MUTOH Rockhopper II Series Specifications

Maintenance Manual
MUTOH EUROPE N.V.
AP-74065, Rev 1.2: , 27/09/2004
Rockhopper II series printers – Maintenance Manual
MUTOH INDUSTRIES LTD.
Tel.:81-(0)3-54867145
Fax.:81-(0)3-54867163
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
3
MUTOH AMERICA INC.
Tel.: (480) 968-7772
Fax: (480) 968-7990
E-mail:Sales@mutoh.com
http://www.mutoh.com
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
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Rockhopper II series printers – Maintenance Manual
COPYRIGHT NOTICE
COPYRIGHT © 2004 Mutoh Europe N.V. All rights reserved.
This document may not be reproduced by any means, in whole or in part, without written permission of the
copyright owner.
This document is furnished to support the Mutoh’s Rockhopper II series Printer. In consideration of the
furnishing of the 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 the article shown and the delivery of this document shall not constitute any right or license to
do so.
September 2004
Published: Mutoh Europe N.V., Archimedesstraat 13, B-8400 Oostende, BELGIUM
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Important Notice
This product has been tested and found to comply with the limits for a Class A digital device, pursuant to Part
15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference
when the product is operated in a commercial environment.
This product generates, uses, and can radiate radio frequency energy and if not installed and used in
accordance with this manual, may cause harmful interference to radio communications. Operation of this
product in a residential area is likely to cause harmful interference in which case the user will be required to
correct the interference at his expense.
1.
Radio interfere
Product generates weak radio signals and may interfere with television reception and utilities. If a
product does interfere with radio or TV reception, try following:
2.
¾
Change the direction of your radio and TV reception antenna or feeder.
¾
Change the direction of the product.
¾
Move either the product or the receiving antenna so there is more distance between them.
¾
Be sure the product and the receiving antenna are on separate power lines.
Trademark mentioned in this manual.
¾
MUTOH, Rockhopper II, Eco-Solvent Plus, MH-GL, MH-GL2, MH-RTL are registered trademarks or
product names of MUTOH INDUSTRIES LTD.
¾
Centronics and Bitronics are registered trademarks or product names of Centronics Data Computer
Corporation.
¾
Windows 95, Windows 98, Windows Me, Windows XP, Windows NT4.0, Windows2000, and
MSDOS are registered trademarks or product names of Microsoft Corporation.
¾
DOS/V is registered trademark and product name of International Business Machine Corporation
(IBM).
¾
Other company and product names may be registered trademarks or product names.
No part of this product or publication may be reproduced, copied or transmitted in any form or by any means,
except for personal use, without the permission of MUTOH EUROPE N.V.
The product and the contents of this publication may be changed without prior notification.
MUTOH EUROPE N.V. has made the best efforts to keep this publication free from error, but if you find any
uncertainties or misprints, please call us or the shop where you bought this equipment.
MUTOH EUROPE N.V. shall not be liable for any damages or troubles resulting from the use of this
equipment or this manual.
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TABLE OF CONTENTS
1. Safety Instructions.......................................................................................................15
1.1. Introduction .......................................................................................................................... 15
1.2. Warnings, Cautions and Note .............................................................................................. 15
1.3. Important safety instructions ................................................................................................ 15
1.3.1. Warning......................................................................................................................................... 15
1.3.2. Caution.......................................................................................................................................... 16
1.4. Warning labels ..................................................................................................................... 17
1.4.1. Handling the operation procedure labels ...................................................................................... 17
1.4.2. Locations and types of operation procedure labels ...................................................................... 17
1.5. Operation procedure labels.................................................................................................. 20
2. Product Overview ........................................................................................................21
2.1. Introduction .......................................................................................................................... 21
2.2. Features ............................................................................................................................... 21
2.3. Part names and functions .................................................................................................... 22
2.3.1. Front.............................................................................................................................................. 22
2.3.2. Back .............................................................................................................................................. 23
2.3.3. Operation panel ............................................................................................................................ 24
2.4. Printer status ........................................................................................................................ 26
2.4.1. Normal........................................................................................................................................... 26
2.4.2. Setup menu display ...................................................................................................................... 26
2.4.3. Self-diagnosis Function Display.................................................................................................... 26
2.4.4. Maintenance Mode Display .......................................................................................................... 26
2.4.5. Selecting 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............................................................................................................................ 35
3.4.1. Conditions of the installation environment .................................................................................... 35
4. Parts Replacement ......................................................................................................37
4.1. Introduction .......................................................................................................................... 37
4.2. Removing the cover ............................................................................................................. 38
4.2.1. Removing the I/H cover ................................................................................................................ 39
4.2.2. Removing side cover R................................................................................................................. 40
4.2.3. Removing side cover L ................................................................................................................. 42
4.2.4. Removing the front cover.............................................................................................................. 44
4.2.5. Removing the carriage cover ........................................................................................................ 46
4.2.6. Removing the panel unit assembly............................................................................................... 47
4.2.7. Removing the Y rail cover............................................................................................................. 48
4.2.8. Removing front paper guide ......................................................................................................... 50
4.2.9. Removing rear paper guide .......................................................................................................... 52
4.2.10. Removing the head cover........................................................................................................... 53
4.2.11. Removing the maintenance cover .............................................................................................. 54
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4.3. Replacement of the heater element ..................................................................................... 55
4.3.1. Rockhopper II 2 heaters : Heater elements .................................................................................. 55
4.3.2. Rockhopper II 4 heaters : Heater elements .................................................................................. 59
4.4. Replacing Board Bases........................................................................................................ 65
4.4.1 Replacing the Mainboard assembly, HDD_Extension board assembly, HEAD_DRV board
assembly, PCI_Linux board assembly and cooling fan assembly.......................................................... 65
4.4.2. Replacing the power source board assembly............................................................................... 70
4.4.3. Replacing the inlet assembly, inlet board assembly and lever foot SW cable assembly ............. 72
4.4.4. Replacing the JUNCTION board assembly .................................................................................. 73
4.5. Replacing the PF Actuator ................................................................................................... 74
4.5.1. Replacing the PF motor assembly................................................................................................ 74
4.5.2. Replacing the PF_ENC assembly and PF scale assembly .......................................................... 75
4.5.3. Replacing the PF deceleration pulley assembly........................................................................... 76
4.5.4. Replacing the PF deceleration belt............................................................................................... 77
4.5.5. Replacing the P_REAR_R sensor assembly and P_REAR_L sensor assembly ......................... 78
4.5.6. Replacing the suction fan assembly ............................................................................................. 79
4.5.7. Replacing the lever motor assembly and the arm motor installation board.................................. 80
4.5.8. Replacing the transmission photosensor...................................................................................... 82
4.5.9. Replacing the flushing box assembly ........................................................................................... 84
4.6. Replacing the CR Actuator................................................................................................... 85
4.6.1. Replacing the CR motor assembly ............................................................................................... 85
4.6.2. Replacing the steel belt................................................................................................................. 86
4.6.3. Replacing the SLIDE motor assembly, HD_SLIDE sensor assembly, and slide motor installation
board ....................................................................................................................................................... 88
4.6.4. Replacing the T fence ................................................................................................................... 89
4.6.5. Replacing the CR slave pulley assembly...................................................................................... 91
4.6.6. Replacing the CR actuator pulley 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. Replacing the H ink tube, tube branch and damper assembly ................................................... 100
4.7.4. Replacing the CR board assembly ............................................................................................. 101
4.7.5. Replacing the CR_ENC assembly.............................................................................................. 103
4.7.6. Replacing the P_EDGE sensor assembly .................................................................................. 104
4.7.7 Replacing black tape on platform ............................................................................................... 105
4.7.8. Replacing the CR cursor assembly ............................................................................................ 107
4.7.9. Replacing the cursor roller assembly.......................................................................................... 108
4.8. Replacing the Maintenance Area ....................................................................................... 112
4.8.1. Replacing the maintenance assembly ........................................................................................ 112
4.8.2. Replacing the wiper and wiperarm ............................................................................................. 115
4.8.3. Replacing the SLIDE motor assembly (wiper arm)..................................................................... 118
4.8.4. Replacing the transmission photosensor (wiper home position and maintenance home position)
.............................................................................................................................................................. 119
4.9. Replacing the Pump Area .................................................................................................. 120
4.9.1. Replacing the pump assembly.................................................................................................... 120
4.9.2. Replacing the pump assembly.................................................................................................... 121
4.9.3. Replacing the pump motor assembly ......................................................................................... 122
4.10. Replacing the Cartridge Area........................................................................................... 123
4.10.1. Replacing the I/H (ink holder) assembly ................................................................................... 123
4.11. Replacing Supports and Scroller...................................................................................... 127
4.11.1. Replacing the waste fluid bottle assembly (Rockhopper II 2H) ................................................ 127
4.11.2. Replacing the waste fluid bottle assembly (Rockhopper II 4H) ................................................ 128
4.11.3. Replacing the waste bottle box sensor assembly (RH II 2H) ................................................... 129
4.11.4. Replacing the waste bottle box sensor assembly (RH II 4H) ................................................... 131
4.11.5. Replacing the scroller R assembly ........................................................................................... 133
4.10.6. Replacing the scroller L assembly ............................................................................................ 135
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5. Self-Diagnosis Function............................................................................................137
5.1. Introduction ........................................................................................................................ 137
5.2. Preparation ........................................................................................................................ 137
5.2.1. Preparations on Machine ............................................................................................................ 137
5.2.2. Starting Up .................................................................................................................................. 138
5.3. Operations in Self-Diagnosis Mode.................................................................................... 139
5.3.1. Operating Self-Diagnosis Mode.................................................................................................. 139
5.3.2. Diagnosis Items in Self-Diagnosis Menu .................................................................................... 141
5.4. Test / Inspection Menu....................................................................................................... 142
5.4.1. RAM Capacity Menu ................................................................................................................... 143
5.4.2. Version Menu.............................................................................................................................. 143
5.4.3. Operation Panel Menu ................................................................................................................ 144
5.4.4. Sensor Menu............................................................................................................................... 145
5.4.5. Encoder Menu............................................................................................................................. 146
5.4.6. Fan Menu.................................................................................................................................... 147
5.4.7. History Menu............................................................................................................................... 147
5.4.8. Head Signal Menu ...................................................................................................................... 149
5.5. Adjustment Menu ............................................................................................................... 150
5.5.1. Skew Check Menu ...................................................................................................................... 151
5.5.2. Head rank input menu................................................................................................................. 152
5.5.3 Head Nozzle Check Menu .......................................................................................................... 153
5.5.4. Head Slant Check Menu ............................................................................................................. 155
5.5.5. Repeatability Adjustment (Bi-Directional) ................................................................................... 164
5.5.6. CW adjustments (Uni-Directional) .............................................................................................. 165
5.5.7. Band Feed Correction Menu (X Length)..................................................................................... 166
5.5.8. Top & bottom adjustment menu.................................................................................................. 168
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 Motor Endurance Menu ........................................................................................................ 186
5.9.2. PF Motor Endurance Menu......................................................................................................... 187
5.9.3. Cutter Endurance menu.............................................................................................................. 188
5.9.4. Head Up/Down Endurance Menu ............................................................................................... 189
5.9.5. Head Lock Endurance menu ...................................................................................................... 190
5.9.6. Pump Endurance menu .............................................................................................................. 191
5.9.7. Lever Motor Endurance Menu .................................................................................................... 192
5.9.8. Sequential Printing Endurance Menu ......................................................................................... 193
5.9.9. General Endurance Menu........................................................................................................... 194
5.9.10. Endurance Running Check Menu............................................................................................. 195
5.10. Head Lock Menu .............................................................................................................. 196
5.11. Heater System menu ....................................................................................................... 197
5.11.1. Heater Status Menu .................................................................................................................. 197
5.11.2. Heater Temperature Menu ....................................................................................................... 197
5.11.3. Heater Test 30 Menu ................................................................................................................ 198
5.11.4. Heater Test 50 Menu ................................................................................................................ 198
5.11.5. Heater Test Max Menu ............................................................................................................. 198
5.11.6. Heater Version Menu ................................................................................................................ 199
5.11.7. Heater Adjust Menu .................................................................................................................. 199
5.12. Eco Prepare menu ........................................................................................................... 200
5.13. Machine size select menu................................................................................................ 201
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6. Maintenance Mode.....................................................................................................203
6.1. Introduction ........................................................................................................................ 203
6.2. Operating Maintenance Mode............................................................................................ 203
6.2.1. Starting Up Maintenance Mode .................................................................................................. 203
6.2.2. Operating Maintenance Mode .................................................................................................... 203
6.3. Maintenance Menu ............................................................................................................ 204
6.3.1. Counter Display Menu ................................................................................................................ 204
6.3.2. Counter Initialization Menu ......................................................................................................... 206
6.3.3. MAC address write enable menu................................................................................................ 207
6.3.4 Head Voltage ............................................................................................................................... 208
7. Adjustments ...............................................................................................................209
7.1. Introduction ........................................................................................................................ 209
7.2. Adjustment ......................................................................................................................... 209
7.3. Parameter backup.............................................................................................................. 212
7.3.1. Tools required for work ............................................................................................................... 212
7.3.2. Procedure for creating backup parameters ................................................................................ 213
7.3.3. Backup parameter installation procedure ................................................................................... 214
7.4. Firmware installation .......................................................................................................... 215
7.4.1. Tools required for work ............................................................................................................... 215
7.4.2. Installation procedure.................................................................................................................. 215
7.5. Steel belt tension adjustment ............................................................................................. 218
7.5.1. Tools required for work ............................................................................................................... 218
7.5.2. Adjustment Procedure ................................................................................................................ 218
7.6. PF deceleration 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 Procedure .............................................................................................................. 232
7.11. Cover sensor adjustment ................................................................................................. 233
7.12. Head height adjustment ................................................................................................... 234
7.12.1. Tools required for work ............................................................................................................. 234
7.12.2. Adjustment Procedure .............................................................................................................. 234
7.13. Media sensor sensitivity adjustment ................................................................................ 236
7.13.1. Tools required for work ............................................................................................................. 236
7.13.2. Adjustment Procedure .............................................................................................................. 236
7.14. Cutter adjustment............................................................................................................. 239
7.15. Pump tubing layout for pump assembly ........................................................................... 240
7.15.1 Pump tubing layout - Rockhopper 4 heater ............................................................................... 240
7.15.2. Pump tubing layout - Rockhopper 2 heater .............................................................................. 243
7.16. Board checklist................................................................................................................. 248
7.16.1. Power supply board. ................................................................................................................. 248
7.16.2. Control board. ........................................................................................................................... 249
7.16.3. Power board.............................................................................................................................. 250
7.16.4. Heater Elements ....................................................................................................................... 250
7.16.5. Checklist ................................................................................................................................... 252
7.17 Flushing box height position adjustment ........................................................................... 253
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8. Maintenance ...............................................................................................................257
8.1. Introduction ...................................................................................................................................... 257
8.2. Cleaning ............................................................................................................................. 258
8.3. Periodical Services ............................................................................................................ 259
8.3.1. Service by end-user .................................................................................................................... 259
8.3.2. Service by authorised Mutoh technician ..................................................................................... 260
8.4. Part Life Information........................................................................................................... 261
8.5. Jig and Tool List................................................................................................................. 262
8.5.1. Required Tools............................................................................................................................ 262
8.6. Lubrication/Bonding ........................................................................................................... 263
8.7. Transportation of Machine ................................................................................................. 265
9. Troubleshooting ........................................................................................................267
9.1. Introduction ........................................................................................................................ 267
9.2. Troubleshooting procedures when a message has been displayed .................................. 267
9.2.1. Operating condition display ........................................................................................................ 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. Problems relating to the paper cutting operation........................................................................ 311
9.3.6. Problems relating to online and functions................................................................................... 314
9.3.7. Other problems ........................................................................................................................... 316
10. Appendix...................................................................................................................317
10.1. Introduction ...................................................................................................................... 317
10.2. Wiring Diagram Rockhopper II 2H ................................................................................... 317
10.3. Wiring Diagram Rockhopper II 4H ................................................................................... 318
10.4. Rockhopper II : Service Parts List/Exploded Views/Configuration Diagrams .................. 318
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Rockhopper II series printers – Maintenance Manual
1. SAFETY INSTRUCTIONS
1.1. INTRODUCTION
This chapter explains the meaning of safety terms for personnel who operate this equipment, important
safety instructions and the positions of the warning labels.
Important :
•
Be sure to follow all instructions and warnings in this manual when using the
equipment.
1.2. WARNINGS, CAUTIONS AND NOTE
Safety terms in this manual and the contents of warning labels attached to the printer are categorized into
the following three types depending on the degree of risk (or the scale of accident).
Read the following explanations carefully, and follow the instructions in this manual.
Safety terms
Important
Caution
Note
Details
Must be followed carefully to avoid death or serious bodily injury.
Must be observed to avoid bodily injury (moderately or lightly) or damage to your
equipment.
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
¾
Do not place the printer in following areas. Doing so may result in the printer falling over and causing
injury.
ƒ Angled place.
ƒ Areas subject to vibration by other equipment.
ƒ Do not stand on the printer or place heavy objects on the printer.
¾
Do not sit on the printer. Doing so may cause the printer to fall and injure people.
¾
Do not cover the ventilation hole of the printer with cloth, such as a blanket or table cloth. Doing so
could obstruct ventilation and cause fire.
¾
Do not place the printer in humid and dusty areas. Doing so may result in electrical shock or fire.
¾
Be sure that the following is performed before replacing parts.
ƒ Turn the printer off.
ƒ Disconnect the power cable from the electric outlet. Not doing so may cause electric shock or
damage to the electric circuit.
ƒ Unplug the cables connected to the printer.
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1.3.2. Caution
¾
Assembling and disassembling the printer are possible only for the parts shown in the operation manual.
Do not disassemble any frame parts or parts of which disassembling procedures are not shown in the
manual. Doing so may cause trouble that cannot be restored, as the printer is originally assembled in
the factory with a high accuracy of 1/100 mm.
¾
Do not touch the elements on the circuit board with bare hands. Doing so may cause static electricity
and break the elements.
¾
Do not press down the transparent film on the sides of the damper assembly with your hands. The
damper assembly is filled with ink and pressing on the film will make the ink spurt out.
¾
Be careful not to scratch the transparent film on the sides of the damper assembly.
¾
Be careful not to touch the surface of the print head’s nozzles or to let dirt adhere to them.
¾
There is some remaining ink in the tubes. Be careful that the ink is not spilled from the tube onto the
printer or objects close to the printer.
¾
If you need to operate the printer with the cover removed for maintenance, be careful not to get hurt by
the moving parts.
¾
Do not oil the printer mechanism with oil other than the oil designated by MUTOH. Doing so may
damage the parts or shorten the lifetime.
¾
If the power substrate assembly needs to be removed, disconnect the power cable and wait for at least 5
minutes before taking it out. This will discharge the residual electrical charge of the electrolytic capacitor.
Touching the substrate before the capacitor discharges may cause electric shock.
¾
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.
¾
When connecting or disconnecting the FFC type cable from the connector of the CR substrate, 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.
¾
Before replacing parts, be sure to adjust the capping position. When the capping position adjustment
has not been implemented, the cleaning position and other operational positions can exit the alignment
and normal operations become impossible.
¾
Pay attention to the following points when performing the cutter endurance operation.
ƒ Install an available ink cartridge.
ƒ Make sure that media initialization has been completed.
¾
Make sure that the power of the printer is OFF before performing the parameter backup. Performing the
parameter backup with the power ON may damage the main substrate or data may not be properly
installed.
¾
Make sure that the power of the printer is OFF before installing the firmware. Installing the firmware with
the power ON may damage the main substrate assembly or data may not be properly installed.
¾
Ensure there is sufficient space around the printer when performing maintenance work.
¾
Maintenance must be done by more than one person for :
ƒ detaching the printer from the stand or attaching it.
ƒ packing the printer for transportation.
¾
Be sure to directly clean when spoiling RH Cleaning Liquid. Because this liquid could damage the paint.
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1.4. WARNING LABELS
The handling, attachment locations, and types of warning labels are explained below.
Warning labels are attached to areas to which attention should be paid. Read and understand the positions
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.
¾ When cleaning labels, use a cloth with water or neutral detergent. Do not use a
solvent or gasoline.
¾ If a warning label has been damaged, lost or cannot be recognized, replace the
label.
¾
1.4.2. Locations and types of operation procedure labels
The locations of warning labels are shown below.
(1) Front Part
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No.
1
Type
CAUTION
VORSICHT
ATTENTION
> Do not open the front cover or touch the media during printing.This will result in poor image quality.
> If no printing is to be done for some time, remove the media and put the hold lever in the up
position. Otherwise the media may lift up and become wrinkled and you will not be able to obtain
good printing results.
> Öffnen Sie wärhend des Druckens die Frontabdeckung nicht und berühren Sie das
Druckmaterial nicht.
> Wenn Sie wärhend längere Zeit den Drucker nicht benutzen, nehmen Sie das Druckmaterial
heraus und stellen Sie den Halthebel in die obersten Position. Sonst kann sich das Druckmaterial
aufheben und 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'obtiendrez
pas de bonne qualité d'impression.
2
Only on a Rockhopper II 2H printer
CAUTION
VORSICHT
ATTENTION
> To avoid injury, keep fingers away from the
cutter blade.
> Um Verletzungen zu vermeiden, berürhen Sie das
Schneidemesser nicht.
> Ne touchez pas la lame afin d'éviter des blessures.
> To avoid injury, do not touch the edge of the
steel belt.
> Um Verletzungen zu vermeiden, berühren Sie den
Stahl-Antriebsriemen nicht .
> Ne touchez pas la courroie de transmission en
acier afin d'éviter des blessures.
A
Only on a Rockhopper II 4H printer
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(2) Back Part
No.
3
Type
CAUTION
THIS UNIT HAS TWO POWER SUPPLY CORDS
STANDARD. TO REDUCE THE RISK OF ELECTRICAL
SHOCK, DISCONNECT ALL POWER SUPPLY CORDS
BEFORE SERVICING.
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1.5. OPERATION PROCEDURE LABELS
The handling, attachment locations and types of operation procedure labels are explained below.
Your printer has labels, which give simple explanations of operations that require particular care. Read and
understand the locations and contents of these labels thoroughly before performing your work.
No.
6
Type
Number
of the
Colours
Ink Type
4
6
1
2
Eco Solvent
2x4 colours
Black
Yellow
Eco Solvent
1x6 colours
Black
Cyan
Refer to
Slot Number of Ink Cartridge
4
3
5
6
Cyan
Magenta Magenta
Transition Transition
Liquid
Liquid
Yellow
7
8
Cyan
Yellow
Black
Magenta
Light
Cyan
Light
Magenta
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
Number
of the
Colours
Ink Type
4
6
1
2
Eco Solvent
2x4 colours
Black
Cyan
Eco Solvent
1x6 colours
Black
Slot Number of Ink Cartridge
4
3
5
6
Magenta
Yellow
Black
Cyan Transition Transition Yellow
Liquid
Liquid
Cyan
Magenta
7
8
Magenta Yellow
Light
Cyan
Light
Magenta
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 87” printer)
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2. PRODUCT OVERVIEW
2.1. INTRODUCTION
This chapter explains the features, part names, and functions of the printer.
2.2. FEATURES
The features of the printer are explained below.
(1) High speed output
Both models feature new print heads and achieve high speed printing.
They also offer printing widths up to 1263 mm in 50-inch, 1643 mm in 64-inch and 2230 mm in 87-inch spec
possible.
(2) Wide variety 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 JOG feature is provided to allow setting of the printing position as required. Because printing
can be performed on media on which was already printed, excess space can be used effectively.
(5) RIP
Software Starter Pack included in-the-box. (To be defined with the order.)
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2.3. PART NAMES AND FUNCTIONS
Part names and functions are explained below.
2.3.1. Front
No.
1
Name
Operation panel
2
3
Ink compartment
Front cover
4
Pressure rollers
5
Maintenance cover
6
Stand
7
Media cut groove
8
Carriage cover
9
10
Foot switch
Paper Guide
Function
This panel is used to set operational conditions, the status of the printer,
and other functions.
This is the place for installing ink cartridges.
This cover keeps the operator safe from the drive parts of the printer
while it is operating. Only open and/or close the cover to perform
following operations:
¾ Media setting and replacement
¾ Cutter blade replacement
¾ Cleaning the cleaning wiper
¾ In case of media jam.
This roller is used to press the media from above and keep it flat when
printing.
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.
This stand is used to install the printer on a surface flat floor.
The following options are available for installation.
¾ Take-up system + scroller receiver
¾ Motorized roll-off / roll-up system
Only onto the Rockhopper II 4H printer !
Used to cut the media straight when it is cut manually.
Only onto the Rockhopper II printer !
This is a cover to protect the user from the internal components of the
unit. This is opened during following operation :
¾ When cleaning the cleaning wiper
This switch is used to raise and lower the pressure rollers.
Support the media during printing
In the Rockhopper II it houses post-heater (dryer).
In the Rockhopper II 4H it houses the fixer, post-fixer and dryer.
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2.3.2. Back
No.
1
2
3
4
5
6
7
8
Name
AC inlet
Interface connector
Foot switch connector
Insertion slot
Interface slot 1
Interface slot 2
Interface slot 3
Hard disk slot
9
Nameplate rating
10
Rear Heater
Function
This is the inlet interface to which the power plug is connected.
This is the connector to which the interface cable is connected.
This is the connector to which the foot switch cable is attached.
This is the slot for inserting media when loading it.
The network interface board attaches here.
This is not used for this printer.
Close it with the cover.
The hard disk attaches here. When not using a hard disk, keep the
cover closed.
The type, name, serial number, rating and other details of the printer are
labelled here.
Supports the media during printing and houses the pre-heaters.
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2.3.3. Operation panel
The operation panel is used to set operation conditions, display the status of the printer and set other
functions.
The names and functions of the operation keys and status lamps are explained below.
(1) Operation Keys.
No.
1
2
3
4
5
6
Name
[POWER] key
[F1] key
[F2] key
[F3] key
[F4] key
[MENU ↑] key
7
[MENU ↓] key
8
[ENTER] key
Normal
Turns the printer on and off.
Executes the function assigned to F1.
Executes the function assigned to F2.
Executes the function assigned to F3.
Executes the function assigned to F4.
Changes the LCD monitor display to
setup menu status.
Changes the LCD monitor display to
setup menu status.
Displays the print mode currently set.
9
[CANCEL] key
-
24
Setup menu display
Turns the printer on and off.
Executes the function assigned to F1.
Executes the function assigned to F2.
Executes the function assigned to F3.
Executes the function assigned to F4.
Changes the menu in reverse order.
Changes the menu in forward order.
Determines the new parameter value and
changes the LCD monitor display to the
next menu. Sets the parameter value and
changes the LCD monitor display to the
next menu.
Cancels the new parameter value and
changes the LCD monitor display to the
next menu. Clears the parameter value
and changes the LCD monitor display to
the next menu.
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(2) LCD monitor and status lamps.
No.
10
Name
LCD monitor
Colour
-
11
POWER lamp
Green
12
ERROR lamp
Red
13
DATA lamp
Orange
14
MEDIA SET lamp
Orange
Status
ON
OFF
Flashing
OFF
ON
Flashing
OFF
ON
OFF
15
ROLL lamp
Orange
16
SHEET lamp
Orange
17
HEATER lamp
Orange
ON
OFF
ON
OFF
ON
Flashing
OFF
Function
The monitor displays the operation status and error
messages of the printer.
The printer is on.
The printer is off.
An error has occurred. The contents will be displayed on
the LCD monitor.
Either there is no error or the power is off.
The printer is receiving print data.
The printer is analysing receiving data.
The printer is waiting to receive print data.
¾ The pressure rollers are in the release position.
¾ Media is not set.
¾ The pressure rollers are in secured position.
¾ The media is set.
The media type is set to roll media.
The media type is set to sheet media.
The media type is set to sheet media.
The media type is set to roll media.
The temperature of the heating elements is the requested
temperature.
The real temperature is the same as the requested
temperature.
The heating elements are warming up.
The real temperature is different as the requested
temperature.
The heating elements are powered OFF.
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2.4. PRINTER STATUS
The status of the printer is explained below.
2.4.1. Normal
Indicates that the printer can print when media is loaded.
You can also make settings using the operation panel.
Notes :
¾
Refer to the User’s Guide.
2.4.2. Setup menu display
Indicates that you can make settings using the operation panel.
Operations for printing can be conducted with the operation panel.
Notes :
¾
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 :
¾
Refer to the chapter “Self-Diagnosis function”.
2.4.4. Maintenance Mode Display
Indicates that you can make settings concerning the life of the printer. Keys of the operation panel have the
same names and functions as the display status of the setup menu.
Notes :
¾
Refer to the chapter “Maintenance mode”.
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2.4.5. Selecting Language
This chapter explains how to select the language on the 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.
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2.5. POSITION AND FUNCTION OF THE HEATING ELEMENTS
2.5.1. Rockhopper II 2 heater printers
Heater element
Pre-heater (Heater A)
Temperature
20 – 50°C
Function
→ Open the pores to make the media more receptive
for eco-solvent or eco-solvent plus™ ink.
Dryer (Heater D)
20 – 50°C
→ Applying heating immediately after printing
improves ink/media anchorage.
→ The dryer helps to make the media touch-dry before
it reaches the automatic take-up system.
2.5.2. Rockhopper II 4 heater printers
Heater element
Pre-heater (Heater A)
Temperature
20 – 50°C
Function
→ 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-fixer finalizes the fixation process and
helps to make the prints touch-dry.
Dryer (Heater D)
20 – 50°C
→ The dryer completes the drying for compatibility
with the take-up in combination with higher output
speeds.
→ Stickiness of printed banner materials is improved.
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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
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3. SPECIFICATIONS
3.1. INTRODUCTION
This section explains the specifications, optional parts and supplies, installation
procedures for optional parts, and user support for this printer.
3.2. PRODUCT SPECIFICATIONS
Printers
Technology
Media Thickness Compensation
Maximum Media Widths
Maximum Print Widths
Media
Thickness
Diameter / Core
Weight
Colour Channels
Inks
Ink Cassette Capacity / Type
Print Modes & Panel Control Options
50”- model
64”- model
87”- model
Drop-on-demand Micro Piezo Inkjet Technology.
Variable drop mass output between 5.4 ng and 41.5 ng
Automatic media thickness compensation.
Variable – RIP controlled – Head Height
1273 mm
1653 mm
2240 mm
1263 mm
1643 mm
2230 mm
Range: 0.08 mm – 1.1 mm
Maximum: 150 mm / 2” & 3” for 50,64 and 3” for 87
Maximum: 50 kg
8 colour channels – 4 or 6 process colour output
Eco-Solvent Plus 2xCMYK speed set-up
Eco-Solvent Plus CMYKLcLm photo tone rendering set-up
220 ml / smart chip ink type & order sensing
Uni & Bi-directional output, Interweaving, Mirror Output, Multi
Copy, Ink Status, Origin Control
Speed Overview Table ( * )
50 & 64
87
914mm (36”) wide output
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
1.5 – 3.0
1.3 – 2.6
{
Output speeds are given for 914 mm (36”) output.
50” output is 7 % faster, 64” output is 12 % faster and 87” output is 18 % faster.
For each mode, the minimum (Super High Quality) and maximum speed (Super Draft) are given.
Mode dependent, there are between 2 and 6 speed levels per mode, accessible via print direction selection
and interweave control from the RIP software.
Top speeds indicated are super draft modes and do not guarantee production output quality on all media
types.
{{{ Variable Drop Compatible
{ Fixed Drop Compatible
LCD Display
Backlight LED – 4 lines x 20 characters
Take-up System (standard)
Automated
Roll Media Core
2” & 3” for 50 & 64 and 3”” for 87
Interface
Centronics, IEEE 1284 compatible / Network, High Speed
Interface (standard high-speed interface card – 4 Mb/s).
Graphics Command Language
RTL-PASS, MH-GL, MH-GL/2
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Printers
Power Consumption
External Dimensions in mm (W x D x H)
Weight
Noise Level
Standard
Standard Items
64”- model
1300 VA
80 VA in stand-by
mode
3100 x 750 x 1250
87”- model
1400 VA
100 VA in stand-by
mode
3700 x 750 x 1250
170 kg
195 kg
215 kg
Operating: 54 dB or less
VCCI (Class A), FCC (Class A), UL, CE, CCIB
Hard Disk: 20.3 GB – Stores 16 jobs – Up to 99 copies/job –
PostScript RIP included
Extra Scroller Bars – Take-up System – Roll-off / roll-up system
Optional Item
Area
50” model
64” model
87” model
Floor loading capability
Electrical
Voltage
Frequency
Capacity
Environmental
50”- model
1100 VA
80 VA in stand-by
mode
2700 x 750 x 1250
Recommended
working environment
Operational
conditions
Rate of change
Storage environment
11.7 m² or larger. Frontage of 4.3 m or greater.
12.7 m² or larger. Frontage of 4.7 m or greater.
14.3 m² or larger. Frontage of 5.3 m or greater.
2490Pa (300kg/m²) or over
AC100V - 120V or AC220V – 240V
50/60Hz±1Hz
AC100V - 120V: 3A or more
AC220V - 240V: 1.5A or more
Temperature: 25°C
Humidity: 40% to 60%, without condensation
Temperature: 18°C to 35°C
Humidity: 40% to 60%, without condensation
Temperature: No more than 2°C per hour
Humidity: No more than 5% per hour
Temperature: -20°C to 60°C
Humidity: 5% to 85%, without condensation (When ink has been
discharged.)
Specifications are liable to changes without prior notice. All trademarks mentioned are property of their
respective owners.
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3.3. INTERFACE SPECIFICATIONS
This section explains the specifications for the interfaces supported by this product.
3.3.1. Centronics Bidirection Parallel Interface:IEEE1284)
(1) Interface Specifications
Item
Transmission modes
Data length
Transmission direction
Connector pin number
Specifications
Compatible , Nibble , ECP Mode
8 bits
Unidirectional (receiving only), Bidirectional
(2) Table of parallel interface pin numbers and signals
Pin
number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Connection
signal
STROBE
DATA1
DATA2
DATA3
DATA4
DATA5
DATA6
DATA7
DATA8
ACK
BUSY
P ERROR
SELECTED
AUTOFD
Not connected
SG
FG
+5V
Signal direction
To printer Å
To and from printer Å Æ
To and from printer Å Æ
To and from printer Å Æ
To and from printer Å Æ
To and from printer Å Æ
To and from printer Å Æ
To and from printer Å Æ
To and from printer Å Æ
From printer Æ
From printer Æ
From printer Æ
From printer Æ
To printer Å
Pin
number
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
Connection signal
SG
SG
SG
SG
SG
SG
SG
SG
SG
SG
SG
SG
INIT
FAULT
Not connected
Not connected
Not connected
SELECTIN
Signal
direction
To printer Å
From printer Æ
To printer Å
(3) Recommended Centronics cable specifications
Item
Interface
Structure
Shield construction
Characteristic impedance
Specifications
Dual-direction Parallel Interface:IEEE1284
AWG28×18 (twisted pair wiring)
Metallic tape + weaving (double shielded cable)
62 Ω
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3.3.2. Network Interface (Optional) Specifications
Item
Network Type
Network I/F
Protocol
Mode
Functions
Specifications
Ethernet IEEE802.3
10 Base-T,100 Base-TX
(RJ-45 connector, twisted pair cable)
* Automatic switching
TCP/IP
• ftp
• lpr
• socket
• Automatic protocol recognition
• Transmission speed up to 4 MB/s
• Network environment setting by Web.
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3.4. INSTALLATION
The Installation of the unit is explained below.
3.4.1. Conditions of the installation environment
Important :
Do not place the printer in following areas. Doing so may result in the printer
falling over and causing injury.
Unstable surfaces
Slanted place
Where vibration of other machines is transmitted.
Do not sit on the printer or put heavy things on the printer. Doing so may cause
the printer to fall and injure people.
Do not cover the ventilation hole of the printer with cloth, such as a blanket or
table cloth. Doing so could obstruct ventilation and cause fire.
Do not place the printer in humid and dusty areas. Doing 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.
Area
50” model
64” model
87” model
Floor loading capability
Electrical
Voltage
Frequency
Capacity
Environmental
Recommended
working environment
Operational conditions
Rate of change
Storage environment
11.7 m² or larger. Frontage of 4.3 m or greater.
12.7 m² or larger. Frontage of 4.7 m or greater.
14.3 m² or larger. Frontage of 5.3 m or greater.
2490Pa (300kg/m²) or over
AC100V - 120V or AC220V – 240V
50/60Hz±1Hz
AC100V - 120V: 3A or more
AC220V - 240V: 1.5A or more
Temperature: 25°C
Humidity: 40% to 60%, without condensation
Temperature: 18°C to 35°C
Humidity: 40% to 60%, without condensation
Temperature: No more than 2°C per hour
Humidity: No more than 5% per hour
Temperature: -20°C to 60°C
Humidity: 5% to 85%, without condensation (When ink has
been discharged.)
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Notes :
Avoid the following places with regard to temperature or humidity. If doing so, it may
affect the printing result.
Places where the temperature of humidity may rapidly change even though it is within
the correct range.
Places 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 printer and the stand.
Notes :
Refer to ‘product specifications’.
a
b
c
d
e
=
=
=
=
=
1500 mm
1500 mm
2500 mm
600 mm
1250 mm
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4. PARTS REPLACEMENT
4.1. INTRODUCTION
This chapter explains the procedures for replacing and removing maintenance parts.
Important :
¾
Before replacing parts, be sure to perform following operations.
ƒ Turn the power OFF.
ƒ Remove the electrical cable from the socket. Otherwise, you may
suffer electric shock or the machine’s electric circuits may be
damaged.
ƒ Disconnect all cables from the machine. Not doing so could cause
damage to the printer.
Caution :
¾
¾
¾
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 cannot be restored, as the printer is originally
assembled in the factory with a high accuracy of 1/100 mm.
Notes :
¾
After replacing the parts, perform necessary lubrication/bonding according to
"Lubrication/Bonding".
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4.2. REMOVING 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
2 = Side cover R
3 = side Cover L
4 = Front cover
5 = Panel unit assembly
6 = Y-rail cover
7 = Front paper guide
8 = Rear paper guide
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4.2.1. Removing the I/H cover
Step 1 :
Remove the ink cartridge.
Step 2 :
Open the I/H cover lid.
Step 3 :
Remove 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.
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4.2.2. Removing side cover R
Step 1 :
Remove the screw from 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
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Step 4 :
Remove the top of the side cover R.
Step 5 :
Remove the 4 bolts from the front and back of the inner surface on the bottom 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.
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4.2.3. Removing side cover L
Step 1 :
Remove the screw from the side of the upper 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
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Step 4 :
Remove the 4 bolts and cover nut from the front and back of the inner surface on the bottom of
side cover L.
1 = Hexagon socket head cap screws (M4x16)
Step 5 :
2 = Cover nut
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.
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4.2.4. Removing the front cover
Step 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
Step 4 :
2 = Screws (M3x8) on the left and right cover spindles
If the machine is a 50-inch model, remove cover spindle L, and then slide and remove the front
cover.
1 = Cover spindle L
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Step 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
3 = E ring
Step 6 :
2 = Sensor cam
Reinstall all parts in the opposite order of the removal procedure.
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4.2.5. Removing the carriage cover
Caution :
Please note that this cover is only on a 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
Step 7 :
2 = Screws (M3x6) fixing the carriage cover
Reinstall all parts in the opposite order of the removal procedure.
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4.2.6. Removing the panel unit assembly
Step 1 :
Remove side cover R.
Step 2 :
Remove the panel tape power cord.
Step 3 :
Remove the 4 screws fixing the panel base.
1 = Panel unit assembly
3 = Tape wire
2 = Screws (M3x6) fixing the panel unit assembly
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 9 :
Reinstall all parts in the opposite order of the removal procedure.
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4.2.7. Removing the Y rail cover
Caution :
Removing the Y rail cover, should be performed by at least two persons.
Otherwise the Y rail cover may be deformed.
Step 1 :
Remove 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
Step 6 :
2 = Screws (M3x6) fixing the Y rail cover and the Y rail cover FG
Remove the 6 screws from the front of the Y rail cover.
1 = Screws (M4x8) on the front of the Y rail cover
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Step 7 :
Remove the 5 screws from the rear of the Y rail cover.
¾ 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.
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4.2.8. Removing front paper guide
Step 1 :
Remove side cover L.
Step 2 :
Remove side cover R.
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 Y rail cover.
Step 6 :
Remove the screws from the top of front media guide.
Notes :
¾
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
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Step 7 :
Remove the screws from the front of front media guide.
Notes :
¾
Please note that the amount of screws is size dependent.
Rockhopper II 2 heater
1 = Screws on the front of front 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 :
¾
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 parts in the opposite order of the removal procedure.
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4.2.9. Removing rear paper guide
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 screws from the top of the rear media guide.
Notes :
¾
Please note that the amount of screws is size dependent.
1 = Screws on the rear paper guide
Step 6 :
Remove the screws from the rear of rear paper guide.
Notes :
¾
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 :
¾
Be sure not to damage the cables or connectors.
Step 10 : Remove the rear paper guide.
Step 11 : Replace the parts inside the printer.
Step 12 : Reinstall all parts in the opposite order of the removal procedure.
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4.2.10. Removing the head cover
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 carriage cover.
Caution :
Please note that this cover is only on a Rockhopper II (2 heaters) printer.
Step 6 :
Remove the Y rail cover.
Step 7 :
Unlock the head.
Notes :
¾
Step 8 :
Please refer to the ‘Head lock menu’.
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.
Step 11 : Replace the parts inside the printer.
Step 12 : Reinstall all parts in the opposite order of the removal procedure.
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4.2.11. Removing the maintenance cover
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 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 removal procedure.
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4.3. REPLACEMENT OF THE HEATER ELEMENT
To replace a heater element of the Rockhopper II series printer, please follow the instructions mentioned in
the explanation of the appropriate heater element.
1. Rockhopper II :
o 1. Replacing the front heater (Heater D) on a Rockhopper II printer
o 2. Replacing the rear heater (Heater A) on a Rockhopper II printer
2. Rockhopper II 4H :
o 1. Replacing the dryer (Heater D) on a Rockhopper II 4H printer
o 2. Replacing the post-fixer (Heater C) on a Rockhopper II 4H printer
o 3. Replacing the fixer (Heater B) on a Rockhopper II 4H printer
o 4. Replacing the heater (Heater A) on a Rockhopper II 4H printer
Caution :
¾ In case the fuse of the heating element is locked, do not replace the fuse but replace
the appropriate heater element. Installation of a fuse of the heater element needs to
be done in a special production environment.
Important :
Before replacing parts, be sure to perform the following operations.
¾ Turn the machine power OFF.
¾ Remove the product's electrical plug from the socket. Otherwise, you may
suffer electric shock or the machine’s electric circuits may be damaged.
¾ Disconnect all cables from the machine. Not doing so could cause damage to
the printer.
4.3.1. Rockhopper II 2 heaters : Heater elements
4.3.1.1. Replacing the front heater (Heater D) on a Rockhopper II printer
Before replacing the front heater, make sure to have following items:
¾ 50” model : Heat Strip Assy Front 1 50 and Heat Strip Assy Front 2 50
¾ 64” model : Heat Strip Assy Front 1 64 and Heat Strip Assy Front 2 64
¾ 87” model : Heat Strip Assy Front 1 87 and Heat Strip Assy Front 2 87
¾ 4 x sensor insul. Patch
To replace the front heater on a Rockhopper 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 carriage cover.
Step 5 :
Remove the Y rail cover.
Step 6 :
Remove the front paper guide.
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Step 7 :
Remove the front heater strip(s).
Step 8 :
Degrease the plate.
Notes :
¾
Step 9 :
Make sure the plate is cleaned properly. Dust, glue and other parts must be
removed.
Stick the front heater strip(s) onto the plate.
Notes :
¾
¾
Make sure 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 :
¾
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 the removal procedure.
Notes :
¾
During reinstallation of the plate, make sure there are no cables stuck.
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4.3.1.2. Replacing the rear heater on a Rockhopper II printer
Before replacing the post fixer, make sure to have following items:
¾ 50” model : Heater strip assy rear 50
¾ 64” model : Heater strip assy rear 64
¾ 87” model : Heater strip assy rear 87
¾ 2 x press plate
¾ Silicone glue
To replace the rear heater on a Rockhopper 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 :
¾
Make sure the plate is cleaned properly. Dust, glue and other parts must be
removed.
Step 8 :
Stick the rear heater strip onto the plate.
Step 9 :
Stick (with silicone glue) the two press plates onto the heater strip.
¾ 50” model : X = 380 mm
¾ 64” model : X = 380 mm / Y = 1060 mm
¾ 87” model : X = 660 mm / Y = 1200 mm / Z = 1750 mm
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Notes :
¾
It will take ± 1 hour to let the glue dry.
Step 10 : Reinstall all parts in the opposite order of the removal procedure.
Notes :
¾
During reinstallation of the plate, make sure there are no cables stuck.
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4.3.2. Rockhopper II 4 heaters : Heater elements
4.3.2.1. Replacing the dryer (Heater D) on a Rockhopper II 4H printer
Before replacing the dryer, make sure to have following items:
¾ 50” model : Dryer D1 50 and Dryer D2 50
¾ 64” model : Dryer D1 64 and Dryer D2 64
¾ 87” model : Dryer D1 87 and Dryer D2 872 x sensor insul. Patch
To replace the dryer 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 cover.
Step 5 :
Remove the front paper guide.
Step 6 :
Remove the dryer strip(s).
Step 7 :
Degrease the plate.
Notes :
¾
Step 8 :
Make sure the plate is cleaned properly. Dust, glue and other parts must be
removed.
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
the front paper guide.
¾ Stick it as close as possible to the assembly holes. Make sure it does not touch the
assembly holes.
¾
¾
Notes :
¾
Step 9 :
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.
Stick onto the sensors a sensor insul. patch.
1 = sensor insul. patch
2 = assembly hole
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Step 10 : Reinstall all parts in the opposite order of the removal procedure.
Notes :
¾
During reinstallation of the plate, make sure there are no cables stuck.
4.3.2.2. Replacing the post fixer (Heater C) on a Rockhopper II 4H printer
Before replacing the heater, make sure to have following items:
¾ 50” model : Post Fixer C 50
¾ 64” model : Post Fixer C 64
¾ 87” model : Post Fixer C 87
¾ 1 x sensor insul. Patch
To replace the post 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.
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 :
¾
Step 8 :
Make sure the plate is cleaned properly. Dust, glue and other parts must be
removed.
Stick the post fixer strip onto the plate.
Notes :
¾
¾
Make sure that the strips connect properly.
Stick it as close as possible to the assembly holes. Make sure it does not touch the
assembly holes.
Notes :
¾
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.
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Step 9 :
Stick onto the sensor a sensor insul. patch.
1 = sensor insul. patch
2 = assembly hole
Step 10 : Reinstall all parts in the opposite order of the removal procedure.
Notes :
¾
During reinstallation of the plate, make sure there are no cables stuck.
4.3.2.3. Replacing the fixer (Heater B1 and Heater B2) on a Rockhopper II 4H printer
Before replacing the fixer, make sure to have following items:
¾ 50” model : Fixer B1 50 and Fixer B2 50
¾ 64” model : Fixer B1 64 and Fixer B2 64
¾ 87” model : Fixer B1 87 and Fixer B2 87
¾ Isolation tape
¾ 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.
Step 4 :
Remove the Y rail cover.
Step 5 :
Remove the front paper guide.
Step 6 :
Place the plot platform calibre onto the plot platforms.
1 = plot platforms
2 = plot platform calibre onto the plot platforms
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Step 7 :
Fix the plot platform calibre onto the plot platform.
1 = Fix plot platform caliber
2 = reachable screws of plot platform
Notes :
¾
Step 8 :
Make sure the screws of the plot platform are reachable.
Remove the screws of 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 :
¾
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 :
¾
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.
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Step 13 : Stick the isolation tape onto the heater strips.
1 = plot platform
3 = isolation tape
2 = fixer heater strip
Step 14 : Reinstall all parts in the opposite order of the removal procedure.
Notes :
¾
During reinstallation of the plate, make sure there are no cables stuck.
4.3.2.4. Replacing the heater (Heater A) on a Rockhopper II 4H printer
Before replacing the post fixer, make sure to have following items:
¾ 50” model : Heater A 50
¾ 64” model : Heater A 64
¾ 87” model : Heater A 87
¾ 2 x press plate
¾ 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 cover.
Step 5 :
Remove the rear paper guide.
Step 6 :
Remove the heater strip.
Step 7 :
Degrease the plate.
Notes :
¾
Make sure the plate is cleaned properly. Dust, glue and other parts must be
removed.
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Step 8 :
Stick the heater strip onto the plate.
Notes :
¾
Step 9 :
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.
Stick (with silicone glue) the two press plates onto the heater strip.
¾ 50” model : X = 380 mm
¾ 64” model : X = 380 mm / Y = 1060 mm
¾ 87” model : X = 660 mm / Y = 1200 mm / Z = 1750 mm
Notes :
¾
It will take ± 1 hour to let the glue dry.
Step 10 : Reinstall all parts in the opposite order of the removal procedure.
Notes :
¾
During reinstallation of the plate, make sure there are no cables stuck.
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4.4. REPLACING BOARD BASES
This chapter explains the procedures for replacing the power source board assembly, mainboard assembly,
PCI_Linux board assembly and cooling fan assembly.
Caution :
When handling circuit boards, do not touch the elements on the board with your bare
hands. Doing so may cause static electricity and break the elements.
4.4.1 Replacing the Mainboard assembly, HDD_Extension board
assembly, HEAD_DRV board assembly, PCI_Linux board assembly
and cooling fan assembly
Notes :
Step 1 :
¾
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, overcurrent could be generated and damage the board.
¾
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 "Adjustment" for details of other adjustment.
¾
Remove the following parts before replacing the Mainboard assembly,
HDD_Extension board assembly, HEAD_DRV board assembly, PCI_Linux board
assembly and cooling fan assembly:
ƒ Panel unit assembly: "Removing the panel unit assembly"
ƒ Hard disk: "User’s Guide”
Remove the 20 screws fixing the Mainboard cover 3.
1 = 2 Screws (M3x6) fixing the Mainboard cover
2 = Mainboard cover 3
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Step 2 :
Remove the Mainboard cover 3.
Step 3 :
Follow the instructions in “Removing the panel unit assembly” to remove the panel unit assembly.
Step 4 :
Remove the connector between the cooling fan cable and the cooling fan assembly.
Step 5 :
Remove the 2 top and 2 bottom screws fixing the cooling fan assembly.
Step 6 :
Replace the cooling fan assembly.
Step 7 :
Remove the 15 screws fixing the Mainboard cover.
1 = Panel unit assembly
3 = Screws (M3x25) fixing the cooling fan assembly
5 = Mainboard cover
Step 8 :
Remove the 4 screws fixing the HEAD_DRV board assembly.
1 = HEAD_DRV board assembly
Step 9 :
2 = Cooling fan assembly
4 = Screws (M3x20) fixing the cooling fan assembly
6 = Screws (M3x6) fixing the Mainboard cover
2 = Screws (M3x6) fixing the HEAD_DRV board
assembly
Replace the HEAD_DRV board assembly.
Step 10 : Remove FFC protection material between HEAD_DRV board assembly and Mainboard
assembly.
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Step 11 : Remove following connectors from the Mainboard assembly.
N°
1
2
3
4
5
6
7
8
9
10
11
12
Connector N°
J101
J102
J103
J104
J105
J106
J107
J108
J109
J110
J111
J112
# of pins
12
6
168
68
28
120
120
120
39
96
3
2
13
J113
14
Colour
White
White
Connected to
Mainboard
Power
DIMM
White or black
Remarks
Lock type
Lock type
Lock type
PCI_LINUX board
PCI_LINUX board
PCI_LINUX board
White
White
Blue
HD_MOTHER board
Adhesion FAN 1
Adhesion FAN 2
2
Red
Adhesion FAN 3
J114
2
Yellow
Adhesion FAN 4
15
J115
2
Black
Adhesion FAN 5
16
17
18
19
20
21
22
23
J116
J117
J118
J119
J120
J121
J122
J123
2
3
3
White
Yellow
Black
Adhesion FAN 6
DRV_FAN 1
3
4
5
4
Red
White
White
Black
Waste fluid BOX sensor cable
Ink cover sensor
Lever foot SW cable
Lever up sensor
24
J124
4
Yellow
Lever down sensor
25
J125
6
White
Maintenance origin sensor
cable
26
27
28
29
30
J126
J127
J128
J129
J130
5
5
4
4
Red
Yellow
Blue
Head slide sensor
P_REAR_L sensor
P_REAR_R sensor
CR origin sensor
31
J131
5
Black
Wiper origin sensor
32
33
34
35
36
37
38
39
40
41
42
43
44
45
J132
J133
J134
J135
J136
J137
J138
J139
J140
J141
J142
J143
J144
J145 (87)
30
30
White or black
White or black
30
30
30
30
30
30
30
30
30
White or black
White or black
White or black
White or black
White or black
White or black
White or black
White or black
White or black
JUNCTION board
JUNCTION board
HEAD_DRV board
HEAD_DRV board
CR board
CR board
CR board
CR board
CR board
CR board
CR board
CR board
CR board
Free
For 50, 64, 87 inch
spec
For 50, 64, 87 inch
spec
For 50, 64, 87 inch
spec
For 50, 64, 87 inch
spec.
For 87 inch spec.
Free
No preparation
67
Transmission
photosensor
Transmission
photosensor
Transmission
photosensor
No preparation
Transmission
photosensor
Transmission
photosensor
No preparation
Lock type
Lock type
Lock type
Lock type
Lock type
Lock type
Lock type
Lock type
Lock type
Lock type
Lock type
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46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
J146 (87)
J147 (87)
J148 (87)
J149 (87)
J150 (87)
J151 (87)
J152 (87)
J153
J154
J155
J156
J157
J158
J159
J160
J161
J162
J163
J164
J165
J167
30
30
30
30
30
30
30
5
5
3
3
2
3
4
4
5
6
7
4
White or black
White or black
White or black
White or black
White or black
White or black
White or black
Black
White
White
Black
White
White
White
White
White
White
White
White
CR board
CR board
CR board
CR board
CR board
CR board
CR board
7
White
Interf. Cable Db9-Jst
1 = PCI_Linux board assembly
PF_ENC
Cover R sensor
Cover L sensor
PF motor
CR motor
Lever motor
Pump 1 motor
Pump 2 motor
HEAD U/D motor
Maintenance U/D motor
Wiper motor
Lock type
Lock type
Lock type
Lock type
Lock type
Lock type
Lock type
Free
Lock type
Lock type
Lock type
2 = Screws fixing the PCI_Linux board assembly (M3x6)
Step 12 : Remove the 2 screws fixing the PCI_Linux board assembly.
Step 13 : Replace the PCI_Linux board assembly.
Step 14 : Remove the 2 screws fixing the cooling fan assembly.
Step 15 : Replace the cooling fan assembly.
Step 16 : Remove the 4 screws fixing the I/F guide.
Step 17 : Remove I/F guide.
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Step 18 : Remove the 6 screws and 4 hexagon spacers fixing the Mainboard assembly.
1 = Mainboard assembly
3 = Hexagon spacer
5 = Cooling fan assembly
7 = I/F guide
2 = HDD_Extension board assembly
4 = Screws (M3x6)
6 = Screws (M3x20) fixing the cooling fan assembly
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 adjustment"
procedure.
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4.4.2. Replacing the power source board assembly
Caution :
When removing the power source board assembly, remove the power cable and set it
aside for at least 5 minutes in order to completely discharge the electric charge
remaining in the electrolytic capacitor before continuing with the procedure.
Touching the substrate before discharging the capacitor causes electric shock.
Step 1 :
Follow the instructions 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
Step 3 :
2 = Screws (M3x6) fixing the PS board cover
Remove the 5 screws fixing the Mainboard base.
1 = Screws (M3x8) fixing the Mainboard base
2 = Mainboard base
Step 4 :
Remove the Mainboard base.
Step 5 :
Remove the following connectors from the power source board assembly.
N°
1
2
3
Connector N°
CN2
CN3
CN4
# of pins
3
4
12
Colour
White
White
White
Connected to
Mainboard J101
+ 5V adhesion FAN
Mainboard J101
70
Remarks
Output four adhesion FAN
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Step 6 :
Remove the 4 screws fixing the power source.
1 = Power source board assembly
3 = Hexagon nut fixing the power board assembly
5 = Screws (M3x6) fixing the power source
2 = Screws (M4x8) fixing the power board assembly
4 = 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 :
¾
When installing the mainboard assembly, be careful not to pinch the foot SW cables
by the mainboard base.
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4.4.3. Replacing the inlet assembly, inlet board assembly and lever foot
SW cable assembly
Step 1 :
Follow the instructions 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 :
Follow step 2 to 4 in "Replacing the power source board assembly" to remove the Mainboard
assembly.
Step 3 :
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
3 = Inlet assembly
2 = Screws (M3x6) fixing the inlet board assembly
4 = Screws (M3x6) fixing the inlet assembly and
lever foot SW cable assembly
6 = Lever foot SW cable assembly
5 = Screw (M4x8) fixing the inlet assembly
Step 5 :
Replace the inlet board assembly.
Step 6 :
Remove the 3 screws fixing the inlet assembly.
Step 7 :
Replace the inlet assembly.
Step 8 :
Remove the 3 screws fixing the lever foot SW cable assembly.
Step 9 :
Replace the lever foot SW cable assembly.
Step 10 : Reinstall all parts in the opposite order of the removal procedure.
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4.4.4. Replacing the JUNCTION board assembly
Notes :
Step 1 :
N°
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
¾
To replace 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.
¾
Remove the following parts before replacing the JUNCTION board assembly.
ƒ I/H cover: refer to "Removing the I/H cover"
ƒ Side cover R: refer to "Removing side cover R"
Remove following connectors from the JUNCTION board assembly.
Connector N°
J401
J402
J403
J404
J405
J406
J407
J408
J409
J410
J411
J412
J413
J414
J415
J416
J417
J418
Step 2 :
# of pins
30
30
4
4
4
4
4
5
5
5
5
5
6
6
6
6
6
7
Colour
White
White
White
Black
Red
Yellow
Blue
White
Black
Red
Yellow
Blue
White
Black
Connected to
Mainboard
Mainboard
Ink sensor K
Ink sensor C
Ink sensor M
Ink sensor Y
Ink sensor LC
Ink sensor LM
Ink sensor O
Ink sensor G
SC cable K
SC cable C
SC cable M
SC cable Y
SC cable LC
SC cable LM
SC cable O
SC cable G
Yellow
Blue
White
Remarks
Lock type or Plug-in
Lock type or Plug-in
Cartridge 1
Cartridge 2
Cartridge 3
Cartridge 4
Cartridge 5
Cartridge 6
Cartridge 7
Cartridge 8
Cartridge 1
Cartridge 2
Cartridge 3
Cartridge 4
Cartridge 5
Cartridge 6
Cartridge 7
Cartridge 8
Remove the 4 screws fixing the JUNCTION board assembly.
1 = JUNCTION board assembly
2 = Screws (M3x6) fixing the JUNCTION board assembly
Step 3 :
Replace the JUNCTION board assembly.
Step 4 :
Reinstall all parts in the opposite order of the removal procedure.
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4.5. REPLACING THE PF ACTUATOR
4.5.1. Replacing the PF motor assembly
Caution :
The motor is hot after the product has been operated, so be careful not to burn yourself.
Notes :
¾
Remove following covers before replacing the parts in the PF motor assembly.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
ƒ Media guide F: refer to "Removing media guide F"
Step 1 :
Remove the PF motor 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.
3 = PF deceleration belt
2 = Screws (M4x10) fixing the PF motor assembly to
the X motor installation board.
Step 3 :
Remove the 2 screws fixing the PF motor assembly to the X motor installation board.
Step 4 :
Replace the PF motor assembly.
Notes :
¾
When installing the PF motor assembly, move the PF deceleration pulley manually
and confirm that the PF deceleration belt is set equally in the center of the PF motor
assembly pulley.
Step 5 :
Reinstall all parts in the opposite order of the removal procedure.
Step 6 :
Adjust the tension of the PF deceleration belt according to "PF deceleration belt tension
adjustment".
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4.5.2. Replacing the PF_ENC assembly and PF scale assembly
Notes :
¾
Remove the following covers before replacing the PF_ENC assembly.
ƒ Side cover L: refer to "Removing side cover L"
Step 1 :
Remove the PF_ENC assembly connector.
Step 2 :
Remove the 2 screws fixing the PF encoder installation board.
1 = Bearing
3 = PF scale
2 = Screws (M3x6) fixing the PF scale installation board
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 assembly to the PF encoder installation board.
1 = PF_ENC assembly
2 = Screws (M2x6) fixing the PF_ENC assembly to
the PF encoder installation board
3 = PF encoder installation board
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Step 9 :
Replace the PF_ENC assembly.
Notes :
¾
When installing the PF_ENC assembly and the PF encoder installation board, make
sure they are aligned with the locating bosses.
Step 10 : Reinstall all parts in the opposite order of the removal procedure.
Step 11 : Adjust the tension of the PF deceleration belt according to "PF deceleration belt tension
adjustment".
4.5.3. Replacing the PF deceleration pulley assembly
Notes :
¾
Remove following covers before replacing the parts in the PF motor assembly.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
ƒ 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 fixing the coupling.
1 = Coupling
3 = Y deceleration pulley axis
2 = Set screw fixing the coupling
Step 3 :
Pull the Y deceleration pulley to the opposite side of the origin and then remove the deceleration
pulley assembly.
Step 4 :
Reinstall all parts in the opposite order of the removal procedure.
Step 5 :
Adjust the tension of the PF deceleration belt according to "PF deceleration belt tension
adjustment".
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4.5.4. Replacing the PF deceleration belt
Notes :
¾
Remove following covers before replacing the parts in the PF motor assembly.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
ƒ 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
Step 4 :
Reinstall all parts in the opposite order of the removal procedure.
Step 5 :
Adjust the tension of the PF deceleration belt according to "PF deceleration belt tension
adjustment".
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4.5.5. Replacing the P_REAR_R sensor assembly and P_REAR_L
sensor assembly
Notes :
¾
Remove following covers before replacing the P_REAR_R sensor assembly and
P_REAR_L sensor assembly.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
ƒ Media 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 fixing the P_REAR_R sensor assembly.
1 = P_REAR_R sensor assembly
2 = Screws (M2x5) fixing the P_REAR_R sensor assembly
Step 5 :
Replace the P_REAR_R sensor assembly.
Step 6 :
Use the same procedure to replace the P_REAR_L sensor assembly.
Step 7 :
Reinstall all parts in the opposite order of the removal procedure.
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4.5.6. Replacing the suction fan assembly
Notes :
¾
Remove following covers before replacing the suction fan assembly.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
ƒ 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 = Screws (M3x12) fixing the suction fan assembly
Step 4 :
Replace the suction fan assembly.
Step 5 :
Reinstall all parts in the opposite order of the removal procedure.
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4.5.7. Replacing the lever motor assembly and the arm motor
installation board
Caution :
The motor is hot after the product has been operated, so be careful not to burn yourself.
Notes :
¾
Remove following covers before replacing the lever motor.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
ƒ 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 installation board.
Step 4 :
Remove the hexagon socket head screws with spring washers (3) fixing the CR motor assembly
to the arm motor installation board.
1 = Lever motor assembly
2 = Hexagon socket head screws with spring
washers (M4x10)
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Step 5 :
Replace the CR motor assembly.
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.
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4.5.8. Replacing the transmission photosensor
Notes :
¾
Remove following covers before replacing the transmission photosensor.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
(1) Replacing the transmission photosensor (lever motor side)
Step 1 :
Remove the screw fixing the sensor installation 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
3 = Transmission photosensor
2 = Connector
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 photosensors to be installed.
Step 7 :
Reinstall all parts in the opposite order of the removal procedure.
Notes :
¾
When installing the U/D cable assembly onto the transmission photosensor, be
careful not to confuse the connectors.
ƒ Lever up cable assembly (white): front
ƒ Lever down cable assembly (blue): rear
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(2) Replacing the transmission photosensor (CR origin side)
Notes :
¾
Refer to ‘Head Lock Menu’
Step 1 :
Unlock the head.
Step 2 :
Move the carriage from the capping position to the left.
Step 3 :
Remove the transmission photosensor from the ORG sensor installation board.
1 = ORG sensor installation board
3 = Transmission photosensor
2 = Connector
Notes :
¾
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 photosensors to be installed.
Step 7 :
Reinstall all parts in the opposite order of the removal procedure.
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4.5.9. Replacing the flushing box assembly
Notes :
¾
Step 1 :
Remove following covers before replacing the flushing box assembly.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
Unlock the head.
Notes :
¾
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 assembly.
Step 6 :
Reinstall all parts in the opposite order of the removal procedure.
Step 7 :
Adjust the head and flushing box assembly so that they do not come into contact.
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4.6. REPLACING THE CR ACTUATOR
4.6.1. Replacing the CR motor assembly
Caution :
The motor is hot after the product has been operated, so be careful not to burn yourself.
Notes :
¾
Remove following covers before replacing the CR motor assembly.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
ƒ 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
3 = Hexagon socket head cap screws (M3x6)
2 = Connector
Step 4 :
Reinstall all parts in the opposite order of the removal procedure.
Step 5 :
Adjust the tension of the CR deceleration belt according to "CR deceleration belt tension
adjustment".
Notes :
¾
When installing the CR motor cable assembly connector, install the white cable on
the right side as shown in the previous figure.
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4.6.2. Replacing the steel belt
Caution :
When replacing the steel belt, be careful not to cut your hands by the belt.
Notes :
Step 1 :
¾
Do not damage the steel belt.
¾
Remove following covers before replacing the steel belt.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
Unlock the head.
Notes :
¾
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 counterclockwisely to loosen the steel belt.
1 = Steel belt adjustment screws
2 = Steel belt
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Step 4 :
Remove the 2 screws fixing the steel belt.
1 = Screws fixing the steel belt
Step 5 :
2 = Steel belt
Replace the steel belt.
Notes :
¾
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".
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4.6.3. Replacing the SLIDE motor assembly, HD_SLIDE sensor
assembly, and slide motor installation board
Caution :
The motor is hot after the product has been operated, so be careful not to burn yourself.
Notes :
¾
Remove following covers before replacing the SLIDE motor assembly, HD_SLIDE
sensor assembly, and slide motor installation board.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: 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
3 = HD_SLIDE sensor assembly
2 = Screws (M3x6) fixing the SLIDE motor assembly
4 = Screws (M2x8) fixing the HD_SLIDE sensor
assembly
6 = Screws (M4x6) fixing the slide motor installation
board
5 = Slide motor installation board
Step 3 :
Replace the SLIDE motor assembly.
Step 4 :
Remove the 2 screws fixing the HD_SLIDE sensor assembly.
Step 5 :
Replace the HD_SLIDE sensor assembly.
Step 6 :
Remove the 2 screws fixing the slide motor installation board.
Step 7 :
Replace the slide motor installation board.
Step 8 :
Reinstall all parts in the opposite order of the removal procedure.
Step 9 :
Make sure that the Idler moves smoothly.
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4.6.4. Replacing the T fence
Notes :
¾
Step 1 :
Remove following covers before replacing the T fence.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
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
3 = T fence
Step 2 :
2 = T fence spring hook
Remove the screw fixing the T fence push plate.
1 = T fence push plate
3 = T fence
2 = Screw (M3x6) fixing the T fence push plate
Step 3 :
Remove the T fence from the hook.
Step 4 :
Remove the screw fixing the T fence stationary plate.
1 = T fence stationary plate
3 = Screw (M3x6) fixing the T fence stationary plate
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Step 5 :
Remove the T fence from the hook.
Step 6 :
Pull out the T fence in the direction of the arrow as shown in the previous figure while being
careful not to damage the CR_ENC assembly.
Step 7 :
Reinstall all parts in the opposite order of the removal procedure.
Notes :
¾
When installing the T fence, pay attention to the following :
ƒ When there is a film on the T fence, remove the film and install the T fence.
ƒ Properly install the T fence to the hooks on the T fence stationary plate.
Refer to the figure in step 2.
ƒ The T fence and the hooks on the stationary plate must have a loose fit.
ƒ When securing the stationary plate with screws, it must be loosened
enough so the T fence can be moved.
ƒ Insert the T fence into the hooks on the T fence push plate and the
CR_ENC assembly. Refer to the following figure.
ƒ Fix the T fence spring hook so that distance A of following diagram is about
1mm.
1 = T fence push plate
3 = CR_ENC assembly
2 = T fence
4 = T fence spring hook
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4.6.5. Replacing the CR slave pulley assembly
Notes :
¾
Remove following covers before replacing the CR slave pulley assembly.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
Step 1 :
Follow the instructions in "Replacing the steel belt" to remove the steel belt.
Step 2 :
Replace the CR slave pulley assembly.
1 = CR slave pulley assembly
3 = Bearing stopper
2 = Steel belt
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 :
¾
Be careful when handling the steel belt. The steel belt may be cut off when
accreting dust to it or creasing it.
¾
The driven pulley shaft is installed one way only. Refer to "Service Parts
List/Exploded Views/Configuration Diagrams", to install it correctly so that the
bearing stoppers are on top.
¾
After installing the CR slave pulley assembly, move the carriage to the left and right
manually to confirm that the steel belt has been set equally in the center of the CR
actuator pulley and the CR slave pulley assembly.
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4.6.6. Replacing the CR actuator pulley and the CR deceleration belt
Notes :
¾
Remove following covers before replacing the CR slave pulley.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
Step 1 :
Follow the instructions 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 according to "CR deceleration belt tension
adjustment".
Notes :
¾
After installing the CR actuator pulley assembly, move the carriage to the left and
right manually to confirm that the steel belt has been set equally in the center of the
CR actuator pulley and the CR slave pulley assembly.
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4.6.7. Replacing the steel bearer, tube guide, CR tape power cable and
ink tube
Notes :
Step 1 :
¾
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, overcurrent could be generated and damage board.
¾
Remove following covers before replacing the steel bearer, tube guide, CR tape
power cable, and ink tube.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
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 assembly and Mainboard
assembly.
Step 3 :
Remove the 2 screws fixing cable push plate.
Step 4 :
Remove the 2 screws fixing the tube clamp.
1 = CR tape power cable
3 = Cable push plate
5 = Screws fixing tube clamp (M3x8)
2 = Steel bearer
4 = Screws fixing cable push plate (M3x8)
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Step 5 :
Completely remove tube bundles 1 and 2.
1 = Tube bundle
2 = Tube bundle 2
Step 6 :
Remove the 4 screws fixing the tube clamp.
Step 7 :
Remove the tube clamp.
Step 8 :
Remove the coupling screws, O-ring and ink tube from the coupling.
Step 9 :
Replace the ink tube.
Step 10 : Remove the 2 screws fixing the cable clamp.
Step 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 = Pipe clamp
4 = Screws fixing tube push plate (M3x8)
2 = Cable clamp
3 = Coupling, O-ring, coupling screws
4 = Screws fixing tube cramp (M3x20)
Step 15 : Reinstall all parts in the opposite order of the removal procedure.
Notes :
¾
¾
¾
The CR tape power cables must be bundled during installation so that they can not
move.
The edge of the tube push plate must be upside when installed.
You should soak the O-ring in cleaning liquid once gain before installing it.
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4.6.8. Replace the cover R sensor assembly and the cover L sensor
assembly
Notes :
¾
Remove following covers before replacing the cover R sensor assembly and the
cover L sensor assembly.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
(1) Replacing the cover R sensor assembly
Step 1 :
Remove the cover R sensor assembly connector from the Mainboard assembly.
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 guide F.
Step 2 :
Remove the cover L sensor assembly connector from the cover L cable.
Step 3 :
Remove the 2 screws fixing the cover L sensor assembly.
1 = Cover L sensor assembly
2 = Screws (M2x8) fixing the cover L sensor assembly
Step 4 :
Replace the cover L sensor assembly.
Step 5 :
Reinstall all parts in the opposite order of the removal procedure.
Step 6 :
Perform cover sensor adjustment according to "Cover sensor adjustment".
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4.7. REPLACING THE CURSOR
4.7.1. Replacing the cutter holder, cutter spring, cutter cap, solenoid
assembly and solenoid spring
(1) Replacing the cutter spring
Step 1 :
Open the front cover.
Step 2 :
Remove the cutter blade from the cutter holder.
Step 3 :
Remove the cutter spring from the cutter holder.
1 = Cutter spring
2 = Cutter 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 :
¾
Remove following covers before replacing the cutter holder, cutter cap, solenoid
assembly, and solenoid spring.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
ƒ Head cover: refer to "Removing the head cover"
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Step 1 :
Remove the 2 screws fixing the cutter holder and holder support.
1 = Holder support
3 = Screws (M3x6) fixing the cutter holder and holder support
2 = Cutter holder
Step 2 :
Remove the cutter holder.
Step 3 :
Remove the cutter blade and cutter spring from the cutter holder.
Step 4 :
Remove the cutter cap and Solenoid spring.
Step 5 :
Remove the screw fixing the solenoid assembly to the cutter cap.
1 = Cutter cap
3 = Solenoid spring
5 = Screws (M2x4) fixing the solenoid assembly to
the cutter holder
2 = Screws (M3x6) fixing the solenoid assembly to
the cutter cap
4 = Solenoid assembly
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 solenoid assembly up from the hole on the cutter holder side.
Step 9 :
Replace the solenoid assembly.
Step 10 : Reinstall all parts in the opposite order of the removal procedure.
Step 11 : Adjust the cutter according to "Cutter adjustment".
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4.7.2. Replacing the print head assembly and head tape power cable
Notes :
¾
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, overcurrent could be generated and damage board.
¾
Remove following covers before replacing the print head assembly and head tape
power cable.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
ƒ Head cover: refer to "Removing the head cover"
¾
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 damper clamp.
1 = Damper clamp
Step 3 :
Remove the damper clamp.
Step 4 :
Remove the head tape power cable.
2 = Screws (M3x6) fixing the damper clamp
1 = Head tape power cable
3 = Head stationary plate / head spacer
5 = Screws (M2.6x5) fixing the head stationary plate
98
2 = Damper assembly
4 = Step-bore screw
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Step 5 :
Remove the damper assembly from the print head assembly.
Step 6 :
Remove the screw and step-bore screw fixing the head stationary plate.
Step 7 :
Remove the rotation adjustment spring under the head with small flat-head driver or another tool.
Step 8 :
Replace the print head assembly.
Step 9 :
Reinstall all parts in the opposite order of the removal procedure.
Notes :
¾
¾
¾
ƒ
ƒ
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 the rear of the cursor convex portion of the
cursor.
B : Insert the rotation adjustment spring into the convex portion of the head base on the right
front.
Step 10 : Perform head precision adjustment according to "Head precision adjustment".
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4.7.3. Replacing the H ink tube, tube branch and damper assembly
Notes :
¾
Remove following covers before replacing the H ink tube, tube branch, and damper
assembly.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
ƒ 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
3 = Ink tube
5 = Coupling screw, O-ring
2 = Tube branch
4 = H ink tube
Step 4 :
Remove the coupling screw and O-ring on the ink tube and the H ink tube sides from the tube
branch.
Step 5 :
Replace the tube branch.
Step 6 :
Remove the damper assembly from the print head assembly.
1 = Head tape power cable
3 = Print head assembly
2 = Damper assembly
4 = H ink tube, O-ring
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Step 7 :
Remove the H ink tube, coupling screw and O-ring from the damper assembly.
Step 8 :
Replace the damper assembly.
Step 9 :
Replace the H ink tube and O-ring.
Notes :
¾
Please soak the O-ring in cleaning liquid before installation.
Step 10 : Reinstall all parts in the opposite order of the removal procedure.
Notes :
¾
When tightening coupling screws, finger-tighten those. If using tools, it may result
in cracking where the screws fix damper and fail to fill the ink.
¾
Do 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 :
Step 1 :
¾
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, overcurrent could be generated and damage the board
¾
Remove following covers before replacing the CR board assembly.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
Remove the 8 screws fixing the CR cover.
1 = CR cover
2 = Screws (M3x8) fixing the CR cover
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Step 2 :
N°
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Remove following connectors from the CR board.
Connector N°
J201
J202
J203
J204
J205
J206
J207
J208
J209
J210
J211
J212
J213
J214
J215
J216
J217
J218
J219
J220
J221
J222
J223
J224
J225
J226
J227
J228
J229
J230
J231
J232
J233
J234
J235
# of pins
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
21
21
21
21
21
21
21
21
21
21
21
21
21
21
21
21
5
5
2
Colour
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White or Black
White
Black
White
Connected to
Mainboard
Mainboard
Mainboard
Mainboard
Mainboard
Mainboard
Mainboard
Mainboard
Mainboard
Mainboard
Mainboard
Mainboard
Mainboard
Mainboard
Mainboard
Mainboard
I160B head
I160B head
I160B head
I160B head
I160B head
I160B head
I160B head
I160B head
I160B head
I160B head
I160B head
I160B head
I160B head
I160B head
I160B head
I160B head
CR_ENC
P_EDGE sensor
Solenoid
Remarks
Lock type or Plug-in
Lock type or Plug-in
Lock type or Plug-in
Lock type or Plug-in
Lock type or Plug-in
Lock type or Plug-in
Lock type or Plug-in
Lock type or Plug-in
Lock type or Plug-in
Lock type or Plug-in
Lock type or Plug-in
Lock type or Plug-in
Lock type or Plug-in
Lock type or Plug-in
Lock type or Plug-in
Lock type or Plug-in
Step 3 :
Remove the 2 screws and 2 hexagon spacers fixing the CR board assembly.
Step 4 :
Replace the CR board assembly.
1 = CR board assembly
3 = Hexagon spacers fixing the CR boar
Step 5 :
2 = Screws fixing the CR board assembly (M3x6)
Reinstall all parts in the opposite order of the removal procedure.
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4.7.5. Replacing the CR_ENC assembly
Notes :
¾
Remove following cover before replacing the CR_ENC assembly.
ƒ Side cover L: refer to "Removing side cover L"
Step 1 :
Follow step 1 in "Replacing the flushing box assembly" to slide the 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 procedure.
Notes :
¾
When removing the T fence from the CR_ENC assembly, be careful not to damage
the T fence.
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4.7.6. Replacing the P_EDGE sensor assembly
Notes :
¾
Remove following covers before replacing the P_EDGE sensor Assembly.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
ƒ 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 parts in the opposite order of the removal procedure.
Step 5 :
Perform media sensor sensitivity adjustment according to "Media sensor sensitivity adjustment".
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4.7.7 Replacing black tape on platform
This black tape optimizes the media detection.
A damaged or faded black tape could cause the printer not to recognize the edge of the media during
loading / detection of media. This is the result of an insufficient reflection difference between the media and
the print platform.
Check if the black tape is not damaged or faded. To check the reflection, please check the media sensor
when no media is loaded.
Notes :
¾
The adjustment value is as follows.
ƒ LOW level (without media) A/D value
• In hexadecimal number : 30 to 0 (H)
• In decimal number : 48 to 0 (H)
In case of a damaged or faded 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:
¾ Turn the machine power OFF.
¾ Remove the product's electrical plug from the socket. Otherwise, you may
suffer electric shock or the machine’s electric circuits may be damaged.
¾ Disconnect all cables from the machine. Not doing so could cause damage to
the printer.
Step 1:
Remove the damaged or faded black tape.
Step 2:
Degrease the print platform.
Notes :
¾
Step 3:
Make sure the print platform is cleaned properly. Dust, glue and other parts must be
removed.
Stick the new black tape onto the print platform, between the middle row and rear row of vacuum
holes.
1 = vacuum holes
2 = black tape
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Notes :
¾
¾
Step 4:
Make sure that the black tape connects properly.
Please make sure that there are no air bubbles under the black tape. Air bubbles
below the black tape could cause the black tape to come loose.
There are grooves between the different print platform plates. Cut the black strip at this place
equal with this groove.
1 = groove
Important :
¾
Make sure not to cut the heater strip below the print platform. Doing so will
damage the printer.
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4.7.8. Replacing the CR cursor assembly
Notes :
¾
Remove following covers before replacing the CR cursor assembly.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
ƒ Head cover: refer to "Removing the head cover"
Step 1 :
Follow the instructions in "Replacing the cutter holder, cutter spring, cutter cap, solenoid
assembly, 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.
1 = CR board installation board
Step 6 :
Remove the T fence.
Step 7 :
Remove the CR blade spring.
2 = Screws (M3x8) fixing the CR board installation board
1 = CR cursor assembly
2 = CR blade spring
Step 8 :
Replace CR cursor assembly.
Step 9 :
Reinstall all parts in the opposite order of the removal procedure.
Step 10 : Perform head height adjustment according to "Head height adjustment".
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4.7.9. Replacing the cursor roller assembly
Notes :
¾
Remove following cover before replacing the Cursor roller assembly.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
ƒ Head cover: refer to "Removing the head cover"
4.7.9.1. Replacing the cursor roller assembly (upper 2 cursor rollers)
Step 1 :
Follow the instructions in "Replacing 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 the cursor roller assembly (6 high-load bearings) : Large bearing
type
Step 1 :
Follow the instructions in "Replacing the CR cursor assembly " to remove the CR cursor
assembly.
Step 2 :
Remove the side cursor roller assemblies and B cursor axises together with flat-head driver or
another tool.
1 = CR cursor assembly
Step 3 :
2 = B cursor axis
Remove the E ring fixing the cursor roller assembly of downside.
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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
3 = Brass spacer of the side cursor roller assy
5 = High-load bearing of the cursor roller assy of downside
Step 6 :
2 = High-load bearing of the side cursor roller assy
4 = E ring of the cursor roller assy
6 = Brass spacer of the cursor roller assy
Apply the screw lock to the cursor axis, and install the cursor roller assembly with the axis at the
lower position.
Notes :
¾
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".
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4.7.9.3. B. Replacing the cursor roller assembly (6 high-load bearings) : open bearing type
Step 1 :
Follow the instructions in "Replacing the CR cursor assembly " to remove the CR cursor
assembly.
Step 2 :
Remove the side cursor roller assemblies and B cursor axises together with flat-head driver or
another tool.
1 = CR cursor assembly
Step 3 :
2 = B cursor axis
Remove the E ring fixing the 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
3 = High-load bearing of the side cursor roller assy
5 = Brass spacer of the side cursor roller assy
7 = Spacer of the cursor roller assy
9 = Spacer of the cursor roller assy
110
2 = Spacer of the side cursor roller assy
4 = Spacer of the side cursor roller assy
6 = E ring of the cursor roller assy
8 = High-load bearing of the cursor roller assy of
downside
10 = Brass spacer of the cursor roller assy
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Step 6 :
Apply the screw lock to the cursor axis, and install the cursor roller assembly with the axis at the
lower position.
Notes :
¾
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".
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4.8. REPLACING THE MAINTENANCE AREA
4.8.1. Replacing the maintenance assembly
Notes :
¾
When replacing the parts inside the maintenance assembly, be sure to perform
following operation to clear the counter.
ƒ "High ink initialization" or " Cleaning initialization": refer to "Counter Display
Menu"
¾
Remove following covers before replacing the parts inside the maintenance
assembly.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ 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 the side plate T
Step 3 :
Remove the side plate T.
Step 4 :
Remove the screw fixing the waste fluid receptacle.
Step 5 :
Remove the waste fluid receptacle.
Step 6 :
Remove the screw fixing the flushing box installation board.
Step 7 :
Remove the flushing box installation board.
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Step 8 :
Remove the connector and tube from the maintenance assembly.
1 = tube connections
Notes :
¾
Step 9 :
There is some remaining ink in the tubes. Be careful that the ink is not spilled from
the tube onto the printer or items close to the printer.
Remove the 6 screws fixing the maintenance assembly.
1 = Waste fluid receptacle
3 = Screws (M3x8) fixing the maintenance assembly
2 = Maintenance assembly
Step 10 : Replace the maintenance assembly.
Notes :
¾
Secure the maintenance assembly so that it abuts against the rear right portion.
¾
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, (4) 0mm For 87 inch model: (1) 90mm, (2) 50mm, (3) 40mm, (4) 70mm,
(5) 0mm, (6) 30mm, (7) 30mm, (8) 0mm
¾
The connection sequence for the tubes is as follows: Numbers in brackets ( ) are
the cap numbers from left to right as viewed from the front of the main body.
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o
o
o
50 or 64 inch model: Cap (a) and Pump (1), Cap (b) and Pump (3), Cap (c) and
Pump (2), Cap (d) and Pump (4)
87 inch model 2 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 (7), Cap (f) and Pump (5), Cap
(g) and Pump (6), Cap (h) and Pump (8)
87 inch model 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 on the nozzle.
1 = Print head (nozzle face)
3 = Cap trace
2 = Nozzle
4 = Mirror
Step 14 : Reinstall all parts in the opposite order of the removal procedure.
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4.8.2. Replacing the wiper and wiperarm
4.8.2.1 Installing the new wipers in the wiperarm.
Please follow the procedure mentioned below.
Step 1 :
Click the new wipers in the new wiperarm on the positions and manor shown in the pictures.
No.
1
2
Part
Well positioned wiper
Malpositioned wiper
For Rockhopper II 50” and 64”
1
2
3
4
5
6
7
For Rockhopper II 87”
8
1
Position 3, 4, 5, 6
2
3
4
5
6
7
8
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
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Step 2 :
Push the carriage to the left side of the machine so you can remove the four screws of the wiper
assembly.
No.
1
Step 3 :
Part
Screws
Remove the wiper assembly
Notes :
¾
Be careful removing the wiper assembly, so you don’t break the sensor located
close to the wiper.
No.
1
Part
Sensor
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Step 4 :
Remove the wiperarm and reinstall the new one.
No.
1
2
Part
Wiperarm assembly
T plate
Step 5 :
To reinstall the wiper assembly, please reverse the removal procedure.
Step 6 :
After complete reinstallation, clean the wipers using Isopropanol.
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4.8.3. Replacing the SLIDE motor assembly (wiper arm)
Caution :
The motor is hot after the product has been operated, 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.
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4.8.4. Replacing the transmission photosensor (wiper home position
and maintenance home position)
Step 1 :
Remove the transmission photosensor from the side plate R.
1 = Transmission photosensor (wiper origin side)
2 = Transmission photosensor (maintenance origin
side)
4 = Maintenance origin cable assembly
3 = Wiper 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 :
¾
When installing the origin cable assembly onto the transmission photosensor, be
careful to not confuse the connectors.
ƒ Wiper origin cable assembly (black): front
ƒ Maintenance origin cable assembly (white): rear
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4.9. REPLACING THE PUMP AREA
4.9.1. Replacing the pump assembly
Notes :
¾
Step 1 :
Remove following covers before replacing the parts in the PF motor assembly.
ƒ Side cover R: refer to "Removing side cover R"
ƒ Side cover L: refer to "Removing side cover L"
ƒ Front cover: refer to "Removing the front cover"
ƒ Carriage cover: refer to "Removing the carriage cover"
ƒ Y rail cover: refer to "Removing the Y rail cover"
ƒ Maintenance cover: refer to "Removing the maintenance cover"
Remove the connector and tube from the pump assembly.
1 = tube connections
Notes :
¾
There is some remaining ink in the tubes. Be careful that the ink is not spilled from
the tube onto the printer or items close to the printer.
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Step 2 :
Remove the 4 screws fixing the pump assembly.
Rockhopper II 2 heater
Rockhopper II 2 heater
1 = Pump assembly
2 = Screws (M3x8) fixing the pump assembly
Step 3 :
Replace the pump assembly.
Step 4 :
Reinstall all parts in the opposite order of the removal procedure.
Notes :
¾
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 opposite order of the removal procedure.
Notes :
¾
Follow the instructions in "Pump tubing layout for pump assembly" to connect the
tube.
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4.9.3. Replacing the pump motor assembly
Caution :
The motor is hot after the product has been 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.
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4.10. REPLACING THE CARTRIDGE AREA
4.10.1. Replacing the I/H (ink holder) assembly
There are 8 I/H assembly 's installed in this printer. Following procedure is for the removal of 1 I/H
assembly.
Notes :
¾
Remove following covers before replacing the parts in the I/H assembly.
ƒ I/H cover: refer to "Removing the I/H cover"
ƒ Side cover R: refer to "Removing side cover R"
ƒ Panel unit assembly: refer to "Removing the panel unit assembly"
(1) Removing the I/H assembly
Step 1 :
Perform the ink discharge operation to discharge the ink from the inside of all ink paths.
Notes :
¾
Step 2 :
For ink draining procedure, refer to "Head wash menu".
Remove the following connectors from the JUNCTION board assembly.
¾ Ink sensor assembly connectors (8)
¾ SC cable assembly connectors (8)
Notes :
¾
For more details of the JUNCTION board assembly connector, refer to "Table
Connectors connected to the JUNCTION board assembly" in "Replacing the
JUNCTION board assembly".
Step 3 :
Remove the sensor assembly harnesses removed in step 2 from their clamps.
Step 4 :
Pull the harnesses out of the grommets on the board base fixing plate.
Step 5 :
Follow the step 1 to 3 in "Replacing the power source board assembly" to remove the Mainboard
base.
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Step 6 :
Remove the 3 screws fixing the P/S board installation board.
Step 7 :
Remove the P/S board installation board.
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
3 = Screws (M3x8) fixing I/C slide 2 and the I/H
assembly
2 = I/C slide 2
Step 10 : Remove the I/H assembly.
Step 11 : Reinstall all parts in the opposite order of the removal procedure.
Notes :
¾
Please soak the O-ring in cleaning liquid before installation.
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(2) Replacing the ink ID board assembly and the holder pressure spring
Step 1 :
Remove the I/H assembly.
Step 2 :
Remove the 2 screws fixing the holder pressure spring.
1 = Holder pressure spring (two-ply use)
3 = Ink ID board assembly
2 = Screws (M3x6) fixing the holder pressure spring
4 = SC cable assembly
Step 3 :
Replace the holder pressure spring.
Step 4 :
Remove the SC cable assembly connector 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 the arrow to remove it.
Step 4 :
Slide the cartridge frame assembly in the direction of the arrow to remove it.
1 = Cartridge frame assembly
2 = Hook
Step 5 :
Replace the cartridge frame assembly.
Step 6 :
Reinstall all parts in the opposite order of the removal procedure.
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(4) Replacing the ink sensor assembly (ink NOT sensor, ink END sensor)
Step 1 :
Remove the I/H assembly.
Step 2 :
Remove the cables from the I/H assembly clamp.
Step 3 :
Remove the cartridge frame assembly.
Step 4 :
Remove the screw fixing the ink END sensor.
1 = Ink END 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 :
¾
When installing the ink NOT sensor, do not tighten the screw firmly. Otherwise, the
switch may not come out.
Step 10 : Make sure that the Ink NOT sensor switch moves.
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4.11. REPLACING SUPPORTS AND SCROLLER
4.11.1. Replacing the waste fluid bottle assembly (Rockhopper II 2H)
Notes :
¾
Step 1 :
When replacing the 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"
Remove the waste fluid tube from the waste fluid bottle assembly.
1 = Waste fluid tube
Step 2 :
2 = Waste fluid bottle assembly
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 the printer.
Step 3 :
Reinstall all parts in the opposite order of the removal procedure.
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4.11.2. Replacing the waste fluid bottle assembly (Rockhopper II 4H)
Notes :
¾
Step 1 :
When replacing the 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"
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.
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4.11.3. Replacing the waste bottle box sensor assembly (RH II 2H)
Step 1 :
Follow the instructions in "Replacing the waste fluid bottle assembly" to remove the waste fluid
bottle assembly.
Step 2 :
Remove the waste liquid BOX sensor assembly connector from the rear side cap R.
1 = Rear side cap R
Step 3 :
2 = Waste liquid BOX sensor assembly connector
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 installation board.
1 = Screws fixing the waste liquid sensor installation board (M3x6)
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Step 6 :
Remove the waste liquid sensor installation board.
Step 7 :
Remove the screws (M2x8) fixing the waste liquid BOX sensor assembly.
1 = Waste liquid sensor installation board
3 = Screws (M2x8)
2 = Waste liquid BOX sensor assembly
Step 8 :
Remove the waste liquid BOX sensor assembly.
Step 9 :
Reinstall all parts in the opposite order of the removal procedure.
Notes :
¾
When installing the waste liquid BOX sensor assembly, pay attention to following
points :
ƒ Adjust the waste liquid BOX sensor assembly before installing the waste
liquid bottle cover.
ƒ Position and install it so that "Sensor : Waste liquid tank" is properly
switched in "Sensor Menu".
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4.11.4. Replacing the waste bottle box sensor assembly (RH II 4H)
Step 1 :
Follow the instructions in "Replacing the waste fluid bottle 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
Step 3 :
2 = Waste liquid BOX sensor assembly connector
Remove the waste liquid box assy from the stand.
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Step 4 :
Remove the screws fixing the waste liquid sensor assembly.
Step 5 :
Reinstall all parts in the opposite order of the removal procedure.
Notes :
¾
When installing the waste liquid BOX sensor assembly, pay attention to following
points :
ƒ Adjust the waste liquid BOX sensor assembly before installing the waste
liquid bottle cover.
ƒ Position and install it so that "Sensor : Waste liquid tank" is properly
switched in "Sensor Menu".
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4.11.5. Replacing the scroller R assembly
(1) Replacing the scroller R assembly
Step 1 :
Remove the 4 hexagon socket head springs fixing the scroller R assembly.
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
3 = Scroller R assembly
Step 2 :
2 = Screws (M3x8) fixing scroller receptacle cover R
Remove the scroller receptacle cover R.
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Step 3 :
Remove the E ring fixing the axes of the rollers to be replaced.
1 = Pressure roller
3 = Roller 2
5 = E ring (E-4)
2 = Roller 1
4 = E ring (E-3)
Step 4 :
Replace the rollers.
Step 5 :
Reinstall all parts in the opposite order of the removal procedure.
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4.10.6. Replacing the scroller L assembly
(1) Replacing the scroller L assembly
Step 1 :
Remove the 4 hexagon socket head springs fixing the scroller 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
3 = Scroller L assembly
Step 2 :
2 = Screws (M3x8) fixing scroller receptacle cover R
Remove scroller receptacle cover R.
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Step 3 :
Remove the E ring fixing the axes of the rollers to be replaced.
1 = Pressure roller
3 = E ring (E-3)
2 = Roller 1
4 = E ring (E-4)
Step 4 :
Replace the rollers.
Step 5 :
Reinstall all parts in the opposite order of the removal procedure.
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5. SELF-DIAGNOSIS FUNCTION
5.1. INTRODUCTION
This chapter provides information on the self-diagnosis function.
The self-diagnosis function adjusts the printing accuracy. It is used in the manufacturing process,
adjustment and maintenance.
The self-diagnosis function is implemented in the system firmware. All functions are available from the
operation panel.
Notes :
¾
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 selfdiagnosis 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 :
¾
Make sure to use coated paper for the adjustment purpose.
(2) Connecting power cable
Connect the power cable to the machine's inlet assembly and insert the power plug into an outlet.
Notes :
¾
Do not connect three or more power plugs to one outlet.
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5.2.2. Starting Up
To use the self-diagnosis function, you should first display the self-diagnosis menu on the operation panel.
The self-diagnosis menu is completely independent of the 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.
¾ 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.
¾ The system will enter the self-diagnosis mode and display the self-diagnosis menu.
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5.3. OPERATIONS IN SELF-DIAGNOSIS MODE
This section explains how to operate in the self-diagnosis mode and provides the list of available 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 diagnosis item.
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Step 3 :
Press the [F2] 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.
¾ The modified set value is stored and a next item is displayed.
Notes :
¾
If you press the [CANCEL] key instead of the [ENTER] key, the modification will not
be stored.
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Step 5 :
To quit the diagnosis menu, press the [CANCEL] key on the operation panel.
¾ The system returns to an upper hierarchy of the diagnosis menu.
Step 6 :
To exit the self-diagnosis menu, press the [POWER] key.
5.3.2. Diagnosis Items in Self-Diagnosis Menu
The Self-Diagnosis menu includes following diagnosis items.
Initialization item
Inspection Menu
Adjustment Menu
Purge Menu
Sample Printing
Menu
Parameter Menu
Endurance
Running Menu
Head Lock Menu
Description
Performs various inspections on the circuit boards,
sensors, and fans.
Performs various adjustments for the printer mechanism.
Performs mode-specified purge.
Performs sample printing necessary for adjustment.
Configures various adjustment parameters.
Performs endurance running of the printer mechanism.
Performs lock and release of the print head.
F1 →
F3 →
* Check *
Test
Cleaning
F1 →
F3 →
* Check *
Parameter
Head lock
F1 →
* Check *
Eco Prepare
Adjustment
Print
(1/3)
← F2
← F4
Life
Heat Syst
(2/3)
← F2
← F4
Reference
Refer to Inspection Menu
Refer to Adjustment Menu
Refer to Purge Menu
Sample Printing Menu
Refer to Parameter Menu
Refer to Endurance
Running Menu
Refer to Head Lock Menu
(3/3)
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5.4. TEST / INSPECTION MENU
In the Inspection menu, you can perform various inspections on the circuit boards, sensors and fans.
The Inspection menu includes the following diagnosis items.
Initialization item
Memory size
Description
This menu displays the memory size.
Refer to
→ Ram Capacity Menu
Version
Displays the versions of the firmware and mainboard
assembly.
¾ Firmware version
¾ Backup parameter version
¾ Setting of dip switches
¾ Revision of mainboard assembly
→ Version Menu
Operation panel
Used to check the functions of the operation panel keys,
LCD, and LED.
→ Operation Panel Menu
Sensor
This menu displays the sensor status in the operation
panel.
¾ CR_HP sensor
¾ Cover sensor
¾ Lever sensor
¾ P_EDGE sensor
¾ P_REAR sensor
¾ HD_SLIDE sensor
¾ Thermistor sensor
¾ Ink ID sensor
¾ Ink NOT sensor
¾ Ink END sensor
→ Sensor Menu
Encoder
Displays the detected values from the following encoders.
¾ CR (Carriage)
¾ PF (Media feed)
→ Encoder Menu
Fan
This menu is used to check if the fan operates normally by
turning ON and OFF the fan.
→ Fan Menu
History
Used to check the following records.
¾ Maintenance history
¾ Serious error history
→ History Menu
Head waveform
This menu is used to check the head-driving signal.
→ Head Signal Menu
F1 →
F3 →
* Test *
RamCapacity
Panel
F1 →
F3 →
* Test *
Encoder
Elec.
142
Version
Sensor
(1/2)
← F2
← F4
Fan
Head Signal
(2/2)
← F2
← F4
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5.4.1. RAM Capacity Menu
This menu displays the memory size.
* RamCapacity *
RamCapacity
256 MB
Notes :
¾
The Memory Size menu displays the size of the memory installed on the mainboard
(128 MB or 256 MB).
5.4.2. Version Menu
This menu displays following contents about the firmware and mainboard assembly.
¾ Firmware version
¾ Backup parameter version
¾ Setting of dip switches of mainboard assembly
¾ Revision of mainboard assembly
Notes :
¾
The details of the dipswitch setting of mainboard assembly are as follows.
• Switch 1: OFF
• Switch 2: OFF
* Ver *
Firm
Parameter
rh 2.08, mA
1.00
(1/2)
* Ver *
DipSW
Board Rev
0x03
10
(2/2)
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5.4.3. Operation Panel Menu
This menu is used to check the functions of the operation panel keys, LCD, and LEDs.
(1) Operation panel key check
When you press a key on the operation panel, 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.
¾ Power lamp
¾ Error lamp
¾ Data lamp
¾ Media set lamp
¾ Roll media lamp
¾ Cut media lamp
¾ Heater lamp
F1 →
F3 →
* Panel *
Key
LED
LCD
* Panel *
Key
← F2
??????
███████████████
███████████████
███████████████
███████████████
* Panel *
LED
Origin
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5.4.4. Sensor Menu
This menu displays the sensor status in the operation panel.
If the displayed sensor status does not match the actual machine status, replace or adjust the relevant
sensor referring to "Table Inspection Items in Sensor Menu".
N°
Sensor name
CR_HP sensor
Waste fluid sensor
Cover sensor
Status in display
ON/OFF
ON/OFF
Open/Close
Ink cover sensor
Lever Up
Lever Down
Foot lever SW sensor
P_EDDE sensor
P_REAR-R sensor
Open/Close
ON/OFF
ON/OFF
ON/OFF
0 to FF (0 to 255)
ON/OFF
P_REAR-L sensor
ON/OFF
HD_SLIDE sensor
ON/OFF
Head thermister
Ink ID sensor
Ink NOT sensor
Ink END sensor
**°C
Pig, Dye, WASH
12345678
12345678
Refer to
Replacing the transmission photosensor
Replacing the waste liquid BOX sensor assembly
Replace the cover R sensor assembly and the
cover L sensor assembly
Removing the I/H cover
Replacing the transmission photosensor
Replacing the transmission photosensor
Replacing the P_EDGE sensor assembly
Replacing the P_REAR_R sensor assembly and
P_REAR_L sensor assembly
Replacing the P_REAR_R sensor assembly and
P_REAR_L sensor assembly
Replacing the SLIDE motor assembly, HD_SLIDE
sensor assembly and slide motor installation board
Replacing the Cartridge Area
Replacing the Cartridge Area
Replacing the Cartridge Area
Notes :
¾
The ink ID sensor indicates the type of ink cartridge installed with the following ID.
• W(ASH): Cleaning fluid
• P(ig): Pigment system ink
• D(ye): Dye system ink
• + : Eco Solvent Plus
¾
The ink NOT sensor indicates the number where a cartridge is missing.
¾
For the ink end sensor, the colour of the ink that has run out is displayed.
* Sensor *
CR Origin
Waste Bin
* Sensor *
Wiper
Cap
* Sensor *
Cover
InkCover
Off
On
(1/9)
CR_HP sensor
Waste fluid sensor
On
Off
(2/9)
Wiper sensor
Cap sensor
Open
Open
(3/9)
* Sensor *
LeverUp
LeverDown
On
On
(4/9)
145
Cover sensor
Ink cover sensor
Lever up sensor
Lever down sensor
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* Sensor *
FootLever
PaperEdgeAD
* Sensor *
PaperRear R
PaperRear L
* Sensor *
Headslide
Temp
* Sensor *
Ink ID
On
04e
(5/9)
Foot lever SW sensor
P_EDGE sensor
Off
Off
(6/9)
P_REAR_R sensor
P_REAR_L sensor
On
25°C
(7/9)
HD_SLIDE sensor
Head thermistor
12 34 5678
++ww++++
(8/9)
* Sensor *
Ink Not
Ink End
Ink ID Sensors
Ink NOT sensor
Ink END sensor
(9/9)
5.4.5. Encoder Menu
This menu displays the detected values from the following encoders.
¾ CR_ENC (Carriage)
¾ PF_ENC (Media feed)
Notes :
¾
For the encoder-detected values, the encoder pulse numbers are displayed in
hexadecimal number.
* Encoder *
CR
PF
0000
0000
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5.4.6. Fan Menu
This menu is used to check if the fan operates normally by turning it ON and OFF the fan.
As soon as you select this menu, the fan will be activated.
When you press the [CANCEL] key, the fan is off and the operation panel displays "Inspection: Fan".
* Fan *
[Cancel] End
5.4.7. History Menu
This menu is used to check the maintenance history and serious error history.
F1 →
* Elec. *
Maintenance
Error
← F2
(1) Maintenance history
Maintenance history for the following parts is displayed.
¾ Waste liquid tank capacity (#)
¾ Number of cuts (#)
¾ Number of wipes of the cleaner head (#)
¾ Number of rubs of the cleaner head (#)
¾ Number of drives of the CR motor (#)
¾ Number of drives of the PF motor (#)
¾ Number of printing copies (#)
¾ Number of cleanings (#)
¾ Discharge amount of head ink 1 (A, B nozzles), M dot
¾ Discharge amount of head ink 2 (A, B nozzles), M dot
¾ Discharge amount of head ink 3 (A, B nozzles), M dot
¾ Discharge amount of head ink 4 (A, B nozzles), M dot
¾ Cutter solenoid down times (#)
Notes :
¾
For the CR motor drive count, 1 pass becomes 1 count.
¾
For the PF motor drive count, 10 meters travel becomes 1 count.
¾
For 87-inch specifications, the discharge amount of head ink 5 to 8 (A, B nozzles)
are added.
* Maintenance *
WasteInk
Cut
* Maintenance *
Wiper
Rubbing
* Maintenance *
CR Motor
PF Motor
00000000
00000000
(1/10)
Waste liquid tank capacity
Number of cuts
00000000
00000000
(2/10)
Number of wipes of the cleaner head
Number of rubs of the cleaner head
00000000
00000000
(3/10)
Number of drives of the CR motor
Number of drives of the PF motor
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* Maintenance *
PrintingNumber
Cleaning
00000000
00000000
(4/10)
Number of printing copies
Number of cleanings
* Maintenance *
Fire 1-A
00000000Mdot
Fire 1-B
00000000Mdot
(5/10)
Discharge amount of head 1-A nozzle ink
Discharge amount of head 1-B nozzle ink
* Maintenance *
Fire 2-A
00000000Mdot
Fire 2-B
00000000Mdot
(6/10)
Discharge amount of head 2-A nozzle ink
Discharge amount of head 2-A nozzle ink
* Maintenance *
Fire 3-A
00000000Mdot
Fire 3-B
00000000Mdot
(7/10)
Discharge amount of head 3-A nozzle ink
Discharge amount of head 3-B nozzle ink
* Maintenance *
Fire 4-A
00000000Mdot
Fire 4-B
00000000Mdot
(8/10)
Discharge amount of head 4-A nozzle ink
Discharge amount of head 4-A nozzle ink
* Maintenance *
Pump A
Pump B
* Maintenance *
Cut Sole.
24926
24980
(9/10)
00000000
Number of cycles of Pump A
Number of cycles of Pump B
Cutter solenoid down time
(10/10)
(2) Serious error history
This menu displays the serious errors that have occurred so far.
Notes :
¾
¾
A serious error history does not include any CPU errors.
A serious error history can contain up to 32 error events.
* Error *
Error0
Error1
* Error *
Error2
Error3
* Error *
Error30
Error31
Y current
X motor
(1/16)
X motor
X motor
(2/16)
Y Current
No Error
(16/16)
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5.4.8. Head Signal Menu
This menu is used to check the head-driving signal.
F1 →
F3 →
* Head Signal *
Flush
Mode2
F1 →
* Head Signal *
Mode5
Mode1
Mode3
(1/2)
← F2
← F4
Mode7
← F2
(2/2)
Select :
* Head Signal *
ENTER :
* Flush *
Drive
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5.5. ADJUSTMENT MENU
In this menu, you can align the printing position and correct the media feed operation.
The Adjustment menu includes following diagnosis menus :
Initialization item
Skew check
Head rank input
Head nozzle check
Head angle check
Repeatability
adjustment
CW adjustment
Band feed correction
Top & bottom
adjustment
P_REAR sensor
position adjustment
Test Print
Head Wash
Software counter
initialization
Feed amount check
Fill pattern
Description
In this menu, you can perform media feed and check
the degree of skew in the media feed operation by
means of the sensors.
Inputs the characteristic value of the installed print
head. Ink is replenished after this input.
Prints out a printing to check the ink discharge
performance of the head nozzles.
Prints out a print to check for printer head slant.
Mechanical adjustment should be performed as
necessary.
Prints out a print to align the two-way printing
position.
Prints out a print to adjust any gaps between the
heads.
Prints out a print to correct the media feed amount
for each pass.
Sets the top and bottom margins.
Adjusts the position of the P_REAR sensor using
sheet media.
Prints out a nozzle check pattern and the adjustment
variables.
Cleans the tubes and heads using cleaning fluid.
Clears various software counters.
Used to check the media feed amount for one band.
A fill printing pattern is printed by both ends of the
head.
F1 →
F3 →
* Adj *
CheckSkew
ChkNozzle
F1 →
F3 →
* Adj *
Bi-D
Feed Adj.
F1 →
F3 →
* Adj *
R. Sns. Pos.
CleanHead
F1 →
F3 →
* Adj *
SendPitch
FillPattern
Input Rank
HeadSlant
(1/4)
← F2
← F4
Uni-D
Top&Bottom
(2/4)
← F2
← F4
TestPrint
CountClear
(3/4)
← F2
← F4
Refer to
Skew Check Menu
Head rank input menu
Head Nozzle Check Menu
Head Slant Check Menu
Repeatability Adjustment
Menu
CW Adjustment Menu
Band Feed Correction
Menu (X Length)
Top & bottom adjustment
menu
P_REAR sensor position
adjustment menu
Test print menu
Head wash menu
Software Counter
Initialization Menu
Feed Pitch Check Menu
Fill printing menu
(4/4)
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5.5.1. Skew Check Menu
In this menu, you can perform media feed and check the degree of skew in the media feed operation by
means of the sensors.
When you select this item from the Adjustment menu, the machine feeds the length specified by the
operation panel and checks for media feed skew by comparing the media edge positions before and after the
media feed detected by the sensors.
Notes :
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.
¾
¾
Media errors occur during skew check and the operation stops.
"Undefined Media" occurs frequently during media initialization when the power is
turned on or media is cut.
* Check Skew *
0.1 m – 10.0 m +
1.0 m -
Set per 0.1 m
↓ ENTER
* Check Skew *
Set Paper
When media is not set
↓ Media set
* Check Skew *
Paper Initial
↓ Finishing media initialization
* Check Skew *
Exc. Skew
↓ Finishing media edge detection normally
* Check Skew *
SkewResult
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5.5.2. Head rank input menu
Inputs the head rank.
The head rank is used to determine the operation voltage of the head and compensate the temperature.
Input head rank following the steps below.
(1) Selecting input method
When inputting head rank, select one of the following methods.
¾ Input using the QR code
¾ Input from the operation panel
(2) When input using the QR code has been selected
Make sure that the operation panel displays "Input HEAD1 QR code".
Input the QR code from the QR code reader.
* QRcode *
Input Head1
* QRcode *
Head ID input
QRcode
↓ ENTER
Correctly entered : Initial charge menu
Incorrectly entered : Error
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 *
ID1 - H
+
7BZ3E3CVXUWVWQQ 21 -
* QRcode *
Head ID input
↓ ENTER
Incorrectly entered : Error
Press “ENTER” to re-enter
* Panel *
ID1 – L
+
00Y012VTTR 40UWJB ↓ ENTER
Correctly entered : Initial charge menu
(4) Initial ink charge menu
When the input head rank has been confirmed, initial ink charge is performed.
* Charge *
Ink charge
→ [CANCEL] Initial charge is not executed.
Voltage input value is updated.
[enter]
↓ ENTER
* Charge *
[1]
No Catridge
↓ Set cartridge
* Charge *
Ink Charge
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5.5.3 Head Nozzle Check Menu
In this menu, you can check if the head nozzles, after refilling, can discharge ink correctly by printing a
sample print.
To print out head nozzle check patterns, follow the steps below. The following is the description of the
printing method.
Step 1 :
Set media as necessary.
Notes :
¾
Refer to the User’s Guide.
¾
Pressing the [ENTER] key in the Diagnosis menu in self-diagnostic mode moves the
lever up and down.
Step 2 :
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.
¾ 1 pass Single way
Step 3 :
Check the printed head nozzle check patterns for the following points. Check points are as
follows.
¾ Ink nozzle discharge amount (omission, discontinuity, meandering)
¾ Satellite
¾ T fence
¾ Nozzle alignment in vertical direction
¾ Nozzle alignment in horizontal direction
Nozzle check: Prints out patterns in the order of 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B.
Nozzle alignment in vertical direction: Prints out patterns in the order of 1A, 1B, 2A, 2B, 3A, 3B,
4A, 4B.
Nozzle alignment in horizontal direction (CW): Prints out patterns in the order of 1A, 1B, 2A, 2B,
3A, 3B, 4A, 4B.
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Nozzle alignment in horizontal direction (CCW): Prints out patterns in the order of 1A, 1B, 2A, 2B,
3A, 3B, 4A, 4B.
Step 4 :
If any abnormal conditions 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
F1 →
* ChkNozzle *
End
Output Pattern
← F2
(1/2)
F1 →
F3 →
* ChkNozzle *
Normal
Little
Powerful
← F2
(2/2)
If Normal cleaning is selected
* Normal *
Cleaning
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5.5.4. Head Slant Check Menu
This menu prints out a sample printing to check for head slant.
Item
Slant
Front and back
All
end
Description
All head slant check.
Front and back position and slant of each head relative to the reference head check.
Confirmation of the forward and rear positions for all nozzle rows and all heads.
Check complete.
5.5.4.1Head slant adjustment
For a 4 head machine
Step 1 :
Start the self-diagnostic function.
Notes :
¾
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
channels. The head sequence shown below.
4 head model: 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B
Step 4 :
Loosen the screw (with one turn) fixing the head stationary plate.
No.
1
2
3
Part
Screw (M2.5x5) fixing the head stationary plate
Angle adjustment screw
Front and back adjustment screw
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Step 5 :
Make adjustments until amount of CW and CCW offset are identical.
Notes :
¾
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 the heads are well seated.
¾
¾
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.
¾
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
No.
1
Step 6 :
What to become
Part
Angle adjustment screw
Tighten the screw fixing the head stationary plate.
Repeat step 1 to 6 until the adjustment is correct for all heads.
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For a 8 head machine
Step 1 :
Start the self-diagnostic function.
Notes :
¾
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
channels. The head sequence shown below.
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.
No.
1
2
3
Step 5 :
Part
Screw (M2.5x5) fixing the head stationary plate
Angle adjustment screw
Front and back adjustment screw
Make adjustments until amount of CW and CCW offset are identical.
Notes :
¾
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 the heads are well seated.
¾
¾
In case you only print uni directional, adjust the CW till it is perfect aligned.
In case you print bi-directional, and CW and CCW cannot be aligned more perfectly.
Divide the fault equally.
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Notes :
¾
8B
8A
7B
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.
7A
6B
6A
5B
5A
Adjustable head slant
No.
1
Step 6 :
4B
4A
2B
2A
1B
1A
3B
3A
Adjusted head slant
Part
Angle adjustment screw
Tighten the screw fixing the head stationary plate.
Repeat step 1 to 6 until the adjustment is correct for all heads.
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5.5.4.2. Front and back
For a 4 head machine
To perform a Head Front/Back Adjustment, 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.
F1 →
F3 →
Step 3 :
* HeadSlant *
Slant
Check
F&B
End
← F2
← F4
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
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Notes :
To help you identify the print heads on the test pattern please refer to the 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.
1
2
Part
Head Fixing plate securing screw
Front/Back Adjustment Screw
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Step 6 :
When the nozzles are not in one row, adjust the head front/back position by moving the Head
Front/Back Adjustment Screw the manner shown below. First adjust nozzle row A (1A, 2A, 3A,
4A). When adjusted perfectly, nozzle row B should 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 :
Tighten the screw which secures the Head Fixing Plate.
Step 8 :
Repeat step 1 to 7 until the adjustment is correct.
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For a 8 head machine
To perform a Head Front/Back Adjustment, 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.
F1 →
F3 →
Step 3 :
* HeadSlant *
Slant
Check
F&B
End
← F2
← F4
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 magnifying glass with an enlargement of at least 10.
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If not, please proceed to step 5.
Step 5 :
Loosen the screw with 1 turn, which secures the Head Fixing Plate.
No.
1
2
Step 6 :
Part
Head Fixing plate securing screw
Front/Back Adjustment Screw
When the nozzles are not in one row, adjust the head front/back position by moving the Head
Front/Back Adjustment Screw the manner shown below. First adjust nozzle row A (1A, 2A, 3A,
4A). When adjusted perfectly, nozzle row B should 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 :
Tighten the screw which secures the Head Fixing Plate.
Step 8 :
Repeat step 1 to 7 until the adjustment is correct.
Notes :
¾
Please note that you also have a third menu in head slant. Notably the check menu.
With this pattern, it is possible to compare every front and back position of every
head to each other
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5.5.5. Repeatability Adjustment (Bi-Directional)
To perform a Repeatability Adjustment, please follow the steps mentioned below.
Step 1 :
Start the self-diagnostic function.
Notes :
¾
Refer to “Self-Diagnosis Function".
Step 2 :
Select "Adj:Bi-D".
Step 3 :
Print a repeatability pattern.
Step 4 :
The odd rows (with each 5 dots) are the references. So the even rows should be adjusted (use a
magnifying with an enlargement of at least 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
4B
4A
3B
3A
2B
2A
1B
1A
Notes :
¾
Step 5 :
For 87-inch specifications, the head 5-A, 5-B, 6-A, 6-B, 7-A, 7-B, 8-A, 8-B are
added.
Adjust reciprocation per head height.
¾
¾
¾
#1: Head height LOW
#2: Head height MIDDLE
#3: Head height HIGH
Notes :
¾
In the event that all parts of unit do not line up due to part or assembly precision
error, make adjustments until everything in the area around center lines up in a
straight line.
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5.5.6. CW adjustments (Uni-Directional)
To perform CW adjustments, please follow the steps mentioned below.
Step 1 :
Start the self-diagnostic function.
Notes :
¾
Refer to “Self-Diagnosis Function".
Step 2 :
Select "Adj:Uni-D".
Step 3 :
Print a CW adjustment pattern.
Step 4 :
The odd rows (alternately 1A and 1B) are the references. So the even rows (2A, 2B, 3A, 3B, 4 A
and 4B) should be adjusted (use a magnifying with an enlargement of at least 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
4B
1A
1B
1A
1B
4A
3B
3A
2B
1A
2A
Notes :
¾
For 87-inch specifications, the head 5-A, 5-B, 6-A, 6-B, 7-A, 7-B, 8-A, 8-B are
added.
Notes :
¾
In the event that all parts of unit do not line up due to part or assembly precision
error, make adjustments until everything in the area around center lines up in a
straight line.
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5.5.7. Band Feed Correction Menu (X Length)
In this menu, you can correct the media feed distance.
To correct the media feed distance, you must first print out check patterns and measure the distance
between lines drawn 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 Band Feed Correction pattern.
Step 5 :
Enter the measured value as the Media Feed Distance parameter.
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* Feed Adj. *
X Length
300 – 1000 +
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
→→
→→→→→
* Feed Adj. *
X Length
Display during adjustment printing
↓ Finish printing
300 – 1010 +
500.0 mm -
↓ ENTER
←←
* Feed Adj. *
Enter Print Start
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5.5.8. Top & bottom adjustment menu
Sets printing margins.
Make adjustments following the steps below.
Step 1 :
Set media as necessary.
Step 2 :
After the media has been set, pattern printing with band feed compensation and media cutting
are performed. The following is the description of the printing method.
¾ Black, one path, one-way
Step 3 :
Measure 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.
¾ Top distance
¾ Bottom distance
¾ 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
* Top&Bottom *
Paper Initial
↓ End Media Initialization
* Top&Bottom *
Adjustment Print
* Top&Bottom *
Top Length
* Top&Bottom *
Top Length
* Top&Bottom *
Side
Display during adjustment printing
0 – 40.0 +
5.0 mm -
0 – 40.0 +
5.0 mm -
0 – 20.0 +
5.0 mm -
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5.5.9. P_REAR sensor position adjustment menu
Adjust the P_REAR sensor position in order to accurately detect the length of the cut media.
During this adjustment, the P_REAR sensor position can be adjusted inside the firmware by referring to the
nozzle, in order to obtain a maximum printable area starting from the ends of the media.
Make adjustments following the steps below.
Step 1 :
Set media as necessary.
Notes :
¾
Use cutting media for adjusting the P_REAR sensor. Set A3 cutting media in
portrait orientation.
¾
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 adjustment is
performed.
The following is the description of the printing method.
¾ Draws a horizontal line (black 1 dot line) 17 mm away from the media end.
Step 3 :
Measure the distance from the media end to the line just drawn.
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Step 4 :
Input the measurement as the parameter of the P_REAR sensor position.
* Rear Sensor *
Set Cutting Paper
↓ Set media
* Rear Sensor *
Paper Initial
If media is not set
↓ End media initialization
* Rear Sensor *
Paper Width
297.0 mm
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.
¾ Nozzle check: Head nozzle check pattern
¾ Adjustment variables: Set values of various adjustment variables
Step 3 :
Perform selected test print.
*Print*
NOZZLE
CheckAdj.Vari.
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5.5.11. Head wash menu
In this menu, ink is drained and the head is cleaned at the completion of the manufacturing process and
before replacing the print head.
Execute a cleaning following the steps below.
Step 1 :
Initialize the waste ink history.
¾ Refer to ‘Parameter Initialization Menu’
Step 2 :
Discharge the waste fluid from the waste fluid bottle.
Step 3 :
Press the [ENTER] key in the operation panel to confirm the head cleaning menu.
Step 4 :
Remove all ink cartridges.
Step 5 :
Press the [ENTER] key in the operation panel to drain the ink.
Step 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 :
¾
When performing the ink cleaning, always initialize the waste ink history then start a
head cleaning. Otherwise, during cleaning, the waste ink tank becomes full and
cleaning is interrupted.
¾
After the head cleaning, always initialize the waste ink history. Otherwise, during
filling, the waste ink tank becomes full, and filling is interrupted.
¾
Before ink filling, discharge the cleaning fluid, and wait for at least 30 minutes.
Otherwise, the printing may be unstable.
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* Clean Head *
Remove cartridge
↓ Eject all cartridge and press the [ENTER] key 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
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5.5.12. Software Counter Initialization Menu
This menu initializes the software counters such as the ink amount counter.
Notes :
¾
Before delivery, always initialize the software counters.
The software counters that can be initialized through this menu are as follows.
Counter
Ink amount counter
Ink consumption counter 1
Ink consumption counter 2
Ink consumption counter 3
Ink consumption counter 4
Ink consumption counter 5
Ink consumption counter 6
Ink consumption counter 7
Ink consumption counter 8
Cumulative printout timer
Waste ink counter
Ink ID mask
Initial ink charge flag
Initial value
0
0
0
0
0
0
0
0
0
0
0
Reset
Set
Pressing the [ENTER] key in the operation panel performs the software counter initialization. Pressing the
[CANCEL] key cancels the initialization.
* CountClear *
Counter reset ?
↓ ENTER
* CountClear *
Wait little time
↓ End initialization
* CountClear *
R. Sns. Pos.
CleanHead
Testprint
CountClear
(3/4)
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5.5.13. Feed Pitch Check Menu
In this menu, you can check the media feed amount for one band by reviewing a sample printing. There is
no adjustment item.
To check the feed pitch, follow the steps below.
Step 1 :
Set media as necessary.
Step 2 :
Select "Adj:SendPitch".
Step 3 :
Select "Pattern 1" or "Pattern 2" to print feed pitch check patterns.
¾ "Pattern 1": Drawn with 1 inch (2.54 cm) intervals
¾ "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 direction
B: 100% print
50-inch specifications and 64-inch specifications are pattern printed in the sequence 1A&4B, 1A&4B, 1A&4B,
while 87-inch specifications are printed in the sequence 1A&8B, 1A&4B, 5A&8B.
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5.6. PURGE MENU
In this menu, you can purge ink from the printer heads.
The Purge menu includes the following diagnosis items.
Diagnosis item
Normal
Powerful
Little
Initial ink charge
Description
Performs normal purge.
Performs powerful purge.
Performs minimum purge.
Performs initial ink charge.
F1 →
F3 →
* Cleaning *
Normal
Little
Powerfull
Ink charge
← F2
← F4
↓ Select item (Normal cleaning)
* Normal *
Cleaning
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5.7. SAMPLE PRINTING MENU
This menu prints out a sample printing.
The Sample printing menu includes the following items.
Diagnosis item
Nozzle Check
Adjustment variables
Description
Prints the head nozzle check pattern.
Prints out the set values of various adjustment items.
Notes :
¾
F1 →
When serial numbers are not input to this product, the serial numbers become blank
spaces.
* Print *
Nozzle
Adj. Variable
← F2
↓ Select item (Nozzle check)
* Check Nozzle *
Adjustment Print
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5.8. PARAMETER MENU
In this menu, you can modify the set values of various adjustment items (adjustment parameter).
The Parameter menu includes the following items.
Initialization item
Initialize.
Description
Initializes the adjustment parameters.
Update
Updates the adjustment parameters.
F1 →
* Parameter *
Initialize
Update
Refer to
Parameter Initialization
Menu
Parameter Update Menu
← 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.
¾ Capping position
¾ Media feed distance
¾ Serial number
¾ Head history
¾ Wiper history
¾ Waste ink history
¾ CR motor history
¾ PF motor history
¾ Pumps
¾ Waste tank
¾ Initialization of all items
F1 →
F3 →
* Initialize *
P. FeedLen
Head
F1 →
F3 →
*Initialize*
CR Motor
Pump A
F1 →
*Initialize*
WasteInk
serialNo.
Wiper
(1/3)
← F2
← F4
PF Motor
Pump B
(2/3)
← F2
← F4
All
← F2
(3/3)
↓ Select item (P. FeedLen.)
* P. FeedLen. *
Initialize OK ?
↓ ENTER
* P. FeedLen. *
Initialize Parameter
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5.8.2. Parameter Update Menu
This menu updates the adjustment parameters. The parameters that can be updated through this menu are
as follows.
¾
¾
¾
¾
¾
¾
¾
¾
Head voltage
Printing position alignment
CW adjustment
Media feed distance
Mechanical parameter
Ink parameter
Ink ID mask
Serial number
Notes :
¾
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.
F1 →
F3 →
* Update *
HeadRank
CW Adj.
F1 →
F3 →
* Update *
Mechparm
Ink ID mask
PrintPos.
P. FeedLen.
(1/2)
← F2
← F4
Inparm
serialNo.
(2/2)
← F2
← F4
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(1) Head ID
In this menu, you can enter a head ID. The head ID is used to determine the printer head-driving voltage
and perform temperature correction.
After a head ID has been entered, the system shifts to the Ink Charge menu.
* HeadRank *
ID1 – H
+
1BZ3E3ECVXUWWQQ -
* HeadRank *
Head ID input
↓ ENTER
Incorrectly entered : Error
Press “ENTER” to re-enter
* HeadRank *
ID1 - L
+
00Y0IZVTTR 40UWJB ↓ ENTER
* HeadRank *
Update Parameter
↓ ENTER
* HeadRank *
Updating Parameter
↓
* HeadRank *
Ink charge [ENTER]
CANCEL
→→→→
Initial charge is not performed
Rank input value is updated
↓ ENTER
* Charge *
[1] No Cartridge
↓
* Charge *
Ink Charge
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(2) Printing position alignment
This updates the printing position alignment parameters.
* PrintPos Adj.*
# 1 Head 1A
* PrintPos Adj. *
#1 Head 1B
+
-28 -
+
-28 If the parameter is updated
* PrintPos Adj. *
#1 Head 4B
+
-48 -
ENTER
→→→→→
* PrintPos Adj. *
Update Parameter ?
↓ ENTER
* PrintPos Adj. *
Updating parameter
(3) CW
This updates the CW adjustment parameters.
* CW Adj. *
Gap 1 - 2
* CW Adj. *
Gap 1 - 3
-400→ 400 +
0 -
-400→ 400 +
0 If the parameter is updated
* CW Adj. *
Gap 1 - 4
-400→ 400 +
0 -
ENTER
→→→→→
* CW Adj. *
Update Parameter ?
↓ ENTER
* CW Adj. *
Updating Parameter
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(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
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(5) Mechanical parameter
Update the mechanical position parameters. The setup items are as follows.
¾
¾
¾
¾
Top distance
Bottom distance
Side margin
P_REAR sensor position
* Mechparm *
Top Length
* Mechparm *
Bottom
* Mechparm *
Side
* Mechparm *
Rear Sensor
0 – 40.0 +
5.0 mm -
0 – 40.0 +
5.0 mm -
0 – 20.0 +
5.0 mm -
0 – 27.0 +
17.0 mm ↓ ENTER
* Mechparm *
Update Parameter
↓ ENTER
* Mechparm *
Updating Parameter
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(6) Ink parameter
This updates the ink parameter. The setup items are as follows.
Set: Ink not filled
Reset: Ink filled
Notes :
¾
When "set" has been selected on the ink parameter update menu, the product
implements initial filling operations at the next start up.
* InkParameter *
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.
¾
¾
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 smart chip.
* Ink ID mask *
Ink ID mask
+
Set ↓ ENTER
* Ink ID mask *
Update Parameter
If parameter is updated
↓ ENTER
* Ink ID mask *
Updating Parameter
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(8) Serial number 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 :
¾
The third figure of a serial number differs with the machine size.
ƒ 5: 50 inch
ƒ 6: 64 inch
ƒ 8: 87 inch
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5.9. ENDURANCE RUNNING MENU
In this menu, you can perform endurance running on the printer heads.
The Endurance Running menu includes the following items.
Initialization item
CR Motor
PF motor
Razor Blade
Head up/down
Description
Performs carriage stroke.
Drives the PF motor.
Cuts media.
Changes over the head height repeatedly.
Head lock
Pump
Lever motor
Tests head lock operation.
Performs wiper up/down operation via the selecting
menu.
Drives the positive/negative pressure pump motor.
Drives the lever motor.
Nozzle print
Prints out a printing by printer heads repeatedly.
General endurance
Performs endurance running on the CR, PF and
head up/down concurrently.
Check the number of endurance running cycles.
Confirmation
F1 →
F3 →
* Life *
CR motor
Cutter
F1 →
F3 →
* Life *
Head Lock
Lever Motor
F1 →
* Life *
Total Life
PF motor
Head U/D
(1/3)
← F2
← F4
Pump
Nozzle
(2/3)
← F2
← F4
Check
← F2
Refer to
CR Motor Endurance Menu
PF Motor Endurance Menu
Cutter Endurance menu
Head Up/Down Endurance
Menu
Head Lock Endurance
menu
Pump Endurance menu
Sequential Printing
Endurance Menu
Sequential Printing
Endurance Menu
General Endurance Menu
Endurance Running Check
Menu
(3/3)
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5.9.1. CR Motor Endurance Menu
This menu performs endurance running for the CR motor.
You can perform carriage stroke according to your desired setting. The available settings are shown below.
Setup item
Operation speed (CW,
CCW)
Number of endurance
running cycles
Description
Sets carriage operation
speed (CW and CCW).
Set the number of
endurance running
cycles
Parameters
240, 300
Remarks
Unit: cps
-1 to 10000
Notes :
¾
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.
¾
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 *
Speed
240 / 300 +
240 cps -
Speed (CW)
↓ ENTER
* Speed CCW *
Speed
240 / 300 +
240 cps -
Speed (CCW)
↓ ENTER
* Aging Count *
Count
-1 → 10000 +
50 -
Number of endurance running cycles
↓ ENTER
* CR Motor *
Count
5
Perform endurance running
↓ ENTER
* CR Motor *
End
50
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5.9.2. PF Motor Endurance Menu
This menu performs endurance running for the PF motor.
You can drive the PF motor according to your desired settings. The available settings are shown below.
Setup item
Media feed amount
Description
Sets amount of media
feeds per endurance
operation.
Set the number of
endurance running
cycles
Number of endurance
running cycles
Parameters
0 to 100
Remarks
Unit: mm
-1 to 10000
Notes :
¾
The motor drive parameters are determined as follows depending on the media feed
amount.
Speed
Acceleration
Deceleration
54 cps
0.1 G
0.1 G
¾
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.
¾
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.
* FeedAmount *
0 – 100.0 mm +
0.1 mm -
Media feed amount
↓ ENTER
* LifeCount *
Count
-1 → 10000 +
50 -
Number of endurance running cycles
↓ ENTER
* PFmotor *
Count
5
Perform endurance running
↓ ENTER
* PFmotor *
End
50
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5.9.3. Cutter Endurance menu
This menu performs endurance running for the cutter.
You can perform the cutting operation according to the settings.
Caution :
Pay attention to the following points when performing the cutter endurance operation.
¾ Install usable ink cartridges.
¾ Make sure that media initialization is complete.
Performing the cutter endurance operation without ink cartridges could result in damage
to the product if the cutter fails outside the cutting range.
The available settings are shown below.
Setup item
Page size
Description
Sets amount of media feeds per
endurance operation.
Set the number of endurance
running cycles
Set the waiting time after one
cycle of endurance running
Number of endurance
running cycles
Waiting time
Parameters
30 to 3000
Remarks
Unit: mm
-1 to 10000
40
Unit: second
Notes :
¾
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.
¾
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.
¾
The waiting time is not modifiable.
* Page size *
30 – 3000 mm +
30 mm -
Page size
↓ ENTER
* Cutter *
Count
-1 → 10000 +
50 -
Count Endurance
↓ ENTER
* Cutter *
Time Wait (sec)
40
Check Waiting time
↓ ENTER
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* Cutter *
Count
5
Perform endurance
↓ ENTER
* Cutter *
End
50
5.9.4. Head Up/Down Endurance Menu
This menu performs endurance running for the head up/down operation.
You can perform the capping operation according to your desired settings. The available settings are shown
below.
Setup item
Waiting time
Number of endurance
running cycles
Description
Set the waiting time after one
cycle of endurance running
Set the number of endurance
running cycles
Parameters
10
Remarks
Unit: second
-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.
¾ 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.
¾ The waiting time is not modifiable.
¾
* LifeCount *
Count
-1 → 10000 +
50 -
Number of endurance running cycles
↓ ENTER
* Head U/D *
Time Wait (sec)
10
Check wait time
↓ ENTER or CANCEL
* Head U/D *
Count
5
Perform endurance running
↓ ENTER or CANCEL
* Head U/D *
End
50
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5.9.5. Head Lock Endurance menu
Test endurance of head lock.
In the Head Lock Endurance menu, you can perform head lock 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 +
Yes -
Wiper up and down
↓ ENTER
* LifeCount *
Count
-1 → 10000 +
50 -
Number of endurance running cycles
↓ 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
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5.9.6. Pump Endurance menu
This menu performs endurance running for the pump.
In the Pump Endurance menu, you can perform the pump motor assembly endurance operation according to
the settings.
The available settings are shown below.
Setup item
Operation speed
Description
Sets the operation speed
of the pump motor
assembly.
Set the number of
endurance running
cycles
Number of endurance
running cycles
Parameters
High/Normal/Low
Remarks
-1 to 10000
Notes :
F1 →
F3 →
¾
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.
¾
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.
* Aging pump *
High
Low
Normal
← F2
↓ Select speed (high)
* LifeCount *
Count
-1 → 10000 +
50 -
Number of endurance running cycles
↓ ENTER
* High *
Count
5
Perform endurance running
↓ ENTER or CANCEL
* High *
End
50
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5.9.7. Lever Motor Endurance Menu
This menu performs endurance running for the lever motor.
You can drive the lever motor according to your desired settings. The available settings are shown below.
Setup item
Number of endurance
running cycles
Description
Set the number of
endurance running
cycles
Parameters
-1 to 10000
Remarks
Notes :
¾
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.
¾
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.
* LifeCount *
Count
-1 → 10000 +
50 -
Number of endurance running cycles
↓ ENTER
* LeverMotor *
Count
5
Perform endurance running
↓ ENTER or CANCEL
* LeverMotor *
End
50
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5.9.8. Sequential Printing Endurance Menu
This menu performs endurance running for the printer heads.
You can operate the printer heads according to your desired settings. The available settings are shown
below.
Setup item
Printing mode
Description
Set printing mode.
Media Cut
Sets whether to cut media each time one
printing is printed out or not.
Set the number of endurance running cycles
Number of endurance
running cycles
Parameters
MODE 1, MODE 2, MODE 3,
MODE 5, MODE 6, MODE 7
Yes, No
-1 to 10000
Notes :
¾
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.
¾
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.
F1 →
F3 →
* Print Mode *
MODE1
MODE3
F1 →
* Print Mode *
MODE6
MODE2
MODE5
(1/2)
← F2
← F4
MODE7
← F2
(2/2)
↓ Select mode
* Cut *
Cut
Yes/No +
Yes ↓ ENTER
* Nozzle *
Count
-1 → 10000 +
50 -
Number of endurance running cycles
↓ ENTER
* Nozzle *
Count
5
Perform endurance running
↓ ENTER or CANCEL
* Nozzle *
End
50
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5.9.9. General Endurance Menu
This menu performs the general endurance running.
You can operate various driving systems according to your desired settings.
The available settings are shown below.
Setup item
Operation speed (CW,
CCW)
Media feed amount
Number of endurance
running cycles
Description
Sets carriage operation speed (CW
and CCW).
Set the media feed amount per cycle
Set the number of endurance running
cycles
Parameters
240/300
Remarks
Unit: cps
0 to 100
-1 to 10000
Unit: mm
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.
¾ 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.
¾
* Speed CW *
Speed
240 / 300 +
240 cps -
Speed (CW)
↓ ENTER
* Speed CCW *
Speed
240 / 300 +
240 cps -
Speed (CCW)
↓ ENTER
* Feed Amount *
0 – 100.0 mm +
0.1 mm -
Media feed amount
↓ ENTER
* Life Count *
Count
-1 → 10000 +
50 -
Number of total endurance running cycles
↓ ENTER
* Total Life *
Count
5
Perform endurance running
↓ ENTER or CANCEL
* Total Life *
End
50
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5.9.10. Endurance Running Check Menu
In this menu, you can confirm the number of endurance running cycles that have been already finished.
The number of endurance running cycles is stored in NVRAM in the system. Therefore, even if a serious
error occurs during endurance running, you can confirm the number of finished cycles just before the
occurrence of the serious error.
* Check *
CR Motor
PF Motor
* Check *
Cutter
Head U/D
* Check *
Head lock
Wiper
* Check *
Pump
Lever Motor
* Check *
Nozzle
Total Life
50
0
(1/5)
Number of endurance running cycles (CR Motor)
Number of endurance running cycles (PF Motor)
33
55
(2/5)
Number of endurance running cycles (Cutter)
Number of endurance running cycles (Head
up/down)
77
77
(3/5)
Number of endurance running cycles (head lock)
Number of endurance running cycles (wiper)
77
77
(4/5)
Number of endurance running cycles (pump mot)
Number of endurance running cycles (sequential
Printing)
77
88
(5/5)
Number of endurance running cycles (All)
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5.10. HEAD LOCK MENU
Lock and unlock the head lock.
The following items are in the head lock menu.
¾
¾
F1 →
Lock: Locks the head.
Unlock: Releases the head lock.
* Head lock *
Lock
Unlock
← F2
(1/1)
↓ Select (unlock)
* Unlock *
Wait Little time
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5.11. HEATER SYSTEM MENU
This section describes the heater system menu.
This menu is used to evaluate the heating elements of the printer.
Initialization item
Status
Temperature
Test 30
Test 50
Test Max
Version
Adjust
Description
This menu displays the status of the heating system.
This menu displays the real temperature of the heating
elements.
This menu heats the temperature up to 30°C.
This menu heats the temperature up to 50°C.
This menu heats the temperature up to the maximum
temperature.
This menu displays the version of the control heater
board.
For calibration of the heaters.
For future use only!
F1 →
F3 →
* Heating System *
Status
Test 30
F1 →
F3 →
* Heating System *
Test Max
Adjust
Temperature
Test 50
(1/2)
← F2
← F4
Version
← F2
Refer to
→ Heater Status Menu
→ Heater Temperature
Menu
→ Heater Test 30 Menu
→ Heater Test 50 Menu
→ Heater Test Max Menu
→ Heater Version Menu
→ Heater Adjust Menu
(2/2)
5.11.1. Heater Status Menu
This menu displays the status of the heating system.
* Status *
Heater Standby
No errors
5.11.2. Heater Temperature Menu
This menu displays the real temperature of the heating elements.
* Temperature *
A : R25
B1 : R24
B2 : R24
D1 : R26
D2 : R26
C : R25
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5.11.3. Heater Test 30 Menu
This menu heats the temperature up to 30°C.
* Test 30 *
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 : R30
B1 : R30
B2 : R30
D1 : R31
D2 : R31
C : R31
5.11.4. 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
D1 : R50
D2 : R50
C : R51
5.11.5. Heater Test Max Menu
This menu heats the temperature up to maximum temperature.
* Test MAx *
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 : R70
B2 : R70
D1 : R50
D2 : R50
C : R70
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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 :
¾
With this menu you can calibrate the heaters. Please note that this function is for
future use only.
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5.12. ECO PREPARE MENU
Loading ink for the first time. Please refer to the User’s Guide.
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5.13. MACHINE SIZE SELECT MENU
This section describes the select menu of the machine size.
Used when the Mainboard 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.
F1 →
F3 →
* MachinSize *
50inch
87inch
- 64inch -
64inch
← F2
(1/1)
↓ Select item
Select Finish !
Please re-starting
Step 4 :
Power OFF the unit.
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6. MAINTENANCE MODE
6.1. INTRODUCTION
This chapter provides information on the maintenance mode.
The maintenance mode provides the user with functions of displaying and initializing the life counters.
It is used in the manufacturing process, adjustment and maintenance.
The maintenance mode is implemented in the system firmware. All functions are available from the
operation panel.
Notes :
¾
Refer to “Operation Panel ".
6.2. OPERATING MAINTENANCE MODE
This section explains how to start up and operate 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 operation mode or the setup menu mode, press the [POWER] key.
Step 2 :
Press and hold the [F1] key, [F3] key and [MENU ↑] key simultaneously. While holding down
these keys, press the [POWER] key.
The system will enter the maintenance mode and display the maintenance menu.
6.2.2. Operating Maintenance Mode
For operating the maintenance mode, refer to "Operations in Self-Diagnosis Mode".
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6.3. MAINTENANCE MENU
The maintenance menu includes the following diagnosis items.
Initialization item
Counter Display Menu
Counter Initialization
Menu
MAC address write
enable menu
F1 →
F3 →
Description
This menu displays the life counters.
Initializes the service life counter.
Refer to
Counter Display Menu
Counter Initialization Menu
Performs network MAC address writing.
MAC address write enable
menu
* Counter *
Indication
MACaddress
InitMenu
Head VLT
← F2
← F4
Notes :
¾
The MAC address write enable menu is added from Farm Ver. 1.08.
6.3.1. Counter Display Menu
This menu displays the life counters. It consists of the following diagnosis items.
Diagnosis item
Rest ink 1
Rest ink 2
Rest ink 3
Rest ink 4
Rest ink 5
Rest ink 6
Rest ink 7
Rest ink 8
Cutter service life
Number of prints
Waste ink
Cleaner
CR motor
PF motor
Pump A
Pump B
Head 1 A
Head 1 B
Head 2 A
Head 2 B
Head 3 A
Head 3 B
Head 4 A
Head 4 B
Description
Displays ink consumption counter (1).
Displays ink consumption counter (2).
Displays ink consumption counter (3).
Displays ink consumption counter (4).
Displays ink consumption counter (5).
Displays ink consumption counter (6).
Displays ink consumption counter (7).
Displays ink consumption counter (8).
Displays the cutter service life counter.
Displays the counter for the total number of prints.
Displays the service life counter for the waste liquid tank (right).
Displays the cleaning unit life counter.
Displays the CR motor service life counter.
Displays the PF motor service life counter.
Displays the number of pump cycles of pump A
Displays the number of pump cycles of pump B
Displays the service life counter for nozzle A of head unit 1.
Displays the service life counter for nozzle B of head unit 1.
Displays the service life counter for nozzle A of head unit 2.
Displays the service life counter for nozzle B of head unit 2.
Displays the service life counter for nozzle A of head unit 3.
Displays the service life counter for nozzle B of head unit 3.
Displays the service life counter for nozzle A of head unit 4.
Displays the service life counter for nozzle B of head unit 4.
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Notes :
¾
¾
All life counters are displayed in decimal number.
For 87-inch specifications, the head 5A, 5B, 6A, 6B, 7A, 7B, 8A, 8B are added.
* Counter Display *
Ink remain 1
Ink remain 2
* Counter Display *
Ink remain 3
Ink remain 4
* Counter Display *
Ink remain 5
Ink remain 6
* Counter Display *
Ink remain 7
Ink remain 8
* Counter Display *
CutterLife
PrintNumber
* Counter Display *
WasteInk
Cleaner
* Counter Display *
CR Motor
PF Motor
* Counter Display *
Pump A
Pump B
* Counter Display *
Head 1A
Head 1B
* Counter Display *
Head 2A
Head 2B
* Counter Display *
Head 3A
Head 3B
* Counter Display *
Head 4A
Head 4B
00000000
00000000
(1/12)
00000000
00000000
(2/12)
00000000
00000000
(3/12)
00000000
00000000
(4/12)
00000000
00000000
(5/12)
00000000
00000000
(6/12)
00000000Mdot
00000000Mdot
(7/12)
00000000
00000000
(8/12)
00000000Mdot
00000000Mdot
(9/12)
00000000Mdot
00000000Mdot
(10/12)
00000000Mdot
00000000Mdot
(11/12)
00000000Mdot
00000000Mdot
(12/12)
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6.3.2. Counter Initialization Menu
This menu initializes the life counters. The parameters that can be initialized in this menu are as follows.
Diagnosis item
Number of prints
initialization
Ink initialization
Waste ink initialization
Head error reset
Ink ID mask initialization
Total initialization
NVRAM initialization
Timer initialization
Cutter initialization
CR motor initialization
PF motor initialization
Cleaning initialization
Head unit 1 initialization
Head unit 2 initialization
Head unit 3 initialization
Head unit 4 initialization
Description
Initializes the total number of printing counter.
Initializes the ink capacity counter.
Initializes the waste fluid tank service life counter.
Resets critical trouble errors due to over-current flowing the head.
Resets the ink ID mask.
Initializes the service life counter.
Initializes NVRAM.
Initializes the timer.
Initializes the cutter cumulative counter.
Initializes the CR motor service life counter.
Initializes the PF motor service life counter.
Initializes the cleaning wiper service life counter.
Initializes the head 1 nozzle service life counter.
Initializes the head 2 nozzle service life counter.
Initializes the head 3 nozzle service life counter.
Initializes the head 4 nozzle service life counter.
* Initialize *
PrintNumber
WasteInk
* Initialize *
Ink
NVRAM
* Initialize *
TotalCut
PF motor
* Initialize *
Head Unit 1
Head Unit 3
Ink ID
Head error
(1/4)
All
Timer
(2/4)
CR motor
Cleaning
(3/4)
Head Unit 2
Head Unit 4
(4/4)
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6.3.3. MAC address write enable menu
It could happen that the computer cannot make connection with the Rockhopper II printer. If this is the case,
the MAC address of the Rockhopper II printer has probably been set to zero or incorrect.
To insert the MAC address into the Rockhopper II printer, please follow the instructions mentioned below.
Notes :
¾
For the MAC address, a unique number is assigned for each unit. Do not use this
function except when intending to recover following deletion of the MAC address.
¾
Please note that this procedure is only available onto the Rockhopper II printers with
following firmware version or higher.
ƒ 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 5 :
Reinstall the covers.
6.3.3.2. Insert the MAC address into the printer
Step 1 :
Power on the unit in a special mode. Press the [POWER] key to power ON the unit, while
simultaneously holding the [F1], [F3] and [Menu ↑] key.
Step 2 :
The unit will start up in special mode. Following message will appear on the display.
F3 →
Step 3 :
* Counter *
Indication
MACaddress
InitMenu
Press the [F3] key to select the option ‘MAC Address’. Following message will appear on the
display.
* MAC address *
Input Password
Step 4 :
Press the [F2] key.
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Step 5 :
Press the [F3] key.
Step 6 :
Press the [F1] key.
Step 7 :
Press the [F4] key.
Step 8 :
The password has been inserted. 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
208
+
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7. ADJUSTMENTS
7.1. INTRODUCTION
Adjustments and adjustment procedures required when replacing parts are explained in this chapter.
Notes :
¾
Refer to “Jig and tool list ".
7.2. ADJUSTMENT
The adjustments required when replacing parts are explained below.
When adjusting or replacing maintenance parts shown in the table below, a printing adjustment is required
using the auto-diagnostic function on the printer. Refer to the table below while making adjustments.
Replaced or
adjusted part
Print head
Mainboard
assembly
Adjustment
order
1
2
Adjustment
Head rank input (including initial filling)
Head nozzle check
3
Head angle check
4
Head precision adjustment
5
Repeatability adjustment
6
7
8
CW adjustment
Test Print
Head unit lifespan count reset
1
2
3
Parameter backup
Firmware installation
Machine size select
4
Backup parameter installation
5
Media sensor sensitivity adjustment
6
7
Head rank input
Head nozzle check
8
Head angle check
9
Repeatability adjustment
10
CW adjustment
209
Refer to
→ Head rank input menu
→ Head Nozzle Check
Menu
→ Head Slant Check
Menu
→ Head precision
adjustment
→ Repeatability
Adjustment Menu
→ CW Adjustment Menu
→ Test print menu
→ Parameter
Initialization Menu
→ Parameter backup
→ Firmware installation
→ Machine size select
menu
→ Backup parameter
installation procedure
→ Media sensor
sensitivity adjustment
→ Head rank input menu
→ Head Nozzle Check
Menu
→ Head Slant Check
Menu
→ Repeatability
Adjustment Menu
→ CW Adjustment Menu
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11
Band feed correction
12
Top and bottom adjustment
13
Rear sensor position adjustment
14
1
Test Print
CR deceleration belt tension adjustment
2
Repeatability adjustment
3
Top and bottom adjustment
4
5
Test Print
Initializing CR motor history
1
PF deceleration belt tension adjustment
2
Band feed correction
3
Top and bottom adjustment
4
Rear sensor position adjustment
5
6
Test Print
Initializing PF motor history
1
Media sensor sensitivity adjustment
2
Top and bottom adjustment
1
Cover sensor assembly position adjustment
1
2
PF_ENC inspection
Band feed correction
3
Top and bottom adjustment
4
1
2
1
2
Test Print
CR encoder inspection
Repeatability adjustment
3
Top and bottom adjustment
CR slave pulley
4
1
Test Print
Steel belt tension adjustment
Cutter holder
assembly
1
2
Cutter adjustment
Cutter endurance operation check
CR motor
assembly
PF motor
assembly
P_EDGE sensor
assembly
Cover sensor
assembly
PF_ENC
assembly
Sub-platen
T fence
Cutter adjustment
Cutter endurance operation check
210
→ Band Feed Correction
Menu (X Length)
→ Top & bottom
adjustment menu
→ P_REAR sensor
position adjustment
menu
→ Test print menu
→ Steel belt tension
adjustment
→ Repeatability
Adjustment Menu
→ Top & bottom
adjustment menu
→ Test print menu
→ Parameter
Initialization Menu
→ PF deceleration belt
tension adjustment
→ Band Feed Correction
Menu (X Length)
→ Top & bottom
adjustment menu
→ P_REAR sensor
position adjustment
menu
→ Test print menu
→ Parameter
Initialization Menu
→ Media sensor
sensitivity adjustment
→ Top & bottom
adjustment menu
→ Cover sensor
adjustment
→ Encoder Menu
→ Band Feed Correction
Menu (X Length)
→ Top & bottom
adjustment menu
→ Test print menu
→ Cutter adjustment
→ Cutter Endurance menu
→ Encoder Menu
→ Repeatability
Adjustment Menu
→ Top & bottom
adjustment menu
→ Test print menu
→ Steel belt tension
adjustment
→ Cutter adjustment
→ Cutter Endurance
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Carriage
assembly
1
Head height adjustment
2
Media sensor sensitivity adjustment
3
Continuous printing endurance operation
check
4
Head nozzle check
5
Head angle check
6
Head precision adjustment
7
Repeatability adjustment
8
CW adjustment
9
Top and bottom adjustment
10
Test Print
211
→ Head height
adjustment
→ Media sensor
sensitivity adjustment
→ Head Nozzle Check
Menu
→ Sequential Printing
Endurance Menu
→ Head Nozzle Check
Menu
→ Head Slant Check
Menu
→ Head precision
adjustment
→ Repeatability
adjustment Menu
→ Repeatability
Adjustment Menu
→ P_REAR sensor
position adjustment
menu
→ Test print menu
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7.3. PARAMETER BACKUP
This chapter explains the different types of parameter backup methods.
The different backup parameters related to the operation of the printer are recorded on the NVRAM (FlashROM or EEPROM) installed on the Mainboard.
There are the following types of backup parameters.
¾ Panel setting values
¾ Mechanism adjustment values
¾ Mainboard adjustment values
Notes :
¾
For the backup parameter, the Mainboard adjustment values cannot 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 be
damaged and the data may not be installed correctly.
7.3.1. Tools required for work
The following tools are required for the parameter backup procedure.
¾ Flash memory card
Notes :
¾
Refer to ‘Jig and tool list’.
¾
Use the memory card written in "Procedure for creating backup parameters" for
parameter backup of the unit only.
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7.3.2. Procedure for creating backup parameters
This section explains the procedure for recording backup parameters from the Mainboard assembly onto a
memory card.
Use the following procedure to create backup parameters.
Important :
¾
Before replacing parts, be sure to perform the following operations.
ƒ Turn the machine power OFF.
ƒ Remove the product's electrical plug from the socket. Otherwise, you
may suffer electric shock or the machine’s electric circuits may be
damaged.
¾
Disconnect all cables from the machine. Not doing so could cause damage to
the printer.
Step 1 :
Remove the memory cover.
Step 2 :
Install the memory card for parameter backup into the memory card connector slot (J104) on the
mainboard assembly.
Notes :
¾
Install the memory card so that its front is toward the inside of the printer.
Step 3 :
Turn the power to the printer on.
¾ 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.
¾ The LED display on the operation panel displays "P→C Started".
¾ Backup parameter creation begins.
Step 5 :
If the backup parameter has been created correctly, "P→C 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.
Notes :
¾
If you do not have backup memory card, output "Adj. Variable" in "Sample Printing
Menu". Required parameter is output.
¾
For the panel setting value, output "Setup" in the Operation Manual. Maintenance
history is not printed.
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7.3.3. Backup parameter installation procedure
The following is the procedure for installing the backup parameter from the memory card into the new
Mainboard assembly.
Use the following procedure to install backup parameters.
(1) When using a flash memory card
Step 1 :
Install the memory card for the backup into the memory card connector slot for the new
Mainboard assembly.
Notes :
¾
Install the memory card so that its front is toward the inside of the printer.
Step 2 :
Turn the power to the printer on.
¾ After all of the lamps on the operation panel come on, the LED display on the panel displays
"PRINTER→CARD".
Step 3 :
Press either the [MENU ↑] key or [MENU ↓] key on the operation panel.
¾ "CARD→PRINTER" is displayed on the LED display on the operation panel.
Step 4 :
Press the [ENTER] key on the operation panel.
¾ The LED display on the operation panel displays "C→P Started".
¾ 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 settings should be input by the panel.
Input following the procedures below.
Step 1 :
Install the firmware according to "Firmware installation".
Step 2 :
Follow the instructions in "Machine size select menu" to select the machine size.
Step 3 :
Initialize NVRAM according to "Counter Initialization Menu".
Step 4 :
Follow the instructions in "Parameter Update Menu" and refer to the printed adjustment variable
to enter following setting value.
¾
¾
¾
¾
¾
¾
¾
¾
Head voltage
Printing position alignment (Bi-D)
CW adjustment
Media feed distance
Mechanical parameter (Top margin, Bottom margin, Side margin, P_REAR sensor position)
Ink parameter (Initial ink charge flag)
Ink ID mask
Serial number
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7.4. FIRMWARE INSTALLATION
The procedure for installing firmware is explained below.
The programs (firmware) that control the operation of the printer are recorded on the NVRAM (Flash-ROM)
installed on the Mainboard.
Install firmware when performing the following maintenance operations.
¾ When replacing the Mainboard assembly
¾ When upgrading firmware
Caution :
Before installing firmware, be sure that the power to the printer is turned off.
Performing these operations 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 :
¾
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 firmware.
Important :
¾
Before replacing parts, be sure to perform following operations.
ƒ Turn the machine power OFF.
ƒ Remove the product's electrical plug from the socket. Otherwise, you
may suffer electric shock or the machine’s electric circuits may be
damaged.
¾
Disconnect all cables from the machine. Not doing so could cause damage to
the printer.
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(1) When using a flash memory card
Step 1 :
Remove the memory cover.
Step 2 :
Install the memory card for the installation of firmware into the memory card connector slot (J104)
of the Mainboard assembly.
Notes :
¾
Install the memory card so that its front points towards the inside of the printer.
Step 3 :
Turn the power of the printer ON.
Step 4 :
Firmware installation starts.
Step 5 :
Check if the buzzer sounded and whether the firmware was installed correctly.
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.
¾ All lamps will flash for an instant.
Step 3 :
Press the [F2] key on the operation panel within 1 second.
¾ The message "Ready to load" is displayed and the firmware install mode takes effect.
Step 4 :
Send new firmware data by MS-DOS copy command etc. (e.g. "COPY /B rh2.04.jfl LPT1")
Firmware installation will take about 60 seconds. The following messages will appear in order on
the LED display on the operation panel during installation.
¾ “Loading"
¾ "Erasing"
¾ "Copying"
¾ "Comparing"
¾ "End"
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Step 5 :
Check if the buzzer sounded and whether the firmware was installed correctly.
Step 6 :
Power the unit OFF.
Important :
After installation of the firmware onto the Rockhopper II 4 heater, you must
upgrade the heater system board.
(3) Updating the heater system board (4 heater printers ONLY!).
To update the heater system board of a Rockhopper II 4 heater printer, please follow the instructions
mentioned below.
Important :
¾ Before updating 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.
F2 →
* User Setting *
Rem Update
Ver Update
(1/1)
Step 4 :
Press the [F2] key.
Step 5 :
The heater system board is now being updated. The display will mention the following
messages.
ƒ Erasing sectors
ƒ Wait flash programming
Step 6 :
At the end the display will mention the following message.
Card Update
DO NOT POWER DOWN
Version Installed
Step 7 :
Press the [CANCEL] key.
Step 8 :
Power OFF the unit.
Step 9 :
Updating the heater system board is completed.
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7.5. STEEL BELT TENSION ADJUSTMENT
The procedure for adjusting the steel belt tension is explained below.
This section explains the procedure for adjusting steel belt tension. When removing/installing the steel belt,
adjust its tension.
7.5.1. Tools required for work
The following tools are required when adjusting the tension of the steel belt.
¾ Tension gauge: max. 2.0 N (200 g)
¾ Steel belt tension attachment 2: for gauge diameter 2mm (0.08in.) or less
Notes :
¾
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 regulation values for the tension of the steel belt are shown below.
¾ 50 inch, 64 inch specifications: 1.0 N ± 0.1 N (100 g ± 10 g)
¾ 87 inch specifications: 0.9 N ± 0.1 N (90 g ± 10 g)
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Step 2 :
If the tension of the steel belt is not within the range of regulated values, adjust the steel belt
tension screws.
1 = Steel belt
3 = CR slave pulley
Step 3 :
2 = Steel belt tension screw
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.
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7.6. PF DECELERATION BELT TENSION ADJUSTMENT
The procedure for adjusting the tension of the PF deceleration belt is explained below.
When removing the PF motor or removing/installing the PF deceleration belt, adjust the tension of the PF
deceleration belt.
7.6.1. Tools required for work
The following tools are required to adjust the tension of the PF deceleration belt.
Tension gauge: max. 50 N (5 kgf)
Notes :
¾
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) fixing the PF motor installation
board
4 = Tension gauge
3 = PF motor installation board
Notes :
¾
Step 3 :
The regulated value of the tension for the PF deceleration belt is 34.32 N ±10 % (3,5
kgf ±10 %).
Tighten the 2 screws fixing the PF motor installation board.
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7.7. HEAD PRECISION ADJUSTMENT (SLANT)
This section explains the procedure for adjusting the head angle.
When replacing the head assembly, use the following procedure to adjust the head angle and head
forward/rear position.
7.7.1 Head slant adjustment
7.7.1.1 For a 4 head machine
Step 1 :
Start the self-diagnostic function.
Notes :
¾
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
channels. The head sequence shown below.
4 head model: 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B
Step 4 :
Loosen the screw (with one turn) fixing the head stationary plate.
No.
1
2
3
Step 5 :
Part
Screw (M2.5x5) fixing the head stationary plate
Angle adjustment screw
Front and back adjustment screw
Make adjustments until amount of CW and CCW offset are identical.
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Notes :
¾
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 the heads are well seated.
¾
¾
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.
Notes :
¾
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
No.
1
Step 6 :
What to become
Part
Angle adjustment screw
Tighten the screw fixing the head stationary plate.
Repeat step 1 to 6 until the adjustment is correct for all heads.
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7.7.1.2 For a 8 head machine
Step 1 :
Start the self-diagnostic function.
Notes :
¾
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
channels. The head sequence shown below.
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.
No.
1
2
3
Step 5 :
Part
Screw (M2.5x5) fixing the head stationary plate
Angle adjustment screw
Front and back adjustment screw
Make adjustments until amount of CW and CCW offset are identical.
Notes :
¾
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 the heads are well seated.
¾
¾
In case you only print uni directional, adjust the CW till it is perfect aligned.
In case you print bi-directional, and CW and CCW cannot be aligned more perfectly.
Divide the fault equally.
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Notes :
¾
8B
8A
7B
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.
7A
6B
6A
5B
5A
Adjustable head slant
No.
1
Step 6 :
4B
4A
2B
2A
1B
1A
3B
3A
Adjusted head slant
Part
Angle adjustment screw
Tighten the screw fixing the head stationary plate.
Repeat step 1 to 6 until the adjustment is correct for all heads.
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7.7.2. Front and back of head adjustment
7.7.2.1 For a 4 head machine
To perform a Head Front/Back Adjustment, 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.
F1 →
F3 →
Step 3 :
* HeadSlant *
Slant
Check
F&B
End
← F2
← F4
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
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Notes :
To help you identify the print heads on the test pattern please refer to the 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.
1
2
Part
Head Fixing plate securing screw
Front/Back Adjustment Screw
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Step 6 :
When the nozzles are not in one row, adjust the head front/back position by moving the Head
Front/Back Adjustment Screw the manner shown below. First adjust nozzle row A (1A, 2A, 3A,
4A). When adjusted perfectly, nozzle row B should 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 :
Tighten the screw which secures the Head Fixing Plate.
Step 8 :
Repeat step 1 to 7 until the adjustment is correct.
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7.7.2.2. For a 8 head machine
To perform a Head Front/Back Adjustment, 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.
F1 →
F3 →
Step 3 :
* HeadSlant *
Slant
Check
F&B
End
← F2
← F4
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 magnifying glass with an enlargement of at least 10.
If not, please proceed to step 5.
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Step 5 :
Loosen the screw with 1 turn, which secures the Head Fixing Plate.
No.
1
2
Step 6 :
Part
Head Fixing plate securing screw
Front/Back Adjustment Screw
When the nozzles are not in one row, adjust the head front/back position by moving the Head
Front/Back Adjustment Screw the manner shown below. First adjust nozzle row A (1A, 2A, 3A,
4A). When adjusted perfectly, nozzle row B should 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 :
Tighten the screw which secures the Head Fixing Plate.
Step 8 :
Repeat step 1 to 7 until the adjustment is correct.
Notes :
¾
Please note that you also have a third menu in head slant. Notably the check menu.
With this pattern, it is possible to compare every front and back position of every
head to each other
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7.8. REPEATABILITY ADJUSTMENT (BI-DIRECTIONAL)
To perform a Repeatability Adjustment, please follow the steps mentioned below.
Step 1 :
Start the self-diagnostic function.
Notes :
¾
Refer to “Self-Diagnosis Function".
Step 2 :
Select "Adj:Bi-D".
Step 3 :
Print a repeatability pattern.
Step 4 :
The odd rows (with each 5 dots) are the references. So the even rows should be adjusted (use a
magnifying with an enlargement of at least 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
4B
4A
3B
3A
2B
2A
1B
1A
Notes :
¾
Step 5 :
For 87-inch specifications, the head 5-A, 5-B, 6-A, 6-B, 7-A, 7-B, 8-A, 8-B are
added.
Adjust reciprocation per head height.
¾
¾
¾
#1: Head height LOW
#2: Head height MIDDLE
#3: Head height HIGH
Notes :
¾
In the event that all parts of unit do not line up due to part or assembly precision
error, make adjustments until everything in the area around center lines up in a
straight line.
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7.9. CW ADJUSTMENTS (UNI-DIRECTIONAL)
To perform CW adjustments, please follow the steps mentioned below.
Step 1 :
Start the self-diagnostic function.
Notes :
¾
Refer to “Self-Diagnosis Function".
Step 2 :
Select "Adj:Uni-D".
Step 3 :
Print a CW adjustment pattern.
Step 4 :
The odd rows (alternately 1A and 1B) are the references. So the even rows (2A, 2B, 3A, 3B, 4 A
and 4B) should be adjusted (use a magnifying with an enlargement of at least 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
4B
1A
1B
1A
1B
4A
3B
3A
2B
1A
2A
Notes :
¾
For 87-inch specifications, the head 5-A, 5-B, 6-A, 6-B, 7-A, 7-B, 8-A, 8-B are
added.
Notes :
¾
In the event that all parts of unit do not line up due to part or assembly precision
error, make adjustments until everything in the area around center lines up in a
straight line.
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7.10. CR DECELERATION BELT TENSION ADJUSTMENT
This section explains the procedure for adjusting the tension of the CR deceleration belt.
When removing/installing the CR deceleration belt, such as when removing the CR motor, adjust the tension
of the CR deceleration belt.
7.10.1. Tools required for work
The following tools are required to adjust the tension of the CR deceleration belt.
¾ Tension gauge: max. 50 N (5 kgf)
Notes :
¾
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
3 = CR motor assembly
2 = Hexagon socket head cap screw
4 = Tension gauge
Step 2 :
Install the tension gauge on the PF motor installation board.
Step 3 :
Pull the tension gauge in the direction of the arrow shown on the figure above.
Notes :
¾
Step 4 :
The regulated value of the tension for the CR deceleration belt is 34.32 N ± 10 %
(3,5 kgf ± 10 %).
Tighten the 4 hexagon socket head cap screws fixing the CR motor installation board.
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7.11. COVER SENSOR ADJUSTMENT
This section explains the procedure for adjusting the cover sensor.
When replacing the cover sensor assembly or removing/installing the front cover, use this procedure to
adjust the cover sensor.
Step 1 :
Start the self-diagnostic function.
Notes :
¾
Refer to “Self-Diagnosis Function ".
Step 2 :
Select "Check:Test" on the self-diagnostic menu.
Step 3 :
In the inspection menu, select "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
Open
Closed
Operation panel display
Sensor: open
Sensor: closed
Notes :
¾
Step 6 :
Use a block gauge to measure the height of the front cover when opening it.
If the opening height of the front cover and the information displayed on the operation panel are
different, adjust the installation position of the sensor cam.
1 = Sensor cam
Step 7 :
2 = Set screw
Use step 5 to check the display on the operation panel once more.
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7.12. HEAD HEIGHT ADJUSTMENT
This section explains the procedure for adjusting the head height.
If CR cursor assembly is changed, adjust head height.
7.12.1. Tools required for work
The following tools are required when adjusting the head height.
CR gap check jig
Notes :
¾
Refer to “Jig and Tool List".
7.12.2. Adjustment Procedure
Perform the head height adjustment following 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
3 = Slide gear
2 = Screws fixing the head U/D eccentric shaft lever
4 = Slide gear triangular mark
Step 6 :
Put the CR gap adjusting jig on the platen.
Step 7 :
Move the CR cursor so that 1.2mm side of adjustment jig makes contact with the side of head.
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Step 8 :
Adjust head U/D eccentric shaft lever so that CR gap adjustment jig can move freely.
Step 9 :
Perform CR cursor right/left adjustment.
1 = Platen
3 = Print head
5 = Height 1.2 mm
7 = CR gap adjustment jig 1.2 mm side
2 = CR gap check jig
4 = CR cursor
6 = Height 1.3 mm
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 :
¾
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 screw
head properly.
1 = Head U/D eccentric shaft cover
3 = Screw fixing the head U/D eccentric shaft cover
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7.13. MEDIA SENSOR SENSITIVITY ADJUSTMENT
This section explains the procedure for adjusting the sensitivity of the media sensor.
When replacing the P_EDGE sensor assembly or Mainboard assembly, adjust the media sensor.
Notes :
¾
Pay attention to the following points when adjusting the media sensor.
ƒ This should be performed in an area where sun light and illumination do not
influence the sensor.
ƒ The front cover and Y rail cover should be installed when performing the
work.
ƒ When making adjustments, hold the media by hand or the media hold lever
so that the media stays still on the sensor.
¾
If the media is lifted off, the accuracy of the sensor may be affected.
ƒ A non-conductive type screw driver should be used when adjusting the
control on the Mainboard assembly.
¾
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 :
¾
Refer to “Jig and Tool List".
7.13.2. Adjustment Procedure
Perform the adjustment following the procedures below.
Notes :
¾
The adjustment values are displayed by a decimal number from the firmware
version 1.08 onwards. Perform the adjustment after checking if the right firmware
version has been installed.
Notes :
¾
The adjustment values are as follows.
ƒ HIGH level (with media) A/D value
ƒ In hexadecimal number : D8 to DF (H)
ƒ In decimal number : 216 to 223 (H)
ƒ LOW level (without media) A/D value
ƒ In hexadecimal number : 30 to 0 (H)
ƒ In decimal number : 48 to 0 (H)
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(1) HIGH level (with media) adjustment of the A/D value
Step 1 :
Set the standard media.
Step 2 :
Select "Check : Head Lock" in the self-diagnosis menu.
Notes :
¾
Refer to “Self-Diagnosis Function ".
Step 3 :
Release the head lock.
Step 4 :
Check if the installation angle 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
Step 9 :
2 = Carriage
Adjust the P_EDGE sensor control shown in the following figure so that the values displayed in
the operation panel become the adjustment value.
¾ Control R693: Rough adjustment
¾ Control R694: Fine adjustment
1 = Volume R693
2 = Volume R694
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(2) LOW level (without media) A/D value check
Step 1 :
Adjust the A/D value of the HIGH level following the "(1) HIGH level A/D value adjustment"
procedure.
Step 2 :
Align the cutter and the 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
¾
Step 3 :
Make sure that the values displayed in the operation panel are as shown below.
¾ In hexadecimal number : 30 to 0
¾ In decimal number : 48 to 0
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7.14. CUTTER ADJUSTMENT
This section explains the procedure for adjusting the cutter.
When replacing the sub-platen, replacing the solenoid assembly, or removing/installing media guide F, use
this procedure to adjust the cutter.
Step 1 :
Confirm if the media has been cut correctly.
Notes :
¾
Step 2 :
Refer to “Cutter Endurance menu".
If media guide F has been installed at an angle, adjust it.
Notes :
¾
Step 3 :
Refer to “Removing media guide F".
Loosen the screw fixing the cutter holder.
1 = Cutter holder
Step 4 :
2 = Screws (M3x6) fixing the cutter holder
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-platen
Step 5 :
Tighten the screw fixing the cutter holder.
Step 6 :
Insert paper into unit. Manually place an indentation into paper.
Step 7 :
Confirm that the distance between paper indentation and cutter groove is between 0.2 and
0.7mm.
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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
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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 connection and/or waste tube connection.
2. Also be careful the tubings do not touch or get stuck in the gears.
1
2
Critical tubings
Gears
(2) For 87 inch spec
1 = connection to the head caps
2 = waste tube connection
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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
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7.15.2. Pump tubing layout - Rockhopper 2 heater
(1) For 50 or 64 inch spec
50” or 64” Rockhopper II 2 heater
Step 1 :
Connect the tubing in the manner shown in the figure below.
1 = Tube connecting to the waste fluid tube
3 = Tube connecting to cap a
Step 2 :
2 = Tube connecting cap b
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
3 = Tube connecting to cap d
5 = 2 tube for linking
2 = Tube connecting to cap c
4 = Newly-added pump tube (DF-43951, length = 40 mm)
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Step 3 :
Insert into the waste fluid tubes from 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.
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(2) For 87 inch spec
87” Rockhopper II 2 heater
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
3 = Tube connecting to cap d
2 = Tube connecting to cap a
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Step 3 :
Connect up the tubing for pump 2 in the manner shown in the figure below.
1 = Tube connecting to waste fluid tube
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
3 = Tube connecting to cap g
Step 5 :
2 = Tube connecting to cap b
2 = Tube connecting to cap f
Connect up the tubing for pump 4 as shown in the figure below.
1 = Tube connecting to waste fluid tube
3 = Tube connecting to cap h
2 = Tube connecting to cap e
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Step 6 :
Insert in the waste fluid tubes from the pumps a piece of 15 cm tube (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.
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7.16. BOARD CHECKLIST
7.16.1. Power supply board.
Green LED on Power
Supply
ON
Power supply works ok
OFF
Power supply is not
working.
→ 220V/110V?
→ Load connected to
PS?
→ Error message on
Rockhopper II: “Heat
system not found”(*)
Flashing
Power supply is not
starting.
→ Load connected?
→ 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) (Malfunction is not caused by
the snubber)
Æ Resistor not cut, capacitor = 100nF (rectangular shape), malfunction may be
caused by snubber, so cut resistor.
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7.16.2. Control board.
LED D8
POWER
GREEN
ON
Board has 5V => ok
LED D2
LED D1
LED D5
LED D7
LED D3
LED D6
SMD L11, L2,L6,L13
ALIVE (*)
ERROR (*)
8000 RX/TX
8000 RX/TX
Programming led
Programming led
Coil
Blinking: OK
No error
Communication ok
Communication ok
Not used for user!!
Not used for user!!
OK
No problem
OFF
Board has no 5V
Power cable connected?
→ Power supply green led ON?
→ Bad cable
Fatal error:µP lockup
Error occurred
No communication
No communication
Burned
Temperature sensor cable shorted
to chassis, indication which cable
has a problem.
Notes :
(*) Will be available in the version after V2.02.
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7.16.3. Power board.
D2
RED/GREEN(revC)
From rev C on, it will be
a green led
D1
RED
110/220V indicator
D23, 21,19,13,6,4
ON
OK
ON
Should be on in a 110V
grid.
RED
ON
Heater is on
During cold start-up, the selftest will run.
All leds should go on, one at a time, for a short period.
OFF
NO +24V present
→ PS ok?
→ Power cable ok?
OFF
Should be off in a 220V
grid.
OFF
Heater is off
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)
A
B1/B2
C
D1/ D2
Thermal Sensor
50”
2 x 48
2 x 97
2 x 48
2 x 27
10k
64”
2 x 32,3
2 x 65,5
2 x 32,3
2 x 22,5
10k
87”
2 x 24,2
2 x 44
2 x 22,5
2 x 22,5
10k
When checking the thermal sensors, also measure them with the chassis as a reference. If the resistance is
not infinite, the sensor has a short circuit, mostly due to a damaged cable.
If the resistance is infinite, the thermal fuse might be blown. Or in minor cases, check for bad connections at
heater elements and connector.
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Connector:
Tips
Safety relay
On the powerboard is a safety relay that will switch 220 or 110V to the solid state relays whenever the
Rockhopper II series printer is powered off. This is to prevent that defective solid state relays can make the
heatstrips overheat and melt its fuses.
Buzzer:
1 small beep for each heater that reached the desired temperature.
3 short beeps when heater accepts new data 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 will be solved in successive firmware releases after 1.04.
FLAT Strip
In case of a DIY replacement of a heatstrip, make sure that the strip is flatly mounted! Air gaps between strip
and plate can cause overheating and cause fire!
Firmware Bugs
Check the firmware division for these.
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7.16.5. Checklist
Product information :
Serial Number
Firmware Version
Firmware Version Heater Control Board
:
:
:
________________________________________________
________________________________________________
________________________________________________
Basic diagnostics :
Grid power
Grid frequency
Fuse 1
110V
50Hz
OK
220V
60Hz
NOK (OPEN)
Power Supply :
LED (Green)
ON :
OFF :
Flashes :
ON
OFF
Flashes
Control Board :
LEDS :
LED D8
LED D1
LED D2
LED D5
LED D7
LED D3
LED D6
Filters
SMD L11
SMD L2
SMD L6
SMD L8
OK
Bad (visual)
Power Board :
D2 Red/Green (revC)
D1
D23, 21,19,13,6,4
Power
110V/220V
Heater On
Cold Start up :
Operation :
ON :
OFF :
ON :
OFF :
Flashes?
_______________________________________________
_______________________________________________
Heater elements :
Resistance (Ω)
A
B1/B2
C
D1/ D2
Thermal Sensor
50”
2 x 48
2 x 97
2 x 48
2 x 27
10k
64”
2 x 32,3
2 x 65,5
2 x 32,3
2 x 22,5
10k
252
87”
2 x 24,2
2 x 44
2 x 22,5
2 x 22,5
10k
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7.17 FLUSHING BOX HEIGHT POSITION ADJUSTMENT
Incorrect position of the flushing box height will cause large ink drops on the printout.
Please follow the steps below to correctly adjust your flushing box height position.
Before adjustment of the flushing box height position, please make sure to have:
1. The “Flush Box Height 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 Head
F1 →
* Head lock *
Lock
Unlock
← F2
(1/1)
↓ Select (unlock)
* Unlock *
Wait Little time
Step 10 : Move the carriage to the left and place the flushing box height jig tool on the flushing box.
1 = Flush box height jig tool
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Step 11 : Turn the wheel of the carriage till the arrow is on the bottom so the carriage is in the lowest
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
2 = Interval 2
3 = Reference of the head
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)
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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.
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8. MAINTENANCE
8.1. INTRODUCTION
This chapter provides information about the periodical services, part life, lubrication/bonding and transport.
Important :
¾
Before replacing parts, be sure to perform following operations.
ƒ Turn the machine power OFF.
ƒ Remove the product's electrical plug from the socket. Otherwise, you
may suffer electric shock or the machine’s electric circuits may be
damaged.
¾
Disconnect all cables from the machine. Not doing so could cause damage to
the printer.
Caution :
¾
Ensure there is sufficient space around the printer when performing maintenance
work.
¾
If you need to operate the printer with the cover removed for maintenance, be
careful not to get hurt by the moving parts.
¾
In the periodical services, the following work must be performed with one or more
assistant worker.
ƒ Removing/attaching the unit and the stand
ƒ Packaging the machine for transport
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8.2. CLEANING
You need to clean the printer periodically to keep it in best working condition.
Notes :
¾
¾
Refer to the User’s Guide.
Refer to “Exploded Views/Service Parts List”.
Part
Platen surface
Media guide F
Pressure rollers
Timing
Several times per year
Timing fence
(CR encoder detection
slit plate)
Several times per year
P_REAR sensor surface
Several times per year
Cleaner head (Cleaning
wiper)
¾
¾
¾
258
Action
Clean it.
Please note : If ink
deposits are present,
remove them with a
dampened cloth and
wipe the area with a
clean dry cloth.
Media dust
accumulation
Foreign objects
Damages
Clean it.
If any damages are
found, replace the part.
Clean it.
¾
Media dust
accumulation
Foreign objects
¾
¾
Ink deposits
Damages
Clean it.
¾
¾
¾
Several times per year
Check point
Media dust
accumulation
Foreign objects
Damages
¾
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
8.3. PERIODICAL SERVICES
This section describes the periodical services required for this machine.
The periodical services ensure stable printout quality of the machine.
In the periodical services, some service parts may be checked, cleaned or replaced.
Caution :
¾
There are to parts of periodical service, namely 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°
1
2
Part number
ME-80771
DF-43694 + DE-35399
Quantity
4
2+1
3
4
5
6
AP-51600
/
/
/
1
/
/
/
N°
1
2
3
4
5
6
Action
Replace the wipers.
Replace the sponge at the back of the capping
station.
Replace the sponge
Clean the wipers.
Clean caps in the maintenance station.
Clean around the bottom of the heads.
(NOT the nozzle plate)
Month
1
2
3
X
X
X
4
5
6
7
X
X
WEEKLY
WEEKLY
WEEKLY
259
8
9
X
X
X
10
11
12
X
X
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Rockhopper II series printers – Maintenance Manual
8.3.2. Service by authorised Mutoh technician
Perform periodical inspections according to the table below.
N°
1
2
3
4
Part number
MY-42110
MY-80300
MY-35380 + ME-80771
ME-18280
Quantity
4
2
1+4
4 x 0.8 m
5
MY-35085 + ME-80385 + ME-60014
1+ 1 m +1
6
7
8
9
10
11
12
MY-80627
/
/
/
/
/
/
1
/
/
/
/
/
/
N°
Action
Replace the dampers.
Replace the pumps.
Replace wiper arm and wipers.
Replace the tubing from the pumps to the waste
bottle
Replace the right spitting box + tube + L
connection
Replace the capping station.
Apply grease on head up-down cams.
Apply grease on Y-motor belt.
Apply grease on roller path carriage.
Apply grease on capping station camm + gears.
Clean the maintenance station area.
Remove dust in fan area underneath print
platform.
Month
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
10
11
12
X
X
X
X
X
X
X
X
X
260
7
8
9
10
11
12
X
X
X
X
X
X
X
X
X
X
X
X
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Rockhopper II series printers – Maintenance Manual
8.4. PART LIFE INFORMATION
This section shows how 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 :
¾
Name
Print head
Refer to "Counter Display Menu" for more details of the counter display menu.
Life expectancy
28 billion dot
261
Warning display
Warning at 95%
(Warning Head Life)
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Rockhopper II series printers – Maintenance Manual
8.5. JIG AND TOOL LIST
This section provides lists of jigs and tools required for service operations.
8.5.1. Required Tools
(1) Tools for part replacement
No.
1
2
3
Name
Philips driver No.2
Philips driver No.2
Philips driver No.1
Part code
Generic product
Generic product
Generic product
4
5
6
7
Generic product
Generic product
Generic product
Generic product
8
9
10
Flat-head driver
Pliers
Tweezers
Hexagon wrench (1.5 mm to
6.0 mm)
Box driver (5.5 mm)
Box driver (7.0 mm)
E ring holder (E-2.5)
Generic product
Generic product
Generic product
11
E ring holder (E-4)
Generic product
12
Head cleaning jig
JD-30410
13
14
Rubber bush
Mini fitting
15
16
Cleaning liquid
Bottle for cleaning liquid (500
ml)
JD-42052
JD-42053 /
Generic product
A29 JD-41844
JD-42054 /
Generic product
Remarks
Shaft length should be 250 mm or more.
Shaft length should be 50 mm or less.
Generic product For head adjustment, shaft length
150 mm or more
For head adjustment, etc.
For exchanging the mainboard
For exchanging the power board
JIS E-2.5
IWATA DENKO Co., Ltd.
JIS E-5
IWATA DENKO Co., Ltd.
¾ Exclusive rubber bush, including mini fitting
¾ 4 set required per a main unit
Expendable supplies (exchange per using 20 times)
Maker: Iuchi Seieido Co., Ltd.
18l
(2) Tools for adjustment
No.
1
2
3
Name
Personal computer
Printer cable
Tension gauge
Part code
Generic product
Generic product
Generic product
4
Tension gauge
Generic product
5
Y-axis tension attachment
JD-42050
6
Y-axis tension attachment 2
JD-42435
7
8
CR gap check jig
Flash memory card
JD-42177
Generic product
9
10
11
12
Loupe (equivalent to 10x)
Block gauge (21 mm)
Hand glass
Double coated media
Generic product
Generic product
Generic product
Exclusive
specified media
13
Straight scale (1000 mm)
Generic product
262
Remarks
Printer port mounted parts
Amphenol 36P, male connector
For measuring 5,000g Max.
Reference maker: Oba Keiki Seisakusho
Max. capacity should be 200 to 500g.
Reference maker: Oba Keiki Seisakusho
For steel belt tension adjustment
¾ Gauge diameter: 4 mm (0.16in.) or less
For steel belt tension adjustment
¾ Gauge diameter: 2 mm (0.08in.) or less
For head height adjustment
Spec.:
4MB Flash Memory Card
Type-II (PCMCIARel.2.1/JEIDAVer.4.2)
5V unique driving spec.
Generic product For head precision adjustment
Generic product For cover sensor adjustment
Generic product For checking the cap trace
For adjusting printing accuracy and sensor sensitivity
Maker: Mitsubishi inkjet media
Product number: IJ-MatteCort 143
Other similar media
RJ6-THCCPAPE 137 (MUTOH)
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Rockhopper II series printers – Maintenance Manual
8.6. LUBRICATION/BONDING
This section covers the lubrication/bonding information.
After disassembling/assembling this machine, always perform necessary lubrication/bonding according to the
table below.
Caution :
¾
PF Driving
Components
Do not oil the printer mechanism with oil other than designated by MUTOH. Doing
so may damage the parts or shorten the lifetime.
Parts
U/D gear of the
pressurizing arm
Arm motor mounting plate
and intermediate gear
boar diameter part
Deceleration pulley
X-axis deceleration belt
CR Driving
Components
Y rail machining drawing
Y rail and Roller guide
Pressurizing axis bearing
Pressurizing cam
Roller guide
Slide idler gear
Driving pulley
CR deceleration belt
Cursor
Components
Head U/D colour
Head U/D cam
Slide gear
Head base
components
Head installation board
Item
Apply to the gear
components
Coating the
intermediate gear
boar part
Apply to the driving
pulley
Coating the
deceleration belt
gear intermesh part
Coating the hole
that fastens the Y
drive base
Coating the hole
that fastens the
return pulley
mounting plate
When inserting the
Y rail, apply to the
lower face of the
roller guide.
Coating the upper
part and shaft
insertion part
Apply to the cam
components
Apply to the roller
guide surface.
Apply to the gear
components
Apply to the driving
pulley
Coating the
deceleration belt
gear intermesh part
Apply to the head
U/D colour
Apply to the head
U/D cam
Apply to the gear
components
Apply to the screw
hole position which
fastens the shoulder
screw
263
Manufacturer
Kanto Kasei Co.,
Ltd.
Kanto Kasei Co.,
Ltd.
Type
FLOIL G-MK-1
Kanto Kasei Co.,
Ltd.
Kanto Kasei Co.,
Ltd.
FLOIL G-MK-1
Kanto Kasei Co.,
Ltd.
FLOIL G-MK-1
Kanto Kasei Co.,
Ltd.
FLOIL G-MK-1
Kanto Kasei Co.,
Ltd.
FLOIL G-MK-1
Kanto Kasei Co.,
Ltd.
FLOIL G-MK-1
Kanto Kasei Co.,
Ltd.
Mitsubishi
FLOIL G-MK-1
Kanto Kasei Co.,
Ltd.
Kanto Kasei Co.,
Ltd.
Kanto Kasei Co.,
Ltd.
Kanto Kasei Co.,
Ltd.
Kanto Kasei Co.,
Ltd.
Kanto Kasei Co.,
Ltd.
Kanto Kasei Co.,
Ltd.
FLOIL G-MK-1
FLOIL G-MK-1
Super multi dia
tetra No.32
FLOIL G-MK-1
FLOIL G-MK-1
FLOIL G-MK-1
FLOIL G-MK-1
FLOIL G-MK-1
FLOIL G-MK-1
FLOIL G-MK-1
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Rockhopper II series printers – Maintenance Manual
Maintenance
components
Maintenance assembly
Pump
Components
Combined gear
Deceleration gear
Idler gear
Idler gear axis
Winding
components
PF Driving
Components
Winding assembly (gear
components)
Set screw
CR Driving
Components
Adjusting screw of the CR
slave pulley
Cursor
Components
Step-bore screw
Maintenance
components
E ring
Scroller
receptacle R
components
Others
Set screw
PF Driving
Components
CR tape power cable
Head base
components
Head 2 tape wire
Pump
Components
Pump assembly
Others
Locations where sharp
edges are likely to occur
Screw
Apply to the gear
and cam
components
Apply to the gear
components
Apply to the gear
components
Apply to the gear
components
Apply between the
pump base and the
idler gear axis.
Apply to the gear
components
Apply the screw lock
to the coupling set
screw.
After adjusting the
steel belt, apply the
screw lock.
Screw lock applying
to the shoulder
screw that fastens
the cursor and head
mounting plate
Apply to each of the
E-rings (prevents
noise due to
vibration).
Apply the screw lock
to the adjusting
knob set screw.
Apply to the position
of the screw lock.
Stick double-sided
tape to the CR tape
power cables
(locating).
Stick double-sided
tape to the head 2
tape power cables
(locating and
preventing
floatation).
Acetate tape is fixed
to the pump
assembly tube
(prevents dislodging
of tube).
Acetate tape is fixed
to tape electrical
wires and
harnesses, where
sharp edges are
likely to occur
(sharp edge
protection).
264
Kanto Kasei Co.,
Ltd.
FLOIL G-MK-1
Kanto Kasei Co.,
Ltd.
Kanto Kasei Co.,
Ltd.
Kanto Kasei Co.,
Ltd.
Kanto Kasei Co.,
Ltd.
FLOIL G-MK-1
Kanto Kasei Co.,
Ltd.
Three Bond Co.,
Ltd.
FLOIL G-MK-1
Three Bond Co.,
Ltd.
1401
Three Bond Co.,
Ltd.
1401
Three Bond Co.,
Ltd.
1401
Three Bond Co.,
Ltd.
1401
Three Bond Co.,
Ltd.
Not specified
1401
FLOIL G-MK-1
FLOIL G-MK-1
FLOIL G-MK-1
1401
Not specified
Not specified
Not specified
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Rockhopper II series printers – Maintenance Manual
8.7. TRANSPORTATION OF MACHINE
This section explains transferring and transporting the printer.
When you transport the printer, the printer should be repackaged using the original box and packing
materials, to protect it from vibration or impact.
Transport the printer following the procedures below.
(1) Task before 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 :
¾
Refer to “Self-Diagnosis Function”.
Step 4 :
Select "Adj:CleanHead".
Step 5 :
Select "CleanHead" menu.
Notes :
¾
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 cable and all other cables.
Step 9 :
Remove the winding system installed.
Notes :
¾
Refer to Users Guide of the Winding Systems.
Step 10 : Install the protective materials.
Notes :
¾
Refer to the User’s Guide.
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Step 11 : Remove the product from the special stand.
Notes :
¾
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 :
¾
Step 3 :
Do not forget to align the winding system after installation. Please refer to the users
guide of your winding system.
Make the machine ready for operation.
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9. TROUBLESHOOTING
9.1. INTRODUCTION
This chapter explains the procedures for troubleshooting this product.
When the product indicates a failure and an error message is also displayed on the control panel, refer to
"Troubleshooting procedures when a message has been displayed" and implement treatment. When the
product indicates failure but an error message has not been displayed, refer to "Troubleshooting procedures
when an error message has not been displayed" and implement treatment.
9.2. TROUBLESHOOTING PROCEDURES WHEN A MESSAGE
HAS BEEN DISPLAYED
This chapter explains the messages displayed when the product is operating normally and when an error
occurs.
There are the following types of messages.
Priority
level
1
Message Type
Description
Refer to
5
Command errors
6
Errors requiring
restart
Displayed when the product is operating
normally
Displayed when heating element errors occurs
during operation.
Message type errors are displayed when trouble
occurs during operation.
Displayed when data communication trouble
occurs between the computer and this product.
Displayed when trouble occurs during analysis
of the command data that is sent to this product
from the computer.
Displayed when trouble that is critical to the
operation of this product occurs.
→ Operating condition
display
→ Heating system error
4
Operating
condition display
Heating system
error
Message type
errors
Data error
2
3
267
→ Message type errors
→ Data error
→ Command errors
→ Errors requiring
restart
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9.2.1. Operating condition display
This chapter explains the messages displayed, the items to be confirmed and the remedy.
No.
1
Message
Cover Open
Phenomenon
The front cover is
open.
Check point
(1) Check if the
cover R/L sensor
assembly comes
on and off properly
when the front
cover is opened
and closed.
(2) Make sure that
cables for the
cover sensor
assembly are
securely
connected.
(3) The Mainboard
assembly may
have a problem.
2
Set Paper
The lever is up
(1) Check the
operation of the
transmission
photosensor for
the lever up/down
via “Test:Sensor”
of the selfdiagnostic
function.
(2) Make sure the
transmission
photosensor at the
lever motor has
been securely
installed.
(3) Check the
sensor element of
the transmission
photosensor at the
lever motor for
contamination.
268
Action
• Adjust the
operating position
of the cover sensor
R/L assembly.
Refer to
→ Cover sensor
adjustment
• Securely connect
the cables for the
cover sensor
assembly to
connectors J155
and J156 on the
mainboard
assembly.
• Securely connect
the cover L sensor
to the cover L
cable.
• Replace the
Mainboard
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Cover sensor
adjustment
• Replace the
transmission
photosensor at the
lever.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Replacing the
transmission
photosensor.
• If the
transmission
photosensor is
detached, fix it
securely.
→ Replacing the
transmission
photosensor.
• Clean the sensor
element using
cotton swabs.
→ Replacing the
transmission
photosensor.
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
3
Paper End
The paper is not
setup
(4) Make sure the
transmission
photosensor
cables at the lever
motor have been
securely installed.
• Securely connect
the transmission
photosensor
cables to
Mainboard
assembly
connectors J123
and J124.
(5) Check the
operation of the
foot lever via
“Test:Sensor” of
the self-diagnostic
function.
(6) The Mainboard
assembly may
have a problem.
• Replace the foot
switch
(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.
• Securely connect
the cables to
Mainboard
assembly
connectors J128
and J129.
(2) Make sure
P_REAR sensor
assembly cables
underneath the
paper guide R are
securely
connected.
• Replace the
Mainboard
assembly.
(3) The P_REAR
sensor assembly
may be damaged.
• Replace the
P_REAR sensor
assembly.
(4) The Mainboard
assembly may
have a problem.
• Replace the
Mainboard
assembly.
269
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Refer to the
User’s Guide
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Replacing the
P_REAR_R
sensor assembly
and P_REAR_L
sensor assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Replacing the
P_REAR_R
sensor assembly
and P_REAR_L
sensor assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
9.2.2. Message type errors
The following explains the messages, items to be confirmed and remedies to take when message type errors
occur while the product is operating.
Message type errors are displayed when trouble occurs during operation.
When message type errors occur, this product displays the following error messages on the operation panel
and stops the operation.
When the causes of errors are removed, message type errors are restored and the printing operation will be
restarted.
No.
1
Message
Undefined
paper
Phenomenon
The printer failed to
detect the media.
Check point
(1) Check the
operation of the
P_EDGE sensor
via “Test:Sensor”
of the selfdiagnostic
function.
(2) Make sure the
P_EDGE sensor
assembly
connector at the
cursor is securely
connected.
Action
• If the sensor
responds to the
presence of the
paper, adjust the
sensor volume.
• If the sensor
does not respond
to the presence of
the paper, replace
the P_EDGE
sensor assembly
• Securely connect
it to CR board
assembly
connector J234.
(3) Make sure the
R_REAR sensor
assembly cables
underneath paper
guide R are
securely
connected.
• Securely connect
the cables to
Mainboard
assembly
connectors J128
and J129.
(4) Check the CR
tape power cables
for skewed
insertion.
• Redo the
connections of the
following
connectors :
• CR board : J201
– J216
• Mainboard : J137
– J152
(5) The CR tape
power cables may
be damaged.
• Replace the CR
tape power cables.
(6) The CR board
assembly may be
damaged.
• Replace the CR
board assembly.
270
Refer to
→ Media sensor
sensitivity
adjustment
→ Replacing the
P_EDGE sensor
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Replacing the
steel bearer, tube
guide, CR tape
power cable and
ink tube.
→ Replacing the
CR board
assembly.
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
(7) The Mainboard
assembly may be
damaged.
• Replace the
Mainboard
assembly.
• If this is caused
by incorrect paper
setup, explain the
correct paper
setup procedure.
• Remove the
accumulated paper
dust along the
direction of the
grooves.
• Reset the cutter
cap securely
2
Paper Slant
The paper is fed
askew.
(1) Reset the
paper and check if
the condition
recurs.
3
Paper Cut
Error
Even though cutting
operation was
performed, the
paper was not
completely cut and
removed.
(1) Check the
cutter grooves for
accumulated paper
dust and slip.
(2) has the cutter
cap securely been
installed?
(3) Check the
cutter’s up and
down sliding
operation.
(4) Check if the
cutter drops to the
bottom end under
its own weight
when the cutter
has been installed
without the cutter
spring.
271
• If it does not rise
: Go to step (4)
• If it rises : Go to
step (5)
•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
replaced, replace
the cutter holder.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
-
→ Please refer to
the User’s Guide.
→ Please refer to
the User’s Guide.
→ Replacing the
cutter holder,
cutter spring,
cutter cap,
solenoid
assembly and
solenoid spring.
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
(5) Check the up
and down
operation of the
solenoid via
“Life/Cutter” of the
self-diagnostic
function.
a) The solenoid
moves up and
down : Check the
cutter’s down
position relative to
the cutter groove.
b) It does not
move up and
down.
(6) Open CR
cable, faulty
solenoid assembly,
faulty board
assembly, etc.,
may be the cause.
4
End of Roll
Displayed when the
end of the roll paper
is detected during
the use of roll paper.
This is released
when the lever has
(1) Check if the
message is still
displayed after
turning the power
off and then back
on again.
272
OK :
The cutter’s
service life is
reached or it is
damaged.
Replace the cutter.
NG :
Adjust the position
of the cutter
holder.
• The connectors
may have poor
contacts.
Check the
connections of the
following
connectors :
CR board : J235
CR board : J201 –
J216
Mainboard : J137
– J152
•Replace the CR
tape power cables.
• Replace the
solenoid assembly
• Replace the CR
board assembly
• Replace the
Mainboard
assembly.
→ Please refer to
the User’s Guide
→ Cutter
adjustment
→ Replacing the
CR board
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Replacing the
steel bearer, tube
guide, CR tape
power cable and
ink tube.
→ Replacing the
cutter holder,
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.
If the message is
displayed : go to
step (2)
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
been set to the up
position.
5
[ ] Near End
The remaining
amount of ink is low.
Printing is still
possible.
6
[ ] Ink End
There is no more ink
left. Printing in
progress is
interrupted
immediately.
(2) Check the
P_REAR sensor
assembly for the
contact condition.
•Redo the
connections of
Mainboard
assembly
connectors J128
and J129. If the
paper is not
initialized, the
sensor may be
damaged.
• Replace the
P_REAR sensor
assembly.
(3) The Mainboard
may be damaged.
• Replace the
Mainboard
assembly.
(1) Check the ink
end via “Test:
Sensor” of the selfdiagnostic
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.
• Redo the
connections of the
following
connectors.
• Junction board :
J401 – J418
• Mainboard : J133
– J134
• If the type of the
installed cartridge
does not match the
displayed type, the
ink ID sensor may
be damaged.
(2) Check the ink
sensor connector
for the contact
conditions.
7
Not Original
Ink
(1) Check the ink
end ID via “Test:
Sensor” of the selfdiagnostic
function. (This is
limited to when
smart chips are
set.)
273
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Replacing the
P_REAR_R
sensor assembly
and P_REAR_L
sensor assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Sensor menu
→ Replacing the
I/H (ink holder)
assembly
→ Replacing the
Junction board
assembly.
→ Sensor menu
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
(2) Check the ink
ID sensor
connector for the
contact conditions.
(3) The Mainboard
may be damaged.
8
9
10
Warning
Waste INK
Tank
Warning
Waste INK
Tank
(Warning
Head Life)
The waste tank will
soon be full.
The service life of
the ink tube will
soon be reached.
The service life of
the print head will
soon be reached.
(1) Check if the
message is still
displayed after
turning the power
off and then back
on again.
(2) The amount of
waste ink inside
the tank reached
the specified level.
(3) If initialization
does take effect
when the waste ink
is disposed of and
waste ink history is
initialized, the
Mainboard may be
damaged.
(1) Check if the
message is still
displayed after
turning the power
off and then back
on again.
(2) The number of
times the ink tube
was used reached
the maximum
allowable times.
(3) If initialization
does take effect
when the CR
motor history is
initialized after the
ink tube is
replaced, the
Mainboard may be
damaged.
(1) Check if the
message is still
displayed after
turning the power
off and then back
on again.
274
• Redo the
connections of the
following
connectors :
• Junction board :
J401 – J418
• Mainboard : J133
– J134
• Replace the
Mainboard
assembly.
• When a message
is displayed : Go to
step (2)
→ Replacing the
JUNCTION board
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
-
• Dispose of the
waste ink in the
waste bottle.
-
• Replace the
Mainboard
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
-
• When a message
is displayed : Go to
step (2)
• Replace the ink
tube.
• Initializing CR
motor history.
• Replace the
Mainboard
assembly.
→ Replacing the
steel bearer, tube
guide, CR tape
power cable and
ink tube.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
• When a message
is displayed : refer
to step (2)
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
11
12
13
Hard disk
status connect
error
Network
initialize error
Waste ink tank
sts. No
There is a problem
in the hard disk
connections.
There is a problem
in the network
board.
The waste tank is
not installed.
(2) The number of
times the print
head was used
reached the
maximum
allowable times.
• Replace the print
head assembly.
• Initialize the head
unit.
(3) If initialization
does not take
effect when the
head unit is
initialized, the
Mainboard
assembly may be
damaged.
• Replace the
Mainboard
assembly.
(1) Check the
connections of
connectors.
• Redo the
connections of the
following
connectors.
• Mainboard : J102
• power source
board (small)
assembly : CN51 –
CN52
• Replace the ink
tube.
• Initializing CR
motor history.
• Replace the hard
disks.
• Replace the
Mainboard
assembly.
• Replace the
PCI_LINUX board
assembly.
(2) The
HDD_MOTHER
board assembly
may be damaged.
(3) Hard disk may
be damaged.
(4) The Mainboard
assembly may be
damaged.
(1) The
PCI_LINUX board
assembly may be
damaged.
(2) The Mainboard
assembly may be
damaged.
(1) Check if the
waste bottle has
been installed.
(2) Check the
operation of the
waste box sensor
assembly via
“Sensor/Waste
Bin” of the selfdiagnostic
function.
275
• Replace the
Mainboard
assembly.
• Install the waste
bottle correctly.
• Replace the
waste box sensor
assembly.
→ Replacing the
print head
assembly and
head tape power
cable.
→ Counter
initialization
menu.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Replacing the
power source
board assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
-
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
(3) Check the
connections of the
connectors.
(4) The Mainboard
assembly may be
damaged.
•Check if the
waste box sensor
connectors are
connected to the
rear side cap R.
• Redo the
connections of the
following
connectors.
• Mainboard : J120
• Replace the
Mainboard
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
Notes :
¾
The number between brackets [ ] on the error display indicates the cartridge
number.
276
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9.2.3. Heating system error
The following explains the messages, items to be confirmed and remedies to take when errors handling
heating system occur while the product is operating.
Heating system errors are displayed when communication trouble occurs between the heater strips and this
product.
If heating system error occurs, the following error messages are displayed and the printer stops.
Solve the problem to delete the error message and restart the printer.
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Message
AC not present
Error sensors A
Error sensor A
Conn. err. Left A
Conn. err. Right A
Error sensors D1
Error sensor D1
Conn. err. Left D1
Conn. err. Right D1
Error sensors D2
Error sensor D2
Conn. err. Left D2
Conn. err. Right D2
Couldn't reach temp
Check point
AC connector.
Sensors A
Sensor A
Sensor A
Sensor A
Sensors D1
Sensor D1
Sensor D1
Sensor D1
Sensors D2
Sensor D2
Sensor D2
Sensor D2
Heater strip
15
Err: Temp > 85°C!
Heater strip
16
17
18
19
20
21
22
23
24
25
Connection err. A
Connection err. D1
Connection err. D2
Error sensor B1
Error sensor C
Connection err. B1
Connection err. C
Error sensor B2
Connection err. B2
Error D group
Rear Heater (A)
Dryer (D1)
Dryer (D2)
Fixer (B1)
Post fixer (C)
Fixer (B1)
Post fixer (C)
Fixer (B2)
Fixer (B2)
Heaters D
26
Error A group
Heaters A
27
Error B group
Heaters B
Action
Check AC connector
Check if the sensors are connected properly.
Check if the sensors are connected properly.
Check if the left sensor is connected properly.
Check if the right sensor is connected properly.
Check if the sensors are connected properly.
Check if the sensors are connected properly.
Check if the left sensor is connected properly.
Check if the right sensor is connected properly.
Check if the sensors are connected properly.
Check if the sensors are connected properly.
Check if the left sensor is connected properly.
Check if the right sensor is connected properly.
After 10 minutes, temperature is not reached. Check
the heater strips.
Temperature comes higher then the limit. Check the
heater strips.
Check the connector of the rear heater.
Check the connector of the front heater (D1).
Check the connector of the front heater (D2).
Check the sensor of the fixer 1 (B1).
Check the sensor of the fixer (C).
Check the connector of the fixer 1 (B1).
Check the connector of the post fixer (c).
Check the sensor of the fixer 2 (B2)
Check the connector of the fixer 2 (B2).
Temperature difference higher than 15°C between
the sensors of the D heaters.
Temperature difference higher then 15°C between
the sensors of the A heaters.
Temperature difference higher then 15°C between
the sensors of the B heaters.
Important :
Before checking the connectors, please power off the unit and remove the power cable.
Notes :
¾
¾
Check if the connectors are properly connected to the power board.
Check if the sensors are connected onto the right connector.
277
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9.2.4. Data error
The following explains the messages, items to be confirmed and remedies to take when data errors occur
while the product is operating.
Data errors are displayed when data communication trouble occurs between the computer and this product.
If data error display occurs, the following error messages are displayed and the printer stops.
Solve the problem to delete the error message and restart the printer.
No.
1
2
3
4
5
6
7
8
9
10
Message
I 15-1 error
command [ ]
I 15-2 error
command [ ]
I 15-3 error
command [ ]
I 15-4 error
command [ ]
I 15-5 error
command [ ]
I 15-6 error
command [ ]
I 15-7 error
command [ ]
I 15-8 error
command [ ]
I 15-9 error
command [ ]
I 15-10 error
command [ ]
Phenomenon
Online frame error
Overrun error
Online parity error
Sum check error
ESC parameter
Check point
(1) Check the
printing data for
contents that may
be judges as an
error.
(2) Mainboard
assembly may be
defective?
Action
• Try a different
drive for the
application.
• Replace
Mainboard
assembly
Refer to
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
Undefined ESC
Incorrect letters
ESC
Numeral character
ESC
Parameter error
ESC
Buffer overflow
Notes :
¾
The command codes for errors may be indicated between brackets [ ].
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9.2.5. Command errors
The following explains the messages, items to be confirmed and remedies to take when command errors
occur while the product is operating.
Command errors are displayed when trouble occurs during analysis of the command data that is sent to this
product from the computer.
If a command error occurs, the following error messages are displayed and the printer stops.
Solve the problem to delete the error message and restart the printer.
No.
1
Message
MH01 error
command [ ]
2
MH02 error
command [ ]
3
MHO3 error
command [ ]
4
MH04 error
command [ ]
5
MH05 error
command [ ]
Phenomenon
Undefined ESC: A
command that has
not been defined in
command modes
was analyzed.
Parameter error :
Number of
parameters
following command
is incorrect.
Numeric error :
Number of
parameters
following command
is incorrect.
Undefined letter set:
Letter sets that
should not exist (do
exist).
Buffer overflow:
Polygon buffer or
downloadable
character buffer
overflows.
Check point
(1) Check the
printing data for
contents that may
be judged as an
error.
(2) The Mainboard
assembly may
have a problem.
Action
• Try a different
drive for the
application
• Replace
Mainboard
assembly
Refer to
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
Notes :
¾
The command codes for errors may be indicated between brackets [ ].
¾
For the settings on a computer, refer to the computer's operation manual.
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9.2.6. Errors requiring restart
The following explains the messages, items to be confirmed and remedies to take when errors requiring
restart occur while the product is operating.
Errors requiring restart are displayed when trouble critical to the operation of this product occurs.
¾ Foreign material disturbing the printer operation has been loaded in the printer.
¾ An electrical circuit (such as board, motor or sensor) failure has occurred.
¾ An error on control program of the printer has occurred.
¾ When errors requiring restart occur.
The product stops operation after the following actions take place.
1. The power supply to the operation has been automatically shut-off.
2. All lamps on the operation panel flash and the buzzer sounds intermittently.
3. Error messages are displayed on the operation panel.
If an error requiring a restart has occurred, solve the problems to restart the printer and delete the error.
(1) CPU system critical errors
No.
1
Message
E 001 error
DRAM
Phenomenon
Standard DRAM
error : Abnormal
condition in
standard memory
mounted on
Mainboard
assembly
Check point
(1) Mainboard
assembly may be
defective.
Action
• Replace
Mainboard
assembly
2
E 002 error
Opt. DRAM
Option DRAM error :
Abnormal condition
in optional memory
mounted on
Mainboard
assembly
(1) If foreign
material is present
in the slot (J103) of
the extended
memory, errors
may result.
(2) Install known
good optional
memory (the
capacity must be
equal to the one in
the user’s unit)
then check the
equipped memory
capacity via
“Test:Ram
Capacity” of the
self-diagnostic
function.
(3) Mainboard
assembly may be
defective.
• Remove dust
using a tool such
as air duster, then
reinstall the
memory.
280
• Replace memory.
Refer to
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
• Replace
Mainboard
assembly
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
3
E 016 error
CPU Err [00]
4
E 016 error
CPU Err [02]
5
E 016 error
CPU Err [03]
6
E 016 error
CPU Err [04]
7
E 016 error
CPU Err [05]
8
E 016 error
CPU Err [06]
9
E 016 error
CPU Err [07]
10
E 016 error
CPU Err [08]
11
E 016 error
CPU Err [09]
12
E 016 error
CPU Err [10]
13
E 016 error
CPU Err [03]
14
E 016 error
CPU Err [12]
15
E 016 error
CPU Err [13]
Interruption
exception error:
Trouble occurred in
the interrupt process
Command boundary
exception errors:
Trouble occurred in
the command
boundary.
Data boundary
exception errors :
Trouble occurred in
the data boundary.
Address exception
error (load or
command fetch):
Address error
occurred while
loading or fetching
commands.
Address exception
error (store) :
Address errors
occurred while
saving.
Address exception
error (command
fetch): Address
errors occurred
while loading or
storing commands
Bus exception
errors (Loading and
storing): buss errors
occurred while
loading and storing
commands
System call
exception errors:
System call trouble
occurred.
Break point
exception error:
trouble occurred in
the break points.
Reservation
command exception
errors: trouble
occurred in the
reservation
commands.
Disable coprocessor exception
errors: trouble
occurred in the coprocessor.
Calculation overflow
exception errors:
overflows occurred.
Trap exception
errors : trap
occurred
(1) Check the AC
power source and
the printer
peripheral
devices(2) Check if
the error recurs. If
not, check by
powering-up the
product several
times.
(3) The Mainboard
assembly may
have a problem.
281
• Replace
Mainboard
assembly
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
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Rockhopper II series printers – Maintenance Manual
16
E 016 error
CPU Err [15]
17
E 016 error
CPU Err [22]
18
E 016 error
CPU Err [32]
19
E 016 error
CPU Err [33]
Floating point
exception error :
trouble occurred in
the floating points
Watch exception
error : trouble
occurred in the
watch.
Watch dog timeout
exception error :
watch dog time out
occurred.
Abort error : Aborts
occurred
Notes :
¾
For the settings on a computer, refer to the computer's operation manual.
(2) Mechanical system critical errors
No.
1
Message
E065 error PF
motor
2
E067 error
Paper feed
encoder
3
E069 error
Paper feed
timeout
Phenomenon
Trouble occurred in
the PF motor (Xaxis) during
operation.
Displayed when the
motor commended
value and feedback
from the encoder
are significantly
different.
Trouble occurred on
paper travel (x-axis)
during operation.
Displayed when
there is no feedback
from the encoder.
Check point
(1) Check error
history from “Test:
history” of selfdiagnosis function.
Action
Refer to
→ History menu
(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 issued.
• Check
connection of
following
connectors in
Mainboard
assembly:
→ PF motor cable
assembly
connector J157
→ PF_ENC
assembly
connector J154
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
Timeout occurred
on paper travel (Xaxis) during
operation.
Displayed when the
pressure roller has
not reached the
commanded
position.
(3) Check
“Encoder:PF”
under “Test:
Encoder” of selfdiagnosis function.
282
→ Encoder Menu
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Rockhopper II series printers – Maintenance Manual
→ Replacing PF
Motor Assembly
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ History Menu
4
E071 error PF
over current
An overload
occurred in the PF
motor (X-axis)
during operation.
(4) PF motor
assembly may be
damaged.
(5) Mainboard
assembly may be
damaged.
• Replace PF
motor assembly
• Replace
Mainboard
assembly
5
E 066 Error
CR Motor
(1) Check the
trouble history via
“Test: Record” of
the self-diagnostic
function
-
6
E 068 Error
CR Encoder
Trouble occurred in
the CF motor (Yaxis) during
operation.
Displayed when the
motor commanded
value and feedback
from the encoder
are significantly
different.
Trouble occurred in
the head travel (Yaxis) 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.
• Clean and
lubricate the rollers
of the CR rail.
→ Lubrication /
Bonding
• Check he
connections of the
following
connectors.
Mainboard
assembly
• CR motor
assembly
connector : J158
• CR tape power
cable connectors :
J137 – J152
CR Board
assembly
• CR tape power
cable connectors :
J201 – J216
• CR_ENC
assembly
connector : J233
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
7
E 070 Error
CR Timeout
Err
Time out occurred in
the head travel (Yaxis) during
operation.
Displayed when he
carriage has not
reached the
commanded
position.
→ Refer to Error
E072
(3) Check if “CR
Motor Error”
occurs by setting
the durability
cycles at 50 over
larger via “Life: CR
Motor” of the selfdiagnostic
function.
283
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Rockhopper II series printers – Maintenance Manual
(4) Check the Tfence for
contamination,
flows and bends.
(5) Check the
“Encoder’s” via
“Test/Encoder” of
the self-diagnostic
functions.
8
E 072 Error
CR Over
Current
An overload
occurred in the CR
motor (Y-axis)
during operation.
(6) The Mainboard
assembly may
have a problem.
→ Error E068
occurs if
Mainboard
assembly
connector
J155/COVER-R or
J156/COVER-L is
not connected.
284
• If contaminated
with grease and
dust, wipe off with
a dry cloth.
• If contaminated
with ink, wipe off
with a lightly damp
cloth and then with
a dry cloth.
• If contamination
is severe, replace
the T fence.
a) If NG :
Check the cable
connections at the
following locations
• CR board
assembly
connector J233
b) Replace the
following parts
• T fence
• CR motor
assembly
• CR BASE board
assembly
• CR tape power
cables
• Replace the
Mainboard
assembly
Make sure 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.
• Replace the
Mainboard
assembly.
• Make sure 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
T fence
→ Replacing the
CR motor
assembly.
→ Replacing the
CR board
assembly
→ Replacing the
steel bearer, tube
guide, CR tape
power cable and
ink tube.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
9
10
11
E 073 Error
CR Origin
E 074 Error
Cover
E 075 Error
Head Over
Current
CR_HP cannot be
detected.
Trouble occurred in
the cover sensor.
Trouble occurred
during printer
operation due to an
overload of the print
head.
(1) Check the
transmission
photosensor for
CR home position
detection via “Test:
Sensor” of the selfdiagnostic
function.
(2) The
transmission
photosensor for
CR home position
detection may be
damaged.
(3) The Mainboard
assembly may
have a problem.
(1) Check the
cover sensor via
“Test/Sensor” of
the self-diagnostic
function.
• Check the
connections of the
transmission
photosensor for
CR home position
detection.
→ Sensor Menu
• Replace the
transmission
photosensor for
the CR home
position detection.
→ Replacing the
transmission
photosensor.
• Replace the
Mainboard
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Sensor Menu
(2) The cover
sensor assembly
may be damaged.
• Make sure that
the connection of
the cover sensor
assembly is good.
• Mainboard : J155
– J156
• Replace the
cover sensor
assembly.
(3) The Mainboard
assembly may
have a problem.
• Replace the
Mainboard
assembly.
(1) Make sure that
the connections of
the head tape
power cables are
good.
•Redo the
connections of the
following
connectors.
• CR board : J217
– J232
• Reset the head
error
•Redo the
connections of the
following
connectors.
• CR board : J201
– J216
• Reset the head
error
(2) Make sure that
the connections of
the CR tape power
cables are good.
285
→ Replace the
cover R sensor
assembly and the
cover L sensor
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Replacing the
CR board
assembly.
→ Counter
initialization menu
→ Replacing the
CR board
assembly
→ Counter
initialization menu
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
12
E 076 Error
PG CR origin
The HD_SLIDE
home position
cannot be detected.
(3) The print head
may be damaged.
•Replace the print
head assembly
(4) The CR board
assembly may be
damaged.
• Replace the CR
board assembly
• Reset the head
error
(5) The Mainboard
assembly may
have a problem
• Replace the
Mainboard
assembly
• Reset the head
error
(1) Check the
HD_SLIDE sensor
via
“Sensor/HD_SLID
E” of the selfdiagnostic function
• Make sure that
the connections of
the HD_SLIDE
sensor assembly
connectors are
good.
• Mainboard : J127
• Replace the
HD_SLIDE sensor
assembly.
(2) Make sure that
the connections of
the HD_SLIDE
sensor assembly
connectors are
good.
(3) The SLIDE
motor assembly
may be damaged.
• Replace the
SLIDE motor
assembly.
(4) The Mainboard
assembly may
have a problem.
• Replace the
Mainboard
assembly.
286
→ Replacing the
print head
assembly and
head tape power
cable.
→ Counter
initialization menu
→ Replacing the
CR board
assembly
→ Counter
initialization menu
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Counter
initialization menu
→ Sensor Menu
→ Replacing the
SLIDE motor
assembly,
HD_SLIDE
sensor assembly
and slide motor
installation board.
→ Replacing the
SLIDE motor
assembly,
HD_SLIDE
sensor assembly
and slide motor
installation board.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
13
14
E 077 Error
Head
Overheat
E 078 Error
Head Cable
Trouble occurred in
the head driver.
Trouble occurred in
the head cable or
head thermister.
(1) The
HEAD_DRV board
assembly may
have a problem.
• Replace the
HEDA_DRV board
assembly.
(2) The Mainboard
assembly may
have a problem
• Replace the
Mainboard
assembly
(1) Make sure that
the connections of
the head tape
power cables are
good.
•Redo the
connections of the
following
connectors.
• CR board : J217
– J232
•Redo the
connections of the
following
connectors.
• CR board : J201J216
• Replace the print
head assembly.
(2) Make sure that
the connections of
the CR tape power
cables are good.
(3) The print head
assembly may be
damaged
15
E 079 Error
Lever Over
Current
An overload
occurred in the lever
motor during
operation.
(4) The CR board
assembly may be
damaged.
(5) The Mainboard
assembly may
have a problem.
• Replace the
Mainboard
assembly.
(1) The lever motor
may be damaged.
• Replace the lever
motor.
287
• Replace the CR
board assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Replacing the
CR board
assembly
→ Replacing the
CR board
assembly
→ Replacing the
print head
assembly and
head tape power
cable.
→ Counter
initialization menu
→ Replacing the
CR board
assembly
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Replacing the
lever motor
assembly and the
arm motor
installation board.
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
16
17
E 080 Error
Lever Sensor
E 081 Error
Cap Sensor.
Trouble occurred in
the lever sensor.
Trouble occurred in
the cap sensor.
(2) The Mainboard
assembly may
have a problem.
• Replace the
Mainboard
assembly.
(1) Check the
operation of the
transmission
photosensor for
the lever up/ down
via “Check: sensor
“ of the selfdiagnostic
function.
(2) Is the
transmission
photosensor at the
lever motor
securely installed?
(3) Is the sensor
element of the
transmission
photosensor at the
lever motor
contaminated?
(4) Is the
transmission
photosensor cable
at the lever motor
securely installed?
• Replace the
transmission
photosensor at the
lever.
(5) The Mainboard
assembly may
have a problem.
• Replace the
Mainboard
assembly.
(1) Check the
operation of the
transmission
photosensor at the
cap via “Sensor:
Head Lock” of the
self-diagnostic
function.
• Replace the
transmission
photosensor at the
cap.
288
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Replacing the
transmission
photosensor.
• If the
transmission
photosensor is
detached, fix it
securely.
• Clean the sensor
element using
cotton swabs.
→ Replacing the
transmission
photosensor.
• 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.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Counter
Initialization
Menu.
→ Replacing the
transmission
photosensor.
→ Replacing the
transmission
photosensor.
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
18
E 082 Error
Wiper Sensor
Trouble occurred in
the wiper sensor.
(2) Is the
transmission
photosensor at the
cap securely
installed?
(3) Is the sensor
element of the
transmission
photosensor at the
cap contaminated?
(4) Is the
transmission
photosensor cable
at the lever motor
securely installed?
• If the
transmission
photosensor is
detached, fix it
securely.
• Clean the sensor
element using
cotton swabs.
→ Replacing the
transmission
photosensor.
• Securely connect
the cable for the
transmission
photosensor cable
to Mainboard
assembly
connectors J123
and J124.
(5) Make sure that
the connections of
the SLIDE motor
assembly for
maintenance U/D
are good.
(6) The Mainboard
assembly may be
damaged.
• Replace the
SLIDE motor
assembly for the
maintenance U/D.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Replacing the
SLIDE motor
assembly (wiper
arm).
(1) Check the
up/down operation
of he cap (wiper)
via “Sensor: Head
Lock” of the selfdiagnostic
function.
(2) Is the
transmission
photosensor at the
wiper up/down
area securely
installed?
(3) Is the sensor
element of the
transmission
photosensor
contaminated?
(4) Is the
transmission
photosensor cable
securely
connected?
• Replace the
transmission
photosensor at the
wiper.
289
• Replace the
Mainboard
assembly.
→ Replacing the
transmission
photosensor.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
→ Replacing the
transmission
photosensor.
• If the
transmission
photosensor is
detached, fix it
securely.
→ Replacing the
transmission
photosensor.
• Clean the sensor
element using
cotton swabs.
→ Replacing the
transmission
photosensor.
• Securely connect
the cable for the
transmission
photosensor cable
to Mainboard
assembly
connector J131.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
(5) Make sure that
the connections of
the SLIDE motor
assembly for the
WIPER slide are
good.
(6) The Mainboard
assembly may be
damaged.
290
• Replace the
SLIDE motor
assembly for the
wiper SLIDE.
→ Replacing the
SLIDE motor
assembly (wiper
arm).
• Replace the
Mainboard
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV
board assembly
and cooling fan
assembly.
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
9.3. TROUBLESHOOTING PROCEDURES WHEN ERRORS ARE
NOT DISPLAYED
The following explains the messages, items to be confirmed and remedies to take when error messages are
not displayed
9.3.1. Problems relating to initial operation
This chapter explains the messages displayed, the items to be confirmed and the remedy.
No.
1
Phenomenon
Power is not supplied.
Check point
(1) Check the panel
unit assembly
cables for open or
shorted conditions.
(2) Make sure that
the connections of
the power supply
board and
Mainboard
assembly are good.
Action
• Replace the panel
cables.
Refer to
→ Removing the
panel unit assembly.
• Redo the
connections of the
following
connectors.
• Mainboard : J101
• power source
board : CN2/CN4
(3) Make sure that
the connections of
the inlet board
assembly are good.
• Redo the
connections of the
following
connectors.
• Inlet board : CN1CN3
• Replace the panel
board assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
→ Replacing the
inlet assembly, inlet
board assembly and
lever foot SW cable
assembly.
(4) The panel board
assembly may be
damaged.
(5) The Mainboard
assembly may have
a problem.
2
LCD failure (no display / garbled
display)
(6) The power
supply board
assembly may have
a problem.
(1) Check if the
DIMM (optional
memory) is
installed.
291
→ Removing the
panel unit assembly.
• Replace the
Mainboard
assembly.
• Replace the power
supply board
assembly.1
• The internal
programs cannot be
started without the
DIMM installed in
the product. Make
sure to install the
one in the
specifications. If not
installed, nothing
will be displayed on
the LCD and all
LEDs will flash.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
→ Replacing the
power source board
assembly.
→ User’s Guide
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
3
Ink replenishment cannot be
performed.
(2) Make sure that
the connections of
the panel cable
connectors at the
panel side and the
Mainboard
assembly side is
good.
• Check the panel
cables for skewed
insertion.
• Make sure that
they are securely
locked.
(3) The DIMM
(optional memory)
may be damaged.
(4) The panel cables
may be damaged.
(5) Check the panel
unit assembly LCD
for damages.
(6) The Mainboard
assembly may have
a problem.
• Redo the
connections of the
following
connectors.
• Mainboard : J109
• Panel board : J301
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.→
Removing the panel
unit assembly.
• Replace the DIMM
(optional memory)
→ User’s Guide
• Replace the panel
cables.
• Replace the panel
board assembly.
→ Removing the
panel unit assembly.
→ Removing the
panel unit assy.
• Replace the
Mainboard
assembly.
(1) Check if “Cover
Open” is displayed
on the LCD when
the front cover is
closed.
(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.
(3) Check if
“LeverUp” is
displayed on the
LCD when the
pressure arm is at
the lower position.
(4) The ink ID board
assembly may be
damaged.
• Adjust the cover
sensor.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
→ Cover sensor
adjustment.
292
•Redo the
connections of the
following
connectors.
• Mainboard : J105
• Panel board : J301
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
• Replace the
transmission
photosensor at the
lever.
→ Replacing the
transmission
photosensor.
• Replace the ink ID
board assembly.
→ Replacing the I.H
(ink holder)
assembly
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
4
5
Although ink replenishment has
started, the ink has not reached
the head.
Ink is not supplied when ink
replenishment is complete.
(5) The JUNCTION
board assembly
may be damaged.
(6) The Mainboard
assembly may have
a problem.
• Replace the
JUNCTION board
assembly.
• Replace the
Mainboard
assembly.
(1) The ink pump
assembly may have
a problem.
(2) The
maintenance parts
may be damaged.
(3) The damper may
be damaged.
• Replace the ink
pump assembly.
(4) The ink tube
may be damaged.
• Replace the ink
tube.
(5) The cartridge
frame may be
damaged.
(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 that
they are securely
connected.
(2) Check the head
cables for the open
conditions.
• Replace the
cartridge frame
assembly.
• Redo the
connections of the
head cables to the
connectors.
(3) The print head
may be damaged.
• Replace the print
head assembly.
(4) Check the CR
cables for open
conditions.
• Replace the CR
tape power cables.
293
Replace the
maintenance
assembly.
• Replace the
damper.
• Replace the head
cables.
→ Replacing the
JUNCTION board
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
→ Replacing the
pump assembly.
→ Replacing the
maintenance
assembly.
→ Replacing the H
ink tube, tube
branch and damper
assembly.
→ Replacing the
steel bearer, tube
guide, CR tape
power cable and ink
tube.
→ Replacing the I/H
(ink holder)
assembly.
→ Replacing the CR
board assembly.
→ Replacing the
print head assembly
and head tape
power cable.
→ Replacing the
print head assembly
and head tape
power cable.
→ Replacing the
steel bearer, tube
guide, CR tape
power cable and ink
tube.
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
6
Operation does not take place at
all after the power is supplied.
7
When power is supplied,
“Initialize” is displayed, then
reset.
Initialization does not take place
even if the paper is set.
8
9
Operation does not take place
even if the front cover is closed.
10
Operation does not stop even if
the front cover is opened.
(5) The HEAD_DRV
board assembly
may have a
problem.
• Replace the
HEAD_DRV board
assembly.
(6) The Mainboard
assembly may have
a problem
• Replace the
Mainboard .
(1) Check if “Cover
Open” is displayed
on the LCD when
the front cover is
closed.
Check the proper
operation of the
cover sensory
assembly via
“TEST: Sensor” of
the self-diagnostic
function.
•Adjust the cover
sensor.
• Redo the
connections of
connectors J155
and J156 on the
Mainboard
assembly.
• Replace he cover
sensor assembly.
(2) Panel unit Make
sure that the
connections of the
panel cable
connectors at the
assembly side and
the Mainboard
assembly side are
good.
• Check the panel
cables for skewed
insertion.
• Make sure that
they are securely
locked.
(3) Check if “Set
Paper” is displayed
on the LCD when
the pressure arm is
at the lower
position.
• Redo the
connections of the
following
connectors.
• Mainboard : J105
• Panel unit : J301
294
• Redo the
connections of
Mainboard
assembly
connectors J123
and J124.
• Replace the
transmission
photosensor at the
lever.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
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.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.→
Replacing the
transmission
photosensor.
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
11
12
Key inputs via operation panel
are disabled.
Printing does not start even if
data is received.
(4) Check if the
detection function of
the P_REAR sensor
assembly is proper
via “Test: Sensor” of
the self-diagnostic
function.
• Redo the
connections of
Mainboard
assembly
connectors J128
and J129.
• Replace the
P_REAR sensor
assembly.
(5) The Mainboard
assembly may have
a problem.
• Replace the
Mainboard
assembly.
(1) Check the
operation panel
cover for breakage
and contamination.
(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.
(3) The panel unit
assembly may be
damaged.
(4) The Mainboard
assembly may have
a problem.
• Replace the
operation panel
cover.
(1) Refer to
“Problems relating
to online and
functions”.
-
295
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.→
Replacing the
P_REAR_R sensor
and P_REAR_L
sensor assembly
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
-
• Check the
connections of the
following
connectors.
• Mainboard : J105
• Panel board : J301
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.Þ
• Replace the panel
board assembly.
→ Removing the
panel unit assembly.
• Replace the
Mainboard
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
→ Problems relating
to online and
functions.
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
9.3.2. Problems relating to paper feed
No.
1
Phenomenon
The paper comes off at paper
set initialization or during the
printing operation.
Check point
(1) Check if the
P_REAR sensor
assembly and
P_EDGE sensor
assembly are
operating correctly
via “Test: Sensor” of
the self-diagnostic
function
Action
• Check if the
connections of the
following
connectors.
• Mainboard
assembly :
J128/J129, J137J152
• CR board : J201J261
• Adjust the
sensitivity of the
P_EDGE sensor
• Replace the
P_REAR sensor
assembly and
P_EDGE sensor
assembly
2
The paper is fed askew or
meanderingly at paper set
initialization or during the
printing operation.
(2) Check the platen
for contamination by
paper dust and ink.
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.
4
The paper jams up at paper set
initialization or during the
printing operation.
(4) Check paper
guide F for
significant
deformation, flaws,
foreign material, etc.
5
After the paper set initialization,
the paper size is detected
incorrectly.
(5) Is the flange
properly installed?
• If the platen is
contaminated by ink
or paper dust, wipe
off with a damped
soft cloth.
• If the surrounding
area of the pressure
roller is
contaminated by
paper dust and
waste paper, wipe
off with a damped
soft cloth.
• If foreign materials
such as wastepaper
are found on the
paper guide F,
remove them.
• Replace the paper
guide F.
• Securely insert
flanges into the
paper tube for the
roll paper.
• Replace the rollers
of the scroller.
(6) Check the rollers
of the paper
receiver for flaws
and wear that may
hinder the rotation
of the scroller.
(7) Check the
scrollers for bends.
296
• Replace the
scrollers.
Refer to
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
→ Replacing the CR
board assembly
→ media sensor
sensitivity
adjustment
→ Replacing the
P_REAR_R sensor
and P_REAR_L
sensor assembly→
Replacing the
P_EDGE sensor
assembly.
→ User’s Guide
→ User’s Guide
→ Removing media
guide F.
→ User’s Guide
→ Replacing the
scroller R assembly.
→ Replacing the
scroller L assembly.
→ User’s Guide
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
9.3.3. Problems relating to the printing operation
No.
1
2
3
Phenomenon
Continuous printing cannot be
performed.
Give an extra feed after the
printing operation has been
completed.
Dots are missed in printing
Check point
(1) The program
ROM may have
failed.
(2) The Mainboard
assembly may have
a problem.
Action
• Upgrade the
firmware version.
Refer to
→ Firmware
installation.
• Replace the
Mainboard
assembly.
(1) Check if the
detection function of
the P_REAR sensor
assembly is correct
via “Test: Sensor” of
the self-diagnostic
function.
• Make sure that the
connections of
Mainboard
assembly
connectors J128 –
J129 are good.
• Replace the
P_REAR sensor
assembly.
(2) Check
adjustments of the
top & bottom and
rear sensor
positions.
(3) The program
ROM may have
failed.
(4) The Mainboard
assembly may have
a problem.
• Adjust the
positions of the top
& bottom and rear
sensors.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
→ Replacing the
P_REAR_R sensor
assembly and
P_REAR_L sensor
assembly.
→ Top & bottom
adjustment menu.
→ P_REAR sensor
position adjustment
menu.
→ Firmware
installation
(1) Perform the
printing operation
via “Print: Nozzle
Check” or “Test:
Print” of the selfdiagnostic function.
(2) Repeat head
cleaning several
times.
• When the nozzle
check pattern is not
printed correctly : go
to step 2
297
• Upgrade the
firmware version.
• Replace the
Mainboard
assembly.
• If the condition is
not restored by
performing the
cleaning operation,
leave the product for
several hours then
recheck it.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
→ Test printing
menu
→ User’s Guide
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
4
Cleaning does not fix problems
such as clogging or split nozzle.
(1) Check the use
conditions of the
product.
(2) Check if the
conditions occur
after ink
replenishment.
(3) Check the
cleaning wipers for
contamination.
(4) Check the
installation
conditions of the
cleaning wipers.
(5) Check if the QR
codes are input
correctly.
(6) The damper may
be damaged.
• Under low
humidity conditions
in particular, printing
is performed poorly.
Check the
conditions under the
guaranteed
operation
conditions.
• Printing
performance is not
stable immediately
after ink
replenishment.
Leave the product
for several hours
then recheck it.
• Using the provided
cleaning cloth for
cleaning the wipers,
slightly dampen with
cleaning liquid it and
wipe the surface of
the cleaning wipers,
then recheck their
condition by
performing the
cleaning operation.
• If the ink is solid
and does not come
off by wiping,
replace the wiper.
• Check the
installation
conditions of the
wipers and fix them
securely.
• Input the correct
QR codes.
→ Specifications
• Replace the
damaged damper.
→ Replacing the H
ink tube, tube
branch and damper
assembly.
→ Replacing the
print head assembly
and head tape
power cable.
→ Replacing the I/H
(ink holder)
assembly.
(7) The print head
assembly may be
damaged.
• Replace the
damaged print head
assembly.
(8) Check if the
remaining amount of
ink in the cartridge
is sufficient.
• If “Near End” or
“Ink End” is not
displayed when the
remaining amount of
ink is insufficient,
the ink sensor
assembly may have
a problem.
• Replace the ink
pump assembly.
(9) The ink pump
assembly may have
a problem.
298
-
User’s Guide
→ Replacing the
cleaner
→ Replacing the
cleaner.
→ Head rank input
menu.
→ Replacing the
pump assembly.
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
(10) The
maintenance
assembly may have
a problem.
(11) The Mainboard
assembly may have
a problem.
• Replace the
maintenance
assembly.
→ Replacing the
maintenance
assembly
• Replace the
Mainboard
assembly.
• Redo the
connections of the
following
connectors.
Connectors for the
print head.
• CR board : J201 –
J232
• Mainboard : J137
– J152
• Replace the CR
tape power cables.
(3) Check ink tubes
for bends, flaws, air
leaks, etc.
• Replace the
damaged ink tubes.
(4) The print head
assembly may be
damaged.
• Replace the print
head assembly.
(5) The damper may
be damaged.
• Replace the
damaged cable.
(6) The ink pump
assembly may have
a problem.
(7) The
maintenance
assembly may have
a problem.
(8) The CR board
assembly may have
a problem.
(9) The HEAD_DRV
board may be
damaged.
• Replace the ink
pump assembly.
→ Replacing the
print head assembly
and head tape
power cable.
→ Replacing the
print head assembly
and head tape
power cable.
→ Replacing the CR
board assembly.
→ Replacing the
print head assembly
and head tape
power cable.
→ Replacing the
steel bearer, tube
guide, CR tape
power cable and ink
tube.
→ Replacing the
steel bearer, tube
guide, CR tape
power cable and ink
tube.
→ Replacing the
print head assembly
and head tape
power cable.
→ Replacing the H
ink tube, tube
branch and damper
assembly.
→ Replacing the
pump assembly.
• Replace the
maintenance
assembly.
→ Replacing the
maintenance
assembly.
• Replace the CR
board assembly.
→ Replacing the CR
board assembly
• Replace the
HEAD_DRV board.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
5
Nothing has been printed
(1) Check the head
and CR cables for
skewed insertion.
6
Only specific colours are not
printed.
(2) The head and
CR cables may be
damaged.
299
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
7
8
Drawn black on a full screen (Or
other specified colour)
Light and slade printing occurs.
(10) The Mainboard
assembly may have
a problem.
• Replace the
Mainboard
assembly.
(1) Check the head
and CR cables for
skewed insertion.
• Redo the
connections of the
following
connectors.
Connectors for the
print head.
• CR board : J201 –
J232
• Mainboard : J137 J152
(2) The head and
CR cables may be
damaged.
• Replace the CR
tape power cables.
(3) The print head
assembly may be
damaged.
• Replace the print
head assembly.
(4) The CR board
assembly may have
a problem.
(5) The HEAD_DRV
assembly board
may be damaged.
• Replace the CR
board assembly.
(6) The Mainboard
assembly may have
a problem.
• Replace the
Mainboard
assembly.
(1) Check if the use
conditions are within
the normal
operation
conditions.
• Be sure to use the
product under the
guaranteed
operation
conditions.
300
• Replace the
HEAD_DRV
assembly board
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
→ Replacing the
print head assembly
and head tape
power cable.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly
→ Replacing the
steel bearer, tube
bearing, CR tape
power cable and ink
tube.
→ Replacing the
print head assembly
and head tape
power cable.
→ Replacing the CR
board assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly
-
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
(2) Check if printing
began immediately
after ink
replenishment.
9
10
11
Irregularities occur in the image
picture.
The lines in the CR direction
split.
Black or white streaks occur in
printings.
(3) Check the band
feed adjustments.
(4) Check the head
adjustments.
(5) Check if the
suction fans are
operating correctly
via “Test: Fan” of
the self-diagnostic
function.
(6) If the paper in
concern is roll
paper, check if the
scroller is rotating
smoothly.
(7) Make sure hat
the PF belt tension
is adjusted correctly.
(8) Check if the
pump is running
during the cleaning
operation.
(9) Check if he
nozzle face is wiped
correctly.
301
→ User’s Guide
• The following
phenomena may
occur for the first
printing that is
processed
immediately after
ink replenishment.
• Faint lines are
drawn.
• White streaks
appear on the
printing.
• If these conditions
are observed,
perform cleaning a
couple of times
before printing, then
check the result.
• If cleaning does
not improve the
result, leave the
products for at least
several hours, redo
the cleaning
operation, then
check the results
again.
• Adjust the band
feed.
• Adjust the head.
• Check the
connections of the
following
connections.
• Mainboard : J111J116
• Make sure the
scroller receivers
are installed in the
correct position.
• Replace the rollers
of the scroller.
• Adjust the tension
of the PF reduction
belt.
• Check that the
connections of
Mainboard
connectors J160J161 are good.
• Replace the pump
motor.
• Replace the
Mainboard
assembly.
• Using the wiper,
wipe the nozzle face
well.
→ Band feed
correction menu
→ Head precision
adjustment
→ Replacing the
suction fan
assembly.
→ Replacing the
scroller R assembly.
→ Replacing the
scroller L assembly.
→ PF deceleration
belt tension
adjustment.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly
→ Replacing the
pump motor
assembly.
→ User’s Guide
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
(10) Check the
cleaning wipers for
contamination.
(11) Check the T
fence for
contamination
(12) Check the
rotation of the
pressure roller with
the pressure arm at
the raised position.
(13) Check if the QR
code is input
correctly.
(14) The head
assembly may be
damaged.
12
The printing boundary is
smeared.
• Using the provided
cleaning cloth for
cleaning the wipers,
slightly dampen it
with cleaning liquid
and wipe the
surface of the
cleaning wipers,
then recheck their
condition by
performing the
cleaning operation.
• If the ink is solid
and does not come
off by wiping,
replace the wiper.
• Clean the T fence.
• If contamination
cannot be cleaned
up, replace the T
fence
• If the surrounding
area of the pressure
roller is
contaminated by
paper dust and
waste paper, wipe it
with a soft
dampened cloth.
• Input the correct
QR codes.
→ User’s Guide
→ Replacing the
cleaner
• Replace the
damaged head
assembly.
→ Replacing the
print head assembly
and head tape
power cable.
→ Replacing the
steel bearer, tube
guide, CR tape
power cable and ink
tube.
→ Replacing the
print head assembly
and head tape
power cable.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly
→ User’s Guide
(15) The ink tube
may be damaged.
• Replace the ink
tube.
(16) The CR board
assembly may have
a problem.
• Replace the CR
board assembly.
(17) The Mainboard
assembly may have
a problem.
• Replace the
Mainboard
assembly
(1) Check if the
condition is
recovered by
cleaning.
• If the condition is
not recovered by
performing the
cleaning operation a
couple of times,
leave the product for
a while then recheck
it.
302
→ Replacing the
fence
→ User’s Guide
→ Head rank input
menu
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
(2) Check if the set
paper is one of
those recommended
by MUTOH.
(3) Check the head
adjustments.
(4) Check if the QR
code is input
correctly.
(5) The CR cables
may be damaged.
13
There are many satellite
droplets (unnecessary dots)
• Reset the
recommended
paper and recheck
the condition. If
paper not
recommended by
MUTOH is used, the
paper may not be
recognized correctly
by the paper sensor.
• Check the
condition using the
printing mode that is
recommended for
the paper.
• Adjust the head.
• Input the correct
QR codes.
• Replace the CR
tape power cables.
(6) Check the head
assembly for
breakage.
• Replace the
damaged head
assembly
(7) The CR board
assembly may have
a problem.
(8) The Mainboard
assembly may have
a problem.
• Replace the CR
board assembly.
(1) Check if the use
conditions are within
the normal
operation
conditions.
• Be sure to use the
product under the
guaranteed
operation
conditions.
303
• Replace the
Mainboard
assembly
→ User’s Guide
→ Head precision
adjustment
→ Head rank input
menu
→ Replacing the
steel bearer, tube
guide, CR tape
power cable and ink
tube.
→ Replacing the
print head assembly
and head tape
power cable.
→ Replacing the CR
board assembly
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
14
Fiber tracking is shown in prints.
(2) Check if printing
began immediately
after ink
replenishment.
15
Lines look blurred when printed.
(3) Check if the
tension of the steel
belt is properly
adjusted.
(4) Check the head
adjustments.
(5) Check the T
fence for
contamination.
(6) Make sure that
the CR_ENC
assembly and the T
fence are not
interfering.
(7) Check if the
pump is running
during the cleaning
operation.
304
• The following
phenomena may
occur for the first
printing processed
immediately after
ink replenishment.
• Faint lines are
drawn.
• White streaks
appear on the
printing.
• If these conditions
are observed,
perform cleaning a
couple of times
before printing, then
check the results.
• If cleaning does
not improve the
results, leave the
products for at least
several hours, redo
the cleaning
operation, then
check the results
again.
• Adjust the steel
belt tension.
→ User’s Guide
• Adjust the head.
→ Head precision
adjustment
→ Replacing the T
fence
→ Steel belt tension
adjustment
• Clean the T fence
• If contaminants
cannot be cleaned
up by cleaning,
replace the T fence.
• If they interfere
with each other,
adjust the
installation positions
of the CR_ENC
assembly and the T
fence.
• If the adjustments
do not improve this,
replace the
CR_ENC assembly
and the T fence.
• Check that
connections of
Mainboard
connectors J160J161 are good.
• Replace the pump
motor assembly.
• Replace the
Mainboard
assembly.
→ Replacing the T
fence.
→ Replacing the
CR_ENC assembly
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly
→ Replacing the
pump motor
assembly.
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
(8) Check if the
nozzle face is wiped
correctly.
(9) Check the
cleaning wipers for
contamination.
(10) Check if the QR
code is input
correctly.
(11) The head
assembly may be
damaged.
16
Mixed colour lines do not
overlap.
17
The positions of black and
colours are not aligned.
• Using the wiper,
wipe the nozzle face
well.
• Using the provided
cleaning cloth for
cleaning the wipers,
slightly dampen it
with cleaning liquid
and wipe the
surfaces of the
cleaning wipers,
then recheck their
conditions by
performing the
cleaning operation.
• If the ink is solid
and does not come
off by wiping,
replace the wiper.
• Input the correct
QR codes.
→ User’s Guide
• Replace the
damaged head
assembly
→ Replacing the
print head assembly
and head tape
power cable.
→ Replacing the
steel bearer, tube
guide, CR tape
power cable and ink
tube.
→ Replacing the CR
board assembly.
(12) The ink tube
may be damaged.
• Replace the ink
tube.
(13) The CR board
may have a
problem.
(14) The Mainboard
assembly may have
a problem.
• Replace the CR
board assembly.
(1) Check if the
tension of the steel
belt is properly
adjusted.
(2) Check the head
inclination and
height adjustments.
(3) Check the twoway printing position
alignment for
problems.
(4) Check if CW
adjustments are
made correctly.
(5) Check if the QR
code is input
correctly.
• Adjust the steel
belt tension.
305
→ User’s Guide.
→ Replacing the
cleaner
→ Head rank input
menu
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly
→ Steel belt tension
adjustment
• Replace the
Mainboard
assembly.
• Adjust the
inclination and
height of the head.
• Adjust the two-way
printing position
alignment.
→ Head precision
adjustment
• Perform the CW
adjustments.
→ CW adjustment
menu
• Input the correct
QR codes.
→ Head rank input
menu
→ Repeatability
alignment menu
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
(6) Make sure that
the CR_ENC
assembly and the T
fence are not
interfering.
(7) The head
assembly may be
damaged.
18
A limited line in the head travel
direction is not accurate (in the
main scanning direction)
(1) Check if the use
conditions are within
the normal
operation
conditions.
(2) Check if the
tension of the steel
belt is adjusted
correctly.
(3) Check the T
fence for
contamination.
A: Paper discharging direction
(4) The internal
process operation of
the Mainboard
assembly may be
malfunctioning.
19
Straight lines in the head travel
direction are not accurate
(straightness)
A: Paper discharging direction
(1) Make sure that
the PF reduction
belt tension is
adjusted correctly.
(2) Check the
rotation of the
pressure roller with
the pressure arm at
the raised position.
(3) Check if rattles
are heard when the
carriage is moved
from side to side.
306
• If they are
interfering with each
other, adjust the
installation positions
of the CR_ENC
assembly and the T
fence.
• If the adjustments
do not improve this,
replace the
CR_ENC assembly
and the T fence.
• Replace the
damaged head
assembly.
• be sure to use the
product under the
operation
conditions.
→ Replacing the T
fence.
→ Replacing the
CR_ENC assembly.
→ Replacing the
print head assembly
and head tape
power cable.
-
• Adjust the steel
belt tension.
→ Steel belt tension
adjustment
• Clean the T fence
• If the contaminants
cannot be cleaned
up, replace the T
fence.
• Check the
operation again
after initializing
parameters and reinputting and readjusting them.
• Adjust the tension
of the PF reduction
belt.
→ Replacing the T
fence.
• If the surrounding
area of the pressure
arm is contaminated
by paper, wipe it
with a soft
dampened cloth.
•Clean the dust from
the carriage
bearings and roller
guide. When the
roller guide is
cleaned, apply a
light coat of grease
on the roller guide
using a cloth soaked
in grease spray.
• Replace the CR
cursor assembly
→ User’s Guide
→ Parameter
initialization menu.
→ PF deceleration
belt tension
adjustment.
→ Replacing the CR
cursor assembly.
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
20
A limited line in the paper feed
direction is not accurate ( in the
sub scanning direction)
A : Paper discharging direction
21
Straightness in the paper feed
direction is not accurate (paper
joint accuracy).
A : Paper discharging direction
(1) Check if the use
conditions are within
the normal
operation
conditions.
(2) Check if distance
is compensated for
the paper in use.
(3) Check the PF
drive pulley for
looseness.
(4) Make sure that
the PF reduction
belt tension is
adjusted correctly.
(5) Check the
rotation of the
pressure roller with
the pressure arm at
the raised position.
(6) Check the grid
roller for rugged
movement. Also,
check the rotary
movement for
irregularities.
(7) If the paper in
concern is roll
paper, check if the
scroller is rotating
smoothly.
(1) Check if the
actually installed
head rank and the
registered head
rank match.
(2) Adjust the
inclination of the
head.
(3) Check if the
tension of the steel
belt is adjusted
correctly.
(4) Check the twoway printing position
alignment for
problems.
(5) Check if the CW
adjustments are
made correctly.
(6) Check the T
fence for
contamination.
(7) Check the CR
cursor assembly for
play.
307
• Be sure to use the
product under the
operation
conditions.
-
• Compensate the
distance.
→ Band feed
correction menu
• Replace the PF
motor assembly.
→ Replacing the PF
motor assembly.
• Adjust the tension
of the PF reduction
belt.
→ PF deceleration
belt tension
adjustment
• If the surrounding
area of the pressure
roller is
contaminated by
paper dust and
waste paper, wipe it
with a soft
dampened cloth.
• If foreign material
such as paper dust
and wastepaper are
found on the grid
rollers, remove them
using a nylon brush.
• Make sure that the
scroller receiver is
installed correctly.
• Replace the rollers
of the scroller.
• Input the correct
head rank.
→ User’s Guide
• Adjust the
inclination of the
head.
• Adjust the steel
belt tension.
→ Head precision
adjustment.
• Adjust the two-way
printing position
alignment.
→ Repeatability
alignment menu
• Perform the CW
adjustments.
→ CW adjustments
menu
• Clean the T fence
• If contaminants
cannot be cleaned
up, replace the T
fence.
• Replace the CR
cursor assembly.
→ Replacing the T
fence
→ User’s Guide
→ Replacing the
scroller R assembly.
→ Replacing the
scroller L assembly.
→ Head rank input
menu.
→ Steel belt tension
adjustment.
→ Replacing the CR
cursor assembly.
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
22
Inaccurate squareness
(1) Check the
installation method
of the paper.
(2) Check the
rotation of the
pressure roller with
the pressure arm at
the raised position.
(3) Check the grid
roller for rugged
movement. Also,
check the rotary
movement for
irregularities.
23
Abnormal discharge occurs.
(1) Check if the two
head tape power
cables stick
together.
(2) Make sure that
the CR tape power
cables are bundled
correctly.
308
Setup the paper
according to the
User’s Guide.
• If the surrounding
area of the pressure
roller is
contaminated by
paper dust and
waste paper, wipe it
with a soft
dampened cloth.
• If the surrounding
area of the pressure
roller is
contaminated by
paper dust and
waste paper, wipe it
with a soft
dampened cloth.
• The cores of the
head tape power
cables should be
aligned for each
head and taped
together with
double-sided tape.
• Bundle the CR
tape power cables
so that they do not
move.
→ User’s Guide
→ User’s Guide
→ User’s Guide
→ Replacing the
print head assembly
and head tape
power cable.
→ Replacing the
steel bearer, tube
guide, CR tape
power cable and ink
tube.
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Rockhopper II series printers – Maintenance Manual
9.3.4. Problems relating to noise
No.
1
Phenomenon
There is noise when the paper is
loaded.
2
You hear some noise during
printing wait.
3
You hear some noise when the
head is moving from side to
side.
Check point
(1) Check the
surroundings of the
suction fan
assembly for
obstructions and
foreign objects.
(2) Check the
cables for damage
and make sure that
the connector
connections are
good.
(3) The suction fan
assembly may have
failed.
(4) The Mainboard
assembly may have
failed.
Action
• Remove
obstructions and
foreign material.
Refer to
→ Replacing the
suction fan
assembly.
• If damage is
found, replace the
appropriate parts.
-
• Replace the
suction fan
assembly.
• Replace the
Mainboard
assembly
(5) The power
supply board
assembly may have
a problem.
(1) Check the area
where there is noise
from for obstruction
and foreign
materials.
(1) Check if the high
pitch sound emitted
while ink is
discharging during
printing, is not
confused with the
noise.
(2) Check the
screws on the cover
for looseness that
causes noise.
(3) Check if rattles
are heard when the
carriage is moving
from side to side.
• Replace the power
supply board
assembly.
→ Replacing the
suction fan
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly
→ Replacing the
power source board
assembly.
309
• Remove the
obstructions and
foreign materials.
-
• Follow the
descriptions in the
specifications.
-
• Re-tighten the
screws.
→ Removing the
cover.
• Clean the dust
from the carriage
bearings and roller
guide. When the
roller guide has
been cleaned, apply
a light coat of
grease on the roller
guide using a cloth
soaked in grease
spray.
• Replace the CR
cursor assembly.
→ Replacing the CR
cursor assembly
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
(4) Check the CR
cables for noise.
(5) Make sure that
the CR_ENC
assembly and the T
fence are not
interfering.
4
You hear some noise when the
paper is fed.
(6) Check the
bearings of the CR
driven pulley for
noise.
(7) Check if the
tension of the steel
belt has been
properly adjusted.
(8) Check the CR
motor assembly for
noise.
(9) Check the cursor
roller of the CR
cursor assembly for
noise.
(1) Check the PF
reduction belt for the
skipping of teeth
between the belt
and PF reduction
pulley.
(2) Check the PF
motor assembly for
noise
(3) Check the grid
roller for rugged
movement. Also,
check the rotary
movement for
irregularities.
310
• Correct the cable’s
tendency and fix the
condition.
• If noise is heard
from between the
steel bearing and
tube guide, replace
the tube guide.
• If interference is
observed, adjust the
installation positions
of the appropriate
components.
• If the adjustment
does not improve
this, replace the
appropriate
components.
• Replace the CR
driven pulley
assembly.
→ Replacing the
steel bearer, tube
guide, CR tape
power cable and ink
tube.
• Adjust the steel
belt tension.
→ Steel belt tension
adjustment.
• Replace the CR
motor assembly.
→ Replacing the CR
motor assembly.
• Replace the cursor
roller.
→ Replacing the
cursor roller
assembly.
• Replace the PF
reduction belt.
→ Replacing the PF
motor assembly
• Replace the PF
motor assembly.
→ Replacing the PF
motor assembly
• If foreign materials
such as paper dust
and waste paper are
found on the grid
rollers, remove it
using a nylon brush.
→ User’s Guide.
→ Replacing the T
fence
→ Replacing the
CR_ENC assembly
→ Replacing the CR
slave pulley
assembly.
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Rockhopper II series printers – Maintenance Manual
9.3.5. Problems relating to the paper cutting operation
No.
1
Phenomenon
The cutting operation
is not performing
correctly.
Check point
(1) Check the operation panel
and make sure that the media
cutting setting is not set to off
or manual.
(2) Check the operation panel
and make sure that PaperDet.
has not been set to
TakeUpRoll.
(3) Check the cutter grooves
for accumulated paper dust
and clips.
(4) Is the cutter cap securely
installed?
(5) Check the cutter’s up and
down sliding operation.
(6) Check if the cutter drops to
the bottom end under its own
weight when the cutter is
installed without the cutter
spring.
(7) Check the up and down
operation
of the solenoid via “Life/Cutter”
of the
self-diagnostic function.
a) The solenoid moves up and
down:
check the cutter’s down
position
relative to the cutter groove.
311
Action
• Change the
setting.
Refer to
→ User’s Guide
• Change the
setting.
→ User’s Guide
• Remove the
accumulated paper
dust along the
direction of the
grooves.
• Reset the cutter
cap securely.
• If it does not rise :
go to step 4
• if it rises : go to
step 5
• 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,
replace the cutter
holder.
→ User’s Guide
OK :
The cutter’s service
life has exceeded or
the cutter is
damaged. Replace
the cutter.
NG :
Adjust the position
of the cutter holder.
→ User’s Guide
→ Cutter adjustment
→ User’s Guide
-
→ Replacing the
cutter holder, cutter
spring, cutter cap,
solenoid assembly
and solenoid spring.
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
b) It does not move up or
down.
(8) Open CR cable, faulty
solenoid assembly, faulty
board assembly, etc. may be
the causes.
2
Cutting has been
performed during
printing.
(1) Check if the paper (output)
size on the application side is
correct.
(2) The program ROM may
have failed.
(3) Check the CR cables for
skewed insertion.
(4) The CR board may have a
problem.
(5) The Mainboard may have a
problem.
312
• The connectors
may have poor
contacts.
Check the
connections of the
following
connectors.
• CR board : J235
• CR board : J201J216
• Mainboard : J137J152
• Replace the CR
tape power cables.
• Replace the
solenoid assembly
• Replace the CR
board assembly
• Replace the
Mainboard
assembly
• Correct the paper
(output) size on the
application side.
• Upgrade the
firmware version.
• Check the
connections of the
following
connectors.
• CR board : J235
• CR board : J201J216
• Mainboard : J137
– J152
• Replace the CR
board.
• Replace the
Mainboard .
→ Replacing the CR
board assembly
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly
→ Replacing the
steel bearer, tube
guide, CR tape
power cable and ink
tube.
→ Replacing the
cutter holder, 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
→ Firmware
installation
→ Replacing the CR
board assembly
→ Replacing the CR
board assembly
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
3
4
The cutting operation
is in process, but the
paper has not been
cut.
The paper has not
been cut as smoothly
as expected,
resulting in jamming.
(1) Check the cutter blade for
shipping and deterioration.
• Replace the cutter.
→ User’s Guide
(2) Check if the cutter cap is
securely installed.
• Reset the cutter
cap securely.
→ User’s Guide
(3) Check if the cutter moves
up and down smoothly.
(4) Check the cutter grooves
for accumulated paper dust
and slips.
• Reinstall the cutter
spring.
• Remove the
accumulated paper
dust along the
direction of the
grooves.
• Make adjustments.
-
(5) Check if the cutter blade is
parallel with the groove.
5
6
The cutting operation
is in process but the
paper does not fall
off.
(1) The sub-platen (cutter
groove) requires daily
maintenance.
(2) The sub-platen, paper
guide or the paper may be
charged with static electricity.
Inaccurate paper
cutting
(1) Check the cutter blade for
chipping and deterioration.
(2) Has the cutter cap been
securely installed?
(3) Check if the cutter moves
up and down smoothly.
(4) Check the cutter grooves
for accumulated paper dust
and slips.
(5) Check if the cutter blade is
parallel with the groove.
7
Cutting starts after
the completion of the
print.
(6) The cutter may have a
problem.
(1) Check the operation panel
and make sure the InkDryTime
has not been set.
(2) Check the LCD and see if
messages for an analysis have
been displayed.
313
→ User’s Guide
→ Replacing the
cutter holder, cutter
spring, cutter cap,
solenoid assembly
and solenoid spring.
• Clean the surface
of the sub-platen
• Provide a proper
ground.
• Check and adjust
the ambient
humidity so that it
meets the normal
operation conditions
of the product and
paper.
• Replace the cutter.
-
• Reset the cutter
cap securely.
• Reinstall the cutter
spring.
• Remove the
accumulated paper
dust along the
direction of the
grooves.
• Make adjustments.
→ User’s Guide
• Replace the cutter.
→ User’s Guide
→ User’s Guide
→ Replacing the
cutter holder, cutter
spring, cutter cap,
solenoid assembly
and solenoid spring.
→ User’s Guide
• Change the
settings.
→ User’s Guide
• Printing data
remains.
→ User’s Guide
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
9.3.6. Problems relating to online and functions
No.
1
Phenomenon
Online has not been
properly established
by Centronics.
Check point
(1) Check the
Centronics settings in
the operation panel.
(2) Replace the
interface cables and
see if errors still occur.
(3) The program ROM
may have failed.
(4) The Mainboard
assembly may have a
problem.
2
3
4
5
6
Online has not been
properly established
by the network.
Scaling is not
functioning correctly.
Mirroring is not
functioning correctly.
Other functions are
not performing
correctly.
The printing position
has been misaligned.
(1) Check if the cables
in use for connections
are correct.
(2) Check the network
settings in the
operation panel for
problems.
(1) The program ROM
may have failed.
(2) The Mainboard
assembly may have a
problem.
(1) Check if CW
adjustments are made
correctly.
(2) Check the top &
bottom adjustments
(3) The program ROM
may have failed.
(4) The Mainboard
assembly may have a
problem.
314
Action
• Change the setting.
Refer to
→ User’s Guide
• Trouble such as an open
interface cable or cables
that are too long may
cause communication
failure. An instruction must
be given so that only
cables compliant with the
standard are used.
• Upgrade the firmware
version.
• Replace the Mainboard
assembly.
-
• Use 100BASE-T cross
cables for direct
connections to the host.
• Use 100BASE-T straight
cables for connections
using HUBs.
• Reset the settings upon
confirmation by an network
administrator.
• Upgrade the firmware
version
• Replace the Mainboard
assembly
• Make adjustments.
• Make adjustments.
• Upgrade the firmware
version
• Replace the Mainboard
assembly
→ Firmware
installation
→ Replacing the
Mainboard assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and cooling
fan assembly
-
→ User’s Guide
→ Firmware
installation
→ Replacing the
Mainboard assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and cooling
fan assembly
→ CW adjustment
menu
→ Top & Bottom
adjustment menu
→ Firmware
installation
→ Replacing the
Mainboard assembly,
HDD_Extension
board assembly,
HEAD_ DRV board
assembly and cooling
fan assembly
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
7
8
A portion of the data
has not been drawn
(is missing).
Garbled characters or
printings are
produced.
(1) The program ROM
may have failed.
• Upgrade the firmware
version.
→ Firmware
installation
(2) Check the T fence
for contamination and
bends.
• If contaminated with
grease and dusts, wipe
with a dry cloth.
• If contaminated with ink,
wipe with a lightly
dampened cloth and then
with a dry cloth.
•If contamination is severe,
replace the T fence.
• Make sure that the
connections of Mainboard
assembly connector J132
are good.
• Replace the T fence.
• Replace the CR_ENC
assembly.
• Replace the CR motor.
• Replace the CR_BASE
board assembly.
• Replace the CR tape
power cables.
→ Replacing the T
fence
(3) Check the
“Encoder:PF” via
“Test: Encoder” of the
self-diagnostic function
9
After printing has
been completed, the
paper is fed an extra
amount.
(4) The Mainboard
assembly may have a
problem.
• Replace the Mainboard
assembly
(1) The program ROM
may have failed.
(2) The Mainboard
assembly may have a
problem.
• Upgrade he firmware
version.
• Replace the Mainboard
assembly
315
→ 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.
→ Replacing the
Mainboard assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and cooling
fan assembly
→ Firmware
installation
→ Replacing the
Mainboard assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and cooling
fan assembly
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
9.3.7. Other problems
No.
1
Phenomenon
A hang up occurs
Check point
(1) The internal
process operation of
the Mainboard
assembly may be
malfunctioning.
(2) The Mainboard
assembly may have
a problem.
2
The power has been cut off
during the printing operation.
(1) Make sure that
the power cables
are not
disconnected.
(2) Check the power
cables for a shorted
condition.
(3) Check for
leakage.
316
Action
• Check the
operation again
after initializing
parameters and reinputting and readjusting them.
• Replace the
Mainboard
assembly.
• Securely connect
the power cables.
• Check the
condition using a
tester.
• Check the cables
for peeled off
insulation and
contact with the
case.
Refer to
→ Parameter
backup
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly
-
-
AP-74065, Rev. 1.2, 27/09/04
Rockhopper II series printers – Maintenance Manual
10. APPENDIX
10.1. INTRODUCTION
This chapter provides referential information such as service data and exploded views.
10.2. WIRING DIAGRAM ROCKHOPPER II 2H
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10.3. WIRING DIAGRAM ROCKHOPPER II 4H
10.4. ROCKHOPPER II : SERVICE PARTS LIST/EXPLODED
VIEWS/CONFIGURATION DIAGRAMS
This section includes the service parts list, exploded views of respective units and configuration diagrams.
Notes :
¾ For the latest ‘exploded views’ and ‘part description’, please refer to the spare part
lists of the printer.
¾ The latest exploded views are available separately from the manual.
¾ For spare parts, please refer to the latest spare part list.
¾ Specifications are liable to changes without prior notice.
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MUTOH INDUSTRIES LTD.
Tel.:81-(0)3-54867145
Fax.:81-(0)3-54867163
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