Falcon Outdoor Maint Man PDF

MAINTENANCE
MANUAL
Eco-Solvent Inkjet Printer
Rockhopper 46/62
Rockhopper: AP-74016, Rev:1.0
Introduction
This equipment is Class 1 communications equipment (communications equipment
to be used in commercial and industrial areas) and conforms to Voluntary
Communications Control Institute (VCCI) standards for data processing and other
equipment for the prevention of radio wave interference in commercial and industrial
areas.
Therefore, if it is used in or near a residential area, it may cause interference with
radio and television reception.
It should be used correctly in accordance with the operation manual.
Concerning interference with reception
Since this product emits weak radio waves, if it is not installed and used correctly
and is thought to be causing interference with radio and television reception, this
may be prevented by trying a combination of the following measures:
Try changing the orientation of the receiving antenna and feeder.
Try changing the orientation of this product.
Change the distance between the receiver and this product.
Try using different power supply systems for the receiver and this product.
Trademarks included in this manual
MUTOH, Model Name:Rockhopper-46/62, MH-GL, MH-GL/2, MH-RTL
are trademarks or trade names of Mutoh Industries Ltd.
HP, HP-GL, HP-GL/2, HP-RTL, HP759X, HP758X, C2848 are trademarks or
trade names of the Hewlett Packard Company.
Centronics and Bitronics are trademarks or trade names of the Centronics Data
Computer Company.
Windows 3.1, Windows 95, Windows NT 3.51, Windows NT 4.0, MS-DOS are
trademarks or trade names of the Microsoft Corporation
Other names of products and companies are the trademarks or trade names of
each relevant company.
Model Name: Rockhopper-46/62
CON1000
This manual contains basic technical details necessary for marketplace servicing to
maintain product quality and performance of Model Name:Rockhopper-46/62 printer.
Model Name:Rockhopper-46/62 printer is equipped with a self-diagnostic program
that will be of service for adjusting and checking whenever a fault is detected or
during maintenance.
This manual contains all the basic items but actual maintenance work should be
undertaken only after a thorough understanding of the functions, operations and
movements has been gained from the operation manual and by other means.
Please note that there may be occasions where the name of a part used in the
explanation in this manual differs from the name of that same part that is used in the
operation manual or in the parts list.
CAUTION:
The details of this product and the contents of this manual are
protected by copyright held by this Company and, except for
legitimate use by individuals, unauthorized copying, reproduction
or distribution in whole or part is forbidden.
Details contained in this manual may be subject to future alteration
without notice.
Details contained in this manual are believed to be correct but
please contact this Company or a dealer if an error is suspected
or a point is not clear.
In no event will this Company be responsible for the consequences
of using this product or this manual.
Published by Mutoh Europe,

Archimedesstraat 13, 8400 Oostende Belgium
Copyright February 2002, Mutoh Europe All rights reserved.
Introduction
Model Name:Rockhopper-46/62
CON1000
Some Thoughts on Maintenance Work

1. Algunas ideas sobre el trabajo de Mantencinn
La mantencion cae en dos categorias, Full mantencion y mantencion preventiva
, both of which are aimed at stable operation of the equipment that has been delivered to the user.
Las posibilidades de mantencion deben considerar.
In principle, fault maintenance and protective maintenance are both carried out by the
one person.
Both fault maintenance and protective maintenance involve the bringing of maintenance
parts.
The cooperation of the user/operator is used effectively.
CON1010
4. The need for user/operator cooperation

! CAUTION: The user cannot be compelled to do the following!
Asking the user/operator to cooperate is not a matter of having the user do the maintenance for you but it is necessary in order to have the equipment working more efficiently
and for having faults rectified quickly.
Actually, even when you do ask for the users cooperation, instead of a simple acknowledgement you will usually get doubts and quibbles such as Im paying for maintenance,
Im not familiar with the equipment and it only benefits the manufacturer.
However, you must try to persuade the user/operator to cooperate by explaining that doing
daily inspections will give better printing quality and giving you all the fine details of a fault
2. Protective maintenance work
La mantencion periodica esta designed to provide the user con mas estabilidad operation of the means that the fault will be rectified quickly.
equipment and involves the periodic cleaning and replacement of replacement parts. Basic
The following explains the items you need in order to understand fault conditions in detail:
ideas on protective maintenance include:
Check error messages
Adhere strictly to preventive maintenance periods.
Check users usage conditions
In a case of carrying out preventive maintenance, gain the approval of the user before Output from diagnostic pattern
hand.
Output from setup lists
Dont press preventive maintenance on the user.
Retest after changing settings
Probability of recovery by implementing daily inspections.
3. Fault maintenance work
A fault will hold up the users work and must be remedied quickly. The following are some
basic ideas on fault maintenance:
3-1
If it is not solved by the primary consultation, take the necessary maintenance items
and make an on-site visit.
Assemble the necessary maintenance parts from the matrix map
At the users premises, first check the symptoms.
Proceed with maintenance work in accordance with the fault tracing procedure.
After the repair work is finished, be sure to check again by testing in accordance
with the test procedure.
3-2
If repair is not possible even though all the work has been done in accordance with
the fault tracing procedure:
Contact the Sales Support Groups in your local distributor.
CON1010
Precautions For Maintaining This Printer

PRECAUTION 1
Head Cleaning
Head cleaning (see REP1620) must be carried out when this printer is to be transported by truck (see CON6000) and when the following parts are to be replaced.
< Replacement parts > Head, Damper, Head Cable, Cartridge Frame Assembly,
Ink Tubes
PRECAUTION 2
Head Cleaning Jig
When the head cleaning jig is to be used, fill the jigs 100 cc bottle with at least 50
cc of cleaning fluid and use it with the cap loosened.
If head cleaning is done with the cap tightened, ink will flow back into the 100 cc
bottle.
When you have finished head cleaning, return the remaining cleaning fluid from the
100 cc bottle to the 500 cc cleaning fluid bottle (JD-42054).
PRECAUTION 3
Printing After Initial Filling
On rare occasions, printing quality may be unstable if printing is carried out immediately after initial filling.
If this occurs, switch off the power and wait for at least 30 minutes before trying to
print again.
PRECAUTION 4
PRECAUTION 5
CON2000
Maintenance Unit Tubes
If you can not lower the maintenance unit cap assembly and the cap assembly and
pump assembly have been replaced:
When the two tubes from the pump assembly are being connected to the cap
assembly, turn them clockwise through 45 to 90 degrees as you insert them.
PRECAUTION 6
Take Care When Inserting Head Cable and Y Cable
When the print head assembly, head board assembly and main board assembly
have been replaced, be careful to insert the head cable and Y cable straight to the
back and dont forget to lock the connectors.
(The connectors fitted with locks are J207 and J208 on the head board.)
If the cables are inserted obliquely or power is applied without locking the connectors, there is a risk that the main board assembly may be damaged and it will be
impossible for ink to be ejected.
PRECAUTION 7
Ink and Cleaning Fluid Conduct Electricity
Ink and cleaning fluid will conduct electricity.

If there is ink or cleaning fluid on the connectors of the head or head cables when
power is applied, there will be a short circuit which may lead to all sorts of damage.
If there is ink on the contacts of the connector, wipe it off with alcohol or ethanol and
allow to dry thoroughly before reconnecting.
Thorough Waste Fluid Bottle Replacement
When the following tasks have been carried out,drain the waste fluid bottle.
1. After head cleaning and initial filling.
2. When it was not possible to capture main board assembly backup parameters.
CON2000
Contents
Rockhopper-46
3
Contents
CON3000
Rockhopper-62
Introduction
CON 1000
CON 1000
CON 1010
CON 1010
CON 2000
CON 2000
Contents
CON 3001 ~ 3
CON 3007 ~ 9
How to use the Maintenance Manual
CON 4000
CON 4000
Trouble-Shooting Lists
TRB 0000
TRB 0000-3
Matrix Map
MAP 0000
MAP 0000-3
Fault-Tracing Procedure
EXA 0000
EXA 0000-3
Replacement and Adjustment Procedures
REP 0000
REP 0000-3
Fundamental Knowledge
GID
0000
GI D 0000-3
Stored Test Patterns
PAT 0000
PAT 0000-3
Self-Diagnosis Functions
BAC 0000
BAC 0000-3
Maintenance Parts
CAT 0000
CAT 0000-3
CON3000
Model Name: Rockhopper-46
CON3001
Rockhopper 46 inch
When Message is Displayed
- How to Use LEDs to Check CPU System and Mechanical System Faults
When Message is not Displayed
- Initialization, Media Feed, Printing
- Noise, Media Cutting, Online, Others
Matrix Map
- Printer Status Messages
- Data Errors
- Command Errors
- CPU System Faults
- Mechanical System Faults
TRB0000
TRB1000
TRB1001
TRB2000
TRB2001
MAP0000
MAP1000
MAP1200
MAP1250
MAP1500
MAP1700
- Data Errors
- Command Errors
- CPU System Faults
EXA1000~
EXA1200~
EXA1250~
EXA1500~
EXA1700~
Heater System Faults
EXA1800

- Trouble with Initialization
- Trouble with Media Feed
- Trouble with Printing
- Problem Involving Noise
- Trouble with Media Cutting
- Online/Function Problems
- Others
Heater System
- Other
Heater System
Rockhopper-46
3 Contents 1
EXA0000
EXA2000~
EXA3000~
EXA4000~
EXA5000~
EXA6000~
EXA7000~
EXA8000~
EXA9000
MAP2000
MAP3000
MAP4000
MAP5000
MAP6000
MAP7000
MAP8000
MAP9000
Rockhopper-46
3 Contents 2
CON3002

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

Y Return Pulley Assembly
Cartridge Frame Assembly
Ink ID Sensor Assembly
Detector Assembly
Y Cable
Ink Tubes
Cutter Solenoid Assembly
Print Head Assembly, Head Cable
REP
REP
REP
REP
REP
REP
REP
REP
REP
1310
1320
1330
1340
1350
1360
1370
1380
1390
Edge Sensor Assembly

Head Board Assembly
Dampers
Cursor Assembly
Origin Sensor Assembly, Y Encoder
REP
REP
REP
REP
REP
1410
1420
1430
1440
1450
Junction Board Assembly
REP 1470
How to Adjust the Platen Height
REP 1520
XR Cable Assembly (Rear Paper Sensor)

Pressure Assembly, Pressure Roller and Blade
Pump Motor Assembly
Cap Assembly
Wiper
Pump Assembly
Maintenance Station Assembly
Y Motor Assembly
Steel Belt
T Fence Assembly
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
Tubes Guides Assemblies

How to Adjust Steel Belt Tension
How to Adjust X Speed Reduction Belt Tension
How to Adjust the Tilt of the Print Head
REP
REP
REP
REP
How to Capture and Install Backup Parameters

How to Install a Program (Software Upgrade)
REP 1590
REP 1600
Head Cleaning Procedure

How to Clean the Head Nozzle Face
REP 1620
REP 1660
Speed Reduction Pulley Assembly

Grid Roller Assembly
REP 1680
REP 1690
F Absorbent Assembly
REP 1700
Front / Rear Heater (or heater sensors)
Rockhopper-46
3 Contents 2
1200
1220
1230
1240
1250
1260
1270
1280
1290
1300
(refer to)RE P 1040
1540
1550
1560
1570
CON3002
Rockhopper-46
3 Contents 3
Basic Specifications
System Block Diagram
Operating Sequence
- Power On Sequence
- Power Off Sequence
- Media Detection Sequence
- Normal Standby Sequence
- Encoder Disconnected Check Sequence
- Origin Detection Sequence
- Media Cutting Sequence
- Printing Sequence (Including Flushing)
GID0000
GID1000
GID3000
GID4010
GID4020
GID4030
GID4040
GID4050
GID4060
GID4070
GID4080

Presentation Pattern
Print quality adjustment pattern
Setup List
PAT0000
PAT1000
PAT3000
PAT4000
BAC0000
Examination
- Memory (RAM) Capacity
- Version
- Panel
- Sensors
- Encoders
- Fans
- Ethernet Board
- History: Last error message
- History: Head nozzle ejection count check
- Head Waveform
BAC1000
BAC1010
BAC1020
BAC1030
BAC1040
BAC1050
BAC1060
BAC1065
BAC1070
BAC1070
BAC1080
Adjustment
- Capping Position Adjustment
- Skew Verification
BAC2000
BAC2010
BAC2030
Rockhopper-46
3 Contents 3
Head Rank Input (Include Initial filling)

Head Nozzle Verification
Left Head Tilt Verification
Right Head Tilt Verification
Repeatability Printing Positioning
CW Adjustment
Flush Pointer Adjustment
Media Feed Distance Compensation
Margin Adjustment
Rear Sensor Position Adjustment
Test Print
Head Wash
CON3003
BAC2040
BAC2050
BAC2060
BAC2070
BAC2080
BAC2090
BAC2110
BAC2120
BAC2130
BAC2140
BAC2150
BAC2160
Cleaning
- Normal
- Powerful
BAC3000
BAC3000
BAC3000
Test Printing
- Head Printing Verification
- Adjustment Parameters
BAC4000
BAC4000
BAC4000
Parameters
- Initialize
- Update
BAC5000
BAC5010
BAC5020
Aging
- Carriage Motor
- Media Feed Motor
- Cutter
- Maintenance Unit
- Head
BAC6000
BAC6010
BAC6020
BAC6030
BAC6040
BAC6050
Maintenance Parts
Maintenance Parts List
Maintenance Tool List
Lubrication Points
Exploded View Drawing
CAT0000
CAT1000
CAT2000
CAT4000
CAT5000
CON3003
Rockhopper-62 Contents 1
Rockhopper
CON3007
62 inch
- How to Use LEDs to Check CPU System and Mechanical System Faults
- Initialization, Media Feed, Printing
- Noise, Media Cutting, Online, Others
Matrix Map
- Data Errors
- Command Errors
- CPU System Faults
- Other
Heater System
TRB0000-3
TRB1000
TRB1001
TRB2000
TRB2001
MAP0000-3
MAP1000
MAP1200
MAP1250
MAP1500
MAP1700-2
MAP2000-2
MAP3000-2
MAP4000-2
MAP5000
MAP6000
MAP7000
MAP8000
-
Data Errors
Command Errors
CPU System Faults
Mechanical System Faults
EXA1000~
(1020-2)
EXA1200~
EXA1250~
EXA1500~
EXA1700~
EXA1800-2

EXA0000-3
Problem Involving Noise

Trouble with Media Cutting
Online/Function Problems
Others
Heater System
EXA2000~
(2070-2)
EXA3000~
(3000-2)
EXA4000~
(4050-2)
(4100-2)
(4130-2)
EXA5000~
EXA6000~
EXA7000~
EXA8000~
(8050-2)
EXA9000-2
MAP9000
CON3007
CON3008
REP0000-2

Front Cover
Panel Cover, Y Rail Cover
Left Side Cap and Right Side Cap
Control Box
Head Cover
X Motor Assembly
Switch Cable Assembly, DC Cable Assembly
Main Board Assembly
Panel Board Assembly
Panel Cable
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
1010
1020
1030
1040-2
1041
1050
1060
1070
1080-2
1090
1100
1110
1120
1130
1140
1150
1160
1170
1180
Cursor Plate Spring, Steel Flexible Guide Assembly

Detector Assembly
Y Cable
Ink Tubes
Print Head Assembly, Head Cable
REP
REP
REP
REP
REP
REP
REP
REP
REP
1310-2
1320
1330
1340
1350
1360-2
1370-2
1380
1390
Edge Sensor Assembly

Head Board Assembly
Dampers
Cursor Assembly
Origin Sensor Assembly, Y Encoder
REP
REP
REP
REP
REP
1410
1420
1430
1440
1450
REP 1470
REP 1520

Pump Motor Assembly
Cap Assembly
Wiper
Pump Assembly
Y Motor Assembly
Steel Belt
T Fence Assembly
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
1200
1220
1230
1240
1250
1260
1270
1280
1290
1300
Tubes Guides Assemblies

How to Adjust the Tilt of the Print Head
REP
REP
REP
REP

REP 1590
REP 1600

REP 1620
REP 1660
Speed Reduction Pulley Assembly

REP 1680
REP 1690
F Absorbent Assembly
Waste Fluid Bottle Assembly
REP 1700
REP 1710
Front / Rear Heater (or heater sensors)
(refer to)RE P 1040-2
1540-2
1550
1560
1570
CON3008
Operating Sequence
- Power On Sequence
- Power Off Sequence
- Media Detection Sequence
- Normal Standby Sequence
- Encoder Disconnected Check Sequence
- Origin Detection Sequence
- Media Cutting Sequence
- Printing Sequence (Including Flushing)
GID0000-3
GID1000-3
GID3000
GID4010
GID4020
GID4030
GID4040
GID4050
GID4060
GID4070
GID4080

Presentation Pattern
Setup List
PAT0000-3
PAT1000
PAT3000
PAT4000
BAC0000-3
Examination
- Memory (RAM) Capacity
- Version
- Panel
- Sensors
- Encoders
- Fans
- Ethernet Board
- History: Last error message
- History: Head nozzle ejection count check
- Head Waveform
BAC1000
BAC1010
BAC1020
BAC1030
BAC1040
BAC1050
BAC1060
BAC1065
BAC1070
BAC1070
BAC1080
Adjustment
- Capping Position Adjustment
- Skew Verification
BAC2000
BAC2010
BAC2030
Head Rank Input (Include Initial filling)

CW Adjustment
Margin Adjustment
Rear Sensor Position Adjustment
Test Print
Head Wash
CON3009
BAC2040
BAC2050
BAC2060
BAC2070
BAC2080
BAC2090
BAC2110
BAC2120
BAC2130
BAC2140
BAC2150
BAC2160
Cleaning
- Normal
- Powerful
BAC3000
BAC3000
BAC3000
Test Printing
- Head Printing Verification
- Adjustment Parameters
BAC4000
BAC4000
BAC4000
Parameters
- Initialize
- Update
BAC5000
BAC5010
BAC5020
Aging
- Carriage Motor
- Media Feed Motor
- Cutter
- Maintenance Unit
- Head
BAC6000
BAC6010
BAC6020
BAC6030
BAC6040
BAC6050
Maintenance Parts
Lubrication Points
Exploded View Drawing
CAT0000-3
CAT1000-3
CAT2000
CAT4000
CAT5000
CON3009
CON4000

Como usar el Manual de Mantenimiento
l
CON4010
How to use the Trouble-Shooting Lists (TRB)
CON4020
How to use the Matrix Map (MAP)
CON4040
How to use the Fault-Tracing Procedure (EXA)
CON4050
Procedimiento de Reemplazo y Ajustes (REP)
CON4060
CON4000
CON4010
Fault maintenance work procedures and how to use the Maintenance Manual
When a user reports an equipment fault, use the following procedure to carry out fault recovery tasks.
A fault occurs
Task
Page
Details
Reference Materials
Check fault circumstances, Trouble-Shooting List

select fault details from
TRB
Check circumstances by fax or telephone. Check error

messages, check user usage conditions, retry after changing settings, output
diagnostic pattern, etc. Select fault symptoms produced by user from
the Trouble-Shooting List.
Conduct a primary
consultation with the user
Conduct a consultation by fax or telephone.

Check possibility of user error or recovery by daily inspection. Check error
messages, check user usage conditions, output diagnostic pattern, output
setup list. Retry after changing settings, etc.
Manual de Operaciones, Conocimiento

basico, Cuidados diarios, Mantencion periodica/
inspeccion/Limpieza
If you are unable to resolve the fault at this point, take the necessary maintenance parts and make an on-site visit.
Task
Page
Details
Reference Materials
Gather the necessary

maintenance parts
Matrix Map
MAP
Gather the necessary maintenance parts
Maintenance Parts list, Maintenance Tools list,

Exploded views
Conduct a tracing inquiry
Fault Tracing Procedures

EXA
Conduct an inquiry to trace the cause of the fault
Basic knowledge
Replace parts and adjust
Replacement and Adjustment

Procedures REP
Replace or readjust parts suspected to be faulty.

Carry out adjustments after replacing parts.
Basic knowledge
Final check
Separate causes of faults and check operation after faults have been
rectified.
CON4010
CON4020
1. How to look up trouble-shooting tables

When a user has reported a fault, first select the applicable details from the trouble-shooting lists (TRB) and jump to the specified primary consultation (ENT).
Faults are broadly classified as those which cause a message to appear in the printer LCD and those which do not.
For troubles that cause a message to be displayed, select the message as it is.
Troubles with no message display are classified into the 10 blocks shown below. First select the block then select the appropriate fault details from that block.
2. Definitions of groupings in the case of faults that produce no message display
TRB1000
Printer Status Messages, Data Errors, Command Errors

CPU System Faults, Mechanical System Faults
When Message is Not Displayed
TRB2000 to TRB2001
Trouble with Initialization:
Troubles that occur when unpacking immediately after delivery are grouped here.
Check this group for a similar trouble occurring other than immediately after delivery.
Troubles concerning the series of operations up to the enabling of printing are grouped here.
Trouble with Media Feed:
This group concerns problems with the media path.
Trouble with Printing:
This group concerns printing quality problems.

Printing precision problems are grouped here.
Problem Involving Noise:
Troubles that produce abnormal noise from the driving section.
Trouble with Media Cutting:
Cutter section problems are grouped here.
Online/Function Problems:
Online printing function problems.
Other:
Troubles concerning the series of operations up to the enabling of printing are grouped here.
Troubles involving driver software, consumable items, peripheral devices are grouped here.
CON4020
CON4040
When the primary consultation (ENT) has not revealed any anomaly, gather the necessary maintenance parts according to the matrix map (MAP) shown below and visit
the user.
Whether an error message is displayed
Names and drawing numbers of
required parts
EXA2000 to EXA2070
Problem
FaultTracing
Procedure
EXA No.
Replacement
and adjustment
procedure page
- Power supply does not come on

- LCD faulty (no display/erratic display)
- Initial filling of inks failed
- Initial filling is completed but no ink comes out
- After power is switched on, nothing works
- When power is applied, Initializing appears and then a reset is executed.
- After mounting media, initial operation fails
- Printer does not work even with the cover closed
- Printer does not stop even with the cover opened
- Ink cartridges are installed but not recognized
- Can not make entries from the operating panel
- Data is received but not plotted
- Media is not suction
Replacement and Adjustment Procedure REP. No.
1140
1160
1170
1110
1100
1410
1420
1200
1360
1130
1150
1130
1350
1350
1350
1350
1350
1350
1240
1260
1270
1390
1390
1120
1080
1080
1080
1080
1340
1340
1340
1340
1340
1340
1470
1470
Fault
details
2000
2000
2010
2020
2030
2030
2030
2030
2030
2040
2050
2060
2070
DF-41586 Main Board Assembly

DF-40097 Panel Board Assembly
DF-41617 Panel Cable
DF-41590 Cover Switch Assembly
DF-41589 Lever Sensor Assembly
DF-41595 Edge Sensor Assembly
DF-41588 Head Board Assembly
DF-41592 XR Cable Assembly (Paper Sensor R)
DF-41600 Y Cable
DF-41619 Switch Cable Assembly
DF-41587 Power Board Assembly
DF-41468 DC Cable Assembly
DF-41593 Detector 1 Assembly
DF-40106 Detector Assembly (Black)
DF-40107 Detector Assembly (Y)
DF-40146 Detector Assembly (M)
DF-40147 Detector Assembly (C)
DF-41602 Cap Assembly
DF-41603 Pump Assembly
DF-41604 Maintenance Station Assembly
DF-40690 Print Head Assembly (Colour)
DF-41601 Head Cable
DF-41591 Waste Fluid Box Sensor
DF-40173 Vacuum Fan Assembly
DF-41620 Fan Extension Cable 1 Assembly
DF-41609 INK ID Sensor 1 Assembly
DF-41615 INK ID Sensor Cable
DF-41536 Junction Board Assembly

[Trouble with Initialization]
Trouble with Initialization

Name and Diagram Number of
Replacement Part
Major classification
of fault details and
range of EXA
numbers
Major classification of fault details
Trouble with Initializatio
Model Name: 46
3
MAP2000
CON4040
CON4050
Gather the parts specified by the matrix map (MAP), visit the user and carry out the task of recovery in accordance with the fault-tracing procedure (EXA) shown below.
First, check again on-site that there was no mistake about the primary consultation. (EXA and ENT page numbers are the same)
Carry out the checking tasks in order, beginning with 1-1, and move to the next task if there is nothing abnormal. If an abnormality is revealed, carry out the task indicated by the arrow [].
Major classification of fault details
Whether an error message is displayed
When No Error is Displayed on the Printer's Liquid Crystal Display

No.
1
Fault details
Fault-tracing
sequence
Symptom
Initial filling is completed but no ink
comes out
(Initial filling means to fill the head
with ink to enable it to print.)
EXA2021
GO TO Ref. Pages
Items to be Confirmed
Sequence
1-10
Page specified by
matrix map (MAP)
R E P
Are there any breaks, cuts or air leaks in the ink tubes?
Change each ink tube, cleaning each time and checking that ink flows during cleaning.
1-11
Check that connectors J207 (HEAD C1) and J208 (HEAD C2) on the head board assembly, and
head cables on the print head are not inserted obliquely, and they are locked securely.
Insert the connectors again.
1-12
Is there a broken lead in head cables?

Replace head cables.
B A C
1370
1400
1-13
Is the print head assembly damaged?

Replace the print head assembly.
1-14
Is the head board assembly damaged?

Replace it.
1-15
Check that the Y cable connector is connected securely and not inserted obliquely.
Reconnect head board assembly connectors J201 (MAIN1) and J202 (MAIN2) and main board
assembly connectors J111 (HEAD1) and J112 (HEAD 2).
1-16
Is there a broken lead in Y cables?

Replace Y cables.
1-17
The main board assembly may be damaged.

Replace it.
Replacement and
adjustment procedure
(REP) page reference
Hidden diagnostic
procedure page
reference
1390
1420
1360
1140
CAUTION:
Power must be off when connectors are being disconnected or reconnected, otherwise you may be injured or a board may be damaged.
The main board assembly will certainly be damaged if power is applied
with main board assembly connectors J111 (HEAD) and J112 (HEAD2) and
head board connectors J201 (MAIN1) and J202 (MAIN2) inserted with
oblique FFP.
Page specified by
matrix map (MAP)
EXA2021
CON4050
How to use Replacement and Adjustment Procedure (REP)
CON4060
If the fault-tracing procedure (EXA) has produced a replacement task, carry out the work of replacement and adjustment in accordance with the replacement and adjustment procedure (REP) shown below.
If you dont know how to go about the removal of covers involved in replacing a part, refer to REP1010 to REP1060.
Page specified by
the fault-tracing
procedure (EXA)
Replacement and adjustment item
How to replace the Y Motor Assembly
Replacement
procedure
Item
If there is to be no replacement that

includes the Y motor assembly, steps 2, 4
and 5 are not necessary.
Screws
Replace the Y Motor Assembly

1. Remove the Left and Right Covers.
2. Remove the Rear Paper Guide.
3. Remove the Steel Belt.
4. Open the Control Box.
5. Disconnect connector J120 (YMOT) from the Main Board
Assembly.
6. Remove the Y Motor Assembly. (3 fastening screws)
7. Assembling is the reverse of the removal procedure.
Adjustment
procedure
and items to
be checked
REFERENCE
2. Adjustment
and
Examination
Procedure
REP1280
Replacement and Adjustment Procedure

REFERENCE
1. Replacement
Procedure
Y motor cable terminal
Since the Y Motor Assembly Cable passes below the Cartridge Unit, the work will
be easier if you remove the two Cartridge
Base screws and push it back.
1. Carry out the Steel Belt Tensioning Adjustment.
Y motor assembly
How to use Replacement and Adjustment Procedure (REP)
REP1280
Page specified by
the fault-tracing
procedure (EXA)
CON4060
Rockhopper-46
3 Trouble-Shooting Lists
TRB0000
TRB0000
Printer Status Messages
Data Errors
Command Errors
CPU System Faults
Heaters System Faults
How to Use LEDs to Check CPU System
and Mechanical System Faults
TRB1000
TRB1000
TRB1000
TRB1000
TRB1000
TRB1000
TRB1001

Trouble with Media Feed
Trouble with Printing
Others
Heater System
Rockhopper-43 Trouble-Shooting Lists
TRB2000
TRB2000
TRB2000
TRB2001
TRB2001
TRB2001
TRB2001
TRB2001
TRB0000-3
TRB0000-3
Data Errors
Command Errors
CPU System Faults
How to Use LEDs to Check CPU System
and Mechanical System Faults
TRB1000
TRB1000
TRB1000
TRB1000
TRB1000
TRB1000
TRB1001

Others
Heater System
TRB2000
TRB2000
TRB2000
TRB2001
TRB2001
TRB2001
TRB2001
TRB2001
Trouble-Shooting 1/3 (List of Faults)
TRB1000
Cover Open
Lever Up
Cover and Lever
Undefined Media
Media Skew Error
[User 1] Media End
Remove Media
Roll Media End
Media Cut Error
Not enough memory SIMM 12 MB
Insert Special Cartridge
[ ] Ink Low
[ ] No Ink
[ ] No Cartridge
Capping position not specified
Not Filled
No Waste Fluid Box
Wrong Ink Type
GO TO EXA No.
EXA1000
EXA1000
EXA1000
EXA1010
EXA1020
EXA1030
EXA1040
EXA1050
EXA1060
EXA1070
EXA1080
EXA1090
EXA1090
EXA1100
EXA1110
EXA1120
EXA1130
EXA1150
Network Detection Error

Network Initialization Error
EXA1230
EXA1230
EXA1250
EXA1250
EXA1250
EXA1250
EXA1250
MH01
MH02
MH03
MH04
MH07
Error
Error
Error
Error
Error
(Undefined Command)
(Parameter Error)
(Numerical Error)
(Undefined Character Set)
(Buffer Overflow)
Command Errors
Data Errors
Minor Faults
CPU System Faults
Cases where an error message is displayed on the liquid crystal display of the main printer unit
CPU System/Mechanical System Faults
GO TO EXA No.
EXA1500
E001 Error DRAM
(Standard DRAM error)
EXA1500
E002 Error Opt.DRAM
(Optional DRAM error)
EXA1510
E016CPUErr[00]
(Interrupt exception error)
EXA1510
E016CPUErr[02]
(Command boundary exception error)
EXA1510
E016CPUErr[03]
(Data boundary exception error)
EXA1510
E016CPUErr[04]
(Address error exception)
(Load or command fetch)
EXA1510
E016CPUErr[05]
(Address error exception) (Store)
EXA1510
E016CPUErr[06]
(Bus error exception) (Command fetch)
EXA1510
E016CPUErr[07]
(Bus error exception) (Data load)
EXA1510
E016CPUErr[08]
(System call exception error)
EXA1510
E016CPUErr[09]
(Break point exception error)
EXA1520
E016CPUErr[10]
(Reserved command exception error)
EXA1520
E016CPUErr[11]
(Unable to use coprocessor exception error)
EXA1520
E016CPUErr[12]
(Operation overflow exception error)
EXA1520
E016CPUErr[13]
(Trap exception error)
EXA1520
E016CPUErr[15]
(Floating point exception error)
EXA1520
E016CPUErr[22]
(Watch exception error)
EXA1520
E016CPUErr[32]
(Watchdog timeout exception error)
EXA1520
E016CPUErr[33]
(Abort error)
Error E237 Transfer memory (Transfer memory error/Transfer memory EXA1520
access error)
EXA1530
Error E129 NVRAM
E065
E069
E071
E073
E066
E070
E072
E074
E075
Error
Error
Error
Error
Error
Error
Error
Error
Error
X Motor
X Encoder
X Timeout
X Overcurrent
Y Motor
Y Encoder
Y Timeout
Y Overcurrent
Sensor Fault

EXA1700
EXA1700
EXA1700
EXA1700
EXA1710
EXA1710
EXA1710
EXA1710
EXA1720
EXA1800
TRB1000
How to Use LEDs to Check CPU System and Mechanical System Faults
When the printer stops working and nothing appears on the liquid crystal display (LCD),
a fault has probably occurred in the CPU system or the mechanical system.
In that case, open the control box and check the error by the LEDs on the main board assembly.
is on,
TRB1001
is off.
LED display
1 2 3 4 5 6 7 8
EXA page
Details of Error
Fallas Sistema CPU
FALLAS SISTEMA
MECANICO
E001 Error DRAM

E002 Error Opt.DRAM
E002 Error Opt.DRAM
E016CPUErr[00]
E016CPUErr[02]
E016CPUErr[03]
E016CPUErr[04]
E016CPUErr[05]
E016CPUErr[06]
E016CPUErr[07]
E016CPUErr[08]
E016CPUErr[09]
E016CPUErr[10]
E016CPUErr[11]
E016CPUErr[12]
E016CPUErr[13]
E016CPUErr[15]
E016CPUErr[22]
E016CPUErr[32]
E016CPUErr[33]
E237 Error Transfer memory
E129 Error NVRAM
E065
E069
E071
E073
E066
E070
E072
E074
E075
(Standard DRAM error)

(Optional DRAM 1 error)
(Optional DRAM 2 error)
(Interrupt exception error)
(Command boundary exception error)
(Data boundary exception error)
(Address error exception) (Load or command fetch)
(Address error exception) (Store)
(Bus error exception) (Command fetch)
(Bus error exception) (Data load)
(System call exception error)
(Break point exception error)
(Reserved command exception error)
(Unable to use coprocessor exception error)
(Operation overflow exception error)
(Trap exception error)
(Floating point exception error)
(Watch exception error)
(Watchdog timeout exception error)
(Abort error)
(Transfer memory error/Transfer memory access error)
Error X Motor
Error X Encoder
Error X Timeout
Error X Overcurrent
Error Y Motor
Error Y Encoder
Error Y Timeout
Error Y Overcurrent
Error Sensor Fault
How to Use LEDs to Check CPU System and Mechanical System Faults
EXA1500
EXA1500
EXA1500
EXA1510
EXA1510
EXA1510
EXA1510
EXA1510
EXA1510
EXA1510
EXA1510
EXA1510
EXA1520
EXA1520
EXA1520
EXA1520
EXA1520
EXA1520
EXA1520
EXA1520
EXA1520
EXA1530
EXA1700
EXA1700
EXA1700
EXA1700
EXA1710
EXA1710
EXA1710
EXA1710
EXA1720
TRB1001
Cases where no error message is displayed

on the liquid crystal display of the main printer unit

GO TO
EXA No.
No power
Faulty liquid crystal display (no display/unstable display)
Initial filling of inks failed
Initial filling is completed but no ink comes out
After power is switched on, nothing works
When power is applied, Initializing appears and then a reset is executed.
Media is mounted but the initialization operation is not done
Printer does not work even with the cover closed
Printer does not stop even with the cover opened
Ink cartridges are installed but not recognized
No se puede entrar al Panel de Operaciones
Data is received but not printed
Media is not suction
EXA2000
EXA2000
EXA2010
EXA2020
EXA2030
EXA2030
EXA2030
EXA2030
EXA2030
EXA2040
EXA2050
EXA2060
EXA2070
The media comes off when it is initialized or during printing

The media is skewed or meanders when it is initialized or during printing
The media becomes wrinkled when it is initialized or during printing
The media jams when it is initialized or during printing
The media tears when it is initialized or during printing
The media size is different after media mounting and initialization
Tracing paper and thin media cannot be detected
EXA3000
EXA3000
EXA3000
EXA3000
EXA3000
EXA3010
EXA3010
TRB2000

GO TO
EXA No.
No imprime en forma continua

There is an extra feed after printing is finished
Dots are missing from the printing
Cleaning does not cure blockage
No imprime nada
No imprime un color especifico
La superficie entera se imprime en negro
Printing becomes shaded
The image contains blurs
Transverse lines appear to be split
AParecen lineas blancas y negras en la impresion
Orillas de la impresion aparecen borrosas
Many satellites (unwanted dots)
The printing has whiskers
Printed lines appear blurred (printing is dirty)
Mixed colour lines do not overlap
Black and colour positions are offset
Inaccurate line length in the direction of head movement (Main scanning direction)
Inaccurate straight line in the direction of head movement (straightness)
Inaccurate line distance in the direction of media feed (Subsidiary scanning distance)
Inaccurate straight line in the direction of media feed (joining precision Y)
Bad right angle precision
EXA4000
EXA4010
EXA4020
EXA4020
EXA4030
EXA4030
EXA4040
EXA4050
EXA4050
EXA4050
EXA4050
EXA4060
EXA4070
EXA4070
EXA4070
EXA4080
EXA4080
EXA4090
EXA4100
EXA4110
EXA4120
EXA4130
TRB2000
GO TO
EXA No.
Abnormal noise when media is sucked down

Abnormal noise when standing by ready to print
Abnormal noise when head is moving left and right
Abnormal noise when media is fed
Abnormal noise when cutting
EXA5000
EXA5010
EXA5020
EXA5030
EXA5040
Does not cut normally

Cutting occurs during printing
The cutting operation is normal but the media is not cut
The cutting is bad and the media jams
The cutting operation is normal but the media does not fall out
Inaccurate media cutting
Cutting is delayed for some time after printing has ended
White paper is cut (Blank print)
EXA6000
EXA6010
EXA6020
EXA6020
EXA6030
EXA6040
EXA6050
EXA6050


Others
TRB2001
GO TO
EXA No.
Cannot connect normally with Centronics

Cannot connect normally with Network
The scale function does not work correctly
The rotate function does not work correctly
The mirror function does not work correctly
Other functions are not working correctly
Printing position is offset
Some data are not printed (omitted)
Text and printing data are garbled (extra lines appear)
There is an extra feed after printing is finished
EXA7000
EXA7000
EXA7020
EXA7020
EXA7020
EXA7020
EXA7030
EXA7040
EXA7050
EXA7060
The printer hangs up

Power shutdown during printing
The ink cartridges will not go in
Ink has overflowed from the waste fluid box
Ink overflows from flushing box
Ink is split around the X-rail
EXA8000
EXA8010
EXA8020
EXA8050
EXA8050
EXA8050
Sistema Calefactores
EXA9000
TRB2001
Rockhopper-46
3 Matrix Map
MAP0000
MAP0000
Matrix Map
Data Errors
Command Errors
CPU System Faults
Heaters Fault
MAP1000
MAP1200
MAP1200
MAP1500
MAP1700
MAP1800

Other
Heater System
Rockhopper-46
3 Matrix Map
MAP2000
MAP3000
MAP4000
MAP5000
MAP6000
MAP7000
MAP8000
MAP9000
Rockhopper-62 Matrix Map
MAP0000-3
MAP0000-3
Matrix Map
Data Errors
Command Errors
CPU System Faults
Heaters Fault
MAP1000-3
MAP1200
MAP1200
MAP1500
MAP1700-2
MAP1800-2

Other
Heater System
Rockhopper-62 Matrix Map
MAP2000-2
MAP3000-3
MAP4000-2, 4001-3
MAP5000-3
MAP6000-2
MAP7000-2
MAP8000-2
MAP9000-2

1470
1470
1690
1340
1340
1340
Problem

DF-41600 Y Cable
DF-40113 Cutter Solenoid Assembly
DF-41593 Detector1 Assembly
DF-41591 Waste Fluid Box Sensor Assembly
DF-41529 Pressure Assembly
DF-41530 Pressure Roller
DF-40127 Cartridge Frame Assembly
DF-41609 Ink ID Sensor1 Assembly
DF-41615 Ink ID Cable
DF-41840 Grid Roller Assembly
FaultTracing
Procedure
EXA No.
1000
1000
1000
1010
1020
1030
1040
1050
1060
1070
1080
1090
1090
1100
1110
1120
1130
1150
1340
1340
EXA1000 to EXA1150
1140
1160
1110
1170
1100
1410
1420
1200
1360
1380
1350
1350
1350
1350
1350
1350
1120
1220
1220
1330
1340

[Printer Status Display]

Replacement Part
Model Name: Rockhopper463
Model Name: Rockhopper463
MAP1000
- Cover open
- Lever up
- Cover & Lever
- Undefined Media
- Media Skew Error
- [User 1] Media End
- Remove Media
- Roll Media End
- Media Cut Error
- Not enough memory SIMM12MB
- Insert Special Cartridge
- [] Ink Low
- [] No Ink
- [] No Cartridge
- Capping position not specified
- Not Filled
- No Waste Fluid Box
- Wrong Ink Type
MAP1000

1470
1470
1690
1690
1340
1340
1340
FaultTracing
Procedure
EXA No.
1000
1000
1000
1010
1020-2
1030
1040
1050
1060
1070
1080
1090
1090
1100
1110
1120
1130
1150
DF-41600 Y Cable
DF-41591 Waste Fluid Box Sensor Assembly
DF-41530 Pressure Roller
DF-41615 Ink ID Cable
Problem
1340
1340
EXA1000 to EXA1150
1140
1160
1110
1170
1100
1410
1420
1200
1360-2
1380
1350
1350
1350
1350
1350
1350
1120
1220
1220
1330
1340

[Printer Status Display]

Replacement Part
Printer Status Messages Model Name: Rockhopper62
Printer Status Messages Model Name: Rockhopper62
MAP1000-3
- Cover open
- Lever up
- Cover & Lever
- Undefined Media
- Media Skew Error
- [User 1] Media End
- Remove Media
- Roll Media End
- Media Cut Error
- Not enough memory SIMM12MB
- Insert Special Cartridge
- [] Ink Low
- [] No Ink
- [] No Cartridge
- Capping position not specified
- Not Filled
- No Waste Fluid Box
- Wrong Ink Type
MAP1000-3
EXA1230 to EXA1250
Problem
MAP1200
Data Errors, Command Errors
MAP1200
- Network Detection Error

- Network Initialization Error
- MH01 Error (Undefined Command)
- MH02 Error (Parameter Error)
- MH03 Error (Numerical Error)
- MH04 Error (Undefined Character Set)
- MH07 Error (Buffer Overflow)
1140
FaultTracing
Procedure
EXA No.
1230
1230
1250
1250
1250
1250
1250
Data Errors, Command Errors

[Data Errors, Command Errors]

Replacement Part
EXA1500 to EXA1530
Problem
MAP1500
CPU System Faults
MAP1500
- E001 Error DRAM (Standard DRAM error)

- E002 Error Opt.DRAM (Optional DRAM error)
- E016 CPUErr[00] (Interrupt exception error)
- E016 CPUErr[02] (Command boundary exception error)
- E016 CPUErr[03] (Data boundary exception error)
- E016 CPUErr[04] (Address error exception load)
- E016 CPUErr[05] (Address error exception store)
- E016 CPUErr[06] (Bus error exception check)
- E016 CPUErr[07] (Bus error exception load)
- E016 CPUErr[08] (System call exception)
- E016 CPUErr[09] (Break point exception)
- E016 CPUErr[10] (Reserved command exception)
- E016 CPUErr[11] (Processor usage denial exception)
- E016 CPUErr[12] (Operation overflow exception)
- E016 CPUErr[13] (Trap exception)
- E016 CPUErr[15] (Floating point exception)
- E016 CPUErr[22] (Watch exception)
- E016 CPUErr[32] (Watchdog timeout error)
- E016 CPUErr[33] (Abort error)
- E237 Error Transfer memory (Transfer memory error/access error)
- Error E129 NVRAM (Backup memory error)
1140
FaultTracing
Procedure
EXA No.
1500
1500
1510
1510
1510
1510
1510
1510
1510
1510
1510
1520
1520
1520
1520
1520
1520
1520
1520
1520
1530
CPU System Faults

[CPU System Faults]

Replacement Part
EXA1700 to EXA1720
Problem
FaultTracing
Procedure
EXA No.
Model N.:Rockhopper-46
3
Model N.: Rockhopper-46

3
MAP1700
1280
1290
1450
1150
1080
1080
1080
1080
- Error E065 X Motor

- Error E069 X Encoder
- Error E071 X Timeout
- Error E073 X Overcurrent
- Error E066 Y Motor
- Error E070 Y Encoder
- Error E072 Y Timeout
- Error E074 Y Overcurrent
- Error E075 Sensor Abnormal
1140
1070
1700
1700
1700
1700
1710
1710
1710
1710
1720

DF-41597 X Motor Assembly
DF-41598 CR Motor Assembly (Y Motor)
DF-41607 T Fence
DF-40109 Origin Sensor Assembly

[Mechanical System Faults]

Replacement Part
MAP1700
EXA1700 to EXA1720
Problem
FaultTracing
Procedure
EXA No.
MAP1700-2
Model Name: Rockhopper 62
MAP1700-2
1280
1290
1450
1150
1080-2
1080-2
1080-2
1080-2
1080-2
- Error E065 X Motor

- Error E069 X Encoder
- Error E071 X Timeout
- Error E073 X Overcurrent
- Error E066 Y Motor
- Error E070 Y Encoder
- Error E072 Y Timeout
- Error E074 Y Overcurrent
- Error E075 Sensor Abnormal
1140
1070
1700
1700
1700
1700
1710
1710
1710
1710
1720

DF-41598 CR Motor Assembly (Y Motor)
DF-41607 T Fence
DF-40109 Origin Sensor Assembly

[Mechanical System Faults]

Replacement Part
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
Heater System
FaultTracing
Procedure
EXA No.
1040
Problem
Front Right Heater Sensor

Front Left Heater Sensor
Rear Right Heater Sensor
Rear Left Heater Sensor
EXA1800
1040
1040
1040
1040

[Heater system]
d
Replacement Part
Heater
r System Faults
Model N:Rockhopper46 3
MAP1800
Heater
r System Faults
MAP1800
- Err : F.R.T. Sensor

- Err : F.L.T. Sensor
- Err : R.L.T. Sensor
- Err : R.R.T. Sensor
- Err : FRFLT Sensor
- Err : FRRLT Sensor
- Err : FRRRT Sensor
- Err : FLRLT Sensor
- Err : FLRRT Sensor
- Err : RRRLT Sensor
- Err : 2FRLT Sensor
- Err : 2FRRT Sensor
- Err : FR2RT Sensor
- Err : FL2RT Sensor
- Err : All T. Sensor
- Err : Heater Stop
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
Heater System
FaultTracing
Procedure
EXA No.
1040 -2
Problem
Front Right Heater Sensor

Front Left Heater Sensor
Rear Right Heater Sensor
Rear Left Heater Sensor
EXA1800
1040 -2
1040 -2
1040 -2
1040 -2

[Heater system]
d
Replacement Part
Heater
r System Faults
MAP1800-2
Heater
r System Faults
MAP1800-2
- Err : F.R.T. Sensor

- Err : F.L.T. Sensor
- Err : R.L.T. Sensor
- Err : R.R.T. Sensor
- Err : FRFLT Sensor
- Err : FRRLT Sensor
- Err : FRRRT Sensor
- Err : FLRLT Sensor
- Err : FLRRT Sensor
- Err : RRRLT Sensor
- Err : 2FRLT Sensor
- Err : 2FRRT Sensor
- Err : FR2RT Sensor
- Err : FL2RT Sensor
- Err : All T. Sensor
- Err : Heater Stop
EXA2000 to EXA2070
FaultTracing
Procedure
EXA No.
2000
2000
2010
2020
2030
2030
2030
2030
2030
2040
2050
2060
2070

DF-41600 Y Cable
DF-41601 Head Cable
DF-41591 Waste Fluid Bottle Sensor
Problem
1140
1160
1170
1110
1100
1410
1420
1200
1360
1130
1150
1130
1350
1350
1350
1350
1350
1350
1240
1260
1270
1390
1390
1120
1080
1080
1080
1080
1340
1340
1340
1340
1340
1340
1470
1470


Replacement Part

Model N. :Rockhopper46
3
Model N. : Rockhopper46
3
MAP2000

MAP2000
EXA2000 to EXA2070-2
FaultTracing
Procedure
EXA No.
2000
2000
2010
2020
2030
2030
2030
2030
2030
2040
2050
2060
2070-2

DF-41600 Y Cable
DF-41601 Head Cable
DF-41591 Waste Fluid Bottle Sensor
Problem
1140
1160
1170
1110
1100
1410
1420
1200
1360-2
1130
1150
1130
1350
1350
1350
1350
1350
1350
1240
1260
1270
1390
1390
1120
1080-2
1080-2
1080-2
1080-2
1080-2
1340
1340
1340
1340
1340
1340
1470
1470


Replacement Part

MAP2000-2

MAP2000-2
EXA3000 to EXA3010
Problem
FaultTracing
Procedure
EXA No.
3
MAP3000
3
MAP3000
- The media comes off when it is initialized or during printing

- The media is skewed or meanders when it is initialized or during printing
- The media becomes wrinkled when it is initialized or during printing
- The media jams when it is initialized or during printing
- The media tears when it is initialized or during printing
- The media size is different after media mounting and initialization
- Tracing paper and thin media cannot be detected
1140
1080
1080
1080
1080
1110
1410
1200
1360
1690
3000
3000
3000
3000
3000
3010
3010

DF-41600 Y Cable

[Trouble with Media Feed]

Replacement Part
EXA3000-2 to EXA3010
Problem
FaultTracing
Procedure
EXA No.
MAP3000-3
Model N. : Rockhopper-62
MAP3000-3
- The media comes off when it is initialized or during printing

- The media is skewed or meanders when it is initialized or during printing
- The media becomes wrinkled when it is initialized or during printing
- The media jams when it is initialized or during printing
- The media tears when it is initialized or during printing
- The media size is different after media mounting and initialization
- Tracing paper and thin media cannot be detected
1140
1080-2
1080-2
1080-2
1080-2
1080-2
1110
1410
1200
1360-2
1690
3000-2
3000-2
3000-2
3000-2
3000-2
3010
3010

DF-41600 Y Cable

[Trouble with Media Feed]

Replacement Part
EXA4000 to EXA4130
(EXA4110 to EXA4130 See MAP4001)
Problem
FaultTracing
Procedure
EXA No.
MAP4000
- Does not print continuously

- There is an extra feed after printing is finished
- Dots are missing from the printing
- Cleaning does not cure blockage
- Does not print at all or does not print a specific colour
- The entire surface is printed black
- Printing becomes shaded
- The image contains blurs
- Transverse lines appear to be split
- Black and white lines appear in the printed image
- Edges of printing are blurred
- Many satellites (unwanted dots)
- The printing has whiskers
- Printed lines appear blurred
- Mixed colour lines do not overlap
- Black and colour positions are offset
- Inaccurate line length in the direction of head movement (Main scanning direction)
- Inaccurate straight line in the direction of head movement (straightness)
1140
1080
1080
1080
1080
1370
1390
1360
1290
1240
1260
1230
1250
1270
1390
1420
1350
1350
1350
1350
1350
1350
1200
1150
4000
4010
4020
4020
4030
4040
4050
4050
4050
4050
4060
4070
4070
4070
4080
4080
4090
4100
3

DF-41605 Ink Tube
DF-41601 Head Cable
DF-41600 Y Cable
DF-41607 T Fence
DF-41599 Pump Motor Assembly
DF-40125 Wiper

[Trouble with Printing]

Replacement Part
3
MAP4000
(EXA4110 to EXA4130-2 See MAP4001-2)
Problem
FaultTracing
Procedure
EXA No.
MAP4000-2
- Does not print continuously

- Dots are missing from the printing
- Cleaning does not cure blockage
- Does not print at all or does not print a specific colour
- The entire surface is printed black
- Printing becomes shaded
- The image contains blurs
- Transverse lines appear to be split
- Black and white lines appear in the printed image
- Edges of printing are blurred
- Many satellites (unwanted dots)
- The printing has whiskers
- Printed lines appear blurred
- Mixed colour lines do not overlap
- Black and colour positions are offset
- Inaccurate line length in the direction of head movement (Main scanning direction)
- Inaccurate straight line in the direction of head movement (straightness)
1140
1080-2
1080-2
1080-2
1080-2
1080-2
1370
1390
1360-2
1290
1240
1260
1230
1250
1270
1390
1420
1350
1350
1350
1350
1350
1350
1200
1150
4000
4010
4020
4020
4030
4040
4050-2
4050-2
4050-2
4050-2
4060
4070
4070
4070
4080
4080
4090
4100-2

DF-41605 Ink Tube
DF-41601 Head Cable
DF-41600 Y Cable
DF-41607 T Fence
DF-41599 Pump Motor Assembly
DF-40125 Wiper


Replacement Part
MAP4000-2
EXA4000 to EXA4130
(EXA4000 to EXA4100 See MAP4000)
Problem
FaultTracing
Procedure
EXA No.
3
MAP4001
3
MAP4001
- Inaccurate line distance in the direction of media feed (Subsidiary scanning distance)
- Inaccurate straight line in the direction of media feed (joining precision Y)
- Bad right angle precision
1140
1080
1080
1080
1080
1220
1310
1310
1690
1680
4110
4120
4130

DF-40854 Cursor Plate Spring
DF-41616 Steel Flexible Cable Assembly
DF-41841 Speed Reduction Pulley Assembly


Replacement Part
(EXA4000 to EXA4100-2 See MAP4000-2)
Problem
FaultTracing
Procedure
EXA No.
MAP4001-3
MAP4001-3
- Inaccurate line distance in the direction of media feed (Subsidiary scanning distance)
- Inaccurate straight line in the direction of media feed (joining precision Y)
- Bad right angle precision
1140
1080-2
1080-2
1080-2
1080-2
1080-2
1220
1310-2
1310-2
1690
1680
4110
4120
4130-2

DF-40854 Cursor Plate Spring
DF-41616 Steel Flexible Cable Assembly
DF-41988 Speed Reduction Pulley Assembly


Replacement Part
EXA5000 to EXA5040
Problem
FaultTracing
Procedure
EXA No.
MAP5000
- Abnormal noise when media is sucked down

- Abnormal noise when standing by ready to print
- Abnormal noise when head is moving left and right
- Abnormal noise when media is fed
- Abnormal noise when cutting
1140
1080
1150
1390
1420
1320
1280
1220
1090
1070
1360
1540
1690
5000
5010
5020
5030
5040
Model N.: Rockhpopper-46/62

DF-41588 Head Board
DF-40144 Y Return Pulley Assembly
DF-41598 Cursor Motor Assembly (Y Motor)
DF-40137 X Speed Reduction Belt
DF-41600 Y Cable
DF-41677 Tube Guide Assembly

[Problem Involving Noise]

Replacement Part
Model N.: Rockhopper-46/62
MAP5000
EXA5000 to EXA5040
Problem
FaultTracing
Procedure
EXA No.
MAP5000-3
MAP5000-3
- Abnormal noise when media is sucked down

- Abnormal noise when standing by ready to print
- Abnormal noise when head is moving left and right
- Abnormal noise when media is fed
- Abnormal noise when cutting
1140
1080-2
1150
1390
1420
1320
1280
1220
1090
1070
1360-2
1540-2
1690
5000
5010
5020
5030
5040

DF-41588 Head Board
DF-40144 Y Return Pulley Assembly
DF-41598 Cursor Motor Assembly (Y Motor)
DF-40137 X Speed Reduction Belt
DF-41600 Y Cable
DF-41677 Tube Guide Assembly

[Problem Involving Noise]

Replacement Part
EXA6000 to EXA6050
Problem
FaultTracing
Procedure
EXA No.
Model N. :Rockhopper-46
3
MAP6000
Model N. :Rockhopper-46
3
MAP6000
- Does not cut normally

- Cutting occurs during printing
- The cutting operation is normal but the media is not cut
- The cutting is bad and the media jams
- The cutting operation is normal but the media does not fall out
- Inaccurate media cutting
- Cutting is delayed for some time after printing has ended
- White paper is cut
1140
1380
1360
1420
6000
6010
6020
6020
6030
6040
6050
6050

DF-41600 Y Cable

[Trouble with Media Cutting]

Replacement Part
EXA6000 to EXA6050
Problem
FaultTracing
Procedure
EXA No.
MAP6000-2
MAP6000-2
- Does not cut normally

- Cutting occurs during printing
- The cutting operation is normal but the media is not cut
- The cutting is bad and the media jams
- The cutting operation is normal but the media does not fall out
- Inaccurate media cutting
- Cutting is delayed for some time after printing has ended
- White paper is cut
1140
1380
1360-2
1420
6000
6010
6020
6020
6030
6040
6050
6050

DF-41600 Y Cable

[Trouble with Media Cutting]

Replacement Part
EXA7000 to EXA7060
Problem
FaultTracing
Procedure
EXA No.

3
MAP7000

3
MAP7000
- Cannot connect normally with RS-232C

- Cannot connect normally with Centronics
- Cannot connect normally with Network
- The scale function does not work correctly
- The rotate function does not work correctly
- The mirror function does not work correctly
- Other functions are not working correctly
- Printing position is offset
- Some data are not printed (omitted)
- Text and printing data are garbled (extra lines appear)
1140
1360
1420
1290
7000
7000
7000
7020
7020
7020
7020
7030
7040
7050
7060
DF-41586 Main Board Assemblym)

DF-41600 Y Cable
DF-41607 T Fence

[Online/Function Problems]

Replacement Part
EXA7000 to EXA7060
Problem
FaultTracing
Procedure
EXA No.
MAP7000-2
MAP7000-2
- Cannot connect normally with RS-232C

- Cannot connect normally with Centronics
- Cannot connect normally with Network
- The scale function does not work correctly
- The rotate function does not work correctly
- The mirror function does not work correctly
- Other functions are not working correctly
- Printing position is offset
- Some data are not printed (omitted)
- Text and printing data are garbled (extra lines appear)
1140
1360-2
1420
1290
7000
7000
7000
7020
7020
7020
7020
7030
7040
7050
7060
DF-41586 Main Board Assemblym)

DF-41600 Y Cable
DF-41607 T Fence

[Online/Function Problems]

Replacement Part
EXA8000 to EXA8050
Problem
FaultTracing
Procedure
EXA No.
MAP8000

3
MAP8000
- The printer hangs up

- Power shutdown during printing
- The ink cartridges will not go in
- Ink has overflowed from the waste fluid bottle
- Ink overflows from flushing box
- Ink is split around the X-rail
1140
1330
1350
1350
1350
1350
1350
1350
1150
1120
1700
8000
8010
8020
8030
8040
8050

3

DF-41591 Waste Fluid Bottle Sensor Assembly
DF-42007 F Absorbent Material Assembly

[Other]
Other
Replacement Part
Other
Problem
FaultTracing
Procedure
EXA No.
MAP8000-2
MAP8000-2
- The printer hangs up

- Power shutdown during printing
- The ink cartridges will not go in
- Ink overflows from flushing box
- Ink is split around the X-rail
1140
1330
1350
1350
1350
1350
1350
1350
1150
1120
1700
1710
8000
8010
8020
8050
8050
8050
8050

DF-41591 Waste Fluid Bottle Sensor Assembly
DF-42007 F Absorbent Material Assembly
DF-42008 Waste Fluid Bottle Assembly

[Other]
Other
Replacement Part
Other
EXA9000
Problem
FaultTracing
Procedure
EXA No.
MAP9000
Heater
r System
MAP9000
- Heater does not stop warming up or is broken
1040
1040
1040
1040
9000
Heater
r System
Front Heater
Rear Heater
Front Heater Sensor
Rear Heater Sensor

[Heater system]

Replacement Part
EXA9000
Problem
FaultTracing
Procedure
EXA No.
MAP9000-2
Heater
r System
MAP9000-2
- Heater does not stop warming up or is broken
1040 -2
1040 -2
1040 -2
1040 -2
9000
Heater
r System
Front Heater
Rear Heater
Front Heater Sensor
Rear Heater Sensor

[Heater system]

Replacement Part
Rockhopper-46
3 Fault-Tracing Procedure
Model Name:
Rockhopper-46
EXA0000
Model Name:
Rockhopper-46
EXA0000
Data Errors
Command Errors
CPU System Faults
EXA1000
EXA1200
EXA1250
EXA1500
EXA1700
EXA1800

Other
Heater System
Rockhopper-46
3 Fault-Tracing Procedure
EXA2000
EXA3000
EXA4000
EXA5000
EXA6000
EXA7000
EXA8000
EXA9000
Rockhopper-62 Fault-Tracing Procedure
EXA0000-3
Data Errors
Command Errors
CPU System Faults
EXA1000
EXA1200
EXA1250
EXA1500
EXA1700
EXA1800-2
(Difference between Rockhopper-46 and 62)

( 1020-2 )

Other
Heater System
Rockhopper-62 Fault-Tracing Procedure
EXA2000
EXA3000
EXA4000
EXA5000
EXA6000
EXA7000
EXA8000
EXA9000-2
( 2070-2 )
( 3000-2 )
( 4050-2, 4100-2, 4130-2 )
Model Name:
Rockhopper-62
EXA0000-3

No.
1
Symptom
Cover Open
This message means that the Front
Cover is open
Lever Up
This message means that the
Pressure Lever is up.
Cover and Lever
This message means that the Front
Cover and Pressure Lever are up.
1-2
1-3
R E P
Is the cover sensor arm loose? (Related to opening and closing the front cover)
Tighten the cover sensor arm screw.
When the front cover is opened and closed, does the cover switch go on and off normally?
Adjust the height of the cover switch assembly.
Adjust the relative positions of the cover shaft R and front cover fulcrum.
Is the cover switch cable connected securely? (Related to opening and closing the front cover)
Connect the sensor cable securely to connector J106 (COVER) on the main board assembly.
1110
1110
Does the pressure lever move smoothly? (Related to raising and lowering the pressure lever)
Adjust the position of the pressure relay plate.
Apply grease G-501 to the elongated round hole in the pressure relay plate. (Refer to CAT4000)
1-5
Is the lever sensor assembly fitted securely? (Related to raising and lowering the pressure lever)
Adjust the lever sensor assembly fitting position.
1-6
Is the sensor unit in the lever sensor assembly dirty? (Related to raising and lowering the pressure lever)
Clean the sensor unit with cotton swabs.
1100
Is the lever sensor assembly cable fitted securely? (Related to raising and lowering the pressure lever)
Connect the lever sensor cable securely to connector J102 (LEVER) on the main board assembly.
1100
The panel board assembly may be damaged. (Related to opening and closing the front cover)
Replace it.
1160
The panel cable may be damaged. (Related to opening and closing the front cover)
Replace it.
1170
Is the cover limit switch working on "Sensor: Cover" in the printer self-diagnostics?
Replace the cover switch assembly
1110
Is the lever sensor working on "Sensor: Lever" in the printer self-diagnostics?

Replace the lever sensor assembly.
1100
The main board assembly may be damaged. (Related to both)

Replace it.
1140
1-8
1-9
1-10
1-11
1-12
B A C
1110
1-4
1-7
EXA1000
GO TO Ref. Pages
Sequence
1-1
1100
1040
1040
EXA1000

No.
1
Symptom
Undefined Media
This message means that when
media was mounted, it was not able
to be recognized.

Sequence
1-1
1-2
EXA1010
GO TO Ref. Pages
R E P
Is the edge sensor assembly cable that is attached to the head unit securely connected?
Connect it securely to connector J204 (P EDGE) on the head board assembly.
1410
Is the XR cable assembly (paper sensor R) cable that is attached below paper guide R
securely connected?
Connect it securely to connector J107 (XR) on the main board assembly.
1200
B A C
1040
1-3
1410
1-4
Check Y cable contacts. Check that they are not inserted obliquely.
Reconnect main board assembly connector J111 (HEAD1) and head board assembly
connector J201 (MAIN1).
1-5
The head board assembly may be damaged.

Replace it.
1420
Check with the self-diagnostic Sensor: X Rear whether the sensor is operating.
Replace paper sensor R if Paper End is displayed when media is mounted.
1200

Replace it.
1140
The Y cable assembly may be damaged

Replace it.
1360
1-6
1-7
1-8
Use the printer's self-diagnostic Sensor: Edge to confirm the amount of sensor reflection. Using thick coated paper, check whether the paper detection value is within 0090 to
00a4.
Replace edge sensor assembly.
Adjust with the head board assembly variable resistor (VR1).
1040
EXA1010

No.
1
Symptom
Media Skew Error
Model Name: Rockhopper 46/62
GO TO Ref. Pages
Sequence
R E P
1-1
Reload the media and confirm its current status.

If the problem is simply due to poor loading, explain to the user how to load the media properly.
1-2
Are the fans working normally according to the self-diagnostic Examination: Fans?
Check the connectors between fan assembly, fan extension cable assembly and main board
assembly.
Fan extension cable 1 assembly is J115 (FAN1) on the main board assembly
Replace fan assembly.
Replace Fan extension cable 1 assembly, Fan extension cable 2 assembly, Fan extension cable
3 assembly and Fan extension cable 4 assembly.
1-3
Is the shielding material securely attached in the proper positions?

Shield material GA-A, shield GA-B, shield GA-C
Re-attach in the proper positions.
1-4
Is there a problem with the movement of the pressure lever?

Apply grease (G501) and adjust the pressure transfer plate.
1-5
With the pressure lever lowered, do all pressure rollers make contact with the grid roller?
(Are any of the pressure rollers idling?)
Replace the pressure rollers or the pressure assembly.
1-6
Is there a uniform gap between head and platen?

Use the rail height jig (JD-30395) to adjust the position of the platen.
1-7
Is there distortion or damage to the grid roller?

Replace grid roller.
2-1
EXA1020
CAUTION:
1060
1080
1220
1520
1690
After carrying out the adjustments according to the procedure above, run the self-diagnostic Skew
Verification.
[ Rated Value ]
Since this task will establish the

reference position for determining skew, it should be adjusted
carefully.
B A C
Condition
Rated Value
Cut media
Roll media
2030
Within 1.5 mm
7m
Within 2.5 mm
50m
Within 10 mm
EXA1020

No.
1
Symptom
[User 1] Media End
This message is displayed when no
media is mounted or printing in cut
media mode has been completed.

Sequence
1-1
1-2
1-3
1-4
1-5
1-6
1-7
EXA1030
GO TO Ref. Pages
R E P
Is the edge sensor assembly cable that is attached to the head unit securely connected?
Connect it securely to connector J204 (P EDGE) on the head board assembly.
1410
Is the XR cable assembly (paper sensor R) cable that is attached below the rear paper
guide securely connected?
Connect it securely to connector J107 (XR) on the main board assembly.
1200
Use the printer's self-diagnostic Sensor: Edge to confirm the amount of sensor reflection.
Using thick coated paper, check whether the paper detection value is within 0090 to
00a4.
1410

Replace it.
1420
Check with the printer's self-diagnostic "Sensor: X Rear" whether the sensor is operating.
Replace paper sensor R if Paper End is displayed when media is mounted.
1200

Replace it.
1140
The Y cable assembly may be damaged.

Replace it.
1360
B A C
1040
1040
EXA1030

No.
1
Symptom
Remove Media
This message is displayed if, after
raising the lever during printing and
cutting the media, the lever is lowered
without the media having been
removed.

Sequence
R E P
Switch off the printer temporarily and check that the message is displayed when you
switch on again.
1-2
Use the printer's self-diagnostic "Sensor: Lever" to make sure that the pressure lever is
working normally.
Check that the liquid crystal display unit does not show that the up and down movement of the pressure lever appears to be chattering when the lever is moved slowly up
and down.
1-3
Check the lever sensor assembly contact.

Reconnect main board assembly connector J104 (LEVER).
If there seems to be chattering, the sensor may be faulty.
1-5
1-6
EXA1040
GO TO Ref. Pages
1-1
1-4
1040
1100
Is the cable of the XR cable assembly (rear paper sensor) that is attached below the rear
paper guide connected securely?
Connect it securely to connector J107 (XR) on the main board.
1200
Use the self-diagnostic Sensor: X Rear to check whether there is media.

If media is loaded but No Media is displayed, replace the rear paper sensor.
1200

Replace it.
1140
B A C
EXA1040

No.
1
Symptom
Roll Media End
This message is displayed when roll
media is being used and the trailing
edge of the media is detected. It will
be cancelled by raising the lever.

Sequence
EXA1050
GO TO Ref. Pages
R E P
1-1
switch on again.
1-2
Use the printer's self-diagnostic "Sensor: X Rear" to make sure that the media end detection is working normally.
Cover the paper sensor R (XR cable assembly) with media and confirm that "SENS: Xr
Paper On" is displayed.
1-3
Check the paper sensor R contact.

Reconnect main board assembly connector J107 (XR).
If "Media Present" does not appear, the sensor may be faulty.
Replace the paper sensor R assembly.
1-4

Replace it.
B A C
1040
1200
1140
EXA1050

No.
1
Symptom
Media Cut Error
This message is displayed when the
media is not cut and does not fall out
despite the cutting operation having
been performed.
GO TO Ref. Pages
Sequence
R E P
1-1
Is there an accumulation of paper dust in the cutter groove?

Remove accumulated paper dust along the paper groove.
1-2
Check how the cutter cap is fitted.

Fit the cutter cap securely.
1-3
Check the up and down movement of the cutter. With the cutter installed, push it down to the bottom with your finger and check that the power of the spring alone brings it back to the top.
If it rises, go to 1-5
If it does not rise, got to 1-4
1-4
Remove the cutter and take out the cutter spring. Fit the cutter and check that in this condition, the
cutter will fall to the bottom under its own weight.
If it falls the cutter spring may be faulty. Refer to the exploded drawings and replace the cutter
spring.
If it does not fall, the cutter may be faulty. Replace the cutter.
1-5
EXA1060
Use the printer's self-diagnostic Aging: Cutter to confirm the up-and-down movement of the solenoid.
B A C
Refer to the
Operation
Manual
(Basic
Manual)
Refer to the
Operation
Manual
(Basic
Manual)
Check the down position of the cutter blade relative to the

cutter groove.
[OK] Cutter blade is damaged or worn out. Replace with a new blade.
[NG] Refer to REP 1380 position adjustment and adjust the position of the cutter
holder.
No up/down movement Connection may be faulty. Check the following connectors.
Head board assembly connector J206 (SOL)
Head board assembly connector J201 (MAIN1)
Main board assembly connector J206 (HEAD1)
Moves up/down
CAUTION:
Power must be off when connectors are being disconnected or

reconnected, otherwise you may be injured or a board may be
damaged. The main board assembly will certainly be damaged if
power is applied with main board assembly connectors J111
(HEAD) and J112 (HEAD2) and head board connectors J201
(MAIN1) and J202 (MAIN2) inserted with oblique FFP.
Continued on next page
EXA1060

No.
1
Symptom
Media Cut Error
media is not cut and does not fall out
despite the cutting operation having
been performed.

Sequence
1-6
EXA1061
GO TO Ref. Pages
R E P
B A C
There may be a broken Y cable lead, faulty solenoid assembly or a faulty board assembly.
a. Try fitting a new Y cable. (Check for continuity between connectors)
If there is up/down movement, replace Y cable.
b. Try fitting a new solenoid assembly. (Check for continuity between connectors)
If there is up/down movement, replace solenoid assembly.
c. Try replacing the head board assembly.
(Reference)
after replacement, use the printer's EXAM: Sensor self-diagnostic "Edge" to
adjust the amount of sensor reflection. (The adjustment volume is on the head
board.)
d. Try replacing the main board assembly.
(Reference)
Back up the parameters before replacing the main board and check the operation
after executing Recovery with the new main board assembly.
EXA1061

No.
1
Symptom
Not enough memory SIMMMB
(Intermediate code buffer overflow)
When this printer has insufficient
memory for the amount of data sent
by the personal computer, this message indicates the required memory
size.

Sequence
EXA1070
GO TO Ref. Pages
R E P
1-1
Check RAM capacity with the printer's self-diagnostic Examination: RAM Capacity.
The capacity without optional extended memory is 8 MB. If SIMM has been extended,
the value Standard memory 8 MB + Extended memory will be displayed.
(If two 36 MB SIMMs have been installed, 80 MB is displayed.)
(With Iris 46 WIDE, since a 16 MB SIMM has been added in Slot 1, the display is normally "24 MB")
1-2
Optional Memory = MB shown in the Setup List is the amount of extended memory
only. If there is a difference between the actual memory capacity and the memory capacity shown on the panel or the memory capacity shown in the setup list, the SIMM may be
damaged. Replace the SIMM.
1-3
Model Name: Rockhoppper-46/62

Replace it.
B A C
1010
1140
1140
EXA1070

No.
1
Symptom
Insert Special Cartridge
This message is displayed when a
cartridge other than a genuine Mutoh
cartridge has been installed.

Sequence
EXA1080
GO TO Ref. Pages
R E P
1-1
Switch off the printer temporarily and check that the message is displayed when you switch on
again.
1-2
Check whether you are using the specified ink cartridge.
1-3
Use the printers self-diagnostic Sensor: Cartridge to make sure that the ink cartridge status
detection is working correctly.
If normal detection fails, the ink ID sensor assembly, junction board assembly, ink ID cable, or main
board assembly may be at fault.
1-4
Check the ink ID sensor assembly connector contacts.

Reconnect junction board assembly connectors J406 (Ink ID Sensor 1 BK), J407 (Ink ID Sensor
2 C), J408 (Ink ID Sensor 3 M), J409 (Ink ID Sensor 4 Y), J412 (Ink ID Sensor 5), J413 (Ink ID
Sensor 6).
If there is no change, move to the next step.
1-5
1040
Using the printers self-diagnostic Sensor: Cartridge, exchange the position of the connector of the
ink ID sensor assembly that is shown as being faulty with the position of any one of J406 to J409,
J412 and J413 on the junction board assembly that appears to be normal.
If after re-inserting the connectors a different ink cartridge unit now appears to be faulty, it means
that the ink ID sensor assembly that was shown as being faulty is damaged.
Replace the faulty ink ID sensor assembly.
If after re-inserting the connectors there is no change in the part that was shown as being faulty,
or all units are shown as being faulty, the damage may be between the junction board assembly
and the main board assembly.
1-6
Check the ink ID cable contacts.

Reconnect junction board assembly connector J401 (INK ID Cable) and main board assembly
connector J109 (INK ID).
1-7
Replace the ink ID cable and repeat procedures 1-3 and 1-4.
(a) If the fault display is cleared, it means that the ID cable may be faulty.
Replace the ink ID cable.
(b) If there is no change at all in the symptoms, it means that the junction board assembly or the
main board assembly may be faulty.
Replace the junction board assembly.
Replace the main board assembly.
B A C
1340
1340
1470
1470
1140
EXA1080

No.
1
Symptom
[65YMCK] Ink Low
amount of ink shown on the operating
panel is low.
Printing can continue.
(Refer to GID2010 for details)

Sequence
1-1
1-2
2
[65YMCK] No Ink
ink shown on the operating panel has
been used up.
If this message appears while an
image is being printed, stop printing
immediately.
(Refer to GID2010 for details)
1-3
EXA1090
GO TO Ref. Pages
R E P
Check the no ink cartridge with the printer's self-diagnostic "Sensor: No Ink".
Remove all cartridges and gently switch the detector assemblies (BK, C, M and Y)
(black plastic levers) on and off to confirm that the displays Sensor: No Ink K (black),
Sensor: No Ink C (cyan), Sensor: No Ink M (magenta) and Sensor: No Ink Y (yellow) change.
Check the detector assembly connector contacts.
Reconnect junction board assembly connector J402 (Detector Assembly BK), J403
(Detector Assembly C), J404 (Detector Assembly M), J410 (Detector1 Assembly [O/5]),
J411 (Detector2 Assembly [G/6]).
Exchange the position of the connector of the ink detector assembly for the ink for which
Ink Low or No Ink is indicated with the position of any one of J402 to J405, J410 and
J411 on the junction board assembly that appears to be normal.
If after re-inserting the connectors a different ink now appears to be No Ink, it means
that the detector assembly is damaged.
Replace the detector assembly.
If after re-inserting the connectors there is no change in the No Ink display, or No
Ink is shown for all inks, the damage may be between the junction board assembly
and the main board assembly.
1-4

J401 (ink ID cable) on the junction board assembly and J109 (INK ID) on the main board
assembly.
Disconnect and reconnect them.
1-5
Replace the ink ID cable and repeat procedure 1-3.

(b) If there is no change at all in the symptoms, it means that the junction board assembly or the main board assembly may be faulty.
B A C
1040
1350
1350
1470
1470
1140
EXA1090

No.
1
Symptom
[65YMCK] No Cartridge
This message indicates that the ink
cartridge that is shown on the operating panel is missing.
GO TO Ref. Pages
Sequence
EXA1100
1-1
switch on again.
1-2
Check the no ink cartridge with the printer's self-diagnostic "Sensor: No Ink".
Remove all the cartridges and, using an object with a flat tip such as a ball pen, press
the switch that detects the presence of the cartridge that is to be checked (these
switches are inside the cartridge frame assembly.)
R E P
B A C
1330
1040
With Sensor: No Cartridge, the following is displayed when all cartridges are
removed:
Sensor: No Cartridge KCMYOG
and the following is displayed when the switch that detects whether the black
cartridge is present is pressed:
Sensor: No Cartridge CMYOG
The same applies to the other cartridges C, M and Y.
(Reference)
The differences between error messages shown to the user and

messages shown by "Test" and "Sensor" diagnostic modes are
as follows.
Display to user
Diagnostic mode display
Cartridge position
No. 5
No. 6
CAUTION: Take care. You can be hurt by the ink filling needle when you
operate the switch showing whether there is ink in the cartridge
frame assembly. For safety, work with the cartridge cover
removed.
1-3
Check the cartridge frame assembly connector contacts.

Reconnect junction board assembly connector J402 (Detector Assembly BK), J403
(Detector Assembly C), J404 (Detector Assembly M), J410 (Detector1 Assembly [O/5]),
J411 (Detector2 Assembly [G/6]).
1350
EXA1100

No.
1
Symptom
[65YMCK] No Cartridge
This message indicates that the ink
cartridge that is shown on the operating panel is missing.

Sequence
1-4
EXA1101
GO TO Ref. Pages
R E P
Exchange the position of the connector of the cartridge detector assembly for the cartridge for which No Cartridge is indicated with the position of any one of J402 to J405,
J410 and J411 on the junction board assembly that appears to be normal.
If after re-inserting the connectors a different ink now appears to have No Cartridge, it
means that the detector assembly is damaged.
Replace the detector assembly.
If after re-inserting the connectors No Cartridge appears, or No Cartridge is shown
for all cartridges, the damage may be between the junction board assembly and the
main board assembly.
B A C
1350
Reference: Take care when you are replacing the detector assembly that senses
whether there is a cartridge present. It can become damaged by overtightening the attaching screw.
1-5

Reconnect junction board assembly connector J401 (INK ID Cable) and main board
assembly connector J109 (INK ID).
1-6

If the No Cartridge display is cleared, it means that the Ink ID may be faulty.
Replace it.
1-7
If there is no change in the symptoms, it means that the junction board assembly or the
main board assembly may be faulty.
1470
1140
EXA1101

No.
1
Symptom
Capping position not specified
The capping position was not displayed at the time of initialization.

Sequence
EXA1110
GO TO Ref. Pages
R E P
B A C
1-1
Adjust the capping position by running the printer's self-diagnostic "Adjust: Capping position".
If the capping position parameter is changed for some reason you will not be able to
shift to the next adjustment task so the capping position adjustment should be done
first.
2010
1-2
Check whether the parameters are set to the initial values by running the printer's selfdiagnostic "Adjust: Test print" to output the parameters that have been set.
Refer to the functions and operations manual for the initial values of parameters.
If the parameters have been restored to their initial values, please contact the "Inquiry
desk" and quote your printer serial number to obtain a setup list for the time your printer was shipped from the factory.
Enter all parameters in accordance with the setup list. (See PAT4000)
2150
1-3

Replace it.
1140
EXA1110

No.
1
Symptom
Not Filled
This message means "Initial filling has
not been done".
R E P
With the specified cartridge inserted securely, use the printer's self-diagnostic mode
"Sensor: No Ink" or "Sensor: No Cartridge" to check whether the presence of ink and cartridge are being detected normally.
For checking, use the [65YMCK] No Ink procedure shown in EXA1090.
After adjustment and replacement, carry out initial filling with the printers self-diagnostic Adjust: Enter Rank.
1-2
B A C
1040
2040
1040
"Sensor: Cartridge" to check whether the status of the special cartridge is operating normally.
For checking, use the Insert Special Cartridge procedure shown in EXA1080.
After adjustment and replacement, carry out initial filling with the printers self-diagnostic Adjust: Enter Rank.
CAUTION:
EXA1120
GO TO Ref. Pages
Sequence
1-1
2040
Wait at least 30 minutes after initial filling before printing. Printing

quality can not be assured unless ink filling has been stabilized.
EXA1120

No.
1
Symptom
No Waste Fluid Box
This message means that the waste
fluid bottle is not installed.

Sequence
EXA1130
GO TO Ref. Pages
R E P
1-1
switch on again.
1-2
Use the printer's self-diagnostic "Sensor: Tank Exist/Tank is not" to make sure that the
waste fluid bottle detection is working normally.
Slowly remove and replace the waste fluid bottle to confirm that the present/absent display appears.
If the display is not normal, the sensor position may be faulty.
Adjust the position of the waste fluid bottle detection switch assembly.
B A C
1040
1120
1-3
Make sure the waste liquid bottle is making contact.

Reconnect main board assembly connector J105 (INK TANK).
1-4
The waste fluid bottle detection switch assembly may be faulty.

Replace it.
1-5

Replace it.
1120
1140
EXA1130

No.
1
Symptom
Check Waste Fluid Box

Sequence
EXA1140
GO TO Ref. Pages
R E P
1-1
switch on again.
1-2
Use the printer's self-diagnostic "Sensor: Tank Exist/Tank is not" to make sure that the
waste fluid bottle detection is working normally.
If the display is not normal, the sensor mounting position may be at fault.
Adjust the mounting position of the waste fluid bottle detection
switch assembly.
1-3
Make sure the waste liquid bottle is making contact.

Reconnect main board assembly connector J105 (INK TANK).
1-4
The waste fluid bottle detection switch assembly may be faulty.

Replace it.
1-5

Replace it.
B A C
1040
1120
1120
1140
EXA1140

No.
1
Symptom
Ink Type Error
wrong type of ink cartridge has been
installed.
EXA1150
GO TO Ref. Pages
Sequence
1-1
R E P
Use the printer's self-diagnostic "Sensor: Cartridge" to check the ink type.
Install all cartridges and check that all six colours have the same type of ink.
Sensor: K
B A C
1040
Depending on the ink type, the following symbols will be displayed at locations _.
D
P
W
N
:
:
:
:
Dye type ink cartridge installed

Pigment or Eco-solvent type ink cartridge installed
Wash fluid cartridge installed
Other ink cartridge installed
1-2
Make sure the detector assembly connector is making contact.

Reconnect junction board assembly connectors J406 (INK ID Sensor1 BK), J407 (INK
ID Sensor2 C), J408 (INK ID Sensor3 M), J409 (INK ID Sensor4 Y), J412 (INK ID
Sensor5), J413 (INK ID Sensor6).
1-3

J401 (ink ID cable) on the junction board assembly and J109 (INK ID) on the main board
assembly.
Disconnect and reconnect them.
1-4

(b) If there is no change at all in the symptoms, it means that the junction board assembly or the main board assembly may be faulty.
1470
1470
1140
EXA1150
Data Errors
No.
Symptom
Network Detection Error

The optional network board can not
be detected
Network Initialization Error

An error has occurred during the
optional network board initialization
operation
Sequence
EXA1230
GO TO Ref. Pages
R E P
1-1

Replace it.
1-2
The Ethernet board assembly may be damaged.

Replace it.
B A C
1140
Go to MAP1200
Data Errors
EXA1230

No.
Symptom
MH01 Error (Undefined Command)

A command that is not defined in any
command mode has been analysed
MH02 Error (Parameter Error)

Wrong number of parameters following the command
MH03 Error (Numerical Error)

Wrong number of parameters following the command
MH04 Error (Undefined Character

Set)
A nonexistent character set is present
MH07 Error (Buffer Overflow)

The polygon buffer or the downloadable character buffer has overflowed
Command Errors
Sequence
EXA1250
GO TO Ref. Pages
R E P
1-1
Try communicating with the available computer and cable.

Contact your Mutoh distributor.
1-2
Is there any record of an error in the printing data?

Try changing the type of application driver.
1-3
If the symptoms persist despite various application driver changes

Obtain the printing data (Report to the your distributor after you have obtained it).
1-4

Replace it.
Command Errors
B A C
1140
EXA1250

No.
1
Symptom
E001 Error DRAM (Standard DRAM
error)
CPU System Faults
GO TO Ref. Pages
Sequence
EXA1500
R E P
1-1

Replace it.
2-1
This error may occur when there is dust, etc. in extended memory slot 1 or slot 2.
Use an air duster to remove the dust and reinstall.
2-2
Install reliable memory of the same capacity and check with the self-diagnostic
Examination: Memory Capacity.
Replace optional memory.
2-3

Replace it.
B A C
1140
This error display means that a fault

has occurred in the standard memory
of the Main Board that controls the
printer.
E002 Error Opt. DRAM (Optional

DRAM error)
This error display means that a fault
has occurred in the optional memory
of the Main Board that controls the
printer.
CAUTION:
1010
1140
If only one extended memory is added, it must be installed in Slot 1.

(Rockhopper-46 has an extra 16 MB SIMM in Slot 1)
(Rockhopper-62 has an extra 32 MB SIMM in Slot 1)
CPU System Faults
EXA1500

No.
Symptom
E016 CPU Err [00] (Interrupt exception

error)
Indicates that handling an interrupt has
generated an error.
E016 CPU Err [02] (Command boundary

exception error)
Indicates that the boundary of a command
has caused an error.
E016 CPU Err [03] (Data boundary exception error)

Indicates that the boundary of a command
has caused an error.
E016 CPU Err [04] (Address error exception) (Load or command check)
Indicates that an address error has
occurred when checking a load or command.
CPU System Faults

Sequence
EXA1510
GO TO Ref. Pages
R E P
1-1
Check AC power supply and printer peripheral devices.

1-2
Check whether the problem recurs. Even if there is no problem, switch on several times.
(Use the same conditions as the customer's)
1-3
Check the serial number.

1-4

Replace it.
B A C
1140
5
E016 CPU Err [05] (Address error exception) (Store)
Indicates that an address error has
occurred when saving.
6
E016 CPU Err [06] (Bus error exception)

(Command check)
Indicates that a bus error has occurred
when loading or storing a command.
E016 CPU Err [07] (Bus error exception)

(Data load)
Indicates that a bus error has occurred
when loading or storing a command.
E016 CPU Err [08] (System call exception

error)
Indicates that a system call has caused an
error.
E016 CPU Err [09] (Break point exception

error)
Indicates that a break point has caused an
error.
CPU System Faults
EXA1510

No.
1
Symptom
E016 CPU Err [10] (Reserved command
exception error)
Indicates that a reserved command has
caused an error.
E016 CPU Err [11] (Unable to use
coprocessor exception error)
Indicates that the coprocessor has caused
an error.
E016 CPU Err [12] (Operation overflow
exception error)
Indicates that an overflow has occurred.
E016 CPU Err [13] (Trap exception error)

Indicates that a trap has occurred.
E016 CPU Err [15] (Floating point exception error)

Indicates that a floating point error has
occurred.
E016 CPU Err [22] (Watchdog timeout

exception error)
Indicates that the watch has caused an
error.
E016 CPU Err [32] (Watchdog timeout

exception error)
Indicates that a watchdog timeout has
occurred.
E016 CPU Err [33] (Abort error)

Indicates that an abort has occurred.
E237 Err Transfer Memory (Transfer

memory error/Transfer memory access
error)
Indicates that a fault has occurred in
transferring printing data that has been
analysed.
CPU System Faults

Sequence
EXA1520
GO TO Ref. Pages
R E P
1-1
Check AC power supply and printer peripheral devices.

1-2
Check whether the problem recurs. Even if there is no problem, switch on several times.
(Use the same conditions as the customer's)
1-3
Check the serial number.

1-4

Replace it.
CPU System Faults
B A C
1140
EXA1520

No.
1
Symptom
E129 Error NVRAM
This message indicates that a fault
has occurred in the NVRAM on the
Main board that records printer settings.
CPU System Faults

Sequence
1-1
EXA1530
GO TO Ref. Pages
R E P

Replace it.
CPU System Faults
B A C
1140
EXA1530

No.
1
Symptom
E065 Error X Motor
has occurred in the media feed motor
(X axis) while the printer was working.
This occurs when there is a large difference between the motor command
value and encoder feedback value.
E069 Error X Encoder
has occurred in the amount of media
movement (X axis) while the printer
was working.
This occurs when there is no encoder
feedback.
E071 Error X Timeout
This message indicates that a timeout
has occurred in the amount of media
movement (X axis) while the printer
was working.
This occurs when the pressure does
not reach its designated position.
GO TO Ref. Pages
Sequence
EXA1700
R E P
B A C
1-1
Use the self-diagnostic Examination: History to check the history of faults.
1070
1-2
Use the self-diagnostic Aging: Media Feed Motor with a setting of 50 times to check
whether the X Motor error occurs.
Check connectors J119 (X MOT) and J121 (X ENC) on the main board.
6020
1-3
Use the self-diagnostic Examination: Encoder to check Encoder X.

If it is no good, check the J121 (X ENC) cable connector.
1050
1-4
Check Power Supply Voltage Check 24 DC
1-5
The X Motor assembly may be damaged.

Replace it.
1070

Replace it.
1140
1-6
CAUTION:
If the Power supply board assembly and Main board assembly are
replaced without checking 24 V DC on those, there is a risk that
the new boards may also be damaged.
E073 Error X Overcurrent

has occurred due to an overload of
the media feed (X-axis) motor while
the printer was working.
EXA1700

No.
1
Symptom
EXA1710
GO TO Ref. Pages
Sequence
R E P
B A C
E066 Error Y Motor

has occurred in the head movement
motor (Y axis) while the printer was
working.
This occurs when there is a large difference between the motor command
value and encoder feedback value.
1-1
Use the self-diagnostic Examination: History to check the history of faults.
1070
1-2
With power off, move the carriage to left and right. Is the movement restricted?
Clean and lubricate the Y rail rollers.
6010
1-3
Use the self-diagnostic Aging: Carriage Motor with a setting of 50 times to check
whether the Y Motor error occurs.
Check cable connector J120 (Y MOT) on the main board.
E070 Error Y Encoder

has occurred in the amount of head
movement (Y axis) while the printer
was working.
This occurs when there is no encoder
feedback.
1-4
Check whether the timing fence (T fence) is dirty or twisted.

If there is grease or dirt on the fence, wipe it away with a dry cloth.
If there is ink on the fence, wet a cloth with neutral cleaner and wipe lightly.
If the T fence is severely soiled and can not be cleaned, it should be replaced
Replace the T fence.
1-5
E072 Error Y Timeout

This message indicates that a timeout
has occurred in the amount of head
movement (Y axis) while the printer
was working.
This occurs when the carriage has not
reached its designated position.
1-6
E074 Error Y Overcurrent

has occurred due to an overload of
the head movement (Y axis) motor
while the printer was working.
Use the self-diagnostic Examination: Encoder to check Encoder Y.

If it is no good, check cable connections J112 (HEAD2) on the main board assembly
and J202 (MAIN2) on the head board assembly.
Replace the Y motor assembly.
Replace the head board assembly.
Replace the Y cable (between J112 (HEAD2) on the main board and J202 (MAIN2) on
the head board)
Replace it.
CAUTION:
1300
1300
1280
1420
1360
1140

damaged.
The main board assembly will certainly be damaged if power is
applied with main board assembly connectors J111 (HEAD) and
J112 (HEAD2) and head board connectors J201 (MAIN1) and J202
(MAIN2) inserted with oblique FFP.
EXA1710

No.
1
Symptom
E075 Error Sensor Fault
This message indicates that condition
has occurred in which the origin cannot be detected.
R E P
1-1
Use the self-diagnostic Sensor: Origin and carry out the origin sensor test.
1-2
Check the origin sensor assembly connection.

J205 (H ORIGN) on the head board assembly.
Reconnect properly.
1-3
Check Y cable connections.

Check that they are not inserted obliquely.
J111 (HEAD1) on the main board assembly and J201 (MAIN1) on the head board assembly.
Insert them properly.
Replace the Y cable between J111 (HEAD1) and J201 (MAIN1).
1-5
EXA1720
GO TO Ref. Pages
Sequence
1-4
B A C
1040
1360
The origin sensor assembly may be faulty.

Replace it.
1450

Replace it.
1140
CAUTION:

damaged.
EXA1720
When Message is Displayed (on LCD heater)

No.
1
Symptom
Err : F.R.T. Sensor
Err : F.L.T. Sensor
Err : R.R.T. Sensor

Err : R.L.T. Sensor
GO TO Ref. Pages
Sequence
EXA1800
R E P
Is Front Right Temperature Sensor not connected / broken?

Reconnect sensor / replace the Front Paper Guide
1040
Is Front Left Temperature Sensor not connected / broken?

1040
Is Rear Right Temperature Sensor not connected / broken?

Reconnect sensor / replace the Rear Paper Guide
1040
Is Rear Left Temperature Sensor not connected / broken?

1040
Err : FRFLT Sensor
Are 2 Front Temperature Sensors not connected / broken?

Reconnect sensors / replace the Front Paper Guide
Err : FRRLT Sensor
Are
I
Front Right and Rear Left Temperature Sensor not connected / broken?
Reconnect sensors / replace the Front/Rear Paper Guide
1040
Err : FRRRT Sensor
Are Front Right and Rear Right Temperature Sensor not connected / broken
1040
Err : FLRLT Sensor
Are Front Left and Rear Left Temperature Sensor not connected / broken?
1040
Err : FLRRT Sensor
Are Front Left and Rear Right Temperature Sensor not connected / broken?
1040
Are two Rear Temperature Sensor not connected / broken?

Reconnect sensors / replace the Rear Paper Guide
Err : RRRLT Sensor
B A C
1040
1040
EXA1800
When Message is Displayed (on LCD Heater)

No.
1
Symptom
Err : 2FRLT Sensor
Err : 2FRRT Sensor
Err : FR2RT Sensor

Err : FL2RT Sensor
GO TO Ref. Pages
Sequence
EXA1800
R E P
Are two Front and Rear LeftTemperature Sensors not connected / broken?
1040
Are two Front and Rear Right Temperature Sensors not connected / broken?
1040
Are two Rear and Front Right Temperature Sensors not connected / broken?
1040
Are two Rear and Front Left Temperature Sensors not connected / broken?
1040
Err : All T Sensor
Are all Temperature Sensors not connected / broken?

Err : Heaters Stop
After
I
the heater start for 10 minutes andREAL temperature could not reach.
Replace the Front/Rear Paper Guide
B A C
1040
1040
EXA1800
When Message is Displayed (on LCD heater)

No.
1
Symptom
Err : F.R.T. Sensor
Err : F.L.T. Sensor
Err : R.R.T. Sensor

Err : R.L.T. Sensor
GO TO Ref. Pages
Sequence
EXA1800-2
R E P
Is Front Right Temperature Sensor not connected / broken?

1040 -2
Is Front Left Temperature Sensor not connected / broken?

1040 -2
Is Rear Right Temperature Sensor not connected / broken?

1040 -2
Is Rear Left Temperature Sensor not connected / broken?

1040 -2
Err : FRFLT Sensor
Are 2 Front Temperature Sensors not connected / broken?

Err : FRRLT Sensor
Are
I
Front Right and Rear Left Temperature Sensor not connected / broken?
1040 -2
Err : FRRRT Sensor
Are Front Right and Rear Right Temperature Sensor not connected / broken
1040 -2
Err : FLRLT Sensor
Are Front Left and Rear Left Temperature Sensor not connected / broken?
1040 -2
Err : FLRRT Sensor
Are Front Left and Rear Right Temperature Sensor not connected / broken?
1040 -2
Are two Rear Temperature Sensor not connected / broken?

Err : RRRLT Sensor
B A C
1040 -2
1040 -2
EXA1800-2
When Message is Displayed (on LCD Heater)

No.
1
Symptom
Err : 2FRLT Sensor
Err : 2FRRT Sensor
Err : FR2RT Sensor

Err : FL2RT Sensor
GO TO Ref. Pages
Sequence
EXA1800-2
R E P
Are two Front and Rear LeftTemperature Sensors not connected / broken?
1040 -2
Are two Front and Rear Right Temperature Sensors not connected / broken?
1040 -2
Are two Rear and Front Right Temperature Sensors not connected / broken?
1040 -2
Are two Rear and Front Left Temperature Sensors not connected / broken?
1040 -2
Err : All T Sensor
Are all Temperature Sensors not connected / broken?

Err : Heaters Stop
After
I
the heater start for 10 minutes andREAL temperature could not reach.
Replace the Front/Rear Paper Guide
B A C
1040 -2
1040 -2
EXA1800-2

No.
1
Symptom
No power
Faulty liquid crystal display (no

display/unstable display)
EXA2000
GO TO Ref. Pages
Sequence
1-1
R E P
Is there a broken or shorted lead in the switch cable assembly (between the switch and main borad
assembly)? Use a tester to check for broken or shorted leads.
Replace the switch cable assembly.
1-2
The inlet assembly may be faulty.

Replace it.
1-3
The power board assembly may be faulty.

Replace it.
1130
1150
2-1
Check the power supply check 120V AC or 240V AC.

(Differs according to sales region.)
2-2
Check the power supply voltage 5 V DC.
2-3
Check the power supply voltage 24, 42 V DC.
2-4
Check the connections of the panel cable connectors on the panel board assembly and main board
assembly.
Check that they are not inserted obliquely and that they are securely locked.
Reconnect main board assembly connector J110 (PANEL) and panel board assembly connector
J301 (MAIN).
2-5
The panel cable may be faulty.

Replace it.
1170
Is there a fault in the panel board assembly liquid crystal display?

Replace the panel board assembly.
1160

Replace it.
1140
2-6
2-7
CAUTION:
B A C
oblique FFP.
EXA2000

No.
1
Symptom
Initial filling of inks failed
This symptom means that when new
cartridges are first installed, or when a
new cartridge is fitted as a result of a
"no ink" message, the initial filling
operation is not performed.
Initial filling begins but the ink does
not reach the head or it reaches the
head but is not ejected.
Go to EXA2020
1-2
1-3
R E P
With the printer cover closed, is the liquid crystal display showing cover open?
Adjust cover switch height.
Check cover switch assembly connector.
J106 (COVER) on the panel board assembly
Replace cover switch assembly.
1110
Check panel cable connectors.

Reconnect main board assembly connector J110 (PANEL) and panel board assembly connector
J301 (MAIN).
Replace them.
1170
With the hold lever down, is the liquid crystal display showing lever up?
Adjust the lever sensor.
1100
1-4
Check J104 (LEVER) cable connection on the main board.

Re-insert it.
1-5
With the specified cartridge inserted securely, use the printer's self-diagnostic mode "Sensor: No
Ink" or "Sensor: No Cartridge" to check whether the presence of ink and cartridge are being detected normally.
Check using EXA1100 [65YMCK] No Cartridge procedure.
After adjustment or replacement, implement initial filling with the printer's self-diagnostic "Adjust:
Head Rank".
1-6
1-7
EXA2010
GO TO Ref. Pages
Sequence
1-1
1040
2040
With the specified cartridge inserted securely, use the printer's self-diagnostic mode "Sensor:
Cartridge" to check whether the status of the special cartridge is operating normally.
Check using EXA1080 "Insert special cartridge" procedure.
Head Rank".
Replace it.
After replacement, start self-diagnostic mode and carry out initial filling from Head Rank menu.
CAUTION:
B A C
1040
2040
1140
2040
Wait at least 30 minutes before printing after initial filling. Printing quality
can not be assured unless the ink filling is stabilized.
EXA2010

No.
1
Symptom
comes out
EXA2020
GO TO Ref. Pages
Sequence
1-1
R E P
Is the cap assembly spring fallen out or broken?

If it has fallen out, refit it.
If it is broken, replace the cap assembly.
1240
1-2
Is the capping position correct?

Adjust the capping position and check that the ink flows during cleaning.
If ink flows, carry out initial filling.
1-3
Are the pump assembly tubes connected to the cap assembly tubes?
Insert the pump assembly tubes into the cap assembly tubes.
1-4
Is there any looseness in the head unit, the flexible cable keeper unit under the head board, the ink
tubes behind the cartridge unit, or the SUS pipe connectors (Bk, Y, M, C, Lm, Lc)? Check that the
O-rings are fitted properly.
Remove the head cover and check the damper assemblies at the base of the tubes for all four
black and colour ink tubes.
Remove the Y Rail cover and cartridge cover and check the flexible cable keeper unit under the
head board assembly and the sides of the cartridge.
1-5
Is there an air leak in the damper assembly shield unit?

Replace the damper assembly and check that ink flows during the cleaning action.
1430
Are the ink tubes damaged inside the pump assembly?

Replace the pump assembly and check that ink flows during the cleaning action.
1260
1-6
1-7
1-8
1-9
B A C
2040
2040
Is the pump motor turning during the cleaning action?

Check the pump motor cable connector J102 (PUMP MOT) on the main board and try again.
Replace the pump motor.
If the pump motor does not turn after performing the above tasks, replace the main board
assembly.
1230
1140
Was there any mismatching of gears during the cleaning operation?

Replace the maintenance station assembly.
1270
Was the transfer gear shaft damaged during cleaning?

1270
EXA2020

No.
1
Symptom
comes out
EXA2021
GO TO Ref. Pages
Sequence
1-10
R E P
Are there any breaks, cuts or air leaks in the ink tubes?
Change each ink tube, cleaning each time and checking that ink flows during cleaning.
1-11
Check that connectors J207 (HEAD C1) and J208 (HEAD C2) on the head board assembly, and
head cables on the print head are not inserted obliquely, and they are locked securely.
Insert the connectors again.
1-12
Is there a broken lead in head cables?

Replace head cables.
B A C
1370
1400
1-13

1-14

Replace it.
1-15
Check that the Y cable connector is connected securely and not inserted obliquely.
Reconnect head board assembly connectors J201 (MAIN1) and J202 (MAIN2) and main board
assembly connectors J111 (HEAD1) and J112 (HEAD 2).
1-16
Is there a broken lead in Y cables?

Replace Y cables.
1-17

Replace it.
1390
1420
1360
1140
CAUTION:
oblique FFP.
EXA2021

No.
1
Symptom
After power is switched on, nothing
works
If nothing is displayed on the panel
liquid crystal display unit.
Go to EXA2000
R E P
With the printer cover closed, is the liquid crystal display showing cover open?
Does the cover switch assembly function work normally with the self-diagnostic
Examination/Sensors?
Adjust cover switch assembly height.
Check cover switch assembly connector and J106 (COVER) on the panel board assembly.
Replace cover switch assembly.
Check panel cable connectors.
Check that they are not inserted obliquely and they are securely locked.
Reconnect the main board assembly connector J110 (PANEL) and the panel board assembly
J301 (MAIN).
Replace them.
When power is applied, Initializing

appears and then a reset is executed.
Media is mounted but the initialization

operation is not done
1-3
Printer does not work even with the

cover closed
1-4
Check J104 (LEVER) cable connection on the main board assembly.

Re-insert it.
1-5
Does the XR cable assembly (rear paper sensor) detect normally with the self-diagnostic
Examination/Sensors?
Check the connections of the paper sensor connectors J107 (XR) on the main board assembly.
Replace the XR cable assembly (rear paper sensor).
Printer does not stop even with the

cover opened.
B A C
1040
1110
1-2
EXA2030
GO TO Ref. Pages
Sequence
1-1
With the hold lever down, is the liquid crystal display showing lever up?
Check the lever sensor connector J104 (LEVER) on the main board assembly.
1170
1110
1100
1-6
Carry out 5 V DC Power Supply Check and 24, 42 V DC Power Supply Check
Replace the power board assembly.
1-7
Is the cable of the switch cable assembly connected properly to J100 (MAIN SW) on the main
board assembly? (Refer to EXA2000)
Reconnect it.
1-8
1190
1200
1150
The switch cable board assembly may be faulty.

Replace it.
1130
EXA2030

No.
1
Symptom
After power is switched on, nothing
works
If nothing is displayed on the panel
liquid crystal display unit.
Go to EXA2000
When power is applied, Initializing

appears and then a reset is executed.
Media is mounted but the initialization

operation is not done
Printer does not work even with the

cover closed
Printer does not stop even with the

cover opened.
1-10
EXA2031
GO TO Ref. Pages
Sequence
1-9
R E P
Is the DC cable assembly connected properly to J001 on the power board assembly and
J101 (MAIN POWER) on the main board assembly? (See EXA2000)
Reconnect it.
Replace it.
1130

Replace it.
1140
B A C
EXA2031

No.
1
Symptom
Ink cartridges are installed but not
recognized
1-2
Model Name: Rockhoppper-46/62
"Sensor: No Ink" or "Sensor: No Cartridge" to check whether the presence of ink and cartridge are being detected normally.
Check using EXA1100 [65YMCK] No Ink procedure.
After adjustment or replacement, implement initial filling with the printer's self-diagnostic "Adjust: Head Rank".
"Sensor: Cartridge" to check whether the status of the special cartridge is operating normally.
Check using EXA1080 "Insert special cartridge" procedure.
After adjustment or replacement, implement initial filling with the printer's self-diagnostic "Adjust: Head Rank".
CAUTION:
EXA2040
GO TO Ref. Pages
Sequence
1-1
R E P
B A C
1350
1040
2040
1040
2040
Wait at least 30 minutes after initial filling before printing. Printing

quality can not be assured unless ink filling has been stabilized.
EXA2040

No.
1
Symptom
Can not make entries from the operating panel
GO TO Ref. Pages
Sequence
EXA2050
R E P
1-1
Is the panel cover key input unit broken?

Replace the panel cover.
1-2
Check the panel cable connectors.

Check that they are inserted obliquely and securely locked.
Reconnect main board assembly connector J110 (PANEL) and panel board assembly
connector J301 (MAIN).
Replace the panel cable.
1170
1-3
The panel board assembly may be damaged.

Replace the panel board assembly.
1160
1-4

1140
B A C
EXA2050

No.
1
Symptom
Data is received but not printed
EXA2060
GO TO Ref. Pages
Sequence
1-1
R E P
B A C
For checking, use Cannot connect normally with Centronics or Ethernet Board procedures shown in EXA7000.
EXA2060

No.
1
Symptom
GO TO Ref. Pages
Sequence
R E P
1-1
Are the media suction fans turning?

If they are not turning, go to consultation 1-4.
1-2
Are XR cable assembly (rear paper sensor) and edge sensor detecting normally according to the self-diagnostic sensor test?
Check the connections of XR cable assembly and edge sensor.
XR cable assembly is the main board assembly J107 (XR).
Edge sensor is the head board assembly J204 (P EDGE).
Replace XR cable assembly and edge sensor.
1-3
EXA2070
Are the fans working normally according to the self-diagnostic test?

Check the connectors between fan assembly, fan extension cable assembly and main
board assembly.
Fan extension cable 1 assembly is J115 (FAN1) on the main board
Replace fan extension cable 1 ~ 3.
1-4
Is shielding material fixed securely in the specified places?

Shield GA-A, Shield GA-B, Shield GA-C
Refit shielding securely.
1-5
Is +24 V being output between Pin 11 (GND) and Pin 10 (+24V) of connector J001 on the
power board assembly?
1-6
Carry out the "24 V and 42 V power voltage check".
1-7

Replace it.
B A C
1040
1190
1200
1060
1080
1140
EXA2070

No.
1
Symptom
GO TO Ref. Pages
Sequence
R E P
1-1
Are the media suction fans turning?

If they are not turning, go to consultation 1-4.
1-2
1-3
EXA2070-2

board assembly.
1-4

1-5
Is +24 V being output between Pin 11 (GND) and Pin 10 (+24V) of connector J001 on the
power board assembly?
1-6
Carry out the "24 V and 42 V power voltage check".
1-7

Replace it.
B A C
1040
1190
1200
1060
1080
1140
EXA2070-2

No.
Symptom
The media is skewed or meanders

when it is initialized or during printing
The media becomes wrinkled when it

is initialized or during printing
The media jams when it is initialized

or during printing
The media tears when it is initialized

or during printing
1-2
R E P
Are XR cable assembly (rear paper sensor) and edge sensor detecting normally according to the
self-diagnostic sensor test?
assembly.
1-3

1-4
When the pressure lever is raised and lowered, does the pressure unit move up and down smoothly at the same time?
Apply grease (G-501) if it does not move smoothly.
1-5
1-6
EXA3000
GO TO Ref. Pages
Sequence
1-1
Is the pressure roller pressing on the media over its entire length?
With the pressure lever up, does the pressure rollers seem reluctant to turn?
With the pressure lever down, does the pressure rollers idle or contact the platen on one side?
With the pressure lever down, is the blade pressing firmly on the media?
If there are paper dust or scraps near the pressure roller, wipe with soft damp cloth.
If necessary, replace pressure assembly, pressure rollers and blade.
If the gap between platen and plate is less than 0.2 mm, adjust platen height.
Is there major distortion, damage or foreign matter on the front and rear paper guides?
Replace front and rear paper guides.
1-7
Are the adjustment of scroller position and fitting of flanges correct?

Adjust scroller position correctly.
Fit flanges correctly into the core of the roll media.
1-8
Is there major distortion or damage to the grid roller?

Replace the grid roller.
B A C
1040
1200
1410
1060
1080
1220
1220
1520
1040
1040-2
1690
EXA3000

No.
Symptom
The media is skewed or meanders

when it is initialized or during printing
The media becomes wrinkled when it

is initialized or during printing
The media jams when it is initialized

or during printing
The media tears when it is initialized

or during printing
1-2
R E P
Are XR cable assembly (rear paper sensor) and edge sensor detecting normally according to the
self-diagnostic sensor test?
assembly.
1-3

1-4
When the pressure lever is raised and lowered, does the pressure unit move up and down smoothly at the same time?
Apply grease (G-501) if it does not move smoothly.
1-5
1-6
1-7
EXA3000-2
GO TO Ref. Pages
Sequence
1-1
B A C
1040
1200
1410
1060
1080
1220
1220
1520
1040
1040-2
Are the adjustment of scroller position and fitting of flanges correct?

Adjust scroller position correctly.
Fit flanges correctly into the core of the roll media.
EXA3000-2

No.
Symptom
The media size is different after

media mounting and initialization
Tracing paper and thin media cannot

be detected
GO TO Ref. Pages
Sequence
EXA3010
R E P
1-1
Is the media mounted recommended by Mutoh?

If it is not media recommended by Mutoh (especially thin tracing paper, etc.), the paper
sensors may read incorrectly and be unable to recognize the media.
Mount recommended media and try again.
1-2
B A C
1040
1200
1410
1-3
1040
Use the printer's self-diagnostic Sensor: Edge to confirm the amount of sensor reflection. Using thick coated paper, check whether the paper detection value is within 0090 to
00a4.
Check edge sensor connector and head board assembly connector J204 (PEDGE).
Adjust the detection value with the head board assembly variable resistor.
1410
1-4
1-5
Check the Y cable connectors.

Reconnect main board assembly connector J111 (HEAD1) and head board assembly
connector J201 (MAIN1).
Replace the Y cable.
1360

Replace it.
1140
CAUTION:

damaged.
EXA3010

No.
1
Symptom
Does not print continuously
GO TO Ref. Pages
Sequence
EXA4000
R E P
1-1
Is there a problem with the printer driver software?

Upgrade the printer driver version.
1-2
Is there a problem with the program ROM?

Upgrade the version.
1-3

Replace it.
B A C
1140
EXA4000

No.
1
Symptom
There is an extra feed after printing is
finished
EXA4010
GO TO Ref. Pages
Sequence
1-1
R E P
Is XR cable assembly (rear paper sensor) detecting normally according to the self-diagnostic sensor test?
Check the connections of XR cable assembly and main board assembly J107 (XR).
Replace XR cable assembly.
1-2

1-3

1-4

Replace it.
B A C
1040
1200
1200
1140
EXA4010

No.
1
Symptom
Bad example
Sequence
Clean twice in succession.
1-2
Are the ink tubes filled with ink?

Carry out initial filling.
GO TO Ref. Pages
Wait at least 30 minutes after initial filling before printing. Printing quality can
not be assured unless ink filling has been stabilized.
Print the self-diagnostic Printing: Nozzle Check Pattern and the Test Printing.
If the nozzle check pattern is printed normally, go to EXA4060.
1-4
Does the pump motor turn during the cleaning operation?

Check the connection of pump motor assembly connector and J102 (PUMP) on the main board
assembly.
Replace the pump motor assembly.
If the pump motor still does not turn, replace the main board assembly.
1230
1140
Are the gears and transfer gear shaft broken or badly meshed during the cleaning operation?
1270

If it is broken, replace the cap assembly of the maintenance station assembly.
1240
1270
Cleaning does not cure clogging or

deflection
1-7
Clogging: There is a discontinuity in line G of

the Test Print.

Adjust the capping position, carry out strong cleaning and try again.
1-8
What is the condition of the wiper section?

Dampen the accessory cleaning cloth slightly with clean water and use it to wipe the surface of
the cleaning wiper. After the wiper has been cleaned, carry out two successive cleanings.
If it is wet with ink, replace it.
1-9
1-10
B A C
2050
or
PAT1000
1-3
1-6
Deflection: There is a deflection or offset in

the step pattern in line G of
the Test Print.
EXA4020
R E P
1-1
1-5
CAUTION:
Good example
1250
Are the nozzle surfaces being wiped and rubbed?

Check how the wiper is fitted and fasten it correctly.
1250
Does the head that is fitted have a rank that is different from the recorded rank?
Re-enter the rank of the head correctly.
1390
2040
EXA4020

No.
1
Symptom
Bad example
Good example
1-13
EXA4021
GO TO Ref. Pages
R E P
Has ink dried on the surface of the print head and inside the nozzles?
Use the self-diagnostic Adjustment: Head Cleaning to clean the print head, carry out initial filling with Adjustment: Head Rank and try again.
Clean the head nozzle face.
CAUTION:
1-12
Sequence
1-11
B A C
1620
1660
Check that the T-fence and Encoder behind the head board assembly are not touching.
If they are touching, adjust them.
If adjustment is not effective, replace both the head board assembly and the T-fence.
1420
1300
Are the tubes crushed inside the pump assembly?

Replace the pump assembly and check the ink flow. If it is good, carry out initial filling.
1260
1-14

Replace the obstructed print head assembly.
1-15

Replace it.
1390
1400
1140
Cleaning does not cure clogging or

deflection
Clogging: There is a discontinuity in line G of
the Test Print.
Deflection: There is a deflection or offset in

the step pattern in line G of
the Test Print.
EXA4021

No
SINTOMA
EXA4030
GO TO Ref. Pages
Sequence
R E P
No imprime nada
1-1
Check 24, 42 V DC Power Supply Check.
Does not print a specific colour
1-2

If it is broken, replace the cap assembly.
Bad example
B A C
1240
1-3

Adjust the capping position and use the cleaning operation to check ink flow.
If ink flow is confirmed, carry out initial filling.
1-4
Check the Y cable connections.

Check that they are not inserted incorrectly.
J201 (MAIN1) and J202 (MAIN2) on the head board
J114 (HEAD1) and J115 (HEAD2) on the main board
Reconnect main board assembly connector J111 (HEAD1) and head board assembly connectors
J201 (MAIN1) and J202 (MAIN2).
Replace both Y cables.
1360
1-5
Is there any looseness in the head unit, the flexible cable keeper unit under the head board assembly, the ink tubes behind the cartridge unit, or the SUS pipe connectors (Bk, Y, M, C, Lm and Lc)?
Check that the O-rings are fitted properly.
Remove the head cover and check the damper.
Remove the Y Rail cover and cartridge cover and check the flexible cable keeper unit under the
head board assembly and the sides of the cartridge.
Good example
1-6
1-7
1-8
Is there an air leak in the damper assembly shield unit?

Replace the damper assembly and check that ink flows during the cleaning action.
1430

Replace the pump assembly and check that ink flows during the cleaning action.
1260
Is there an air leak in the ink tubes?

Replace each ink tube, cleaning each time to check for ink flow.
1370
CAUTION: Wait at least 30 minutes after initial filling before printing. Printing quality can
EXA4030

No.
Symptom
NO IMPRIME NADA
Does not print a specific colour

Bad example
1-10
1-11
1-12
1-13
Good example
1-14
EXA4031
GO TO Ref. Pages
Sequence
1-9
R E P
Head Rank".
1040
2040
Check the connections of head cables 1 and 2.

Check that they are not inserted obliquely and they are securely locked.
J207 (HEAD BK), J208 (HEAD COL) on the head board assenmbly
Reconnect head board assembly connectors J207 (HEAD C1) and J208 (HEAD C2).
Replace head cables 1 and 2.
1390

Replace it.
1420
Is the main board assembly damaged?

Replace it.
1140

1390

Check the pump motor cable connector J102 on the main board.
Replace the pump motor.
assembly.
1230
1-15
Was there any gear damage or mismatching of gears during the cleaning operation?
Replace the pump assembly.
1260
1-16
Was the transfer gear shaft damaged during cleaning?

1270
CAUTION:
B A C
Power must be off when connectors are being disconnected or reconnected,

otherwise you may be injured or a board may be damaged.
The main board assembly will certainly be damaged if power is applied with
main board assembly connectors J111 (HEAD) and J112 (HEAD2) and head
board connectors J201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP.
EXA4031

No.
1
Symptom
The entire surface is printed black
Bad example
1-2
EXA4040
GO TO Ref. Pages
Sequence
1-1
R E P
Check the connections for head cables 1 and 2.

Check that they are not inserted obliquely and they are locked securely.
Reconnect the head board assembly connectors J207 (HEAD C1) and J208 (HEAD
C2).
Replace the connectors.
B A C
1390
Check the Y cable connections

Reconnect main board assembly connectors J111 (HEAD1) and J112 (HEAD2), and
head board assembly connectors J201 (MAIN1) and J202 (MAIN@).
Replace both Y cables.
1360
1-3

Replace it.
1-4
The head head assembly may be damaged.

1420
Good example
1390
Replace it.
1-5
1140
CAUTION: Power must be off when connectors are being disconnected or reconnected, otherwise you may be injured or a board may be damaged.
applied with main board assembly connectors J111 (HEAD) and J112
(HEAD2) and head board connectors J201 (MAIN1) and J202 (MAIN2)
inserted with oblique FFP.
EXA4040

No.
Symptom
GO TO Ref. Pages
Sequence
R E P
Printing becomes shaded.
1-1
Is the usage site environment in accordance with the operating environment?

Use the printer in a proper operating environment.
The image contains blurs.
1-2
Transverse lines appear to be split.
Was the printing done immediately after initial filling?

Wait at least 30 minutes after initial filling before printing. Printing quality can not be assured
unless ink filling has been stabilized.
1-3

1-4
Are the fans working normally according to the self-diagnostic Examination: Fan?
assembly.
Replace Fan extension cables 1 ~ 3.
Split line
Direction of
media feed
Shading and
blurring
Black and white lines appear in the

printed image
(Not including gaps in the step patterns in locations 1G to 7G of the test
pattern)
If dots are missing, go to EXA4020
EXA4050
B A C
1060
1080
1080
1-5

Shield material GA-A, shield material GA-B, shield material GA-C
1-6
If the media in question is roll media, does the scroller rotate smoothly?
Adjust the position of the scroller support rollers.
Replace any roller that is damaged or that moves badly.
1-7
Is the X speed reduction belt tension adjusted to the prescribed value?

41.2 N (4.2 kg 0.2 Kg).
1-8

1250

Carry out repairs.
Replace the wiper.
1250
Direction of
media feed
Bad example
Good example
1-9
1560
Continued on next page (EXA4051)
EXA4050

No.
Symptom
GO TO Ref. Pages
Sequence
R E P
1-1

1-2
Was the printing done immediately after initial filling?

1-3

1-4
assembly.
Replace Fan extension cables 1 ~ 4.
Split line
Direction of
media feed
Shading and
blurring

printed image
pattern)
1080
1080

1-6
1-7

41.2 N (4.2 kg 0.2 Kg).
1-8

1250

Carry out repairs.
Replace the wiper.
1250
Good example
1-9
B A C
1060
1-5
Bad example
Direction of
media feed
EXA4050-2
1560
EXA4050-2

No.
Symptom
1-11
Split line
Direction of
media feed
Shading and
blurring
1-10
1-12

printed image
pattern)
R E P
Is the T-fence dirty?

Clean it.
If the T fence is severely soiled and can not be cleaned, replace it.

Check the pump motor assembly connector J102 (PUMP) on the main board assembly and try
again.
assembly.
Was there any mismatching of gears during the cleaning operation?
1-14

If the part has fallen out, refit it.
Replace the cap assembly or the maintenance station assembly.
B A C
1300
1220
1520
1230
1270
1-15
1-16
1-17
1240
1270
Are the tubes crushed inside the pump assembly?

Replace the pump assembly and check the ink flow. If it is good, carry out initial filling.
CAUTION:
Direction of
media feed
EXA4051
GO TO Ref. Pages
1-13
Bad example
Good example
Sequence
Re-insert print head rank correctly.
2040
The print head assembly may be damaged.

1390
EXA4051

No.
Symptom
R E P
1-19
Head Rank".
Split line
CAUTION:

printed image
pattern)
1-20
1-21
EXA4052
GO TO Ref. Pages
1-18
Direction of
media feed
Shading and
blurring
Sequence
B A C
1040
2040

Replace it.
1140

Replace it.
1420
Direction of
media feed
Bad example
Good example
EXA4052

No.
1
Symptom
Edges of printing are blurred
EXA4060
GO TO Ref. Pages
Sequence
R E P
1-1
Does cleaning restore normal operation?

Carry out three successive cleanings.
1-2
Is media recommended by Mutoh being used?

If the media is causing the symptoms, and it is not recommended media, the results
cannot be guaranteed. Please use recommended media.
1-3
Re-enter the rank of the print head correctly.
1390
Check that the T-fence and Encoder behind the head board assembly are not touching.
If adjustment is not effective, replace both the head board assembly and the T-fence.
1420
1300

Replace it.
1140
Bad example
1-4
1-5
Good example
B A C
2040
EXA4060

No.
Symptom
Printed lines appear blurred (printing

is dirty)
[ Bad example ]
1. Satellites
2. Whiskers
3. Blurring
GO TO Ref. Pages
Sequence
EXA4070
R E P
1-1

1-2
Is there sufficient ink remaining?

Replace with a new cartridge.
1-3
Do three cleanings in succession.
1-4
Have the Test Print printed. (Refer to PAT1000)

If the nozzle check pattern is printed normally, return to EXA4020.
1-5
Is the printing less than 30 minutes after initial filling?

1-6
Is the steel belt tension adjusted properly?

0.98 N (100 g 20 g)
1-7
Make sure the encoder and T-fence mounted on the back of the head board assembly are not
touching.
If adjustment does not solve the problem, replace both the head board assembly and the fence.
B A C
2050
or
PAT1000
1550
1-8
Is there a loose set screw on the Y drive pulley?

Re-tighten the set screw.
1-9

Adjust the capping position and try again after strong cleaning.
1-10

1420
1300
1250
[ Good example ]
EXA4070

No.
Symptom
Printed lines appear blurred (printing

is dirty)
1-12
1-13
[ Bad example ]
1. Satellites
2. Whiskers
1-14
1-15
1-16
1-17
3. Blurring
1-18
1-19
EXA4071
GO TO Ref. Pages
R E P
Is it able to wipe/rub the nozzle face normally?

Check how the wiper is fitted and fasten it correctly.
1250
1390

Replace the pump assembly and check that ink flows during the cleaning action. If ink flows,
carry out initial filling.
1260

Check the pump motor assembly connector J102 (PUMP) on the main board assembly and try
again.
assembly.
2040
1230
1270
Has the cap assembly spring fallen out or been broken?

If a part has fallen out, refit it.
Replace the cap assembly or maintenance station assembly.
1240
1270
B A C
2040
During the cleaning operation, was there any mismatching or damage to the gears or transfer gear
shaft?
CAUTION:
[ Good example ]
Sequence
1-11
1620
2040
1660

1390

Replace it.
1140
EXA4071

No.
1
Symptom
Bad example
1-2
1-3
Good example
1-4
1-5
1-6
Bad example
1-7
EXA4080
GO TO Ref. Pages
Sequence
1-1
R E P

0.98 N (100 g 20 g)
Readjust steel belt tension.
1550
Is the Y drive pulley set screw loose?

Re-tighten the set screw securely.
1310
Is there any mistake in the rank of the head that is actually installed and the rank that is
recorded?
B A C
2040
1390
Is the problem with the head tilt adjustment?

Adjust it.
2060
Is there a problem with the reciprocal printing position alignment?

Adjust it.
2080
Is there a problem with the CW adjustment?

Adjust it.
2090
Make sure the encoder and fence mounted on the back of the head board assembly are
not touching.
If adjustment does not solve the problem, replace the T fence.
1300
Good example
EXA4080

No.
1
Symptom
Inaccurate line length in the direction
of head movement (Main scanning
direction)
GO TO Ref. Pages
Sequence
EXA4090
R E P
1-1

1-2

0.98 N (100 g 20 g)
Re-adjust steel belt tension.
1550
Is the timing fence dirty or has foreign matter stuck to it?

Clean it.
Replace if soiling is not removed by washing or if there is damage.
1300

Re-tighten the set screw securely.
1280
1-3
1-4
1-5
The internal processing operation of the main board may be faulty.

Initialize, re-enter or re-adjust the parameters and try again.
B A C
5010
2000
Direction of media feed
EXA4090

No.
1
Symptom
Inaccurate straight line in the direction
of head movement (straightness)
EXA4100
GO TO Ref. Pages
Sequence
1-1
R E P
assembly.
Replace fan extension cables 1 to 3.
1060
1080
1080
1-2
Are the front paper guide and platen securely screwed?

Tighten it.
1-3

1-4
Is the X drive pulley set screw loose?

Replace the X motor assembly.
1070

41.2 N (4.2 kg 0.2 kg)
Readjust the X speed reduction belt tension.
1560
1-5

1-6
1-7
If the gap between platen and blade is less than 0.2 mm, adjust platen height.
B A C
1220
1520
EXA4100

No.
1
Symptom
of head movement (straightness)
EXA4100-2
GO TO Ref. Pages
Sequence
1-1
R E P
assembly.
1060
1080
1080
1-2
Are the front paper guide and platen securely screwed?

Tighten it.
1-3

1-4
Is the X drive pulley set screw loose?

1070

41.2 N (4.2 kg 0.2 kg)
Readjust the X speed reduction belt tension.
1560
1-5
1-6
1-7
B A C
1220
1520
EXA4100-2

No.
1
Symptom
Inaccurate line distance in the direction of media feed
(Subsidiary scanning distance)
R E P
1-1

1-2
Are you using adjusting the distance with the media that is being used?
Carry out distance adjustment.
Even if the distance adjustment is being done with the media that is in use, do it for the sake of
confirmation.
1-4
1-5
1-6

1-7
EXA4110
GO TO Ref. Pages
Sequence
1-3
[Standard value]
500 mm 0.1%
Since the adjustment here is 300 mm,
the measured value, x is such that
299.7 mm x 300.3 mm
2120
Is the X drive pulley loose?

1070
Is the X speed reduction belt tension adjusted to the specified value?

41.2 N (4.2 kg 0.2 kg)
Readjust X speed reduction belt tension.
1560
Is there major distortion in the X speed reduction pulley?

Replace the X speed reduction pulley.
1680
Is the rough surface of the grid roller worn in some places?

Is the grid roller heavy to turn? Or does it not turn smoothly?
Use a nylon brush to clean away any paper dust or paper scraps from the grid roller.
Adjust platen height or refit the rear paper guide.
1-8
1-9
If roll media is being used, does the scroller rotate smoothly?

Replace the scroller shaft.
Change the media that is being used.
B A C
1220
1520
1040-2
1520, 1040
1690
1040
1040-2
EXA4110

No.
1
Symptom
of media feed (joining precision Y)
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
EXA4120
GO TO Ref. Pages
Sequence
1-1
R E P
B A C
Is there any mistake in the rank of the head that is actually installed and the rank that is
recorded?
Enter the rank of the print head correctly.
1390
2040
Is the problem with the head tilt adjustment?

Adjust it.
1390
2060
Is the steel belt tension adjusted to the specified value?

0.98 N (100 g 20 g)
Readjust steel belt tension.
1550

Replace it.
1280
Is there a problem with the reciprocal printing position alignment?

Adjust it.
2080

Adjust it.
2090
Is the T fence dirty?

Clean it.
Replace if soiling is not removed by washing or if there is damage.
1300
Although the step pattern of the self-diagnostic "Head Nozzle Check" is well adjusted, if
the vertical lines of the "Black Head Tilt Check" do not join, carry out the following tasks.
Replace the steel flexible belt assembly.
1310
Is there play in the cursor?

Replace the CR flat spring or the cursor assembly.
1310
EXA4120

No.
1
Symptom
R E P
board assembly.
1-2

1-3
With the pressure lever down, does the pressure rollers idle or contact the platen on one
side?
1-4
EXA4130
GO TO Ref. Pages
Sequence
1-1

B A C
1060
1080
1080
1220
1520
1520, 1040
1690
EXA4130

No.
1
Symptom
R E P
board assembly.
1-2

1-3
With the pressure lever down, does the pressure rollers idle or contact the platen on one
side?
1-4
EXA4130-2
GO TO Ref. Pages
Sequence
1-1
B A C
1060
1080
1080
1220
1520

1520
1040-2(-2)
EXA4130-2

No.
1
Symptom
Abnormal noise when media is
sucked down
GO TO Ref. Pages
Sequence
EXA5000
R E P
1-1

1-2
Are the rotating fins of the suctions fans touching the cable or are there paper scraps and
foreign matter?
Remove obstructions and foreign matter.
1-3
Check for a broken cable and connections.

Replace any parts that are broken.
1-4
The fan itself may be faulty.

Replace it.
1080
The main board assembly may be faulty.

Replace it.
1140
The power board assembly may be faulty.

Replace it.
1150
1-5
1-6
B A C
EXA5000

No.
1
Symptom
Abnormal noise when standing by
ready to print
GO TO Ref. Pages
Sequence
EXA5010
R E P
1-1
Is there something touching or some foreign matter at the place producing the abnormal
noise?
Remove the obstruction or foreign matter.
1-2
It a board producing the noise?

Replace the board assembly in question.
Power board assembly
Main board assembly
Head board assembly
Print head assembly
B A C
1150
1140
1420
1390
EXA5010

No.
1
Symptom
Abnormal noise when head is moving
left and right
GO TO Ref. Pages
Sequence
EXA5020
R E P
1-1
The abnormal noise could be squirting noise when printing.

Explain specifications.
1-2
Is the abnormal noise caused by a loose screw on the cover?

Tighten the screws.
1-3
Is it a rattle when the cursor moves left and right?

Remove dirt from the carriage bearings and roller tracks.
Be sure to apply a light Sumi-grease spray to the roller tracks when you clean them.
1-4
Is the noise coming from the Y flexible plate?

Repair it by taking out warping.
If the noise is coming from between the steel flexible belt and the tube guide, replace
the tube guide assembly.
1540
1-5
Check whether the cable connected to the head board on the carriage is touching the
cover. Also, check whether is it touching the encoder and fence mounted at the back of
the head board.
If adjusting the position does not solve the problem, replace it.
1-6
Is the noise coming from the Y pulley box assembly bearing?

Replace the Y Motor assembly.
1280
1-7
Is the noise coming from the Y return pulley bearing?

Replace it.
1320
1-8

0.98 N (100 g 20 g)
Re-adjust steel belt tension.
1550
1-9
Is the Y drive pulley screw loose?

it securely.
1280
1-10
Is the noise coming from the Y motor assembly?

Replace it.
1280
B A C
EXA5020

No.
1
Symptom
Abnormal noise when media is fed
1-2
1-3
1-4
EXA5030
GO TO Ref. Pages
Sequence
1-1
R E P
Is the abnormal noise due to pressure roller deformation?

Replace them. Also, explain the need to raise the lever, as shown in the caution label,
when the printer is not printing.
1220
Is the X speed reduction belt out of tooth with the X speed reduction pulley?
Replace the X speed reduction belt.
1090
Is the noise coming from the X motor?

Replace it.
1070

B A C
1040-2
1520, 1040
1690
EXA5030

No.
1
Symptom
Abnormal noise when cutting
GO TO Ref. Pages
Sequence
EXA5040
R E P
1-1
Has the cutter cap been fixed securely on the top of the cutter as a result of checking in
the primary consultation?
Refit it.
1-2
Does the cutter move up and down smoothly?

Refit the spring and remove any foreign matter.
1-3
Is there foreign matter in the cutter groove and front surface of the printing board section?
Remove the foreign matter.
1-4
Is the cutter blade parallel with the printing board cutter groove?
Adjust it.
1-5
The cutter itself may be no good.

Replace it.
1-6

Replace it.
1420
The Y cable may be damaged.

Replace it.
1360
The power assembly board may be faulty.

Replace it.
1150
1-7
1-8
B A C
EXA5040

No.
1
Symptom
Does not cut normally
(Since there is no cutting of cut sheet
media, this item applies only to roll
media)
GO TO Ref. Pages
Sequence
EXA6000
R E P
1-1
Is the tip of the cutter blade chipped or worn?

Replace the cutter.
1-2
Is the cutter cap set securely on the top of the cutter?

Refit it.
1-3

1-4
Remove foreign matter.
Remove paper dust from the cutter groove.
1-5
Adjust it.
1-6
Use self-diagnostic "Aging:Cutter" to confirm up and down movement.

Check the connections on cutter solenoid assembly connector and head board assembly connector J206 (SOL).
If there is no up and down movement, the solenoid may be damaged.
Replace the cutter solenoid assembly.
1380
Check the Y cable connectors

Re-insert the main board assembly connector J111 (HEAD1) and the head board assembly connector J201 (MAIN1).
Replace them.
1360

Replace it.
1420

Replace it.
1140
1-7
1-8
1-9
CAUTION:
B A C
6030
Power must be off when connectors are being disconnected or reconnected,

otherwise you may be injured or a board may be damaged.
The main board assembly will certainly be damaged if power is applied with
main board assembly connectors J111 (HEAD) and J112 (HEAD2) and head
board connectors J201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP.
EXA6000

No.
1
Symptom

media)
R E P
1-1

1-2

1-3
Check the Y cable connectors.

Insert the main board assembly connector J111 (HEAD1) and the head board assembly J201 (MAIN1).
Replace them.
1-4
1-5
EXA6010
GO TO Ref. Pages
Sequence
Cutting occurs during printing

Replace it.
1360

Replace it.
1420
B A C
1-6
1140
Cut
EXA6010

No.
Symptom
GO TO Ref. Pages
Sequence
R E P
The cutting operation is normal but

the media is not cut
1-1
Is the cutter blade chipped or deteriorated as checked in the primary consultation?

Replace the cutter.
The cutting is bad and the media jams
1-2

Replace the cutter.
1-3
Refit it.
1-4
Is there foreign matter in the cutter groove and on the surface of front paper guide?
1-5
Is the cutter blade parallel with the front of the paper guide?
Adjust it.

media)
EXA6020
B A C
EXA6020

No.
1
Symptom
The cutting operation is normal but
the media does not fall out
media)
GO TO Ref. Pages
Sequence
EXA6030
R E P
1-1
Are paper guide surfaces being cleaned daily?

Clean the surfaces.
1-2
There may be a static charge on the front paper guide or media.

Make a proper earth connection.
Check the humidity of the usage environment and bring it within usage environment
specifications.
B A C
EXA6030

No.
1
Symptom
R E P
1-1

Replace the cutter.
1-2
Refit it.
1-3

1-4
1-5
Adjust it.
1-6
The cutter itself may be no good.

Replace it.
EXA6040
GO TO Ref. Pages
Sequence
Inaccurate media cutting
B A C
The media cutting precision of this

machine is x 0.3 mm
EXA6040

No.
Symptom
GO TO Ref. Pages
Sequence
EXA6050
R E P
Cutting is delayed for some time after

printing has ended
1-1
Are internal sample prints output without trouble?

Refer to EXA4030 "Does not print at all"
White paper is cut
1-2

1-3

1-4

Replace it.
B A C
PAT1000
1140
EXA6050

No.
Symptom
GO TO Ref. Pages
Sequence
EXA7000
R E P
Cannot connect normally with

Centronics
1-1
Try communicating with the available computer and cable.

Cannot connect normally with

Network
1-2
Does the error occur after the interface cable has been changed?
There may be a broken lead in the interface cable or the cable itself may be too long for good
communication.
Advise the use of a cable that conforms to specifications.
1-3

1-4

1-5
For network connections, make sure of the type of cable that is to be used for the connection environment.
For direct connection of one host and one printer Use a cross cable (100/10Base-T)
For connection of several hosts and one printer through a hub Use a straight cable (100/10BaseT)
B A C
To check connections to the network board, use the board accessory setup utilities or connect
directly to the computer (using a crossed cable in the case of 10BASE-T) and use the PING
command.
Example of use of PING command
PING (ping) is run from the MS-DOS prompt under Windows 95/NT.
Example: C:\WINDOWS>PING 192.168.41.34 [Enter]
PING may be upper or lower case.
Connection is indicated by a response such as:
Reply from 192.168.41.15: bytes=32 time=4ms TTL32
(This address is the default value.)
1-6
Replace it.
1140
EXA7000

No.
Symptom
GO TO Ref. Pages
Sequence
EXA7020
R E P
The scale function does not work correctly
1-1

The mirror function does not work correctly
1-2

Other functions are not working correctly
1-3

Replace it.
B A C
1140
EXA7020

No.
1
Symptom
Printing position is offset
GO TO Ref. Pages
Sequence
EXA7030
R E P
B A C
1-1

Adjust it.
2090
1-2
Is the front-sensor-to-head distance or the cutter-to-head distance causing a problem for

top and bottom margin distance adjustments?
Adjust them.
2130
1-3

1-4

1-5

Replace it.
1140
EXA7030

No.
1
Symptom
Some data are not printed (omitted)
GO TO Ref. Pages
Sequence
R E P
1-1

1-2

1-3
Check whether the timing fence is dirty or twisted.

If it is greasy or dusty, wipe it clean.
If it is ink stained wipe it lightly with a cloth damped in a neutral detergent.
If it is severely soiled and can not be cleaned, replace the T fence.
1-4
Check Encoder: Y that is in the self-diagnostics examinations. (Examination: Encoder)

If it is no good, check the cable connections of J112 (HEAD2) on the main board
assembly and J202 (MAIN2) on the head board assembly.
Replace the Y cable (between J112 (HEAD2) on the main board assembly and J202
(MAIN2) on the head board assembly).
1-5
EXA7040

Replace it.
B A C
1300
1300
1280
1420
1360
1140
EXA7040

No.
1
Symptom
Text and printing data are garbled
(extra lines appear)
GO TO Ref. Pages
Sequence
R E P
1-1

1-2

1-3
Check whether the timing fence is dirty or twisted.

If it is greasy or dusty, wipe it clean.
If it is ink stained wipe it lightly with a cloth damped in a neutral detergent.
If it is severely soiled and can not be cleaned, replace the T fence.
1-4
Check Encoder: Y that is in the self-diagnostics examinations. (Examination: Encoder)

If it is no good, check the cable connections of J112 (HEAD2) on the main board
assembly and J202 (MAIN2) on the head board assembly.
Replace the Y cable (between J112 (HEAD2) on the main board assembly and J202
(MAIN2) on the head board assembly).
1-5
EXA7050

Replace it.
B A C
1300
1300
1280
1420
1360
1140
EXA7050

No.
1
Symptom
There is an extra feed after printing is
finished
GO TO Ref. Pages
Sequence
EXA7060
R E P
1-1
Are the printing position and location method settings suitable?

Set them to suitable values.
1-2

1-3

1-4

Replace it.
B A C
1140
EXA7060

No.
1
Symptom
The printer hangs up
1-2
EXA8000
GO TO Ref. Pages
Sequence
1-1
Others
R E P
Bad internal processing in the main board?

Initialize parameters after switching the printer off and on temporarily, enter settings
manually and the check the operation.
Install the program and try again.
1600

Replace it.
1140
Others
B A C
EXA8000
Others

No.
1
Symptom
Power shutdown during printing
GO TO Ref. Pages
Sequence
EXA8010
R E P
1-1
Is there a short in the power cable.

Check it with a tester.
1-2
Is there a power leak?

Check for contact with the frame due to frayed covering.
1-3
Check power voltages

Power supply voltage check V AC (: 100, 120 or 240)
Power supply voltage check 5 V DC
Power supply voltage check 24, 42 V DC
1-4

Replace it.
Others
B A C
1150
EXA8010

No.
1
Symptom
The ink cartridges will not go in
1-2
EXA8020
GO TO Ref. Pages
Sequence
1-1
Others
R E P
Is the cartridge holder assembly needle deformed or broken?

Replace the cartridge frame assembly.
1330
Is the ink present/absent sensor (a black plastic lever switch) on the detector assembly
damaged?
Replace it.
1350
Others
B A C
EXA8020

No.
1
Symptom
Ink has overflowed from the waste fluid bottle
Check inside the waste fluid bottle. If it is full of ink, explain to the customer as you replace the waste fluid bottle.
1-2
Use the self-diagnostic "Sensor: No Ink" to check the cartridge that has no ink.
Remove all cartridges and check that the "No Ink" display changes when you gently press the black plastic
switches of all the detector assemblies On and Off.
Ink overflows from flushing box
Ink is spilt around the X rail
Ink has overflowed from the waste fluid bottle
R E P
B A C
1350
1040
Use the printer's self-diagnostic "Sensor: Tank Exist/Tank is not" to make sure that the waste fluid bottle detection
is working normally.
If the display is not normal, the sensor mounting position may be at fault.
Adjust the mounting position of the waste fluid bottle detection switch assembly.
Check the waste fluid bottle detection switch contact.
J109 (INK TANK) on the main board
Insert it correctly.
Replace it.
1040
1120
1-5
Is the waste fluid tube from the flushing bottle kinked?

Fix it and attach it again.
2-1
Is the flushing box choked with trash?

Remove the trash.
Replace it.
2-2
Is the waste fluid tube from the flushing box kinked?

Fix it and attach it again.
2-3
Is the absorbent material for flushing box full of ink?

Replace it.
1700
The extension tube under the pump assembly may have come away.
Remove the maintenance station assembly and check whether the extension tube has come away.
Replace the pump assembly.
Replace the cap assembly.
1270
1260
1230
1240
The ink tube may be cut.

Replace the ink tube.
1370
3-1
3-2
EXA8050
GO TO Ref. Pages
1-1
1-4
Sequence
1-3
Others
3-3
Print head, main board assembly and head board assembly may be damaged.
Remove ink cartridges and check that each board is normal.
4-1
Is the waste liquid bottle full of ink?

Replace it.
1710
Others
EXA8050

No.
1
Symptom
Heater does not stop warming up.
Heater does not work.
Heater System
1-2
1-3
1-4
1-5
EXA9000
GO TO Ref. Pages
Sequence
1-1
R E P
Is Sensor Rear Heater broken?

Replace the Rear Paper Guide
1040
Is Sensor Front Heater broken?

Replace the Front Paper Guide
1040
Is cable damaged/broken of Rear or Front Heater?

Replace Rear or Front Paper Guide
1040
Is Front Heater broken?

1040
Is Rear Heater broken?

Heater System
B A C
1040
EXA9000

No.
1
Symptom
Heater does not stop warming up.
Heater does not work.
Heater System
1-2
1-3
1-4
1-5
EXA9000-2
GO TO Ref. Pages
Sequence
1-1
R E P
Is Sensor Rear Heater broken?

1040-2
Is Sensor Front Heater broken?

1040-2
Is cable damaged/broken of Rear or Front Heater?

Replace Rear or Front Paper Guide
1040-2
Is Front Heater broken?

1040-2
Is Rear Heater broken?

Heater System
B A C
1040-2
1040
EXA9000-2
Rockhopper-46
3 Replacement and Adjustment Procedures
REP0000
REP0000
Procesos de Ajuste y Recambio
Rockhopper-46
Rockhopper-62 Replacement and Adjustment Procedures
REP0000-3
Procedimiento de Ajustes y Recambio
REP0000-3
Rockhopper-46
REP0010

Front Cover
Panel Cover and Y Rail Cover
Right Side Cap and Left Side Cap
Control Box
Head Cover
X Motor Assembly
Switch Cable Assembly and DC Cable Assembly
Main Board Assembly
Panel Board Assembly and HeateryPanel Board Assembly
Panel Cable
REP 1010
REP 1020
REP 1030
REP 1040
REP 1041
REP 1050
REP 1060
REP 1070
REP 1080
REP 1090
REP 1100
REP 1110
REP 1120
REP 1130
REP 1140
REP 1150
REP 1160ly
REP 1170
REP 1180

Pump Motor Assembly
Cap Assembly
Wiper
Pump Assembly
Y Motor Assembly
Steel Belt
T Fence Assembly
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
Front / Rear Heater (or sensors)
1200
1220
1230
1240
1250
1260
1270
1280
1290
1300
Cursor Plate Spring and Steel Flexible Guide Assembly

Detector Assembly
Y Cable
Ink Tubes
Print Head Assembly and Head Cable
REP
REP
REP
REP
REP
REP
REP
REP
REP
1310
1320
1330
1340
1350
1360
1370
1380
1390
Y Paper Sensor Assembly

Head Board Assembly
Dampers
Cursor Assembly
Origin Sensor and Y Encoder
REP
REP
REP
REP
REP
REP
1410
1420
1430
1440
1450
1470
Platen Height Adjustment

Tube Guide Assembly
How to Adjust Print Head
REP
REP
REP
REP
REP
1520
1540
1550
1560
1570

REP 1590
REP 1600

X Speed Reduction Pulley Assembly
F Absorbent Material Assembly
REP
REP
REP
REP
REP
1620
1660
1680
1690
1700
(refer to)REP 1040
Rockhopper-46
REP0010
REP0010-3

Front Cover
Panel Cover and Y Rail Cover
Right Side Cap and Left Side Cap
Control Box
Head Cover
X Motor Assembly
Switch Cable Assembly and DC Cable Assembly
Main Board Assembly
Panel Board Assembly
Panel Cable
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
1010
1020
1030
1040-2
1041
1050
1060
1070
1080-2
1090
1100
1110
1120
1130
1140
1150
1160
1170
1180

Pump Motor Assembly
Cap Assembly
Wiper
Pump Assembly
Y Motor Assembly
Steel Belt
T Fence Assembly
REP
REP
REP
REP
REP
REP
REP
REP
REP
REP
1200
1220
1230
1240
1250
1260
1270
1280
1290
1300
Front / Rear Heater (or sensors)
(refer to)REP 1040-2
Cursor Plate Spring and Steel Flexible Guide Assembly

Detector Assembly
Y Cable
Ink Tubes
Print Head and Head Cable
REP
REP
REP
REP
REP
REP
REP
REP
REP
1310-2
1320
1330
1340
1350
1360-2
1370-2
1380
1390
Y Paper Sensor Assembly

Head Board Assembly
Dampers
Cursor Assembly
Origin Sensor and Y Encoder
REP
REP
REP
REP
REP
REP
1410
1420
1430
1440
1450
1470

Tube Guide Assembly
How to Adjust Print Head
REP
REP
REP
REP
REP
1520
1540-2
1550
1560
1570

REP 1590
REP 1600

X Speed Reduction Pulley Assembly
F Absorbent Material Assembly
Waste Fluid Bottle Assembly
REP
REP
REP
REP
REP
REP
1620
1660
1680
1690
1700
1700
REP0010-3
How to remove and replace the Right and Left Covers

Item
1. Removal and
Replacement
Procedure
REP1010

Before carrying out this operation, switch off the power supply and remove
the power plug.
Before removing the covers, remove roll media with scroller from scroller
receiver.
A
Right cover
Screw
Screw
Right Cover
1. Remove four screws.
2. The cover is caught at the place shown by arrow A. Remove the cover while
lifting in the direction of arrow B.
Left Cover
1. Remove in the same way as for the Right Cover.
Right cover
Screws
How to remove and replace the Right and Left Covers
REP1010
How to remove and replace the Front Cover

Item
1. Removal and
Replacement
Procedure
REP1020

Front Cover
1. Remove the Right Cover.
2. Loosen the two fastening screws on the right side of the Front
Cover. (Refer to the diagram on the right)
3. Loosen the Panel Cover Screw and remove the Panel Cover by
sliding it about 3 mm to the left.
4. Slide the right side Front Cover Shaft to the right.
5. Remove the Front Cover by sliding it to the right.
6. Replacement is the reverse of the removal procedure but before
replacing the Right Cover, open and close the Front Cover to
check that the Cover Switch is being pressed correctly.
Cover shaft R2
fastening screws
Slide the
cover shaft
Front cover
Pull out
How to remove and replace the Front Cover
REP1020
How to remove and replace the Panel Cover and Y Rail Cover
Item
1. Removal and
Replacement
Procedure
REP1030

Panel Cover
1. Loosen the two screws on the Front Cover Right Cover Shaft and
push the Front Cover to the left.
2. Loosen the Panel Cover Screw (1 screw) by 3 mm or remove it.
3. Slide the Panel Cover to the left (in the direction of arrow A) and
remove it towards you (in the direction of arrow B).
Panel cover
A
Screw
Y Rail Cover
1. Remove the Panel Cover.
2. Remove the Front Cover.
3. Remove the Cartridge Cover. (5 screws)
4. Remove the Y Rail Cover Screws (3 front/4 rear).
5. Remove the Y Rail Cover by lifting it upwards.
Screw
Screws
Screws
How to remove and replace the Panel Cover and Y Rail Cover
REP1030
How to remove and replace the Front Paper Guide and Rear Paper Guide
Item
REP1040

Rear Paper Guide
2. Remove the Left Cover.
3. Remove the Key Panel.
5. Remove the Y-rail Cover.
6. Remove the Ink Carriage Cover. (3 top/2 bottom screws)
7.. Remove the Small Rear Guide at the left rear side of
. the printer.
8 Remove the protection board at the left bottom side of the printer (6 screws).
Rear side
Small Rear Guide
.
9.. Loosen the cables from their cable clamps.
10.. Carefully loosen the connectors . Be sure not to damage
.. the cables or connectors.
11.. Carefully pull out the cables. Do not damage the cables
. or connectors.
12
. Remove the rear paper guide (with front heater).
13
. Assembling is the reverse of the removal procedure.
.
.
CAUTION:
When replacing the Rear Paper Guide, please be
Be carefully otherwise you may suffer an electrical shock.
Do not forget to lock the cables in their cable clamps.
sure
not
to
damage
the
cables.
REP1040
How to remove and replace the Front Paper Guide and Rear Paper Guide (bis)
Item
REP1040

Front Paper Guide
.
1.. Remove the protection board at the left bottom side of the printer (6 screws).
2.. Loosen the cables from their cable clamps.
3.. Carefully loosen the connectors . Be sure not to damage the cables or connectors.
4.. Carefully pull out the cables. Do not damage the cables or connectors.
5.. Remove the Front Paper Guide. Be sure not to damage any cables.
. Pull the Front Paper Guide carefully forward.
6.. Assembling is the reverse of the removal procedure.
.
.
CAUTION:
When replacing the Rear Paper Guide, please . be sure not
.
Be carefully otherwise you may suffer an electrical shock.
.
Do not forget to lock the cables in their cable clamps.
.
to
damage
the
cables.
Screws
Front side
Front paper guide
Screws
REP1040
Item
REP1040-2

Front Paper Guide
Heater Panel screws

2. Remove the Left Cover.
3. Remove the Key Panel.
5. Remove the Y-rail Cover.
6. Remove the Ink Carriage Cover. (3 top/2 bottom screws)
7.. Remove the Heater Panel Cover. (2 top screws)
. Loosen connectors J12 & J15
8 Remove screws from Front Paper Guide (with Front Heater).
Screws
Front side
Front paper guide
Screws
. (Remove 6 top/5 bottom screws)

9.. Remove the connectors & sensors. (2 yellow, 2 red, 1 brown ; use
. Tool TL-24000) (connector 240 VAC)
10. Remove Front Paper Guide (with Front Heater).
CAUTION:
Front Heaters
Connectors
When replacing the Front Paper Guide,

please be sure not to damage the cables.
Also keep the cables away from the fans and grid rollers.
REP1040-2
Item
REP1040-2

Rear Paper Guide
.
1.. Remove the Front Paper Guide.
2.. Remove the Support Brackets.
3.. Loosen cables and connectors from the rear heater.
4.. Open the PCB box.
5. Loosen the connectors from the rear hater to the heater panel.
Pull them to the top front side of the printer body.
6. Remove the first three Platen Fitting Boards starting from the righ.
. Mark their place, reinstallation must be on the same place.
7 Loosen the screws of the Rear Paper Guide. (6 top / 5 bottom screws) .
8. To remove the Rear Paper Guide, be sure you do not
. damage any cables. Pull the Rear Paper Guide
. carefully backwards.
Support Brackets
Rear side
Rear paper guide
Platen Fitting Board
REP1040-2
Item
REP1040-2

. Reinstallation of the Rear Paper Guide.
1. Place the Rear Paper Guide on the printer body.
2. Place the connectors and cables to the front of the machine.
3. When reinstalling the Rear Paper Guide be sure not to damage
. or block a cable or connector.
4. Place and lock the cables so that they can not touch the
. Grid Rollers.
5. Fix the Rear Paper Guide.
6. Reinstall the Platen Fitting Boards. (exact same place as before)
. Push downwards on the front (arrow A) so the boards can not
. touch the Grid Rollers.
7. Reconnect cables and connectors of the Rear Paper Guide.
8. Reinstall the Support Brackets. Be sure not to damage the cables.
9. Reinstall the Front Paper Guide
.
CAUTION:
Platen Fitting Board
When replacing the Rear Paper Guide,

please be sure not to damage the cables.
Also keep the cables away from the fans and grid rollers.
Connectors
Rear Heater
REP1040-2
How to remove and replace the Right Side Cap and Left Side Cap
Item
1. Removal and
Replacement
Procedure
REP1041

Right Side Cap
1. Remove the Front Paper Guide.
2. Remove Panel Bottom Cover. (4 screws)
3. Bring the Head to the middle.
4. Hold up the Front Box.
5. Remove two screws from the Front Side Cap.
6. Turn the Right Side Cap clockwise and remove it.
7. Refitting is the reverse of the removal procedure.
Front box
Left Side Cap

2. Remove X Motor Cover. (4 screws)
3. Hold up the Front Box.
4. Remove two screws from the Left Side Cap.
5. Remove the Left Side Cap upwards.
6. Refitting is the reverse of the removal procedure.
Right side cap
Left side cap
How to remove and replace the Right Side Cap and Left Side Cap
REP1041
How to open and close the Control Box

Item
REP1050

Before working, be sure to switch off power and remove the
power cable from the inlet.
Since the Control Box will hit the roll media when it is
opened and can not be opened completely, the scroller
must be removed.
Opening and closing the Control Box

1. Removal and
Replacement
Procedure
1.
(Front)
Remove three hexagonal socket head bolts from the front of

the Control Box so that the Control Box Cover can be
removed.
2. Remove the three screws holding the Control Box.

Since the Control Box will fall open when the three fastening
screws are removed, support it with your hand as you
remove the screws.
3. Slide the Control Box Cover to the rear and lift it out.
Screws holding
Control box
Hexagonal socket head bolts
(Side)

2
1
Control box
Control box cover
How to open and close the Control Box
REP1050
How to remove and replace the Head Cover

Item
1. Removal and
Replacement
Procedure
REP1060

Head Cover
1. Open the Front Cover.
2. Slide the Head out from the Maintenance Station.
Caution:
When you pull the Head, dont press the cutter cap, otherwise the cutter blade will be
damaged.
Screw
3. Remove the Head Cover.

(2 fastening screws)
Screw
Head
How to remove and replace the Head Cover
REP1060
How to replace the X Motor Assembly

Item
1. Replacement
Procedure

1.
2.
3.
4.
5.
Remove the Front Paper Guide.

Remove the Left Cover.
Remove the Control Box.
Remove the X Motor Cover.
Disconnect connectors J120 and J121 from the Main Board
Assembly.
6. Remove one cable clamp (black) from the bottom surface of
the Rear Frame X Reinforcement and cut the cable tie that
holds the cables together.
7. Remove two cable clamps (metal) from the top surface of the
Front Frame X Reinforcement and withdraw the cables from
the hole in the Front X Reinforcement.
8. Loosen four screws holding the X Motor Assembly so that it
does not apply tension to the Speed Reduction Belt.
9. Remove the two screws that hold the X Motor to the X Motor
mounting plate and pull out the motor.
2. Adjustment
and
Examination
Procedure
REP1070
Adjust X Motor tension.
Front X Reinforcement
X Motor Assembly
fastening screws
X Motor fastening
screws
Slide
X Motor Assembly
fastening screws
Pull out
REP1070
How to replace the Fan Assembly and Fan Cable

Item
1. Replacement
Procedure
REP1080

Replace the Fan Assembly
2. Remove the Fan Duct. (3 fastening screws)
3. Remove the Fan Cable Connector.
4. Remove the Fan. (1 fastening screw)
Fan Assembly
Fan duct
fastening screws
Cable clamp
Replace Fan Extension Cables 1, 2 and 3
Fan duct
Fastening screw

3. Remove each Fan Cable Connector.
4. Remove each cable clamp.
6. Remove the two cable clamps on the Front Frame X
Reinforcement.
7. Remove one cable clamp on the Rear Frame X Reinforcement
and cut the cable tie that holds the cables together.
8. Disconnect connectors (J115, J116 and J117) from the Main
Board Assembly and remove the cables.
Fan connector
Fan connector
J117, J116 and J115
REP1080

Item
1. Replacement
Procedure
REP1080-2

Replace the Fan Assembly
2. Remove the Fan Duct. (3 fastening screws)
3. Remove the Fan Cable Connector.
4. Remove the Fan. (1 fastening screw)
Fan Assembly
Fan duct
fastening screws
Cable clamp
Replace Fan Extension Cables 1, 2, 3 and 4

Fan duct
Fastening screw

3. Remove each Fan Cable Connector.
4. Remove each cable clamp.
6. Remove one cable clamp on the Rear Frame X Reinforcement
and cut the cable tie that holds the cables together.
7. Disconnect connectors (J115, J116, J117 and J118) from the
Main Board Assembly and remove the cables.
Fan connector
Fan connector
J118, J117, J116
and J115
REP1080-2
How to replace the Speed Reduction Belt

Item
1. Replacement
Procedure

Replace the X Speed Reduction Belt
1. Loosen the four screws that fasten the X Motor Assembly to
loosen the belt tension.
2. Remove the X Motor (2 fastening screws) from the X Motor
Mounting Plate and take off the X Motor.
3. Undo the four screws holding the Speed Reduction Pulley
Support and remove the Speed Reduction Pulley Support.
4. Remove the X Speed Reduction Belt from the X Speed
Reduction Pulley.
2. Adjustment
and
Examination
Procedure
REP1090
X Motor Assembly
fastening screws
X Motor fastening
screws
X Motor Assembly
fastening screws
Speed reduction
pulley support
Adjust X Motor tension.
X speed
reduction belt
How to replace the Speed Reduction Belt
REP1090
How to replace the Lever Sensor Assembly

Item
REP1100
1. Replacement
Procedure
Replace the Lever Sensor Assembly

1.
2.
3.
4.
5.
6.
Remove the Front Paper Guide.

Remove the Panel Cover.
Remove the Panel Bottom Cover.
Remove the Right Cover.
Open the Control Box.
Disconnect the Main Board connector J104 (LEVER) and
cut the cable tie that holds the cables together.
7. Remove the Panel Cable connector and Tube Holder (one
fastening screw) and pull out connector J301 and the
Panel Cable (FFC).
8. Remove the Panel Mounting Plate.
(3 fastening
screws)
9. Remove the two black cable clamps attached to the Front
X Reinforcement and pull out the Lever Sensor Assembly
cable from the hole.
10. Remove the Lever Sensor Mounting Plate. (1 fastening
screw)
11. Remove the Lever Sensor. (2 fastening screws)
Dowel
Lever sensor
Assembly
+
Push up
Lever sensor mounting plate
Sensor fastening
screws
Cable clamp
2. Adjustment and Open the Lever and confirm that Lever Up is displayed.
Examination
Procedure
How to replace the Lever Sensor Assembly
REP1100
How to replace the Cover Switch Assembly
Item
1. Replacement
Procedure

Replace the Cover Switch Assembly
1. Remove the Panel Cover, Front Cover and Rail Cover
in that order then undo the two screws holding the Y
Rail Cover Support and remove the Y Rail Cover
Support. Then remove the Rear Paper Guide.
3. Undo the two screws holding the Ink Cartridge Unit
then lift it up a little and slide it so that you can see the
cable that passes beneath it.
4. Open the Control Box and pull out connector J106 from
the Main Board.
5. Remove the black cable clamp and cut the cable tie
that holds the cables together.
6. Remove the Cover Switch (2 fastening screws).
2. Adjustment
and
Examination
Procedure
REP1110
Cover sensor
arm
Sensor mounting
plate
Two fastening screws
of switch
Open the Front Cover and confirm that Cover Open is

displayed.
CAUTION: If the Cover Sensor Arm does not press
the Cover Switch when the Front Cover
is opened and closed, carry out the
"Sensor Mounting Plate Position Adjustment".
Fastening screws
Cover switch
+
+
Adjust timing
by sliding
Tighten after adjustment
How to replace the Cover Switch Assembly
REP1110
How to replace the Waste Fluid Bottle Sensor Assembly

Item
1. Replacement
Procedure
REP1120

Replace the Cover Switch Assembly
1. Remove the Waste Fluid Bottle.
2. Disconnect connector
3. Remove the Waste Fluid Bottle Sensor Assembly. (2 fastening
screws)
CAUTION: Be careful not to over-tighten when mounting the Waste Fluid Bottle Sensor Assembly.
How to replace the Waste Fluid Box Sensor Assembly
REP1120
How to replace the Switch Cable Assembly/CD Cable Assembly

Item
REP1130

CAUTION: The power cable connector must be disconnected before this operation.
1. Replacement
Procedure
Switch cable
assembly
Switch Cable Assembly Replacement

2. Disconnect connector J100 (SW) from the Main Board
Assembly.
3. Press the Switch Lock and remove it by pushing it out.
4. Remove the cable from the white Cable Clamp.
After fitting, check that the switch cable is not touching
power supply board.
Connector
J100 (SW)
DC Cable Replacement
2. Disconnect connector J001 from the Power Board Assembly.
3. Disconnect connector J101 (POWER) from the Main Board
Assembly and remove the cable.
Power board
assembly
Connector
J001 (POWER)
Connector J001
Connector
J100 (SW)
Main board
assembly
How to replace the Switch Cable Assembly/CD Cable Assembly
REP1130
How to replace the Main Board Assembly

Item
REP1140

For main board replacement, in addition to the new main board you must arrange for (1) a memory card for firmware installation and (2) a memory card
for backup parameters (Fujitsu 4 MB card is recommended).
Some memory cards do not always work.
This main board assembly is constructed to accept backup parameters (user parameters and adjustment parameters) in a flash memory card.
Caution:
Be sure to capture these backup parameters

before the board is replaced.
1. Capture back- 1. Be sure to take up backup parameters before the Main Board
up parameis replaced.
ters
Caution:
If you are unable to do this operation, ask to

see the user setup list.
For adjustment parameters, you can also
contact the Inquiry Desk with the serial number of your plotter and receive adjustment
parameters.
Memory card
slot
REP1140

Item
2. Replacement
Procedure
REP1141

2. Replace the Main Board
1) Disconnect all communications connectors.
2) If the Optional Interface is connected with the two Centronics
Interface connector screws, remove it now.
3) Open the Control Box.
4) Disconnect all Main Board Assembly connectors.
5) Remove the Extension Board Assembly (4 screws) and SIMM.
6) Remove the Main Board Assembly. (5 fastening screws)
7) Assembling is the reverse of the removal procedure.
Five main board

assembly fastening
screws
REFERENCE SIMM must be inserted from Slot 1.

REFERENCE Main board assembly DIP switches are for testing and have no settings.
CAUTION: Firmware installation and parameter recovery will be
carried out after this but these tasks must be done
after the connections have been checked and with the Four extension board assembly
fastening screws
Control Box closed.
Otherwise you may suffer an electric shock or components may be damaged.
3. Install latest
program
Extension board Main board

assembly
assembly
3. Install the latest program.
4. Install backup 4. Install the backup parameters that were taken up in Step 1 in the new
Main Board Assembly.
parameters
CAUTION: If backup parameters were not taken up in Step 1, enter them manually.
For the user setup list, refer to the section on How to set parameters in the Users Guide and Functional Operation Edition.
Also, for adjustment parameters, refer to BAC5020 (parameter update).
CAUTION: Replace the Waste Fluid Box if backup parameters were not taken up in Step 1.
The message Change Tank?: will appear on the panel display. You should confirm by answering Yes.
REP1141
How to replace the Power Supply Board Assembly

Item
1. Replacement
Procedure
REP1150

CAUTION:
The power cable connector must be disconnected before this operation.
CAUTION:
Since the power supply remains hot after the power is switched off, wait until it has cooled before performing this operation.
Replace the Power Supply Board Assembly
Connector J001
Connector J000

2. Disconnect Power Supply Board Assembly connectors J000
and J001.
3. Remove the Power Supply Board Assembly. (5 fastening
screws)
How to replace the Power Supply Board Assembly
REP1150
How to replace the Panel Board Assembly and Heater Panel Board Assembly
Item
1. Replacement
Procedure
REP1160

Replace the Panel Board Assembly
Panel board assembly

2. Disconnect connector J301 from the Panel Board Assembly.
3. Remove the Panel Board Assembly. (4 fastening screws)
Do not forget to peel the LCD protection film off.
Screws
1. Replacement
Procedure
Screws
Replace the Heater Panel Board Assembly

2. Remove the Heater Panel Cover (2 screws top/ 2 screws front)
3. Open the PCB box and remove the PCB cover plate.
4. Loosen connector J10
5. Carefully pull out the heater panel cable to the heater panel board.
6. Remove theHeater Panel Board.
.
Cable of
Heater Panel
Board
5 . For replacing the Heater Panel board on a Rockhopper 62"

CAUTION:
. please refer to REP 1040-2.
.
.
How to replace the Panel Board Assembly and Heater Panel Board Assembly
REP1160
How to replace the Panel Cable

Item
1. Replacement
Procedure
REP1170

Replace the Panel Cable
2. Remove the Panel Bottom Cover. (4 screws)
4. Disconnect connector J301 from the Panel Board Assembly.
5. Remove the Tube Guide. (1 screw)
6. Disconnect connector J110 (PANEL) from the Main Board
Assembly and remove the cable.
Connector J110
When re-laying a new Panel Cable, refer to the positions of

the bends in the previous cable and proceed after first making the bends in the new cable.
Use double-sided tape to stick the cable to the underside of
the X Rail.
How to replace the Panel Cable
REP1170
How to replace the Extension Board Assembly

Item
1. Replacement
Procedure
REP1180

Replace the Extension Board Assembly
1. Disconnect all communications connectors.
3. Remove the Extension Board Assembly. (4 fastening screws)
Four extension board assembly

fastening screws
How to replace the Extension Board Assembly
Extension board assembly
REP1180
How to replace the XR Cable Assembly (Rear Paper Sensor)

Item
1. Replacement
Procedure
REP1200

Replace the XR Cable Assembly (Rear Paper Sensor)
2. Remove connector J107 (XR) from the Main Board Assembly.
5. Remove the Y Rail Cover.
7. Remove the two screws holding the Sensor Mounting Plate
through the hole in the Flexible Support Cable Guide.
Five holes for removal
of rear paper guide
CAUTION: Be careful not to damage the Y Cable covering.
Two holes for removal

of sensor
8. Remove the sensor from the sensor mounting plate (2 screws)

on the Rear Frame X Reinforcement.
2. Adjustment
and
Examination
Procedure
1. Adjust the bundle of Y cable, N belt and ink tubes.

(Make sure the pressure arm is lowered then move the head
left and right so that there is no twisting.)
2. Carry out "Rear sensor position" with the printer's self-diagnostics under the adjustments menu.
Sensor fastening screws
XR cable assembly
(Rear paper sensor)
How to replace the XR Cable Assembly (Rear Paper Sensor)
REP1200
How to replace the Pressure Assembly, Pressure Roller and Blade

Item
1. Replacement
Procedure
REP1220

Replacing the Pressure Assembly
1. Remove right and left covers.
2. Remove panel cover.
3. Remove front cover.
4. Remove Y rail cover.
5. Remove front paper guide
6. Remove rear paper guide
7. Loosen two steel belt tensioning screws.
Tension screws
Steel belt
8. Remove one steel belt fastening screw.

9. Remove the steel belt.
Steel belt fastening screw
CAUTION: Be careful not to cut your finger on the edge

of the steel belt.
10. Remove the Y motor assembly. (3 fastening screws)
Three Y motor
fastening screws
Y motor assembly
REP1220

Item
1. Replacement
Procedure
REP1221
11. With the pressure roller down, loosen the set screw on the
pressure axle fastening spacer.
X rail
Fastening spacer
Ball screw driver
12. Operate the pressure lever and with the pressure roller up,
remove the E-ring holding the link.
E-ring
Link
13. The pressure axle that is stuck into the hexagonal hole in the
link should be pushed a little way in.
At this time, the stepped collar will come off so be careful not
to lost it.
REP1221

Item
1. Replacement
Procedure
REP1222

14. Pull out the pressure shaft from the right side of the frame.
CAUTION: Be careful. If the pressure axle is taken out
completely, the pressure axle fastening spacer and the media keeper will fall into the body
of the printer.
Pull out
Pressure shaft
Four
screws
15. Remove the four hexagonal nuts holding tube bracket and lift
the entire Y cable tube bracket while you undo the four nuts
holding the Y cable guide.
16. Remove the screws (5 at the back and 4 below) holding the
Y rail reinforcement plate and pull the entire pressure
assembly to the back while you slide it towards the X motor
and remove it.
REFERENCE A special ratchet tool is required for the
bottom screw holding the Y rail reinforcement plate (hex. 4 10 mm double SEMS).
Four hexagonal nuts

Hex. screw
Y rail reinforcement plate
17. Remove the pressure assemblies from the Y rail reinforcement plate. (2 screws for each assembly)
18. Refitting is the reverse of the removal precedure.
Ratchet screw
driver
Pressure assembly
REP1222

Item
1. Replacement
Procedure
REP1223

Blade Replacement
1. Open the front cover.
2. Use a fine straight screwdriver to slightly prize apart the blade
attachment and remove the blade.
Pressure arm
CAUTION: When removing the blade, dont use excessive force to part it as there is a risk of damaging the blade.
Open
Blade
3. To refit, insert the blade on the pressure arm.
Pressure Roller Replacement

1. Follow the blade replacement procedure to remove the blade.
2. Use a fine straight screwdriver to slightly prize apart the pressure roller attachment and remove the pressure roller.
CAUTION: When removing the blade, dont use excessive force to part the blade and pressure arm
as there is a risk of damaging the pressure
arm and the blade.
Pressure arm
Open
Pressure roller
3. To refit, insert the pressure roller and then the blade on the
pressure arm.
REP1223
How to replace the Pump Motor Assembly

Item
REP1230
1. Replacement
Procedure
Replace the Pump Motor Assembly

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Remove the Front Cover.
Remove the Right Cover.
Remove the Y Rail Cover.
Remove the Panel Cable connector and Tube Fixer (1 fastening
screw) and disconnect connector J301.
Remove the Panel Mounting Plate. (3 fastening screws)
Disconnect connector J102 (PUMP) from the Main Board
Assembly.
Remove the cable clamp fastened to the Front X Reinforcement.
Slide the head to the left (in the center section) and remove the
entire Maintenance Assembly. (2 top screws/2 front screws)
Remove the two screws holding the Pump Motor Plate and lift out
the Pump Unit.
Remove the four screws holding the Pump Motor Assembly.
Assembling is the reverse of the removal procedure.
CAUTION:
Apply silicone grease to motor gears.
CAUTION:
Pass the motor cable through the round hole in

the pump motor plate.
2. Adjustment and 1. Carry out the Capping Position Adjustment.

Examination
Procedure
How to replace the Pump Motor Assembly
REP1230
How to replace the Cap Assembly

Item
1. Replacement
Procedure
REP1240

Replace the Cap Assembly
Draw out the tube
(2 places)

4. Remove the Panel Bottom Cover.
6. Remove the Maintenance Assembly.
7. Draw out the tube on the panel side.
8. Remove one screw holding the Cap Assembly.
9. Slide the Cap Assembly towards the gear and lift it out.
Screw
CAUTION: Be careful not to touch the cap surface and

the wiper with your hand while you are working.
CAUTION: When you insert the tubes into the cap
assembly refer to the picture on the right so
that the tubes do not exert any load.
Otherwise the cap assembly will not move
smoothly.
CAUTION: When screwing the cap assembly to the maintenance frame, push it right back before fastening.
2. Adjustment
and
Examination
Procedure
1. Carry out the Capping Position Adjustment.
How to replace the Cap Assembly
REP1240
How to replace the Wiper

Item
1. Replacement
Procedure
REP1250

Replace the Wiper
2. Move the Wiper back and, with the Wiper rack disconnected,
pull the Wiper up and remove it.
Pull up
CAUTION: When refitting the Wiper, be careful not to

damage the Head contact surface by touching
it with your hand or with forceps.
2 Adjustment
and
Inspection
Procedure
1. Initialize the wiper count.

Wiper
Rack section
Felt surface
[ Printing roller side ]
How to replace the Wiper
Rubber surface
[ Cap side ]
REP1250
How to replace the Pump Assembly

Item
REP1260

REFERENCE When the pump assembly is replaced, the wiper
should also be replaced at the same time so be
sure to have a spare wiper ready.
Replace the Pump Assembly
1. Replacement
Procedure
1.
2.
3.
4.
5.
6.
7.

Remove the Panel Mounting Plate.
Take out the Maintenance Station Assembly.
Disconnect and remove the tubes between the Pump Assembly and the
Cap Assembly.
8. Remove the waste liquid tube that is clamped to the outside of the
Right Frame.
9. Remove the metal plate to which the gear is attached together with two
screws.
10. Remove the pump assembly (1 screw), slide it towards the wiper and
lift it out.
REFERENCE Before assembly, check that the wiper is installed
on the pump assembly.
2. Adjustment and 1. Carry out the Capping Position Adjustment.

Examination
Procedure
CAUTION:
Be sure to clamp the waste liquid tube in the

proper position on the outside of the right frame.
Otherwise the ink will spill and soil the floor and
clothing.
CAUTION:
When you insert the tubes into the cap assembly

refer to the picture on the right so that the tubes
do not exert any load.
Otherwise the cap assembly will not move smoothly.
How to replace the Pump Assembly
REP1260
How to replace the Maintenance Station Assembly

Item
1. Replacement
Procedure

Replace the Maintenance Station Assembly
4. Remove the Panel Bottom Cover.
7. Disconnect the pump motor connector J102.
8. Undo the bundle of cables.
9. Remove the waste liquid tube from the clamp.
10. Remove the Maintenance Station. (2 top screws/2 front
screws)
Screw
CAUTION: Be sure to clamp the waste liquid tube in the

proper position on the outside of the right
frame.
Otherwise the ink will spill and soil the floor
and clothing.
2. Adjustment
and
Examination
Procedure
REP1270
Screws
1. Carry out the Capping Position Adjustment.

How to replace the Maintenance Station
REP1270

Item
If there is to be no replacement that

includes the Y motor assembly, steps 2, 4
and 5 are not necessary.
Screws
Replace the Y Motor Assembly

3. Remove the Steel Belt.
5. Disconnect connector J120 (YMOT) from the Main Board
Assembly.
6. Remove the Y Motor Assembly. (3 fastening screws)
REFERENCE
2. Adjustment
and
Examination
Procedure
REP1280

REFERENCE
1. Replacement
Procedure
Y motor cable terminal
Since the Y Motor Assembly Cable passes below the Cartridge Unit, the work will
be easier if you remove the two Cartridge
Base screws and push it back.
Y motor assembly
REP1280
How to replace the Steel Belt
Item
REP1290

CAUTION:
Do this work with the pressure roller down.
Replace the Steel Belt
1. Replacement
Procedure
1.
2.
3.
4.
5.
Remove left and right covers.

Move the head to near the center.
Remove the head cover. (2 fastening screws)
Loosen the two steel belt tensioning screws.
Remove the belt fastening screw and take off half the steel belt
towards the Y motor side
6. overlap the end of the steel belt removed in 5. with the end of a new
steel belt and attach it with tape.
7. Pass the taped part around the drive pulley, press it into the Y rail
and pull it from the return pulley side and fit the new belt into the Y
rail.
Up to here
Press in
Tension adjustment screws
Tape to old belt using the fitting on

the front of the new belt
Steel belt
New steel belt

Old steel belt
CAUTION:
Check that there is no foreign matter or dust on

the new steel belt, drive pulley or return pulley as
this may cause abnormal printing or belt damage.
CAUTION:
Be careful not to cut your finger with the end of

the steel belt.
Fastening screws
8. Remove the tape and fasten the new steel tape to the head with the
two fastening screws.
CAUTION:
Be careful that the belt is not twisted in the Y rail.
2. Adjustment and 1. Adjust the steel belt tension.

Examination
Procedure
How to replace the Steel Belt
REP1290
How to replace the T Fence
Item
1. Replacement
Procedure
REP1300

Replace the T Fence
4. Loosen the 12 screws holding the T Fence keeper plate
(11 on 62-inch model), slide the
plate towards the Y Cable side, then remove the T Fence.
CAUTION: Mind the Head Board and take out the T
Fence on the X Motor side.
X motor
REFERENCE
2. Cleaning
Procedure
The T Fence has a front and a back.

Assemble it so that the round hole is at
the top on the X motor side or on the bottom on the maintenance unit side.
or
Correct
or
Wrong
Twelve fastening screws
T Fence
How to clean the T Fence

1. Gently wipe the T Fence with a lint-free cloth which has been
wet with water or ethanol. (Lint-free cloth is closely woven from
extremely fine threads and has no nap and produces no dust.)
CAUTION: When wiping the T Fence, be careful not to
rub it vigorously.
How to replace the T Fence
REP1300
How to Replace the Steel Flexible Guide Assembly and Cursor Plate Spring
Item
REP1310
1. Replacement
Replace the Steel Flexible Guide Assembly
Procedure
Removal 1. Remove the Panel Cover.
Hexagonal nut
(H for fitting flexible cable support is included.)
4. Remove 2 screws holding the Steel Flexible Cable Support to the H Board Fitting Plate.
5. Move the head towards the X Motor side.
Tube bracket
6. Remove the Cable Keeper on the Tube Keeper. (2 screws)
7. Undo the four places where the Tube Guide is clamping the Steel Flexible Cable Support and
remove the Steel Flexible Cable Support.
Cable keeper
Tube keeper
Screw
Cartridge pipe
Assembling 1.
2.
3.
4.
Screw the steel bare to the H Board Fitting Plate.

Clamp the Steel Flexible Cable Support to the Tube Guide.
Fully tighten the screws holding the Steel Flexible Cable Support to the H Board Fitting Plate.
Temporarily fasten the CableKeeper to hold the Steel Flexible Cable Support to the Tube
Guide.
5. Move the head inside the maintenance assembly then tighten the cable keeper.
Tube guide assembly
Steel flexible guide
Cursor plate spring
Replace the Cursor Plate Spring
1. Replacement
Procedure
(1) Press and remove
(2) Press
1.
2.
3.
4.

(3) Remove to left
Bring the head to center of the printer,
press down the left and right ends of
the cursor plate spring and pull it out to the right.
Ink tube
Tube guide assembly
Steel flexible guide
REP1310
Item
1. Replacement
Procedure
Removal 1.
2.
3.
4.
Replace the Steel Flexible Guide Assembly

Undo the two screws holding the steel bare to the H board mounting
plate (flexible cable support keeper on 62-inch models).
5. Move the head towards the X Motor side.
6. Remove the Cable Keeper on the Tube Keeper. (2 screws)
7. Undo the part that is clamping the steel bare for the ribbon cable
guide and remove the steel bare.
1. Screw the steel bare to the H Board Fitting Plate.

Assembling 2. Clamp the Steel Flexible Cable Support to the Tube Guide.
3. Fully tighten the screws holding the Steel Flexible Cable Support to
the H Board Fitting Plate.
4. Temporarily fasten the CableKeeper to hold the Steel Flexible Cable
Support to the Tube Guide.
5. Move the head inside the maintenance assembly then tighten
the cable keeper.
Steel flexible cable

Cable keeper
Tube keeper
[ 62 inch ]
H board mounting plate

Flexible cable support keeper
Cursor plate spring
Replace the Cursor Plate Spring

1. Replacement
Procedure
REP1310-2
(1) Press and remove

(2) Press
Ribbon cable guide
1.
2.
3.
4.

(3) Remove to left
Bring the head to center of the printer, press down
the left and right ends of the cursor plate spring and
pull it out to the right.
Clamping part
REP1310-2
How to replace the Y Return Pulley Assembly

Item
REP1320

Replace the Y Return Pulley Assembly
1. Replacement
Procedure
2. Adjustment
and
Examination
Procedure

5. Move the Head to the left (X Motor side).
6. Loosen the Steel Belt tension (loosen two tensioning screws).
7. Remove the Steel Belt fastening screws on the left side and
slide it out to the Return Pulley.
8. Remove the Y Return Pulley.
Tension screw
Belt fastening screw
Belt fastening screw
Return pulley
Steel belt
How to replace the Y Return Pulley Assembly
REP1320
How to replace the Cartridge Frame Assembly

Item
1. Replacement
Procedure
REP1330

Replace the Cartridge Frame Assembly
1. Carry out Head Cleaning.
2. Remove the Right Paper Guide.
3. Disconnect all connectors J402 to J413 from the
junction board assembly leaving only J401
(FFC) connected.
4. Remove the connectors of the cartridge pipes

and ink tubes on the cable guide.
CAUTION:
CAUTION:
If there is wash liquid remaining in the ink tubes and head

dampers, it may flow out from
the head nozzles and spill
around the maintenance
assembly. Use cotton waste to
wipe up any spilt wash liquid.
When pipes and tubes are
being removed, mark the
tubes so that they will not be
confused when they are reassembled.
5. Remove the Y Rail Cover Support. (2 fastening

screws)
Connector Table
J401
MAIN
J402
Detector K Black 4-core
FFC 16-core
J403
Detector C Cyan 4-core
J404
Detector M Magenta 4-core
J405
Detector Y Yellow 4-core
J406
Ink ID K
Black 5-core
J407
Ink ID C
Cyan 5-core
J408
Ink ID M
Magenta 5-core
J409
Ink ID Y
Yellow 5-core
J410
Detector 5 Black 6-core
J411
Detector 6 White 6-core
J412
Ink ID 5
Black 6-core
J413
Ink ID 5
White 6-core
Detector assembly
connector
Ink ID sensor
connector
On panel display,
5 = O (Orange)
6 = G (Green)
J413 has twisted lines
Fastening
screw
Fastening
screw
REP1330
Item
1. Replacement
Procedure
REP1331

6. Remove two screws holding the cartridge base.
Slide the cartridge base towards (1) then lift as in (2) to separate it from the rear X reinforcement.
Lift
2
Slide
Cartridge slide 2
Two screws
2. Adjustment
and
Examination
Procedure
Two screws
7. Cut the cable tie holding the cables.

8. Remove the cartridge pipes from the cartridge frame.
REFERENCE
Be careful not to lose the nuts and Orings on the disconnected cartridge
pipes.
9. Undo the two screws holding cartridge slide 2.
REP1331

Item
1. Replacement
Procedure
REP1332

10. Remove 2 screws holding the cartridge frame to the cartridge base,
slide the cartridge frame in the direction of arrow a and lift to separate it from the cartridge base.
11. To dismantle the cartridge frame, open the upper claw of the frame
assembly and needles as in (1) then slide it down (arrow (2)).
Next, slide the cartridge in the direction of arrow (3) to remove it.
CAUTION:
I/C guide base
Please work carefully as there is a risk of injury

from the sharp needles on the frame assembly.
REFERENCE
Replacements related to the sensors

attached to the cartridge frame can be carried out with "cartridge side plates" after
this work.
Cartridge base
12. The I/C guide base attached to the cartridge base can be dismantled when the four claws are disconnected from the back.
At the same time, the plates for preventing incorrect insertion and
the cushioning spring and felt can be removed.
CAUTION:
Cartridge frame
Cartridge slide
Take care not to mistake the positioning of the

plates for preventing incorrect insertion otherwise
it will be impossible to insert the cartridges correctly.
1
Cartridge side plate

2
Frame assembly and needles
REP1332

Item
1. Replacement
Procedure
REP1333

CAUTION: Dont use a tool to tighten the coupling
screws but get them as tight as possible with
your fingers. If you use a tool, there is a risk
of breaking the plastic taps.
2. Adjustment
and
Examination
Procedure
1. Carry out the initial filling.

CAUTION: Wait at least 30 minutes after the initial filling
before printing. Otherwise the printing quality can not be assured.
2. Carry out a test print.

3. Fit a new Waste Fluid Box.
CAUTION: About 100 cc of waste fluid will be expelled
into the Waste Fluid Box from head cleaning
and initial filling. Fit a new Waste Fluid Box.
The message Change Tank?: will appear on
the panel display. You should confirm by
answering Yes.
REP1333
How to replace the Ink ID Sensor Assembly

Item
1. Replacement
Procedure
REP1340

1. Carry out replacement steps 1 to 10 of the previous item
"Cartridge Frame Assembly Replacement" (REP1330-1332).
2. Remove two screws holding the ink ID sensor.
3. Assembly is the reverse of dismantling.
Ink ID sensor
connector
CAUTION: The ink ID sensor must be installed in the

same place as the previous sensor.
The printer will not work if the ID is unsuitable.
Ink ID sensor
assembly
Two fastening
screws
REP1340
How to replace the Detector Assembly

Item
1. Replacement
Procedure
REP1350

Replace the Detector Assembly
1. Carry out replacement steps 1 to 11 of the previous item
"Cartridge Frame Assembly Replacement" (REP1330-1332).
Detector assembly
Ink detection switch
2. The no ink detection sensor and cartridge detection sensor of

the detector assembly are each held to the cartridge side plate
by one screw. Remove the screws and carry out the replacement.
Fastening screw
CAUTION: Be careful not to over-tighten when refitting

the cartridge sensor.
If it is over-tightened the detection section of
the sensor will not slide. Tightening torque is
29.4 Ncm (3 kgcm).
Cartridge detection switch

Fastening screw
Cartridge frame assembly
CAUTION: Detector assemblies have different cable

lengths and connectors depending on which
slot they are fitted to. Be careful not to confuse them.
How to replace the Detector Assembly
REP1350
How to replace the Y Cable
Item
1. Replacement
Procedure
Replace the Y Cable

Remove the Rear Paper Guide.
Disconnect connectors J111 (HEAD1) and J112 (HEAD2) from the Main
Board Assembly.
REFERENCE The flat core will come away at the same time. Be
careful not to drop it.
7. Remove the cable keeper from the Head Board Assembly. (2 fastening
screws)
8. Disconnect connectors J201 (MAIN1) and J202 (MAIN2) from the Main Board
Assembly.
9. Remove 4 hex. nuts holding the tube bracket.
10. Withdraw the Y Cable that passes through the Right X Reinforcement into the
Control Box, straighten out the bends and pass it through the hole in the left
Flexible Cable Guide Support.
REFERENCE This work will be easier if you remove the screw
holding the ink cartridge base and move the base.
11. Lift the tube bracket up and remove Y Cable together with the N Belt.
REFERENCE The new Y cable has no fold crease. Make a fold
crease in the new cable to match the old cable.
Cable keeper (2)
1.
2.
3.
4.
5.
6.
CAUTION:
2. Adjustment
REP1360
Power must be off when connectors are being disconnected or reconnected, otherwise you may be injured or a
board may be damaged.
The main board assembly will certainly be damaged if
power is applied with main board assembly connectors
J111 (HEAD) and J112 (HEAD2) and head board connectors
J201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP.
Two fastening
screws
Y cable
Cable keeper
Hexagonal
nut
Fastening screw
Tube keeper
Tube
bracket
Cartridge pipe
Junction board
assembly
Y cable
X reinforcement R
Screw
1. When the Y Cable has been laid, first fit the Y Rail Cover only then move the
head by hand to confirm does not produce any hindrance, noise or jamming. If
there is a fault, adjust by moving the part of the Y Cable on the Head Board
Assembly Cable keeper.
REP1360

Item
1. Replacement
Procedure
Replace the Y Cable

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Remove the Rear Paper Guide.
Disconnect connectors J111 (HEAD1) and J112 (HEAD2) from the Main
Board Assembly.
REFERENCE The flat core will come away at the same time. Be
careful not to drop it.
Remove the cable keeper from the Head Board Assembly. (2 fastening
screws)
Disconnect connectors J201 (MAIN1) and J202 (MAIN2) from the Main Board
Assembly.
Remove the ribbon cable guide clamp parts.
Remove 4 hex. nuts holding the tube bracket.
Withdraw the Y Cable that passes through the Right X Reinforcement into the
Control Box, straighten out the bends and pass it through the hole in the left
Flexible Cable Guide Support.
REFERENCE This work will be easier if you remove the screw
holding the ink cartridge base and move the base.
Lift the tube bracket up and remove Y Cable together with the N Belt.
Assembling is the reverse of the removal procedure.
REFERENCE The new Y cable has no fold crease. Make a fold
crease in the new cable to match the old cable.
CAUTION:
2. Adjustment
REP1360-2
Cable keeper
Cable keeper Hexagonal nut

Tube keeper
Clamping part
Ribbon cable guide
X reinforcement R
Junction board assemb
Power must be off when connectors are being disconnected or reconnected, otherwise you may be injured or a
board may be damaged.
The main board assembly will certainly be damaged if
power is applied with main board assembly connectors
J111 (HEAD) and J112 (HEAD2) and head board connectors
J201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP.
1. When the Y Cable has been laid, first fit the Y Rail Cover only then move the
head by hand to confirm does not produce any hindrance, noise or jamming. If
there is a fault, adjust by moving the part of the Y Cable on the Head Board
Assembly Cable keeper.
Y cable
Tube bracket
Y cable
REP1360-2
How to replace the Ink Tubes
Item
REP1370
1. Replacement
Procedure
Replace the Ink Tubes

Carry out Head Cleaning and empty the ink inside the tubes.
Remove the Head Board Assembly Cable keeper and disconnect
the Y Cable from the connector.
6. Remove the ten tube guide clamps.
7. Undo the two screws holding the tube keeper.
8. Remove the four joining screws and O-rings on the Flexible Cable
Guide.
9. Remove the four joining screws and O-rings below the cursor.
Tube fastening
screw (small)
1.
2.
3.
4.
5.
CAUTION:
Joining
screw
(large)
Open the
clamp here
Be careful not to lose the O-rings. Initial filling

and printing can not be done if the O-rings are
missing.
Flexible
cable
guide
Joining screw
Joining
screw
Head side
Cartridge side
Dont use a tool to tighten the coupling screws

but get them as tight as possible with your fingers. If you use a tool, there is a risk of breaking
the plastic taps.
REFERENCE
Ink tubes have a tendency to bend. Laying
the tubes in the direction of that tendency
prevents the tubes from behaving badly
and jamming.
REFERENCE
Couplings have a definite orientation. (See
diagram below)
Ink tube
CAUTION:
Continued on next page (REP1371)
REP1370
Item
REP1370-2
1. Replacement
Procedure
Replace the Ink Tubes

1.
2.
3.
4.
5.
Carry out Head Cleaning and empty the ink inside the tubes.
Remove the head board assembly cable keeper and disconnect the
Y cable from the connector.
6. Remove the ribbon cable guide and tube guide clamps.
7. Undo the two screws holding the tube keeper.
8. Remove the tube bracket cable keeper.
9. Remove the four joining screws and O-rings on the Flexible Cable
Guide.
10. Remove the four joining screws and O-rings below the cursor.
I
CAUTION:
Ink tube
Joining screw (small)
Joining screw (large)
Be careful not to lose the O-rings. Initial filling

and printing can not be done if the O-rings are
missing.
Tube keeper
Ribbon cable guide
Flexible cable guide
Head side
Dont use a tool to tighten the coupling screws

but get them as tight as possible with your fingers. If you use a tool, there is a risk of breaking
the plastic taps.
REFERENCE
Ink tubes have a tendency to bend. Laying
the tubes in the direction of that tendency
prevents the tubes from behaving badly
and jamming.
REFERENCE
Couplings have a definite orientation. (See
diagram below)
Cartridge side
CAUTION:
Tube guide
Clamping parts
Joining screw
Cable keeper
REP1370-2
Item
1. Replacement
Procedure
REP1371

Diagram showing construction of joiners
(Cartridge side)
Cartridge pipe
Joint nut (large)
DE-49778
Ink tube
O-ring (large)
DE-49777
Coupling (black)
DE-49992
Joint nut (large)

DE-49778
O-ring (large)
DE-49777
Coupling (white)
DE-49993
O-ring (large)
DE-49777
Coupling screw (large)
DE-49778
Tube fastening O-ring (small)

DE-48949
Ink tube
Tube stop screw (small)

DE-48950
(Head side)
Head pipe
2. Adjustment
and
Examination
Procedure
1. Carry out the initial filling.

CAUTION:
CAUTION:
Wait at least 30 minutes after the initial filling before printing. Otherwise the printing quality can not be assured.
If possible, ink cartridges used for initial filling should be cartridges that have not been used previously.
Since a large amount of ink is required for filling, filling may fail if there is insufficient ink remaining.

3. Fit a new Waste Fluid Box.
CAUTION:
About 100 cc of waste fluid will be expelled into the Waste Fluid Box from head cleaning and initial filling. Fit a new Waste Fluid Box. The
message Change Tank?: will appear on the panel display. You should confirm by answering Yes.
REP1371
How to replace the Cutter Solenoid Assembly

Item
REP1380
1. Replacement
Procedure
Replace the Cutter Solenoid Assembly

1.
2.
3.
4.
5.
6.
7.

Disconnect connector J206 (SOL) from the Head Board Assembly.
Remove the Head Cover.
Move the Head 20 to 30 cm to the left.
Undo the two screws on the left edge of the head and remove the
cutter unit.
8. Remove the screw holding the cutter cap.
9. Undo the two screws holding the solenoid to the cutter box and
take the solenoid from the box.
When removing the cutter blade, the head
must first be moved to a position over the
cutter mat. If the tip of the cutter blade hits
against the front paper guide, the tip will be
chipped and will no longer be able to cut.
REFERENCE There are two types of springs inside the cutter unit, the solenoid spring and the cutter
spring. Be careful not to lose them when you
are dismantling.
1. When the cutter unit is being assembled its position relative to the
cutter mat must be adjusted. Refer to Figure A and fasten it in the
correct position.
Plate nut
CAUTION:
Cutter blade
Platen
Cutter mat
[Diagram A]
Cutter cap
Solenoid
assembly
Cutter solenoid
assembly
Cutter spring
Fix so that the front corner of

the cutter mat groove and the
flat part of the cutter blade are
aligned.
REFERENCE
This rib should cover at least half
the flat part of the cutter mat. Move
the head to make sure that both left
and right edges cover at least one-third.
How to replace the Cutter Solenoid Assembly
REP1380
How to replace the Head and Head Cable

Item
REP1390
1. Replacement
Procedure
Head, Head Cable Replacement

Do head washing. If HEAD1 (left) only is to be replaced, change "6 places" to "3 places".
1.
2.
3.
4.
5.
6.
7.
Remove panel cover.

Remove front cover.
Remove Y rail cover.
Remove head cover.
Unlock and disconnect FFC entering the head board assembly connectors J207 (HEAD C1) and J208 (HEAD C2)
Cut the cable tie holding the head pipes.
Undo the tube stop screws holding the head pipes on the damper (6 places) and disconnect the head pipes.
REFERENCE When the tube stop screws are removed, there will be O-rings on the head pipes. Be careful not to lose them.
8. Remove the damper positioning materials. (1 screw)
9. Disconnect the dampers from the print head. (6 places)
CAUTION: The damper will not function if the film part of the damper is gripped strongly and printing may not work.
10. With a small straight-bladed screwdriver remove the compression spring from where it is attached on the
aluminum die-cast side of the head fastening material. (2 places)
11. Remove the screw holding the print head together with H spacer.
12. Slide the left print head, Head 1, towards arrow (1) and after disconnecting the insertion section, lift it out.
13. Remove Head 2 in the same manner.
REFERENCE When print heads and head cables are to be replaced:
For dismantling, remove Head 1 (left)then Head 2 (right)
For assembly, refit Head 2 (right) then Head 1 (left)
Cabling makes it impossible to work in the opposite order.
Insertion section
14. Disconnect head cables from the print head connectors.
REP1390
Item
2. Assembling
REP1391

1. For bending, refer to the head cable that was previously used.
Example of head cable bending for Head 1 (left)
CAUTION: The bend on the print head side of the head cable used with Head 1
(left) should be made such that the protrusion from the connector is
minimal. Otherwise the range for adjusting head inclination becomes
too small and adjustment is impossible.
2. Print the head rank of the print head that is to be used on the head cable. If the previous
head rank is inscribed, this should be cancelled with two lines before the print.
Wrong
Correct
CAUTION: The parts inside the print head that are shown in diagram A must not
be touched. Otherwise oil and dirt may make it impossible for them to
be used properly.
[Diagram A]
Damper connection
Nozzle face
REP1391

Item
REP1392
3. Adjustment and
Examination
Procedure
1.
REFERENCE
If a head has been replaced, the nozzle ejection count value should be reset.
Carry out initial filling with ink.

REFERENCE
Head washing and initial filling consumes a large quantity of waste liquid.
The waste liquid box should be replaced when initial filling is finished.
CAUTION: After initial filling, wait for at least 30 minutes before printing.
Otherwise the printing quality cannot be assumed.
2.
3.
Load roll media in the printer.

Do a "Nozzle check" to confirm whether there is incomplete filling or abnormal ejection.
If there is a fault, try again after "Cleaning".
REFERENCE
At rare intervals a dirty wiper may cause faulty ejection and the wiper should be rubbed with a wiper cleaning cloth.
4.
Do Left Tilt adjustment.
5.
Do Right Tilt adjustment.
6.
Do Repeatability (Normal) adjustment.
7.
Do Repeatability (Microdot) adjustment.
8.
Do "Unidirectional" adjustment.
9.
Do "Unidirectional (Microdot)" adjustment.
10. Do "Test print" to confirm results of adjustments.
REP1392
How to replace the Edge Sensor Assembly

Item
1. Replacement
Procedure
REP1410

Edge Sensor Replacement
1. Remove front cover.
2. Remove panel cover.
3. Remove Y rail cover.
4. Remove head board assembly connector J204 (P EDGE).
5. Remove head cover.
6. Remove edge sensor. (1 fastening screw)
Use straight blade screwdriver No. 1.
Screw
(self-tapping)
Edge sensor a

CAUTION: Fastening screws are self-tapping screws. Be
careful not to over-tighten.
Tightening torque is 29.4 N.cm (3 kg.cm).
How to replace the Edge Sensor Assembly
REP1410
How to replace the Head Board Assembly

Item
1. Replacement
Procedure
REP1420

Replace the Head Board Assembly
Screws

4. Disconnect all connectors from the Head Board.
5. Remove the Head Board. (4 fastening screws)
Connector J201 (MAIN1)
J202 (MAIN2)
CAUTION: Be sure to switch off the power whenever

connectors are disconnected or inserted.
Incorrect operation will lead to injury and
component damage.
The main board assembly will certainly be
damaged if power is applied with main board
assembly connectors J111 (HEAD) and J112
(HEAD2) and head board connectors J201
(MAIN1) and J202 (MAIN2) inserted with
oblique FFP.
How to replace the Head Board Assembly
Screws
REP1420
How to replace the Dampers

Item
REP1430
1. Replacement
Procedure
Dampers Replacement
1.
2.
3.
4.
5.
6.
7.
8.
9.
Carry out Head Cleaning.

Remove the damper fixer (2 fastening screws).
Remove joint screws and move the head pipes up out of the way.
Remove the colour dampers.
CAUTION:
Head board assembly
Head cable
When removing the colour dampers, be careful not

to grip the transparent film surface of the damper.
Rough handling of the transparent film surface
may cause an air leak and prevent printing.

2. Adjustment and 1. Carry out initial filling.
Examination
Procedure
CAUTION: Wait at least 30 minutes after the initial filling
before printing. Otherwise the printing quality can
not be assured.
Damper fixer
Tube fixer

3. Fit a new Waste Fluid Bottle.
CAUTION:
About 150 cc of waste fluid will be expelled into

the Waste Fluid Bottle from head cleaning and initial
filling.
Fit a new Waste Fluid Bottle.
The message Change Tank? will appear on the
panel display. You should confirm by answering
Yes.
How to replace the Dampers
REP1430
How to replace the Cursor Assembly

Item
1. Replacement
Procedure
REP1440

Cursor Assembly Replacement
1.
2.
3
4.
5.
6.
7.
8.
9.
10.
11.
Wash the head to remove the ink.

Remove the Right and Left Covers.
Disconnect connectors J204 (P EDGE), J206 (SOL), J207 (HEAD C1), J208 (HEAD C2) from the head board assembly.
Remove tube stop screws and disconnect head pipes from dampers.
Remove two screws from each outer side of the upper part of the cursor and separate the cursor unit from the head board unit.
Reverse the disconnected head board unit so as to extend the steel bare and place it on top of the X motor side of the flexible cable guide.
CAUTION: Be careful not to damage the T fence when taking out the head board unit.
Scarring may cause abnormal print quality.
12.
13.
14.
15.
16.
Loosen the steel belt tension with the Y return pulley.

Undo the screws that fasten the belt at both ends of the cursor unit and separate the steel belt.
Move the cursor unit between the drive roller on the right and the cap unit.
Bend the CR flat spring and remove it.
To remove the cursor unit from the Y rail, after undoing one side of the cursor axle E-ring, take out the cursor axle together with both roller bearings.
The cursor unit will drop down and can be taken from the Y rail.
Be careful not to touch or damage the nozzle face of the head when removing the cursor unit from the Y rail.
REP1440

Item
1. Replacement
Procedure
2. Assembling
and fitting
REP1441

17. Remove the head sub-plate that is on the cursor roller side.
(2 screws)
18. Remove three fastening screws on the print head side and
separate the hear unit and cursor assembly. The belt attachment plate will come away at the same time.
1.
2.
3.
4.
5.
6.
7.
1.
3. Adjustment
and confirma- 2.
tion
3.
Align the cursor assembly with the head unit, bring the head
unit in the direction of the arrow (up) and hold it temporarily
with three fastening screws.
Temporarily attach the head sub-plate.
Following the reverse procedure, fit the cursor assembly to
the Y rail and continue until just before attaching the head
cover.
Move the cursor assembly over the right end of platen on the
cap side.
Place the head height jig under the nozzle face of the print
head, press the flat part of the upper edge of the print head
and, while the metal part surrounding the nozzles is in close
even contact with the head height jig, firmly tighten the
screws that had been held temporarily.
Withdraw the jig without touching the nozzle face and, using
the pressure bracket gap at the back of the printer, firmly
fasten the head sub-plate that had been held temporarily.
After fitting the Y rail cover, do the initial filling and proceed
with item 3. Adjustment and Checking. Fit the remaining covers after adjustment and checking.
Execute the "Cap position" adjustment.
Execute a "Test print" to see whether any printing adjustments are needed. Depending on the result, carry out any
necessary adjustments.
Apply the "Margin" adjustment.
All screws shown here are temporarily tightened

Cursor assembly
M3 16 (cap screw)
Belt attachment plate
M4 10
(double SEMS)
Head sub-plate
M3 5
(double SEMS round)
Head unit
Press places shown

by arrows
Fastening screws (3)
Head height jig

Right edge platen
CAUTION:
As shown below, make sure nozzle face does

not touch jig.
Wrong
This will touch nozzle face.
REP1441
How to replace the Origin Sensor, Y Encoder

Item
REP1450
1. Replacement
Procedure
Origin Sensor and Y Encoder Replacement

1.
2.
3.
4.
5.
Remove panel cover.

Remove front cover.
Remove Y rail cover.
Disconnect all connectors plugged into the head board.
Remove head board from the H board mounting plate. (4
screws)
6. Remove Y cable together with the cable keeper.
7. Remove tube guide keeper. (2 screws)
8. Remove steel belt. (2 screws)
9. Remove pipe fittings with head pipes still connected. (2
screws)
10. Remove two screws holding the H board mounting plate.
11. Remove origin sensor or Y encoder from the H board mounting plate. (2 screws each)
Origin sensor fitting direction
Cable from origin sensor

board in on the cap side
Sensor
Cable
Y encoder and encoder cable fitting direction
CAUTION: Encoder cable connection errors will damage

the encoder.
2. Adjustment
1. Execute the "Cap position" adjustment.
Connector mark to left

as seen from front of
printer
How to replace the Origin Sensor, Y Encoder
Encoder terminal comes to H

board mounting plate
attachment section.
REP1450
How to replace the Junction Board Assembly, Ink ID Cable

Item
1. Replacement
Procedure
REP1470

Junction Board Assembly Ink ID Cable
Replacement
Junction cable
connection J109
(INK ID) behind
here

6. Disconnect junction cable connector J109 (INK ID).
7. Disconnect all junction board assembly connectors.
8. Remove the junction board assembly. (4 fastening
screws)
9. Assembly is the reverse of the removal procedure.
Detector assembly
connector
CAUTION: Power must be off when connectors

are being disconnected or reconnected, otherwise you may be
injured or a board may be damaged.
applied with main board assembly
connectors J111 (HEAD) and J112
How to replace the Junction Board Assembly, Ink ID Cable
Four fastening
screws
Junction cable
connector J401
Ink ID sensor
connector
Junction cable
(FFP)
REP1470

Item
1. Adjustment
and
Inspection
Procedure
REP1520

1. Adjust using rail height jig (JD-30395).
Mount the rail height jig on a standard base and set the dial
gauge to "0" (2.00 mm).
Standard value : 0
(2.00 mm)
Rail height
jig
Standard base
Mount the rail height gauge over the ribs at both ends of the
platen, loosen the platen retaining screws and adjust the
platen up and down until the dial gauge reads 2.10 to 2.20
mm.
Standard value
2.10 to 2.20 mm by dial gauge
Measuring
position (rib)
Slide
Platen
Adjusting screw
REP1520
How to replace the Tube Guide Assembly

Item
1. Replacement
Procedure
REP1540

Tube Guide Assembly Replacement
1. Disconnect all connectors from head board.
2. Remove head board. (4 screws)
3. Remove tube guide keeper. (2 screws)
4. Remove two tube guide fastening screws.
5. Undo all parts clamping tube guide ink tubes and steel bares
and remove the tube guide.
Hexagonal
nut
Cable keeper
Tube keeper
Screw
Tube
bracket
Cartridge pipe
Tube guide
assembly
Steel bare
Ink tube
Steel bare
Tube guide
assembly
REP1540

Item
REP1540-2

Tube Guide Assembly Replacement
1. Remove panel cover, IC slot cover and Y rail cover
2. Remove H mounting plate cable keeper.
3. Remove all ribbon cable guide clamping parts.
4. Remove the cable keeper on the tube keeper and remove the
steel bare.
5. Remove all tube guide clamping parts.
6. Remove tube keeper.
7. Undo tube bracket nut.
8. Lift the tube bracket gently and remove the tube guide assembly.
Cable keeper
Tube keeper
Tube bracket
Ribbon cable
guide
Clamping parts
Tube guide
REP1540-2
Item
REP1550

CAUTION:
CAUTION:
Steel belt are highly susceptible to breakage

and end damage and must be handled carefully.
Be careful not to cut your hands when handling the steel belt.
Adjusting
screws
Steel Belt Tension Adjustment

Steel belt
1. Adjustment
and
Verification
1. Set the steel belt in the middle of the return pulley and motor
pulley. (Center of Y rail)
2. While moving the cursor left and right, turn the return pulley
adjusting screw until the steel belt does not tend to come off
the pulley or move across the pulley.
3. When the belt adjustment is completed, use a belt tensioning
jig to adjust the tension. Move the cursor to the capping position and measure the deflection of the belt at the center of the
Y rail.
Specification values:
Belt tension attachment

JD-42050
0.98 N
(100 g 20 g)
4. Finally, move the cursor left and right to check for belt skew.
REP1550

Item
REP1560

CAUTION: When the Speed Reduction Belt has been
replaced, apply grease to the belt evenly.
(Silicone Grease G501)
X Speed Reduction Belt Tension Adjustment

1. Adjustment
and
Verification
1. Hook a 5 kgf Bar Tension Gauge to the X motor mounting

plate, tension the belt and fasten the mounting plate.
Specification value: 41.16 N 1.96 N (4.2 kg 0.2 kg)
41.16 N 1.96 N (4.2 kg 0.2 kg)
REP1560
How to Adjust the Print Head

Item
1. Adjustment
and
Verification
REP1570

CAUTION:
Avoid touching, knocking or rubbing the nozzle

face of the Print Head Assembly.
CAUTION:
Cada Print Head Assembly tiene un rank that has a

major effect on the ejection of ink. Entering a
wrong rank will adversely affect the life of the
head and the emission of inks. Rank is
inscribed on the print head assembly (see diagram on right). The value to be input is a 5-digit
number.
1 2 3 4 5
Print Head Adjustment

When the Print Head and the Head Cable are removed, make the following adjustments in Diagnostic Mode.
Capping Position Adjustment
Head Rank Input (Initial filling function is available.)
Repeatability Printing Positioning, Repeatability Printing Positioning
(Microdot)
Unidirectional, Unidirectional (Microdot)
Margin
Head rank
(5-digit)
1. Run Diagnostic Mode.

2. Lower the Pressure Lever and select Adjustment.
3. After initialization, load media on the printer.
If the Print Head is not replaced or removed, go to Step 7.
REP1570

Item
REP1571
1. Adjustment and 4.
Verification
5.
Execute "Capping position adjustment".

Apply "Head rank entry".
Initial filling can now be done.
6. Enter Head 1 rank.
If Head 1 has not been replaced, rank will be recorded as is.
7. Execute "Ink filling".
After ink filling, return to the previous level.
8. Mount media.
9. Execute "Head nozzle check".
Check whether ejection is normal from all nozzles and proceed to
the next item.
10. Execute Left Head Tilt.
Adjust with head adjustment material A so that printing with all
Head 1 colours forms a straight line.
11. Loosen the screw holding Head 1 and move the head adjustment
material A towards (b) if the offset rises to the right, or towards (a) if
the offset rises to the left.
After gently pressing with a straight-bladed watchmaker's screwdriver or similar in the same direction as the compression spring holding the print head, tighten the screw.
(One click changes head adjustment place A by about 0.005 mm)
[Fig. 1]
Here is lined up.

2
1 2 1
Test pattern
1 3 1
3 2 1
Media
eject
direction
[Fig. 2]
In this case, adjust towards (a). In this case, adjust towards (b).
[Fig. 3]
Head adjustment plate A
REFERENCE Sometimes simply moving the head adjustment material does not alter the inclination.)
Press gently
12. Execute Left Tilt.
Repeat steps 10 and 11 until the test pattern is properly aligned.
13. When the inclination adjustment is finished, proceed to the next
item.
(b)
(a)
REP1571

Item
REP1572
1. Adjustment and 14. Execute Right Head Tilt.

Verification
With Head 1 as a standard, adjust the inclination and depth of Head
2 with head adjustment material A (mainly for inclination) and head
adjustment material B (mainly for depth) so that the printed band is
a straight line.
[Display when looking at the print head from above]

HEAD1
HEAD2
(K) (C) (G)
(M) (Y) (O)
1
15. Loosen the screw holding Head 2 and, if the parts printed by Head
2 (4 to 6) rise to the right relative to the parts printed by Head 1 (1
to 3), move the head adjustment material towards (b), or towards
(a) if the offset rises to the left. Also, if the offset is to the front or
back, move the head adjustment material towards (c) or (d).
After gently pressing with a straight-bladed watchmaker's screwdriver or similar in the same direction as the compression spring holding the print head, tighten the screw.
Test pattern
5 2 5
4 6 1
6 4 1
Media eject
direction
d
16. Execute Right Head Tilt.
Repeat steps 14 and 15 until the test pattern is properly aligned.
c
c
17. When the right head tilt is properly adjusted, proceed to the next
item.
Fastening screw
Press gently
b
REP1572

Item
1. Adjustment
and
Verification
REP1573

18. Execute "Repeatability"
This makes three 1-pass bi-directional scans and compensates for
the offset of the second scan (CCW printing) relative to the first and
third scans (CW printing).
Media eject
direction
Third line
19. Check the printing, first for black then for colour, and record a positive increment if the second scan (CCW printing) is offset towards
the cap side, or a negative decrement for the opposite direction.
(Repeat the printing after the registration.)
Repeat until both directions are aligned.
20. When repeatability printing position alignment has been achieved,

proceed with the Repeatability (Microdot) adjustment in the same
manner.
Second line
First line
Plus
Minus
21. Execute "Unidirectional".

This corrects the initial printing position (5 mm from media edge)
and compensates for the position of Head 2 relative to Head 1
(head pitch).
22. With a steel ruler, measure from the edge of the media to the position of the black printing and enter the measured value.
Distance to edge of media (5 mm)
REP1573

Item
1. Adjustment
and
Verification
REP1574

23. Next, check the printing and record a positive increment if Head 2 is
to be moved towards the cap side relative to Head 1, or a negative
decrement for the opposite direction.
Repeat items 20 to 23 until the starting position and the printing
positions of Head 1 and Head 2 are aligned.
Pitch between heads
24. When "Unidirectional" is finished, execute the "Unidirectional

(Microdot)" adjustment in the same manner.
25. Execute "Margin".

This corrects the printer's media detection position and the actual
printing position.
26. Use a steel ruler and a loupe to measure from the edge of the
media to the printing position and make the correction by entering
the actual measured value.
Bottom distance
(20 mm)
Left side margin
(5 mm)
Right side margin

(5 mm)
Top distance
(25 mm)
27. Complete the adjustments by switching off the power.
REP1574

Item
REP1590

CAUTION: Failure to switch off the power before mounting and unmounting flash memory card may cause damage to the Main Board and
make it impossible to install data properly.
1. Capture
Backup
Parameters
1. Switch off power to the printer.

2. Mount a backup-only flash memory card in the slot at the back of the printer.
3. Turn on the power. All LEDs light up instantly and PLOTTER CARD appears in the printers LCD display unit.
4. When ENTER is pressed, P C Started appears in the printers LCD display unit and parameters start to be absorbed.
5. When parameters have been completely absorbed, P C Completed appears in the printers LCD display unit to indicate that the comparison of
absorbed parameters has ended normally.
6. Switch off and remove the flash memory.
2. Install

2. Mount a backup-only flash memory card in the same slot at the back of the printer.
3. Turn on the power. All LEDs light up instantly and PLOTTER CARD appears in the printers LCD display unit.
Menu Up or Menu Down will change this to CARD PLOTTER.
4. When ENTER is pressed, C P Started appears in the printers LCD display unit and parameters start to be installed.
5. When parameters have been completely installed, C P Completed appears in the printers LCD display unit to indicate that the comparison of
installed parameters has ended normally.
6. Switch off and remove the flash memory card.
3. Verify
1. Switch on power to the printer and verify that it is working normally.
REP1590
Item

CAUTION:
1. Install
REP1600
Failure to switch off the power before mounting and unmounting flash memory may cause damage to the Main Board and
make it impossible to install data properly.

2. Mount the latest program flash memory card in the slot at the back of the printer.
3. Switch on the power.
4. The following message will appear in the liquid crystal display:
Erase
Copy
Compare
End
The buzzer will sound. (It will end after about 60 seconds)
6. Remove the flash memory card.
2. Verify
1. Switch on power to the printer and verify from the initialization and panel display that the version has been upgraded.
REFERENCE:
The following flash memory card is used for program installation:

SDMP Vx.xx
4 MB
REP1600
Head Cleaning Procedure 1

CAUTION 1:
When to Clean the Head
Head Wash must be carried out whenever this printer is moved by truck, befoe using
Eco-Solvent ink or when the parts shown below are replaced.
When this operation is performed, there is a risk that the inks remaining in the head
and ink tubes may be spilt and soil the printer.
< Replacement Parts > Head, Damper, Cursor Assembly, Cartridge Frame
Assembly, Ink Tubes
CAUTION 2:
Head Cleaning Jig
When you are using the Head Cleaning Jig, the 100 cc jig bottle should contain at
least 50 cc of cleaning fluid and its cap should be loosened.
If the cap of the jig bottle is tightly closed, the ink will flow back into the bottle.
Also, when you have finished using the Head Cleaning Jig, return the cleaning fluid
from the 100 cc bottle to the 500 cc cleaning fluid bottle (JD-42054).
CAUTION 3:
What to do After the Initial Filling
Wait for at least 30 minutes after the initial filling before you use the printer for printing. Otherwise picture quality can not be assured.
Head Cleaning is a self-diagnostic function not available to the user.
REFERENCE
Head washing includes all six colours at the same time.

Therefore, you should prepare six sets of head washing
jigs.
Single colour or separate head washing is not possible.
REP1620
Panel diagnostic functions (when implemented from panel only)

1. To start panel diagnosis, switch on while pressing [Cleaning], [Menu Display] and
[Shift] at the same time.
2. Select "Adjustment" menu "Head Wash" self-diagnosis.
3. Rm All Cartridge
When this display appears, take out the specified cartridge.
(Alternatively, the ink cartridges may be removed beforehand.)
4. Set Wash Jig
When this display appears, mount the cleaning jig.
5. Ink Absorb
When this display appears, cleaning fluid is being sucked from within the head
and tubes.
6. Rm Wash Jig
When this display appears, remove the cleaning jig.
7. Washing
When this display appears, cleaning fluid remaining inside the head and tubes is
being ejected.
8. AJST: Home
CAUTION:
Before using Eco-Solvent ink, perform a head wash.

Use the special Eco-Solvent Transition Liquid.
Once you have worked with Eco-Solvent inks, it is forbitten to change
to another ink type.
Head Cleaning Procedure 1
When this display appears, it is the end.
REP1620
REP1660
REP1660
If the nozzles are clogged by paper dust or foreign matter clinging to the Head
Nozzle Face, use the following procedure to remove it.
CAUTION: Be careful not to touch the nozzle face directly with your fingers otherwise normal ejection may not be possible.
1. Turn off the Power Switch and return the Head to the home position.
(The Power Cable may remain connected)
2. Open the front cover and remove "Panel bottom cover" and "Panel bottom cover
support"
3. Move the head to the place where the "Panel bottom cover" was removed.
4. Soak a lint-free cloth in water or distiled water and gently wipe the Head Nozzle
Face. (Lint-free cloth is closely woven from extremely fine threads and has no
nap and produces no dust.)
CAUTION: Dont wipe with fluffy cloth or tissue paper as these tend to
make the clogging worse.
CAUTION: Be careful not to rub the nozzle face too hard.
5. Move the head to the maintenance assembly.
6. Refit the "Panel bottom cover" and "Panel bottom cover support"
7. Turn on the Power Switch and print out a diagnostic pattern. If there are no dots
missing from the G-line step pattern, the task is completed.
If some dots are missing, repeat Steps 1 to 7.
How to replace Speed Reduction Pulley Assembly

Item
REP1670
1. Replacement
Procedure
Speed Reduction Pulley Replacement

Remove the left cover.
Remove the X motor cover.
Loosen the four screws on the X motor mounting plate and
relieve the belt tension.
4. Loosen the bearing stopper screw and remove it.
5. Remove the speed reduction pulley support and bearing.
6. Loosen the two coupling screws.
7. Loosen the stopper screw.
8. Remove the X speed reduction belt from the speed reduction
pulley.
9. Withdraw the speed reduction pulley assembly towards the
right side.
Bearing stopper
Bearing
1.
2.
3.
Speed reduction
pulley assembly
Speed reduction
pulley support
X motor mounting plate
Stopper
2. Adjustment
and
Inspection
Procedure
1.
Coupling
Adjust the X speed reduction belt tension.
Speed reduction
pulley assembly
How to replace Speed Reduction Pulley Assembly
REP1670
How to replace Grid Roller Assembly

Item
1. Replacement
Procedure
REP1690

Grid Roller Assembly Replacement
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Remove left cover.

Remove front paper guide.
Remove rear paper guide.
Remove X motor cover.
Remove right and left side caps.
Remove speed reduction pulley assembly.
Remove platen mounting plate (with platen attached).
Raise pressure lever.
Remove all bearing box screws.
Move all bearing boxes to a position where the grid roller can be
taken out upwards.
CAUTION:
In order to install bearing boxes and adjustment

spacers in the positions prior to replacement,
check their distribution. Take care not to lose any
adjustment spacers.
Platen mounting plate
Grid roller assembly Bearing keeper
Coupling
Bearing Box
11. Remove the bearing keepers from both sides of the grid roller to be
replaced.
12. Loosen the coupling screws, slide the bearing boxes to the side and
take out the grid roller assembly.
CAUTION:
Install bearing boxes and spacers in the same

positions as before the replacement.
Install bearing boxes by pushing them far back
and moving them to the left.
Apply lock-tight to the screw threads when
installing bearing boxes.
Be careful not to damage the grid roller.
1. Adjustment and 1. Adjust the platen height.

Inspection
2. Adjust X speed reduction belt tension.
Procedure
How to replace Grid Roller Assembly
[46 inch]
[62 inch]
Adjusting spacer
REP1690
How to replace F Absorbent Assembly

Item
1. Replacement
Procedure
REP1700

F Absorbent Assembly Replacement
1. Remove the absorbent material from the F box.
2. Insert the absorbent material assembly in the F box.
How to replace F Absorbent Assembly
F box
Absorbent material
REP1700
How to replace Waste Liquid Tank Assembly

Item
1. Replacement
Procedure
REP1710

Waste Liquid Tank Assembly Replacement
1. Remote X motor cover.
2. Take out the waste liquid tube from the left waste liquid bottle.
Waste fluid bottle mounting plate
Waste fluid tube
CAUTION: Be careful not to scatter the ink.

3. Remove the left waste liquid bottle mounting plate.
4. Undo the waste liquid bottle cap and remove the left waste liquid bottle.
Waste fluid bottle L
How to replace Waste Liquid Tank Assembly
REP1710
Rockhopper-46
3 Fundamental Knowledge
GID0000
GID1000
GID3000
Operating Sequence
Power On Sequence
Power Off Sequence
Media Detection Sequence
Normal Standby Sequence
Encoder Disconnected Check Sequence
Origin Detection Sequence
Media Cutting Sequence
Printing Sequence (Including Flushing)
GID4010
GID4020
GID4030
GID4040
GID4050
GID4060
GID4070
GID4080
Rockhopper-46
3 Fundamental Knowledge
GID0000
Rockhopper-62 Fundamental Knowledge
GID0000-3
GID1000-3
GID3000
Operating Sequence
Power On Sequence
Power Off Sequence
GID4010
GID4020
GID4030
GID4040
GID4050
GID4060
GID4070
GID4080
Rockhopper-62 Fundamental Knowledge
GID0000-3
Rockhopper-46
3 Basic Specifications
System
Printing System
46 inch
Drop-on-demand piezo driving system
(Large capacity, 6-colour, independently removable ink cartridges: 220 cc 5 cc)
Eco-solvent nk
Printing Direction
Shortest distance printing (bidirectional or unidirectional)
Resolution
360 dpi x 360 dpi
Media Transport
Multi-point pressure grid roller system
Media Supply and Eject
Cut Media: Front supply/front eject
CPU
Input Buffer
GID1000
46 inch
System
Area Available for Printing (Margins)
Standard:
Cut media
Roll media
Compatible: Cut media
Roll media
Front
25mm
25mm
25mm
25mm
Media Holding System
Pressure roller lowered by manually operated lever
64 bit RISC CPU
Media Cutting System
Transverse auto-cut system
Standard: 8 MB (main) + 4 MB (plain)

Extended: 16 MB, 32 MB
Expansion slots: 2 slots (16 MB installed in one slot as standard)
Maximum: 72 MB (main) + 1 MB (plain)
Ink Cartridges
Black, cyan, magenta, yellow , light cyan, light magenta: each 220 cc 5 cc
After using Eco-solvent ink, only use Eco-solvent ink in future
Kanji
Conforms to JIS1, JIS2 (1990 edition stroke font built-in)

(Font has some independent codes unspecified by JIS)
Commands
Printer commands: MH-GL, MH-GL/2, (MH-RTL), RTL-PASS
Interfaces
Linear Precision
The larger of 0.1% of movement distance or 0.5 mm

Media: Thick coated paper (roll media)
Working temperature: 20C, Humidity: 60%, Printing mode: High quality/720 dpi
Angular Precision
Media Types
720 dpi x 720 dpi
1440 dpi x 720 dpi
Roll Media: Rear supply/front eject
Within 0.5 mm/500.0 mm

High quality paper, coated paper, thick coated paper, art paper, glossy paper, glossy
photographic paper, glossy film, Yupo film, Yupo tac film, cloth, fire-resistant cloth, glossy PVC
tac film (Media other than the above and new media are based on OEM assessment.)
Roll Media Tube Diameter
Standard 2-inch & 3-inchh
Maximum Media Width
1089.6 mm (42.9 inch)
Media Sizes
1069.6 mm (42.1 inch)
Maximum Roll Media Length
50 m (maximum size roll that can be mounted)
Maximum Cutting Media Length
1300 mm
Media longer than this can be loaded but media size cannot be detected and
it is handled as roll media.
Rockhopper-46
3 Basic Specifications
Standard
Option
Back
20mm
20mm
20mm
20mm
Right
10mm
10mm
5mm
5mm
Left
10mm Printing quality is assured
within standard margins
10mm
5mm If media wider than 1361.6 mm
is used, the left and right
5mm
margins will be different from
those shown on the left.
Bidirectional Centronics: IEEE 1284 (compatible, nibble, ECP modes)

Ethernet: WindowsNT, Windows95, TCP/IP, NetWare, EtherTalk support
Head Life
Environmental
Conditions
Operating environment
Temperature: 10C to 35C, humidity 20% to 80% (no condensation)
Rate of change
Temperature: 2C/h, Humidity: 5%/h
Storage environment
Temperature: -10C to 60C, humidity 20% to 90% (no condensation)
Power Supply
(Voltage)
AC100 ~ 120 V 10%, AC200 ~ 240 V 10% Auto Change
Power Supply
(Frequency)
50 Hz 1 Hz / 60 Hz 1 Hz Auto Change
Power
Consumption
Standby
60 W or less
Printing
75 W or less
Cleaning
75 W or less
Height
1264 mm
Width
1656 mm
Depth
580 mm
Body
49.0 kg (480.2 N)
Legs
15.5 kg (151.9 N)
External
Dimensions
Weight
GID1000
Rockhopper-62 Basic Specifications

System
GID1000-3
Printing System
62 inch
Drop-on-demand piezo driving system
(Large capacity, 6-colour, independently removable ink cartridges: 220 cc 5 cc)
Eco solvent ink
Printing Direction
Shortest distance printing (bidirectional or unidirectional)
Resolution
360 dpi x 360 dpi
Media Transport
Multi-point pressure grid roller system
Media Supply and Eject
Cut Media: Front supply/front eject
CPU
Input Buffer
62 inch
System
Area Available for Printing (Margins)
Standard:
Cut media
Roll media
Compatible: Cut media
Roll media
Front
25mm
25mm
25mm
25mm
Media Holding System
Pressure roller lowered by manually operated lever
64 bit RISC CPU
Media Cutting System
Transverse auto-cut system
Standard: 8 MB (main) + 4 MB (plain)

Extended: 16 MB, 32 MB
Expansion slots: 2 slots (32 MB installed in one slot as standard)
Maximum: 72 MB (main) + 8 MB (plain)
Ink Cartridges
Black, cyan, magenta, yellow, light cyan, light magenta: each 220 cc 5 cc
After using Eco-solvent ink, only use Eco-solvent ink in future
Kanji
Conforms to JIS1, JIS2 (1990 edition stroke font built-in)

(Font has some independent codes unspecified by JIS)
Commands
Printer commands: MH-GL, MH-GL/2, (MH-RTL), RTL-PASS
Interfaces
Linear Precision
The larger of 0.1% of movement distance or 0.5 mm

Angular Precision
Media Types
720 dpi x 720 dpi
1440 dpi x 720 dpi
Roll Media: Rear supply/front eject
Within 0.5 mm/500.0 mm

High quality paper, coated paper, thick coated paper, art paper, glossy paper, glossy
photographic paper, glossy film, Yupo film, Yupo tac film, cloth, fire-resistant cloth, glossy PVC
tac film (Media other than the above and new media are based on OEM assessment.)
Roll Media Tube Diameter
Standard 2-inch & 3- inch
Maximum Media Width
1574.8 mm (62 inch)
Media Sizes
1554.8 mm (61.2 inch)
Maximum Roll Media Length
50 m (maximum size roll that can be mounted)
Maximum Cutting Media Length
1300 mm
Media longer than this can be loaded but media size cannot be detected and
it is handled as roll media.
Rockhopper-62 Basic Specifications
Standard
Option
Back
20mm
20mm
20mm
20mm
Right
10mm
10mm
5mm
5mm
Left
10mm Printing quality is assured
within standard margins
10mm
5mm If media wider than 1361.6 mm
is used, the left and right
5mm
margins will be different from
those shown on the left.
Bidirectional Centronics: IEEE 1284 (compatible, nibble, ECP modes)

Ethernet: WindowsNT, Windows95, TCP/IP, NetWare, EtherTalk support
Head Life
Environmental
Conditions
Operating environment
Temperature: 10C to 35C, humidity 20% to 80% (no condensation)
Rate of change
Temperature: 2C/h, Humidity: 5%/h
Storage environment
Temperature: -10C to 60C, humidity 20% to 90% (no condensation)
Power Supply
(Voltage)
AC100 ~ 120 V 10%, AC200 ~ 240 V 10%
Power Supply
(Frequency)
50 Hz 1 Hz / 60 Hz 1 Hz
Power
Consumption
Standby
60 W or less
Printing
110 W or less
Cleaning
75 W or less
Height
1163.5 mm
Width
2350 mm
Depth
650 mm (680 mm)
Body
85 kg (833 N)
Legs
17.5 kg (171.5 N)
External
Dimensions
Weight
Auto Change
Auto Change
GID1000-3
Names of Parts
GID1100
1. Exterior parts of the Main Unit (Front)
Front Cover
Y-rail Cover
Operating Panel
Right Cover
Left Cover
Heater Panel
Pressure Lever
Front Paper
Guide
Waste Bottle
Control Box
Names of Parts
Take-up System
GID1100
Names of Parts
GID1100
1. Exterior parts of the Main Unit (Rear)
Cartridge Cover
6 Ink Slots
Rear Paper
Guide
Waste
Bottle
Scroller
Adjusting
Screw
Names of Parts
Scroller
Scroller Slip Ring
GID1100
Names of Parts
GID1110
2. Parts of the Main Unit media transport system and left and right frames
Suction Fan Assembly
Platen
Y rail
Flushing Box
Y Rail
Pressure Bracket
Protector board cover

with connectors .
Pressure Roller
Pressure Arm
Blade
Grid Roller
Names of Parts
GID1110
Names of Parts
GID1120
3. Main Unit Y Drive Section
T Fence
Y Return Pulley Shaft
Y Cable
Belt Fastening Screws (2)
Cover Switch
Drive Pulley
Left Frame
Y Motor Assembly
Steel Belt
Right Frame
Cutter Guide
Cutter Groove
Front Paper Guide

Waste Fluid Bottle
Lever Lock
Pressure Lever
Names of Parts
Pressure Relay Plate
Lever sensor Assembly
GID1120
Names of Parts
GID1130
4. Head Section
Origin Sensor Head Board Assembly
Head pipes (6)

Head cables (2)
Printer Head Assembly (Colour)
Cable Tie
Cutter Cap
Linear Encoder
Cutter Blade (s)
Cursor
Cutter Holder
Damper Fixer
Paper Sensor Assembly
H Adjustor B (1)
Head Mount
H Adjustor A (2)
Tube Stop Screws (6)
Dampers (6)
Head Section
Names of Parts
GID1130
Names of Parts
GID1140
5. Maintenance Station Parts
Pump Motor Assembly
P Motor Flange
Pump Motor Gear

Pump Motor Plate
Damper CR
Flat Washer
Cap Assembly
CR Damper Axle
Wiper
Pump Speed
Reduction Gear 1
Pump Speed
Reduction Gear 2
Pump Idler Gear

Pump Gear
Pump Assembly
Ink Tube
Extension Tube
Maintenance Base
Maintenance Unit
Names of Parts
Speed Reduction
Gear Bearer
GID1140
Names of Parts
GID1150
6. Cartridge Holder Section

Cartridge Sensor
Ink Tubes
Coupling Screws
Coupling BK
Coupling Screws
Cartridge Side Plate (6)

Cartridge Pipe (6)
Insertion Error Prevention

Plates (4)
IC Guide Bases (6)
Ink Cartridge Needle
Cartridge Base
Ink ID Sensor (6 types)
Remaining Ink Sensor
Waste Bottle
Names of Parts
GID1150
GID3000
GID3000
System Block Diagram - Heater System
GID3001
MK-24200
MK-24201
MK-41314
MK-24210
MK-24204
MK-24209
MK-21000
MK-24205
MK-41461
GID3001
GID3002
GID3002
Power On Sequence
Power Switch ON
[Checks Standard DRAM]
error occurs
Serious Error (StdDRAM)
error occurs
[Checks Optional DRAM]

error occurs
[Checks NVRAM]
error occurs
[Read NVRAM]
GID4010
Serious Error (OptDRAM)

[Write initial values to NVRAM]
Serious Error (NVRAM)
[Initialize Tasks]
< Enter Self-diagnostic Key >
Self-diagnostic Standby
[Cover & Lever monitoring begins]

error occurs
[Encoder diagnostic check]
Serious Error (Encoder)
[Motor excitation on]

error occurs
[Origin detection]
Serious Error (Sensor)
< Is capping position registered? >
Origin position not set
< Carriage not at capping position on startup >
Error Display
No
Strong Cleaning
Normal Standby
Power On Sequence
GID4010
Power Off Sequence
Power Switch Off
< Origin detection in progress >
GID4020
[Servo slows and stops]
< Media initialization in progress >
< Media cutting in progress >
< Open Cover >

< Lever up and location other than capping position >
< Cleaning in progress >
< Printing in progress >
< Lever down and location other than capping position >
[Move to capping position]
[Write settings to NVRAM]

< Is Power Switch on ? >
[Reset software]
[Power off]
Power Off Sequence
GID4020
GID4030
GID4030
< Panel setting: cut sheet >
No
YES
[Media trailing edge detection]
[Media width detection at trailing edge detection position]

Media feed
Media rewind
[Media width detection]
[Media leading edge detection]

[End]
GID4031
(1) Media Edge Base Value Detection

[Moves the carriage to a position where the reflection sensor has no media]
[Sets media edge gain to half, waits 2 ms]
[ad1 = reads reflection sensor]
[Sets media edge gain to normal, waits 2 ms]
[ad2 = reads reflection sensor]
[Sets media edge gain to half]
[Moves the carriage to a position where the reflection sensor is over media]
< Reflection sensor reading <= 0 x 56 ? >
Yes
[Sets media edge gain to normal]

[Waits 2 ms]
[Base value = ad2]
No
[Base value = ad1]
GID4031
(2) Media Leading Edge Detection
GID4032
Head
A direction
B direction
Rear Sensor
(XR)
[Moves carriage to a position where the reflection sensor comes over the media, a = reflection sensor reading]
[Moves 10 mm towards B, b = reflection sensor reading]
[Moves 5 mm towards A, c = reflection sensor reading]
[Media edge Z = { (a + b + c) + c x 3} 6 = { c + (a + b + c)3}2]
[Moves media slowly back to a position where reflective sensor value becomes Z]
< Cut media moved 200 mm >
No < Roll media moved 3010 mm >
< Reflective sensor value became Z >
Yes
Yes
[Media detection error]
No
[Moves forward 7 mm]

[Moves media slowly back to a position where reflective sensor value becomes Z]
No
Yes
< Media moved 10 mm >

< Reflective sensor value became Z >
Yes
No
[End]
GID4032

(3) Media width detection
GID4033
A direction B direction
Carriage
Maintenance unit
Media width
detection
< Is the carriage over the maintenance unit? >
No
[Move carriage to maintenance unit]
Yes
[Media edge base value detection]
Switch gain and read again, then select the more suitable
of the two values to determine gain.
[Moves the carriage to a position where the reflection sensor is over media, a = reflection sensor reading]
[Moves 5 mm towards A, b = reflection sensor reading]
[Moves 10 mm towards B, c = reflection sensor reading]
[Media edge (Z) = ( + (a+b+c) 3) 2]
[Moves the carriage slowly towards B to a position where the reflection sensor becomes equal to the Z value]
[Quick detection]
144.875mm
[Slow detection]
50.0mm
Right edge
detection
No
Yes
< Moved 144.875 mm >

< Reflection sensor reached Z >
Yes
No
[e1 = encoder count]

[Move the carriage to a position where the reflection sensor is over media]
[Move the carriage slowly towards A to a position where the reflection sensor becomes equal
to the Z value]
< 46 inch: Moved 1098.125 mm >
Left edge
[Quick detection]
46 inch: 1098.125mm detection
No
62 inch: 1555.425mm
[Slow detection]
Yes
50.0mm
Yes
< 62 inch: Moved 1555.425 mm >

< Reflection sensor reached Z >
No
[e2 = encoder count]

[Media width = e2-e1 : move carriage to the position of e1]
GID4033
GID4034
Head
Rear sensor
(XR)
[Move media forward until XR sensor goes "off" status]
No
Yes
< Media moved 1300 mm > Yes

< XR sensor becomes
"off" status >
No
[Recognizes that
roll media is loaded]
[Move forward 7 mm]

[Move media slowly back until XR sensor goes "off" status]
No
Yes
< Media moved 30 mm >

< XR sensor becomes
"off" status >
Yes
No
[End]
GID4034
Normal Standby Condition
GID4040
< Receive online data >

< Analyse received data >
< Mount media >
[Initializes media]
[Media is mounted when either XF or XR sensor is on]
< Enter the Cancel key >
< Printing in progress >
[Printing is forcibly ended]
< Reception/Analysis in progress >
[Data already received/analysed is ignored]
< Standby >
[If roll media is mounted, it is cut]
< End data analysis >
[Begins printing]
GID4040
Compete check for

disconnected encoder
GID4050
[Initializes PWM gate array]

[Checks X-axis + direction]
< Origin sensor ? >
ON
[Check Y-axis + direction]
OFF
[Checks Y-axis - direction]
[Check X-axis - direction]
[Checks X-axis - direction]
[Check Y-axis - direction]
[Checks Y-axis + direction]
[END]
Check each axis

in each direction
for disconnection
[PWM output on]

[PWM torque output]
< Move 5 pulses ? >
No
Yes
< 20 msec elapsed ? >
No
Yes
[Increases PWM torque]
< Moves 5 pulses ? >

Yes
No
< 20 msec elapsed ? > No
Yes
[End]
[Encoder error]
GID4050
GID4060
Origin Detection
A direction
Machine Origin Flag
B direction
Origin
Origin
Detection
< Inside origin flag ? >

No
Yes
[Move (200 mm) towards A while monitoring Origin sensor off]

Yes
< Moved 200 mm ? >
[Faulty sensor error]

No
< Origin sensor off ? >

Yes
[Moves 1 mm towards A and set origin sensor off]
[Moves (46 inch: 1410 mm, 62 inch 1890 mm) towards B while monitoring Origin sensor off]
No
< Origin sensor off ? >

Yes
[Moves 2 mm towards A and set origin sensor off]
[Moves carriage 10 mm towards A]

< Origin sensor on ? >
No
Yes
[Moves 20 mm towards B and set origin sensor on]
[Moves carriage 25 mm towards B]

< Origin sensor on ? >
Yes
(Go to next page)
GID4060
GID4061
[Moves 10 mm towards B]
[Moves (50 mm) towards A until origin sensor goes off]
No
< Moved 50 mm without sensor going off ? >
Yes
[Faulty sensor error]
[Let current position be "a"]

[Moves 5 mm towards A]
[Moves (35 mm) towards B until origin sensor goes off]
Yes
< Moved 35 mm without sensor going off ? >
No
[Let current position be "b"]
[Set the origin between points "a" and "b"]
[Moves to origin]
[End]
GID4061
GID4070
Detects trailing edge of media

(2)
(3)
(1)
Maintenance Unit
Media Cutting
No
No
Yes
< Printing in progress ? >

< Manual cutting requested ? >
< XR sensor is "off" status ? >
Yes
If media has just been initialized, feed 10 mm
No
[Wait ink drying period]
< Is ink drying period finished ? >

< Manual cutting requested ? >
Yes
[Moves forward 186 mm]

Yes
[Moves to a point 1/3 of media from right edge]

[Cut towards (1)]
[ End ]
< Manual cut finished key entry occurred >

[Waiting for key entry]
[Moves to a point 1/3 of media from left edge]

[Cut towards (2)]
[Moves to a point 1/3 of media from left edge]
[Cut towards (3)]
[Try to shake out the media]

[Moves 20 mm forward] (45 mm in the case of a retry)
[Moves 20 mm back] (45 mm in the case of a retry)
Yes < Tried 3 times ? >
No
[Moves 5 mm forward]
[Moves 5 mm back]
Yes
< Tried 3 times ? >
No
Retry once if media can not be shaken out

Yes
< There is media at the position detected by

the edge sensor >
No
[Media cutting error]
[ End ]
GID4070

Colour Printing
Sequence
< Are you printing with media already mounted when power was switched on ?>
Yes
GID4080
[Pull media 300 mm forward]
No
< Did you wait for 20 minutes after initialization ? >
Yes
No

[Move to position for starting to plot]
< Printing Mode ?>
Yes
360dpi High Speed
360dpi Standard
360 360: 2-pass bidirectional

[Moves carriage and prints]

360dpi High Quality

360 360: 4-pass unidirectional
[Moves media 4.3 mm forward]
< Printing finished ? >
No
Yes
[End]
No
Yes
No
[End]
[End]
720dpi High Speed

720dpi Standard
720dpi High Quality

< Printing Mode ?>
Yes
No
Yes
[End]
No
Yes
No
[End]
[End]
1440dpi High Speed

1440dpi Standard
1440dpi High Quality

[Moves media1.13 mm forward]
< Printing Mode ?>
Yes
No
Yes
[End]
Note: Flushing occurs each time.
[End]
No
Yes
No
[End]
46-inch: Flushes on right side

62-inch: Flushes on right side (for bidirectional printing with pigment inks, flush left & right)
GID4080
Rockhopper-46
3 Stored Test Patterns
PAT 0 0 0 0

< Stored Test Patterns >
These are patterns that are stored in the printer and can be output by the user or the serviceman when required without using a host computer.
The printer contains the following three stored test patterns, any of which can be output directly by keys.
No.
Name of Stored Test Pattern
Name of Direct Keys
Purpose and Details
Reference Page
1.
Test Pattern
[Shift]+[PRINT LAYOUT]
When trouble related to printing (such as picture quality or printing precision)

has occurred, having this pattern output in the field can become the basis for
identifying the cause of the problem from the maintenance manual.
In A3 size, it is a 7-colour pattern showing picture quality and printing precision.
When printing with A0 media mounted, in addition to the A3 size pattern,
the J line pattern will be printed over the entire width in the Y direction.
Printing will be in accordance with the printing mode set on the panel.
PAT1000
3.
Print Quality Adjustment Pattern
[Shift]+[CLEANING]
Print quality adjustment pattern for obtaining the best printing quality.
Mount A3 or bigger cut media or roll media.
Pattern A is for adjusting the Repeatability printing position of the left head.
Pattern B is for adjusting the Repeatability printing position of the right head.
Pattern C is for aligning the printing positions of the left and right heads.
The printing mode set on the panel will be ignored.
PAT3000
4.
Setup List
[Shift]+[MEDIA]
Outputs the user information currently set in the printer

A4 size, settings are output as test.
PAT4000
2.
Rockhopper-46
3 Stored Test Patterns
PAT 0 0 0 0
Rockhopper-62 Stored Test Patterns
PAT 0 0 0 0 - 3

< Stored Test Patterns >
These are patterns that are stored in the printer and can be output by the user or the serviceman when required without using a host computer.
The printer contains the following three stored test patterns, any of which can be output directly by keys.
No.
Name of Stored Test Pattern
Name of Direct Keys
Purpose and Details
Reference Page
1.
Test Pattern
[Shift]+[PRINT LAYOUT]
When trouble related to printing (such as picture quality or printing precision)

has occurred, having this pattern output in the field can become the basis for
identifying the cause of the problem from the maintenance manual.
When printing with A0 media mounted, in addition to the A3 size pattern,
the J line pattern will be printed over the entire width in the Y direction.
Printing will be in accordance with the printing mode set on the panel.
PAT1000
3.
Print Quality Adjustment Pattern
[Shift]+[CLEANING]
Print quality adjustment pattern for obtaining the best printing quality.
Mount A3 or bigger cut media or roll media.
PAT3000
4.
Setup List
[Shift]+[MEDIA]
Outputs the user information currently set in the printer

A4 size, settings are output as test.
PAT4000
2.
Rockhopper-62 Stored Test Patterns
PAT 0 0 0 0 - 3
Stored Test Patterns/Test Pattern
PAT 1 0 0 0
PAT 1 0 0 0
Test Pattern
When trouble related to printing (such as picture quality or printing precision) has
occurred, having this pattern output in the field can become the basis for identifying
the cause of the problem from the maintenance manual.
When plotting with A0 media mounted, in addition to the A3 size pattern, the J line
pattern will be printed over the entire width in the Y direction.
1. Make sure no data are being received then mount an A3 or larger sheet of cut
media or roll media in the printer.
2. Start printing by pressing [Shift]+[PLOT LAYOUT] at the same time.
During printing, [Printing
] will appear in the liquid crystal display unit.
When the image quality faults shown below have occurred, you can investigate
the type of problem by consultation based on reports using the location numbers
on the consultation pattern.
Image Quality Fault
Printed result differs from other machines
No printing at all
Entire surface printed black
Printing density varies
Black and white stripes appear in the printing
Edges of printing are blurred
Dots missing from printing Row
Whiskers on the printing
Lines are blurred Frame and
Printed length is abnormal
Location for Confirmation

Whole
Whole
Whole
Rows C, D, E, H
Rows C, D, E, H, J
Rows C, D, E, G
Row G
Whole
Rows A, B, I
Frame, Row I
Rows A, B, I
Row I
Frame
Plotted over the entire width of the media

that is loaded
Stored Test Patterns/Test Pattern
Stored Test Patterns/Print quality adjustment pattern
PAT 3 0 0 0

This prints patterns shown in the diagram on the right for making fine adjustments of printing
quality.
Alignment Print
1. Make sure no data are being received then mount an A3 or larger sheet of cut media or
roll media in the printer.
2. Start printing by pressing [Shift]+[CLEANING] at the same time.
During printing, [Accur. Adj Plot] will appear in the liquid crystal display unit.
3. Choose the best precision from lines 1) to 7) in patterns A, B and C and make adjustments using the following procedures.
4. [Pattern A:
4] is displayed.
Use the setting Value + and - keys to enter the number of the best image and press
[ENTER].
5. [Pattern B:
4] is displayed.
[ENTER].
6. [Pattern C:
4] is displayed.
[ENTER].
7. [[User 1] Plot OK] is displayed.
The specified values are now stored in the printer.
Good and bad examples of Patterns A and B
Bad
Good
Bad
Good and bad examples of Patterns C
Bad
Good
Bad
Stored Test Patterns/Print quality adjustment pattern
PAT 3 0 0 0
Stored Test Patterns/Setup List
PAT 4 0 0 0
PAT 4 0 0 0
Setup List
This prints out a list of user data currently set in the printer.
1. Make sure no data are being received then mount an A4 or larger sheet of cut media or roll media in the printer.
2. Start printing by pressing [Shift]+[Print Settings] at the same time.
During printing, [Printing
] will appear in the liquid crystal display unit.
Stored Test Patterns/Setup List
Rockhopper-46
3 Self-Diagnostic Functions
BAC0000
Self-Diagnostic Functions
This chapter explains about self-diagnostic functions that are not available to the user.
These functions are intended for use during manufacture, adjustment and maintenance and
include Panel Diagnosis operated from the panel.
For the Rockhopper-46, since post-adjustment parameters (settings and mechanical constants)
are saved in non-volatile memory, due care is needed in using them.
Self-Diagnosis Tree -------------------------------------------------------------------------BAC0010

How to Start Self-Diagnosis ---------------------------------------------------------------BAC0020
1. Examination ----------------------------------------------------------------------------------BAC1000
Memory Capacity-----------------------------------------------------------------------BAC1010
Version ------------------------------------------------------------------------------------BAC1020
Panel --------------------------------------------------------------------------------------BAC1030
Sensors -----------------------------------------------------------------------------------BAC1040
Encoders ---------------------------------------------------------------------------------BAC1050
Fans ---------------------------------------------------------------------------------------BAC1060
Ethernet Board --------------------------------------------------------------------------BAC1065
History: Last error message ---------------------------------------------------------BAC1070
History: Head nozzle ejection count check --------------------------------------BAC1070
Head Drive Waveform ----------------------------------------------------------------BAC1080
2. Adjustment -----------------------------------------------------------------------------------BAC2000
Capping Position Adjustment -------------------------------------------------------BAC2010
Skew Verification -----------------------------------------------------------------------BAC2030
Head Rank Input (Initial Filling)-----------------------------------------------------BAC2040
Head Nozzle Verification -------------------------------------------------------------BAC2050
Left Head Tilt Verification ------------------------------------------------------------BAC2060
Right Head Tilt Verification ----------------------------------------------------------BAC2070
Repeatability Printing Positioning (Normal dot, Micro dot) ------------------BAC2080
CW Adjustment (Normal dot, Micro dot) -----------------------------------------BAC2090
Rockhopper-46
3 Self-Diagnostic Functions
Flush Pointer Adjustment ------------------------------------------------------------BAC2110

Media Feed Distance Compensation ---------------------------------------------BAC2120
Margin Adjustment ---------------------------------------------------------------------BAC2130
Rear Sensor Position Adjustment--------------------------------------------------BAC2140
Test Print ---------------------------------------------------------------------------------BAC2150
Head Wash ------------------------------------------------------------------------------BAC2160
3. Cleaning ---------------------------------------------------------------------------------------BAC3000
Normal, Powerful
4. Test Printing ---------------------------------------------------------------------------------BAC4000
Head Printing Verification
Check Black In-filling
Adjustment Parameters
5. Parameters -----------------------------------------------------------------------------------BAC5000
Initialize -----------------------------------------------------------------------------------BAC5010
Update ------------------------------------------------------------------------------------BAC5020
6. Aging -------------------------------------------------------------------------------------------BAC6000
Carriage Motor --------------------------------------------------------------------------BAC6010
Media Feed Motor----------------------------------------------------------------------BAC6020
Cutter --------------------------------------------------------------------------------------BAC6030
Maintenance Unit-----------------------------------------------------------------------BAC6040
Head ---------------------------------------------------------------------------------------BAC6050
BAC0000
Rockhopper-62 Self-Diagnostic Functions
BAC0000-3
Self-Diagnostic Functions
This chapter explains about self-diagnostic functions that are not available to the user.
These functions are intended for use during manufacture, adjustment and maintenance and
include Panel Diagnosis operated from the panel.
For the Rockhopper-62, since post-adjustment parameters (settings and mechanical constants)
are saved in non-volatile memory, due care is needed in using them.
Self-Diagnosis Tree -------------------------------------------------------------------------BAC0010

How to Start Self-Diagnosis ---------------------------------------------------------------BAC0020
1. Examination ----------------------------------------------------------------------------------BAC1000
Memory Capacity-----------------------------------------------------------------------BAC1010
Version ------------------------------------------------------------------------------------BAC1020
Panel --------------------------------------------------------------------------------------BAC1030
Sensors -----------------------------------------------------------------------------------BAC1040
Encoders ---------------------------------------------------------------------------------BAC1050
Fans ---------------------------------------------------------------------------------------BAC1060
Ethernet Board --------------------------------------------------------------------------BAC1065
History: Last error message ---------------------------------------------------------BAC1070
History: Head nozzle ejection count check --------------------------------------BAC1070
Head Drive Waveform ----------------------------------------------------------------BAC1080
2. Adjustment -----------------------------------------------------------------------------------BAC2000
Capping Position Adjustment -------------------------------------------------------BAC2010
Skew Verification -----------------------------------------------------------------------BAC2030
Head Rank Input (Initial Filling)-----------------------------------------------------BAC2040
Head Nozzle Verification -------------------------------------------------------------BAC2050
Left Head Tilt Verification ------------------------------------------------------------BAC2060
Right Head Tilt Verification ----------------------------------------------------------BAC2070
Repeatability Printing Positioning (Normal dot, Micro dot) ------------------BAC2080
CW Adjustment (Normal dot, Micro dot) -----------------------------------------BAC2090
Rockhopper-62 Self-Diagnostic Functions
Flush Pointer Adjustment ------------------------------------------------------------BAC2110

Media Feed Distance Compensation ---------------------------------------------BAC2120
Margin Adjustment ---------------------------------------------------------------------BAC2130
Rear Sensor Position Adjustment--------------------------------------------------BAC2140
Test Print ---------------------------------------------------------------------------------BAC2150
Head Wash ------------------------------------------------------------------------------BAC2160
3. Cleaning ---------------------------------------------------------------------------------------BAC3000
Normal, Powerful
4. Test Printing ---------------------------------------------------------------------------------BAC4000
Check Black In-filling
5. Parameters -----------------------------------------------------------------------------------BAC5000
Initialize -----------------------------------------------------------------------------------BAC5010
Update ------------------------------------------------------------------------------------BAC5020
6. Aging -------------------------------------------------------------------------------------------BAC6000
Carriage Motor --------------------------------------------------------------------------BAC6010
Media Feed Motor----------------------------------------------------------------------BAC6020
Cutter --------------------------------------------------------------------------------------BAC6030
Maintenance Unit-----------------------------------------------------------------------BAC6040
Head ---------------------------------------------------------------------------------------BAC6050
BAC0000-3
Self-Diagnosis Tree 1
1.
Examination
1.1
1.2
Memory Capacity
Versions
1.3
Panel
1.4
Sensors
1.5
Encoder
1.6
Fan
1.7
1.8
Ethernet Board
History
1.9
Head Drive Waveform
BAC0010
BAC1000
Memory Capacity
Firmware
Parameters
DIP Switches
Keys
LCD
LEDs and Buzzer
X Front, X Rear, Cover, Lever
Origin, No Ink, No Cartridge, Ink ID, Media Edge
Temperature, Waste Fluid Tank
Encoder X
Encoder Y
Fan Check
On
Fan Check
Off
Maintenance
(Head Nozzle Ejection Count)
CPU System and Mechanical System Errors

(Last error message display)
Head Waveform
BAC1010
BAC1020
BAC1030
BAC1040
BAC1050
BAC1060
BAC1065
BAC1070
L Head Ejections: mdot

L Wiping Count:
L Rubbing Count:
R Head Ejections: mdot
R Wiping Count:
R Rubbing Count:
W Wiping Count:
W Rubbing Count:
Quantity of Ink in Waste Fluid Tank
Black Ink Remaining
Cyan Ink Remaining
Magenta Ink Remaining
Yellow Ink Remaining
G Ink Remaining
O Ink Remaining
Failure Error 1 ~ 7
BAC1070
VK
KC1
CHG
ND2
ND1
TR1
FLUSH
BAC1080
BAC0010
2.
BAC0011
Adjustments
2.1
2.2
2.3

Skew Verification
Head Rank Input (including Initial Filling)
2.4
2.5
2.6
2.7

Repeatability Printing Positioning (Normal dot)
2.8
Repeatability Printing Positioning (Micro dot)
2.9
CW Adjustment (Normal dot)
2.10 CW Adjustment (Micro dot)

2.11 Flush Pointer Adjustment
Left Rank:
Right Rank:
Filling
Printing
Normal Cleaning
Powerful Cleaning
Printing
Printing
Left Differential
Right Differential
Left Differential
Right Differential
BAC2050
Gap adjustment
BAC2090
Gap adjustment
BAC2090
Left Pointer
Right Pointer
Left Pointer (left flushing)
Right Pointer (right flushing)
2.12 Media Feed Distance Compensation

2.13 Front-to-Head, Cutter-to-Head Distance Adjustment
2.14 Rear Sensor Position Adjustment

2.15 Test Print
2.16 Head Wash
BAC2010
BAC2030
BAC2040
BAC2060
BAC2070
BAC2080
BAC2080
BAC2110
BAC2120
Top Distance
Bottom Distance
Distance
Distance
Black in-filling
BAC2130
BAC2140
BAC2150
BAC2160
BAC0011
3.
Cleaning
3.1 Normal
3.2 Powerful
BAC3000
4.
Test Printing
4.1 Head Printing Verification
4.2 Black infill printing
4.3 Adjustment Parameters
BAC4000
5.
Parameters
5.1 Initialization
5.2
Updating
Capping Position
X Encoder Resolution
Maintenance History
Error History
Serial Number
Complete
Capping Position
Head Rank
Print Positioning
Print Positioning (Micro dot)
Media Transport Distance
Mechanical Parameters
6.
Aging
6.1 Carriage Motor
6.2 Media Feed Motor
6.3 Cutter
6.4 Maintenance Unit
6.5 Head
Left
Right
BAC0012
BAC5000
BAC5010
Left Head
Right Head
Wiper
BAC5020
Left
Right
L Delay
R Delay
Gap
L Delay
R Delay
Gap
Head-to-Edge Sensor
X Front-to-Head
Head-to-Cutter
X Front-to-X Rear
Media Edge
(Black) Left Flash Pointer
(Colour) RIght Flash Pointer
Left Flashing Left Flash Pointer
RIght Flashing RIght Flash Pointer
PaperWidAdj
BAC6000
BAC6010
BAC6020
BAC6030
BAC6040
BAC6050
BAC0012
How to Start Self-Diagnosis

These pages deal with the hidden diagnostic functions of the Rockhopper-46/62
Inkjet Printer. These hidden diagnostics are mainly intended for examining boards
and determining mechanical and firmware adjustment parameters. These functions
are incorporated into the printer firmware but they are not disclosed to end users.
They are enabled by applying power to the printer while holding down several special panel keys. It is not possible to access the hidden diagnostic functions from the
normal printer mode. Updated firmware adjustment parameters can be registered
by exiting diagnostic mode or by switching off the power. Firmware adjustment
parameters are also registered when there is a serious MOE failure error on adjustment. The printer will be reset on exiting diagnostic mode. Diagnostic functions are
as follows.
BAC0020
Operations for selecting Diagnostics items are shown below.
Table 1: Hidden diagnostic functions

Item
Examination
Adjustment
Cleaning
Test printing
Parameters
Aging
Details
Verification of RAM capacity, version, panel, sensors, encoders, fans,
network board, history and waveform
Manufacturing processes, adjustments on head replacement and
adjustments to media feed system
Mode specified head cleaning
Head nozzle verification printing, black in-filling and adjustment parameters
Initialization, updating
Carriage motor, media feed, cutter, maintenance unit, head
DIAG: Exam
To terminate self-diagnostics, switch off the power.

Menu Up
ENTER
DIAG: Exam
Menu Down
Examination Menu
Menu Up
Back
ENTER
DIAG: Adjustment
Adjustment Menu
Back
Menu Down
Menu Up
ENTER
DIAG: Cleaning
Cleaning Menu
Back
1. Power supply to the printer is off.

2. Switch on the power with the [Head Cleaning] + [Menu Display] + [Shift] keys
held down.
3. The panel LCD will display DIAG: EXAM. X and Y excitation remains off.
Menu Down
Menu Up
ENTER
DIAG: Test Print
Test Print Menu

Back
Menu Down
Menu Up
ENTER
DIAG: Parameter
Note 1:
Note 2:
Note 3:
Note 4:
Note 5:
The system will not revert to normal mode even if there is no key entry for three minutes.
Roll media mode is set automatically.
Panel keys that can be operated are [CANCEL] and the keys for menu display (Menu Up
and Down, Back, Value + and , ENTER)
To terminate self-diagnostics, switch off the power.
To feed media, press [MENU] while holding down the [Shift] key when the Diagnostics Menu
is displayed.
How to Start Self-Diagnosis
Menu Down
Parameter Menu
Menu Up
Back
ENTER
DIAG: Aging
Aging Menu
Back
Menu Down
BAC0020
Examination
This is intended for board checking. X and Y excitation is not turned on by selecting
Examination from the Diagnostics Menu.
The X and Y excitation condition will be preserved as it is at the time you select an
item to be examined.
Items to be examined are as follows.
To return to the Diagnostics Menu from the Examination Menu, press [Back].
EXAM:
Menu Up
ENTER
EXAM: Ram Capacity
Table 1-1: Board examination items

Item
Details
Memory Capacity
Check memory capacity
Versions
Programs, Backup parameters, DIP Switches
Panel
Keys, LCD, LEDs, Buzzer
Sensors
XF, XR, Covers, Levers, Origin, Ink out, No cartridge, Ink ID,
Media edge, Thermistor, Waste fluid tank
Encoders
X-axis (media feed), Y-axis (carriage)
Fans
Check on/off
Network
Initializing, None, Error, Initialization Error, Initialization OK
History
Maintenance, Major failure
Head Waveform
Check head drive waveform
BAC1000
Menu Down
Memory Capacity Display
Menu Up
Back
ENTER
EXAM: Version
Version Display
Back
Menu Down
Menu Up
ENTER
EXAM: Panel
Panel Check
Back
Menu Down
Menu Up
ENTER
EXAM: Sensor
Sensor Check
Back
Menu Down
Menu Up
ENTER
EXAM: Encoder
Encoder Check
Back
Menu Down
Menu Up
ENTER
EXAM: Fan
Menu Down
Fan Check
Menu Up
Back
ENTER
EXAM: Option Board

Menu Down
Initialize Data Display

Menu Up
Back
ENTER
EXAM: Record
Menu Down
History Display
Menu Up
Back
ENTER
EXAM: Head Drive
Waveform Check
Back
Menu Down
Examination
BAC1000
Examination: Memory Capacity
BAC1010
BAC1010
This procedure is used to check the capacity of the memory on a board. When this
item is selected, the memory capacity is displayed on the panel or terminal.
EXAM: Memory Capacity
Ram Capacity:
40 MB
Press [ENTER] to shift to EXAM: Version or [Back] to shift to EXAM: Memory

Capacity.
Examination: Memory Capacity
Examination: Version
BAC1020
BAC1020
This confirms firmware version (program, backup parameters) and DIP switches
(On:0, Off:1, switch No. 1 is the least significant byte, 8 is the most significant byte).
Each is displayed on the panel when this item is selected.
EXAM: Version
Menu Up
VER: Firm
Menu Down
1.00
Menu Up
VER: Param
Menu Down
Program version display
1.00
Backup parameter version display
Menu Up
VER: Dip SW
0xFF
Verify DIP switches
Menu Down
Reference
DIP switch
1 Off
1 On
1 Off
1 On
2 Off
2 Off
2 On
2 On
:
:
:
:
0 X 03
0 X 02
0 X 01
0 X 00
Press [ENTER] to shift to EXAM: Panel or [Back] to shift to EXAM: Version.
Examination: Version
Examination: Panel
BAC1030
This procedure is used to check panel keys, LCD, LEDs and buzzer.
EXAM: Panel
PANEL: Key
Menu Up
ENTER
PANEL: L c d
Menu Up
Panel key check
Under key check, when each key is pressed that

key is shown on the LCD. Press the [ENTER] key
to shift to LCD check after 2 seconds.
Panel LCD check
Under LCD check, the screen is repeatedly filled

with black from the right edge.
Panel LED and buzzer check
Under LED and buzzer check, LEDs are lit in

sequence from Data, Error, Standard, Thin,
High Quality, Normal, High Speed, Low, High
Roll Media, Cut Sheet and finally the sounding of
the buzzer is checked.
Menu Down
PANEL: L e d B u z z e r
Menu Down
Press [ENTER] to shift to EXAM: Sensor or [Back] to shift to EXAM: Panel.
Examination: Panel
BAC1030
Examination: Sensors
This procedure is used for checking, from displays on panel or terminal, the status of
sensors for XF (the X Front Sensor), XR (the X Rear Sensor), cover, lever, origin, no ink
(K, C, G, M, Y, O), cartridge (K, C, G, M, Y, O), ink ID, media edge sensor level, head
thermistor value and whether or not the waste fluid tank is present.
SENS: Xf Paper
Off
SENS: Cover
Menu Down
SENS: Lever
Menu Down
SENS: No Ink
Menu Down
SENS: No Car
Menu Down
SENS: TEMP
Off
X Rear sensor check
Menu Down
SENS: Tank
Menu Up
Open
Cover sensor check
Menu Up
Down
Lever sensor check
Menu Up
SENS: Origin
Menu Down
X Front sensor check
Menu Up
SENS: Xr Paper
Menu Down
SENS: K D C D G D M P Y W O N
SENS: Edge
Menu Up
Menu Down
Menu Up
Menu Down
EXAM: Sensor
On
Origin sensor check
BAC1040
Ink type check
Menu Up
004e
Media edge sensor check
Menu Up
25, 25C
Temperature sensor check
Menu Up
Exist
Waste fluid tank sensor check
Menu Down
No Cart. means No Cartridge.

Colour is expressed by an alphabetical letter.
Cartridge indicates the Special Cartridge sensor.
KCGMYO ink ID display
D = dye, P = pigment, W = cleaning liquid, N = other brand,
= no cartridge
Menu Up
KCGMYO
No Ink sensor check
Press [ENTER] to shift to [EXAM: Encoder] or [Back] to shift to [EXAM: Sensor].
Menu Up
KCGMYO
Cartridge sensor check
Menu Down
Examination: Sensors
BAC1040
Examination: Encoders
BAC1050
BAC1050
This procedure is used to verify the values of X-axis (media feed) and Y-axis (carriage) from displays on the panel or the terminal.
EXAM: Encoder
Menu Up
ENCODER : X
Menu Down
0000
X encoder check
Menu Up
ENCODER : Y
FFFF
Y encoder check
Menu Down
Press [ENTER] to shift to EXAM: Fan or [Back] to shift to EXAM: Encoder.
Examination: Encoders
Examination: Fans
BAC1060
BAC1060
This procedure is used to verify that the fans are working by turning them on and
off.
EXAM: Fan
Fan: On
Fan goes off 10 seconds after starting
Fan: Off
Displayed for 5 seconds after fan has gone off
Panel keys are ignored during fan on/off display. 5 seconds after displaying Fan Off,
the display will shift to EXAM: Fan.
Examination: Fans
Examination: Ethernet Board
BAC1065
BAC1065
This procedure is used to verify the initialization of Ethernet board data.

EXAM: Option Board
OptBoard: Initialize
Ethernet board initialization is in progress.

Wait until the next message is displayed.
OptBoard: No
There is no Ethernet board.
OptBoard: Wrong
The Ethernet board is wrong.
OptBoard: Error
An error has occured during

initialization of the Ethernet board.
OptBoard: OK
Ethernet board has been initialized.
After confirming the status of initialization of the Ethernet Board from the messages
shown above, press [ENTER] to move to EXAM: Record.
Examination: Ethernet Board
Examination: History
BAC1070
BAC1070
This procedure is used to verify the history of maintenance (head ejection count and
numbers of wipings and rubbings, the numbers of wipings and rubbings with the
wiper, volume of waste fluid, and the amount of ink remaining) and serious failures
(MOE type). Operations for the selection of history items are shown below.
EXAM: Record
Menu Up
RECORD:
Menu Down
RECORD:
Mainte
Verify maintenance history
Menu Up
Error
Verify error history
Menu Down
If [Back] is pressed while the History menu is displayed, the display will shift to
EXAM: Record.
BAC1071
Maintenance History
Panel and Terminal displays are shown below.
EXAM: Mainte
Waste-Ink:
Menu Down
Menu Up
L Head Count:
Menu Down
0M
Menu Down
Menu Down
MRemainder:
Menu Down
0M
Number of Colour head ejections

(Unit 1 Mdot)
Menu Up
YRemainder:
Menu Down
Number of times Colour head wipings
Menu Up
GRemainder:
Menu Down
Number of times Colour head rubbings
Menu Up
W Wiping:
Menu Down
Number of times Black head rubbings
Menu Up
R Rubbing:
CRemainder:
Menu Down
R Wiping:
Menu Down
Number of times Black head wipings
Menu Up
R Head Count:
KRemainder:
Menu Down
L Rubbing:
Menu Down
Number of Black head ejections

(Unit 1 Mdot)
Menu Up
L Wiping:
Menu Down
Menu Up
ORemainder:
120 cc
Volume of ink waste fluid
Menu Up
Full
Number of ejections remaining to end of black ink
Menu Up
Full
Number of ejections remaining to end of cyan ink
Menu Up
Full
Number of ejections remaining to end of magenta ink
Menu Up
Full
Number of ejections remaining to end of yellow ink
Menu Up
Full
Number of ejections remaining to end of G ink
Menu Up
Full
Number of ejections remaining to end of O ink
Menu Down
4
Number of times Wiper wipings
Number of times Wiper rubbings
Menu Up
W Rubbing:
Menu Down
Quit from Maintenance History by entering the [ENTER] or [Back] key.

Press the [ENTER] key to shift to "RECORD: Error" or the [Back] key to shift
to RECORD: Mainte.
BAC1071
BAC1072
BAC1072
Serious Failure History

This procedure is used to verify the history of serious failures.
CPU errors are not included in the serious failure history.
Error 0 is the latest error, up to 7 previous errors are displayed. Panel displays
are shown below.
RECORD: Error
Menu Up
Err0
: Y
Menu Down
Err1
Y over-current error
Menu Up
: X
Menu Down
Err2
CURRENT
MOTOR
X motor error
Menu Up
: X
ENCODER
X encoder error
Menu Down
Quit from Maintenance History by entering the [ENTER] or [Back] key. Press the
[ENTER] key to shift to RECORD: Mainte or the [Back] key to shift to RECORD:
Error.
Examination: Head Waveform
BAC1080
This confirms the ejection action waveform for both heads.

CAUTION: When this item is selected, it will try to force the head nozzles to eject.
Therefore the cables connected to the head board should be disconnected.
EXAM: Head Drive
Menu Up
ENTER
Head Driver: VK
Menu Down
VK voltage
COM
VK voltage
COM
[Terminal]
TP17
Q5E
TP15
Q3E
PullOut Head Cable
Menu Up
ENTER
ENTER KEY to END
Head Driver: KC1

Menu Down
Left Head
Left Head
Right Head
Right Head
Menu Up
Head Driver: CHG

Menu Down
Menu Up
Head Driver: ND2

Menu Down
Menu Up
Head Driver: ND1

Menu Down
Menu Up
Head Driver: TRI

Menu Down
Menu Up
Head Driver: FLUSH

Menu Down
Press [ENTER] for "Test: Memory", [PREV] for "Test: Head Driver"
Examination: Head Waveform
BAC1080
Adjustment
BAC2000
BAC2000
This procedure is used for correcting media feed and printing position. This is done
by mechanical adjustments (head tilt) and firmware parameter adjustments. If this
item is selected when X and Y excitations are off, the X and Y excitations will be
turned on and the initialization sequence will be carried out. Items for adjustment
are listed in Table 2-1. All these procedures are implemented during production.
When the head is replaced, head cleaning (followed by switching off and replacing
the head), head rank input, ink filling and print positioning are implemented. CW
adjustment, reciprocal printing positioning and zone delay compensation are carried
out when the printing position is to be corrected after a change of media type. If
media feed is off, the media feed distance is compensated.
Table 2-1 Adjustment items
Item
Skew Verification
Head Rank Input
Black Head Tilt Verification
Colour Head Tilt Verification
CW Adjustment
XF-XR Sensor Distance
XF, Cutter-to-Head Distance
Test Print
Head Wash
Adjustment
Details
To adjust capping position parameters in the firmware
To use sensor results to check for media skew
To enter a specific value for a specific head and fill inks
After filling inks, to check head nozzle ejection by print results
To check left head tilt by printing (mechanical adjustment)
To check right head tilt by printing (mechanical adjustment)
To align reciprocal printing position by printing
To align the shafts of the two heads by printing and adjust left
margin
To adjust the position for flushing into the flushing box
To print a line in the X direction and enter its distance (X resolution adjustment)
To measure the distance XF and XR sensors with cut media
To adjust top, bottom, left and right margins
To check head nozzles and adjust parameters (enter serial numbers)
Done after manufacturing and before head replacement
Adjustment
BAC2001
Press [Back] to return to the self-diagnostics Menu from the Adjustment Menu.
DIAG: Adjustment
Menu Up
Menu Up
ENTER
AJST: Home
Menu Down

Menu Up
AJST: Chk Paper Mov

Menu Down
Menu Up
Menu Up
Menu Up
AJST: Left Tilt

Menu Down
Menu Up
Menu Down
Menu Up
Menu Down
Menu Up
Menu Down
Menu Up
Menu Down
Menu Up
AJST: Test Print

Menu Up
AJST: BiDir Print

Menu Down
AJST: Flash Point
AJST: Rear Sns Posi
AJST: Right Tilt

Menu Down
Menu Up
AJST: Margin
AJST: ChkNozzles
Menu Down
Menu Down
AJST: X Length
AJST: Head Rank

Menu Down
Back
AJST: UniDir Print
Menu Down
Menu Up
AJST: Head Wash

Menu Up
AJST: UniDir (MD)

Menu Down
Menu Up
AJST: UniDir Print
Note: MD = Microdot
Adjustment
BAC2001
Adjustment: Capping Position
BAC2010
BAC2010
This procedure is used for aligning the capping position correctly by adjusting the
capping position parameters in the firmware.
When this item is selected, the printer carries out the home position detection
sequence and then automatically pushes the carriage against the maintenance unit
to detect the carriage position at that time. The position displayed is the distance
from the home position flag.
AJST: Home
Origin Detect
After the origin has been detected,
the capping position will be detected
Home Detect
After the carriage has moved to the capping position,
that position is displayed
Home:
-74.000
Press [ENTER] to update the capping positions and move to AJST:

Measure High, press [Back] to move to AJST: Home without updating
the capping position.
Adjustment: Capping Position
Adjustment: Media Skew
This procedure will feed a specific amount of paper (a single pass band feed) and the sensors will read the position of the edge of the media before and after feeding and check for
any discrepancy. If no media is loaded when this item is selected, you will be asked to load
the media. After media initialization, when the amount of media feed is entered, the edge
sensors will detect the left and right edges of the media and media feed will begin. After
feeding the specified amount, the edge sensors will again detect the left and right edges of
the media and any difference from the readings before media was fed will be checked and
displayed. A media recognition error before and after feeding, or detection by the rear sensor
of no paper during feeding, will cause a media error to be displayed and this procedure may
be terminated by pressing any key. To terminate the procedure when processing is not in
progress, press [Back] on the panel. To escape from this item, press [Back] while no processing is in progress.
CAUTION:
Make sure media is properly loaded.
BAC2030
Press [ENTER] to move to Adjustment: Rank Input or [Back] to move to

AJST: ChkPaperMov. Other panel keys are ignored during processing.
Standard values
Condition
A0
1.5 mm or less
Cut Sheet
7m
2.5 mm or less
50 m
10 mm or less
Roll Media
Media
Thick
coated
paper
The first time this adjustment is made, the reference position for media skew will be determined by detecting the right edge (origin side). If the adjustment is made with a bad media
loading position, that position will become the reference position and Media skew error will
occur frequently.
AJST: Chk Paper Mov

Set Paper
If no media is loaded
After media has been loaded
Paper Initial
Paper Feed
After media initialization has been completed

Setting can be specified in units of
1.0 m
0.1 m using the VALUE + and - keys
ENTER
Paper Edge Detect
Paper Feed
Media feed ends normally
Paper Edge Detect
Media edge detection ends normally
>0.100 mm>
+0.100 mm
Non-origin side
Capping position side
Adjustment: Media Skew
+ for cap side, - for opposite side
BAC2030
Adjustment: Head Rank
This is to enter the rank for the left or right head. This is used to determine
the head operating voltage and for temperature correction. The panel holds
rank setting ranges. A rank outside the range that is entered from the terminal
is invalid. When the right rank is set, pressing the [ENTER] key will switch to
the ink filling menu.
AJST: Head Rank
Settings are changed by + and -, from

the left normal rank, frequency ID,
micro-rank are all displayed when
Menu Down
Menu Up
everything is confirmed.
Right Rank:
26
Parameters are updated by setting the
entire right rank.
Press [ENTER] to
move to the following item
Left Rank:
21117
BAC2040
CAUTION:
The following operations must not be performed during ink filling.
Printing will not work properly if ink filling is stopped or interrupted.
Switching off the power
Opening the front cover
Raising the pressure lever
Removing an ink cartridge
CAUTION:
The ink filling operation will not proceed unless all six ink cartridges are
of the same kind.
FILL START
Press [ENTER] to
move to the following item
Set Cartridge
Ink fill * min
Update head rank with [ENTER]. Shift to ink filling menu by entering right rank
and pressing [ENTER]. Under the ink filling menu, [ENTER] starts ink filling and
[Back] shifts to "Adjust: Nozzle check".
Adjustment: Head Rank
BAC2040
Adjustment: Head Nozzles

After filling the inks, this procedure uses printing results to check whether the head
nozzles are ejecting the ink properly. If the nozzles are ejecting ink badly, implement the cleaning treatment in this procedure. If there is no media, the printer will
request media. If it is out of ink, it will ask for an ink cartridge. If there is media and
ink, the Head Nozzle Check Pattern will be printed.
This and subsequent items that require printing for adjustment or checking include
requests for media and inks. If the [CANCEL] key is pressed during printing, the
printer will stop printing.
If [ENTER] is pressed while Nozzle check completed is displayed, the AJST:

BlackTilt menu will be appear. If [Back] is pressed while no processing is in
progress, AJST: ChkNozzles will be restored.
Head Nozzle Check Pattern (6 colours)
Check Items
Printing method
AJST: ChkNozzles
Set Paper
BAC2050
Nozzle ink eject check (missing, discontinuous, meandering)

Satellite
Timing fence
Single-pass, bidirectional
X 180 dpi Y 360 dpi
If media is not loaded

After media has been loaded
Paper Initial
Media initialization in progress
Adjustment Print
If there is no cyan ink for instance

After installing a cyan ink cartridge
Adjustment print is displayed
Printing is finished
Menu Up is output
END: ChkNozzles
Menu Down
Menu Up
CLEAN: Normal
Menu Down
Menu Up
CLEAN: Powerful
Menu Down
Menu Up
[Menu Down] completed
START: ChkNozzles
Select cleaning [Enter] to move to the following
5
G C K O Y M G C K O Y M G C K O Y M G C K O Y M G C K
25
[C] no ink
Cleaning
After cleaning is finished, the menu will return to the start
Head Nozzle Check Pattern

Lettering is not printed in the Head Nozzle Check Pattern.
Adjustment: Head Nozzles
BAC2050
Adjustment: Left Head Tilt
This procedure uses printing results to check whether the left head is tilted. If it is
tilted, it needs to be adjusted mechanically.
AJST: Left Tilt
Adjustment Print
Displayed during printing

Printing finished
END: Check Tilt

Menu Down
BAC2060
Left Head Tilt Check Pattern

Check Items
Left head tilt
Print Method
Single-pass, uni-direction
X 180 dpi, Y 720 dpi
[Menu Down] is output

Menu Up
START: Check Tilt
Press [ENTER] to print again,

next menu is end
Width 4.5
Press [ENTER] while END: Check Tilt is displayed to move to AJST:

Right Tilt.
5
c k c k g k g k c k c k g k g k c k c k g k g k
25
Paint Vertical width 6
30 m or less
k g k
Right side (g side) is

too far forward.
Adjustment: Left Head Tilt
30 m or less
Right side (g side) is

too far back.
BAC2060
Adjustment: Right Head Tilt

This procedure uses printing results to check whether the right head is tilted. If it is
tilted, it needs to be adjusted mechanically.
AJST: Right Tilt
Adjustment Print
Right Head Tilt Check Pattern

Check Items
Right head tilt (based on Left head)
Print Method
Single-pass, uni-directional
Printing finished
[Menu Down] is output
END: Check Tilt

Menu Down
BAC2070
Menu Up
START: Check Tilt
The center of the right head
Press [ENTER] to print again,

next menu is end
Press [ENTER] while END: Check Tilt is displayed to move to

AJST: BiDirPrint.
Width 9
5
k
Paint Vertical width 6

25
The center of the left head
Standard values
y
30 m or less
Adjustment: Right Head Tilt
y
30 m or less
BAC2070
Adjustment: Repeatability Printing Position
BAC2080
This procedure is used to align left and right Normal-Dot and Micro-Dot repeatability printing positions. This involves making a bidirectional test print and from the results
adjusting the CCW printing delay (position and timing) by entering into the firware the differences between the CW printing position and the CCW printing position. There are
separate differences for both black and colour normal dots and micro dots.
Bidirectional position adjustment for Normal-Dot
Bidirectional position adjustment for Micro -Dot
DIAG: Adjustment
DIAG: Adjustment
AJST: BiDirPrint
AJST: BiDir (MD)

ENTER
ENTER
Adjustment Print
Adjustment Print
ENTER
ENTER
KCG Err: -250 m
Menu Down
Menu Up

10 m using the VALUE + and - keys
Press [ENTER] to update reciprocal difference

MYO Err: -250 m
Press [ENTER]
Press [ENTER] Press [ENTER] to update the reciprocal difference
after correction
without correction
Print Start?
ENTER
If [ENTER] is pressed at MYO Err: and the parameter has been changed,
the left and right CCW printing delays (position and timing) will each be updated
in the firmware and another adjustment print will be made.
If the parameter was not changed, Print Start? will be displayed.
If [ENTER] is pressed, another adjustment print will be made.
If [Back] is pressed, the display will move to AJST: BiDir (MD).
KCG Err: -250 m

Menu Down
MYO Err: -250 m
Press [ENTER]
after correction
Menu Up

Press [ENTER] to update reciprocal difference

Press [ENTER] Press [ENTER] to update the reciprocal
without correction difference
Print Start?
ENTER
If [ENTER] is pressed at MYO Err: and the parameter has been changed,
the left and right CCW printing delays (position and timing) will each be updated
in the firmware and another adjustment print will be made.
If the parameter was not changed, Print Start? will be displayed.
If [ENTER] is pressed, another print will be made.
If [Back] is pressed, the display will move to AJST: UniDirPrint. (BAC2090)
Continued next page
BAC2080
BAC2081
BAC2081
Repeatability printing position alignment pattern (6 colours)

Adjustment items Left and right repeatability printing position alignment
Printing method
Single-pass, bidirectional
CW printing
CCW printing
CW printing
Standard values
50 m or less
70 m or less
Adjustment: CW
BAC2090
Left and right head axial adjustment for normal dots and microdots.
Have the printer print unidirectionally and from the results enter the position error for CW printing (separately for Normal-Dot and Micro-Dot) to adjust the right head CW
printing delay (position and time) and the left head CCW printing delay (position and time) in the firmware.
CW Adjustment for Normal-Dot
CW Adjustment for Micro-Dot
Panel DIAG: Adjustment
Panel DIAG: AJST
AJST: UniDirPrint
AJST: UniDir (MD)

ENTER
Adjustment Print
ENTER
ENTER
Head Gap: -34765m
Adjustment Print

ENTER
Setting can be specified in units of 5 m

Press [ENTER] to update gap
Press [ENTER]
after correction
Set values are updated by [ENTER]. In the case where [ENTER] was pressed
under "Head Gap:", if the parameter change is changed another adjustment print
will be made.
If [ENTER] is pressed without the parameter being changed, control shifts to
"Adjust: CW (MD)".
Head Gap: -34765 m
Setting can be specified in units of 5 m

Press [ENTER] to update gap
Press [ENTER]
after correction
Set values are updated by [ENTER]. In the case where [ENTER] was pressed
under "Head Gap:", if the parameter change is changed another adjustment print
will be made.
If [ENTER] is pressed without the parameter being changed, control shifts to "Flush
Pointer adjustment".
Adjustment: CW
BAC2090
Adjustment: CW
BAC2091
BAC2091
CW Adjustment Pattern (6 colours)

Adjustment Items Left and right head axial alignment
Printing method
Single-pass, uni-directional
0.7
c
o
k
o
25
Standard value
50 m or less
Adjustment: CW
+
Enter this distance
Adjustment: Flush Pointer
BAC2110
BAC2110
This procedure is for adjusting the position for flushing over the flushing boxes on
both sides of the left and right heads. The adjustment causes flushing into the
flushing box and from the results the flushing positions for both left and right heads
are entered in 720 dpi units. Enter a positive value to shift the flushing position
towards the cap unit side, or a negative value for the opposite direction.
AJST: FlushPoint
Flushing
Left Point:
Cap unit side flushing box ejection finished

Setting can be specified in 1 pulse units
2424 using the VALUE + and - keys
(- for cap unit side, + for opposite side)
ENTER
Right Point:
3699
[ENTER] causes flushing to the flushing box on the opposite side
Flushing
Opposite side flushing box ejection finished
Left Point:
38700
ENTER
Right Point:
40000
Press [ENTER] to update the settings.

If a change has been made, flushing will be repeated. If [ENTER] was pressed with no change
having been made, the display will move to the AJST: XLength menu.
Adjustment: Flush Pointer
Adjustment: Media Feed Distance

This procedure is used to adjust the distance for media transport. The adjustment
determines the resolution in the firmware for the X encoder by causing lines to be
printed in the direction of media feed and entering their distance.
BAC2120
Media feed distance adjustment pattern

Adjustment items
Printing method
Adjust the distance for media transport

Four-pass, bidirectional 360 dpi
AJST: X Length
Displayed during adjustment printing
Adjustment Print
Printing finished
XLine Len:
Setting can be specified in 0.1 mm units

using the VALUE + and - keys
When parameter is changed and [ENTER] is pressed
300.0 mm
k m c
Print Start?
Press [ENTER] for another adjustment print, [Back] to
move to next menu
Press [ENTER] to update the settings. If settings have been changed, another adjustment print
will be made. If there was no change, the display will move to the AJST: Margin menu.
150
300
k r g y bmc
100 %
k
70
Output direction
Standard values
Up to 500 mm 0.1%
Here, the adjustment is 300 mm so the actual value,
x, will be 299.7 x 300.3 mm
Adjustment: Media Feed Distance
BAC2120
Adjustment: Top and Bottom, Left and Right Margins
BAC2130
This procedure involves cutting the media, printing and cutting the media again,
then entering the distances between front sensor and head, cutter and head, and
the media edge sensors and head. Moreover, in order to know the media width
exactly, it determines the correction value of the media edge detecting position.
Front/Cutter to Head Distance Adjustment Pattern
AJST: Margin
An adjustment print is made after the leading edge of the media is cut.
Adjustment Print
Displayed during adjustment printing
Adjustment Items
Printing Method
Top and bottom margins, left and right margins

Black, single-pass, uni-directional 360 dpi
After print finished and the media was cut

T Margin:
Menu Down
B Margin:
Menu Down
> Margin:
Menu Down
< Margin:
25.0 mm

Bottom distance 20
Menu Up
20.0 mm

Menu Up
5.0 mm
Menu Up
Black paint, vertical width 9

Top distance 25
5.0 mm
Press [ENTER] to update settings.

Press [ENTER] at Bottom Distance to move to AJST: Rear Sns Posi.
Output direction
Adjustment: Top and Bottom, Left and Right Margins
BAC2130
Adjustment: Rear Sensor Position
BAC2140
BAC2140
This procedure is used to ensure the proper detection of the length of cut sheet
media. It adjusts the position of the rear sensor in the firmware by entering the
media length after cut media has been loaded and detected.
This item is essential in the production process but it is no longer necessary once
media feed distance compensation has been carried out.
When this item is selected, whether media is loaded or not, it will ask for cut sheet
media. If panel diagnosis decides that media is loaded, this will be assumed to be
cut sheet media and media initialization will begin. Therefore roll media should not
be loaded. After the media has been initialized, it will be ejected.
To terminate this program without updating the setting, press the [Back] while no
processing is in progress.
AJST: Rear Sns Posi

Set CuttingPaper
After loading media
Paper Initial
After initializing media
Paper X:
594.0 mm
Enter
Paper Y:
840.0 mm

Press [ENTER] to update the setting, and move to AJST: Test Print.
Adjustment: Rear Sensor Position
Adjustment: Test Print
BAC2150
BAC2150
This procedure is used to check adjustments by printing a test pattern. it also prints
adjustment parameters and if no serial number has been entered at that time, serial
number input will be requested. Online data signal reception is always enabled but
any data should not be transmitted during the processing of a self-diagnostic
sequence.
AJST: TestPrint
ENTER
PRINT: ChkNozzles
Menu Up
Menu Down
Print
Printing finished
ENTER
Print
Printing finished
Menu Down
ENTER
PRINT: Black Fill

Menu Up
Print
Printing finished
On [ENTER], if no serial number is registered
PRINT: Parameters
Register Serial Number
Back
ENTER
1
BZ400001
Adjustment parameter printing

begins
Parameter is printed but serial

number is not printed.
Digits to be entered will blink from the left.

Use the VALUE + and - keys to change the
settings
Use [ENTER], [Menu Up] and [Menu Down]
to move between digits
Press [Back] after adjustment parameter printing has finished to move to

AJST: HeadWash. At other times, press [Back] to move to AJST: TestPrint.
1 Display varies according to type of printer.
Adjustment: Test Print
Adjustment: Head Wash
BAC2160
BAC2160
This procedure is used at the end of the production process or before prior to head
replacement.
Note: If you suspect the cartridge sensor to be faulty, you can carry out the following procedure by pressing the [ENTER] key.
AJST: Head Wash

Rm All Cartridge
After all cartridges are removed
Set Wash Jig
After withdrawing a specified amount of ink
Ink Absorb
After all cleaning jigs are installed
Washing
After cleaning fluid has been extracted
Rm Wash Jig
After cleaning jig has been removed
Washing
After head cleaning has been completed, the display will move to AJST: Home.
Adjustment: Head Wash
Cleaning: Normal, Powerful
This procedure is used for head nozzle cleaning. The items are as follows.
Item
Normal
Powerful
Details
Normal cleaning (wiping)
Powerful cleaning (wiping and rubbing)
BAC3000
Normal
Normal cleaning (wiping). It moves to next menu, CLEAN: Powerful when
Normal cleaning is finished.
Powerful
This procedure carries out powerful cleaning (wiping and rubbing). The operation
is the same as for normal cleaning.
Cleaning selection operation is shown below.

Press [Back] to return to the Diagnostics Menu
ENTER
Printing finished To next menu
CLEAN: Normal
Menu Down
Menu Up
when Normal
cleaning is finished
CLEAN: Powerful
Menu Down
Cleaning: Normal, Powerful
BAC3000
Test Printing: Head Printing, Black in-filling, Parameters

This procedure is used for test printing. The items are as shown below. For adjustment parameter prints, if no serial number has been entered, a serial number will
be requested. Online data signal reception is always enabled but no signals are
transmitted during the processing of a diagnostic sequence.
Item
Details
Head Printing Verification Adjustment pattern printing
Check in-filling Black in-filling
Adjustment
Parameters Display firmware adjustment parameters
Procedures for the selection of items from panel are shown below.
Press [Back] to return to the Diagnostics Menu.
BAC4000
1. Head Printing Verification

To check that the head prints and print an adjustment pattern.
Panel
Adjustment Print
After the adjustment pattern printing has been finished, PRINT: ChkNozzles will
appear.
2. Check black in-filling

To print by filling an area with black colour.
Panel
DIAG: Test Print
Adjustment Print
Menu Up
PRINT: ChkNozzles
Menu Down
End
Menu Up
PRINT: Black Fill

Menu Down
After the adjustment pattern printing has finished, "Print: black in-fill" appears.
ENTER
Print
3. Adjustment Parameters
This procedure is used to print firmware adjustment parameters.
ENTER
End
Black infill printing
Menu Up
Panel
Adjustment Print
PRINT: Parameters
Menu Down
Press [ENTER] to print firmware adjustment parameters but if no serial number has
been registered, registration will be requested.
Test Printing: Head Printing, Black in-filling, Parameters
BAC4000
Parameters
BAC5000
BAC5000
This procedure concerns changing adjustment parameters. Details are as shown

below. A special purpose memory card is used to back up backup parameters to
the memory card and to update the backup parameters from the memory card.
Item
Initialize
Update
Details
Initalize adjustment parameters
Input adjustment parameter values
DIAG: Parameter
Menu Up
ENTER
PARAM: Initial
Menu Down
Menu Up
Back
Parameter
initialization
PARAM: Update
Menu Down
Parameters
Parameters: Initialize
BAC5010
BAC5010
Initialization
This procedure is used to initialize adjustment parameters. Items are: Capping
Position, X Resolution, Zone Delay, Head Height, Maintenance History
(Left Head, Right Head, Wiper), Serial Number and Complete Initialization.
INIT: Parameter
INIT: Home
Menu Down
Menu Up
INIT: X Length
Menu Down
Menu Up
INIT: Maintenance
Menu Down
INIT: Left Head

Menu Up
INIT: Right Head
INIT: ErrorRecord
Menu Down
Menu Up
INIT: Wiper
INIT: Serial No.

Menu Down
ENTER
Menu Up
INIT: All
Menu Down
Menu Up
Press [ENTER] to display Param Initial?. Press [ENTER] again to initialize.

After initialization, INIT: Parameter is restored.
Press the [BACK] key to restore PARM: Initial without initializing.
Parameters: Initialize
Parameters: Update
BAC5020
BAC5020
Update
This procedure will update adjustment parameters.
Note: The actual writing to flash memory is done when diagnostics are completed or power is switched off.
PARAM: Update
UPDATE: Home
Menu Down
Previou menu is "UPDATE: Mech Param"

Menu Up
UPDATE: Head Rank

Menu Down
Menu Up
UPDATE: Print Posi

Menu Down
Menu Up
UPDATE: Microdot
Menu Down
Menu Up
UPDATE: X Length
Menu Down
Menu Up
UPDATE: Mech Param
Next menu is "UPDATE: Home"
Press [ENTER] to input the adjustment parameter.

Press [BACK] to return to PARM: Update.
Parameters: Update
Update: Capping Position Parameter
BAC5021
BAC5021
This procedure will update the capping position parameter.

UPDATE: Home
Home:
Use the VALUE + and - keys to change

-2162
the setting
If there is a change, a confirmation message will
appear when you press [ENTER]
Param Update?
After this display, [Menu Down] will

appear
The update message will appear when you press [ENTER]
Update Parameter
If [Back] is pressed instead of the second [ENTER], a message that

the parameter is not updated will appear and the display will move to UPDATE: Home
Update: Capping Position Parameter
Update: Head Rank Parameter
BAC5022
BAC5022
This procedure will update the head rank parameter.

UPDATE: Head Rank
Left Rank:
Menu Down
Right Rank:
21117

setting and press [ENTER] to confirm the change.
Menu Up
21117

If there is a change, a confirmation message will appear

when you press [ENTER].
Param Update?
Update Parameter
After this display, [Menu Down] will appear
If [Back] was pressed, a message that the parameter is not updated will
appear and the display will move to UPDATE: Head Rank.
Update: Head Rank Parameter
Update: Print Positioning Parameter
BAC5023
BAC5023
This procedure will update the print positioning parameter.

UPDATE: PrintPosi (and Micro-Dot)
DelayL: -0.250 mm
Menu Down
Menu Up
DelayR: -0.250 mm
Menu Down

Use the Setting + and - keys to change the

Menu Up
L-RGap: -34.290 mm
Use the Setting + and - keys to change the


when you press [ENTER]
Param Update?
Update Parameter
If [Back] was pressed, a message that the parameter is not updated will appear
and the display will move to UPDATE: PrintPosi.
Update: Print Positioning Parameter
Update: Media Transport Distance Parameter
BAC5024
BAC5024
This procedure will update the media transport distance parameter.

UPDATE: X Length
the setting
Xlength: 300.0 mm
Param Update?
Update Param
If [Back] was pressed, a message that the parameter is not updated will appear
and the display will move to UPDATE: X Length.
Update: Media Transport Distance Parameter
Update: Mechanical Parameters
BAC5025
BAC5025
This procedure will update the mechanical parameters.

UPDATE: Mech Param
HtoEdge: 25.180 mm
Menu Up
Menu Down
XFtoH:
30.890 mm
Menu Down
HtoCut:
Use the VALUE + and - keys to change the setting

and press [ENTER] to confirm the change.

Menu Up
15.390 mm
Menu Down
Menu Up
XFtoXR: 123.700 mm
Menu Down
2809
2424
3699
38700

Menu Up
AnotherRFP:
Menu Down

Menu Up
AnotherLFP:
Menu Down

Menu Up
RightFlushP:
Menu Down

Menu Up
LeftFlushP:
Menu Down

Menu Up
Paper Edge:
Menu Down

40000

Menu Up
PaperWidAdj:

-5
Param Update?
Update Param
If [Back] was pressed, a message that the parameter is not updated will appear and
the display will move to UPDATE: Mech Param.
Update: Mechanical Parameters
Aging
BAC6000
BAC6000
This procedure concerns the aging of the mechanism and head. Details of the items
are as follows.
Item
Carriage Motor
Media Feed Motor
Cutter
Maintenance
Head
Details
Reciprocal carriage scanning
Media feed roller drive
Media cutting
Capping
In-fill printing
Selection of items from the panel is shown below.

DIAG: Aging
Menu Up
ENTER
AGING: Y Motor
Menu Down
Carriage motor aging

Menu Up
Back
End
AGING: X Motor
Menu Down
Menu Up
AGING: Cutter
Menu Down
Menu Up
AGING: Mainte Unit

Menu Down
Menu Up
AGING: Head
Menu Down
Aging
Aging: Carriage Motor
BAC6010
BAC6010
This procedure is used for aging the carriage motor. Select uni-directional print
scanning mode or bidirectional print scanning mode and specify a number of times
for repeatability scanning of the carriage. If the specified number is -1, aging will
continue until a key is entered.
AGING: Y Motor
AGING Y: UniDir Prn
Menu Up
Menu Down
AGING Y: BiDirPrn
Press [ENTER] to move to number of agings
[ENTER]
AGING COUNT:
50

the setting
Press [ENTER] to begin aging

AGING:
10
Terminate endurance with [ENTER], [Back] or

[CANCEL]
50
Escape with [ENTER] or [Back]
End
AGING END:
Aging: Carriage Motor
Aging: Media Feed
BAC6020
BAC6020
This procedure is used for aging the media feed motor. Repeatability operation is
carried out for a specified number of times.
AGING: X Motor
AGING COUNT:
50

the setting

AGING:
10
Press [ENTER], [Back] or [CANCEL]

to end aging.
End
AGING END:
Aging: Media Feed
50
Aging: Cutter
BAC6030
BAC6030
This procedure is used for aging the cutter. Media is cut a specified number of
times.
AGING: Cutter
AGING COUNT:
50

the setting

AGING:
10

to end aging
End
AGING END:
Aging: Cutter
50
Aging: Maintenance Unit
BAC6040
BAC6040
This procedure is used for aging the capping. Capping is carried out a specified
number of times.
AGING: Mainte Unit
AGING COUNT:
50

the setting

AGING:
10

to end aging.
End
AGING END:
Aging: Maintenance Unit
50
Aging: Head
BAC6050
BAC6050
This procedure is used for aging the print head. Select left or right and carry out infill printing a specified number of times.
AGING: Head
AGING HEAD:
Menu Down
Left
Menu Up
AGING HEAD:
Right
ENTER
AGING COUNT:
50
AGING:
10
End
AGING END:
50
Press [ENTER] to specify a number of times to carry out aging in the same way
as the carriage motor and return to AGING: Head when finished.
Aging: Head
Rockhopper-46
3 Maintenance Parts
C AT 0 0 0 0
Maintenance Parts Still Under Construction

Lubrication Points
Exploded Drawings
Periodical Maintenance
s
Rockhopper-46
3 Maintenance Parts
CAT1000
CAT2000
CAT4000
CAT5000
CAT7000
C AT 0 0 0 0
Rockhopper-62 Maintenance Parts
C AT 0 0 0 0 - 3
Maintenance Parts Still Under Construction

Lubrication Points
Exploded Drawings (Not yet available)
Periodical Maintenance
s
CAT1000-3
CAT2000
CAT4000
CAT6000
CAT8000
C AT 0 0 0 0 - 3
Rockhopper-46
3 Maintenance Parts List
Description
Model Name: Rrockhopper-46
Technical
Reference
Preferred
Order N
Main Board Assy
DF-41586
DE-34498
Power Supply Board Assy
DF-41587
DE-34535
Head Board Assy
DF-41588
DE-34456
Panel Board Assy
DF-40097
DE-33585
Mother Board Assy
DF-40098
DE-48667
Lever Sensor Assy
DF-41589
DF-41469
Cover Sw. R. Assy
DF-41590
DF-41478
Paper Sensor XR cable Assy
DF-41592
DF-41468
Detection Unit Assy (Black)
DF-40106
DF-40011
Detection Unit Assy (Yellow)
DF-40107
DF-40012
Detection Unit Assy (Magenta)
DF-40146
DF-40013
Detection Unit Assy (Cyan)
DF-40147
DF-40014
Detection Unit Assy (LC/Orange)
DF-41593
DF-41480
Detection Unit Assy (LM/Green)
DF-41594
DF-41481
Paper Sensor Y Assy
DF-41595
DF-41470
Origin Sensor Assy
DF-40109
DE-49921
X Motor Assy
DF-41597
MY-34558
Y Motor Assy
DF-41598
Pump Motor Assy PE
DF-41599
MY-34087
DE-34187 +
DF-41060
Cutter Solenoid Assy
DF-40113
Vacuum Fan Assy
DF-40173
Fan extension cable RH 46
Description
Technical
Reference
Panel Cable Assy
DF-41617
DF-41461
SW Cable Assy
DE-41619
DF-41477
DC Cable Assy
DF-41468
DF-41464
Y Cable Assy (46")
DF-41600
DF-41460
Head Cable (Colour)
DF-41601
DF-41462
Print Head (Colour)
DF-40690
DE-49732
Cap Assy
DF-41602
DF-41406
Pump Assy
DF-41603
DF-41603
Wiper
DF-40125
DE-49771
Maintenance Station Assy
DF-41604
MY-21474
Cartridge Frame Assy
MY-44051
MY-44051
Damper (Colour)
DF-40129
DE-49734
Ink Tube (2.0 BK) 46"
DF-42726
DF-42726
Grid Roller Assy
DF-41840
DE-34525
Pressure Assy
DF-42727
MY-33987P
Pressure Roller Assy
DF-41530
DF-40982
Blade
DF-42728
DE-21612
DF-40137
DE-49802
Steel Belt 46"
DF-41606
DE-49764C
T Fence (46")
DF-41607
DE-34516
DE-33659
Cursor Assy
DF-42729
MY-34986
MY-49761
DE-33353
Y Return Pulley Assy
DF-40144
MK-24210
Fuse
DF-40345
DF-40317
DF-40446
DE-33602
Fan extension cable 2 assy
DF-41621
DF-41483
Flange(2")
DF-41622
DF-41484
Flange(3")
DF-40447
DE-21303
2 Core flange set
MY-33602
MY-33602
Rockhopper-46
C AT 1 0 0 0
C AT 1 0 0 0
Rockhopper-46
Description
Model Name: Rrockhopper-46
Technical
Reference
Preferred
Order N
3 Core flange set
MY-40447
MY-40447
O Ring (Small) 100 pcs.
DF-40487
DF-40487
O Ring (Large) 100 pcs.
DF-40488
Tube Guide 46"

Cursor Plate Spring
Technical
Reference
Preferred
Order N
Cartridge Pipe slot 1
DE-34514A
DE-34514A
DE-34514B
DE-34514B
DF-40488
DE-34514C
DE-34514C
DF-41677
MY-34517
DE-34515A
DE-34515A
DF-40854
DF-40854
DE-34515B
DE-34515B
Steel Bare (46")
DF-41616
DE-33943C
DE-34515C
DE-34515C
Junction Board Assy
DE-34540
DE-34540
Waste tank sensor plate
ME-24124
Ink ID Sensor 1 Assy (Blk)
DF-41609
DF-41471
Waste tank sensor Cable
MK-24208
Ink ID Sensor 2 Assy (Cy)
DF-41610
DF-41472
Waste connection tube small
ME-24115
Ink ID Sensor 3 Assy (Mg)
DF-41611
DF-41473
Flush box spare part
MY-24115
Ink ID Sensor 4 Assy (Ye)
DF-41612
DF-41474
Paper guide assy F 46" SDMP
MY-24159
Ink ID Sensor 5 Assy (Lcy)
DF-41613
DF-41475
Heating strip for SDMP 46 Assy
MY-24218
Ink ID Sensor 6 Assy (Lmg)
DF-41614
DF-41476
Paper guide rear assy 46
MY-24206
Ink ID Cable
DF-41615
DF-41463
Heating strip rear SDMP 46 assy
MY-24217
Spring Cutting blade
DF-40936
DE-49743
MC-7001
Spring Plunger Magnet
DE-49194
DE-49194
Bearing Grid Roller
DE-48846
DE-48846
Power AC-inlet schutter 10A

External waste bottle system SDMP
V2
Encoder reader (incl. Cable)
DF-41626
DF-41465
Media Distance Pieces (10 pcs)
MY-40650
MY-40650
X motor extension cable assy
DF-41623
DF-41485
X ENC extension cable assy
DF-41624
DF-41486
Switch Head Height
DF-42733
DF-42340
N Belt 46"
DF-42735
DE-34522
Scroller Lock receiver roller
DF-41634
DE-49811
Scroller Roller assy
DF-41633
DF-41633
Y-motor cable assy
DF-41625
DF-41466
Rockhopper-46
Description
C AT 1 0 0 0
MY-24146
Cleaning bottle 500ml
JD-42054
Keyboard assy for SDMP 46
EY-24502
Panel cable
DF-41461
Keyboard sheet SDMP V2
LB-242000
Heater PCB for SDMP 46
EY-24501
C AT 1 0 0 0
Rockhopper-62 Maintenance Parts List
Technical
Reference
Preferred
Order N
DF-41622
DF-41484
DE-34535
DF-41993
DF-41773
DE-34456
Panel Cable Assy
DF-41617
DF-41461
DF-40097
DE-33585
SW Cable Assy
DE-41619
DF-41477
DF-40098
DE-48667
DC Cable Assy
DF-41468
DF-41464
Lever Sensor Assy
DF-41589
DF-41469
Y Cable Assy (62")
DF-41998
DF-41775
Cover Sw. R. Assy
DF-41590
DF-41478
Head Cable (Colour)
DF-41601
DF-41462
Paper Sensor XR cable Assy
DF-41592
DF-41468
Print Head (Colour)
DF-40690
DE-49732
Detection Unit Assy (Black)
DF-40106
DF-40011
Cap Assy
DF-41602
DF-41406
Detection Unit Assy (Yellow)
DF-40107
DF-40012
Pump Assy
DF-41603
DF-41603
Detection Unit Assy (Magenta)
DF-40146
DF-40013
Wiper
DF-40125
DE-49771
Detection Unit Assy (Cyan)
DF-40147
DF-40014
Maintenance Station Assy
DF-41604
MY-21474
Detection Unit Assy (LC/Orange)
DF-41593
DF-41480
Cartridge Frame Assy
MY-44051
MY-44051
Detection Unit Assy (LM/Green)
DF-41594
DF-41481
Damper (Colour)
DF-40129
DE-49734
Paper Sensor Y Assy
DF-41595
DF-41470
Ink Tube (2.0 BK) 62"
DF-41999
DF-41999
Origin Sensor Assy
DF-40109
DE-49921
Grid Roller Assy
DF-41840
DE-34525
X Motor Assy
DF-41597
MY-34558
Coupling assy
DE-34776
DE-34776
Y Motor Assy
DF-41598
Pressure Assy
DF-42727
MY-33987P
Pump Motor Assy PE
DF-41599
MY-34087
DE-34187 +
DF-41060
Pressure Roller Assy
DF-41530
DF-40982
Cutter Solenoid Assy
DF-40113
DE-33659
Blade
DF-42728
DE-21612
DE-33353
DF-40137
DE-49802
DF-41482
Steel Belt 62"
DF-42001
DE-41754
MK-42403
T Fence (62")
DF-42002
DE-34698
DF-42729
MY-34986
Description
Technical
Reference
Preferred
Order N
Main Board Assy
DF-42010
DE-34719
Power Supply Board Assy
DF-41587
Head Board Assy
DF-41588
Panel Board Assy

Mother Board Assy
Vacuum Fan Assy

Fan extension cable 1/3 assy
DF-40173
DF-41620
MK-42403
Description
MK-42401
MK-42401
Cursor Assy
DF-41621
DF-41483
Y Return Pulley Assy
DF-40144
MY-49761
Fuse
DF-40345
DF-40317
C AT 1 0 0 0 - 3
C AT 1 0 0 0 - 3
Description
Technical
Reference
Preferred
Order N
Flange(2")
DF-40446
DE-33602
Switch Head Height
DF-42733
DF-42340
Flange(3")
DF-40447
DE-21303
2 Core flange set
MY-33602
MY-33602
N Belt 62"
Head fixing assy
DF-42737
DF-42734
3 Core flange set
MY-40447
MY-40447
O Ring (Small) 100 pcs.
DF-40487
DF-40487
DE-34700
DE-34987 +
DF-42345 +
DF-42344 +
DF-40836
O Ring (Large) 100 pcs.
DF-40488
DF-40488
Scroller Lock receiver roller
DF-41634
DE-49811
Tube Guide 62"
DF-42732
MY-34983
Scroller Roller assy
DF-41633
DF-41633
Cursor Plate Spring
DF-40854
DF-40854
Absorbent assy set
DF-42007
MY-41326 (2x)
Steel Bare (62")
DF42004
DF-41738
X pulley assy RJ54&62
DF-41988
MY-41739
DF-41625
DF-41466
DF-42008
Description
Technical
Reference
Junction Board Assy
DE-34540
DE-34540
Y-motor cable assy
Ink ID Sensor 1 Assy (Blk)
DF-41609
DF-41471
Waste ink bottle RJ-6100 54 & 62
Ink ID Sensor 2 Assy (Cy)
DF-41610
DF-41472
Ink ID Sensor 3 Assy (Mg)
DF-41611
DF-41473
Ink ID Sensor 4 Assy (Ye)
DF-41612
DF-41474
Ink ID Sensor 5 Assy (Lcy)
DF-41613
DF-41475
Ink ID Sensor 6 Assy (Lmg)
DF-41614
DF-41476
Ink ID Cable
DF-41615
DF-41463
Spring Cutting blade
DF-40936
DE-49743
Spring Plunger Magnet
DE-49194
DE-49194
Bearing Grid Roller
DE-48846
DE-48846
Encoder reader (incl. Cable)
DF-41626
DF-41465
Media Distance Pieces (10 pcs)
MY-40650
MY-40650
Flange set roll tubs
ZMY-46040
E-HEDS9200#Q00
ZMY-46040
E-HEDS9200#Q00
X motor extension cable assy
DF-41994
DF-41771
X ENC extension cable assy
DF-41995
DF-41772
Linear encoder 180 LPI
Preferred
Order N
DF-40693
DF-42008
DE-34776 +
3x NS-21040031
DE-34702
DE-34702
DE-34703
DE-34703
DE-34704
DE-34704
DE-34705
DE-34705
DE-34706
DE-34706
DE-34707
DE-34707
Hooked screw driver Rockhopper
TL-24000
Waste tank sensor plate
ME-24124
Waste tank sensor
MS-24000
Waste tank sensor Cable
MK-24208
Waste connection tube small
ME-24115
Flush box spare part
MY-24115
Paper guide assy F 62" SDMP
MY-11249
Coupling assy
C AT 1 0 0 0 - 3
C AT 1 0 0 0 - 3
Description
Technical
Reference
Temp sensor long SDMP 62 front
MS-24004
Temp sensor short SDMP 62 short
MS-24005
Keyboard sheet SDMP
LB-24100
PCBA heater system Falcon
EY-24500
Paper guide assy R 62 SDMP
MY-11250
Temp sensor long SDMP 62 rear
MS-24001
Temp sensor short SDMP 62 rear
MS-24002
Inlet assy : DF-40775 + MC-5131
EY-27775
Power supply 5V/24V 0.5A/2.5A
EY-25580
Relais solid state realy
MM-1003
Wago connection blok A-1701620
MC-5136
External waste bottle system
MY-24100
Cleaning bottle 500 ml
JD-42054
Silicone glue for rockhopper
AG-91240
C AT 1 0 0 0 - 3
C AT 1 0 0 0 - 3
Preferred
Order N

No.
Remarks
No.
Personal Computer
Commercial
item
Drawing No.

Name
Appearance
Drawing No.
Name
Appearance
C AT 2 0 0 0
Remarks
Bar tension gauge

49 N (5 kgf)
(made by Ooba S/S)
Commercial
item
JD-30410
Head cleaning jig

assembly
(6 sets required)
Special item,
includes rubber
bush and
mini-fitting
JD-30395
Rail height jig

assembly
Special item
2.1
JD-42052
Rubber bushing
Replace after
using 20 times
Special item
(consumable)
JD-30432
Rail height reference

base assembly
Special item
2.2
JD-42053
Mini-fitting
(made by Inaiseieido)
Special item
(commercial
item)
JD-42050
Belt tension
attachment
Special item
Phillips screwdriver
No. 1
Commercial
item
9
Bar tension gauge
4.9 N (500 gf)
(made by Ooba S/S)
Commercial
item
Phillips screwdriver
No. 2
Commercial
item
10
Hex nut driver 5.5 mm
Commercial
item
C AT 2 0 0 0

No.
Drawing No.

Name
Appearance
Remarks
11
Standard screwdriver
Commercial
item
12
Allen key 1.5 mm
Commercial
item
13
Allen key 2 mm
Commercial
item
14
Allen key 2.5 mm
Commercial
item
15
Allen key 3 mm
Commercial
item
16
Spanner 5.5 mm
Commercial
item
17
Spanner 17 mm
Commercial
item
18
Tweezers
19
Jeweller's screwdriver
No.
Drawing No.
20
Name
Appearance
C AT 2 0 0 1
Remarks
Multimeter
Commercial
item
21
JD-41844
Cleaning fluid A-29

(18-liter)
Special item
22
JD-42054
Cleaning fluid bottle,

500 ml
Special item
(Commercial
item)
23
Ball driver 1.5 mm
Commercial
item
Commercial
item
24
Ball driver 2.5 mm
Commercial
item
Commercial
item
25
Hexagon ratchet
spanner
Commercial
item
C AT 2 0 0 1

No.
Drawing No.
26
27
JD-42145
28
29
TL-24000

Name
Appearance
Remarks
M-block (Height: 20)
Commercial
item
Head height jig
Special item
Pocket microscope
(Magnification: 25x to 50x)
Commercial
item
Hooked screwdriver
For Rockhopper 62"
No.
Drawing No.
Name
Appearance
C AT 2 0 0 2
Remarks
Commercial
item
C AT 2 0 0 2
Lubrication Points
No.
Name of Unit
Lubrication Point
Brand, Product Number
Application
Remarks
Pressurization
Unit
Pressure cam
Shin-Etsu Chemical Co., Ltd.,

Silicone Grease G501
To improve sliding
or similar
Maintenance Unit
Transfer gear bearings

To improve durability
or similar
R Frame
Sliding parts around pressurizing

relay plate

To improve sliding
or similar
X Drive
X speed reduction belt parts

To improve durability
Y Rail
Back of roller track

For inserting roller, reducing

cursor noise
or similar
Y Rail
Cursor track
Sumiko Lubricants Co., Ltd

Sumi Grease Spray
To prevent burning
Soak a cloth and

apply lightly
Covers
Cover pins and frame holes

For cover opening/closing

action and noise
or similar
Lubrication Points
C AT 4 0 0 0
C AT 4 0 0 0
ROCKHOPPER 46
UNIT-SDMP46
REV. /
DE-10873
NS-11040081
LB-10080(2x)
DF-40027
DE-21469
LB-10031
DE-21470
DE-33950C
LB-10082
NS-05030081
DF-41386
NS-05030081
DE-11174
NS-05030081
DE-34501
NS-11040081
DF-41388
NS-11030061
NS-51040101
NS-05030081
NS-05030081
DE-21467
DF-40650
NS-11040081
DF-40411C
ME-24233
DE-10872
NS-05030081
NS-05040081
DE-10973
NS-21030031
NS-11030061
NS-51040101
DE-31567
DE-47066
DF-40521C
NS-05030081
NS-05030081
DF-41387
NS-05030081
DF-41376
NS-11030061
DR-4014-43315
NS-11040081
DF-41490(A/E)
DE-11159
DE-21469
NS-11030061
ME-24206
MY-24217
ME-24205
NS-05030081
NS-11030061
DF-41429
ME-24232
NS-05030081
NS-11040081
DR-4001-43993(4x)
ME-24124
DR-4001-43993(2x)
NS-11030061
DE-10972
LB-10250
NS-05030081
ME-24236
DF-41375
ME-24237(2x)
EY-24502
LB-24200
NS-06030061(4x)
MY-24218=
ME-24227+AP-52128+ME-24218
DF-41461
MY-24205
NS-11030061
CAT5001-00
ROCKHOPPER 46
UNIT-SDMP46
REV. /
ME-23046(5x)
NS-05040101
DE-33609
DF-41384
NS-05040081
DE-49815
DE-11170
NS-11040041
DE-49814
DS-1074-41211K
NS-04040101
NS-06040061(3x)
DP-3022-40153
DF-49828
NS-35040201
NS-21030031
E-P-20
DE-49811
DE-49796
DE-33991
DE-33992
ME-24231
NS-05040081(3x)
NS-05040081
DE-47866X(1,5x)
DE-49812
DE-49801
NS-05040081
DF-40981
E-P-20
DE-49904
DF-41378
DF-40091
DF-41793
ME-24211
DE-49651
DF-40470
DE-46552
NS-21030031
DE-49813
DF-41428
DE-49796
DF-40469
DE-46552
DE-49651
MY-41793
DE-49810
E-NAD-06
DE-49811
DE-46552
DF-40520
NS-05040081
NS-05030061
DE-47866F
DF-40469
DE-46552
NS-05040101
NS-05030061
DE-40615
DE-33608
NS-05030401
NS-05030081
NS-05030401
DE-33608
DE-33608
DF-40137
DE-49804
E-P-25
NS-05030401
DE-40321
DE-49812
DF-40470
DE-49802
NS-05030101
NS-05030101
E-NAD-06
DE-46562
DE-49803
DF-41622
DF-41484
N-40202C
NS-05030101
DE-34558
DE-41597
DE-33353
DF-40173
DE-33353
DF-41483
DF-40173
DF-41621
DE-33353
DF-41485
DF-41623
DF-41486
DF-41624
MK-24210
DF-40173
NS-05030061
CAT5002-00
ROCKHOPPER 46
CAT5003-00
UNIT-SDMP46
REV. /
ME-24128(0,7 m)
MK-24207
DE-49738(2x0,44 m)
DF-41792
DE-49891(8x0,02 m)
ME-24239
ME-24100
DE-49812
ME-24101
DE-46552
NS-04030061 (2x)
DE-48958 (2x)
MY-24146
DF-40470
MY-40469 (3x)
DE-44113
ME-24103
ME-24240
MY-41792
DE-49827
DF-40561
NS-04030061 (4x)
ME-24102
AE-91025 (3x)
NS-05040101
NS-05040101
DF-40469 DE-46552
NS-04030061 (4x)
NS-51030051
DP-3022-40153
NS-06030061
DR-4010-41280
JD-42054
NS-04040101
BM-1301-003006
DE-49947
DE-49142
NS-04030061
ME-24104
NS-04030061 (4x)
DE-45115
E-P-25
DF-42340
DF-42733
MK-24208
NS-11040041
DF-42342
DF-41536
DE-34540
NS-01020081
DF-42341
DE-49826
DE-49782
NS-05030081
NS-11040041
DE-49781
DE-10868
NS-01020081
NS-06020051
NS-06020051
DF-41590
DF-41478
NS-51030051
DF-41469
DF-41592
DE-45115
DF-41468
DF-41615
DF-41589
DF-41433
DF-40553
DE-47071
DF-40562
DF-41463
DR-4014-43892
DF-41374
DE-47046
ME-24234
DF-41329
DF-40564
NS-35040201
E-P-25
DF-41931
NS-05040101
NS-05040121
NS-05030061
DE-48931
NS-05040101
DR-4010-41280
E-NAD-06
DE-49948
DF-41329
NS-05040401
DE-49950
NS-05040121
DE-33999
DE-47866E
DF-41425
DF-40081
DE-47866H
NS-05040081
E-NAD-06
DF-41581
DE-49651(3x)
DE-32692
DE-49949
NS-06030061
DF-40556
ROCKHOPPER 46
UNIT-SDMP 46
REV. /
DF-41602
DF-41400
NS-41030061
DF-41406
DF-42725
NS-11030061
DE-34187
ME-24138
DF-41403
DE-40176
NS-35030101
NS-05030061
NS-21030031
DF-40514
DE-48846
DF-40522
DF-41401
DF-41060
DF-41599
DE-49771
DE-34508
DF-40125
DE-34069
DE-34525
DE-21394
NS-05030061
DF-40682
NS-41030061
NS-35030061
DE-48918C
ME-24138
DF-40523
DE-21465
DP-3022-40153
NS-05030121
DF-41405
NS-35030101
DF-40681
DF-41603
DE-34068
DF-41582
DE-48846
NS-21030031
DE-34521
DF-40514
DF-41840
ME-24118
DE-34525
DE-21394
NS-05030061
NS-05030061
NS-41030061
NS-35030061
DF-40522
DF-40523
DE-21608
NS-05030061
DE-48846
DE-34999
ME-24138
DE-21465
NS-35030101
DF-40693
NS-21030031
DF-40514
DE-48846
ME-24118
DE-48846
DE-21394
NS-05030061
NS-41030061
NS-35030061
ME-24138
DF-40522
DE-21465
DF-40523
DE-34525
NS-35030101
E-P-25
NS-35030101
DF-42007
DF-41326
DE-48846
NS-05030081
DF-41327
DF-41382
ME-24118
DE-21394
(t=0.1) DF-41578A
(t=0.2)
B
(t=0.3)
NS-05030061
ME-24128
DF-40523
DE-34521
DE-11158
DF-40522
DF-44183
CAT5004-00
ROCKHOPPER 46
UNIT-SDMP 46
REV. /
DE-11172
NS-05030061
NS-05030081
DE-21303 (3")
DE-33602 (2")
DR-4010-43353
NS-01030301
DE-49763
DF-40447 (3")
DF-40446 (2")
DF-41427
NS-05030061
DE-47091
DF-41435
DE-34519
DE-47040
NS-21030061
DE-44181
DF-41607
DE-34500
DE-34516
DR-4010-43353
DP-3022-40153
DF-41259
DE-49780
DE-44181
DF-41460
DE-35084
DS-4104-40904
DF-41600
DE-33602
DF-42735
DF-40144
NS-05030061
DE-34521
DE-11171
DF-40559
DE-34499
DP-3022-40153
NS-04030061
DE-34520
ME-27065
NS-05030081
DE-11173
NS-05030061
DF-40641
DE-21479
NS-05040101
DF-40558
NS-05030081
DF-40555
NS-35040101
NS-05040081
DE-42544
DE-49752C
DE-21395
DE-33598
NS-04030061
NS-05040081
DF-40551
NS-05040101
DR-7032-41990
DR-7032-41990
DF-40510
DE-49753C
DF-40555
MY-33987P
DE-47092
DE-49760
DF-40550
NS-35040201
DE-21395
DF-41422
DE-33987
DE-21612
DF-40982
DF-41530
DR-7032-41990
NS-35040101
DF-40510
NS-04030061
DE-33987
DF-42728
DE-49883
DF-40551
NS-05030081
NS-23040041
DE-34521
DF-40550
DF-41424
DF-40552C
DF-40982
N-40202C
DF-40360
DE-21612
NS-05030081
DE-49764C
DR-7032-41990
DF-41606
NS-51040101
DE-49753C
DE-34087
DF-41625
DF-41466
DF-41518
DF-41598
CAT5005-00
ROCKHOPPER 46
UNIT-SDMP 46
REV. /
DE-34979
DF-41392
DF-41393
M
DF-41394
DF-41460
Y
DF-41395
DE-35084
LC
DF-41398
M38(W)
NS-05030081
DF-41460
DF-42731
LM
DF-41399
DE-33943C
DF-41616
DE-34978
I/C2
DE-21537
DF-41609
I/C
DE-21473
DF-41471
DF-40011
DE-49738G
DE-49772
DF-40106
DF-40978
DF-42726
DF-41610
DF-41472
M38(W)
NS-05030081
DF-40014
DF-40147
DF-41611
DE-49778
DF-41473
DE-49778
DE-49993
DF-40013
DE-49992
DE-11166
DF-40146
DE-48950
,
DF-41612
DE-49777
DF-41474
DF-40488
DE-49777
DF-40012
DF-40488
DF-40107
DE-48949
DF-41475
DF-40487
DE-34513
DF-41480
DF-41593
DE-34514A
(SLOT1)
DE-21477C
DE-21477E
DE-21477F
DF-41410
DF-41476
NS-41030061
DE-34514C
(SLOT3)
DE-21477D
DF-41614
DE-33600
DE-34514B
(SLOT2)
DE-21477A
DE-21477B
DE-34746
DF-41613
NS-05030081
DE-34515A
(SLOT4)
NS-05030081
DF-40488
DE-34515B
(SLOT5)
DE-34515C
(SLOT6)
DF-41481
DE-49777
DF-41594
DE-21300
DE-49778
DF-44051
+
DE-49892
NS-41030121
NS-41020081
CAT5006-00
ROCKHOPPER 46
UNIT-SDMP 46
REV. /
DF-40129
DE-41588
DE-48950
DE-49734
DF-41426
NS-05030101
DE-34456
DF-41626
NS-05030081
NS-11030061
DF-41465
DF-40129
DE-48950
DF-41462
DE-49734
DE-33943C
DF-41601
DF-41430
DF-40853
DE-48949
NS-06020121
DF-40487
NS-05030081
NS-11030061
E-HEDS-9200#Q00
180LPI
DE-48949
DF-40820
DE-49194
DF-40487
NS-11030061 DF-40934
NS-05030081
DF-41462
DF-40690
NS-11030061
DF-41601
DE-33659
DE-49921
DF-40613
DF-40113
DF-40934
DF-40836
DF-40936
DF-41669
DE-40109
DF-41404
DF-40690
Rev.1
NS-05030081
DE-21478
DF-40613
NS-11030061
DF-41404
NS-05030081
DF-41409
DF-41416
DF-41443
DF-42344
DE-21476
DF-41595
DF-41439A
DF-40854
NS-41020041
DF-42332
NS-05030061
DE-34513
DF-41470
DE-34067
DE-49744
DF-42343
DF-41444
DF-42729
DR-7032-41990
DR-4010-43353
NS-05030061
DE-49746
NS-41030051
DE-44197
DE-42051
DF-41411
DF-41445
DF-42345
DF-40685
DE-34065
DE-44197
DF-42337
DE-44197
DE-49879
DP-3022-40153
DF-42335
DF-41444
DF-42336
DF-40683
DE-44197
DE-47014
DE-42051
DE-42051
NS-11030061
DF-41445
DR-7032-41990
DF-42734
DE-34986
DE-44197
DE-34987
DE-34066
DF-41432
DE-42051
DE-49744
DP-5005-40189
DF-40718
DF-40951
DF-42339
DF-42333
NS-11030061
DE-44197
DE-49746
NS-41030061
DE-49879
NS-05040081
DR-7032-41990
NS-06020051
DR-7032-41990
DF-42334
DE-11167
DE-47014
DR-7032-41990
NS-11030061
DF-42338
DE-47014
DR-7032-41990
DE-44197
DE-42051
DF-42331
DF-42330
DF-42330
DP-3022-40153
DF-40683
DP-3022-40153
CAT5007-00
ROCKHOPPER 46
UNIT-SDMP 46
REV. /
J11
SENSORS
MK-24200
DF-41439A
DR-4001-43993 (3x)
DF-41437
ME-24230
DE-48958
NS-06030061
DF-41439B
DE-48667
(DF-40098)
ME-24238
1
2
J09
E-MSFC-6KEX
DE-33641
DF-41391
POWER
MK-24201
DF-41439C (3x)
NS-06030061
DE-46951
DE-34505
NS-05040081
NS-11040041
DF-41494
E-SSC-58-12-F
DE-11165
E-MTFC231114
MK
-24
209
DF-41464
MAIN PCB
DE-34498
NS-05030081
(DF-41586)
DF-41439A
EY-24501
NS-06030041
DF-41439B
DE-49832
000
J2
NS-11030061
-21
SIMM(16MB)
DF-41340B
MK
J0
(DF-41618)
DE-33585
(DF-40097)
J02
DE-10871
J000
MK-24204
MK-24204
J1
DF-41439C (7x)
NS-11030061
DE-34535
NS-05030081
(DF-41587)
NS-51030061
NS-05040081
NS-05030081
MK-41314
NS-11040041
MC-7001
AE-91025 (3x)
DF-41461
NS-05030081
DF-41617
DE-49749
ME-24200
NS-35030061
DF-41477
E-SL10K2-5
DF-41619
PCB Layout + cables

refer to drawing AP-76128
CAT5008-00
Rockhopper-46
2 Maintenance Parts
C AT 7 0 0 0
C AT 7 0 0 0
You have to change some parts of the Rockhopper printer to obtain a good quality. Please refer to the
tables for an overview of periodical maintenance.
You will notice that the X-marks indicate a renewal of the mentioned part(s) after this many months.
You have to change the absorbents every week.
IMPORTANT :
Note that the x-marks in month 6 and month 12 are only to be done by authorised Mutoh
technicians.
Maintenance cycle on Rockhopper 46

Description
Print Head
Flush Box Spare Part
Wiper
Sensor on ext. Waste Bottle syst.
Maint. Station GA Assy RJ-6100
Waste Connection tube small
Dust removal in fan area
Cleaning maintenance Station
Cleaning bottle
Blade on press roller 4100/6100P
F-absorbent 1 RJ-4100
Qty
2
1
1
1
1
2
1
18
4
Rockhopper-46
2 Maintenance Parts
Monthly
6
7
X
X
10
11
12
X
X
X
X
X
X
X
X
X
X
X
X
X
X
WEEKLY
C AT 8 0 0 0
C AT 8 0 0 0
You have to change some parts of the Rockhopper printer to obtain a good quality. Please refer to the
tables for an overview of periodical maintenance.
You will notice that the X-marks indicate a renewal of the mentioned part(s) after this many months.
You have to change the absorbents every week.
IMPORTANT :
Note that the x-marks in month 6 and month 12 are only to be done by authorised Mutoh
technicians.
Maintenance cycle on Rockhopper 62

Description
Print Head
Flush Box Spare Part
Wiper
Sensor on ext. Waste Bottle syst.
Maint. Station GA Assy RJ-6100
Waste Connection tube small
Dust removal in fan area
Cleaning maintenance Station
Cleaning bottle
Blade on press roller 4100/6100P
F-absorbent 1 RJ-4100
Qty
2
1
1
1
1
2
1
24
4
Monthly
6
7
X
X
10
11
12
X
X
X
X
X
X
X
X
X
X
X
X
X
X
WEEKLY

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MAINTENANCE

Rockhopper: AP-74016, Rev:1.0

Model Name: Rockhopper-46/62

Published by Mutoh Europe,

Some Thoughts on Maintenance Work

4. The need for user/operator cooperation

Some Thoughts on Maintenance Work

Precautions For Maintaining This Printer

Head Cleaning Jig

Printing After Initial Filling

Maintenance Unit Tubes

Take Care When Inserting Head Cable and Y Cable

Ink and Cleaning Fluid Conduct Electricity

Ink and cleaning fluid will conduct electricity.

Thorough Waste Fluid Bottle Replacement

Precautions For Maintaining This Printer

Some Thoughts on Maintenance Work

Precautions For Maintaining This Printer

How to use the Maintenance Manual

Replacement and Adjustment Procedures

Stored Test Patterns

Model Name: Rockhopper-46

Heater System Faults

When Message is not Displayed

Model Name: Rockhopper-46

Replacement and Adjustment Procedures

Cursor Plate Spring, Steel Flexible Guide Assembly

Edge Sensor Assembly

Junction Board Assembly

How to Adjust the Platen Height

XR Cable Assembly (Rear Paper Sensor)

Tubes Guides Assemblies

How to Capture and Install Backup Parameters

Head Cleaning Procedure

Speed Reduction Pulley Assembly

Front / Rear Heater (or heater sensors)

(refer to)RE P 1040

Model Name: Rockhopper-46

Stored Test Patterns

Head Rank Input (Include Initial filling)

Model Name: Rockhopper-46

Model Name: Rockhopper-62

Heater System Faults

When Message is not Displayed

Problem Involving Noise

Model Name: Rockhopper-62

Replacement and Adjustment Procedures

Model Name: Rockhopper-62

Right and Left Covers

Cursor Plate Spring, Steel Flexible Guide Assembly

Edge Sensor Assembly

Junction Board Assembly

How to Adjust the Platen Height

XR Cable Assembly (Rear Paper Sensor)

Tubes Guides Assemblies

How to Capture and Install Backup Parameters

Head Cleaning Procedure

Speed Reduction Pulley Assembly