover Media guide F refer to Removing media guide F Step 1 Follow step 1 to 6 in Replacing the PF_ENC assembly and PF scale assembly to remove the PF scale installation board Step 2 Loosen the set screw ...

Page 76: ...age cover Y rail cover refer to Removing the Y rail cover Media guide F refer to Removing media guide F Step 1 Follow the instructions in Replacing the PF motor assembly to remove the PF motor Step 2 Follow the instructions in Replacing the PF_ENC assembly and PF scale assembly to remove the PF_ENC assembly and the PF scale assembly Step 3 Replace the PF deceleration belt 1 PF deceleration belt St...

Page 77: ...ia guide F refer to Removing media guide F Step 1 Remove the connectors for the P_REAR_R sensor assembly and P_REAR_L sensor assembly from the Mainboard assembly Step 2 Remove the screw fixing the media sensor installation board 1 Media sensor installation board 2 Screw M3x8 fixing the media sensor installation board Step 3 Remove the media sensor installation board Step 4 Remove the 2 screws fixi...

Page 78: ...oving the carriage cover Y rail cover refer to Removing the Y rail cover Media guide F refer to Removing media guide F Step 1 Remove the suction fan assembly connector from the suction fan cable assembly Step 2 When replacing the suction fan cable assembly first remove the connector from the Mainboard assembly Step 3 Remove the 2 screws fixing the suction fan assembly 1 Suction fan assembly 2 Scre...

Page 79: ...fer to Removing the front cover Carriage cover refer to Removing the carriage cover Y rail cover refer to Removing the Y rail cover Media guide F refer to Removing media guide F Step 1 Remove the lever motor assembly connector Step 2 Remove the screw fixing the sensor installation board 1 Sensor installation board 2 Screw M3x8 fixing the sensor installation board Step 3 Remove the sensor installat...

Page 80: ... Step 6 Remove the hexagon socket head screws with spring washers 2 fixing the arm motor installation board 1 Arm motor installation board 2 Hexagon socket head screws with spring washers M4x10 Step 7 Replace the arm motor installation board Step 8 Reinstall all parts in the opposite order of the removal procedure ...

Page 81: ...ion board 1 Sensor installation board 2 Screw M3x8 fixing the sensor installation board Step 2 Remove the sensor installation board Step 3 Remove the transmission photosensor from the sensor installation board 1 Sensor installation board 2 Connector 3 Transmission photosensor Step 4 Remove the connector from the transmission photosensor Step 5 Remove the transmission photosensor Step 6 Apply the s...

Page 82: ...om the ORG sensor installation board 1 ORG sensor installation board 2 Connector 3 Transmission photosensor Notes The ORG sensor installation board has been adjusted at the origin in factory Do not loosen the fixed screws Step 4 Remove the connector from the transmission photosensor Step 5 Remove the transmission photosensor Step 6 Apply the screw lock to the tab portions of the transmission photo...

Page 83: ...e carriage cover Y rail cover refer to Removing the Y rail cover Step 1 Unlock the head Notes Refer to Head Lock Menu Step 2 Move the carriage from the capping position to the left Step 3 Remove the screw fixing the flushing box assembly 1 Flushing box assembly 2 Screw M3x8 fixing the flushing box assembly Step 4 Remove the tube from the flushing box assembly Step 5 Replace the flushing box assemb...

Page 84: ...riage cover Y rail cover refer to Removing the Y rail cover Media guide F refer to Removing media guide F Step 1 Remove the CR motor cable assembly connector from the CR motor assembly Step 2 Remove the 4 hexagon socket head cap screws fixing the CR motor assembly Step 3 Replace the CR motor assembly 1 CR motor assembly 2 Connector 3 Hexagon socket head cap screws M3x6 Step 4 Reinstall all parts i...

Page 85: ...ide cover R refer to Removing side cover R Side cover L refer to Removing side cover L Front cover refer to Removing the front cover Carriage cover refer to Removing the carriage cover Y rail cover refer to Removing the Y rail cover Step 1 Unlock the head Notes Refer to Head Lock Menu Step 2 Move the carriage from the capping position to the left Step 3 Rotate the 2 steel belt adjustment screws co...

Page 86: ...ing the steel belt 2 Steel belt Step 5 Replace the steel belt Notes Be careful when handling the steel belt The steel belt may be cut off when accreting dust to it or creasing it Step 6 Reinstall all parts in the opposite order of the removal procedure Step 7 Perform steel belt tension adjustment according to Steel belt tension adjustment ...

Page 87: ...er refer to Removing the Y rail cover Step 1 Remove the connectors on the SLIDE motor assembly and HD_SLIDE sensor assembly Step 2 Remove the 2 screws fixing the SLIDE motor assembly 1 SLIDE motor assembly 2 Screws M3x6 fixing the SLIDE motor assembly 3 HD_SLIDE sensor assembly 4 Screws M2x8 fixing the HD_SLIDE sensor assembly 5 Slide motor installation board 6 Screws M4x6 fixing the slide motor i...

Page 88: ...over Y rail cover refer to Removing the Y rail cover Step 1 Remove the T fence from the T fence spring hook on the side of the L side frame Rockhopper II 2 heater Rockhopper II 4 heater 1 T fence spring 2 T fence spring hook 3 T fence Step 2 Remove the screw fixing the T fence push plate 1 T fence push plate 2 Screw M3x6 fixing the T fence push plate 3 T fence Step 3 Remove the T fence from the ho...

Page 89: ...re is a film on the T fence remove the film and install the T fence Properly install the T fence to the hooks on the T fence stationary plate Refer to the figure in step 2 The T fence and the hooks on the stationary plate must have a loose fit When securing the stationary plate with screws it must be loosened enough so the T fence can be moved Insert the T fence into the hooks on the T fence push ...

Page 90: ...ley assembly 1 CR slave pulley assembly 2 Steel belt 3 Bearing stopper Step 3 Reinstall all parts in the opposite order of the removal procedure Step 4 Perform steel belt tension adjustment according to Steel belt tension adjustment Notes Be careful when handling the steel belt The steel belt may be cut off when accreting dust to it or creasing it The driven pulley shaft is installed one way only ...

Page 91: ...in Replacing the CR motor assembly to remove the CR motor assembly Step 2 Follow the instructions in Replacing the steel belt to remove the steel belt Step 3 Replace the CR actuator pulley Step 4 Replace the CR deceleration belt 1 CR slave pulley 2 CR deceleration belt Step 5 Reinstall all parts in the opposite order of the removal procedure Step 6 Adjust the tension of the CR deceleration belt ac...

Page 92: ...k tube Side cover R refer to Removing side cover R Side cover L refer to Removing side cover L Front cover refer to Removing the front cover Carriage cover refer to Removing the carriage cover Y rail cover refer to Removing the Y rail cover Step 1 Remove the 8 screws fixing the CR cover 1 CR cover 2 Screws M3x8 fixing the CR cover Step 2 Remove the CR tape power cable connector from the CR board a...

Page 93: ...p 11 Replace the steel bearing Step 12 Replace the tube guide Step 13 Remove the pipe clamp Step 14 Replace the CR tape power cable 1 Tube push plate 2 Cable clamp 2 Pipe clamp 3 Coupling O ring coupling screws 4 Screws fixing tube push plate M3x8 4 Screws fixing tube cramp M3x20 Step 15 Reinstall all parts in the opposite order of the removal procedure Notes The CR tape power cables must be bundl...

Page 94: ...embly Step 2 Remove the 2 screws fixing the cover R sensor assembly 1 Cover R sensor assembly 2 Screws M2x8 fixing the cover R sensor assembly Step 3 Replace the cover R sensor assembly Step 4 Reinstall all parts in the opposite order of the removal procedure Step 5 Perform cover sensor adjustment according to Cover sensor adjustment 2 Replacing the cover L sensor assembly Step 1 Remove media guid...

Page 95: ...tter holder Step 4 Replace the cutter spring Step 5 Reinstall all parts in the opposite order of the removal procedure 2 Replacing the cutter holder cutter cap solenoid assembly and solenoid spring Notes Remove following covers before replacing the cutter holder cutter cap solenoid assembly and solenoid spring Side cover R refer to Removing side cover R Side cover L refer to Removing side cover L ...

Page 96: ...the solenoid assembly to the cutter cap 1 Cutter cap 2 Screws M3x6 fixing the solenoid assembly to the cutter cap 3 Solenoid spring 4 Solenoid assembly 5 Screws M2x4 fixing the solenoid assembly to the cutter holder 6 Cutter holder Step 6 Replace the cutter cap and solenoid spring Step 7 Remove the 2 screws fixing the solenoid assembly to the cutter holder Step 8 Use a screwdriver to push the sole...

Page 97: ...refer to Removing side cover L Front cover refer to Removing the front cover Carriage cover refer to Removing the carriage cover Y rail cover refer to Removing the Y rail cover Head cover refer to Removing the head cover The print head assembly has been pre adjusted Do not disassemble it Step 1 Drain the ink from all ink paths according to Head wash menu Step 2 Loosen the 2 screws fixing the dampe...

Page 98: ...edure Notes Place the removed damper assembly facing upward and fix with tape or place it in a container to prevent the ink from leaking Ink adhesion on board may cause faulty print head Align the head tape power cables one by one to each head and paste together with double faced tape Make sure that the head does not float when installing the head A Insert the concave portion of the head base in t...

Page 99: ...r Head cover refer to Removing the head cover Step 1 Drain the ink from all ink paths according to Head wash menu Step 2 Follow step 1 in Replacing the print head assembly and head tape power cable to remove the damper clamp Step 3 Remove the ink tube and tube branch from the branch fixing material 1 Branch fixing material 2 Tube branch 3 Ink tube 4 H ink tube 5 Coupling screw O ring Step 4 Remove...

Page 100: ...o not grasp the film area of the damper strongly Doing so may cause faulty damper and print failure 4 7 4 Replacing the CR board assembly Notes To replace the board and connect or disconnect the FFC type cable you should leave the plug disconnected from the power socket for a while Otherwise over current could be generated and damage the board Remove following covers before replacing the CR board ...

Page 101: ... 30 White or Black Mainboard Lock type or Plug in 15 J215 30 White or Black Mainboard Lock type or Plug in 16 J216 30 White or Black Mainboard Lock type or Plug in 17 J217 21 White or Black I160B head 18 J218 21 White or Black I160B head 19 J219 21 White or Black I160B head 20 J220 21 White or Black I160B head 21 J221 21 White or Black I160B head 22 J222 21 White or Black I160B head 23 J223 21 Whi...

Page 102: ...he CR cursor to the left Step 2 Remove the CR_ENC assembly connector from the CR board assembly Step 3 Remove the T fence from the T fence spring and then from the CR_ENC assembly Step 4 Remove the 2 screws fixing the CR_ENC assembly 1 CR_ENC assembly 2 Screws M2x12 fixing the CR_ENC assembly Step 5 Replace the CR_ENC assembly Step 6 Reinstall all parts in the opposite order of the removal procedu...

Page 103: ...er to Removing the carriage cover Y rail cover refer to Removing the Y rail cover Head cover refer to Removing the head cover Step 1 Remove the P_EDGE sensor assembly connector from the CR board assembly Step 2 Remove the screw fixing the P_EDGE sensor assembly Step 3 Replace the P_EDGE sensor assembly 1 P_EDGE sensor assembly 2 Screw M2x12 fixing the P_EDGE sensor assembly Step 4 Reinstall all pa...

Page 104: ...black tape you have to stick a new black tape onto the print platform This black tape can be ordered with Mutoh Europe s order entry department To stick the black tape onto the print platform please follow the instructions mentioned below Important Before replacing parts be sure to perform the following operations Turn the machine power OFF Remove the product s electrical plug from the socket Othe...

Page 105: ...ere are no air bubbles under the black tape Air bubbles below the black tape could cause the black tape to come loose Step 4 There are grooves between the different print platform plates Cut the black strip at this place equal with this groove 1 groove Important Make sure not to cut the heater strip below the print platform Doing so will damage the printer ...

Page 106: ...sembly and solenoid spring to Replacing the P_EDGE sensor assembly to remove the parts in cursor components Step 2 Slide the CR cursor assembly to the opposite side of the home position Step 3 Follow the instructions in Replacing the steel belt to remove the steel belt from the CR cursor Step 4 Remove the 4 screws fixing the CR board installation board Step 5 Remove the CR board installation board...

Page 107: ...the CR cursor assembly to remove the CR cursor assembly Step 2 Remove the E ring fixing the cursor roller assembly 1 CR cursor assembly KY 80040 2 E ring fixing the cursor roller assembly Step 3 Replace the cursor roller assembly Step 4 Reinstall all parts in the opposite order of the removal procedure Step 5 Perform head height adjustment according to Head height adjustment 4 7 9 2 A Replacing th...

Page 108: ...of the side cursor roller assy 3 Brass spacer of the side cursor roller assy 4 E ring of the cursor roller assy 5 High load bearing of the cursor roller assy of downside 6 Brass spacer of the cursor roller assy Step 6 Apply the screw lock to the cursor axis and install the cursor roller assembly with the axis at the lower position Notes Be sure that the screw lock does not contaminate the cursor r...

Page 109: ...cursor roller assembly MY 43272 of downside 1 CR cursor assembly 2 E ring fixing the cursor roller assembly Step 4 Replace the cursor roller assembly Step 5 Install the spacers and the other parts as shown in the following figure 1 E ring fixing the side cursor roller assy 2 Spacer of the side cursor roller assy 3 High load bearing of the side cursor roller assy 4 Spacer of the side cursor roller ...

Page 110: ...ew lock to the cursor axis and install the cursor roller assembly with the axis at the lower position Notes Be sure that the screw lock does not contaminate the cursor roller or the spacer 1 Applying position of the screw lock Step 7 Perform head height adjustment according to Head height adjustment ...

Page 111: ...r to Removing side cover R Side cover L refer to Removing side cover L Front cover refer to Removing the front cover Carriage cover refer to Removing the carriage cover Y rail cover refer to Removing the Y rail cover Step 1 Follow step 1 in Replacing the flushing box assembly to move the CR cursor to the left Step 2 Remove the 4 screws fixing the side plate T 1 Side plate T 2 Screws M3x6 fixing th...

Page 112: ...M3x8 fixing the maintenance assembly Step 10 Replace the maintenance assembly Notes Secure the maintenance assembly so that it abuts against the rear right portion If the cap tube has not been cut cut it to the length below measured from the end of the tube Numbers in brackets are the cap numbers from left to right as viewed from the front of the main body For 50 64 inch model 1 50mm 2 0mm 3 40mm ...

Page 113: ...del 4 heater Cap a and Pump 1 Cap b and Pump 3 Cap c and Pump 4 Cap d and Pump 2 Cap e and Pump 5 Cap f and Pump 7 Cap g and Pump 8 Cap h and Pump 6 50 or 64 Rockhopper II 2 heater 87 Rockhopper II 2 heater 50 or 64 Rockhopper II 4 heater 87 Rockhopper II 4 heater Step 11 Move the cursor to the opposite side of the origin Step 12 Cap once Step 13 Use a mirror to check that the cap does not impinge...

Page 114: ...ick the new wipers in the new wiperarm on the positions and manor shown in the pictures No Part 1 Well positioned wiper 2 Malpositioned wiper For Rockhopper II 50 and 64 For Rockhopper II 87 Position 3 4 5 6 Position 1 3 5 7 4 8 2 2 Installing the wiperarm Step 1 Power ON the printer and go to the WiperClean Menu This will cause the unlocking of the carriage WiperClean Changed wiper ENTER 1 2 3 4 ...

Page 115: ...Step 2 Push the carriage to the left side of the machine so you can remove the four screws of the wiper assembly No Part 1 Screws Step 3 Remove the wiper assembly Notes Be careful removing the wiper assembly so you don t break the sensor located close to the wiper No Part 1 Sensor ...

Page 116: ...065 Rev 1 2 27 09 04 Step 4 Remove the wiperarm and reinstall the new one No Part 1 Wiperarm assembly 2 T plate Step 5 To reinstall the wiper assembly please reverse the removal procedure Step 6 After complete reinstallation clean the wipers using Isopropanol ...

Page 117: ...rated so be careful not to burn yourself Step 1 Follow the instructions in Replacing the maintenance assembly to remove the maintenance assembly Step 2 Remove the 2 screws fixing the SLIDE motor assembly 1 SLIDE motor assembly 2 Screws M3x6 fixing the SLIDE motor assembly Step 3 Replace the SLIDE motor assembly Step 4 Reinstall all parts in the opposite order of the removal procedure ...

Page 118: ... assembly 4 Maintenance origin cable assembly 5 Side plate R Step 2 Remove each origin cable assembly from the transmission photosensor Step 3 Remove the transmission photosensor Step 4 Apply the screw lock to the tab portions of the transmission photosensors to be installed Step 5 Reinstall all parts in the opposite order of the removal procedure Notes When installing the origin cable assembly on...

Page 119: ...de cover L refer to Removing side cover L Front cover refer to Removing the front cover Carriage cover refer to Removing the carriage cover Y rail cover refer to Removing the Y rail cover Maintenance cover refer to Removing the maintenance cover Step 1 Remove the connector and tube from the pump assembly 1 tube connections Notes There is some remaining ink in the tubes Be careful that the ink is n...

Page 120: ...al procedure Notes Follow the instructions in Pump tubing layout for pump assembly to connect the tube 4 9 2 Replacing the pump assembly Step 1 Follow the instructions in Replacing the pump assembly to remove the pump assembly Step 2 Remove the screw fixing the pump assembly 1 Pump assembly 2 Screws M3x6 fixing the pump assembly Step 3 Replace the pump assembly Step 4 Reinstall all parts in the op...

Page 121: ... operated so be careful not to burn yourself Step 1 Follow the instructions in Replacing the pump assembly to remove the pump assembly Step 2 Remove the 2 screws fixing the pump motor assembly 1 Pump motor assembly 2 Screws M3x6 fixing the pump motor assembly Step 3 Replace the pump motor assembly Step 4 Reinstall all parts in the opposite order of the removal procedure ...

Page 122: ...Step 1 Perform the ink discharge operation to discharge the ink from the inside of all ink paths Notes For ink draining procedure refer to Head wash menu Step 2 Remove the following connectors from the JUNCTION board assembly Ink sensor assembly connectors 8 SC cable assembly connectors 8 Notes For more details of the JUNCTION board assembly connector refer to Table Connectors connected to the JUN...

Page 123: ...d Step 8 Remove the coupling screws and O ring from the I H assembly Step 9 Remove the 4 screws fixing I C slide 2 and the I H assembly 1 I H assembly 2 I C slide 2 3 Screws M3x8 fixing I C slide 2 and the I H assembly Step 10 Remove the I H assembly Step 11 Reinstall all parts in the opposite order of the removal procedure Notes Please soak the O ring in cleaning liquid before installation ...

Page 124: ... from the ink ID board assembly Step 5 Replace the ink ID board assembly Step 6 Reinstall all parts in the opposite order of the removal procedure 3 Replacing the cartridge frame assembly Step 1 Remove the I H assembly Step 2 Remove the cables from the I H assembly clamp Step 3 Disengage the hook fixing the cartridge frame assembly and then slide the cartridge frame assembly in the direction of th...

Page 125: ...D sensor 2 Screw M3x10 fixing the ink END sensor Step 5 Remove the ink END sensor Step 6 Remove the screw fixing the Ink NOT sensor to the Cartridge frame assembly 1 Ink NOT sensor 2 Screw M2x8 fixing the ink NOT sensor Step 7 Remove the ink NOT sensor Step 8 Replace the ink sensor assembly Step 9 Reinstall all parts in the opposite order of the removal procedure Notes When installing the ink NOT ...

Page 126: ...e counter High ink initialization or Cleaning initialization refer to Counter Initialization Menu Step 1 Remove the waste fluid tube from the waste fluid bottle assembly 1 Waste fluid tube 2 Waste fluid bottle assembly Step 2 Replace the waste fluid bottle assembly Caution Waste ink will remain inside the tubes Be careful that the ink is not spilled from the tube onto the printer or items close to...

Page 127: ...e waste fluid bottle assembly be sure to perform following operation to clear the counter High ink initialization or Cleaning initialization refer to Counter Initialization Menu Step 1 Remove the waste fluid bottle assembly Caution Waste ink will remain inside the tubes Be careful that the ink is not spilled from the tube onto the printer or items close to the printer ...

Page 128: ...ove the waste liquid BOX sensor assembly connector from the rear side cap R 1 Rear side cap R 2 Waste liquid BOX sensor assembly connector Step 3 Remove the screws 3 at the front and 12 at the right and left fixing the waste liquid bottle cover 1 Waste liquid bottle cover 2 Screws M3x6 Step 4 Remove the waste liquid bottle cover Step 5 Remove the screws 2 fixing the waste liquid sensor installatio...

Page 129: ... 2 Waste liquid BOX sensor assembly 3 Screws M2x8 Step 8 Remove the waste liquid BOX sensor assembly Step 9 Reinstall all parts in the opposite order of the removal procedure Notes When installing the waste liquid BOX sensor assembly pay attention to following points Adjust the waste liquid BOX sensor assembly before installing the waste liquid bottle cover Position and install it so that Sensor W...

Page 130: ...ttle assembly to remove the waste fluid bottle assembly Caution Waste ink will remain inside the tubes Be careful that the ink is not spilled from the tube onto the printer or items close to the printer Step 2 Remove the waste liquid BOX sensor assembly connector from the rear side cap R 1 Rear side cap R 2 Waste liquid BOX sensor assembly connector Step 3 Remove the waste liquid box assy from the...

Page 131: ...p 5 Reinstall all parts in the opposite order of the removal procedure Notes When installing the waste liquid BOX sensor assembly pay attention to following points Adjust the waste liquid BOX sensor assembly before installing the waste liquid bottle cover Position and install it so that Sensor Waste liquid tank is properly switched in Sensor Menu ...

Page 132: ...mbly 1 Scroller R assembly 2 Hexagon socket head springs Step 2 Replace the scroller R assembly Step 3 Reinstall all parts in the opposite order of the removal procedure 2 Replacing the pressure roller roller 1 and roller 2 Step 1 Remove the 4 screws fixing scroller receptacle cover R 1 Scroller receptacle cover R 2 Screws M3x8 fixing scroller receptacle cover R 3 Scroller R assembly Step 2 Remove...

Page 133: ...4065 Rev 1 2 27 09 04 Step 3 Remove the E ring fixing the axes of the rollers to be replaced 1 Pressure roller 2 Roller 1 3 Roller 2 4 E ring E 3 5 E ring E 4 Step 4 Replace the rollers Step 5 Reinstall all parts in the opposite order of the removal procedure ...

Page 134: ...L assembly 1 Scroller L assembly 2 Hexagon socket head springs Step 2 Replace the scroller L assembly Step 3 Reinstall all parts in the opposite order of the removal procedure 2 Replacing the pressure roller and roller 1 Step 1 Remove the 4 screws fixing scroller receptacle cover R 1 Scroller receptacle cover R 2 Screws M3x8 fixing scroller receptacle cover R 3 Scroller L assembly Step 2 Remove sc...

Page 135: ... AP 74065 Rev 1 2 27 09 04 Step 3 Remove the E ring fixing the axes of the rollers to be replaced 1 Pressure roller 2 Roller 1 3 E ring E 3 4 E ring E 4 Step 4 Replace the rollers Step 5 Reinstall all parts in the opposite order of the removal procedure ...

Page 136: ...from the operation panel Notes Refer to Part names and functions 5 2 PREPARATION Before you can use the self diagnosis function you should make the machine ready and display the self diagnosis menu 5 2 1 Preparations on Machine Before starting up the self diagnosis function perform following preparations 1 Setting printing media Set a roll media for adjustment Notes Make sure to use coated paper f...

Page 137: ...the normal operation mode and self diagnosis display mode To call up the self diagnosis menu follow the steps below Step 1 If the system is in the operation mode or the self diagnosis menu mode press the POWER key to power off the unit The power is turned off Step 2 Press and hold the F2 key F4 key and MENU key simultaneously While holding down these keys press the POWER key The system will enter ...

Page 138: ...ailable diagnosis items 5 3 1 Operating Self Diagnosis Mode Follow the operation flow shown below to operate the self diagnosis mode For more detailed operation steps refer to the flow chart of the applicable diagnosis item Step 1 Press the MENU key or the MENU key on the operation panel to change over the diagnosis menu Step 2 Press the F1 key F2 key F3 key or F4 key to select the applicable diag...

Page 139: ... key or the F4 key on the operation panel to modify the set value Step 4 To save the modified value press the ENTER key on the operation panel The modified set value is stored and a next item is displayed Notes If you press the CANCEL key instead of the ENTER key the modification will not be stored ...

Page 140: ...ensors and fans Refer to Inspection Menu Adjustment Menu Performs various adjustments for the printer mechanism Refer to Adjustment Menu Purge Menu Performs mode specified purge Refer to Purge Menu Sample Printing Menu Performs sample printing necessary for adjustment Sample Printing Menu Parameter Menu Configures various adjustment parameters Refer to Parameter Menu Endurance Running Menu Perform...

Page 141: ...functions of the operation panel keys LCD and LED Operation Panel Menu Sensor This menu displays the sensor status in the operation panel CR_HP sensor Cover sensor Lever sensor P_EDGE sensor P_REAR sensor HD_SLIDE sensor Thermistor sensor Ink ID sensor Ink NOT sensor Ink END sensor Sensor Menu Encoder Displays the detected values from the following encoders CR Carriage PF Media feed Encoder Menu F...

Page 142: ...alled on the mainboard 128 MB or 256 MB 5 4 2 Version Menu This menu displays following contents about the firmware and mainboard assembly Firmware version Backup parameter version Setting of dip switches of mainboard assembly Revision of mainboard assembly Notes The details of the dipswitch setting of mainboard assembly are as follows Switch 1 OFF Switch 2 OFF Ver Firm rh 2 08 mA Parameter 1 00 1...

Page 143: ...el the name of the key is displayed on the LCD To exit the operation panel key check press the CANCEL key twice 2 LCD check The entire LCD screen is filled in black You can check for any missing dots 3 LED check The following LEDs light up in order The LCD displays the name of the LED that is currently illuminated Power lamp Error lamp Data lamp Media set lamp Roll media lamp Cut media lamp Heater...

Page 144: ...R R sensor ON OFF Replacing the P_REAR_R sensor assembly and P_REAR_L sensor assembly P_REAR L sensor ON OFF Replacing the P_REAR_R sensor assembly and P_REAR_L sensor assembly HD_SLIDE sensor ON OFF Replacing the SLIDE motor assembly HD_SLIDE sensor assembly and slide motor installation board Head thermister C Ink ID sensor Pig Dye WASH Replacing the Cartridge Area Ink NOT sensor 12345678 Replaci...

Page 145: ...9 Sensor Headslide On HD_SLIDE sensor Temp 25 C Head thermistor 7 9 Sensor Ink ID 12 34 5678 Ink ID Sensors ww 8 9 Sensor Ink Not Ink NOT sensor Ink End Ink END sensor 9 9 5 4 5 Encoder Menu This menu displays the detected values from the following encoders CR_ENC Carriage PF_ENC Media feed Notes For the encoder detected values the encoder pulse numbers are displayed in hexadecimal number Encoder ...

Page 146: ...mber of drives of the CR motor Number of drives of the PF motor Number of printing copies Number of cleanings Discharge amount of head ink 1 A B nozzles M dot Discharge amount of head ink 2 A B nozzles M dot Discharge amount of head ink 3 A B nozzles M dot Discharge amount of head ink 4 A B nozzles M dot Cutter solenoid down times Notes For the CR motor drive count 1 pass becomes 1 count For the P...

Page 147: ...ad 3 A nozzle ink Fire 3 B 00000000Mdot Discharge amount of head 3 B nozzle ink 7 10 Maintenance Fire 4 A 00000000Mdot Discharge amount of head 4 A nozzle ink Fire 4 B 00000000Mdot Discharge amount of head 4 A nozzle ink 8 10 Maintenance Pump A 24926 Number of cycles of Pump A Pump B 24980 Number of cycles of Pump B 9 10 Maintenance Cut Sole 00000000 Cutter solenoid down time 10 10 2 Serious error...

Page 148: ...ance Manual 149 AP 74065 Rev 1 2 27 09 04 5 4 8 Head Signal Menu This menu is used to check the head driving signal Head Signal F1 Flush Mode1 F2 F3 Mode2 Mode3 F4 1 2 Head Signal F1 Mode5 Mode7 F2 2 2 Select Head Signal ENTER Flush Drive ...

Page 149: ...n Repeatability Adjustment Menu CW adjustment Prints out a print to adjust any gaps between the heads CW Adjustment Menu Band feed correction Prints out a print to correct the media feed amount for each pass Band Feed Correction Menu X Length Top bottom adjustment Sets the top and bottom margins Top bottom adjustment menu P_REAR sensor position adjustment Adjusts the position of the P_REAR sensor ...

Page 150: ...s Before performing skew check ensure that the media is set correctly Since the reference position where media has been set is determined the first time the media left edge is detected errors may result as follows if the media is not setup correctly Media errors occur during skew check and the operation stops Undefined Media occurs frequently during media initialization when the power is turned on...

Page 151: ... the QR code reader QRcode QRcode Input Head1 QRcode Head ID input ENTER Incorrectly entered Error Correctly entered Initial charge menu Press ENTER to re enter 3 When input from the operation panel is selected Input the parameters of the upper and lower sections of the head rank using the operation panel keys Panel QRcode ID1 H Head ID input 7BZ3E3CVXUWVWQQ 21 ENTER Incorrectly entered Error Pres...

Page 152: ...After media has been set the machine prints out head nozzle check patterns in the following modes The following is the description of the printing method 1 pass Single way Step 3 Check the printed head nozzle check patterns for the following points Check points are as follows Ink nozzle discharge amount omission discontinuity meandering Satellite T fence Nozzle alignment in vertical direction Nozz...

Page 153: ...nditions are found in the ink discharge status of the head nozzles perform ink purge on the relevant heads Step 5 After the ink purge the system returns to the purge selection menu ChkNozzle Set Paper If media is not set Media set ChkNozzle Paper Initial End Media initialization ChkNozzle F1 End Output Pattern F2 1 2 ChkNozzle F1 Normal Powerful F2 F3 Little 2 2 If Normal cleaning is selected Norm...

Page 154: ...ead machine Step 1 Start the self diagnostic function Notes Refer to Self Diagnosis Function Step 2 Select Adj HeadSlant Step 3 Print Slant pattern If dotted lines on pattern CW and CCW are not a straight line which you can check with a magnifying glass enlargement of at least 10 please go to step 4 Notes When the printing pattern is printed you will only see lines and no notifications of ink chan...

Page 155: ...e heads are well seated In case you only print uni directional adjust the CW till it is aligned perfectly In case you print bi directional and CW and CCW cannot be aligned more perfectly Divide the fault equally When printing the pattern the head identifications 1A 1B etc are not printed Analyse the pattern as shown below Be sure to have five lines for each color How to adjust What to become No Pa...

Page 156: ...8 head model 3A 3B 1A 1B 2A 2B 4A 4B 5A 5B 6A 6B 7A 7B 8A 8B Step 4 Loosen the screw with one turn fixing the head stationary plate Step 5 Make adjustments until amount of CW and CCW offset are identical Notes In theory the alignment of CW and CCW should be identical But in practice it is almost impossible to become a perfect alignment When there is a slight difference between CW and CCW be sure t...

Page 157: ... etc are not printed Analyse the pattern as shown below Be sure to have five lines for each color 8B 8A 7B 7A 6B 6A 5B 5A 4B 4A 2B 2A 1B 1A 3B 3A Adjustable head slant Adjusted head slant No Part 1 Angle adjustment screw Step 6 Tighten the screw fixing the head stationary plate Repeat step 1 to 6 until the adjustment is correct for all heads ...

Page 158: ...llow the steps mentioned below Step 1 In diagnostic mode go to Adjust Head Slant Step 2 Press the F2 key for F B front and back adjustment HeadSlant F1 Slant F B F2 F3 Check End F4 Step 3 Print out Front Back pattern First pattern A with 1A as reference is printed then pattern B with 4B as reference and finally A B A B B 4B is the reference head A 1A is the reference head ...

Page 159: ... diagram below Know you see 1A is Black 1B is Yellow etc in our color combination Step 4 Check if all nozzles are in 1 row by using a magnifying glass with an enlargement of at least 10 If not please proceed to step 5 Step 5 Loosen the screw with 1 turn which secures the Head Fixing Plate No Part 1 Head Fixing plate securing screw 2 Front Back Adjustment Screw ...

Page 160: ...ould automatically be adjusted But in practice this isn t always a fact When your determine a small misalignment after adjusting A well readjust again until all nozzles of row A and B are perfectly aligned NOTE We only give an example for one colour combination Please refer to Operation Procedure Labels in the Maintenance Manual where you can find the other possible colour combinations Step 7 Tigh...

Page 161: ...B front and back adjustment HeadSlant F1 Slant F B F2 F3 Check End F4 Step 3 Print out Front Back pattern A B B 3B is the reference A 6A is the reference NOTE To help you identify the print heads on the test pattern please refer to the diagram below Now you can see 1A is black 1B is LM follow the line till you reach the junction Then go up to Light Magenta Step 4 Check if all nozzles are in 1 row ...

Page 162: ...utomatically be adjusted But in practice this isn t always a fact When your determine a small misalignment after adjusting A well readjust again until all nozzles of row A and B are perfectly aligned NOTE We only give an example for one colour combination Please refer to Operation Procedure Labels in the Maintenance Manual where you can find the other possible colour combinations Step 7 Tighten th...

Page 163: ...ots to the right you have to increase the value For example The value is 20 adjust it to 30 for example The value is 20 adjust it to 10 for example When you want to move the even rows with dots to the left you have to decrease the value For example The value is 20 adjust it to 10 for example The value is 20 adjust it to 30 for example 4B 4A 3B 3A 2B 2A 1B 1A Notes For 87 inch specifications the he...

Page 164: ...ast 10 When you want to move the even rows with dots to the right you have to increase the value For example The value is 20 adjust it to 30 for example The value is 20 adjust it to 10 for example When you want to move the even rows with dots to the left you have to decrease the value For example The value is 20 adjust it to 10 for example The value is 20 adjust it to 30 for example 1B 1A 1B 1A 1B...

Page 165: ... in the media feed direction Then you enter the measured value through this menu The system uses this entered value to determine the PF encoder resolution parameter in the firmware To perform an X length Adjustment please follow the steps mentioned below Step 1 Go to Feed Adjustment Step 2 Set the parameter value to 900 mm Step 3 Print out the Feed Adjustment pattern Step 4 Measure the printed Ban...

Page 166: ...00 500 mm ENTER CANCEL Feed Adj Enter Print Start ENTER Feed Adj Set paper A media is not set Media setting Feed Adj Paper Initial Finish media initialization Feed Adj Adjustment Print Display during adjustment printing Finish printing Feed Adj X Length 300 1010 500 0 mm ENTER Feed Adj Enter Print Start ...

Page 167: ... the following adjustment items for the results of the printing of the top bottom adjustment pattern Measurements are carried out at the center of the media The adjustment items are as follows Top distance Bottom distance Side margin 1 Top distance 2 Bottom distance 3 Side margin 4 Media feed direction Step 4 Input each measurement as a parameter Top Bottom Set Paper If media is not set Set media ...

Page 168: ... adjustments following the steps below Step 1 Set media as necessary Notes Use cutting media for adjusting the P_REAR sensor Set A3 cutting media in portrait orientation P_REAR sensor position adjustment is a process necessary during manufacturing This does not need to be done when band feed is compensated Step 2 After the media has been set a pattern printing with the P_REAR sensor position adjus...

Page 169: ... Check media width ENTER Rear Sensor Rear Sensor 7 0 27 0 17 0 mm 5 5 10 Test print menu In this menu you can print out adjustment patterns for checking various adjustment items Make adjustments following the steps below Step 1 Set media as necessary Step 2 After media has been set the machine prints out the following test Printings Nozzle check Head nozzle check pattern Adjustment variables Set v...

Page 170: ... 6 After the ink has been drained install the head cleaning fixture Step 7 Press the ENTER key in the operation panel to supply the cleaning fluid Step 8 After the cleaning fluid has been supplied remove the head cleaning fixture Step 9 Drain the cleaning fluid by pressing the ENTER key in the operation panel Step 10 Initialize the waste ink history Notes When performing the ink cleaning always in...

Page 171: ...y to drain ink Clean Head Ink Discharge End Ink draining Clean Head Set Cleaning jig Set the head cleaning jig and press the ENTER key to charge the cleaning liquid Clean Head Head Cleaning Charge cleaning liquid Clean Head Remove cleaning jig Remove the head cleaning jig and press the ENTER key to drain the cleaning liquid Clean Head Head Cleaning ...

Page 172: ...onsumption counter 1 0 Ink consumption counter 2 0 Ink consumption counter 3 0 Ink consumption counter 4 0 Ink consumption counter 5 0 Ink consumption counter 6 0 Ink consumption counter 7 0 Ink consumption counter 8 0 Cumulative printout timer 0 Waste ink counter 0 Ink ID mask Reset Initial ink charge flag Set Pressing the ENTER key in the operation panel performs the software counter initializat...

Page 173: ... patterns Pattern 1 Drawn with 1 inch 2 54 cm intervals Pattern 2 Draw a repetitive pattern with 1 4 inch 0 635 cm intervals every 4 lines and 0 63 cm intervals between each of the 4 lines Step 4 Confirm that it is drawn at 1 inch intervals as shown in the following drawing A Media feed direction 5 5 14 Fill printing menu A fill printing pattern is printed by both ends of the head A Media feed dir...

Page 174: ... printer heads The Purge menu includes the following diagnosis items Diagnosis item Description Normal Performs normal purge Powerful Performs powerful purge Little Performs minimum purge Initial ink charge Performs initial ink charge Cleaning F1 Normal Powerfull F2 F3 Little Ink charge F4 Select item Normal cleaning Normal Cleaning ...

Page 175: ...enu includes the following items Diagnosis item Description Nozzle Check Prints the head nozzle check pattern Adjustment variables Prints out the set values of various adjustment items Notes When serial numbers are not input to this product the serial numbers become blank spaces Print F1 Nozzle Adj Variable F2 Select item Nozzle check Check Nozzle Adjustment Print ...

Page 176: ...er Update Menu Parameter F1 Initialize Update F2 5 8 1 Parameter Initialization Menu This menu initializes the adjustment parameters The parameters that can be initialized in this menu are as follows Capping position Media feed distance Serial number Head history Wiper history Waste ink history CR motor history PF motor history Pumps Waste tank Initialization of all items Initialize F1 P FeedLen s...

Page 177: ...osition alignment CW adjustment Media feed distance Mechanical parameter Ink parameter Ink ID mask Serial number Notes If you update any parameter in the Parameter Update menu always turn the power OFF after quitting the menu The updated parameters will not be stored in the flash memory unless the system power is turned OFF Update F1 HeadRank PrintPos F2 F3 CW Adj P FeedLen F4 1 2 Update F1 Mechpa...

Page 178: ...ion After a head ID has been entered the system shifts to the Ink Charge menu HeadRank HeadRank ID1 H Head ID input 1BZ3E3ECVXUWWQQ ENTER Incorrectly entered Error Press ENTER to re enter HeadRank ID1 L 00Y0IZVTTR 40UWJB ENTER HeadRank Update Parameter ENTER HeadRank Updating Parameter HeadRank CANCEL Ink charge ENTER Initial charge is not performed Rank input value is updated ENTER Charge 1 No Ca...

Page 179: ... 1 Head 1A 28 PrintPos Adj 1 Head 1B 28 If the parameter is updated PrintPos Adj PrintPos Adj 1 Head 4B ENTER Update Parameter 48 ENTER PrintPos Adj Updating parameter 3 CW This updates the CW adjustment parameters CW Adj Gap 1 2 400 400 0 CW Adj Gap 1 3 400 400 0 If the parameter is updated CW Adj CW Adj Gap 1 4 400 400 ENTER Update Parameter 0 ENTER CW Adj Updating Parameter ...

Page 180: ...rs Maintenance Manual 181 AP 74065 Rev 1 2 27 09 04 4 Media feed distance This updates the media feed distance parameters PaperFeedLen X Length 290 1010 500 0 mm ENTER PaperFeedLen Update Parameter ENTER Update Updating Parameter ...

Page 181: ...chanical position parameters The setup items are as follows Top distance Bottom distance Side margin P_REAR sensor position Mechparm Top Length 0 40 0 5 0 mm Mechparm Bottom 0 40 0 5 0 mm Mechparm Side 0 20 0 5 0 mm Mechparm Rear Sensor 0 27 0 17 0 mm ENTER Mechparm Update Parameter ENTER Mechparm Updating Parameter ...

Page 182: ...nkParameter Init Fill Flag Set ENTER InkParameter Update Parameter If the parameter is changed ENTER InkParameter Updating Parameter 7 Ink ID mask Update the ink ID mask parameters The setup items are as follows Set Ink ID is always fixed When a mask has been set any cartridge inserted will be handled as dye 4 colours fixed Reset Resets the ink ID mask Cartridge recognition becomes available via s...

Page 183: ...umber entry This is for entering the serial number SerialNo DD5 000001 SerialNo DD5C 00001 SerialNo DD5C1 0001 SerialNo DD5C12 001 SerialNo DD5C123 01 SerialNo DD5C1234 1 SerialNo DD5C12345 Notes The third figure of a serial number differs with the machine size 5 50 inch 6 64 inch 8 87 inch ...

Page 184: ... Menu Head lock Tests head lock operation Performs wiper up down operation via the selecting menu Head Lock Endurance menu Pump Drives the positive negative pressure pump motor Pump Endurance menu Lever motor Drives the lever motor Sequential Printing Endurance Menu Nozzle print Prints out a printing by printer heads repeatedly Sequential Printing Endurance Menu General endurance Performs enduranc...

Page 185: ... cycles Set the number of endurance running cycles 1 to 10000 Notes If the number of endurance running cycles has been set to 1 the units continuously repeat endurance running until a key input is given from the operation panel The maximum counter value for endurance running cycles is 99999999 up to 8 digit number If the number of cycles exceeds the maximum value the counter is reset to 0 Speed CW...

Page 186: ...cycles 1 to 10000 Notes The motor drive parameters are determined as follows depending on the media feed amount Speed 54 cps Acceleration 0 1 G Deceleration 0 1 G If the number of endurance running cycles is set to 1 the units continuously repeat endurance running until a key input is given from the operation panel The maximum counter value for endurance running cycles is 99999999 up to 8 digit nu...

Page 187: ... item Description Parameters Remarks Page size Sets amount of media feeds per endurance operation 30 to 3000 Unit mm Number of endurance running cycles Set the number of endurance running cycles 1 to 10000 Waiting time Set the waiting time after one cycle of endurance running 40 Unit second Notes If the number of endurance running cycles is set to 1 the units continuously repeat endurance running ...

Page 188: ...0 Unit second Number of endurance running cycles Set the number of endurance running cycles 1 to 10000 Notes If the number of endurance running cycles is set to 1 the units continuously repeat endurance running until a key input is given from the operation panel The maximum counter value for endurance running cycles is 99999999 up to 8 digit number If the number of cycles exceeds the maximum value...

Page 189: ... operation according to the set items Notes Refer to Head Up Down Endurance Menu The wait time for head lock endurance is set to 10 seconds Head lock Wiper U D Yes No Wiper up and down Yes ENTER LifeCount Count 1 10000 Number of endurance running cycles 50 ENTER Head Lock Time Wait sec 10 Check wait time ENTER to perform endurance Head Lock Count 5 Perform endurance running End Head Lock End 50 ...

Page 190: ... High Normal Low Number of endurance running cycles Set the number of endurance running cycles 1 to 10000 Notes If the number of endurance running cycles is set to 1 the units continuously repeat endurance running until a key input is given from the operation panel The maximum counter value for endurance running cycles is 99999999 up to 8 digit number If the number of cycles exceeds the maximum va...

Page 191: ...unning cycles Set the number of endurance running cycles 1 to 10000 Notes If the number of endurance running cycles is set to 1 the units continuously repeat endurance running until a key input is given from the operation panel The maximum counter value for endurance running cycles is 99999999 up to 8 digit number If the number of cycles exceeds the maximum value the counter is reset to 0 LifeCoun...

Page 192: ... Yes No Number of endurance running cycles Set the number of endurance running cycles 1 to 10000 Notes If the number of endurance running cycles is set to 1 the units continuously repeat endurance running until a key input is given from the operation panel The maximum counter value for endurance running cycles is 99999999 up to 8 digit number If the number of cycles exceeds the maximum value the c...

Page 193: ...ing cycles Set the number of endurance running cycles 1 to 10000 Notes If the number of endurance running cycles is set to 1 the units continuously repeat endurance running until a key input is given from the operation panel The maximum counter value for endurance running cycles is 99999999 up to 8 digit number If the number of cycles exceeds the maximum value the counter is reset to 0 Speed CW Sp...

Page 194: ...efore the occurrence of the serious error Check CR Motor 50 Number of endurance running cycles CR Motor PF Motor 0 Number of endurance running cycles PF Motor 1 5 Check Cutter 33 Number of endurance running cycles Cutter Head U D 55 Number of endurance running cycles Head 2 5 up down Check Head lock 77 Number of endurance running cycles head lock Wiper 77 Number of endurance running cycles wiper 3...

Page 195: ...al 196 AP 74065 Rev 1 2 27 09 04 5 10 HEAD LOCK MENU Lock and unlock the head lock The following items are in the head lock menu Lock Locks the head Unlock Releases the head lock Head lock F1 Lock Unlock F2 1 1 Select unlock Unlock Wait Little time ...

Page 196: ...nu Test 50 This menu heats the temperature up to 50 C Heater Test 50 Menu Test Max This menu heats the temperature up to the maximum temperature Heater Test Max Menu Version This menu displays the version of the control heater board Heater Version Menu Adjust For calibration of the heaters For future use only Heater Adjust Menu Heating System F1 Status Temperature F2 F3 Test 30 Test 50 F4 1 2 Heat...

Page 197: ... Heater Test 50 Menu This menu heats the temperature up to 50 C Test 50 Sending to heat system The display will mention de current temperature You can follow the heating of the heater elements on the display up to 30 C Temperature A R50 B1 R50 B2 R50 C R51 D1 R50 D2 R50 5 11 5 Heater Test Max Menu This menu heats the temperature up to maximum temperature Test MAx Sending to heat system The display...

Page 198: ... 74065 Rev 1 2 27 09 04 5 11 6 Heater Version Menu This menu displays the version of the control heater board Version Ver 2 03 5 11 7 Heater Adjust Menu Notes With this menu you can calibrate the heaters Please note that this function is for future use only ...

Page 199: ...Rockhopper II series printers Maintenance Manual 200 AP 74065 Rev 1 2 27 09 04 5 12 ECO PREPARE MENU Loading ink for the first time Please refer to the User s Guide ...

Page 200: ...d is exchanged etc Step 1 If the system is in the operation mode or the self diagnosis menu mode press the POWER key to power off the unit Step 2 Press the POWER key while simultaneously pressing and holding the MENU key and the MENU key Step 3 Select the machine size MachinSize F1 50inch 64inch F2 F3 87inch 64inch 1 1 Select item Select Finish Please re starting Step 4 Power OFF the unit ...

Page 201: ...Rockhopper II series printers Maintenance Manual 202 AP 74065 Rev 1 2 27 09 04 ...

Page 202: ...erate the 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 ...

Page 203: ...est ink 6 Displays ink consumption 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 ...

Page 204: ...remain 6 00000000 3 12 Counter Display Ink remain 7 00000000 Ink remain 8 00000000 4 12 Counter Display CutterLife 00000000 PrintNumber 00000000 5 12 Counter Display WasteInk 00000000 Cleaner 00000000 6 12 Counter Display CR Motor 00000000Mdot PF Motor 00000000Mdot 7 12 Counter Display Pump A 00000000 Pump B 00000000 8 12 Counter Display Head 1A 00000000Mdot Head 1B 00000000Mdot 9 12 Counter Displ...

Page 205: ...tialization Initializes NVRAM Timer initialization Initializes the timer Cutter initialization Initializes the cutter cumulative counter CR motor initialization Initializes the CR motor service life counter PF motor initialization Initializes the PF motor service life counter Cleaning initialization Initializes the cleaning wiper service life counter Head unit 1 initialization Initializes the head...

Page 206: ...n or higher Rockhopper II V2 00 6 3 3 1 Request correct MAC address Step 1 Remove the Right Cover Step 2 Remove the Ethernet Board Cover Step 3 Onto the installed card you can see a sticker with a FM0 number Notes Write down this number FM0 xxxxxx Important are the 6 digits x Step 4 Based on this number Mutoh Europe s service department can provide you the correct MAC address for your printer Step...

Page 207: ...serted Use the F1 F2 F3 and F4 key to insert the MAC address Step 9 Press the ENTER key to confirm Step 10 Press the POWER key to power OFF the unit 6 3 4 Head Voltage In this menu you can change the head voltage compensation value from 9 to 2 5 The default value is 0 If your Rockhopper does not print perfectly in 360x360 change the value to optimize your printquality Head VLT 0 0 ...

Page 208: ...t menu 2 Head nozzle check Head Nozzle Check Menu 3 Head angle check Head Slant Check Menu 4 Head precision adjustment Head precision adjustment 5 Repeatability adjustment Repeatability Adjustment Menu 6 CW adjustment CW Adjustment Menu 7 Test Print Test print menu Print head 8 Head unit lifespan count reset Parameter Initialization Menu 1 Parameter backup Parameter backup 2 Firmware installation ...

Page 209: ...adjustment menu 5 Test Print Test print menu PF motor assembly 6 Initializing PF motor history Parameter Initialization Menu 1 Media sensor sensitivity adjustment Media sensor sensitivity adjustment P_EDGE sensor assembly 2 Top and bottom adjustment Top bottom adjustment menu Cover sensor assembly 1 Cover sensor assembly position adjustment Cover sensor adjustment 1 PF_ENC inspection Encoder Menu ...

Page 210: ...ce operation check Head Nozzle Check Menu Sequential Printing Endurance Menu 4 Head nozzle check Head Nozzle Check Menu 5 Head angle check Head Slant Check Menu 6 Head precision adjustment Head precision adjustment 7 Repeatability adjustment Repeatability adjustment Menu 8 CW adjustment Repeatability Adjustment Menu 9 Top and bottom adjustment P_REAR sensor position adjustment menu Carriage assemb...

Page 211: ...be changed or deleted If it is necessary to replace the Mainboard while performing maintenance work make a parameter backup You can shorten some of the adjustment procedures by matching the printer mechanism with the new Mainboard Caution Before making a parameter backup make sure that the power source to the printer is OFF If the operation is performed with the power source on the Mainboard could...

Page 212: ...card for parameter backup into the memory card connector slot J104 on the mainboard assembly Notes Install the memory card so that its front is toward the inside of the printer Step 3 Turn the power to the printer on After all of the lamps on the operation panel light up the LED display on the panel displays PRINTER CARD Step 4 Press the ENTER key on the operation panel The LED display on the oper...

Page 213: ... the operation panel The LED display on the operation panel displays C P Started Backup parameter creation begins Step 5 If the backup parameter has been created correctly C P Completed is displayed on the operation panel Step 6 Turn off the power source to the printer Step 7 Remove the memory card for parameter backup Step 8 Reinstall the memory cover 2 When not using a flash memory card The sett...

Page 214: ...s with the power on could result in damage to the Mainboard assembly or cause the data to not be installed correctly 7 4 1 Tools required for work The following tools are required to install firmware Flash memory card or compatible computer Notes Refer to Jig and Tool list 7 4 2 Installation procedure The procedure for installing firmware is explained below Use the following procedure to install f...

Page 215: ...ly Step 6 Turn off the power source to the printer Step 7 Remove the memory card for firmware installation Step 8 Reinstall the memory cover 2 When using a computer Step 1 Using a printer cable connect the PC to the printer Step 2 Turn the power of the printer ON All lamps will flash for an instant Step 3 Press the F2 key on the operation panel within 1 second The message Ready to load is displaye...

Page 216: ...the heater system board make sure you already installed the firmware into the Rockhopper II 4 heater printer Step 1 Make sure the printer is OFF Step 2 Press simultaneously the CANCEL and the ENTER key while turning the printer ON Step 3 The display will mention the following message User Setting Rem Update F2 Ver Update 1 1 Step 4 Press the F2 key Step 5 The heater system board is now being updat...

Page 217: ...ols are required when adjusting the tension of the steel belt Tension gauge max 2 0 N 200 g Steel belt tension attachment 2 for gauge diameter 2mm 0 08in or less Notes Refer to jig and Tool list 7 5 2 Adjustment Procedure Use the following procedure to adjust the tension of the steel belt Step 1 Place the tension gauge at the center of the steel belt 1 steel belt 2 Tension gauge Notes The regulati...

Page 218: ...f regulated values adjust the steel belt tension screws 1 Steel belt 2 Steel belt tension screw 3 CR slave pulley Step 3 Move the CR cursor to the left and right once or twice Adjust the CR driven pulley until the upper and lower margins are identical Caution If the tension is not equivalent across the entire belt it could snap during operation ...

Page 219: ...elt Tension gauge max 50 N 5 kgf Notes Refer to Jig and tool list 7 6 2 Adjustment Procedure Use the following procedure to adjust the tension of the PF deceleration belt Step 1 Loosen the 2 screws fixing the PF motor installation board Step 2 Install the tension gauge on the PF motor installation board and pull it in the direction shown on the figure below 1 PF deceleration belt 2 Screws M3x6 fix...

Page 220: ...Step 2 Select Adj HeadSlant Step 3 Print Slant pattern If dotted lines on pattern CW and CCW are not a straight line which you can check with a magnifying glass enlargement of at least 10 please go to step 4 Notes When the printing pattern is printed you will only see lines and no notifications of ink channels The head sequence shown below 4 head model 1A 1B 2A 2B 3A 3B 4A 4B Step 4 Loosen the scr...

Page 221: ...y print uni directional adjust the CW till it is aligned perfectly In case you print bi directional and CW and CCW cannot be aligned more perfectly Divide the fault equally Notes When printing the pattern the head identifications 1A 1B etc are not printed Analyse the pattern as shown below Be sure to have five lines for each color How to adjust What to become No Part 1 Angle adjustment screw Step ...

Page 222: ...low 8 head model 3A 3B 1A 1B 2A 2B 4A 4B 5A 5B 6A 6B 7A 7B 8A 8B Step 4 Loosen the screw with one turn fixing the head stationary plate Step 5 Make adjustments until amount of CW and CCW offset are identical Notes In theory the alignment of CW and CCW should be identical But in practice it is almost impossible to become a perfect alignment When there is a slight difference between CW and CCW be su...

Page 223: ... etc are not printed Analyse the pattern as shown below Be sure to have five lines for each color 8B 8A 7B 7A 6B 6A 5B 5A 4B 4A 2B 2A 1B 1A 3B 3A Adjustable head slant Adjusted head slant No Part 1 Angle adjustment screw Step 6 Tighten the screw fixing the head stationary plate Repeat step 1 to 6 until the adjustment is correct for all heads ...

Page 224: ...nt please follow the steps mentioned below Step 1 In diagnostic mode go to Adjust Head Slant Step 2 Press the F2 key for F B front and back adjustment HeadSlant F1 Slant F B F2 F3 Check End F4 Step 3 Print out Front Back pattern First pattern A with 1A as reference is printed then pattern B with 4B as reference and finally A B A B B 4B is the reference head A 1A is the reference head ...

Page 225: ... diagram below Know you see 1A is Black 1B is Yellow etc in our color combination Step 4 Check if all nozzles are in 1 row by using a magnifying glass with an enlargement of at least 10 If not please proceed to step 5 Step 5 Loosen the screw with 1 turn which secures the Head Fixing Plate No Part 1 Head Fixing plate securing screw 2 Front Back Adjustment Screw ...

Page 226: ...ould automatically be adjusted But in practice this isn t always a fact When your determine a small misalignment after adjusting A well readjust again until all nozzles of row A and B are perfectly aligned NOTE We only give an example for one colour combination Please refer to Operation Procedure Labels in the Maintenance Manual where you can find the other possible colour combinations Step 7 Tigh...

Page 227: ...back adjustment HeadSlant F1 Slant F B F2 F3 Check End F4 Step 3 Print out Front Back pattern A B B 3B is the reference A 6A is the reference NOTE To help you identify the print heads on the test pattern please refer to the diagram below Now you can see 1A is black 1B is LM follow the line till you reach the junction Then go up to Light Magenta Step 4 Check if all nozzles are in 1 row by using a m...

Page 228: ...adjusted But in practice this isn t always a fact When your determine a small misalignment after adjusting A well readjust again until all nozzles of row A and B are perfectly aligned NOTE We only give an example for one colour combination Please refer to Operation Procedure Labels in the Maintenance Manual where you can find the other possible colour combinations Step 7 Tighten the screw which se...

Page 229: ...ts to the right you have to increase the value For example The value is 20 adjust it to 30 for example The value is 20 adjust it to 10 for example When you want to move the even rows with dots to the left you have to decrease the value For example The value is 20 adjust it to 10 for example The value is 20 adjust it to 30 for example 4B 4A 3B 3A 2B 2A 1B 1A Notes For 87 inch specifications the hea...

Page 230: ...st 10 When you want to move the even rows with dots to the right you have to increase the value For example The value is 20 adjust it to 30 for example The value is 20 adjust it to 10 for example When you want to move the even rows with dots to the left you have to decrease the value For example The value is 20 adjust it to 10 for example The value is 20 adjust it to 30 for example 1B 1A 1B 1A 1B ...

Page 231: ... 50 N 5 kgf Notes Refer to Jig and Tool List 7 10 2 Adjustment Procedure Use the following procedure to adjust the tension of the CR deceleration belt Step 1 Loosen the 4 hexagon socket head cap screws fixing the CR motor installation board 1 CR motor installation board 2 Hexagon socket head cap screw 3 CR motor assembly 4 Tension gauge Step 2 Install the tension gauge on the PF motor installation...

Page 232: ...ct Check Check Step 4 Select Sensor Etc on the sensor menu Step 5 Open and close the front cover assembly and make sure the dimension between the media guide and the front cover end is 21 mm and the display in the operation panel is switched as follows Front cover Operation panel display Open Sensor open Closed Sensor closed Notes Use a block gauge to measure the height of the front cover when ope...

Page 233: ...wing the procedures below Step 1 Unlock the head lock according to Head Lock Menu Step 2 Move the CR cursor on the platen Step 3 Remove the head cover according to Removing the head cover Step 4 Point slide gear mark down so that heads move into low position Step 5 Loosen the screws 2 one on the right one on the left that fasten the head U D eccentric shaft lever 1 Head U D eccentric shaft lever 2...

Page 234: ...ent jig 1 2 mm side Step 10 Fasten the screws 2 one on the right one on the left that fasten the head U D eccentric shaft lever Step 11 Apply non reflective tape to the head U D eccentric shaft lever as shown in the following printing Notes Completely cover the screw heads with non reflective tape If non reflective tape cannot be applied to chosen location the head slide sensor may not detect scre...

Page 235: ... A non conductive type screw driver should be used when adjusting the control on the Mainboard assembly Otherwise a short circuit may result if the driver contacts the metal parts such as electronics parts on the Mainboard assembly or the frame 7 13 1 Tools required for work The following tools are required for adjusting the P_EDGE sensor Reference media Double coated media recommended media Notes...

Page 236: ...le of the P_EDGE sensor is 15 Step 5 In the inspection menu select Check Check Step 6 Display Sensor PaperEdgeAD Step 7 Open the front cover Step 8 Move the carriage so that the dimension between the right edge of the standard media and the cutter is 5 to 10 cm 1 Razor Blade 2 Carriage Step 9 Adjust the P_EDGE sensor control shown in the following figure so that the values displayed in the operati...

Page 237: ...e right edge of the standard media by moving the carriage 1 Razor Blade Notes Perform the following if the A D values of the edge sensor are not the adjustment value 1 Checking the installation angle about 15 of the P_EDGE sensor assembly 2 Replacing the P_EDGE sensor assembly 3 Re inspecting the Mainboard assembly Step 3 Make sure that the values displayed in the operation panel are as shown belo...

Page 238: ...lled at an angle adjust it Notes Refer to Removing media guide F Step 3 Loosen the screw fixing the cutter holder 1 Cutter holder 2 Screws M3x6 fixing the cutter holder Step 4 Slide the cutter holder forward and backward as shown in the following figure so that the dimension between the cutter blade and the cutter groove of the sub platen is 0 2 to 0 7 mm 1 Cutter holder 2 Cutter groove of the sub...

Page 239: ...nce Manual 240 AP 74065 Rev 1 2 27 09 04 7 15 PUMP TUBING LAYOUT FOR PUMP ASSEMBLY 7 15 1 Pump tubing layout Rockhopper 4 heater 1 For 50 or 64 inch spec 1 connection to the head caps 2 waste tube connection 50 or 64 Rockhopper II 4 heater ...

Page 240: ...s it is possible to have kinks in the tubings Please avoid this by turning the tubing to the left or the right at the head connection and or waste tube connection 2 Also be careful the tubings do not touch or get stuck in the gears 1 Critical tubings 2 Gears 2 For 87 inch spec 1 connection to the head caps 2 waste tube connection ...

Page 241: ... 27 09 04 87 Rockhopper II 4 heater Notes 1 Please be careful when replacing the tubings it is possible to have kinks in the tubings Please avoid this by turning the tubing to the left or the right at the head connections and or waste tube connections 1 Critical tubings ...

Page 242: ...he tubing in the manner shown in the figure below 1 Tube connecting to the waste fluid tube 2 Tube connecting cap b 3 Tube connecting to cap a Step 2 Use a linking tube to connect the new part pump tube DF 43951 to the tube connecting cap 2 1 Tube connecting to waste fluid side 2 Tube connecting to cap c 3 Tube connecting to cap d 4 Newly added pump tube DF 43951 length 40 mm 5 2 tube for linking ...

Page 243: ...m the pumps a piece of tube DF 43951 15 cm 1 piece of tube 15 cm Step 4 Bundle the waste fluid tubes in the large waste fluid tube 1 large waste fluid tube Step 5 Bundle the connectors together in the locking wire saddle Step 6 Bundle the remaining tubes cables and connectors together in the manner shown in the figure below ...

Page 244: ...r Step 1 Waste fluid tube E and an ink tube joining tube are added between fluid tube A and the pump 4 tube fitting that groups together the waste fluid side tubes Step 2 Connect up the tubing for pump 1 as shown on the figure below 1 Tube connecting to waste fluid tube 2 Tube connecting to cap a 3 Tube connecting to cap d ...

Page 245: ... fluid tube 2 Tube connecting to cap b 3 Tube connecting to cap c Step 4 Connect up the tubing for pump 3 as shown in the figure below 1 Tube connecting to waste fluid tube 2 Tube connecting to cap f 3 Tube connecting to cap g Step 5 Connect up the tubing for pump 4 as shown in the figure below 1 Tube connecting to waste fluid tube 2 Tube connecting to cap e 3 Tube connecting to cap h ...

Page 246: ...DF 43951 1 piece of tube 15 cm Step 7 Stick the locking wire saddle onto side plate F Step 8 Bundle the tubes and connectors together in the locking wire saddle Step 9 Bundle the waste fluid tubes in the large waste fluid tube 1 large waste fluid tube Step 10 Bundle the remaining tubes cables and connectors together in the manner shown in the figure below ...

Page 247: ...d Restart machine wait 10 sec after power off Error message Heat System Not Found Damaged power supply replace Notes In case of this error message it is possible that the supply does not work due to a snubber problem on the power distribution board EY 80203 3 possibilities Æ Snubber resistor cut with cap 100nF Malfunction is not caused by the snubber Æ Resistor not cut capacitor 4 7nF disc shape M...

Page 248: ...linking OK Fatal error µP lockup LED D1 ERROR No error Error occurred LED D5 8000 RX TX Communication ok No communication LED D7 8000 RX TX Communication ok No communication LED D3 Programming led Not used for user LED D6 Programming led Not used for user OK Burned SMD L11 L2 L6 L13 Coil No problem Temperature sensor cable shorted to chassis indication which cable has a problem Notes Will be avail...

Page 249: ...r a short period After a warm start up the selftest will not run During normal operation leds can go on in a random manner 7 16 4 Heater Elements Resistance Ω 50 64 87 A 2 x 48 2 x 32 3 2 x 24 2 B1 B2 2 x 97 2 x 65 5 2 x 44 C 2 x 48 2 x 32 3 2 x 22 5 D1 D2 2 x 27 2 x 22 5 2 x 22 5 Thermal Sensor 10k 10k 10k When checking the thermal sensors also measure them with the chassis as a reference If the ...

Page 250: ...ta coming from the RHII 4 seconds beep error Heater D In case of a defective fuse on a D heater check for isolation on the temperature sensors Some machines were released without isolation patches on the temperature sensors and cause the strips to overheat Heater A In earlier machines strips were mounted with a fuse with a critical narrow margin Please do not pass 48 C in the menu setting This wil...

Page 251: ...60Hz Fuse 1 OK NOK OPEN Power Supply LED Green ON OFF Flashes Control Board LEDS ON OFF Flashes LED D8 LED D1 LED D2 LED D5 LED D7 LED D3 LED D6 Filters OK Bad visual SMD L11 SMD L2 SMD L6 SMD L8 Power Board D2 Red Green revC Power ON OFF D1 110V 220V ON OFF D23 21 19 13 6 4 Heater On Flashes Cold Start up _______________________________________________ Operation __________________________________...

Page 252: ...Jig Tool JD 80001 2 The Spacer kit flush box KY 80002 Step 1 Remove the I H cover Step 2 Remove side cover R Step 3 Remove side cover L Step 4 Remove the front cover Step 5 Remove the 4 screws fixing the carriage cover Caution Please note that this cover is only on a Rockhopper II 2 heaters and Falcon II printer Step 8 Remove the carriage cover Step 9 Start up in Diagnostic Mode and Unlock the Hea...

Page 253: ...st position 1 Carriage wheel 2 Arrow Step 12 Carefully move the carriage to the right The carriage should pass the first interval but not the second 1 Interval 1 3 Reference of the head 2 Interval 2 Step 13 When the carriage pass both intervals move the carriage to the left Loosen the screw of the flushing box a bit and install one or more spacers 1 Screw 2 Spacer 0 5 mm or 1 mm ...

Page 254: ...Rev 1 2 27 09 04 Note The Spacer kit flush box KY 80002 consists out of 10 spacers with thickness 0 5 mm and 10 with thickness 1 0 mm Thickness 0 5 mm DF 44237 Thickness 1 0 mm DF 44236 Step 14 Tighten the screw and repeat step 10 to 12 until adjustment is correct ...

Page 255: ...Rockhopper II series printers Maintenance Manual 256 AP 74065 Rev 1 2 27 09 04 ...

Page 256: ...ket Otherwise you may suffer electric shock or the machine s electric circuits may be damaged Disconnect all cables from the machine Not doing so could cause damage to the printer Caution Ensure there is sufficient space around the printer when performing maintenance work If you need to operate the printer with the cover removed for maintenance be careful not to get hurt by the moving parts In the...

Page 257: ...al times per year Media dust accumulation Foreign objects Damages Clean it Please note If ink deposits are present remove them with a dampened cloth and wipe the area with a clean dry cloth Timing fence CR encoder detection slit plate Several times per year Media dust accumulation Foreign objects Damages Clean it If any damages are found replace the part P_REAR sensor surface Several times per yea...

Page 258: ...ly the parts that can be replaced by the end user and the parts that needs to be done by authorized Mutoh technicians 8 3 1 Service by end user Perform periodical inspections according to the table below N Part number Quantity Action 1 ME 80771 4 Replace the wipers 2 DF 43694 DE 35399 2 1 Replace the sponge at the back of the capping station 3 AP 51600 1 Replace the sponge 4 Clean the wipers 5 Cle...

Page 259: ...80 4 x 0 8 m Replace the tubing from the pumps to the waste bottle 5 MY 35085 ME 80385 ME 60014 1 1 m 1 Replace the right spitting box tube L connection 6 MY 80627 1 Replace the capping station 7 Apply grease on head up down cams 8 Apply grease on Y motor belt 9 Apply grease on roller path carriage 10 Apply grease on capping station camm gears 11 Clean the maintenance station area 12 Remove dust i...

Page 260: ...to check the life of a service part To know the life of a service part check the maintenance counter from the counter display menu in the maintenance mode Notes Refer to Counter Display Menu for more details of the counter display menu Name Life expectancy Warning display Print head 28 billion dot Warning at 95 Warning Head Life ...

Page 261: ...Seieido Co Ltd 15 Cleaning liquid A29 JD 41844 18l 16 Bottle for cleaning liquid 500 ml JD 42054 Generic product 2 Tools for adjustment No Name Part code Remarks 1 Personal computer Generic product Printer port mounted parts 2 Printer cable Generic product Amphenol 36P male connector 3 Tension gauge Generic product For measuring 5 000g Max Reference maker Oba Keiki Seisakusho 4 Tension gauge Gener...

Page 262: ...l machining drawing Coating the hole that fastens the return pulley mounting plate Kanto Kasei Co Ltd FLOIL G MK 1 Y rail and Roller guide When inserting the Y rail apply to the lower face of the roller guide Kanto Kasei Co Ltd FLOIL G MK 1 Pressurizing axis bearing Coating the upper part and shaft insertion part Kanto Kasei Co Ltd FLOIL G MK 1 Pressurizing cam Apply to the cam components Kanto Ka...

Page 263: ...ew lock Three Bond Co Ltd 1401 Cursor Components Step bore screw Screw lock applying to the shoulder screw that fastens the cursor and head mounting plate Three Bond Co Ltd 1401 Maintenance components E ring Apply to each of the E rings prevents noise due to vibration Three Bond Co Ltd 1401 Scroller receptacle R components Set screw Apply the screw lock to the adjusting knob set screw Three Bond C...

Page 264: ... transportation Step 1 Turn on the power to the product Step 2 Verify if the product is at a normal status Step 3 Start the auto diagnostic function Notes Refer to Self Diagnosis Function Step 4 Select Adj CleanHead Step 5 Select CleanHead menu Notes Refer to Head wash menu Step 6 When the head cleaning has been finished turn the power OFF Step 7 Remove the scroller Step 8 Disconnect the power cab...

Page 265: ...es Refer to the User s Guide Step 12 Package the machine 2 Task after transportation Step 1 Unpack assemble and install the machine Step 2 Reinstall the winding system Notes Do not forget to align the winding system after installation Please refer to the users guide of your winding system Step 3 Make the machine ready for operation ...

Page 266: ... when the product is operating normally and when an error occurs There are the following types of messages Priority level Message Type Description Refer to 1 Operating condition display Displayed when the product is operating normally Operating condition display 2 Heating system error Displayed when heating element errors occurs during operation Heating system error 3 Message type errors Message t...

Page 267: ..._Extension board assembly HEAD_DRV board assembly and cooling fan assembly Cover sensor adjustment 1 Cover Open The front cover is open 3 The Mainboard assembly may have a problem Replace the Mainboard assembly Replacing the Mainboard assembly HDD_Extension board assembly HEAD_DRV board assembly and cooling fan assembly 1 Check the operation of the transmission photosensor for the lever up down vi...

Page 268: ...d cooling fan assembly 1 Check he operation of the Test Sensor via the self diagnostic function If OFF is displayed when he paper is setup replace he P_REAR sensor assembly Replacing the P_REAR_R sensor assembly and P_REAR_L sensor assembly 2 Make sure P_REAR sensor assembly cables underneath the paper guide R are securely connected Securely connect the cables to Mainboard assembly connectors J128...

Page 269: ...ing the P_EDGE sensor assembly 2 Make sure the P_EDGE sensor assembly connector at the cursor is securely connected Securely connect it to CR board assembly connector J234 Replacing the Mainboard assembly HDD_Extension board assembly HEAD_DRV board assembly and cooling fan assembly 3 Make sure the R_REAR sensor assembly cables underneath paper guide R are securely connected Securely connect the ca...

Page 270: ...uide 2 has the cutter cap securely been installed Reset the cutter cap securely Please refer to the User s Guide 3 Check the cutter s up and down sliding operation If it does not rise Go to step 4 If it rises Go to step 5 3 Paper Cut Error Even though cutting operation was performed the paper was not completely cut and removed 4 Check if the cutter drops to the bottom end under its own weight when...

Page 271: ...ard assembly HDD_Extension board assembly HEAD_DRV board assembly and cooling fan assembly 6 Open CR cable faulty solenoid assembly faulty board assembly etc may be the cause Replace the CR tape power cables Replace the solenoid assembly Replace the CR board assembly Replace the Mainboard assembly Replacing the steel bearer tube guide CR tape power cable and ink tube Replacing the cutter holder cu...

Page 272: ...elf diagnostic function Operate the lever at the end detecting element of the ink sensor assembly to check if the ink end indication changes At this time the sensor for detecting the presence of cartridges is set to Yes If there is no response replace the ink sensor assembly Sensor menu Replacing the I H ink holder assembly 5 6 Near End Ink End The remaining amount of ink is low Printing is still ...

Page 273: ...board may be damaged Replace the Mainboard assembly Replacing the Mainboard assembly HDD_Extension board assembly HEAD_DRV board assembly and cooling fan assembly 1 Check if the message is still displayed after turning the power off and then back on again When a message is displayed Go to step 2 2 The number of times the ink tube was used reached the maximum allowable times Replace the ink tube In...

Page 274: ...CR motor history 3 Hard disk may be damaged Replace the hard disks 11 Hard disk status connect error There is a problem in the hard disk connections 4 The Mainboard assembly may be damaged Replace the Mainboard assembly Replacing the Mainboard assembly HDD_Extension board assembly HEAD_DRV board assembly and cooling fan assembly Replacing the power source board assembly 1 The PCI_LINUX board assem...

Page 275: ...of the following connectors Mainboard J120 Replacing the Mainboard assembly HDD_Extension board assembly HEAD_DRV board assembly and cooling fan assembly 4 The Mainboard assembly may be damaged Replace the Mainboard assembly Replacing the Mainboard assembly HDD_Extension board assembly HEAD_DRV board assembly and cooling fan assembly Notes The number between brackets on the error display indicates...

Page 276: ...s are connected properly 12 Conn err Left D2 Sensor D2 Check if the left sensor is connected properly 13 Conn err Right D2 Sensor D2 Check if the right sensor is connected properly 14 Couldn t reach temp Heater strip After 10 minutes temperature is not reached Check the heater strips 15 Err Temp 85 C Heater strip Temperature comes higher then the limit Check the heater strips 16 Connection err A R...

Page 277: ...error command Online frame error 2 I 15 2 error command Overrun error 3 I 15 3 error command Online parity error 4 I 15 4 error command Sum check error 5 I 15 5 error command ESC parameter 6 I 15 6 error command Undefined ESC 7 I 15 7 error command Incorrect letters ESC 8 I 15 8 error command Numeral character ESC 9 I 15 9 error command Parameter error ESC 10 I 15 10 error command Buffer overflow ...

Page 278: ...ot been defined in command modes was analyzed 2 MH02 error command Parameter error Number of parameters following command is incorrect 3 MHO3 error command Numeric error Number of parameters following command is incorrect 4 MH04 error command Undefined letter set Letter sets that should not exist do exist 5 MH05 error command Buffer overflow Polygon buffer or downloadable character buffer overflow...

Page 279: ... restart has occurred solve the problems to restart the printer and delete the error 1 CPU system critical errors No Message Phenomenon Check point Action Refer to 1 E 001 error DRAM Standard DRAM error Abnormal condition in standard memory mounted on Mainboard assembly 1 Mainboard assembly may be defective Replace Mainboard assembly Replacing the Mainboard assembly HDD_Extension board assembly HE...

Page 280: ...eption errors Loading and storing buss errors occurred while loading and storing commands 10 E 016 error CPU Err 08 System call exception errors System call trouble occurred 11 E 016 error CPU Err 09 Break point exception error trouble occurred in the break points 12 E 016 error CPU Err 10 Reservation command exception errors trouble occurred in the reservation commands 13 E 016 error CPU Err 03 D...

Page 281: ...back from the encoder are significantly different 1 Check error history from Test history of self diagnosis function History menu 2 E067 error Paper feed encoder Trouble occurred on paper travel x axis during operation Displayed when there is no feedback from the encoder 2 Set endurance running cycles to 50 or more from Life PF motor of self diagnosis function and check if X axis motor error is is...

Page 282: ...ncoder Trouble occurred in the head travel Y axis during operation Displayed when there is no feedback from the encoder 2 With the power supply off move the carriage side to side to check for jamming Refer to Error E072 Clean and lubricate the rollers of the CR rail Lubrication Bonding 7 E 070 Error CR Timeout Err Time out occurred in the head travel Y axis during operation Displayed when he carri...

Page 283: ...ure that the connections of the Mainboard assembly connector J155 J156 are good and check the operation of the cover sensor via Test Sensor of the self diagnostic function Replacing the CR motor assembly Replacing the CR board assembly Replacing the steel bearer tube guide CR tape power cable and ink tube 8 E 072 Error CR Over Current An overload occurred in the CR motor Y axis during operation 6 ...

Page 284: ...tion of the cover sensor assembly is good Mainboard J155 J156 Sensor Menu 2 The cover sensor assembly may be damaged Replace the cover sensor assembly Replace the cover R sensor assembly and the cover L sensor assembly 10 E 074 Error Cover Trouble occurred in the cover sensor 3 The Mainboard assembly may have a problem Replace the Mainboard assembly Replacing the Mainboard assembly HDD_Extension b...

Page 285: ...e HD_SLIDE sensor via Sensor HD_SLID E of the self diagnostic function Make sure that the connections of the HD_SLIDE sensor assembly connectors are good Mainboard J127 Sensor Menu 2 Make sure that the connections of the HD_SLIDE sensor assembly connectors are good Replace the HD_SLIDE sensor assembly Replacing the SLIDE motor assembly HD_SLIDE sensor assembly and slide motor installation board 3 ...

Page 286: ...re that the connections of the CR tape power cables are good Redo the connections of the following connectors CR board J201 J216 Replacing the CR board assembly 3 The print head assembly may be damaged Replace the print head assembly Replacing the print head assembly and head tape power cable Counter initialization menu 4 The CR board assembly may be damaged Replace the CR board assembly Replacing...

Page 287: ...ated Clean the sensor element using cotton swabs Replacing the transmission photosensor 4 Is the transmission photosensor cable at the lever motor securely installed Securely connect the cable for the transmission photosensor cable to Mainboard assembly connectors J123 and J124 Replacing the Mainboard assembly HDD_Extension board assembly HEAD_DRV board assembly and cooling fan assembly 16 E 080 E...

Page 288: ... SLIDE motor assembly wiper arm 6 The Mainboard assembly may be damaged Replace the Mainboard assembly Replacing the Mainboard assembly HDD_Extension board assembly HEAD_DRV board assembly and cooling fan assembly 1 Check the up down operation of he cap wiper via Sensor Head Lock of the self diagnostic function Replace the transmission photosensor at the wiper Replacing the transmission photosenso...

Page 289: ...E motor assembly for the WIPER slide are good Replace the SLIDE motor assembly for the wiper SLIDE Replacing the SLIDE motor assembly wiper arm 6 The Mainboard assembly may be damaged Replace the Mainboard assembly Replacing the Mainboard assembly HDD_Extension board assembly HEAD_DRV board assembly and cooling fan assembly ...

Page 290: ...embly and cooling fan assembly 3 Make sure that the connections of the inlet board assembly are good Redo the connections of the following connectors Inlet board CN1 CN3 Replacing the inlet assembly inlet board assembly and lever foot SW cable assembly 4 The panel board assembly may be damaged Replace the panel board assembly Removing the panel unit assembly 5 The Mainboard assembly may have a pro...

Page 291: ...y have a problem Replace the Mainboard assembly Replacing the Mainboard assembly HDD_Extension board assembly HEAD_DRV board assembly and cooling fan assembly 1 Check if Cover Open is displayed on the LCD when the front cover is closed Adjust the cover sensor Cover sensor adjustment 2 Make sure that the connections of the panel cable connectors at the panel unit assembly side and the Mainboard ass...

Page 292: ...uide CR tape power cable and ink tube 4 Although ink replenishment has started the ink has not reached the head 5 The cartridge frame may be damaged Replace the cartridge frame assembly Replacing the I H ink holder assembly 1 Make sure that the connections of the head cable connectors at the CR board assembly side and the print head side is good Check the head cables for open conditions Make sure ...

Page 293: ...ctions of connectors J155 and J156 on the Mainboard assembly Replace he cover sensor assembly Cover sensor adjustment Replacing the Mainboard assembly HDD_Extension board assembly HEAD_DRV board assembly and cooling fan assembly Replace the cover R sensor assembly and the cover L sensor assembly 2 Panel unit Make sure that the connections of the panel cable connectors at the assembly side and the ...

Page 294: ...ace the operation panel cover 2 Make sure that the connections of the panel cable connectors at the panel unit assembly side and the Mainboard assembly side is good Check the panel cables for skewed insertion Make sure that they are securely locked Check the connections of the following connectors Mainboard J105 Panel board J301 Replacing the Mainboard assembly HDD_Extension board assembly HEAD_DR...

Page 295: ...contamination by paper dust and ink If the platen is contaminated by ink or paper dust wipe off with a damped soft cloth User s Guide 3 The paper is wrinkled at paper set initialization or during the printing operation 3 Check the rotation of pressure roller with the pressure arm at the raised position If the surrounding area of the pressure roller is contaminated by paper dust and waste paper wip...

Page 296: ...y and cooling fan assembly Replacing the P_REAR_R sensor assembly and P_REAR_L sensor assembly 2 Check adjustments of the top bottom and rear sensor positions Adjust the positions of the top bottom and rear sensors Top bottom adjustment menu P_REAR sensor position adjustment menu 3 The program ROM may have failed Upgrade the firmware version Firmware installation 2 Give an extra feed after the pri...

Page 297: ...g replace the wiper User s Guide Replacing the cleaner 4 Check the installation conditions of the cleaning wipers Check the installation conditions of the wipers and fix them securely Replacing the cleaner 5 Check if the QR codes are input correctly Input the correct QR codes Head rank input menu 6 The damper may be damaged Replace the damaged damper Replacing the H ink tube tube branch and damper...

Page 298: ...arer tube guide CR tape power cable and ink tube 3 Check ink tubes for bends flaws air leaks etc Replace the damaged ink tubes Replacing the steel bearer tube guide CR tape power cable and ink tube 4 The print head assembly may be damaged Replace the print head assembly Replacing the print head assembly and head tape power cable 5 The damper may be damaged Replace the damaged cable Replacing the H...

Page 299: ...bearer tube bearing CR tape power cable and ink tube 3 The print head assembly may be damaged Replace the print head assembly Replacing the print head assembly and head tape power cable 4 The CR board assembly may have a problem Replace the CR board assembly Replacing the CR board assembly 5 The HEAD_DRV assembly board may be damaged Replace the HEAD_DRV assembly board Replacing the Mainboard asse...

Page 300: ...erating correctly via Test Fan of the self diagnostic function Check the connections of the following connections Mainboard J111 J116 Replacing the suction fan assembly 6 If the paper in concern is roll paper check if the scroller is rotating smoothly Make sure the scroller receivers are installed in the correct position Replace the rollers of the scroller Replacing the scroller R assembly Replaci...

Page 301: ...paper wipe it with a soft dampened cloth User s Guide 13 Check if the QR code is input correctly Input the correct QR codes Head rank input menu 14 The head assembly may be damaged Replace the damaged head assembly Replacing the print head assembly and head tape power cable 15 The ink tube may be damaged Replace the ink tube Replacing the steel bearer tube guide CR tape power cable and ink tube 16...

Page 302: ... The CR cables may be damaged Replace the CR tape power cables Replacing the steel bearer tube guide CR tape power cable and ink tube 6 Check the head assembly for breakage Replace the damaged head assembly Replacing the print head assembly and head tape power cable 7 The CR board assembly may have a problem Replace the CR board assembly Replacing the CR board assembly 8 The Mainboard assembly may...

Page 303: ...teel belt tension Steel belt tension adjustment 4 Check the head adjustments Adjust the head Head precision adjustment 5 Check the T fence for contamination Clean the T fence If contaminants cannot be cleaned up by cleaning replace the T fence Replacing the T fence 6 Make sure that the CR_ENC assembly and the T fence are not interfering If they interfere with each other adjust the installation pos...

Page 304: ...be Replacing the steel bearer tube guide CR tape power cable and ink tube 13 The CR board may have a problem Replace the CR board assembly Replacing the CR board assembly 14 The Mainboard assembly may have a problem Replace the Mainboard assembly Replacing the Mainboard assembly HDD_Extension board assembly HEAD_DRV board assembly and cooling fan assembly 16 Mixed colour lines do not overlap 1 Che...

Page 305: ...fence 18 A limited line in the head travel direction is not accurate in the main scanning direction A Paper discharging direction 4 The internal process operation of the Mainboard assembly may be malfunctioning Check the operation again after initializing parameters and re inputting and re adjusting them Parameter initialization menu 1 Make sure that the PF reduction belt tension is adjusted corre...

Page 306: ...direction is not accurate in the sub scanning direction A Paper discharging direction 7 If the paper in concern is roll paper check if the scroller is rotating smoothly Make sure that the scroller receiver is installed correctly Replace the rollers of the scroller Replacing the scroller R assembly Replacing the scroller L assembly 1 Check if the actually installed head rank and the registered head...

Page 307: ... for rugged movement Also check the rotary movement for irregularities If the surrounding area of the pressure roller is contaminated by paper dust and waste paper wipe it with a soft dampened cloth User s Guide 1 Check if the two head tape power cables stick together The cores of the head tape power cables should be aligned for each head and taped together with double sided tape Replacing the pri...

Page 308: ...e paper is loaded 5 The power supply board assembly may have a problem Replace the power supply board assembly Replacing the power source board assembly 2 You hear some noise during printing wait 1 Check the area where there is noise from for obstruction and foreign materials Remove the obstructions and foreign materials 1 Check if the high pitch sound emitted while ink is discharging during print...

Page 309: ...ng the CR slave pulley assembly 7 Check if the tension of the steel belt has been properly adjusted Adjust the steel belt tension Steel belt tension adjustment 8 Check the CR motor assembly for noise Replace the CR motor assembly Replacing the CR motor assembly 9 Check the cursor roller of the CR cursor assembly for noise Replace the cursor roller Replacing the cursor roller assembly 1 Check the P...

Page 310: ...ot rise go to step 4 if it rises go to step 5 6 Check if the cutter drops to the bottom end under its own weight when the cutter is installed without the cutter spring If it drops The cutter spring may have a problem Replace the cutter spring while referring to the unfolded view If it does not drop The cutter may have a problem Replace the cutter If the cutter does not drop after it is replaced re...

Page 311: ...older cutter spring cutter cap solenoid assembly and solenoid spring Replacing the CR board assembly Replacing the Mainboard assembly HDD_Extension board assembly HEAD_DRV board assembly and cooling fan assembly 1 Check if the paper output size on the application side is correct Correct the paper output size on the application side 2 The program ROM may have failed Upgrade the firmware version Fir...

Page 312: ...fall off 2 The sub platen paper guide or the paper may be charged with static electricity Provide a proper ground Check and adjust the ambient humidity so that it meets the normal operation conditions of the product and paper 1 Check the cutter blade for chipping and deterioration Replace the cutter User s Guide 2 Has the cutter cap been securely installed Reset the cutter cap securely User s Guid...

Page 313: ... the host Use 100BASE T straight cables for connections using HUBs 2 Online has not been properly established by the network 2 Check the network settings in the operation panel for problems Reset the settings upon confirmation by an network administrator User s Guide 3 Scaling is not functioning correctly 1 The program ROM may have failed Upgrade the firmware version Firmware installation 4 Mirror...

Page 314: ...e CR_ENC assembly Replace the CR motor Replace the CR_BASE board assembly Replace the CR tape power cables Replacing the Mainboard assembly HDD_Extension board assembly HEAD_DRV board assembly and cooling fan assembly Replacing the T fence Replacing the CR motor assembly Replacing the CR board assembly Replacing storing the steel bearing tube guide CR tape power cable and ink tube 4 The Mainboard ...

Page 315: ...ackup 1 A hang up occurs 2 The Mainboard assembly may have a problem Replace the Mainboard assembly Replacing the Mainboard assembly HDD_Extension board assembly HEAD_DRV board assembly and cooling fan assembly 1 Make sure that the power cables are not disconnected Securely connect the power cables 2 Check the power cables for a shorted condition Check the condition using a tester 2 The power has ...

Page 316: ...eries printers Maintenance Manual 317 AP 74065 Rev 1 2 27 09 04 10 APPENDIX 10 1 INTRODUCTION This chapter provides referential information such as service data and exploded views 10 2 WIRING DIAGRAM ROCKHOPPER II 2H ...

Page 317: ...s 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 The latest exploded views are available separately from the manual For spare parts please refer to the latest spare part list Specifications are liable to changes without prior notice ...

Page 318: ...Rockhopper II series printers Maintenance Manual 319 AP 74065 Rev 1 2 27 09 04 ...

Page 319: ...utoh co jp MUTOH EUROPE N V Tel 32 0 59 561400 Fax 32 0 59 807117 E mail mutoh mutoh be http www mutoh be MUTOH DEUTSCHLAND GmbH Tel 49 0 2159 913430 Fax 49 0 2159 913456 E mail Mutoh Sales t online de MUTOH AMERICA INC Tel 480 968 7772 Fax 480 968 7990 E mail Sales mutoh com http www mutoh com ...

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