Falcon Outdoor Maintenance Manual PDF

MAINTENANCE
MANUAL
Eco-Solvent Inkjet Printer

Rockhopper 46/62
Rockhopper: AP-74016, Rev:1.0

Introduction Model Name: Rockhopper-46/62 CON1000
This equipment is Class 1 communications equipment (communications equipment This manual contains basic technical details necessary for marketplace servicing to
to be used in commercial and industrial areas) and conforms to Voluntary maintain product quality and performance of Model Name:Rockhopper-46/62 printer.
Communications Control Institute (VCCI) standards for data processing and other Model Name:Rockhopper-46/62 printer is equipped with a self-diagnostic program
equipment for the prevention of radio wave interference in commercial and industrial that will be of service for adjusting and checking whenever a fault is detected or
areas. during maintenance.
Therefore, if it is used in or near a residential area, it may cause interference with
radio and television reception. This manual contains all the basic items but actual maintenance work should be
It should be used correctly in accordance with the operation manual. undertaken only after a thorough understanding of the functions, operations and
movements has been gained from the operation manual and by other means.
■ Concerning interference with reception
Since this product emits weak radio waves, if it is not installed and used correctly Please note that there may be occasions where the name of a part used in the
and is thought to be causing interference with radio and television reception, this explanation in this manual differs from the name of that same part that is used in the
may be prevented by trying a combination of the following measures: operation manual or in the parts list.
• 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. CAUTION:
• Try using different power supply systems for the receiver and this product.
• The details of this product and the contents of this manual are
■ Trademarks included in this manual protected by copyright held by this Company and, except for
• MUTOH, Model Name:Rockhopper-46/62, MH-GL, MH-GL/2, MH-RTL legitimate use by individuals, unauthorized copying, reproduction
are trademarks or trade names of Mutoh Industries Ltd. or distribution in whole or part is forbidden.
• HP, HP-GL, HP-GL/2, HP-RTL, HP759X, HP758X, C2848 are trademarks or • Details contained in this manual may be subject to future alteration
trade names of the Hewlett Packard Company. without notice.
• Centronics and Bitronics are trademarks or trade names of the Centronics Data • Details contained in this manual are believed to be correct but
Computer Company. please contact this Company or a dealer if an error is suspected
• Windows 3.1, Windows 95, Windows NT 3.51, Windows NT 4.0, MS-DOS are or a point is not clear.
trademarks or trade names of the Microsoft Corporation • In no event will this Company be responsible for the consequences
• Other names of products and companies are the trademarks or trade names of of using this product or this manual.
each relevant company.
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 Model Name:Rockhopper-46/62 CON1010
1. Algunas ideas sobre el trabajo de Mantenciónn 4. The need for user/operator cooperation
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 deliv- ! CAUTION: The user cannot be compelled to do the following!
ered to the user.
Las posibilidades de mantencion deben considerar. Asking the user/operator to cooperate is not a matter of having the user do the mainte-
• In principle, fault maintenance and protective maintenance are both carried out by the nance for you but it is necessary in order to have the equipment working more efficiently
one person. and for having faults rectified quickly.
• Both fault maintenance and protective maintenance involve the bringing of maintenance Actually, even when you do ask for the user’s cooperation, instead of a simple acknowl-
parts. edgement you will usually get doubts and quibbles such as “I’m paying for maintenance”,
• The cooperation of the user/operator is used effectively. “I’m not familiar with the equipment” and “it only benefits the manufacturer.”
However, you must try to persuade the user/operator to cooperate by explaining that doing
2. Protective maintenance work daily inspections will give better printing quality and giving you all the fine details of a fault
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
ideas on protective maintenance include: The following explains the items you need in order to understand fault conditions in detail:
• Adhere strictly to preventive maintenance periods. • Check error messages
• In a case of carrying out preventive maintenance, gain the approval of the user before- • Check user’s usage conditions
hand. • Output from diagnostic pattern
• Don’t press preventive maintenance on the user. • Output from setup lists
• Retest after changing settings
3. Fault maintenance work • Probability of recovery by implementing daily inspections.
A fault will hold up the user’s 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 user’s premises, first check the symptoms.
• Proceed with maintenance work in accordance with the fault tracing procedure.
• After the repair work is finished, be sure to check again by testing in accordance
with the test procedure.
3-2 If repair is not possible even though all the work has been done in accordance with
the fault tracing procedure:
• Contact the Sales Support Groups in your local distributor.
Some Thoughts on Maintenance Work Model Name:Rockhopper-46/62 CON1010

Precautions For Maintaining This Printer Model Name:Rockhopper-46/62 CON2000
PRECAUTION 1 Head Cleaning PRECAUTION 5 Maintenance Unit Tubes

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

When the following tasks have been carried out,drain the waste fluid bottle.
1. After head cleaning and initial filling.

2. When it was not possible to capture main board assembly backup parameters.
Precautions For Maintaining This Printer Model Name:Rockhopper-46/62 CON2000

Contents Model Name:Rockhopper-46/62 CON3000
Rockhopper-46
3 Rockhopper-62
Introduction CON 1000 CON 1000

Some Thoughts on Maintenance Work CON 1010 CON 1010
Precautions For Maintaining This Printer CON 2000 CON 2000
Contents CON 3001 ~ 3 CON 3007 ~ 9
How to use the Maintenance Manual CON 4000 CON 4000
Trouble-Shooting Lists TRB 0000 TRB 0000-3
Matrix Map MAP 0000 MAP 0000-3
Fault-Tracing Procedure EXA 0000 EXA 0000-3
Replacement and Adjustment Procedures REP 0000 REP 0000-3
Fundamental Knowledge GID 0000 GI D 0000-3
Stored Test Patterns PAT 0000 PAT 0000-3
Self-Diagnosis Functions BAC 0000 BAC 0000-3
Maintenance Parts CAT 0000 CAT 0000-3
Contents Model Name:Rockhopper-46/62 CON3000

Model Name: Rockhopper-46 CON3001
Rockhopper 46 inch
Trouble-Shooting Lists TRB0000 Fault-Tracing Procedure EXA0000

• When Message is Displayed TRB1000 • When Message is Displayed
- How to Use LEDs to Check CPU System and Mechanical System Faults TRB1001 - Printer Status Messages EXA1000~
- Data Errors EXA1200~
• When Message is not Displayed - Command Errors EXA1250~
- Initialization, Media Feed, Printing TRB2000 - CPU System Faults EXA1500~
- Noise, Media Cutting, Online, Others TRB2001 - Mechanical System Faults EXA1700~
Heater System Faults EXA1800
• When Message is not Displayed
Matrix Map MAP0000 - Trouble with Initialization EXA2000~
• When Message is Displayed - Trouble with Media Feed EXA3000~
- Printer Status Messages MAP1000 - Trouble with Printing EXA4000~
- Data Errors MAP1200 - Problem Involving Noise EXA5000~
- Command Errors MAP1250 - Trouble with Media Cutting EXA6000~
- CPU System Faults MAP1500 - Online/Function Problems EXA7000~
- Mechanical System Faults MAP1700 - Others EXA8000~
Heater System EXA9000
• When Message is not Displayed
- Trouble with Initialization MAP2000
- Trouble with Media Feed MAP3000
- Trouble with Printing MAP4000
- Problem Involving Noise MAP5000
- Trouble with Media Cutting MAP6000
- Online/Function Problems MAP7000
- Other MAP8000
Heater System MAP9000
Rockhopper-46
3 Contents 1 Model Name: Rockhopper-46
Rockhopper-46
3 Contents 2 CON3002
Replacement and Adjustment Procedures
Right and Left Covers REP 1010 Cursor Plate Spring, Steel Flexible Guide Assembly REP 1310
Front Cover REP 1020 Y Return Pulley Assembly REP 1320
Panel Cover, Y Rail Cover REP 1030 Cartridge Frame Assembly REP 1330
Front Paper Guide and Rear Paper Guide REP 1040 Ink ID Sensor Assembly REP 1340
Left Side Cap and Right Side Cap REP 1041 Detector Assembly REP 1350
Control Box REP 1050 Y Cable REP 1360
Head Cover REP 1060 Ink Tubes REP 1370
X Motor Assembly REP 1070 Cutter Solenoid Assembly REP 1380
Fan Assembly and Fan Cable REP 1080 Print Head Assembly, Head Cable REP 1390
X Speed Reduction Belt REP 1090
Lever Sensor Assembly REP 1100 Edge Sensor Assembly REP 1410
Cover Switch Assembly REP 1110 Head Board Assembly REP 1420
Waste Fluid Box Sensor Assembly REP 1120 Dampers REP 1430
Switch Cable Assembly, DC Cable Assembly REP 1130 Cursor Assembly REP 1440
Main Board Assembly REP 1140 Origin Sensor Assembly, Y Encoder REP 1450
Power Supply Board Assembly REP 1150
Panel Board Assembly and Heater anel Board Assembly REP 1160 Junction Board Assembly REP 1470
Panel Cable REP 1170
Extension Board Assembly REP 1180 How to Adjust the Platen Height REP 1520
XR Cable Assembly (Rear Paper Sensor) REP 1200 Tubes Guides Assemblies REP 1540
Pressure Assembly, Pressure Roller and Blade REP 1220 How to Adjust Steel Belt Tension REP 1550
Pump Motor Assembly REP 1230 How to Adjust X Speed Reduction Belt Tension REP 1560
Cap Assembly REP 1240 How to Adjust the Tilt of the Print Head REP 1570
Wiper REP 1250
Pump Assembly REP 1260 How to Capture and Install Backup Parameters REP 1590
Maintenance Station Assembly REP 1270 How to Install a Program (Software Upgrade) REP 1600
Y Motor Assembly REP 1280
Steel Belt REP 1290 Head Cleaning Procedure REP 1620
T Fence Assembly REP 1300 How to Clean the Head Nozzle Face REP 1660
Speed Reduction Pulley Assembly REP 1680

Grid Roller Assembly REP 1690
Front / Rear Heater (or heater sensors) (refer to)RE P 1040
F Absorbent Assembly REP 1700
Rockhopper-46
3 Contents 2 CON3002
Rockhopper-46
3 Contents 3 Model Name: Rockhopper-46 CON3003
Fundamental Knowledge GID0000 - Head Rank Input (Include Initial filling) BAC2040
• Basic Specifications GID1000 - Head Nozzle Verification BAC2050
• System Block Diagram GID3000 - Left Head Tilt Verification BAC2060
• Operating Sequence - Right Head Tilt Verification BAC2070
- Power On Sequence GID4010 - Repeatability Printing Positioning BAC2080
- Power Off Sequence GID4020 - CW Adjustment BAC2090
- Media Detection Sequence GID4030 - Flush Pointer Adjustment BAC2110
- Normal Standby Sequence GID4040 - Media Feed Distance Compensation BAC2120
- Encoder Disconnected Check Sequence GID4050 - Margin Adjustment BAC2130
- Origin Detection Sequence GID4060 - Rear Sensor Position Adjustment BAC2140
- Media Cutting Sequence GID4070 - Test Print BAC2150
- Printing Sequence (Including Flushing) GID4080 - Head Wash BAC2160
• Cleaning BAC3000
Stored Test Patterns PAT0000 - Normal BAC3000
• Presentation Pattern PAT1000 - Powerful BAC3000
• Print quality adjustment pattern PAT3000
• Setup List PAT4000 • Test Printing BAC4000
- Head Printing Verification BAC4000
- Adjustment Parameters BAC4000
Self-Diagnosis Functions BAC0000
• Parameters BAC5000
• Examination BAC1000 - Initialize BAC5010
- Memory (RAM) Capacity BAC1010 - Update BAC5020
- Version BAC1020
- Panel BAC1030 • Aging BAC6000
- Sensors BAC1040 - Carriage Motor BAC6010
- Encoders BAC1050 - Media Feed Motor BAC6020
- Fans BAC1060 - Cutter BAC6030
- Ethernet Board BAC1065 - Maintenance Unit BAC6040
- History: Last error message BAC1070 - Head BAC6050
- History: Head nozzle ejection count check BAC1070
- Head Waveform BAC1080
Maintenance Parts CAT0000
• Adjustment BAC2000 Maintenance Parts List CAT1000
- Capping Position Adjustment BAC2010 Maintenance Tool List CAT2000
- Skew Verification BAC2030 Lubrication Points CAT4000
Exploded View Drawing CAT5000
Rockhopper-46
3 Contents 3 Model Name: Rockhopper-46 CON3003
Rockhopper-62 Contents 1 Model Name: Rockhopper-62 CON3007
Rockhopper 62 inch
Trouble-Shooting Lists TRB0000-3 Fault-Tracing Procedure EXA0000-3

• When Message is Displayed TRB1000 • When Message is Displayed
- How to Use LEDs to Check CPU System and Mechanical System Faults TRB1001 - Printer Status Messages EXA1000~
(1020-2)
• When Message is not Displayed - Data Errors EXA1200~
- Initialization, Media Feed, Printing TRB2000 - Command Errors EXA1250~
- Noise, Media Cutting, Online, Others TRB2001 - CPU System Faults EXA1500~
- Mechanical System Faults EXA1700~
Heater System Faults EXA1800-2
Matrix Map MAP0000-3 • When Message is not Displayed
• When Message is Displayed - Trouble with Initialization EXA2000~
- Printer Status Messages MAP1000 (2070-2)
- Data Errors MAP1200 - Trouble with Media Feed EXA3000~
- Command Errors MAP1250 (3000-2)
- CPU System Faults MAP1500 - Trouble with Printing EXA4000~
- Mechanical System Faults MAP1700-2 (4050-2)
(4100-2)
• When Message is not Displayed (4130-2)
- Trouble with Initialization MAP2000-2 - Problem Involving Noise EXA5000~
- Trouble with Media Feed MAP3000-2 - Trouble with Media Cutting EXA6000~
- Trouble with Printing MAP4000-2 - Online/Function Problems EXA7000~
- Problem Involving Noise MAP5000 - Others EXA8000~
- Trouble with Media Cutting MAP6000 (8050-2)
- Online/Function Problems MAP7000 Heater System EXA9000-2
- Other MAP8000

Replacement and Adjustment Procedures REP0000-2
Right and Left Covers REP 1010 Cursor Plate Spring, Steel Flexible Guide Assembly REP 1310-2
Panel Cover, Y Rail Cover REP 1030 Cartridge Frame Assembly REP 1330
Front Paper Guide and Rear Paper Guide REP 1040-2 Ink ID Sensor Assembly REP 1340
Left Side Cap and Right Side Cap REP 1041 Detector Assembly REP 1350
Control Box REP 1050 Y Cable REP 1360-2
Head Cover REP 1060 Ink Tubes REP 1370-2
Fan Assembly and Fan Cable REP 1080-2 Print Head Assembly, Head Cable REP 1390
Lever Sensor Assembly REP 1100 Edge Sensor Assembly REP 1410
Switch Cable Assembly, DC Cable Assembly REP 1130 Cursor Assembly REP 1440
Main Board Assembly REP 1140 Origin Sensor Assembly, Y Encoder REP 1450
Power Supply Board Assembly REP 1150
Panel Board Assembly REP 1160 Junction Board Assembly REP 1470
Panel Cable REP 1170
Extension Board Assembly REP 1180 How to Adjust the Platen Height REP 1520
XR Cable Assembly (Rear Paper Sensor) REP 1200 Tubes Guides Assemblies REP 1540-2
Pressure Assembly, Pressure Roller and Blade REP 1220 How to Adjust Steel Belt Tension REP 1550
Pump Motor Assembly REP 1230 How to Adjust X Speed Reduction Belt Tension REP 1560
Cap Assembly REP 1240 How to Adjust the Tilt of the Print Head REP 1570
Wiper REP 1250
Pump Assembly REP 1260 How to Capture and Install Backup Parameters REP 1590
Maintenance Station Assembly REP 1270 How to Install a Program (Software Upgrade) REP 1600
Y Motor Assembly REP 1280
Steel Belt REP 1290 Head Cleaning Procedure REP 1620
T Fence Assembly REP 1300 How to Clean the Head Nozzle Face REP 1660
Speed Reduction Pulley Assembly REP 1680

Grid Roller Assembly REP 1690
Front / Rear Heater (or heater sensors) (refer to)RE P 1040-2
F Absorbent Assembly REP 1700
Waste Fluid Bottle Assembly REP 1710

Fundamental Knowledge GID0000-3 - Head Rank Input (Include Initial filling) BAC2040
• Basic Specifications GID1000-3 - Head Nozzle Verification BAC2050
• System Block Diagram GID3000 - Left Head Tilt Verification BAC2060
• Operating Sequence - Right Head Tilt Verification BAC2070
- Power On Sequence GID4010 - Repeatability Printing Positioning BAC2080
- Power Off Sequence GID4020 - CW Adjustment BAC2090
- Media Detection Sequence GID4030 - Flush Pointer Adjustment BAC2110
- Normal Standby Sequence GID4040 - Media Feed Distance Compensation BAC2120
- Encoder Disconnected Check Sequence GID4050 - Margin Adjustment BAC2130
- Origin Detection Sequence GID4060 - Rear Sensor Position Adjustment BAC2140
- Media Cutting Sequence GID4070 - Test Print BAC2150
- Printing Sequence (Including Flushing) GID4080 - Head Wash BAC2160
• Cleaning BAC3000
Stored Test Patterns PAT0000-3 - Normal BAC3000
• Presentation Pattern PAT1000 - Powerful BAC3000
• Print quality adjustment pattern PAT3000
• Setup List PAT4000 • Test Printing BAC4000
- Head Printing Verification BAC4000
- Adjustment Parameters BAC4000
Self-Diagnosis Functions BAC0000-3
• Parameters BAC5000
• Examination BAC1000 - Initialize BAC5010
- Memory (RAM) Capacity BAC1010 - Update BAC5020
- Version BAC1020
- Panel BAC1030 • Aging BAC6000
- Sensors BAC1040 - Carriage Motor BAC6010
- Encoders BAC1050 - Media Feed Motor BAC6020
- Fans BAC1060 - Cutter BAC6030
- Ethernet Board BAC1065 - Maintenance Unit BAC6040
- History: Last error message BAC1070 - Head BAC6050
- History: Head nozzle ejection count check BAC1070
- Head Waveform BAC1080
Maintenance Parts CAT0000-3
• Adjustment BAC2000 Maintenance Parts List CAT1000-3
- Capping Position Adjustment BAC2010 Maintenance Tool List CAT2000
- Skew Verification BAC2030 Lubrication Points CAT4000
Exploded View Drawing CAT5000

How to use the Maintenance Manual Model Name: Rockhopper-46/62 CON4000
How to use the Maintenance Manual
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

■ 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 circumstances by “fax” or “telephone”. Check error

Check fault circumstances, Trouble-Shooting List
messages, check user usage conditions, retry after changing settings, output
select fault details from
TRB❉❉❉❉ diagnostic pattern, etc. Select fault symptoms produced by user from
Trouble-Shooting Lists
the Trouble-Shooting List.
Manual de Operaciones, Conocimiento

Conduct a consultation by “fax” or “telephone”.
Conduct a primary Check possibility of user error or recovery by daily inspection. Check error báasico, Cuidados diarios, Mantencion periodica/
consultation with the user messages, check user usage conditions, output diagnostic pattern, output inspeccion/Limpieza
setup list. Retry after changing settings, etc.
• 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 Matrix Map Gather the necessary maintenance parts Maintenance Parts list, Maintenance Tools list,
maintenance parts MAP❉❉❉❉ Exploded views
Conduct a tracing inquiry Fault Tracing Procedures Conduct an inquiry to trace the cause of the fault Basic knowledge
EXA❉❉❉❉
Replace parts and adjust Replacement and Adjustment Replace or readjust parts suspected to be faulty. Basic knowledge
Procedures REP❉❉❉❉ Carry out adjustments after replacing parts.
Final check Separate causes of faults and check operation after faults have been
rectified.

How to use the Trouble-Shooting Lists (TRB) Model Name: Rockhopper-46/62 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
When Message is Displayed TRB1000
• Printer Status Messages, Data Errors, Command Errors

• CPU System Faults, Mechanical System Faults
When Message is Not Displayed TRB2000 to TRB2001
• Trouble with Initialization: Troubles that occur when unpacking immediately after delivery are grouped here.
Check this group for a similar trouble occurring other than immediately after delivery.
Troubles concerning the series of operations up to the enabling of printing are grouped here.
• Trouble with 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.
How to use the Trouble-Shooting Lists (TRB) Model Name: Rockhopper-46/62 CON4020
How to use the Matrix Map (MAP) Model Name: Rockhopper-46/62 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 Major classification of fault details
required parts
When Message is Not Displayed Trouble with Initialization
Name and Diagram Number of

Major classification
DF-41592 XR Cable Assembly (Paper Sensor R)

of fault details and When Message is Not Displayed
DF-41620 Fan Extension Cable 1 Assembly

Replacement Part
range of EXA [Trouble with Initialization]
DF-41604 Maintenance Station Assembly

DF-40690 Print Head Assembly (Colour)
numbers
DF-41609 INK ID Sensor 1 Assembly

DF-40106 Detector Assembly (Black)
EXA2000 to EXA2070
DF-41536 Junction Board Assembly

DF-41591 Waste Fluid Box Sensor
DF-41589 Lever Sensor Assembly
DF-41590 Cover Switch Assembly
DF-41619 Switch Cable Assembly

DF-41595 Edge Sensor Assembly
DF-41587 Power Board Assembly
DF-40173 Vacuum Fan Assembly

DF-40146 Detector Assembly (M)
DF-40097 Panel Board Assembly
DF-40147 Detector Assembly (C)

DF-40107 Detector Assembly (Y)
DF-41588 Head Board Assembly
DF-41586 Main Board Assembly
DF-41615 INK ID Sensor Cable

DF-41593 Detector 1 Assembly
DF-41468 DC Cable Assembly
DF-41603 Pump Assembly

DF-41602 Cap Assembly
DF-41617 Panel Cable
DF-41601 Head Cable

DF-41600 Y Cable
Problem
Fault-
Tracing
Procedure
EXA No.
2000 - Power supply does not come on
2000 - LCD faulty (no display/erratic display)
2010 - Initial filling of inks failed
2020 - Initial filling is completed but no ink comes out
2030 - After power is switched on, nothing works
2030 - When power is applied, “Initializing” appears and then a reset is executed.
2030 - After mounting media, initial operation fails
2030 - Printer does not work even with the cover closed
2030 - Printer does not stop even with the cover opened
Fault 2040 - Ink cartridges are installed but not recognized
details 2050 - Can not make entries from the operating panel
2060 - Data is received but not plotted
2070 - Media is not suction
Replacement
and adjustment
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
procedure page
When Message is Not Displayed Trouble with Initializatio Model Name: 46

3 MAP2000
How to use the Matrix Map (MAP) Model Name: Rockhopper-46/62 CON4040
How to use the Fault-Tracing Procedure (EXA) Model Name: Rockhopper-46/62 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 indi-
cated by the arrow [→].
Whether an error message is displayed Major classification of fault details

Page specified by
matrix map (MAP)
When No Error is Displayed on the Printer's Liquid Crystal Display Trouble with Initialization Model Name: Rockhopper-46/62 EXA2021
GO TO Ref. Pages
No. Symptom Items to be Confirmed
Sequence R E P B A C
1 • Initial filling is completed but no ink 1-10 • Are there any breaks, cuts or air leaks in the ink tubes?
Replacement and
comes out → Change each ink tube, cleaning each time and checking that ink flows during cleaning. 1370 adjustment procedure
1-11 • Check that connectors J207 (HEAD C1) and J208 (HEAD C2) on the head board assembly, and (REP) page reference
(Initial filling means to fill the head head cables on the print head are not inserted obliquely, and they are locked securely.
Fault details with ink to enable it to print.) → Insert the connectors again.
1-12 • Is there a broken lead in head cables? Hidden diagnostic

→ Replace head cables. 1400 procedure page
1-13 • Is the print head assembly damaged? reference
→ Replace the print head assembly.
Fault-tracing 1390
sequence 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. 1420
→ 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. 1360
1140
CAUTION: Power must be off when connectors are being disconnected or reconnect-
ed, otherwise you may be injured or a board may be damaged.
The main board assembly will certainly be damaged if power is 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)
How to use the Fault-Tracing Procedure (EXA) Model Name: Rockhopper-46/62 CON4050
How to use Replacement and Adjustment Procedure (REP) Model Name: Rockhopper-46/62 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 adjust-
ment procedure (REP) shown below.
• If you don’t know how to go about the removal of covers involved in replacing a part, refer to REP1010 to REP1060.
Page specified by
the fault-tracing
Replacement and adjustment item procedure (EXA)
How to replace the Y Motor Assembly Model Name: Rockhopper-46/62 REP1280

Replacement
procedure Item Replacement and Adjustment Procedure
« REFERENCE » If there is to be no replacement that

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

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

es below the Cartridge Unit, the work will
be easier if you remove the two Cartridge
Base screws and push it back.
2. Adjustment 1. Carry out the Steel Belt Tensioning Adjustment.

and
Examination
Procedure
Y motor assembly
Page specified by
the fault-tracing
How to replace the Y Motor Assembly Model Name: Rockhopper-46/62 REP1280 procedure (EXA)
How to use Replacement and Adjustment Procedure (REP) Model Name: Rockhopper-46/62 CON4060
Rockhopper-46
3 Trouble-Shooting Lists Model Name: Rockhopper-46 TRB0000
When Message is Displayed
Printer Status Messages TRB1000

Data Errors TRB1000
Command Errors TRB1000
CPU System Faults TRB1000
Mechanical System Faults TRB1000
Heaters System Faults TRB1000
How to Use LEDs to Check CPU System TRB1001

and Mechanical System Faults
When Message is Not Displayed
Trouble with Initialization TRB2000

Trouble with Media Feed TRB2000
Trouble with Printing TRB2000
Problem Involving Noise TRB2001
Trouble with Media Cutting TRB2001
Online/Function Problems TRB2001
Others TRB2001
Heater System TRB2001
Rockhopper-43 Trouble-Shooting Lists Model Name: Rockhopper-46 TRB0000

Rockhopper-62 Trouble-Shooting Lists Model Name: Rockhopper-62 TRB0000-3
Printer Status Messages TRB1000

Data Errors TRB1000
Command Errors TRB1000
CPU System Faults TRB1000
Mechanical System Faults TRB1000
Heaters System Faults TRB1000
How to Use LEDs to Check CPU System TRB1001

and Mechanical System Faults
Trouble with Initialization TRB2000

Trouble with Media Feed TRB2000
Trouble with Printing TRB2000
Problem Involving Noise TRB2001
Trouble with Media Cutting TRB2001
Online/Function Problems TRB2001
Others TRB2001
Heater System TRB2001
Rockhopper-62 Trouble-Shooting Lists Model Name: Rockhopper-62 TRB0000-3

Trouble-Shooting 1/3 (List of Faults) When Message is Displayed Model Name: Rockhopper-46/62 TRB1000
Cases where an error message is displayed on the liquid crystal display of the main printer unit
Minor Faults GO TO EXA No. CPU System/Mechanical System Faults GO TO EXA No.
• Cover Open EXA1000 • E001 Error DRAM (Standard DRAM error) EXA1500
• Lever Up EXA1000 • E002 Error Opt.DRAM (Optional DRAM error) EXA1500
• Cover and Lever EXA1000 •E016CPUErr[00] (Interrupt exception error) EXA1510
• Undefined Media EXA1010 •E016CPUErr[02] (Command boundary exception error) EXA1510
• Media Skew Error EXA1020 •E016CPUErr[03] (Data boundary exception error) EXA1510
• [User 1] Media End EXA1030 •E016CPUErr[04] (Address error exception) EXA1510
Printer Status Messages
• Remove Media EXA1040 (Load or command fetch)
CPU System Faults

• Roll Media End EXA1050 •E016CPUErr[05] (Address error exception) (Store) EXA1510
• Media Cut Error EXA1060 •E016CPUErr[06] (Bus error exception) (Command fetch) EXA1510
• Not enough memory SIMM 12 MB EXA1070 •E016CPUErr[07] (Bus error exception) (Data load) EXA1510
• Insert Special Cartridge EXA1080 •E016CPUErr[08] (System call exception error) EXA1510
• [ ∗ ] Ink Low EXA1090 •E016CPUErr[09] (Break point exception error) EXA1510
• [ ∗ ] No Ink EXA1090 •E016CPUErr[10] (Reserved command exception error) EXA1520
• [ ∗ ] No Cartridge EXA1100 •E016CPUErr[11] (Unable to use coprocessor exception error) EXA1520
• Capping position not specified EXA1110 •E016CPUErr[12] (Operation overflow exception error) EXA1520
• Not Filled EXA1120 •E016CPUErr[13] (Trap exception error) EXA1520
• No Waste Fluid Box EXA1130 •E016CPUErr[15] (Floating point exception error) EXA1520
• Wrong Ink Type EXA1150 •E016CPUErr[22] (Watch exception error) EXA1520
•E016CPUErr[32] (Watchdog timeout exception error) EXA1520
•E016CPUErr[33] (Abort error) EXA1520
• Error E237 Transfer memory (Transfer memory error/Transfer memory EXA1520
access error)
• Error E129 NVRAM EXA1530
• E065 Error X Motor EXA1700

Data Errors
• Network Detection Error EXA1230

• Network Initialization Error EXA1230 • E069 Error X Encoder EXA1700
Mechanical System Faults

• E071 Error X Timeout EXA1700
• E073 Error X Overcurrent EXA1700
• E066 Error Y Motor EXA1710
• E070 Error Y Encoder EXA1710
• E072 Error Y Timeout EXA1710
• MH01 Error (Undefined Command) EXA1250 • E074 Error Y Overcurrent EXA1710
• E075 Error Sensor Fault EXA1720
Command Errors
• MH02 Error (Parameter Error) EXA1250

• MH03 Error (Numerical Error) EXA1250
• MH04 Error (Undefined Character Set) EXA1250
• MH07 Error (Buffer Overflow) EXA1250
Heater System Faults EXA1800
Trouble-Shooting 1/3 (List of Faults) When Message is Displayed Model Name: Rockhopper-46/62 TRB1000
How to Use LEDs to Check CPU System and Mechanical System Faults Model Name: Rockhopper-46/62 TRB1001
• When the printer stops working and nothing appears on the liquid crystal display (LCD),
a fault has probably occurred in the CPU system or the mechanical system.
In that case, open the control box and check the error by the LEDs on the main board assembly. is on, is off.
LED display
1 2 3 4 5 6 7 8
Details of Error Fault-Tracing Procedure
EXA page
• E001 Error DRAM (Standard DRAM error) EXA1500
Fallas Sistema CPU • E002 Error Opt.DRAM (Optional DRAM 1 error) EXA1500
• E002 Error Opt.DRAM (Optional DRAM 2 error) EXA1500
• 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) EXA1510
• 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) EXA1520
• E237 Error Transfer memory (Transfer memory error/Transfer memory access error) EXA1520
• E129 Error NVRAM EXA1530
• E065 Error X Motor EXA1700

FALLAS SISTEMA • E069 Error X Encoder EXA1700
MECANICO • E071 Error X Timeout EXA1700
• E073 Error X Overcurrent EXA1700
• E066 Error Y Motor EXA1710
• E070 Error Y Encoder EXA1710
• E072 Error Y Timeout EXA1710
• E074 Error Y Overcurrent EXA1710
• E075 Error Sensor Fault EXA1720
How to Use LEDs to Check CPU System and Mechanical System Faults Model Name: Rockhopper-46/62 TRB1001
Trouble-Shooting 2/3 (List of Faults) When Message is Not Displayed Model Name: Rockhopper-46/62 TRB2000
Cases where no error message is displayed GO TO Cases where no error message is displayed GO TO
on the liquid crystal display of the main printer unit EXA No. on the liquid crystal display of the main printer unit EXA No.
• No power EXA2000 • No imprime en forma continua EXA4000
• Faulty liquid crystal display (no display/unstable display) EXA2000 • There is an extra feed after printing is finished EXA4010
• Initial filling of inks failed EXA2010 • Dots are missing from the printing EXA4020
• Initial filling is completed but no ink comes out EXA2020 • Cleaning does not cure blockage EXA4020
Trouble with Initialization
• After power is switched on, nothing works EXA2030 • No imprime nada EXA4030
Trouble with Printing

• When power is applied, “Initializing” appears and then a reset is executed. EXA2030 • No imprime un color especifico EXA4030
• Media is mounted but the initialization operation is not done EXA2030 • La superficie entera se imprime en negro EXA4040
• Printer does not work even with the cover closed EXA2030 • Printing becomes shaded EXA4050
• Printer does not stop even with the cover opened EXA2030 • The image contains blurs EXA4050
• Ink cartridges are installed but not recognized EXA2040 • Transverse lines appear to be split EXA4050
• No se puede entrar al Panel de Operaciones EXA2050 • AParecen lineas blancas y negras en la impresion EXA4050
• Data is received but not printed EXA2060 • Orillas de la impresion aparecen borrosas EXA4060
• Media is not suction EXA2070 • Many satellites (unwanted dots) EXA4070
• The printing has whiskers EXA4070
• Printed lines appear blurred (printing is dirty) EXA4070
• Mixed colour lines do not overlap EXA4080
• Black and colour positions are offset EXA4080
• Inaccurate line length in the direction of head movement (Main scanning direction) EXA4090
• Inaccurate straight line in the direction of head movement (straightness) EXA4100
• Inaccurate line distance in the direction of media feed (Subsidiary scanning distance) EXA4110
• Inaccurate straight line in the direction of media feed (joining precision Y) EXA4120
• The media comes off when it is initialized or during printing EXA3000 • Bad right angle precision EXA4130
• The media is skewed or meanders when it is initialized or during printing EXA3000
• The media becomes wrinkled when it is initialized or during printing EXA3000
• The media jams when it is initialized or during printing EXA3000
Trouble with Media Feed
• The media tears when it is initialized or during printing EXA3000

• The media size is different after media mounting and initialization EXA3010
• Tracing paper and thin media cannot be detected EXA3010
Cases where no error message is displayed GO TO Cases where no error message is displayed GO TO
on the liquid crystal display of the main printer unit EXA No. on the liquid crystal display of the main printer unit EXA No.
• Abnormal noise when media is sucked down EXA5000
• Abnormal noise when standing by ready to print EXA5010 • Cannot connect normally with Centronics EXA7000
• Abnormal noise when head is moving left and right EXA5020 • Cannot connect normally with Network EXA7000
• Abnormal noise when media is fed EXA5030 • The scale function does not work correctly EXA7020
Online/Function Problems
• Abnormal noise when cutting EXA5040 • The rotate function does not work correctly EXA7020
Problem Involving Noise
• The mirror function does not work correctly EXA7020

• Other functions are not working correctly EXA7020
• Printing position is offset EXA7030
• Some data are not printed (omitted) EXA7040
• Text and printing data are garbled (extra lines appear) EXA7050
• There is an extra feed after printing is finished EXA7060
• Does not cut normally EXA6000 • The printer hangs up EXA8000

• Cutting occurs during printing EXA6010 • Power shutdown during printing EXA8010
• The cutting operation is normal but the media is not cut EXA6020 • The ink cartridges will not go in EXA8020
• The cutting is bad and the media jams EXA6020 • Ink has overflowed from the waste fluid box EXA8050
Trouble with Media Cutting
• The cutting operation is normal but the media does not fall out EXA6030 • Ink overflows from flushing box EXA8050
• Inaccurate media cutting EXA6040 • Ink is split around the X-rail EXA8050
• Cutting is delayed for some time after printing has ended EXA6050
Others
• White paper is cut (Blank print) EXA6050 Sistema Calefactores EXA9000
Rockhopper-46
3 Matrix Map Model Name: Rockhopper-46 MAP0000
Matrix Map
Printer Status Messages MAP1000

Data Errors MAP1200
Command Errors MAP1200
CPU System Faults MAP1500
Mechanical System Faults MAP1700
Heaters Fault MAP1800
Trouble with Initialization MAP2000

Trouble with Media Feed MAP3000
Trouble with Printing MAP4000
Problem Involving Noise MAP5000
Trouble with Media Cutting MAP6000
Online/Function Problems MAP7000
Other MAP8000
Rockhopper-46
3 Matrix Map Model Name: Rockhopper-46 MAP0000
Rockhopper-62 Matrix Map Model Name: Rockhopper-62 MAP0000-3
Matrix Map
Printer Status Messages MAP1000-3

Data Errors MAP1200
Command Errors MAP1200
CPU System Faults MAP1500
Mechanical System Faults MAP1700-2
Heaters Fault MAP1800-2
Trouble with Initialization MAP2000-2

Trouble with Media Feed MAP3000-3
Trouble with Printing MAP4000-2, 4001-3
Problem Involving Noise MAP5000-3
Trouble with Media Cutting MAP6000-2
Online/Function Problems MAP7000-2
Other MAP8000-2
Heater System MAP9000-2
Rockhopper-62 Matrix Map Model Name: Rockhopper-62 MAP0000-3

Fault-
Tracing
EXA No.
1150
1130
1120
1110
1100
1090
1090
1080
1070
1060
1050
1040
1030
1020
1010
1000
1000
1000
Procedure
- Lever up
- Not Filled
- [✼✼] No Ink
- Cover open
- [✼✼] Ink Low

- Cover & Lever
- Remove Media
- Roll Media End
- Wrong Ink Type

- Media Cut Error
- Undefined Media
- [✼✼] No Cartridge
- Media Skew Error
- [User 1] Media End
- No Waste Fluid Box

- Insert Special Cartridge

EXA1000 to EXA1150
[Printer Status Display]
Problem
- Capping position not specified

- Not enough memory SIMM12MB
Replacement Part

1140 DF-41586 Main Board Assembly
1160 DF-40097 Panel Board Assembly
1110 DF-41590 Cover Switch Assembly
1170 DF-41617 Panel Cable
1100 DF-41589 Lever Sensor Assembly
1410 DF-41595 Edge Sensor Assembly
1420 DF-41588 Head Board Assembly
1200 DF-41592 XR Cable Assembly (Paper Sensor R)
1360 DF-41600 Y Cable
1380 DF-40113 Cutter Solenoid Assembly
1350 DF-41593 Detector1 Assembly
1350 DF-40106 Detector Assembly (Black)
1350 DF-40107 Detector Assembly (Y)
1350 DF-40146 Detector Assembly (M)
1350 DF-40147 Detector Assembly (C)
1120 DF-41591 Waste Fluid Box Sensor Assembly
1220 DF-41529 Pressure Assembly
1220 DF-41530 Pressure Roller
1330 DF-40127 Cartridge Frame Assembly

1340 DF-41609 Ink ID Sensor1 Assembly
1470 DF-41615 Ink ID Cable
1470 DF-41536 Junction Board Assembly
1690 DF-41840 Grid Roller Assembly
Model Name: Rockhopper463
Model Name: Rockhopper463
MAP1000
MAP1000
Fault-
Tracing
EXA No.
1150
1130
1120
1110
1100
1090
1090
1080
1070
1060
1050
1040
1030
1020-2
1010
1000
1000
1000
Procedure
- Lever up
- Not Filled
- [✼✼] No Ink
- Cover open
- [✼✼] Ink Low

- Cover & Lever
- Remove Media
- Roll Media End
- Wrong Ink Type

- Media Cut Error
- Undefined Media
- [✼✼] No Cartridge
- Media Skew Error
- [User 1] Media End
- No Waste Fluid Box

- Insert Special Cartridge

EXA1000 to EXA1150
[Printer Status Display]
Problem
- Capping position not specified

- Not enough memory SIMM12MB
Replacement Part

1360-2 DF-41600 Y Cable
1380 DF-40113 Cutter Solenoid Assembly
1120 DF-41591 Waste Fluid Box Sensor Assembly
1220 DF-41529 Pressure Assembly
1220 DF-41530 Pressure Roller
1330 DF-40127 Cartridge Frame Assembly
1470 DF-41615 Ink ID Cable
1690 DF-41840 Grid Roller Assembly
1690
Printer Status Messages Model Name: Rockhopper62
Printer Status Messages Model Name: Rockhopper62
MAP1000-3
MAP1000-3
When Message is Displayed Data Errors, Command Errors Model Name: Rockhopper-46/62 MAP1200

Replacement Part
[Data Errors, Command Errors]
EXA1230 to EXA1250

Problem
Fault-
Tracing
Procedure
EXA No.
1230 - Network Detection Error
1230 - Network Initialization Error
1250 - MH01 Error (Undefined Command)
1250 - MH02 Error (Parameter Error)
1250 - MH03 Error (Numerical Error)
1250 - MH04 Error (Undefined Character Set)
1250 - MH07 Error (Buffer Overflow)
1140
When Message is Displayed Data Errors, Command Errors Model Name: Rockhopper-46/62 MAP1200
When Message is Displayed CPU System Faults Model Name: Rockhopper-46/62 MAP1500

Replacement Part
[CPU System Faults]
EXA1500 to EXA1530

Problem
Fault-
Tracing
Procedure
EXA No.
1500 - E001 Error DRAM (Standard DRAM error)
1500 - E002 Error Opt.DRAM (Optional DRAM error)
1510 - E016 CPUErr[00] (Interrupt exception error)
1510 - E016 CPUErr[02] (Command boundary exception error)
1510 - E016 CPUErr[03] (Data boundary exception error)
1510 - E016 CPUErr[04] (Address error exception load)
1510 - E016 CPUErr[05] (Address error exception store)
1510 - E016 CPUErr[06] (Bus error exception check)
1510 - E016 CPUErr[07] (Bus error exception load)
1510 - E016 CPUErr[08] (System call exception)
1510 - E016 CPUErr[09] (Break point exception)
1520 - E016 CPUErr[10] (Reserved command exception)
1520 - E016 CPUErr[11] (Processor usage denial exception)
1520 - E016 CPUErr[12] (Operation overflow exception)
1520 - E016 CPUErr[13] (Trap exception)
1520 - E016 CPUErr[15] (Floating point exception)
1520 - E016 CPUErr[22] (Watch exception)
1520 - E016 CPUErr[32] (Watchdog timeout error)
1520 - E016 CPUErr[33] (Abort error)
1520 - E237 Error Transfer memory (Transfer memory error/access error)
1530 - Error E129 NVRAM (Backup memory error)
1140
When Message is Displayed CPU System Faults Model Name: Rockhopper-46/62 MAP1500
When Message is Displayed Mechanical System Faults Model N.:Rockhopper-46
3 MAP1700


Replacement Part
[Mechanical System Faults]
DF-41598 CR Motor Assembly (Y Motor)

EXA1700 to EXA1720
DF-40109 Origin Sensor Assembly

DF-41597 X Motor Assembly
DF-41607 T Fence
Problem
Fault-
Tracing
Procedure
EXA No.
1700 - Error E065 X Motor
1700 - Error E069 X Encoder
1700 - Error E071 X Timeout
1700 - Error E073 X Overcurrent
1710 - Error E066 Y Motor
1710 - Error E070 Y Encoder
1710 - Error E072 Y Timeout
1710 - Error E074 Y Overcurrent
1720 - Error E075 Sensor Abnormal

1140
1070
1280
1290
1450
1150
1080
1080
1080
1080
When Message is Displayed Mechanical System Faults Model N.: Rockhopper-46

3 MAP1700
When Message is Displayed Mechanical System Faults Model Name: Rockhopper 62 MAP1700-2


Replacement Part
[Mechanical System Faults]
DF-41598 CR Motor Assembly (Y Motor)

EXA1700 to EXA1720
DF-40109 Origin Sensor Assembly

DF-41607 T Fence
Problem
Fault-
Tracing
Procedure
EXA No.
1700 - Error E065 X Motor
1700 - Error E069 X Encoder
1700 - Error E071 X Timeout
1700 - Error E073 X Overcurrent
1710 - Error E066 Y Motor
1710 - Error E070 Y Encoder
1710 - Error E072 Y Timeout
1710 - Error E074 Y Overcurrent
1720 - Error E075 Sensor Abnormal
1080-2
1080-2
1080-2
1080-2
1080-2
1140
1070
1280
1290
1450
1150
When Message is Displayed Mechanical System Faults Model Name: Rockhopper 62 MAP1700-2
When Message is Displayed d Heater
r System Faults Model N:Rockhopper46 3 MAP1800

Replacement Part
[Heater system]
EXA1800
Front Right Heater Sensor
Rear Right Heater Sensor

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

1040
1040
1040
1040
1040
When Message is Displayed Heater

r System Faults Model N:Rockhopper46 3 MAP1800
When Message is Displayed d Heater
r System Faults Model N:Rockhopper62 3 MAP1800-2

Replacement Part
[Heater system]
EXA1800
Front Right Heater Sensor
Rear Right Heater Sensor

Rear Left Heater Sensor
Front Left Heater Sensor
Heater System
Problem
Fault-
Tracing
Procedure
EXA No.
1800 - Err : F.R.T. Sensor
1800 - Err : F.L.T. Sensor
1800 - Err : R.L.T. Sensor
1800 - Err : R.R.T. Sensor
1800 - Err : FRFLT Sensor
1800 - Err : FRRLT Sensor
1800 - Err : FRRRT Sensor
1800 - Err : FLRLT Sensor
1800 - Err : FLRRT Sensor
1800 - Err : RRRLT Sensor
1800 - Err : 2FRLT Sensor
1800 - Err : 2FRRT Sensor
1800 - Err : FR2RT Sensor
1800 - Err : FL2RT Sensor
1800 - Err : All T. Sensor
1800 - Err : Heater Stop
1040 -2
1040 -2
1040 -2
1040 -2
1040 -2
When Message is Displayed Heater

r System Faults Model N:Rockhopper62 3 MAP1800-2
Fault-
Tracing
EXA No.
2070
2060
2050
2040
2030
2030
2030
2030
2030
2020
2010
2000
2000
Procedure
- Media is not suction

- Initial filling of inks failed
EXA2000 to EXA2070
[Trouble with Initialization]
Problem

- Data is received but not plotted

- Power supply does not come on

- LCD faulty (no display/erratic display)
- After power is switched on, nothing works
- After mounting media, initial operation fails
- Ink cartridges are installed but not recognized

- Initial filling is completed but no ink comes out
- Can not make entries from the operating panel

- Printer does not work even with the cover closed
- Printer does not stop even with the cover opened
Replacement Part
- When power is applied, “Initializing” appears and then a reset is executed.

1360 DF-41600 Y Cable
1130 DF-41619 Switch Cable Assembly
1150 DF-41587 Power Board Assembly
1130 DF-41468 DC Cable Assembly
1350 DF-41593 Detector 1 Assembly
1240 DF-41602 Cap Assembly

1260 DF-41603 Pump Assembly
1270 DF-41604 Maintenance Station Assembly
1390 DF-40690 Print Head Assembly (Colour)
1390 DF-41601 Head Cable
1120 DF-41591 Waste Fluid Bottle Sensor
1080 DF-40173 Vacuum Fan Assembly
1080 DF-41620 Fan Extension Cable 1 Assembly
1340 DF-41609 INK ID Sensor 1 Assembly
3
Model N. :Rockhopper46
3
Model N. : Rockhopper46

1470 DF-41615 INK ID Sensor Cable
MAP2000
MAP2000
Fault-
Tracing
EXA No.
2070-2
2060
2050
2040
2030
2030
2030
2030
2030
2020
2010
2000
2000
Procedure
- Media is not suction

- Initial filling of inks failed
EXA2000 to EXA2070-2
[Trouble with Initialization]
Problem

- Data is received but not plotted

- Power supply does not come on

- LCD faulty (no display/erratic display)
- After power is switched on, nothing works
- After mounting media, initial operation fails
- Ink cartridges are installed but not recognized

- Initial filling is completed but no ink comes out
- Can not make entries from the operating panel

- Printer does not work even with the cover closed
- Printer does not stop even with the cover opened
Replacement Part
- When power is applied, “Initializing” appears and then a reset is executed.

1360-2 DF-41600 Y Cable
1130 DF-41619 Switch Cable Assembly
1150 DF-41587 Power Board Assembly
1130 DF-41468 DC Cable Assembly
1240 DF-41602 Cap Assembly

1260 DF-41603 Pump Assembly
1270 DF-41604 Maintenance Station Assembly
1390 DF-40690 Print Head Assembly (Colour)
1390 DF-41601 Head Cable
1120 DF-41591 Waste Fluid Bottle Sensor
1080-2 DF-40173 Vacuum Fan Assembly
1080-2 DF-41620 Fan Extension Cable 1 Assembly
Model Name: Rockhopper 62
Model Name: Rockhopper 62

1470 DF-41615 INK ID Sensor Cable
MAP2000-2
MAP2000-2
When Message is Not Displayed Trouble with Media Feed Model N. :Rockhopper46
3 MAP3000


Replacement Part
[Trouble with Media Feed]
EXA3000 to EXA3010

DF-41840 Grid Roller Assembly

DF-41529 Pressure Assembly
DF-41600 Y Cable
Problem
Fault-
Tracing
Procedure
EXA No.
3000 - The media comes off when it is initialized or during printing
3000 - The media is skewed or meanders when it is initialized or during printing
3000 - The media becomes wrinkled when it is initialized or during printing
3000 - The media jams when it is initialized or during printing
3000 - The media tears when it is initialized or during printing
3010 - The media size is different after media mounting and initialization
3010 - Tracing paper and thin media cannot be detected

1140
1080
1080
1080
1080
1110
1410
1200
1360
1690
When Message is Not Displayed Trouble with Media Feed Model N. :Rockhopper46
3 MAP3000
When Message is Not Displayed Trouble with Media Feed Model N. : Rockhopper-62 MAP3000-3


Replacement Part
[Trouble with Media Feed]
EXA3000-2 to EXA3010


DF-41600 Y Cable
Problem
Fault-
Tracing
Procedure
EXA No.
3000-2 - The media comes off when it is initialized or during printing
3000-2 - The media is skewed or meanders when it is initialized or during printing
3000-2 - The media becomes wrinkled when it is initialized or during printing
3000-2 - The media jams when it is initialized or during printing
3000-2 - The media tears when it is initialized or during printing
3010 - The media size is different after media mounting and initialization
3010 - Tracing paper and thin media cannot be detected
1080-2
1080-2
1080-2
1080-2
1080-2
1360-2

1140
1110
1410
1200
1690
When Message is Not Displayed Trouble with Media Feed Model N. : Rockhopper-62 MAP3000-3
When Message is Not Displayed Trouble with Printing Model N. : Rockhopper-46
3 MAP4000


Replacement Part
[Trouble with Printing]

EXA4000 to EXA4130

(EXA4110 to EXA4130 → See MAP4001)


DF-41599 Pump Motor Assembly


DF-41601 Head Cable
DF-41605 Ink Tube
DF-41607 T Fence
DF-41600 Y Cable
DF-40125 Wiper
Problem
Fault-
Tracing
Procedure
EXA No.
4000 - Does not print continuously
4010 - There is an extra feed after printing is finished
4020 - Dots are missing from the printing
4020 - Cleaning does not cure blockage
4030 - Does not print at all or does not print a specific colour
4040 - The entire surface is printed black
4050 - Printing becomes shaded
4050 - The image contains blurs
4050 - Transverse lines appear to be split
4050 - Black and white lines appear in the printed image
4060 - Edges of printing are blurred
4070 - Many satellites (unwanted dots)
4070 - The printing has whiskers
4070 - Printed lines appear blurred
4080 - Mixed colour lines do not overlap
4080 - Black and colour positions are offset
4090 - Inaccurate line length in the direction of head movement (Main scanning direction)
4100 - 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
3 MAP4000
When Message is Not Displayed Trouble with Printing Model Name: Rockhopper 62 MAP4000-2


Replacement Part


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


DF-41599 Pump Motor Assembly


DF-41601 Head Cable
DF-41605 Ink Tube
DF-41607 T Fence
DF-41600 Y Cable
DF-40125 Wiper
Problem
Fault-
Tracing
Procedure
EXA No.
4000 - Does not print continuously
4020 - Dots are missing from the printing
4020 - Cleaning does not cure blockage
4030 - Does not print at all or does not print a specific colour
4040 - The entire surface is printed black
4050-2 - Printing becomes shaded
4050-2 - The image contains blurs
4050-2 - Transverse lines appear to be split
4050-2 - Black and white lines appear in the printed image
4060 - Edges of printing are blurred
4070 - Many satellites (unwanted dots)
4070 - The printing has whiskers
4070 - Printed lines appear blurred
4080 - Mixed colour lines do not overlap
4080 - Black and colour positions are offset
4090 - Inaccurate line length in the direction of head movement (Main scanning direction)
4100-2 - Inaccurate straight line in the direction of head movement (straightness)
1080-2
1080-2
1080-2
1080-2
1080-2
1360-2

1140
1370
1390
1290
1240
1260
1230
1250
1270
1390
1420
1350
1350
1350
1350
1350
1350
1200
1150
When Message is Not Displayed Trouble with Printing Model Name: Rockhopper 62 MAP4000-2
3 MAP4001

DF-41841 Speed Reduction Pulley Assembly

Replacement Part
DF-41616 Steel Flexible Cable Assembly

EXA4000 to EXA4130
(EXA4000 to EXA4100 → See MAP4000)


DF-40854 Cursor Plate Spring
Problem
Fault-
Tracing
Procedure
EXA No.
4110 - Inaccurate line distance in the direction of media feed (Subsidiary scanning distance)
4120 - Inaccurate straight line in the direction of media feed (joining precision Y)
4130 - Bad right angle precision

1140
1080
1080
1080
1080
1220
1310
1310
1690
1680

3 MAP4001
When Message is Not Displayed Trouble with Printing Model N. : Rockhopper-62 MAP4001-3

DF-41988 Speed Reduction Pulley Assembly

Replacement Part
DF-41616 Steel Flexible Cable Assembly

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


DF-40854 Cursor Plate Spring
Problem
Fault-
Tracing
Procedure
EXA No.
4110 - Inaccurate line distance in the direction of media feed (Subsidiary scanning distance)
4120 - Inaccurate straight line in the direction of media feed (joining precision Y)
4130-2 - Bad right angle precision 1080-2
1080-2
1080-2
1080-2
1080-2
1310-2
1310-2

1140
1220
1690
1680
When Message is Not Displayed Trouble with Printing Model N. : Rockhopper-62 MAP4001-3
When Message is Not Displayed Problem Involving Noise Model N.: Rockhpopper-46/62 MAP5000

DF-41598 Cursor Motor Assembly (Y Motor)

Replacement Part
[Problem Involving Noise]
DF-40144 Y Return Pulley Assembly

EXA5000 to EXA5040
DF-40137 X Speed Reduction Belt

DF-41677 Tube Guide Assembly



DF-41588 Head Board
DF-41600 Y Cable
Problem
Fault-
Tracing
Procedure
EXA No.
5000 - Abnormal noise when media is sucked down
5010 - Abnormal noise when standing by ready to print
5020 - Abnormal noise when head is moving left and right
5030 - Abnormal noise when media is fed
5040 - Abnormal noise when cutting

1140
1080
1150
1390
1420
1320
1280
1220
1090
1070
1360
1540
1690
When Message is Not Displayed Problem Involving Noise Model N.: Rockhopper-46/62 MAP5000
When Message is Not Displayed Problem Involving Noise Model N. : Rockhopper-62 MAP5000-3

DF-41598 Cursor Motor Assembly (Y Motor)

Replacement Part
[Problem Involving Noise]
DF-40144 Y Return Pulley Assembly

EXA5000 to EXA5040
DF-40137 X Speed Reduction Belt

DF-41677 Tube Guide Assembly



DF-41588 Head Board
DF-41600 Y Cable
Problem
Fault-
Tracing
Procedure
EXA No.
5000 - Abnormal noise when media is sucked down
5010 - Abnormal noise when standing by ready to print
5020 - Abnormal noise when head is moving left and right
5030 - Abnormal noise when media is fed
5040 - Abnormal noise when cutting
1080-2
1360-2
1540-2
1140
1150
1390
1420
1320
1280
1220
1090
1070
1690
When Message is Not Displayed Problem Involving Noise Model N. : Rockhopper-62 MAP5000-3
When Message is Not Displayed Trouble with Media Cutting Model N. :Rockhopper-46
3 MAP6000

Replacement Part
[Trouble with Media Cutting]
EXA6000 to EXA6050
DF-40113 Cutter Solenoid Assembly

DF-41600 Y Cable
Problem
Fault-
Tracing
Procedure
EXA No.
6000 - Does not cut normally
6010 - Cutting occurs during printing
6020 - The cutting operation is normal but the media is not cut
6020 - The cutting is bad and the media jams
6030 - The cutting operation is normal but the media does not fall out
6040 - Inaccurate media cutting
6050 - Cutting is delayed for some time after printing has ended
6050 - White paper is cut
1140
1380
1360
1420
When Message is Not Displayed Trouble with Media Cutting Model N. :Rockhopper-46
3 MAP6000
When Message is Not Displayed Trouble with Media Cutting Model Name: Rockhopper 62 MAP6000-2

Replacement Part
[Trouble with Media Cutting]
EXA6000 to EXA6050
DF-40113 Cutter Solenoid Assembly

DF-41600 Y Cable
Problem
Fault-
Tracing
Procedure
EXA No.
6000 - Does not cut normally
6010 - Cutting occurs during printing
6020 - The cutting operation is normal but the media is not cut
6020 - The cutting is bad and the media jams
6030 - The cutting operation is normal but the media does not fall out
6040 - Inaccurate media cutting
6050 - Cutting is delayed for some time after printing has ended
6050 - White paper is cut
1360-2

1140
1380
1420
When Message is Not Displayed Trouble with Media Cutting Model Name: Rockhopper 62 MAP6000-2
When Message is Not Displayed Online/Function Problems Model N.: Rockhopper-46
3 MAP7000

Replacement Part
[Online/Function Problems]
EXA7000 to EXA7060
DF-41586 Main Board Assemblym)

DF-41607 T Fence
DF-41600 Y Cable
Problem
Fault-
Tracing
Procedure
EXA No.
7000 - Cannot connect normally with RS-232C
7000 - Cannot connect normally with Centronics
7000 - Cannot connect normally with Network
7020 - The scale function does not work correctly
7020 - The rotate function does not work correctly
7020 - The mirror function does not work correctly
7020 - Other functions are not working correctly
7030 - Printing position is offset
7040 - Some data are not printed (omitted)
7050 - Text and printing data are garbled (extra lines appear)

1140
1360
1420
1290
When Message is Not Displayed Online/Function Problems Model N.: Rockhopper-46

3 MAP7000
When Message is Not Displayed Online/Function Problems Model Name: Rockhopper 62 MAP7000-2

Replacement Part
[Online/Function Problems]
EXA7000 to EXA7060
DF-41586 Main Board Assemblym)

DF-41607 T Fence
DF-41600 Y Cable
Problem
Fault-
Tracing
Procedure
EXA No.
7000 - Cannot connect normally with RS-232C
7000 - Cannot connect normally with Centronics
7000 - Cannot connect normally with Network
7020 - The scale function does not work correctly
7020 - The rotate function does not work correctly
7020 - The mirror function does not work correctly
7020 - Other functions are not working correctly
7030 - Printing position is offset
7040 - Some data are not printed (omitted)
7050 - Text and printing data are garbled (extra lines appear)
1360-2
1140
1420
1290
When Message is Not Displayed Online/Function Problems Model Name: Rockhopper 62 MAP7000-2
When Message is Not Displayed Other Model N.: Rockhopper-46
3 MAP8000
DF-41591 Waste Fluid Bottle Sensor Assembly

Replacement Part
DF-42007 F Absorbent Material Assembly

[Other]
DF-40127 Cartridge Frame Assembly

EXA8000 to EXA8050


Problem
Fault-
Tracing
Procedure
EXA No.
8000 - The printer hangs up
8010 - Power shutdown during printing
8020 - The ink cartridges will not go in
8030 - Ink has overflowed from the waste fluid bottle
8040 - Ink overflows from flushing box
8050 - Ink is split around the X-rail

1140
1330
1350
1350
1350
1350
1350
1350
1150
1120
1700
When Message is Not Displayed Other Model N.: Rockhopper-46

3 MAP8000
When Message is Not Displayed Other Model Name: Rockhopper 62 MAP8000-2
DF-41591 Waste Fluid Bottle Sensor Assembly

Replacement Part
DF-42007 F Absorbent Material Assembly

[Other]
DF-42008 Waste Fluid Bottle Assembly

DF-40127 Cartridge Frame Assembly



Problem
Fault-
Tracing
Procedure
EXA No.
8000 - The printer hangs up
8010 - Power shutdown during printing
8020 - The ink cartridges will not go in
8050 - Ink overflows from flushing box
8050 - Ink is split around the X-rail

1140
1330
1350
1350
1350
1350
1350
1350
1150
1120
1700
1710
When Message is Not Displayed Other Model Name: Rockhopper 62 MAP8000-2

When Message is Not Displayed Heater
r System Model N:Rockhopper46 3 MAP9000

Replacement Part
[Heater system]
EXA9000
Front Heater Sensor

Rear Heater Sensor
Problem
Front Heater
Rear Heater
Fault-
Tracing
Procedure
EXA No.
9000 - Heater does not stop warming up or is broken

1040
1040
1040
1040

r System Model N:Rockhopper46 3 MAP9000
r System Model N:Rockhopper62 3 MAP9000-2

Replacement Part
[Heater system]
EXA9000
Front Heater Sensor

Rear Heater Sensor
Problem
Front Heater
Rear Heater
Fault-
Tracing
Procedure
EXA No.
9000 - Heater does not stop warming up or is broken
1040 -2
1040 -2
1040 -2
1040 -2

r System Model N:Rockhopper62 3 MAP9000-2
Rockhopper-46
3 Fault-Tracing Procedure Model Name: Rockhopper-46 EXA0000
Fault-Tracing Procedure
Printer Status Messages EXA1000

Data Errors EXA1200
Command Errors EXA1250
CPU System Faults EXA1500
Mechanical System Faults EXA1700
Heaters System Faults EXA1800
Trouble with Initialization EXA2000

Trouble with Media Feed EXA3000
Trouble with Printing EXA4000
Problem Involving Noise EXA5000
Trouble with Media Cutting EXA6000
Online/Function Problems EXA7000
Other EXA8000
Heater System EXA9000
Rockhopper-46
3 Fault-Tracing Procedure Model Name: Rockhopper-46 EXA0000
Rockhopper-62 Fault-Tracing Procedure Model Name: Rockhopper-62 EXA0000-3
Fault-Tracing Procedure

(Difference between Rockhopper-46 and 62)
Printer Status Messages EXA1000 ( 1020-2 )
Data Errors EXA1200
Command Errors EXA1250
CPU System Faults EXA1500
Mechanical System Faults EXA1700
Heaters System Faults EXA1800-2
Trouble with Initialization EXA2000 ( 2070-2 )

Trouble with Media Feed EXA3000 ( 3000-2 )
Trouble with Printing EXA4000 ( 4050-2, 4100-2, 4130-2 )
Problem Involving Noise EXA5000
Trouble with Media Cutting EXA6000
Online/Function Problems EXA7000
Other EXA8000
Heater System EXA9000-2
Rockhopper-62 Fault-Tracing Procedure Model Name: Rockhopper-62 EXA0000-3

When Message is Displayed Printer Status Messages Model Name: Rockhopper-46/62 EXA1000
GO TO Ref. Pages
1 • Cover Open 1-1 • Is the cover sensor arm loose? (Related to opening and closing the front cover)
This message means that the Front → Tighten the cover sensor arm screw. 1110
Cover is open 1-2 • 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. 1110
2 • Lever Up → Adjust the relative positions of the cover shaft R and front cover fulcrum.
This message means that the
Pressure Lever is up. 1-3 • 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
3 • Cover and Lever 1-4 • Does the pressure lever move smoothly? (Related to raising and lowering the pressure lever)
This message means that the Front → Adjust the position of the pressure relay plate.
Cover and Pressure Lever are up. → 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) 1100
→ 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
1-7 • 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
1-8 • The panel board assembly may be damaged. (Related to opening and closing the front cover)
1-9 • The panel cable may be damaged. (Related to opening and closing the front cover)
1-10 • Is the cover limit switch working on "Sensor: Cover" in the printer self-diagnostics? 1040
→ Replace the cover switch assembly 1110
1-11 • Is the lever sensor working on "Sensor: Lever" in the printer self-diagnostics? 1040
→ Replace the lever sensor assembly. 1100
1-12 • The main board assembly may be damaged. (Related to both)

GO TO Ref. Pages
1 • Undefined Media 1-1 • Is the edge sensor assembly cable that is attached to the head unit securely connected?
This message means that when → Connect it securely to connector J204 (P EDGE) on the head board assembly. 1410
media was mounted, it was not able
to be recognized. 1-2 • 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
1040
1-3 • Use the printer's self-diagnostic “Sensor: Edge” to confirm the amount of sensor reflec-
tion. Using thick coated paper, check whether the paper detection value is within 0090 to
00a4.
→ Replace edge sensor assembly. 1410
→ Adjust with the head board assembly variable resistor (VR1).
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.

1-6 • Check with the self-diagnostic “Sensor: X Rear” whether the sensor is operating. 1040
→ Replace paper sensor R if “Paper End” is displayed when media is mounted. 1200

1-8 • The Y cable assembly may be damaged

Printer Status Messages Model Name: Rockhopper 46/62 EXA1020
GO TO Ref. Pages
1 • Media Skew Error 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”? 1060
→ Check the connectors between fan assembly, fan extension cable assembly and main board 1080
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?) 1220
→ Replace the pressure rollers or the pressure assembly.
1-6 • Is there a uniform gap between head and platen? 1520

→ 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. 1690
2-1 • After carrying out the adjustments according to the procedure above, run the self-diagnostic “Skew 2030
Verification”.
CAUTION:
[ Rated Value ] Condition Rated Value
Since this task will establish the
reference position for determin- Cut media Within 1.5 mm
ing skew, it should be adjusted
carefully.
7m Within 2.5 mm
Roll media
50m Within 10 mm
Printer Status Messages Model Name: Rockhopper 46/62 EXA1020

GO TO Ref. Pages
1 • [User 1] Media End 1-1 • Is the edge sensor assembly cable that is attached to the head unit securely connected?
This message is displayed when no → Connect it securely to connector J204 (P EDGE) on the head board assembly. 1410
media is mounted or printing in cut
media mode has been completed. 1-2 • 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
1-3 • Use the printer's self-diagnostic “Sensor: Edge” to confirm the amount of sensor reflec-
tion.
Using thick coated paper, check whether the paper detection value is within 0090 to 1040
00a4.
→ Replace edge sensor assembly. 1410

1-5 • Check with the printer's self-diagnostic "Sensor: X Rear" whether the sensor is operating. 1040
→ Replace paper sensor R if “Paper End” is displayed when media is mounted. 1200

1-7 • The Y cable assembly may be damaged.

GO TO Ref. Pages
1 • Remove Media 1-1 • Switch off the printer temporarily and check that the message is displayed when you
This message is displayed if, after switch on again.
raising the lever during printing and
cutting the media, the lever is lowered 1-2 • Use the printer's self-diagnostic "Sensor: Lever" to make sure that the pressure lever is 1040
without the media having been working normally.
removed. → Check that the liquid crystal display unit does not show that the up and down move-
ment of the pressure lever appears to be chattering when the lever is moved slowly 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. 1100
Replace the lever sensor assembly.
1-4 • 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
1-5 • 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

GO TO Ref. Pages
1 • Roll Media End 1-1 • Switch off the printer temporarily and check that the message is displayed when you
This message is displayed when roll switch on again.
media is being used and the trailing
edge of the media is detected. It will 1-2 • Use the printer's self-diagnostic "Sensor: X Rear" to make sure that the media end detec- 1040
be cancelled by raising the lever. tion 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. 1200
Replace the paper sensor R assembly.

GO TO Ref. Pages
1 • Media Cut Error 1-1 • Is there an accumulation of paper dust in the cutter groove?
This message is displayed when the → Remove accumulated paper dust along the paper groove.
media is not cut and does not fall out
1-2 • Check how the cutter cap is fitted. Refer to the
despite the cutting operation having → Fit the cutter cap securely. Operation
been performed. Manual
1-3 • Check the up and down movement of the cutter. With the cutter installed, push it down to the bot- (Basic
tom with your finger and check that the power of the spring alone brings it back to the top. Manual)
→ 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 Refer to the
spring. Operation
→ If it does not fall, the cutter may be faulty. Replace the cutter. Manual
(Basic
1-5 • Use the printer's self-diagnostic “Aging: Cutter” to confirm the up-and-down movement of the sole- Manual)
noid.
Moves up/down → Check the down position of the cutter blade relative to the
cutter groove.
[OK] → Cutter blade is damaged or worn out. Replace with a new blade.
[NG] → Refer to REP 1380 position adjustment and adjust the position of the cutter
holder.
No up/down movement → Connection may be faulty. Check the following connectors.
• Head board assembly connector J206 (SOL)
• Head board assembly connector J201 (MAIN1)
• Main board assembly connector J206 (HEAD1)
CAUTION: Power must be off when connectors are being disconnected or

reconnected, otherwise you may be injured or a board may be
damaged. The main board assembly will certainly be damaged if
power is applied with main board assembly connectors J111
(HEAD) and J112 (HEAD2) and head board connectors J201
(MAIN1) and J202 (MAIN2) inserted with oblique FFP.
→ Continued on next page
GO TO Ref. Pages
1 • Media Cut Error 1-6 • There may be a broken Y cable lead, faulty solenoid assembly or a faulty board assembly.
This message is displayed when the
a. Try fitting a new Y cable. (Check for continuity between connectors)
media is not cut and does not fall out
→ If there is up/down movement, replace Y cable.
despite the cutting operation having
been performed. 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.
When Message is Displayed Printer Status Messages Model Name: Rockhoppper-46/62 EXA1070
GO TO Ref. Pages
1 • Not enough memory SIMM✼✼MB 1-1 • Check RAM capacity with the printer's self-diagnostic “Examination: RAM Capacity”. 1010
(Intermediate code buffer overflow) → The capacity without optional extended memory is 8 MB. If SIMM has been extended,
When this printer has insufficient the value “Standard memory 8 MB + Extended memory” will be displayed.
memory for the amount of data sent (If two 36 MB SIMMs have been installed, “80 MB” is displayed.)
by the personal computer, this mes- (With Iris 46 WIDE, since a 16 MB SIMM has been added in Slot 1, the display is nor-
sage indicates the required memory mally "24 MB")
size.
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 capac-
ity shown on the panel or the memory capacity shown in the setup list, the SIMM may be 1140
damaged. Replace the SIMM.
1-3 • The main board assembly may be damaged. 1140

→ Replace it.
GO TO Ref. Pages
1 • Insert Special Cartridge 1-1 • Switch off the printer temporarily and check that the message is displayed when you switch on
This message is displayed when a again.
cartridge other than a genuine Mutoh
cartridge has been installed. 1-2 • Check whether you are using the specified ink cartridge. 1040
1-3 • Use the printer’s 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 1340
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 • Using the printer’s 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. 1340
→ 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. 1470
(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. 1470
→ Replace the main board assembly. 1140
GO TO Ref. Pages
1 • [65YMCK] Ink Low 1-1 • Check the no ink cartridge with the printer's self-diagnostic "Sensor: No Ink".
This message is displayed when the → Remove all cartridges and gently switch the detector assemblies (BK, C, M and Y)
amount of ink shown on the operating (black plastic levers) on and off to confirm that the displays “Sensor: No Ink K (black)”, 1040
panel is low. “Sensor: No Ink C (cyan)”, “Sensor: No Ink M (magenta)” and “Sensor: No Ink Y (yel-
Printing can continue. low)” change.
(Refer to GID2010 for details)
1-2 • Check the detector assembly connector contacts.
2 • [65YMCK] No Ink → Reconnect junction board assembly connector J402 (Detector Assembly BK), J403
This message is displayed when the (Detector Assembly C), J404 (Detector Assembly M), J410 (Detector1 Assembly [O/5]),
ink shown on the operating panel has J411 (Detector2 Assembly [G/6]). 1350
been used up. If there is no change, move to the next step.
If this message appears while an
image is being printed, stop printing 1-3 • Exchange the position of the connector of the ink detector assembly for the ink for which
immediately. “Ink Low” or “No Ink” is indicated with the position of any one of J402 to J405, J410 and
(Refer to GID2010 for details) 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. 1350
→ 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.

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 assem-
bly or the main board assembly may be faulty.
GO TO Ref. Pages
1 • [65YMCK] No Cartridge 1-1 • Switch off the printer temporarily and check that the message is displayed when you
This message indicates that the ink switch on again.
cartridge that is shown on the operat-
ing panel is missing. 1-2 • Check the no ink cartridge with the printer's self-diagnostic "Sensor: No Ink". 1330 1040
→ 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.)
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
5 O No. 5
6 G 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
GO TO Ref. Pages
1 • [65YMCK] No Cartridge 1-4 • Exchange the position of the connector of the cartridge detector assembly for the car-
This message indicates that the ink tridge for which “No Cartridge” is indicated with the position of any one of J402 to J405,
cartridge that is shown on the operat- J410 and J411 on the junction board assembly that appears to be normal.
ing panel is missing. → 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. 1350
→ 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.
Reference: Take care when you are replacing the detector assembly that senses
whether there is a cartridge present. It can become damaged by over-
tightening the attaching screw.

→ Reconnect junction board assembly connector J401 (INK ID Cable) and main board
assembly connector J109 (INK ID).

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.
GO TO Ref. Pages
1 • Capping position not specified 1-1 • Adjust the capping position by running the printer's self-diagnostic "Adjust: Capping posi- 2010
The capping position was not dis- tion".
played at the time of initialization. → 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.
1-2 • Check whether the parameters are set to the initial values by running the printer's self- 2150
diagnostic "Adjust: Test print" to output the parameters that have been set.
Refer to the functions and operations manual for the initial values of parameters.
→ If the parameters have been restored to their initial values, please contact the "Inquiry
desk" and quote your printer serial number to obtain a setup list for the time your print-
er was shipped from the factory.
Enter all parameters in accordance with the setup list. (See PAT4000)

→ Replace it.
GO TO Ref. Pages
1 • Not Filled 1-1 • With the specified cartridge inserted securely, use the printer's self-diagnostic mode 1040
This message means "Initial filling has "Sensor: No Ink" or "Sensor: No Cartridge" to check whether the presence of ink and car-
not been done". tridge are being detected normally.
→ For checking, use the [65YMCK] “No Ink” procedure shown in EXA1090. 2040
→ After adjustment and replacement, carry out initial filling with the printer’s self-diagnos-
tic “Adjust: Enter Rank”.
1-2 1040
• With the specified cartridge inserted securely, use the printer's self-diagnostic mode
"Sensor: Cartridge" to check whether the status of the special cartridge is operating nor-
mally. 2040
→ For checking, use the “Insert Special Cartridge” procedure shown in EXA1080.
→ After adjustment and replacement, carry out initial filling with the printer’s self-diagnos-
tic “Adjust: Enter Rank”.
CAUTION: Wait at least 30 minutes after initial filling before printing. Printing
quality can not be assured unless ink filling has been stabilized.
GO TO Ref. Pages
1 • No Waste Fluid Box 1-1 • Switch off the printer temporarily and check that the message is displayed when you
This message means that the waste switch on again.
fluid bottle is not installed.
1-2 • Use the printer's self-diagnostic "Sensor: Tank Exist/Tank is not" to make sure that the 1040
waste fluid bottle detection is working normally.
→ Slowly remove and replace the waste fluid bottle to confirm that the present/absent dis-
play appears.
If the display is not normal, the sensor position may be faulty.
Adjust the position of the waste fluid bottle detection switch assembly.
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.
1120
→ Replace it.
1140
GO TO Ref. Pages
1 • Check Waste Fluid Box 1-1 • Switch off the printer temporarily and check that the message is displayed when you
switch on again.
1-2 • Use the printer's self-diagnostic "Sensor: Tank Exist/Tank is not" to make sure that the 1040
waste fluid bottle detection is working normally.
→ Slowly remove and replace the waste fluid bottle to confirm that the present/absent dis-
play appears.
If the display is not normal, the sensor mounting position may be at fault.
Adjust the mounting position of the waste fluid bottle detection
switch assembly. 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.
1120
→ Replace it.
1140
GO TO Ref. Pages
1 • Ink Type Error 1-1 • Use the printer's self-diagnostic "Sensor: Cartridge" to check the ink type.
This message is displayed when the → Install all cartridges and check that all six colours have the same type of ink. 1040
wrong type of ink cartridge has been
installed. Sensor: K C M Y O G
Depending on the ink type, the following symbols will be displayed at locations _.
D : Dye type ink cartridge installed

P : Pigment or Eco-solvent type ink cartridge installed
W : Wash fluid cartridge installed
N : 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).

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

(b) If there is no change at all in the symptoms, it means that the junction board assem-
bly or the main board assembly may be faulty.
When Message is Displayed Data Errors Model Name: Rockhopper-46/62 EXA1230
GO TO Ref. Pages
1 • Network Detection Error 1-1 • The main board assembly may be damaged. 1140
The optional network board can not → Replace it.
be detected
1-2 • The Ethernet board assembly may be damaged.
2 • Network Initialization Error → Replace it.
An error has occurred during the
optional network board initialization
operation Go to MAP1200
When Message is Displayed Data Errors Model Name: Rockhopper-46/62 EXA1230

When Message is Displayed Command Errors Model Name: Rockhopper-46/62 EXA1250
GO TO Ref. Pages
1 • MH01 Error (Undefined Command) 1-1 • Try communicating with the available computer and cable.
A command that is not defined in any → Contact your Mutoh distributor.
command mode has been analysed
1-2 • Is there any record of an error in the printing data?
2 • MH02 Error (Parameter Error) → Try changing the type of application driver.
Wrong number of parameters follow-
ing the command 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).
3 • MH03 Error (Numerical Error)
Wrong number of parameters follow- 1-4 • The main board assembly may be damaged.
ing the command → Replace it. 1140
4 • MH04 Error (Undefined Character

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

The polygon buffer or the download-
able character buffer has overflowed
When Message is Displayed Command Errors Model Name: Rockhopper-46/62 EXA1250

When Message is Displayed CPU System Faults Model Name: Rockhopper-46/62 EXA1500
GO TO Ref. Pages
1 • E001 Error DRAM (Standard DRAM 1-1 • The main board assembly may be damaged. 1140
error) → Replace it.
This error display means that a fault

has occurred in the standard memory
of the Main Board that controls the
printer.
2 • E002 Error Opt. DRAM (Optional 2-1 • This error may occur when there is dust, etc. in extended memory slot 1 or slot 2.
DRAM error) → Use an air duster to remove the dust and reinstall.
This error display means that a fault 2-2 • Install reliable memory of the same capacity and check with the self-diagnostic 1010
has occurred in the optional memory “Examination: Memory Capacity”.
of the Main Board that controls the → Replace optional memory.
printer.
→ Replace it.
CAUTION: If only one extended memory is added, it must be installed in Slot 1.

(Rockhopper-46 has an extra 16 MB SIMM in Slot 1)
(Rockhopper-62 has an extra 32 MB SIMM in Slot 1)
GO TO Ref. Pages
1 • E016 CPU Err [00] (Interrupt exception 1-1 • Check AC power supply and printer peripheral devices.
error) → Contact your Mutoh distributor.
Indicates that handling an interrupt has
generated an error.
1-2 • Check whether the problem recurs. Even if there is no problem, switch on several times.
2 • E016 CPU Err [02] (Command boundary (Use the same conditions as the customer's)
exception error)
Indicates that the boundary of a command → Contact your Mutoh distributor.
has caused an error.
1-3 • Check the serial number.
3 • E016 CPU Err [03] (Data boundary excep-
tion error) → Contact your Mutoh distributor.
Indicates that the boundary of a command
has caused an error. 1-4 • The main board assembly may be damaged. 1140
4 • E016 CPU Err [04] (Address error excep- → Replace it.
tion) (Load or command check)
Indicates that an address error has
occurred when checking a load or com-
mand.
5
• E016 CPU Err [05] (Address error excep-
tion) (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.
7 • E016 CPU Err [07] (Bus error exception)

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

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

error)
Indicates that a break point has caused an
error.
GO TO Ref. Pages
1 • E016 CPU Err [10] (Reserved command 1-1 • Check AC power supply and printer peripheral devices.
exception error) → Contact your Mutoh distributor.
Indicates that a reserved command has
caused an error.
1-2 • Check whether the problem recurs. Even if there is no problem, switch on several times.
2 • E016 CPU Err [11] (Unable to use (Use the same conditions as the customer's)
coprocessor exception error) → Contact your Mutoh distributor.
Indicates that the coprocessor has caused
an error.
1-3 • Check the serial number.
3 • E016 CPU Err [12] (Operation overflow → Contact your Mutoh distributor.
exception error)
Indicates that an overflow has occurred. 1-4 • The main board assembly may be damaged. 1140
→ Replace it.
4 • E016 CPU Err [13] (Trap exception error)
Indicates that a trap has occurred.
5 • E016 CPU Err [15] (Floating point excep-

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

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

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

Indicates that an abort has occurred.
9 • 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.
GO TO Ref. Pages
1 • E129 Error NVRAM 1-1 • The main board assembly may be damaged. 1140
This message indicates that a fault → Replace it.
has occurred in the NVRAM on the
Main board that records printer set-
tings.
When Message is Displayed Mechanical System Faults Model Name: Rockhopper-46/62 EXA1700
GO TO Ref. Pages
1 • E065 Error X Motor 1-1 • Use the self-diagnostic “Examination: History” to check the history of faults. 1070
This message indicates that a fault
has occurred in the media feed motor 1-2 • Use the self-diagnostic “Aging: Media Feed Motor” with a setting of 50 times to check 6020
(X axis) while the printer was working. whether the X Motor error occurs.
This occurs when there is a large dif- → Check connectors J119 (X MOT) and J121 (X ENC) on the main board.
ference between the motor command
value and encoder feedback value. 1-3 • Use the self-diagnostic “Examination: Encoder” to check Encoder X. 1050
→ If it is no good, check the J121 (X ENC) cable connector.
2 • E069 Error X Encoder
This message indicates that a fault 1-4 • Check “Power Supply Voltage Check 24 DC”
has occurred in the amount of media
movement (X axis) while the printer 1-5 • The X Motor assembly may be damaged.
was working. → Replace it. 1070
This occurs when there is no encoder
feedback. 1-6 • The main board assembly may be damaged.
3 • E071 Error X Timeout
This message indicates that a timeout
has occurred in the amount of media CAUTION: If the Power supply board assembly and Main board assembly are
movement (X axis) while the printer replaced without checking “24 V DC” on those, there is a risk that
was working. the new boards may also be damaged.
This occurs when the pressure does
not reach its designated position.
4 • E073 Error X Overcurrent

has occurred due to an overload of
the media feed (X-axis) motor while
the printer was working.
GO TO Ref. Pages
1 • E066 Error Y Motor 1-1 • Use the self-diagnostic “Examination: History” to check the history of faults. 1070
has occurred in the head movement 1-2 • With power off, move the carriage to left and right. Is the movement restricted? 6010
motor (Y axis) while the printer was → Clean and lubricate the Y rail rollers.
working.
This occurs when there is a large dif- 1-3 • Use the self-diagnostic “Aging: Carriage Motor” with a setting of 50 times to check
ference between the motor command whether the Y Motor error occurs.
value and encoder feedback value. → Check cable connector J120 (Y MOT) on the main board.
2 • E070 Error Y Encoder 1-4 • Check whether the timing fence (T fence) is dirty or twisted.
This message indicates that a fault → If there is grease or dirt on the fence, wipe it away with a dry cloth.
has occurred in the amount of head → If there is ink on the fence, wet a cloth with neutral cleaner and wipe lightly.
movement (Y axis) while the printer → If the T fence is severely soiled and can not be cleaned, it should be replaced
was working. → Replace the T fence. 1300
This occurs when there is no encoder
feedback. 1-5 • 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
3 • E072 Error Y Timeout and J202 (MAIN2) on the head board assembly.
This message indicates that a timeout → Replace the T fence. 1300
has occurred in the amount of head → Replace the Y motor assembly. 1280
movement (Y axis) while the printer → Replace the head board assembly. 1420
was working. → Replace the Y cable (between J112 (HEAD2) on the main board and J202 (MAIN2) on 1360
This occurs when the carriage has not the head board)
reached its designated position.
4 • E074 Error Y Overcurrent → Replace it. 1140
has occurred due to an overload of CAUTION: Power must be off when connectors are being disconnected or
the head movement (Y axis) motor reconnected, otherwise you may be injured or a board may be
while the printer was working. 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.
GO TO Ref. Pages
1 • E075 Error Sensor Fault 1-1 • Use the self-diagnostic “Sensor: Origin” and carry out the origin sensor test. 1040
This message indicates that condition
has occurred in which the origin can- 1-2 • Check the origin sensor assembly connection.
not be detected. 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 assem-
bly.
→ Insert them properly. 1360
→ Replace the Y cable between J111 (HEAD1) and J201 (MAIN1).
1-4 • The origin sensor assembly may be faulty.



damaged.
When Message is Displayed (on LCD heater) Heater System Faults Model Name: Rockhopper-46 EXA1800
GO TO Ref. Pages
1 • Err : F.R.T. Sensor • Is Front Right Temperature Sensor not connected / broken?
→ Reconnect sensor / replace the Front Paper Guide 1040
• Err : F.L.T. Sensor • Is Front Left Temperature Sensor not connected / broken?
→ Reconnect sensor / replace the Front Paper Guide 1040
• Err : R.R.T. Sensor • Is Rear Right Temperature Sensor not connected / broken?
→ Reconnect sensor / replace the Rear Paper Guide 1040
• Err : R.L.T. Sensor • Is Rear Left Temperature Sensor not connected / broken?
→ Reconnect sensor / replace the Rear Paper Guide 1040
• Err : FRFLT Sensor • Are 2 Front Temperature Sensors not connected / broken? 1040
→ Reconnect sensors / replace the Front Paper Guide
• Err : FRRLT Sensor • Are

I Front Right and Rear Left Temperature Sensor not connected / broken?
1040
→ Reconnect sensors / replace the Front/Rear Paper Guide
• 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?
→ Reconnect sensors / replace the Front/Rear Paper Guide 1040
• Err : FLRRT Sensor • Are Front Left and Rear Right Temperature Sensor not connected / broken?
→ Reconnect sensors / replace the Front/Rear Paper Guide 1040
• Err : RRRLT Sensor • Are two Rear Temperature Sensor not connected / broken? 1040
→ Reconnect sensors / replace the Rear Paper Guide
• I
When Message is Displayed Heater System Faults Model Name: Rockhopper-46 EXA1800
When Message is Displayed (on LCD Heater) Heater System Faults Model Name: Rockhopper-46 EXA1800
GO TO Ref. Pages
1 • Err : 2FRLT Sensor • Are two Front and Rear LeftTemperature Sensors not connected / broken?
→ Reconnect sensors / replace the Front Paper Guide 1040
• Err : 2FRRT Sensor • Are two Front and Rear Right Temperature Sensors not connected / broken?
→ Reconnect sensors / replace the Front Paper Guide 1040
• Err : FR2RT Sensor • Are two Rear and Front Right Temperature Sensors not connected / broken?
→ Reconnect sensors / replace the Rear Paper Guide 1040
• Err : FL2RT Sensor • Are two Rear and Front Left Temperature Sensors not connected / broken?
→ Reconnect sensors / replace the Rear Paper Guide 1040
• Err : All T Sensor • Are all Temperature Sensors not connected / broken? 1040
• Err : Heaters Stop • After

I the heater start for 10 minutes andREAL temperature could not reach.
1040
→ Replace the Front/Rear Paper Guide
•
→
•
→
•
→
•
→
• I
When Message is Displayed Heater System Faults Model Name: Rockhopper-46 EXA1800
When Message is Displayed (on LCD heater) Heater System Faults Model Name: Rockhopper-62 EXA1800-2
GO TO Ref. Pages
1 • Err : F.R.T. Sensor • Is Front Right Temperature Sensor not connected / broken?
→ Reconnect sensor / replace the Front Paper Guide 1040 -2
• Err : F.L.T. Sensor • Is Front Left Temperature Sensor not connected / broken?
→ Reconnect sensor / replace the Front Paper Guide 1040 -2
• Err : R.R.T. Sensor • Is Rear Right Temperature Sensor not connected / broken?
→ Reconnect sensor / replace the Rear Paper Guide 1040 -2
• Err : R.L.T. Sensor • Is Rear Left Temperature Sensor not connected / broken?
→ Reconnect sensor / replace the Rear Paper Guide 1040 -2
• Err : FRFLT Sensor • Are 2 Front Temperature Sensors not connected / broken? 1040 -2
• 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?
→ Reconnect sensors / replace the Front/Rear Paper Guide 1040 -2
• Err : FLRRT Sensor • Are Front Left and Rear Right Temperature Sensor not connected / broken?
→ Reconnect sensors / replace the Front/Rear Paper Guide 1040 -2
• Err : RRRLT Sensor • Are two Rear Temperature Sensor not connected / broken? 1040 -2
→ Reconnect sensors / replace the Rear Paper Guide
• I
When Message is Displayed Heater System Faults Model Name: Rockhopper-62 EXA1800-2
When Message is Displayed (on LCD Heater) Heater System Faults Model Name: Rockhopper-62 EXA1800-2
GO TO Ref. Pages
1 • Err : 2FRLT Sensor • Are two Front and Rear LeftTemperature Sensors not connected / broken?
→ Reconnect sensors / replace the Front Paper Guide 1040 -2
• Err : 2FRRT Sensor • Are two Front and Rear Right Temperature Sensors not connected / broken?
→ Reconnect sensors / replace the Front Paper Guide 1040 -2
• Err : FR2RT Sensor • Are two Rear and Front Right Temperature Sensors not connected / broken?
→ Reconnect sensors / replace the Rear Paper Guide 1040 -2
• Err : FL2RT Sensor • Are two Rear and Front Left Temperature Sensors not connected / broken?
→ Reconnect sensors / replace the Rear Paper Guide 1040 -2
• Err : All T Sensor • Are all Temperature Sensors not connected / broken? 1040 -2
• Err : Heaters Stop • After

I the heater start for 10 minutes andREAL temperature could not reach.
1040 -2
→ Replace the Front/Rear Paper Guide
•
→
•
→
•
→
•
→
• I
When Message is Displayed Heater System Faults Model Name: Rockhopper-62 EXA1800-2
GO TO Ref. Pages
1 • No power 1-1 • 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. 1130
1-2 • The inlet assembly may be faulty.

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

2 • Faulty liquid crystal display (no 2-1 • Check the power supply check 120V AC or 240V AC.
display/unstable display) (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.

2-6 • Is there a fault in the panel board assembly liquid crystal display?
→ Replace the panel board assembly. 1160

oblique FFP.
GO TO Ref. Pages
1 • Initial filling of inks failed 1-1 • With the printer cover closed, is the liquid crystal display showing cover open?
❈ This symptom means that when new → Adjust cover switch height.
→ Check cover switch assembly connector.
cartridges are first installed, or when a
J106 (COVER) on the panel board assembly
new cartridge is fitted as a result of a → Replace cover switch assembly. 1110
"no ink" message, the initial filling
operation is not performed. 1-2 • Check panel cable connectors.
→ Reconnect main board assembly connector J110 (PANEL) and panel board assembly connector
J301 (MAIN).
2 • Initial filling begins but the ink does
→ Replace them. 1170
not reach the head or it reaches the
head but is not ejected. 1-3 • With the hold lever down, is the liquid crystal display showing lever up?
Go to EXA2020 → Adjust the lever sensor. 1100
1-4 • Check J104 (LEVER) cable connection on the main board.

→ Re-insert it.
→ Replace the lever sensor assembly.
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 detect-
ed normally. 1040
→ Check using EXA1100 “[65YMCK] No Cartridge” procedure.
→ After adjustment or replacement, implement initial filling with the printer's self-diagnostic "Adjust:
Head Rank". 2040
1-6 • 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. 1040
Head Rank". 2040

→ Replace it.
→ After replacement, start self-diagnostic mode and carry out initial filling from “Head Rank” menu. 1140 2040
CAUTION: Wait at least 30 minutes before printing after initial filling. Printing quality
can not be assured unless the ink filling is stabilized.
GO TO Ref. Pages
1 • Initial filling is completed but no ink 1-1 • Is the cap assembly spring fallen out or broken?
comes out → If it has fallen out, refit it.
→ If it is broken, replace the cap assembly. 1240
(Initial filling means to fill the head 1-2 • Is the capping position correct?
with ink to enable it to print.) → 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
→ If ink flows, carry out initial filling. 2040
1-6 • Are the ink tubes damaged inside the pump assembly?
→ Replace the pump assembly and check that ink flows during the cleaning action. 1260
→ If ink flows, carry out initial filling. 2040
1-7 • 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 1230
assembly. 1140
1-8 • Was there any mismatching of gears during the cleaning operation?
→ Replace the maintenance station assembly. 1270
1-9 • Was the transfer gear shaft damaged during cleaning?

GO TO Ref. Pages
1 • Initial filling is completed but no ink 1-10 • Are there any breaks, cuts or air leaks in the ink tubes?
comes out → Change each ink tube, cleaning each time and checking that ink flows during cleaning. 1370
1-11 • Check that connectors J207 (HEAD C1) and J208 (HEAD C2) on the head board assembly, and
(Initial filling means to fill the head head cables on the print head are not inserted obliquely, and they are locked securely.
with ink to enable it to print.) → Insert the connectors again.
1-12 • Is there a broken lead in head cables?

→ Replace head cables. 1400
1-13 • Is the print head assembly damaged?

→ Replace the print head assembly.
1390
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. 1420
→ 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.

1140
oblique FFP.
GO TO Ref. Pages
1 • After power is switched on, nothing 1-1 • With the printer cover closed, is the liquid crystal display showing cover open?
works Does the cover switch assembly function work normally with the self-diagnostic 1040
“Examination/Sensors”?
→ Adjust cover switch assembly height.
If nothing is displayed on the panel → Check cover switch assembly connector and J106 (COVER) on the panel board assembly.
liquid crystal display unit. → Replace cover switch assembly.
Go to EXA2000 1110
1-2 • Check panel cable connectors.
Check that they are not inserted obliquely and they are securely locked.
2 • When power is applied, “Initializing”
→ Reconnect the main board assembly connector J110 (PANEL) and the panel board assembly
appears and then a reset is executed. J301 (MAIN).
3 • Media is mounted but the initialization
operation is not done 1-3 • 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. 1110
→ Replace the lever sensor assembly.
4 • Printer does not work even with the
cover closed 1-4 • Check J104 (LEVER) cable connection on the main board assembly.
→ Re-insert it.
5 • Printer does not stop even with the → Replace the lever sensor assembly.
1100
cover opened.
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. 1190
→ Replace the XR cable assembly (rear paper sensor). 1200
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) 1150
→ Reconnect it.
1-8 • The switch cable board assembly may be faulty.

→ Replace it.
1130
GO TO Ref. Pages
1 • After power is switched on, nothing 1-9 • Is the DC cable assembly connected properly to J001 on the power board assembly and
works J101 (MAIN POWER) on the main board assembly? (See EXA2000)
→ Reconnect it.
If nothing is displayed on the panel → Replace it. 1130
liquid crystal display unit.
Go to EXA2000 1-10 • The main board assembly may be damaged.
2 • When power is applied, “Initializing”
appears and then a reset is executed.
3 • Media is mounted but the initialization

operation is not done
4 • Printer does not work even with the

cover closed
5 • Printer does not stop even with the

cover opened.
When No Error is Displayed on the Printer's Liquid Crystal Display Trouble with Initialization Model Name: Rockhoppper-46/62 EXA2040
GO TO Ref. Pages
1 • Ink cartridges are installed but not 1-1 • With the specified cartridge inserted securely, use the printer's self-diagnostic mode 1350 1040
recognized "Sensor: No Ink" or "Sensor: No Cartridge" to check whether the presence of ink and car-
tridge are being detected normally.
→ Check using EXA1100 “[65YMCK] No Ink” procedure.
→ After adjustment or replacement, implement initial filling with the printer's self-diagnos-
tic "Adjust: Head Rank". 2040
1-2 • With the specified cartridge inserted securely, use the printer's self-diagnostic mode
"Sensor: Cartridge" to check whether the status of the special cartridge is operating nor- 1040
mally.
→ Check using EXA1080 "Insert special cartridge" procedure.
→ After adjustment or replacement, implement initial filling with the printer's self-diagnos-
tic "Adjust: Head Rank". 2040
CAUTION: Wait at least 30 minutes after initial filling before printing. Printing
quality can not be assured unless ink filling has been stabilized.
GO TO Ref. Pages
1 • Can not make entries from the operat- 1-1 • Is the panel cover key input unit broken?
ing panel → 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. 1160

→ Replace the panel board assembly.

→ Replace the main board assembly.
GO TO Ref. Pages
1 • Data is received but not printed 1-1 • For checking, use “Cannot connect normally with Centronics or Ethernet Board” proce-
dures shown in EXA7000.
GO TO Ref. Pages
1 • Media is not suction 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 accord- 1040
ing to the self-diagnostic sensor test?
→ Check the connections of XR cable assembly and edge sensor.
XR cable assembly is the main board assembly J107 (XR). 1190
Edge sensor is the head board assembly J204 (P EDGE). 1200
→ Replace XR cable assembly and edge sensor.
1-3 • Are the fans working normally according to the self-diagnostic test? 1060
→ 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 assembly. 1080
→ 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".

When No Error is Displayed on the Printer's Liquid Crystal Display Trouble with Initialization Model Name: Rockhopper-46/62 EXA2070-2
GO TO Ref. Pages
1 • Media is not suction 1-1 • Are the media suction fans turning?
→ If they are not turning, go to consultation 1-4.
board assembly.

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".

When No Error is Displayed on the Printer's Liquid Crystal Display Trouble with Initialization Model Name: Rockhopper-46/62 EXA2070-2
When No Error is Displayed on the Printer's Liquid Crystal Display Trouble with Media Feed Model Name: Rockhopper-46/62 EXA3000
GO TO Ref. Pages
1 • The media comes off when it is initial- 1-1 • Are XR cable assembly (rear paper sensor) and edge sensor detecting normally according to the 1040
ized or during printing self-diagnostic sensor test?
2 • The media is skewed or meanders Edge sensor is the head board assembly J204 (P EDGE). 1410
when it is initialized or during printing → Replace XR cable assembly and edge sensor.
3 • The media becomes wrinkled when it → Check the connectors between fan assembly, fan extension cable assembly and main board
is initialized or during printing assembly.
4 • The media jams when it is initialized Fan extension cable 2 assembly is J116 (FAN2) on the main board
or during printing → Replace fan assembly. 1080
5 • The media tears when it is initialized
or during printing Shield GA-A, Shield GA-B, Shield GA-C
1-4 • When the pressure lever is raised and lowered, does the pressure unit move up and down smooth-
ly at the same time?
→ Apply grease (G-501) if it does not move smoothly. 1220
1-5 • 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. 1220
→ If the gap between platen and plate is less than 0.2 mm, adjust platen height. 1520
1-6 • Is there major distortion, damage or foreign matter on the front and rear paper guides?
→ Replace front and rear paper guides. 1040
1040-2
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. 1690
When No Error is Displayed on the Printer's Liquid Crystal Display Trouble with Media Feed Model Name: Rockhopper-46/62 EXA3000-2
GO TO Ref. Pages
1 • The media comes off when it is initial- 1-1 • Are XR cable assembly (rear paper sensor) and edge sensor detecting normally according to the 1040
ized or during printing self-diagnostic sensor test?
2 • The media is skewed or meanders Edge sensor is the head board assembly J204 (P EDGE). 1410
when it is initialized or during printing → Replace XR cable assembly and edge sensor.
3 • The media becomes wrinkled when it → Check the connectors between fan assembly, fan extension cable assembly and main board
is initialized or during printing assembly.
4 • The media jams when it is initialized Fan extension cable 2 assembly is J116 (FAN2) on the main board
or during printing Fan extension cable 4 assembly is J117 (FAN4) on the main board
5 • The media tears when it is initialized → Replace fan extension cable 1 ~ 4.
or during printing 1-3 • Is shielding material fixed securely in the specified places?
1-4 • When the pressure lever is raised and lowered, does the pressure unit move up and down smooth-
ly at the same time?
→ Apply grease (G-501) if it does not move smoothly. 1220
→ If necessary, replace pressure assembly, pressure rollers and blade. 1220
→ Replace front and rear paper guides. 1040
1040-2
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.
When No Error is Displayed on the Printer's Liquid Crystal Display Trouble with Media Feed Model Name: Rockhopper-46/62 EXA3000-2
GO TO Ref. Pages
1 • The media size is different after 1-1 • Is the media mounted recommended by Mutoh?
media mounting and initialization 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.
2 • Tracing paper and thin media cannot → Mount recommended media and try again.
be detected
→ Check the connections of XR cable assembly and edge sensor. 1200
XR cable assembly is the main board assembly J107 (XR).
1-3 1040
• Use the printer's self-diagnostic “Sensor: Edge” to confirm the amount of sensor reflec-
tion. Using thick coated paper, check whether the paper detection value is within 0090 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
→ Replace edge sensor assembly.
1-4
• 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
damaged.
When No Error is Displayed on the Printer's Liquid Crystal Display Trouble with Printing Model Name: Rockhopper-46/62 EXA4000
GO TO Ref. Pages
1 • Does not print continuously 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.

GO TO Ref. Pages
1 • There is an extra feed after printing is 1-1 • Is XR cable assembly (rear paper sensor) detecting normally according to the self-diag- 1040
finished nostic sensor test?
→ Check the connections of XR cable assembly and main board assembly J107 (XR). 1200
→ Replace XR cable assembly. 1200
1-2 • Is there a problem with the printer driver software?



GO TO Ref. Pages
1 • Dots are missing from the printing 1-1 • Clean twice in succession. 2050
or
Bad example
1-2 • Are the ink tubes filled with ink? PAT1000
→ Carry out initial filling.
CAUTION: Wait at least 30 minutes after initial filling before printing. Printing quality can
not be assured unless ink filling has been stabilized.
1-3 • 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?
Good example
→ Check the connection of pump motor assembly connector and J102 (PUMP) on the main board
assembly.
→ Replace the pump motor assembly. 1230
→ If the pump motor still does not turn, replace the main board assembly. 1140
1-5 • Are the gears and transfer gear shaft broken or badly meshed during the cleaning operation?
1-6 • Is the cap assembly spring fallen out or broken?

→ If it has fallen out, refit it. 1240
→ If it is broken, replace the cap assembly of the maintenance station assembly. 1270
2 • Cleaning does not cure clogging or
deflection 1-7 • Is the capping position correct?
→ Adjust the capping position, carry out strong cleaning and try again.
Clogging: There is a discontinuity in line G of
the “Test Print”. 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 1250
the cleaning wiper. After the wiper has been cleaned, carry out two successive cleanings.
→ If it is wet with ink, replace it.
1-9 • Are the nozzle surfaces being wiped and rubbed?

Deflection: There is a deflection or offset in → Check how the wiper is fitted and fasten it correctly. 1250
the step pattern in line G of
the “Test Print”. 1-10 • Does the head that is fitted have a rank that is different from the recorded rank? 2040
→ Re-enter the rank of the head correctly. 1390
GO TO Ref. Pages
1 • Dots are missing from the printing 1-11 • Has ink dried on the surface of the print head and inside the nozzles?
→ Use the self-diagnostic “Adjustment: Head Cleaning” to clean the print head, carry out initial fill- 1620
Bad example
ing with “Adjustment: Head Rank” and try again.
→ Clean the head nozzle face. 1660
1-12 • Check that the T-fence and Encoder behind the head board assembly are not touching.
→ If they are touching, adjust them. 1420
→ If adjustment is not effective, replace both the head board assembly and the T-fence. 1300
Good example
1-13 • 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

→ Replace the obstructed print head assembly.
1390
→ Replace it.
1140
2 • 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”.
GO TO Ref. Pages
No SINTOMA Items to be Confirmed
1 • No imprime nada 1-1 • Check 24, 42 V DC Power Supply Check.
1-2 • Is the cap assembly spring fallen out or broken?

2 • Does not print a specific colour
→ If it has fallen out, refit it. 1240
Bad example → If it is broken, replace the cap assembly.
1-3 • Is the capping position correct?

→ Adjust the capping position and use the cleaning operation to check ink flow.
→ If ink flow is confirmed, carry out initial filling.
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). 1360
→ Replace both Y cables.
1-5
• Is there any looseness in the head unit, the flexible cable keeper unit under the head board assem-
bly, the ink tubes behind the cartridge unit, or the SUS pipe connectors (Bk, Y, M, C, Lm and Lc)?
Check that the O-rings are fitted properly.
Good example → 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.
1-6 • 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
1-7 • Are the ink tubes damaged inside the pump assembly?
→ Replace the pump assembly and check that ink flows during the cleaning action. 1260
1-8 • Is there an air leak in the ink tubes?

→ Replace each ink tube, cleaning each time to check for ink flow. 1370
GO TO Ref. Pages
1 • NO IMPRIME NADA 1-9 • With the specified cartridge inserted securely, use the printer's self-diagnostic mode "Sensor: No 1040
Ink" or "Sensor: No Cartridge" to check whether the presence of ink and cartridge are being detect-
ed normally.
2 • Does not print a specific colour
Bad example → After adjustment or replacement, implement initial filling with the printer's self-diagnostic "Adjust:
Head Rank". 2040
1-10 • 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
1-11 • Is the head board assembly damaged?

1-12 • Is the main board assembly damaged?


→ Replace the print head assembly. 1390
Good example
→ Check the pump motor cable connector J102 on the main board.
→ Replace the pump motor.
→ If the pump motor does not turn after performing the above tasks, replace the main board 1230
assembly.
1-15 • Was there any gear damage or mismatching of gears during the cleaning operation? 1260
→ Replace the pump assembly.
1-16 • Was the transfer gear shaft damaged during cleaning? 1270
→ Replace the maintenance station assembly.
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.
GO TO Ref. Pages
1 • The entire surface is printed black 1-1 • Check the connections for head cables 1 and 2.
Bad example 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. 1390
1-2 • 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
• The head board assembly may be damaged.
1-3 → Replace it.
1420
Good example • The head head assembly may be damaged.
1-4 → Replace the print head assembly.
1390
• The main board assembly may be damaged.
→ Replace it.
1-5
1140
CAUTION: Power must be off when connectors are being disconnected or recon-
nected, 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.
When No Error is Displayed on the Printer's Liquid Crystal Display Trouble with Printing Model Name: Rockhopper-46 EXA4050
GO TO Ref. Pages
1 • Printing becomes shaded. 1-1 • Is the usage site environment in accordance with the operating environment?
→ Use the printer in a proper operating environment.
2 • The image contains blurs. 1-2 • Was the printing done immediately after initial filling?
→ Wait at least 30 minutes after initial filling before printing. Printing quality can not be assured
3 • Transverse lines appear to be split. unless ink filling has been stabilized.
Shading and Split line
blurring
Direction of
media feed
1-4 • Are the fans working normally according to the self-diagnostic “Examination: Fan”?
→ Check the connectors between fan assembly, fan extension cable assembly and main board
assembly. 1060
→ Replace fan assembly.
4 • Black and white lines appear in the → Replace Fan extension cables 1 ~ 3. 1080
printed image 1080
(Not including gaps in the step pat- Shield material GA-A, shield material GA-B, shield material GA-C
terns in locations 1G to 7G of the test → Re-attach in the proper positions.
pattern)
If dots are missing, go to EXA4020 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.
Bad example
1-7 • Is the X speed reduction belt tension adjusted to the prescribed value? 1560
41.2 N (4.2 kg ± 0.2 Kg).
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
Direction of
media feed
the cleaning wiper. After the wiper has been cleaned, carry out two successive cleanings. 1250
→ If it is wet with ink, replace it.
Good example
→ Carry out repairs. 1250
→ Replace the wiper.
→ Continued on next page (EXA4051)
When No Error is Displayed on the Printer's Liquid Crystal Display Trouble with Printing Model Name: Rockhopper 62 EXA4050-2
GO TO Ref. Pages
1 • Printing becomes shaded. 1-1 • Is the usage site environment in accordance with the operating environment?
2 • The image contains blurs. 1-2 • Was the printing done immediately after initial filling?
3 • Transverse lines appear to be split. unless ink filling has been stabilized.
Shading and Split line
blurring
Direction of
media feed
1-4 • Are the fans working normally according to the self-diagnostic “Examination: Fan”?
→ Check the connectors between fan assembly, fan extension cable assembly and main board
assembly.
Fan extension cable 1 assembly is J115 (FAN1) on the main board 1060
4 • Black and white lines appear in the → Replace fan assembly. 1080
printed image → Replace Fan extension cables 1 ~ 4. 1080
(Not including gaps in the step pat- 1-5 • Is the shielding material securely attached in the proper positions?
terns in locations 1G to 7G of the test Shield material GA-A, shield material GA-B, shield material GA-C
pattern) → Re-attach in the proper positions.
If dots are missing, go to EXA4020
1-6 • If the media in question is roll media, does the scroller rotate smoothly?
Bad example → Replace any roller that is damaged or that moves badly.
1-7 • Is the X speed reduction belt tension adjusted to the prescribed value? 1560
41.2 N (4.2 kg ± 0.2 Kg).

Direction of
media feed
the cleaning wiper. After the wiper has been cleaned, carry out two successive cleanings. 1250
Good example → If it is wet with ink, replace it.

→ Carry out repairs. 1250
→ Replace the wiper.
GO TO Ref. Pages
1 • Printing becomes shaded. 1-10 • Is the T-fence dirty?

→ Clean it.
→ If the T fence is severely soiled and can not be cleaned, replace it. 1300
2 • The image contains blurs.
3 • Transverse lines appear to be split. • With the pressure lever up, does the pressure rollers seem reluctant to turn?
Shading and Split line • With the pressure lever down, does the pressure rollers idle or contact the platen on one side?
blurring • With the pressure lever down, is the blade pressing firmly on the media?
→ If necessary, replace pressure assembly, pressure rollers and blade.
Direction of
media feed
1520
→ Check the pump motor assembly connector J102 (PUMP) on the main board assembly and try
again. 1230
→ Replace the pump motor assembly.
4 • Black and white lines appear in the → If the pump motor does not turn after performing the above tasks, replace the main board
printed image assembly.
(Not including gaps in the step pat- 1-13 • Was there any mismatching of gears during the cleaning operation?
terns in locations 1G to 7G of the test → Replace the maintenance station assembly.
pattern) 1270
If dots are missing, go to EXA4020 1-14 • Is the cap assembly spring fallen out or broken?
→ If the part has fallen out, refit it.
→ Replace the cap assembly or the maintenance station assembly. 1240
Bad example 1270
1-15 • 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.
Direction of

media feed
1-16 • Does the head that is fitted have a rank that is different from the recorded rank?
Good example → Re-insert print head rank correctly. 2040
1-17 • The print head assembly may be damaged.

→ Replace the obstructed print head assembly.
1390
GO TO Ref. Pages
1 • Printing becomes shaded. 1-18 • Has ink dried on the surface of the print head and inside the nozzles?
→ Use the self-diagnostic “Adjustment: Head Cleaning” to clean the print head, carry out initial fill-
2 • The image contains blurs.
→ Clean the head nozzle face.
3 • Transverse lines appear to be split. 1-19 • With the specified cartridge inserted securely, use the printer's self-diagnostic mode "Sensor: No 1040
Shading and Split line Ink" or "Sensor: No Cartridge" to check whether the presence of ink and cartridge are being detect-
blurring ed normally.
Direction of
2040
media feed
Head Rank".
4 • Black and white lines appear in the 1-20 • The main board assembly may be damaged.
printed image → Replace it. 1140
(Not including gaps in the step pat- 1-21 • The head board assembly may be damaged.
terns in locations 1G to 7G of the test → Replace it. 1420
pattern)
If dots are missing, go to EXA4020
Bad example
Direction of
media feed
Good example
GO TO Ref. Pages
1 • Edges of printing are blurred 1-1 • Does cleaning restore normal operation?
Bad example → 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 • Does the head that is fitted have a rank that is different from the recorded rank? 2040
→ Re-enter the rank of the print head correctly. 1390
1-4 • 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. 1300

Good example → Replace it. 1140
GO TO Ref. Pages
1 • Many satellites (unwanted dots) 1-1 • Is the usage site environment in accordance with the operating environment?
2 • The printing has whiskers
1-2 • Is there sufficient ink remaining?
→ Replace with a new cartridge.
3 • Printed lines appear blurred (printing
is dirty) 1-3 • Do three cleanings in succession. 2050
or
1-4 • Have the Test Print printed. (Refer to PAT1000) PAT1000
[ Bad example ] → If the nozzle check pattern is printed normally, return to EXA4020.
1. Satellites 1-5 • Is the printing less than 30 minutes after initial filling?
unless ink filling has been stabilized.
1-6 • Is the steel belt tension adjusted properly? 1550

0.98 N (100 g ±20 g)
2. Whiskers 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. 1300
1-8 • Is there a loose set screw on the Y drive pulley?

→ Re-tighten the set screw.
3. Blurring 1-9 • Is the capping position correct?

→ Adjust the capping position and try again after strong cleaning.

the cleaning wiper. After the wiper has been cleaned, carry out two successive cleanings.
→ If it is wet with ink, replace it. 1250
[ Good example ]
GO TO Ref. Pages
1 • Many satellites (unwanted dots) 1-11 • Is it able to wipe/rub the nozzle face normally?
→ Check how the wiper is fitted and fasten it correctly. 1250
2 • The printing has whiskers
1-12 • Does the head that is fitted have a rank that is different from the recorded rank? 2040
→ Re-enter the rank of the print head correctly. 1390
3 • Printed lines appear blurred (printing
is dirty) 1-13 • Are the ink tubes damaged inside the pump assembly?
→ Replace the pump assembly and check that ink flows during the cleaning action. If ink flows, 1260 2040
carry out initial filling.
[ Bad example ]
1. Satellites → Check the pump motor assembly connector J102 (PUMP) on the main board assembly and try
again.
→ If the pump motor does not turn after performing the above tasks, replace the main board
assembly.
1-15 • During the cleaning operation, was there any mismatching or damage to the gears or transfer gear
2. Whiskers shaft?
1-16 • Has the cap assembly spring fallen out or been broken?
→ If a part has fallen out, refit it. 1240
→ Replace the cap assembly or maintenance station assembly. 1270
1-17 • Has ink dried on the surface of the print head and inside the nozzles?
3. Blurring → Use the self-diagnostic “Adjustment: Head Cleaning” to clean the print head, carry out initial fill- 1620 2040
→ Clean the head nozzle face. 1660
[ Good example ]
→ Replace the obstructed print head assembly. 1390

GO TO Ref. Pages
1 • Mixed colour lines do not overlap 1-1 • Is the steel belt tension adjusted properly?
Bad example 0.98 N (100 g ± 20 g)
→ Readjust steel belt tension. 1550
1-2 • Is the Y drive pulley set screw loose?

→ Re-tighten the set screw securely. 1310
1-3 • Is there any mistake in the rank of the head that is actually installed and the rank that is 2040
recorded?
Good example → Re-enter the rank of the print head correctly. 1390
1-4 • Is the problem with the head tilt adjustment?

→ Adjust it. 2060
1-5 • Is there a problem with the reciprocal printing position alignment?

→ Adjust it. 2080
2 • Black and colour positions are offset 1-6 • Is there a problem with the CW adjustment?
Bad example → Adjust it. 2090
1-7 • Make sure the encoder and fence mounted on the back of the head board assembly are
not touching.
→ If they are touching, adjust them.
→ If adjustment does not solve the problem, replace the T fence. 1300
Good example
GO TO Ref. Pages
1 • Inaccurate line length in the direction 1-1 • Is the usage site environment in accordance with the operating environment?
of head movement (Main scanning → Use the printer in a proper operating environment.
direction)
1-2 • Is the steel belt tension adjusted properly?
0.98 N (100 g ± 20 g)
→ Re-adjust steel belt tension. 1550
1-3 • 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
1-5 • The internal processing operation of the main board may be faulty. 5010
→ Initialize, re-enter or re-adjust the parameters and try again. 2000
Direction of media feed
GO TO Ref. Pages
1 • Inaccurate straight line in the direction 1-1 • Are the fans working normally according to the self-diagnostic “Examination: Fan”? 1060
of head movement (straightness) → Check the connectors between fan assembly, fan extension cable assembly and main board
assembly.
→ Replace fan extension cables 1 to 3. 1080
1-2 • Are the front paper guide and platen securely screwed?
→ Tighten it.

Shield material GA-A, shield material GA-B, shield material GA-C
1-4 • Is the X drive pulley set screw loose?

→ Replace the X motor assembly. 1070
1-5 • Is the X speed reduction belt tension adjusted to the prescribed value?
41.2 N (4.2 kg ±0.2 kg)
Direction of media feed → Readjust the X speed reduction belt tension. 1560
→ If the gap between platen and blade is less than 0.2 mm, adjust platen height. 1220
1520
GO TO Ref. Pages
1 • Inaccurate straight line in the direction 1-1 • Are the fans working normally according to the self-diagnostic “Examination: Fan”? 1060
of head movement (straightness) → Check the connectors between fan assembly, fan extension cable assembly and main board
assembly.
1-2 • Are the front paper guide and platen securely screwed?
→ Tighten it.

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

1-5 • Is the X speed reduction belt tension adjusted to the prescribed value?
Direction of media feed 41.2 N (4.2 kg ±0.2 kg)
→ Readjust the X speed reduction belt tension. 1560
1520
GO TO Ref. Pages
1 • Inaccurate line distance in the direc- 1-1 • Is the usage site environment in accordance with the operating environment?
tion of media feed → Use the printer in a proper operating environment.
(Subsidiary scanning distance)
1-2 • Are you using adjusting the distance with the media that is being used?
→ Carry out distance adjustment. 2120
→ Even if the distance adjustment is being done with the media that is in use, do it for the sake of
confirmation.
1-3 • Is the X drive pulley loose?

1-4 • 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
1-5 • Is there major distortion in the X speed reduction pulley?

→ Replace the X speed reduction pulley. 1680
Direction of media feed → If necessary, replace pressure assembly, pressure rollers and blade.
1520
[Standard value] 1-7 • Is the rough surface of the grid roller worn in some places?
500 mm ±0.1% • Is the grid roller heavy to turn? Or does it not turn smoothly?
Since the adjustment here is 300 mm, → Use a nylon brush to clean away any paper dust or paper scraps from the grid roller.
the measured value, x is such that → Adjust platen height or refit the rear paper guide. 1040-2
299.7 mm ≤ x ≥ 300.3 mm → Replace grid roller. 1520, 1040
1690
→ Replace front and rear paper guides.
1040
1-9 • If roll media is being used, does the scroller rotate smoothly? 1040-2
→ Replace the scroller shaft.
→ Change the media that is being used.
GO TO Ref. Pages
1 • Inaccurate straight line in the direction 1-1 • Is there any mistake in the rank of the head that is actually installed and the rank that is
of media feed (joining precision Y) recorded?
→ Enter the rank of the print head correctly. 1390 2040
1-2 • Is the problem with the head tilt adjustment?

→ Adjust it. 1390 2060
1-3 • Is the steel belt tension adjusted to the specified value?

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

1-5 • Is there a problem with the reciprocal printing position alignment?

→ Adjust it. 2080
1-6 • Is there a problem with the CW adjustment?

→ Adjust it. 2090
1-7 • Is the T fence dirty?
→ Clean it.
→ Replace if soiling is not removed by washing or if there is damage. 1300
1-8 • 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
1-9 • Is there play in the cursor?

→ Replace the CR flat spring or the cursor assembly. 1310
GO TO Ref. Pages
1 • Bad right angle precision 1-1 • Are the fans working normally according to the self-diagnostic “Examination: Fan”? 1060
board assembly.

• With the pressure lever down, does the pressure rollers idle or contact the platen on one
side?
Direction of media feed → If there are paper dust or scraps near the pressure roller, wipe with soft damp cloth.
1520
1-4 • Is the rough surface of the grid roller worn in some places?
• Is the grid roller heavy to turn? Or does it not turn smoothly?
→ Use a nylon brush to clean away any paper dust or paper scraps from the grid roller.
→ Adjust platen height or refit the rear paper guide.
→ Replace grid roller. 1520, 1040
1690
GO TO Ref. Pages
1 • Bad right angle precision 1-1 • Are the fans working normally according to the self-diagnostic “Examination: Fan”? 1060
board assembly.

• With the pressure lever down, does the pressure rollers idle or contact the platen on one
side?
Direction of media feed • With the pressure lever down, is the blade pressing firmly on the media?
1520
→ 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.
1520
1040-2(-2)
When No Error is Displayed on the Printer's Liquid Crystal Display Problem Involving Noise Model Name: Rockhopper-46/62 EXA5000
GO TO Ref. Pages
1 • Abnormal noise when media is 1-1 • Is the shielding material securely attached in the proper positions?
sucked down Shield material GA-A, shield material GA-B, shield material GA-C
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.

1-5 • The main board assembly may be faulty.

1-6 • The power board assembly may be faulty.

GO TO Ref. Pages
1 • Abnormal noise when standing by 1-1 • Is there something touching or some foreign matter at the place producing the abnormal
ready to print noise?
→ Remove the obstruction or foreign matter.
1-2 • It a board producing the noise?

→ Replace the board assembly in question.
• Power board assembly 1150
• Main board assembly 1140
• Head board assembly 1420
• Print head assembly 1390
GO TO Ref. Pages
1 • Abnormal noise when head is moving 1-1 • The abnormal noise could be squirting noise when printing.
left and right → 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 1540
the tube guide assembly.
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? 1280
→ Replace the Y Motor assembly.
1-7 • Is the noise coming from the Y return pulley bearing? 1320
→ Replace it.
1-8 • Is the steel belt tension adjusted properly?

0.98 N (100 g ± 20 g) 1550
→ Re-adjust steel belt tension.
1-9 • Is the Y drive pulley screw loose? 1280

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

→ Replace it.
GO TO Ref. Pages
1 • Abnormal noise when media is fed 1-1 • 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, 1220
when the printer is not printing.
1-2 • Is the X speed reduction belt out of tooth with the X speed reduction pulley?
→ Replace the X speed reduction belt. 1090
1-3 • Is the noise coming from the X motor?

→ Use a nylon brush to clean away any paper dust or paper scraps from the grid roller. 1040-2
→ Adjust platen height or refit the rear paper guide. 1520, 1040
→ Replace grid roller. 1690
GO TO Ref. Pages
1 • Abnormal noise when cutting 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.

1-7 • The Y cable may be damaged.

1-8 • The power assembly board may be faulty.

When No Error is Displayed on the Printer's Liquid Crystal Display Trouble with Media Cutting Model Name: Rockhopper-46/62 EXA6000
GO TO Ref. Pages
1 • Does not cut normally 1-1 • Is the tip of the cutter blade chipped or worn?
→ Replace the cutter.
(Since there is no cutting of cut sheet
1-2 • Is the cutter cap set securely on the top of the cutter?
media, this item applies only to roll → Refit it.
media)
→ Remove foreign matter.
→ Remove paper dust from the cutter groove.
→ Adjust it.
1-6 • Use self-diagnostic "Aging:Cutter" to confirm up and down movement. 6030

→ Check the connections on cutter solenoid assembly connector and head board assembly con-
nector J206 (SOL).
→ If there is no up and down movement, the solenoid may be damaged.
Replace the cutter solenoid assembly. 1380
1-7 • Check the Y cable connectors

→ Re-insert the main board assembly connector J111 (HEAD1) and the head board assembly con-
nector J201 (MAIN1).


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.
GO TO Ref. Pages
1 • Cutting occurs during printing 1-1 • Is there a problem with the printer driver software?
media, this item applies only to roll 1-2 • Is there a problem with the program ROM?
media) → Upgrade the version.
1-3 • Check the Y cable connectors.

→ Insert the main board assembly connector J111 (HEAD1) and the head board assem-
1-4 bly J201 (MAIN1).
→ Replace them.
• The head board assembly may be damaged.


1-6
Cut 1140
Direction of media feed nected, otherwise you may be injured or a board may be damaged.
GO TO Ref. Pages
1 • The cutting operation is normal but 1-1 • Is the cutter blade chipped or deteriorated as checked in the primary consultation?
the media is not cut → Replace the cutter.
2 • The cutting is bad and the media jams 1-2 • Is the cutter blade chipped or deteriorated as checked in the primary consultation?
media, this item applies only to roll 1-3 • Has the cutter cap been fixed securely on the top of the cutter as a result of checking in
media) the primary consultation?
→ 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.
GO TO Ref. Pages
1 • The cutting operation is normal but 1-1 • Are paper guide surfaces being cleaned daily?
the media does not fall out → Clean the surfaces.
(Since there is no cutting of cut sheet 1-2 • There may be a static charge on the front paper guide or media.
media, this item applies only to roll → Make a proper earth connection.
media) → Check the humidity of the usage environment and bring it within usage environment
specifications.
GO TO Ref. Pages
1 • Inaccurate media cutting 1-1 • Is the cutter blade chipped or deteriorated as checked in the primary consultation?
1-2 • Has the cutter cap been fixed securely on the top of the cutter as a result of checking in
the primary consultation?
→ Refit it.

X
→ Adjust it.
1-6 • The cutter itself may be no good.

→ Replace it.
The media cutting precision of this

machine is x ≤ 0.3 mm
GO TO Ref. Pages
1 • Cutting is delayed for some time after 1-1 • Are internal sample prints output without trouble? PAT1000
printing has ended → Refer to EXA4030 "Does not print at all"
2 • White paper is cut 1-2 • Is there a problem with the printer driver software?


When No Error is Displayed on the Printer's Liquid Crystal Display Online/Function Problems Model Name: Rockhopper-46/62 EXA7000
GO TO Ref. Pages
1 • Cannot connect normally with 1-1 • Try communicating with the available computer and cable.
Centronics → Contact your Mutoh distributor.
2 • Cannot connect normally with 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
Network
communication.
Advise the use of a cable that conforms to specifications.


1-5 • For network connections, make sure of the type of cable that is to be used for the connection envi-
ronment.
For direct connection of one host and one printer → Use a cross cable (100/10Base-T)
For connection of several hosts and one printer through a hub → Use a straight cable (100/10Base-
T)
❈ To check connections to the network board, use the board accessory setup utilities or 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
• The main board assembly may be damaged. 1140
→ Replace it.
GO TO Ref. Pages
1 • The scale function does not work cor- 1-1 • Is there a problem with the printer driver software?
rectly → Upgrade the printer driver version.
2 • The mirror function does not work cor- 1-2 • Is there a problem with the program ROM?
rectly → Upgrade the version.
3 • Other functions are not working cor- 1-3 • The main board assembly may be damaged.
rectly → Replace it. 1140
GO TO Ref. Pages
1 • Printing position is offset 1-1 • Is there a problem with the CW adjustment? 2090
→ Adjust it.
1-2 • Is the front-sensor-to-head distance or the cutter-to-head distance causing a problem for 2130
top and bottom margin distance adjustments?
→ Adjust them.



→ Replace it.
1140
GO TO Ref. Pages
1 • Some data are not printed (omitted) 1-1 • Is there a problem with the printer driver software?

1-3 • Check whether the timing fence is dirty or twisted. 1300

→ 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 T fence. 1300
→ Replace the Y motor assembly. 1280
→ Replace the head board assembly. 1420
→ Replace the Y cable (between J112 (HEAD2) on the main board assembly and J202
(MAIN2) on the head board assembly). 1360

GO TO Ref. Pages
1 • Text and printing data are garbled 1-1 • Is there a problem with the printer driver software?
(extra lines appear) → Upgrade the printer driver version.

1-3 • Check whether the timing fence is dirty or twisted. 1300

→ 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 T fence. 1300
→ Replace the Y motor assembly. 1280
→ Replace the head board assembly. 1420
→ Replace the Y cable (between J112 (HEAD2) on the main board assembly and J202
(MAIN2) on the head board assembly). 1360

GO TO Ref. Pages
1 • There is an extra feed after printing is 1-1 • Are the printing position and location method settings suitable?
finished → Set them to suitable values.



→ Replace it.
1140
When No Error is Displayed on the Printer's Liquid Crystal Display Others Model Name: Rockhopper-46/62 EXA8000
GO TO Ref. Pages
1 • The printer hangs up 1-1 • 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

GO TO Ref. Pages
1 • Power shutdown during printing 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

GO TO Ref. Pages
1 • The ink cartridges will not go in 1-1 • Is the cartridge holder assembly needle deformed or broken?
→ Replace the cartridge frame assembly. 1330
1-2 • Is the ink present/absent sensor (a black plastic lever switch) on the detector assembly
damaged?
When No Error is Displayed on the Printer's Liquid Crystal Display Others Model Name: Rockhopper 46/62 EXA8050
GO TO Ref. Pages
1 • Ink has overflowed from the waste fluid bottle 1-1 • 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. 1350 1040
1-3 • 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 mounting position may be at fault.
Adjust the mounting position of the waste fluid bottle detection switch assembly. 1040
1-4 • Check the waste fluid bottle detection switch contact.

J109 (INK TANK) on the main board
→ Insert it correctly.
1-5 • Is the waste fluid tube from the flushing bottle kinked?
→ Fix it and attach it again.
2 • Ink overflows from flushing box 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?

3 • Ink is spilt around the X rail 3-1 • 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. 1270
→ Replace the pump assembly. 1260
→ Replace the cap assembly. 1240
3-2 • The ink tube may be cut.

→ Replace the ink tube. 1370
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 • Ink has overflowed from the waste fluid bottle 4-1 • Is the waste liquid bottle full of ink?
→ Replace it.
1710
When No Error is Displayed on the Printer's Liquid Crystal Display Others Model Name: Rockhopper 46/62 EXA8050
When Message is not Displayed Heater System Model Name: Rockhopper-46 EXA9000
GO TO Ref. Pages
1 • Heater does not stop warming up. 1-1 • Is Sensor Rear Heater broken?
→ Replace the Rear Paper Guide 1040
• Heater does not work.
1-2 • Is Sensor Front Heater broken?
→ Replace the Front Paper Guide 1040
1-3 • Is cable damaged/broken of Rear or Front Heater?

→ Replace Rear or Front Paper Guide 1040
1-4 • Is Front Heater broken?

→ Replace the Front Paper Guide 1040
1-5 • Is Rear Heater broken? 1040

→ Replace the Rear Paper Guide
• I
When Message is not Displayed Heater System Model Name: Rockhopper-46 EXA9000
When Message is not Displayed Heater System Model Name: Rockhopper-62 EXA9000-2
GO TO Ref. Pages
1 • Heater does not stop warming up. 1-1 • Is Sensor Rear Heater broken?
→ Replace the Rear Paper Guide 1040-2
• Heater does not work.
1-2 • Is Sensor Front Heater broken?
→ Replace the Front Paper Guide 1040-2
1-3 • Is cable damaged/broken of Rear or Front Heater?

→ Replace Rear or Front Paper Guide 1040-2
1-4 • Is Front Heater broken?

→ Replace the Front Paper Guide 1040-2
1-5 • Is Rear Heater broken? 1040-2

1040
→ Replace the Rear Paper Guide
• I
When Message is not Displayed Heater System Model Name: Rockhopper-62 EXA9000-2
Rockhopper-46
3 Replacement and Adjustment Procedures Model Name: Rockhopper-46 REP0000
Procesos de Ajuste y Recambio
Rockhopper-46
Rockhopper-62 Replacement and Adjustment Procedures Model Name: Rockhopper-62 REP0000-3
Procedimiento de Ajustes y Recambio

Rockhopper-46
Replacement and Adjustment Procedure
Right and Left Covers REP 1010 Cursor Plate Spring and Steel Flexible Guide Assembly REP 1310
Panel Cover and Y Rail Cover REP 1030 Cartridge Frame Assembly REP 1330
Front Paper Guide and Rear Paper Guide REP 1040 Ink ID Sensor Assembly REP 1340
Right Side Cap and Left Side Cap REP 1041 Detector Assembly REP 1350
Control Box REP 1050 Y Cable REP 1360
Head Cover REP 1060 Ink Tubes REP 1370
Fan Assembly and Fan Cable REP 1080 Print Head Assembly and Head Cable REP 1390
Lever Sensor Assembly REP 1100 Y Paper Sensor Assembly REP 1410
Switch Cable Assembly and DC Cable Assembly REP 1130 Cursor Assembly REP 1440
Main Board Assembly REP 1140 Origin Sensor and Y Encoder REP 1450
Power Supply Board Assembly REP 1150 Junction Board Assembly REP 1470
Panel Board Assembly and HeateryPanel Board Assembly REP 1160ly
Panel Cable REP 1170 Platen Height Adjustment REP 1520
Extension Board Assembly REP 1180 Tube Guide Assembly REP 1540
How to Adjust Steel Belt Tension REP 1550
XR Cable Assembly (Rear Paper Sensor) REP 1200 How to Adjust X Speed Reduction Belt Tension REP 1560
Pressure Assembly, Pressure Roller and Blade REP 1220 How to Adjust Print Head REP 1570
Pump Motor Assembly REP 1230
Cap Assembly REP 1240 How to Capture and Install Backup Parameters REP 1590
Wiper REP 1250 How to Install a Program (Software Upgrade) REP 1600
Pump Assembly REP 1260
Maintenance Station Assembly REP 1270 Head Cleaning Procedure REP 1620
Y Motor Assembly REP 1280 How to Clean the Head Nozzle Face REP 1660
Steel Belt REP 1290 X Speed Reduction Pulley Assembly REP 1680
T Fence Assembly REP 1300 Grid Roller Assembly REP 1690
F Absorbent Material Assembly REP 1700
Front / Rear Heater (or sensors) (refer to)REP 1040
Rockhopper-46
Replacement and Adjustment Procedure
Right and Left Covers REP 1010 Cursor Plate Spring and Steel Flexible Guide Assembly REP 1310-2
Panel Cover and Y Rail Cover REP 1030 Cartridge Frame Assembly REP 1330
Front Paper Guide and Rear Paper Guide REP 1040-2 Ink ID Sensor Assembly REP 1340
Right Side Cap and Left Side Cap REP 1041 Detector Assembly REP 1350
Control Box REP 1050 Y Cable REP 1360-2
Head Cover REP 1060 Ink Tubes REP 1370-2
Fan Assembly and Fan Cable REP 1080-2 Print Head and Head Cable REP 1390
Lever Sensor Assembly REP 1100 Y Paper Sensor Assembly REP 1410
Switch Cable Assembly and DC Cable Assembly REP 1130 Cursor Assembly REP 1440
Main Board Assembly REP 1140 Origin Sensor and Y Encoder REP 1450
Power Supply Board Assembly REP 1150 Junction Board Assembly REP 1470
Panel Board Assembly REP 1160
Panel Cable REP 1170 Platen Height Adjustment REP 1520
Extension Board Assembly REP 1180 Tube Guide Assembly REP 1540-2
How to Adjust Steel Belt Tension REP 1550
XR Cable Assembly (Rear Paper Sensor) REP 1200 How to Adjust X Speed Reduction Belt Tension REP 1560
Pressure Assembly, Pressure Roller and Blade REP 1220 How to Adjust Print Head REP 1570
Pump Motor Assembly REP 1230
Cap Assembly REP 1240 How to Capture and Install Backup Parameters REP 1590
Wiper REP 1250 How to Install a Program (Software Upgrade) REP 1600
Pump Assembly REP 1260
Maintenance Station Assembly REP 1270 Head Cleaning Procedure REP 1620
Y Motor Assembly REP 1280 How to Clean the Head Nozzle Face REP 1660
Steel Belt REP 1290 X Speed Reduction Pulley Assembly REP 1680
T Fence Assembly REP 1300 Grid Roller Assembly REP 1690
F Absorbent Material Assembly REP 1700
Front / Rear Heater (or sensors) (refer to)REP 1040-2 Waste Fluid Bottle Assembly REP 1700

How to remove and replace the Right and Left Covers Model Name: Rockhopper-46/62 REP1010
Item Replacement and Adjustment Procedure
1. Removal and ❈ Before carrying out this operation, switch off the power supply and remove
Replacement the power plug. A
Procedure ❈ Before removing the covers, remove roll media with scroller from scroller
receiver. 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 Model Name: Rockhopper-46/62 REP1010
How to remove and replace the Front Cover Model Name: Rockhopper-46/62 REP1020
1. Removal and Front Cover

Replacement
Procedure 1. Remove the Right Cover.
2. Loosen the two fastening screws on the right side of the Front Cover shaft R2
Cover. (Refer to the diagram on the right) fastening screws
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. Slide the
6. Replacement is the reverse of the removal procedure but before cover shaft
replacing the Right Cover, open and close the Front Cover to
check that the Cover Switch is being pressed correctly.
Front cover
Pull out
How to remove and replace the Front Cover Model Name: Rockhopper-46/62 REP1020
How to remove and replace the Panel Cover and Y Rail Cover Model Name: Rockhopper-46/62 REP1030
1. Removal and Panel Cover B

Replacement
Procedure 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. Panel cover
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). A
Screw
Y Rail Cover
Screw Screws
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.
Screws
How to remove and replace the Panel Cover and Y Rail Cover Model Name: Rockhopper-46/62 REP1030
How to remove and replace the Front Paper Guide and Rear Paper Guide Model Name: Rockhopper-46 REP1040
Rear Paper Guide
1. Remove the Right Cover.

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 sure not to damage the cables.
Be carefully otherwise you may suffer an electrical shock.
Do not forget to lock the cables in their cable clamps.
How to remove and replace the Front Paper Guide and Rear Paper Guide (bis) Model Name: Rockhopper-46 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 to damage the cables.
. Be carefully otherwise you may suffer an electrical shock.
. Do not forget to lock the cables in their cable clamps.
.
Screws
Front side
Front paper guide
Screws
How to remove and replace the Front Paper Guide and Rear Paper Guide Model Name: Rockhopper-62 REP1040-2
Front Paper Guide

Heater Panel screws
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).
Front Heaters
11. Assembling is the reverse of the removal procedure. Connectors
CAUTION: When replacing the Front Paper Guide,

please be sure not to damage the cables.
Also keep the cables away from the fans and grid rollers.
How to remove and replace the Front Paper Guide and Rear Paper Guide (bis) Model Name: Rockhopper-62 REP1040-2
Rear Paper Guide Support Brackets

.
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.
Rear side
Rear paper guide
Platen Fitting Board
How to remove and replace the Front Paper Guide and Rear Paper Guide (bis) Model Name: Rockhopper-62 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) A
. 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
. Platen Fitting Board
CAUTION: When replacing the Rear Paper Guide,

please be sure not to damage the cables.
Also keep the cables away from the fans and grid rollers.
Connectors
Rear Heater
How to remove and replace the Right Side Cap and Left Side Cap Model Name: Rockhopper-46/62 REP1041
1. Removal and Right Side Cap

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

2. Remove X Motor Cover. (4 screws)
3. Hold up the Front Box. Right side cap
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.
Left side cap
How to remove and replace the Right Side Cap and Left Side Cap Model Name: Rockhopper-46/62 REP1041
How to open and close the Control Box Model Name: Rockhopper-46/62 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 (Front)
1. Removal and 1. Remove three hexagonal socket head bolts from the front of
Replacement the Control Box so that the Control Box Cover can be
Procedure removed.
2. Remove the three screws holding the Control Box.

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

2
Control box
Control box cover
How to open and close the Control Box Model Name: Rockhopper-46/62 REP1050
How to remove and replace the Head Cover Model Name: Rockhopper-46/62 REP1060
1. Removal and Head Cover

Replacement
Procedure 1. Open the Front Cover.
2. Slide the Head out from the Maintenance Station.
Caution: When you pull the Head, don’t press the cut-
ter 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 Model Name: Rockhopper-46/62 REP1060
How to replace the X Motor Assembly Model Name: Rockhopper-46/62 REP1070
1. Replacement How to replace the X Motor Assembly

Procedure
3. Remove the Control Box.
4. Remove the X Motor Cover.
5. Disconnect connectors J120 and J121 from the Main Board Front X Reinforcement
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. X Motor Assembly
8. Loosen four screws holding the X Motor Assembly so that it fastening screws
does not apply tension to the Speed Reduction Belt.
9. Remove the two screws that hold the X Motor to the X Motor X Motor fastening
mounting plate and pull out the motor. screws
Slide
X Motor Assembly
fastening screws
2. Adjustment Adjust X Motor tension.
and
Examination
Procedure
Pull out
How to replace the X Motor Assembly Model Name: Rockhopper-46/62 REP1070

How to replace the Fan Assembly and Fan Cable Model Name: Rockhopper-46 REP1080
1. Replacement Replace the Fan Assembly

Procedure
1. Remove the Front Paper Guide. Fan Assembly
2. Remove the Fan Duct. (3 fastening screws)
3. Remove the Fan Cable Connector. Fan duct
fastening screws
4. Remove the Fan. (1 fastening screw)
Cable clamp
Fastening screw Fan duct

Replace Fan Extension Cables 1, 2 and 3
1. Remove the Front Paper Guide. Fan connector

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.
Fan connector
8. Disconnect connectors (J115, J116 and J117) from the Main J117, J116 and J115
Board Assembly and remove the cables.
How to replace the Fan Assembly and Fan Cable Model Name: Rockhopper-46 REP1080
How to replace the Fan Assembly and Fan Cable Model Name: Rockhopper 62 REP1080-2
1. Replacement Replace the Fan Assembly

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

Fastening screw Fan duct
3. Remove each Fan Cable Connector. Fan 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
J118, J117, J116
and J115
How to replace the Fan Assembly and Fan Cable Model Name: Rockhopper 62 REP1080-2
How to replace the Speed Reduction Belt Model Name: Rockhopper-46/62 REP1090
1. Replacement Replace the X Speed Reduction Belt

Procedure
X Motor Assembly
1. Loosen the four screws that fasten the X Motor Assembly to
fastening screws
loosen the belt tension.
2. Remove the X Motor (2 fastening screws) from the X Motor X Motor fastening
Mounting Plate and take off the X Motor. screws
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. X Motor Assembly
Speed reduction
5. Assembling is the reverse of the removal procedure. fastening screws
pulley support
2. Adjustment Adjust X Motor tension.

and
Examination
Procedure
X speed
reduction belt
How to replace the Speed Reduction Belt Model Name: Rockhopper-46/62 REP1090
How to replace the Lever Sensor Assembly Model Name: Rockhopper-46/62 REP1100
1. Replacement Replace the Lever Sensor Assembly

Procedure
3. Remove the Panel Bottom Cover. Dowel
6. Disconnect the Main Board connector J104 (LEVER) and
Lever sensor
cut the cable tie that holds the cables together.
Assembly
7. Remove the Panel Cable connector and Tube Holder (one
+
fastening screw) and pull out connector J301 and the
Panel Cable (FFC). Push up
8. Remove the Panel Mounting Plate. (3 fastening
screws)
9. Remove the two black cable clamps attached to the Front Lever sensor mounting plate
X Reinforcement and pull out the Lever Sensor Assembly
cable from the hole.
10. Remove the Lever Sensor Mounting Plate. (1 fastening
screw) Sensor fastening
Cable clamp
11. Remove the Lever Sensor. (2 fastening screws) screws
2. Adjustment and Open the Lever and confirm that “Lever Up” is displayed.
Examination
Procedure
How to replace the Lever Sensor Assembly Model Name: Rockhopper-46/62 REP1100
How to replace the Cover Switch Assembly Model Name: Rockhopper-46/62 REP1110
1. Replacement Replace the Cover Switch Assembly

Procedure
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. Sensor mounting
4. Open the Control Box and pull out connector J106 from Cover sensor plate
the Main Board. arm
5. Remove the black cable clamp and cut the cable tie Two fastening screws
of switch
that holds the cables together.
6. Remove the Cover Switch (2 fastening screws).
2. Adjustment Open the Front Cover and confirm that “Cover Open” is
and displayed.
Examination
CAUTION: If the Cover Sensor Arm does not press Fastening screws
Procedure
the Cover Switch when the Front Cover
is opened and closed, carry out the
"Sensor Mounting Plate Position Adjustment". Cover switch
+
+ +
Adjust timing
+ by sliding
Tighten after adjustment
How to replace the Cover Switch Assembly Model Name: Rockhopper-46/62 REP1110
How to replace the Waste Fluid Bottle Sensor Assembly Model Name: Rockhopper-46/62 REP1120
1. Replacement Replace the Cover Switch Assembly

Procedure
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 mount-

ing the Waste Fluid Bottle Sensor Assembly.
How to replace the Waste Fluid Box Sensor Assembly Model Name: Rockhopper-46/62 REP1120
How to replace the Switch Cable Assembly/CD Cable Assembly Model Name: Rockhopper-46/62 REP1130
CAUTION: The power cable connector must be discon-

nected before this operation.
Switch cable
1. Replacement Switch Cable Assembly Replacement assembly
Procedure
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
Power board
assembly
2. Disconnect connector J001 from the Power Board Assembly.
3. Disconnect connector J101 (POWER) from the Main Board
Assembly and remove the cable. Connector
4. Assembling is the reverse of the removal procedure. J001 (POWER)
Connector J001
Connector
J100 (SW)
Main board
assembly
How to replace the Switch Cable Assembly/CD Cable Assembly Model Name: Rockhopper-46/62 REP1130
How to replace the Main Board Assembly Model Name: Rockhopper-46/62 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 parame- is 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 num-
ber of your plotter and receive adjustment
parameters.
Memory card
slot
2. Replacement 2. Replace the Main Board

Procedure 1) Disconnect all communications connectors. Five main board
2) If the Optional Interface is connected with the two Centronics assembly fastening
Interface connector screws, remove it now. screws
3) Open the Control Box.
4) Disconnect all Main Board Assembly connectors.
5) Remove the Extension Board Assembly (4 screws) and SIMM.
6) Remove the Main Board Assembly. (5 fastening screws)
7) Assembling is the reverse of the removal procedure.
« REFERENCE » SIMM must be inserted from Slot 1.
« REFERENCE » Main board assembly DIP switches are for test-

ing and have no settings.
CAUTION: Firmware installation and parameter recovery will be

carried out after this but these tasks must be done
after the connections have been checked and with the Four extension board assembly Extension board Main board
fastening screws assembly assembly
Control Box closed.
Otherwise you may suffer an electric shock or compo-
nents may be damaged.
3. Install latest 3. Install the latest program.

program
4. Install backup 4. Install the backup parameters that were taken up in Step 1 in the new
parameters Main Board Assembly.
CAUTION: If backup parameters were not taken up in Step 1, enter them manually.
For the user setup list, refer to the section on “How to set parameters” in the Users Guide and Functional Operation Edition.
Also, for adjustment parameters, refer to BAC5020 (parameter update).
CAUTION: Replace the “Waste Fluid Box” if backup parameters were not taken up in Step 1.
The message “Change Tank?:” will appear on the panel display. You should confirm by answering “Yes”.
How to replace the Power Supply Board Assembly Model Name: Rockhopper-46/62 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.
1. Replacement Replace the Power Supply Board Assembly Connector J001 Connector J000
Procedure
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 Model Name: Rockhopper-46/62 REP1150
How to replace the Panel Board Assembly and Heater Panel Board Assembly Model Name: Rockhopper-46/62 REP1160
1. Replacement Replace the Panel Board Assembly

Procedure 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 Screws
1. Replacement Replace the Heater Panel Board Assembly

Procedure
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
5 . For replacing the Heater Panel board on a Rockhopper 62"
CAUTION: Heater Panel
. please refer to REP 1040-2. Board
.
.
How to replace the Panel Board Assembly and Heater Panel Board Assembly Model Name: Rockhopper-46/62 REP1160
How to replace the Panel Cable Model Name: Rockhopper-46/62 REP1170
1. Replacement Replace the Panel Cable

Procedure
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 mak-
ing 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 Model Name: Rockhopper-46/62 REP1170

How to replace the Extension Board Assembly Model Name: Rockhopper-46/62 REP1180
1. Replacement Replace the Extension Board Assembly

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

fastening screws
How to replace the Extension Board Assembly Model Name: Rockhopper-46/62 REP1180
How to replace the XR Cable Assembly (Rear Paper Sensor) Model Name: Rockhopper-46/62 REP1200
1. Replacement Replace the XR Cable Assembly (Rear Paper Sensor)

Procedure
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.
CAUTION: Be careful not to damage the Y Cable cover- Five holes for removal
of rear paper guide
ing.
8. Remove the sensor from the sensor mounting plate (2 screws) Two holes for removal
on the Rear Frame X Reinforcement. of sensor
2. Adjustment 1. Adjust the bundle of Y cable, N belt and ink tubes.

and (Make sure the pressure arm is lowered then move the head
Examination left and right so that there is no twisting.)
Procedure 2. Carry out "Rear sensor position" with the printer's self-diagnos-
tics under the adjustments menu. Sensor fastening screws
XR cable assembly
(Rear paper sensor)
How to replace the XR Cable Assembly (Rear Paper Sensor) Model Name: Rockhopper-46/62 REP1200
How to replace the Pressure Assembly, Pressure Roller and Blade Model Name: Rockhopper-46/62 REP1220
1. Replacement Replacing the Pressure Assembly

Procedure
1. Remove right and left covers.
2. Remove panel cover.
3. Remove front cover.
4. Remove Y rail cover. Tension screws
5. Remove front paper guide
6. Remove rear paper guide
7. Loosen two steel belt tensioning 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
1. Replacement 11. With the pressure roller down, loosen the set screw on the
Procedure pressure axle fastening spacer.
X rail
Fastening spacer
Ball screw driver
12. Operate the pressure lever and with the pressure roller up, E-ring
remove the E-ring holding the link.
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.
1. Replacement 14. Pull out the pressure shaft from the right side of the frame.
Procedure
CAUTION: Be careful. If the pressure axle is taken out
completely, the pressure axle fastening spac-
er 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. Four hexagonal nuts
« REFERENCE » A special ratchet tool is required for the Hex. screw

bottom screw holding the Y rail reinforce- Y rail reinforcement plate
ment plate (hex. 4 × 10 mm double SEMS).
17. Remove the pressure assemblies from the Y rail reinforce-

ment plate. (2 screws for each assembly)
18. Refitting is the reverse of the removal precedure. Ratchet screw

Pressure assembly driver
1. Replacement Blade Replacement

Procedure
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, don’t use exces-

sive force to part it as there is a risk of dam- Open
aging the blade.
Blade
3. To refit, insert the blade on the pressure arm.
Pressure Roller Replacement
1. Follow the blade replacement procedure to remove the blade.

2. Use a fine straight screwdriver to slightly prize apart the pres- Pressure arm
sure roller attachment and remove the pressure roller.
CAUTION: When removing the blade, don’t use exces-

sive force to part the blade and pressure arm
as there is a risk of damaging the pressure Pressure roller Open
arm and the blade.
3. To refit, insert the pressure roller and then the blade on the
pressure arm.
How to replace the Pump Motor Assembly Model Name: Rockhopper-46/62 REP1230
1. Replacement Replace the Pump Motor Assembly

Procedure
3. Remove the Panel Bottom Cover.
6. Remove the Panel Cable connector and Tube Fixer (1 fastening
screw) and disconnect connector J301.
7. Remove the Panel Mounting Plate. (3 fastening screws)
9. Disconnect connector J102 (PUMP) from the Main Board
Assembly.
10. Remove the cable clamp fastened to the Front X Reinforcement.
11. Slide the head to the left (in the center section) and remove the
entire Maintenance Assembly. (2 top screws/2 front screws)
12. Remove the two screws holding the Pump Motor Plate and lift out
the Pump Unit.
13. Remove the four screws holding the Pump Motor Assembly.
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 Model Name: Rockhopper-46/62 REP1230
How to replace the Cap Assembly Model Name: Rockhopper-46/62 REP1240
1. Replacement Replace the Cap Assembly

Procedure
1. Remove the Panel Cover. Draw out the tube
(2 places)
5. Remove the Panel Mounting Plate.
6. Remove the Maintenance Assembly.
7. Draw out the tube on the panel side.
8. Remove one screw holding the Cap Assembly.
9. Slide the Cap Assembly towards the gear and lift it out.
Screw
CAUTION: Be careful not to touch the cap surface and

the wiper with your hand while you are work-
ing.
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 main-

tenance frame, push it right back before fas-
tening.
2. Adjustment 1. Carry out the Capping Position Adjustment.

and
Examination
Procedure
How to replace the Cap Assembly Model Name: Rockhopper-46/62 REP1240

How to replace the Wiper Model Name: Rockhopper-46/62 REP1250
1. Replacement Replace the Wiper

Procedure
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 1. Initialize the wiper count.

and
Inspection
Wiper Rack section
Procedure
Felt surface Rubber surface
[ Printing roller side ] [ Cap side ]
How to replace the Wiper Model Name: Rockhopper-46/62 REP1250

How to replace the Pump Assembly Model Name: Rockhopper-46/62 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.
1. Replacement Replace the Pump Assembly

Procedure
6. Take out the Maintenance Station Assembly.
7. Disconnect and remove the tubes between the Pump Assembly and the
Cap Assembly.
8. Remove the waste liquid tube that is clamped to the outside of the
Right Frame.
9. Remove the metal plate to which the gear is attached together with two
screws.
10. Remove the pump assembly (1 screw), slide it towards the wiper and
lift it out.
« REFERENCE » Before assembly, check that the wiper is installed

on the pump assembly.
2. Adjustment and 1. Carry out the Capping Position Adjustment.

Examination 2. Initialize the wiper count.
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 Model Name: Rockhopper-46/62 REP1260

How to replace the Maintenance Station Assembly Model Name: Rockhopper-46/62 REP1270
1. Replacement Replace the Maintenance Station Assembly

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

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

and 2. Initialize the wiper count.
Examination
Procedure
How to replace the Maintenance Station Model Name: Rockhopper-46/62 REP1270

« REFERENCE » If there is to be no replacement that

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

Procedure
3. Remove the Steel Belt.
5. Disconnect connector J120 (YMOT) from the Main Board
Assembly.
6. Remove the Y Motor Assembly. (3 fastening screws) Y motor cable terminal
« REFERENCE » Since the Y Motor Assembly Cable pass-

es below the Cartridge Unit, the work will
be easier if you remove the two Cartridge
Base screws and push it back.

and
Examination
Procedure
Y motor assembly

How to replace the Steel Belt Model Name: Rockhopper-46/62 REP1290
CAUTION: Do this work with the pressure roller down.
1. Replacement Replace the Steel Belt

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

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.
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 Model Name: Rockhopper-46/62 REP1290

How to replace the T Fence Model Name: Rockhopper-46/62 REP1300
1. Replacement Replace the T Fence

Procedure
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.
« REFERENCE » 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 bot-
tom on the maintenance unit side. Twelve fastening screws
or Correct
X motor
T Fence
or Wrong
2. Cleaning How to clean the T Fence

Procedure
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 Model Name: Rockhopper-46/62 REP1300

How to Replace the Steel Flexible Guide Assembly and Cursor Plate Spring Model Name: Rockhopper-46/62 REP1310
1. Replacement Replace the Steel Flexible Guide Assembly

Procedure
Cable keeper
Removal 1. Remove the Panel Cover.
(H for fitting flexible cable support is included.) Hexagonal nut Tube keeper
3. Remove the Y Rail Cover. Screw
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 Cartridge pipe
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.
Assembling 1. Screw the steel bare to the H Board Fitting Plate.

2. Clamp the Steel Flexible Cable Support to the Tube Guide.
Tube guide assembly
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. Steel flexible guide
5. Move the head inside the maintenance assembly then tighten the cable keeper.
Cursor plate spring
1. Replacement Replace the Cursor Plate Spring
(1) Press and remove (2) Press
Procedure
1. Remove the Panel Cover. Ink tube
4. Bring the head to center of the printer, (3) Remove to left
press down the left and right ends of Tube guide assembly
the cursor plate spring and pull it out to the right.
Steel flexible guide
How to Replace the Steel Flexible Guide Assembly and Cursor Plate Spring Model Name: Rockhopper-46/62 REP1310
How to Replace the Steel Flexible Guide Assembly and Cursor Plate Spring Model Name: Rockhopper 62 REP1310-2
1. Replacement Replace the Steel Flexible Guide Assembly

Procedure
Removal 1. Remove the Panel Cover.
3. Remove the Y Rail Cover. Steel flexible cable
Cable keeper
4. Undo the two screws holding the steel bare to the H board mounting
plate (flexible cable support keeper on 62-inch models).
Tube keeper
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. [ 62 inch ]
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. H board mounting plate
5. Move the head inside the maintenance assembly then tighten
the cable keeper. Flexible cable support keeper
Cursor plate spring Steel flexible cable
(1) Press and remove (2) Press
Replace the Cursor Plate Spring
1. Replacement
Procedure 1. Remove the Panel Cover. Ribbon cable guide
3. Remove the Y Rail Cover. (3) Remove to left
4. Bring the head to center of the printer, press down Clamping part
the left and right ends of the cursor plate spring and
pull it out to the right.
Steel flexible cable
How to Replace the Steel Flexible Guide Assembly and Cursor Plate Spring Model Name: Rockhopper 62 REP1310-2
How to replace the Y Return Pulley Assembly Model Name: Rockhopper-46/62 REP1320
Replace the Y Return Pulley Assembly
1. Replacement 1. Remove the Panel Cover.

Procedure 2. Remove the Front Cover.
5. Move the Head to the left (X Motor side). Tension screw
6. Loosen the Steel Belt tension (loosen two tensioning screws).
7. Remove the Steel Belt fastening screws on the left side and
slide it out to the Return Pulley.
8. Remove the Y Return Pulley.
9. Assembling is the reverse of the removal procedure. Belt fastening screw
Belt fastening screw

and
Examination
Procedure
Return pulley
Steel belt
How to replace the Y Return Pulley Assembly Model Name: Rockhopper-46/62 REP1320
How to replace the Cartridge Frame Assembly Model Name: Rockhopper-46/62 REP1330
1. Replacement Replace the Cartridge Frame Assembly

Procedure Connector Table
1. Carry out Head Cleaning.
J401 MAIN FFC 16-core
2. Remove the Right Paper Guide. Detector assembly
3. Disconnect all connectors J402 to J413 from the J402 Detector K Black 4-core Ink ID sensor connector
junction board assembly leaving only J401 J403 Detector C Cyan 4-core connector
(FFC) connected. 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
4. Remove the connectors of the cartridge pipes
and ink tubes on the cable guide. J409 Ink ID Y Yellow 5-core
J410 Detector 5 Black 6-core
CAUTION: If there is wash liquid remain- J411 Detector 6 White 6-core
ing in the ink tubes and head J412 Ink ID 5 Black 6-core
dampers, it may flow out from J413 Ink ID 5 White 6-core
the head nozzles and spill ❈ On panel display,
around the maintenance 5 = O (Orange)
assembly. Use cotton waste to 6 = G (Green)
wipe up any spilt wash liquid. ❈ J413 has twisted lines
CAUTION: When pipes and tubes are

being removed, mark the
tubes so that they will not be
confused when they are re-
Fastening
assembled.
screw
5. Remove the Y Rail Cover Support. (2 fastening

screws) Fastening
screw
1. Replacement 6. Remove two screws holding the cartridge base.

Procedure Slide the cartridge base towards (1) then lift as in (2) to sepa-
rate it from the rear X reinforcement.
Lift
2
Slide
Cartridge slide 2
Two screws Two screws

2. Adjustment
and 7. Cut the cable tie holding the cables.
Examination
Procedure 8. Remove the cartridge pipes from the cartridge frame.
« REFERENCE » Be careful not to lose the nuts and O-

rings on the disconnected cartridge
pipes.
9. Undo the two screws holding cartridge slide 2.
1. Replacement 10. Remove 2 screws holding the cartridge frame to the cartridge base,
Procedure slide the cartridge frame in the direction of arrow a and lift to sepa-
rate it from the cartridge base.
11. To dismantle the cartridge frame, open the upper claw of the 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. a
I/C guide base Cartridge frame
CAUTION: 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 car-
ried out with "cartridge side plates" after Cartridge base
this work.
12. The I/C guide base attached to the cartridge base can be disman-
tled when the four claws are disconnected from the back.
At the same time, the plates for preventing incorrect insertion and Cartridge slide
the cushioning spring and felt can be removed.
CAUTION: Take care not to mistake the positioning of the

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

2
Frame assembly and needles
1. Replacement 13. Assembling is the reverse of the removal procedure.

Procedure
CAUTION: Don’t use a tool to tighten the coupling

screws but get them as tight as possible with
your fingers. If you use a tool, there is a risk
of breaking the plastic taps.
2. Adjustment 1. Carry out the initial filling.

and
Examination CAUTION: Wait at least 30 minutes after the initial filling
Procedure before printing. Otherwise the printing quali-
ty 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”.
How to replace the Ink ID Sensor Assembly Model Name: Rockhopper-46/62 REP1340
1. Replacement How to replace the Ink ID Sensor Assembly

Procedure
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 unsuit-
able.
Ink ID sensor
assembly
Two fastening
screws
How to replace the Ink ID Sensor Assembly Model Name: Rockhopper-46/62 REP1340
How to replace the Detector Assembly Model Name: Rockhopper-46/62 REP1350
1. Replacement Replace the Detector Assembly

Procedure
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 replace-
ment. Fastening screw
Cartridge detection switch

CAUTION: Be careful not to over-tighten when refitting
the cartridge sensor. Fastening screw
If it is over-tightened the detection section of
the sensor will not slide. Tightening torque is
29.4 N•cm (3 kg•cm).
Cartridge frame assembly
CAUTION: Detector assemblies have different cable
lengths and connectors depending on which
slot they are fitted to. Be careful not to con-
fuse them.
How to replace the Detector Assembly Model Name: Rockhopper-46/62 REP1350

How to replace the Y Cable Model Name: Rockhopper-46 REP1360
1. Replacement Replace the Y Cable Cable keeper (2)

Procedure
3. Remove the Y Rail Cover. Two fastening
4. Open the Control Box. screws
6. Disconnect connectors J111 (HEAD1) and J112 (HEAD2) from the Main
Board Assembly.
« REFERENCE » The flat core will come away at the same time. Be Y cable
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 Cable keeper
Hexagonal
Assembly.
9. Remove 4 hex. nuts holding the tube bracket. nut
10. Withdraw the Y Cable that passes through the Right X Reinforcement into the Fastening screw
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 Tube keeper
holding the ink cartridge base and move the base. Tube
11. Lift the tube bracket up and remove Y Cable together with the N Belt.
bracket
12. Assembling is the reverse of the removal procedure. Cartridge pipe
« REFERENCE » The new Y cable has no fold crease. Make a fold
crease in the new cable to match the old cable.
CAUTION: Power must be off when connectors are being disconnect-

ed or reconnected, otherwise you may be injured or a
Junction board
board may be damaged.
The main board assembly will certainly be damaged if assembly
power is applied with main board assembly connectors X reinforcement R Y cable
J111 (HEAD) and J112 (HEAD2) and head board connectors
J201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP.
Screw
2. Adjustment 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.
How to replace the Y Cable Model Name: Rockhopper-46 REP1360

How to replace the Y Cable Model Name: Rockhopper 62 REP1360-2
1. Replacement Replace the Y Cable

Procedure
2. Remove the Front Cover. Y cable Cable keeper Clamping part Ribbon cable guide
6. Disconnect connectors J111 (HEAD1) and J112 (HEAD2) from the Main
Board Assembly.
« REFERENCE » The flat core will come away at the same time. Be
careful not to drop it.
7. Remove the cable keeper from the Head Board Assembly. (2 fastening
screws)
8. Disconnect connectors J201 (MAIN1) and J202 (MAIN2) from the Main Board
Assembly.
9. Remove the ribbon cable guide clamp parts.
10. Remove 4 hex. nuts holding the tube bracket.
11. Withdraw the Y Cable that passes through the Right X Reinforcement into the
Control Box, straighten out the bends and pass it through the hole in the left
Flexible Cable Guide Support. Cable keeper Hexagonal nut
« REFERENCE » This work will be easier if you remove the screw Tube keeper X reinforcement R
holding the ink cartridge base and move the base. Junction board assemb
12. 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.
CAUTION: Power must be off when connectors are being disconnect-
ed 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.
2. Adjustment 1. When the Y Cable has been laid, first fit the Y Rail Cover only then move the Tube bracket Y cable
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.
How to replace the Y Cable Model Name: Rockhopper 62 REP1360-2

How to replace the Ink Tubes Model Name: Rockhopper-46 REP1370
1. Replacement Replace the Ink Tubes

Procedure
1. Carry out Head Cleaning and empty the ink inside the tubes. Tube fastening
2. Remove the Panel Cover. screw (small)
5. Remove the Head Board Assembly Cable keeper and disconnect
the Y Cable from the connector. Joining
6. Remove the ten tube guide clamps. screw
7. Undo the two screws holding the tube keeper. (large)
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. Open the
10. Assembling is the reverse of the removal procedure. clamp here
CAUTION: Be careful not to lose the O-rings. Initial filling

and printing can not be done if the O-rings are
missing.
CAUTION: Don’t use a tool to tighten the coupling screws Ink tube
but get them as tight as possible with your fin-
gers. If you use a tool, there is a risk of breaking
the plastic taps.
« REFERENCE » Ink tubes have a tendency to bend. Laying Flexible
the tubes in the direction of that tendency cable
prevents the tubes from behaving badly guide
and jamming.
« REFERENCE » Couplings have a definite orientation. (See
diagram below) Joining screw
Joining
screw
Cartridge side
Head side
→ Continued on next page (REP1371)
How to replace the Ink Tubes Model Name: Rockhopper-46 REP1370

How to replace the Ink Tubes Model Name: Rockhopper 62 REP1370-2
1. Replacement Replace the Ink Tubes

Procedure
1. Carry out Head Cleaning and empty the ink inside the tubes.
5. Remove the head board assembly cable keeper and disconnect the
Y cable from the connector.
6. Remove the ribbon cable guide and tube guide clamps.
7. Undo the two screws holding the tube keeper.
8. Remove the tube bracket cable keeper.
9. Remove the four joining screws and O-rings on the Flexible Cable
Guide.
10. Remove the four joining screws and O-rings below the cursor.
I Joining screw (small) Ink tube
Joining screw (large)
CAUTION: Be careful not to lose the O-rings. Initial filling
and printing can not be done if the O-rings are
missing. Tube keeper Flexible cable guide
Ribbon cable guide
CAUTION: Don’t use a tool to tighten the coupling screws
but get them as tight as possible with your fin-
gers. 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
Head side
Tube guide Clamping parts Joining screw Cable keeper
How to replace the Ink Tubes Model Name: Rockhopper 62 REP1370-2

How to replace the Ink Tubes Model Name: Rockhopper-46/62 REP1371
1. Replacement
Diagram showing construction of joiners (Cartridge side)
Procedure Cartridge pipe
Joint nut (large)
DE-49778 Ink tube
O-ring (large)
DE-49777
Joint nut (large)
Coupling (black)
DE-49778
DE-49992
O-ring (large)
DE-49777 O-ring (large)
DE-49777
Coupling (white)
Coupling screw (large)
DE-49993
DE-49778
Tube fastening O-ring (small)
DE-48949
Ink tube Tube stop screw (small)
DE-48950 (Head side)
Head pipe
2. Adjustment 1. Carry out the initial filling.

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

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”.
How to replace the Ink Tubes Model Name: Rockhopper-46/62 REP1371

How to replace the Cutter Solenoid Assembly Model Name: Rockhopper-46/62 REP1380
1. Replacement Replace the Cutter Solenoid Assembly

Procedure
4. Disconnect connector J206 (SOL) from the Head Board Assembly.
5. Remove the Head Cover.
6. Move the Head 20 to 30 cm to the left.
7. Undo the two screws on the left edge of the head and remove the
cutter unit.
8. Remove the screw holding the cutter cap.
9. Undo the two screws holding the solenoid to the cutter box and Plate nut
take the solenoid from the box.
10. Assembling is the reverse of the removal procedure. Two fastening screws
CAUTION: 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. Solenoid Cutter cap
« REFERENCE » There are two types of springs inside the cut- assembly
ter 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 solenoid
cutter mat must be adjusted. Refer to Figure A and fasten it in the Cutter spring
assembly
correct position.
Cutter blade Fix so that the front corner of

Platen Cutter mat the cutter mat groove and the
flat part of the cutter blade are
aligned.
« REFERENCE »
[Diagram A] This rib should cover at least half
the flat part of the cutter mat. Move Two fastening screws
the head to make sure that both left
and right edges cover at least one-third.
How to replace the Cutter Solenoid Assembly Model Name: Rockhopper-46/62 REP1380
How to replace the Head and Head Cable Model Name: Rockhopper-46/62 REP1390
1. Replacement Head, Head Cable Replacement

Procedure
❈ Do head washing. ❈ If HEAD1 (left) only is to be replaced, change "6 places" to "3 places".

3. Remove Y rail cover.
4. Remove head cover.
5. Unlock and disconnect FFC entering the head board assembly connectors J207 (HEAD C1) and J208 (HEAD C2)
6. Cut the cable tie holding the head pipes.
7. Undo the tube stop screws holding the head pipes on the damper (6 places) and disconnect the head pipes.
« REFERENCE »When the tube stop screws are removed, there will be O-rings on the head pipes. Be careful not to lose them.
8. Remove the damper positioning materials. (1 screw)
9. Disconnect the dampers from the print head. (6 places)
CAUTION: The damper will not function if the film part of the damper is gripped strongly and print-
ing may not work.
Insertion section
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. 1
14. Disconnect head cables from the print head connectors.
2. Assembling 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.
3. Assembly is the reverse of dismantling. 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
3. Adjustment and « REFERENCE » If a head has been replaced, the nozzle ejection count value should be reset.
Examination
Procedure 1. Carry out initial filling with ink.
« REFERENCE » Head washing and initial filling consumes a large quantity of waste liquid.
The waste liquid box should be replaced when initial filling is finished.
CAUTION: After initial filling, wait for at least 30 minutes before printing.
Otherwise the printing quality cannot be assumed.
2. Load roll media in the printer.
3. Do a "Nozzle check" to confirm whether there is incomplete filling or abnormal ejection.
If there is a fault, try again after "Cleaning".
« REFERENCE » At rare intervals a dirty wiper may cause faulty ejection and the wiper should be rubbed with a wiper cleaning cloth.
4. Do “Left Tilt” adjustment.
5. Do “Right Tilt” adjustment.
6. Do “Repeatability (Normal)” adjustment.
7. Do “Repeatability (Microdot)” adjustment.
8. Do "Unidirectional" adjustment.
9. Do "Unidirectional (Microdot)" adjustment.
10. Do "Test print" to confirm results of adjustments.
How to replace the Edge Sensor Assembly Model Name: Rockhopper-46/62 REP1410
1. Replacement Edge Sensor Replacement

Procedure Screw
1. Remove front cover. (self-tapping)
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. 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 Model Name: Rockhopper-46/62 REP1410
How to replace the Head Board Assembly Model Name: Rockhopper-46/62 REP1420
1. Replacement Replace the Head Board Assembly

Procedure 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 Screws
(HEAD2) and head board connectors J201
(MAIN1) and J202 (MAIN2) inserted with
oblique FFP.
How to replace the Head Board Assembly Model Name: Rockhopper-46/62 REP1420
How to replace the Dampers Model Name: Rockhopper-46/62 REP1430
1. Replacement Dampers Replacement

Procedure
1. Carry out Head Cleaning.
2. Remove the Panel Cover. Head board assembly
Head cable
7. Remove the damper fixer (2 fastening screws).
8. Remove joint screws and move the head pipes up out of the way.
9. Remove the colour dampers.
CAUTION: When removing the colour dampers, be careful 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.
Damper fixer
2. Adjustment and 1. Carry out initial filling.

Examination Tube fixer
Procedure
CAUTION: Wait at least 30 minutes after the initial filling
before printing. Otherwise the printing quality can
not be assured.

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 Model Name: Rockhopper-46/62 REP1430

How to replace the Cursor Assembly Model Name: Rockhopper-46/62 REP1440
1. Replacement Cursor Assembly Replacement

Procedure
1. Wash the head to remove the ink.
3 Remove the Panel Bottom Cover.
6. Remove the Right and Left Covers.
8. Disconnect connectors J204 (P EDGE), J206 (SOL), J207 (HEAD C1), J208 (HEAD C2) from the head board assembly.
10. Remove tube stop screws and disconnect head pipes from dampers.
11. Remove two screws from each outer side of the upper part of the cursor and separate the cursor unit from the head board unit.
Reverse the disconnected head board unit so as to extend the steel bare and place it on top of the X motor side of the flexible cable guide.
CAUTION: Be careful not to damage the T fence when taking out the head board unit.
Scarring may cause abnormal print quality.
12. Loosen the steel belt tension with the Y return pulley.
13. Undo the screws that fasten the belt at both ends of the cursor unit and separate the steel belt.
14. Move the cursor unit between the drive roller on the right and the cap unit.
15. Bend the CR flat spring and remove it.
16. To remove the cursor unit from the Y rail, after undoing one side of the cursor axle E-ring, take out the cursor axle together with both roller bearings.
The cursor unit will drop down and can be taken from the Y rail.
Be careful not to touch or damage the nozzle face of the head when removing the cursor unit from the Y rail.

1. Replacement 17. Remove the head sub-plate that is on the cursor roller side.
Procedure (2 screws)
18. Remove three fastening screws on the print head side and All screws shown here are temporarily tightened
separate the hear unit and cursor assembly. The belt attach- Cursor assembly
ment plate will come away at the same time.
2. Assembling 1. Align the cursor assembly with the head unit, bring the head
and fitting unit in the direction of the arrow (up) and hold it temporarily M3 × 16 (cap screw) Belt attachment plate
with three fastening screws. M4 × 10 Head sub-plate
2. Temporarily attach the head sub-plate. (double SEMS)
3. Following the reverse procedure, fit the cursor assembly to M3 × 5
the Y rail and continue until just before attaching the head (double SEMS round)
cover. Head unit
4. Move the cursor assembly over the right end of platen on the
cap side.
5. Place the head height jig under the nozzle face of the print
Press places shown
head, press the flat part of the upper edge of the print head by arrows
and, while the metal part surrounding the nozzles is in close Fastening screws (3)
even contact with the head height jig, firmly tighten the
screws that had been held temporarily.
6. Withdraw the jig without touching the nozzle face and, using
Head height jig
the pressure bracket gap at the back of the printer, firmly
fasten the head sub-plate that had been held temporarily. Right edge platen
7. After fitting the Y rail cover, do the initial filling and proceed
with item 3. Adjustment and Checking. Fit the remaining cov- CAUTION: As shown below, make sure nozzle face does
ers after adjustment and checking. not touch jig.
3. Adjustment 1. Execute the "Cap position" adjustment.

and confirma- 2. Execute a "Test print" to see whether any printing adjust-
tion ments are needed. Depending on the result, carry out any Wrong
necessary adjustments. This will touch nozzle face.
3. Apply the "Margin" adjustment.

How to replace the Origin Sensor, Y Encoder Model Name: Rockhopper-46/62 REP1450
1. Replacement Origin Sensor and Y Encoder Replacement

Procedure
Origin sensor fitting direction
4. Disconnect all connectors plugged into the head board.
5. Remove head board from the H board mounting plate. (4
screws)
6. Remove Y cable together with the cable keeper. Cable from origin sensor
7. Remove tube guide keeper. (2 screws) board in on the cap side
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. Sensor Cable
11. Remove origin sensor or Y encoder from the H board mount-
ing plate. (2 screws each)
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 Encoder terminal comes to H

as seen from front of board mounting plate
printer attachment section.
How to replace the Origin Sensor, Y Encoder Model Name: Rockhopper-46/62 REP1450
How to replace the Junction Board Assembly, Ink ID Cable Model Name: Rockhopper-46/62 REP1470
1. Replacement Junction Board Assembly Ink ID Cable

Procedure Replacement Junction cable
connection J109
1. Remove the Front Cover. (INK ID) behind
2. Remove the Panel Cover. 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
Four fastening
CAUTION: Power must be off when connectors screws
are being disconnected or recon- Junction cable
nected, otherwise you may be connector J401
injured or a board may be damaged.
The main board assembly will cer- Ink ID sensor
tainly be damaged if power is connector
applied with main board assembly
connectors J111 (HEAD) and J112
(HEAD2) and head board connec-
Junction cable
tors J201 (MAIN1) and J202 (MAIN2) (FFP)
How to replace the Junction Board Assembly, Ink ID Cable Model Name: Rockhopper-46/62 REP1470
How to Adjust the Platen Height Model Name: Rockhopper-46/62 REP1520
1. Adjustment Platen Height Adjustment

and
Inspection 1. Adjust using rail height jig (JD-30395).
Procedure Mount the rail height jig on a standard base and set the dial Standard value : 0
gauge to "0" (2.00 mm). (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
How to Adjust the Platen Height Model Name: Rockhopper-46/62 REP1520

How to replace the Tube Guide Assembly Model Name: Rockhopper-46/62 REP1540
1. Replacement Tube Guide Assembly Replacement Cable keeper

Procedure
Hexagonal Tube keeper
1. Disconnect all connectors from head board.
nut
2. Remove head board. (4 screws)
3. Remove tube guide keeper. (2 screws) Screw
4. Remove two tube guide fastening screws.
5. Undo all parts clamping tube guide ink tubes and steel bares Tube Cartridge pipe
and remove the tube guide. bracket
Tube guide
assembly
Steel bare
Ink tube
Steel bare
Tube guide
assembly
How to replace the Tube Guide Assembly Model Name: Rockhopper-46/62 REP1540
How to replace the Tube Guide Assembly Model Name: Rockhopper 62 REP1540-2
Tube Guide Assembly Replacement
1. Remove panel cover, IC slot cover and Y rail cover

Cable keeper
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 Tube keeper
steel bare.
5. Remove all tube guide clamping parts.
6. Remove tube keeper. Tube bracket
7. Undo tube bracket nut.
8. Lift the tube bracket gently and remove the tube guide assem-
bly.
Ribbon cable
guide
Clamping parts
Tube guide
How to replace the Tube Guide Assembly Model Name: Rockhopper 62 REP1540-2
How to Adjust Steel Belt Tension Model Name: Rockhopper-46/62 REP1550
CAUTION: Steel belt are highly susceptible to breakage

and end damage and must be handled care-
fully.
CAUTION: Be careful not to cut your hands when han-
dling the steel belt. Adjusting
screws
Steel Belt Tension Adjustment

Steel belt
1. Adjustment 1. Set the steel belt in the middle of the return pulley and motor
and pulley. (Center of Y rail)
Verification 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 posi-
tion and measure the deflection of the belt at the center of the Belt tension attachment
Y rail. JD-42050
Specification values: 0.98 N

(100 g ± 20 g)
4. Finally, move the cursor left and right to check for belt skew.
How to Adjust Steel Belt Tension Model Name: Rockhopper-46/62 REP1550

How to Adjust X Speed Reduction Belt Tension Model Name: Rockhopper-46/62 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 1. Hook a 5 kgf Bar Tension Gauge to the X motor mounting

and plate, tension the belt and fasten the mounting plate.
Verification
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)
How to Adjust X Speed Reduction Belt Tension Model Name: Rockhopper-46/62 REP1560
How to Adjust the Print Head Model Name: Rockhopper-46/62 REP1570
1. Adjustment CAUTION: Avoid touching, knocking or rubbing the nozzle

and face of the Print Head Assembly.
Verification
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 dia-
gram 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 follow-
ing adjustments in Diagnostic Mode.
“Capping Position Adjustment”
“Head Rank Input” (Initial filling function is available.)
“Head Nozzle Verification” Head rank
“Left Head Tilt Verification” (5-digit)
“Right Head Tilt Verification”
“Repeatability Printing Positioning”, “Repeatability Printing Positioning
(Microdot)”
“Unidirectional”, “Unidirectional (Microdot)’
“Margin”
1. Run Diagnostic Mode.

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

1. Adjustment and 4. Execute "Capping position adjustment".

Verification 5. Apply "Head rank entry".
Initial filling can now be done. [Fig. 1]
6. Enter Head 1 rank. Here is lined up. Test pattern
If Head 1 has not been replaced, rank will be recorded as is.
7. Execute "Ink filling". 2 1 2 1 3 1 3 1 2 3 2 1
After ink filling, return to the previous level.
Media
8. Mount media. eject
9. Execute "Head nozzle check". direction
Check whether ejection is normal from all nozzles and proceed to
the next item. [Fig. 2]
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 In this case, adjust towards (a). In this case, adjust towards (b).
the offset rises to the left.
After gently pressing with a straight-bladed watchmaker's screwdriv-
er or similar in the same direction as the compression spring hold-
ing the print head, tighten the screw.
(One click changes head adjustment place A by about 0.005 mm) [Fig. 3] Head adjustment plate A
« REFERENCE » Sometimes simply moving the head adjust-

ment 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.
→ Continued on next page (b) (a)

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 [Display when looking at the print head from above]
a straight line.
HEAD1 HEAD2
(K) (C) (G) (M) (Y) (O)
1 2 3 4 5 6
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). Test pattern
After gently pressing with a straight-bladed watchmaker's screwdriv-
er or similar in the same direction as the compression spring hold- 5 2 5 3 4 6 1 3 6 4 1
ing the print head, tighten the screw. Media eject
direction
d d
16. Execute “Right Head Tilt”.
Repeat steps 14 and 15 until the test pattern is properly aligned.
c
17. When the right head tilt is properly adjusted, proceed to the next
item.
Press gently Fastening screw
b a

1. Adjustment 18. Execute "Repeatability" Media eject

and This makes three 1-pass bi-directional scans and compensates for
direction
Verification the offset of the second scan (CCW printing) relative to the first and
third scans (CW printing).
Third line
Second line
19. Check the printing, first for black then for colour, and record a posi-
tive increment if the second scan (CCW printing) is offset towards
the cap side, or a negative decrement for the opposite direction. First line
(Repeat the printing after the registration.)
Repeat until both directions are aligned.
20. When repeatability printing position alignment has been achieved, Plus Minus
proceed with the “Repeatability (Microdot)” adjustment in the same
manner.
21. Execute "Unidirectional".

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

1. Adjustment 23. Next, check the printing and record a positive increment if Head 2 is
and to be moved towards the cap side relative to Head 1, or a negative
Verification 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.
Bottom distance
26. Use a steel ruler and a loupe to measure from the edge of the (20 mm)
media to the printing position and make the correction by entering
the actual measured value. Left side margin Right side margin
(5 mm) (5 mm)
Top distance
(25 mm)
27. Complete the adjustments by switching off the power.

How to Capture and Install Backup Parameters Model Name: Rockhopper-46/62 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 1. Switch off power to the printer.

Backup
Parameters 2. Mount a backup-only flash memory card in the slot at the back of the printer.
3. Turn on the power. All LEDs light up instantly and “PLOTTER” → CARD” appears in the printer’s LCD display unit.
4. When “ENTER” is pressed, “P → C Started” appears in the printer’s LCD display unit and parameters start to be absorbed.
5. When parameters have been completely absorbed, “P → C Completed” appears in the printer’s LCD display unit to indicate that the comparison of
absorbed parameters has ended normally.
6. Switch off and remove the flash memory.
2. Install 1. Switch off power to the printer.
2. Mount a backup-only flash memory card in the same slot at the back of the printer.
3. Turn on the power. All LEDs light up instantly and “PLOTTER” → CARD” appears in the printer’s LCD display unit.
“Menu Up” or “Menu Down” will change this to “CARD → PLOTTER”.
4. When “ENTER” is pressed, “C → P Started” appears in the printer’s LCD display unit and parameters start to be installed.
5. When parameters have been completely installed, “C → P Completed” appears in the printer’s LCD display unit to indicate that the comparison 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.
How to Capture and Install Backup Parameters Model Name: Rockhopper-46/62 REP1590
How to Install a Program (Software Upgrade) Model Name: Rockhopper-46/62 REP1600
CAUTION: 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.
1. Install 1. Switch off power to the printer.

2. Mount the latest program flash memory card in the slot at the back of the printer.
3. Switch on the power.
4. The following message will appear in the liquid crystal display:
Erase
Copy
Compare
End
The buzzer will sound. (It will end after about 60 seconds)
5. Switch off power to the printer.

6. Remove the flash memory card.
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
How to Install a Program (Software Upgrade) Model Name: Rockhopper-46/62 REP1600

Head Cleaning Procedure 1 Model Name: Rockhopper-46/62 REP1620
CAUTION 1: When to Clean the Head Panel diagnostic functions (when implemented from panel only)
“Head Wash” must be carried out whenever this printer is moved by truck, befoe using
1. To start panel diagnosis, switch on while pressing [Cleaning], [Menu Display] and
Eco-Solvent ink or when the parts shown below are replaced. [Shift] at the same time.
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. 2. Select "Adjustment" menu → "Head Wash" self-diagnosis.
< Replacement Parts > Head, Damper, Cursor Assembly, Cartridge Frame
Assembly, Ink Tubes 3. Rm All Cartridge
CAUTION 2: Head Cleaning Jig When this display appears, take out the specified cartridge.
(Alternatively, the ink cartridges may be removed beforehand.)
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. 4. Set Wash Jig
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 When this display appears, mount the cleaning jig.
from the 100 cc bottle to the 500 cc cleaning fluid bottle (JD-42054).
5. Ink Absorb
CAUTION 3: What to do After the Initial Filling
When this display appears, cleaning fluid is being sucked from within the head
and tubes.
Wait for at least 30 minutes after the initial filling before you use the printer for print-
ing. Otherwise picture quality can not be assured. 6. Rm Wash Jig
★ Head Cleaning is a self-diagnostic function not available to the user. When this display appears, remove the cleaning jig.
7. Washing
« REFERENCE » Head washing includes all six colours at the same time.
Therefore, you should prepare six sets of head washing When this display appears, cleaning fluid remaining inside the head and tubes is
jigs. being ejected.
❈ Single colour or separate head washing is not possible.
8. AJST: Home
CAUTION: Before using Eco-Solvent ink, perform a head wash.
Use the special Eco-Solvent Transition Liquid. When this display appears, it is the end.
Once you have worked with Eco-Solvent inks, it is forbitten to change
to another ink type.
Head Cleaning Procedure 1 Model Name: Rockhopper-46/62 REP1620

How to Clean the Head Nozzle Face Model Name: Rockhopper-46/62 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 fin-
gers otherwise normal ejection may not be possible.
1. Turn off the Power Switch and return the Head to the home position.
(The Power Cable may remain connected)
2. Open the front cover and remove "Panel bottom cover" and "Panel bottom 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: Don’t 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 Clean the Head Nozzle Face Model Name: Rockhopper-46/62 REP1660
How to replace Speed Reduction Pulley Assembly Model Name: Rockhopper-46/62 REP1670
1. Replacement Speed Reduction Pulley Replacement Bearing stopper Bearing

Procedure
1. Remove the left cover.
2. Remove the X motor cover.
3. Loosen the four screws on the X motor mounting plate and Speed reduction
relieve the belt tension. pulley assembly
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. Speed reduction
9. Withdraw the speed reduction pulley assembly towards the pulley support
right side.
X motor mounting plate
Stopper
Coupling
2. Adjustment 1. Adjust the X speed reduction belt tension.
and
Inspection
Procedure
Speed reduction
pulley assembly
How to replace Speed Reduction Pulley Assembly Model Name: Rockhopper-46/62 REP1670
How to replace Grid Roller Assembly Model Name: Rockhopper-46/62 REP1690
1. Replacement Grid Roller Assembly Replacement

Procedure
1. Remove left cover.
2. Remove front paper guide.
3. Remove rear paper guide.
4. Remove X motor cover.
5. Remove right and left side caps.
6. Remove speed reduction pulley assembly.
7. Remove platen mounting plate (with platen attached).
8. Raise pressure lever.
9. Remove all bearing box screws.
10. Move all bearing boxes to a position where the grid roller can be
taken out upwards.
CAUTION: In order to install bearing boxes and adjustment Platen mounting plate Grid roller assembly Bearing keeper Coupling
spacers in the positions prior to replacement,
check their distribution. Take care not to lose any Bearing Box
adjustment spacers.
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. [46 inch] [62 inch]
• Be careful not to damage the grid roller.
1. Adjustment and 1. Adjust the platen height. Adjusting spacer
Inspection 2. Adjust X speed reduction belt tension.
Procedure
How to replace Grid Roller Assembly Model Name: Rockhopper-46/62 REP1690

How to replace F Absorbent Assembly Model Name: Rockhopper-46/62 REP1700
1. Replacement F Absorbent Assembly Replacement

Procedure
1. Remove the absorbent material from the F box. F box Absorbent material
2. Insert the absorbent material assembly in the F box.
How to replace F Absorbent Assembly Model Name: Rockhopper-46/62 REP1700

How to replace Waste Liquid Tank Assembly Model Name: Rockhopper 62 REP1710
1. Replacement Waste Liquid Tank Assembly Replacement

Procedure
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 liq-
uid bottle.
Waste fluid bottle L
How to replace Waste Liquid Tank Assembly Model Name: Rockhopper 62 REP1710
Rockhopper-46
3 Fundamental Knowledge Model Name: Rockhopper-46 GID0000
Fundamental Knowledge
Basic Specifications GID1000
System Block Diagram GID3000
Operating Sequence
• Power On Sequence GID4010
• Power Off Sequence GID4020
• Media Detection Sequence GID4030
• Normal Standby Sequence GID4040
• Encoder Disconnected Check Sequence GID4050
• Origin Detection Sequence GID4060
• Media Cutting Sequence GID4070
• Printing Sequence (Including Flushing) GID4080
Rockhopper-46
3 Fundamental Knowledge Model Name: Rockhopper-46 GID0000
Rockhopper-62 Fundamental Knowledge Model Name: Rockhopper-62 GID0000-3
Fundamental Knowledge
Basic Specifications GID1000-3
System Block Diagram GID3000
Operating Sequence
• Power On Sequence GID4010
• Power Off Sequence GID4020
• Media Detection Sequence GID4030
• Normal Standby Sequence GID4040
• Encoder Disconnected Check Sequence GID4050
• Origin Detection Sequence GID4060
• Media Cutting Sequence GID4070
• Printing Sequence (Including Flushing) GID4080
Rockhopper-62 Fundamental Knowledge Model Name: Rockhopper-62 GID0000-3

Rockhopper-46
3 Basic Specifications Model Name: Rockhopper-46 GID1000
System 46 inch System 46 inch
Printing System Drop-on-demand piezo driving system Area Available for Printing (Margins) Front Back Right Left
(Large capacity, 6-colour, independently removable ink cartridges: 220 cc ± 5 cc) Standard: Cut media 25mm 20mm 10mm 10mm ❉ Printing quality is assured
Eco-solvent nk
Roll media 25mm 20mm 10mm 10mm within standard margins
Printing Direction Shortest distance printing (bidirectional or unidirectional) Compatible: Cut media 25mm 20mm 5mm 5mm ❉ If media wider than 1361.6 mm
Roll media 25mm 20mm 5mm 5mm is used, the left and right
Resolution 360 dpi x 360 dpi 720 dpi x 720 dpi 1440 dpi x 720 dpi
margins will be different from
Media Transport Multi-point pressure grid roller system those shown on the left.
Media Supply and Eject Cut Media: Front supply/front eject Roll Media: Rear supply/front eject Media Holding System Pressure roller lowered by manually operated lever
CPU 64 bit RISC CPU Media Cutting System Transverse auto-cut system
Input Buffer Standard: 8 MB (main) + 4 MB (plain) Ink Cartridges Black, cyan, magenta, yellow , light cyan, light magenta: each 220 cc ± 5 cc
Extended: 16 MB, 32 MB After using Eco-solvent ink, only use Eco-solvent ink in future
Expansion slots: 2 slots (16 MB installed in one slot as standard)
Kanji Conforms to JIS1, JIS2 (1990 edition stroke font built-in)
Maximum: 72 MB (main) + 1 MB (plain)
(Font has some independent codes unspecified by JIS)
Commands Printer commands: MH-GL, MH-GL/2, (MH-RTL), RTL-PASS Interfaces Standard Bidirectional Centronics: IEEE 1284 (compatible, nibble, ECP modes)
Linear Precision The larger of ±0.1% of movement distance or ±0.5 mm Option Ethernet: WindowsNT, Windows95, TCP/IP, NetWare, EtherTalk support
Media: Thick coated paper (roll media) Head Life
Working temperature: 20°C, Humidity: 60%, Printing mode: High quality/720 dpi
Environmental Operating environment Temperature: 10°C to 35°C, humidity 20% to 80% (no condensation)
Angular Precision Within ±0.5 mm/500.0 mm Conditions
Media: Thick coated paper (roll media) Rate of change Temperature: 2°C/h, Humidity: 5%/h
Working temperature: 20°C, Humidity: 60%, Printing mode: High quality/720 dpi Storage environment Temperature: -10°C to 60°C, humidity 20% to 90% (no condensation)
Media Types High quality paper, coated paper, thick coated paper, art paper, glossy paper, glossy Power Supply (Voltage) AC100 ~ 120 V ±10%, AC200 ~ 240 V ±10% Auto Change
photographic paper, glossy film, Yupo film, Yupo tac film, cloth, fire-resistant cloth, glossy PVC Power Supply (Frequency) 50 Hz ±1 Hz / 60 Hz ±1 Hz Auto Change
tac film (Media other than the above and new media are based on OEM assessment.)
Power Standby 60 W or less
Roll Media Tube Diameter Standard 2-inch & 3-inchh Consumption Printing 75 W or less
Maximum Media Width 1089.6 mm (42.9 inch)
Cleaning 75 W or less
Media Sizes 1069.6 mm (42.1 inch)
External Height 1264 mm
Maximum Roll Media Length 50 m (maximum size roll that can be mounted) Dimensions
Width 1656 mm
Maximum Cutting Media Length 1300 mm
Depth 580 mm
Media longer than this can be loaded but media size cannot be detected and
Weight Body 49.0 kg (480.2 N)
it is handled as roll media.
Legs 15.5 kg (151.9 N)
Rockhopper-46
3 Basic Specifications Model Name: Rockhopper-46 GID1000
Rockhopper-62 Basic Specifications Model Name: Rockhopper-62 GID1000-3
System 62 inch System 62 inch
Printing System Drop-on-demand piezo driving system Area Available for Printing (Margins) Front Back Right Left
(Large capacity, 6-colour, independently removable ink cartridges: 220 cc ± 5 cc) Standard: Cut media 25mm 20mm 10mm 10mm ❉ Printing quality is assured
Eco solvent ink
Roll media 25mm 20mm 10mm 10mm within standard margins
Printing Direction Shortest distance printing (bidirectional or unidirectional) Compatible: Cut media 25mm 20mm 5mm 5mm ❉ If media wider than 1361.6 mm
Roll media 25mm 20mm 5mm 5mm is used, the left and right
Resolution 360 dpi x 360 dpi 720 dpi x 720 dpi 1440 dpi x 720 dpi
margins will be different from
Media Transport Multi-point pressure grid roller system those shown on the left.
Media Supply and Eject Cut Media: Front supply/front eject Roll Media: Rear supply/front eject Media Holding System Pressure roller lowered by manually operated lever
CPU 64 bit RISC CPU Media Cutting System Transverse auto-cut system
Input Buffer Standard: 8 MB (main) + 4 MB (plain) Ink Cartridges Black, cyan, magenta, yellow, light cyan, light magenta: each 220 cc ± 5 cc
Extended: 16 MB, 32 MB After using Eco-solvent ink, only use Eco-solvent ink in future
Expansion slots: 2 slots (32 MB installed in one slot as standard)
Kanji Conforms to JIS1, JIS2 (1990 edition stroke font built-in)
Maximum: 72 MB (main) + 8 MB (plain)
(Font has some independent codes unspecified by JIS)
Commands Printer commands: MH-GL, MH-GL/2, (MH-RTL), RTL-PASS Interfaces Standard Bidirectional Centronics: IEEE 1284 (compatible, nibble, ECP modes)
Linear Precision The larger of ±0.1% of movement distance or ±0.5 mm Option Ethernet: WindowsNT, Windows95, TCP/IP, NetWare, EtherTalk support
Media: Thick coated paper (roll media) Head Life
Working temperature: 20°C, Humidity: 60%, Printing mode: High quality/720 dpi
Environmental Operating environment Temperature: 10°C to 35°C, humidity 20% to 80% (no condensation)
Angular Precision Within ±0.5 mm/500.0 mm Conditions
Media: Thick coated paper (roll media) Rate of change Temperature: 2°C/h, Humidity: 5%/h
Working temperature: 20°C, Humidity: 60%, Printing mode: High quality/720 dpi Storage environment Temperature: -10°C to 60°C, humidity 20% to 90% (no condensation)
Media Types High quality paper, coated paper, thick coated paper, art paper, glossy paper, glossy Power Supply (Voltage) AC100 ~ 120 V ±10%, AC200 ~ 240 V ±10% Auto Change
photographic paper, glossy film, Yupo film, Yupo tac film, cloth, fire-resistant cloth, glossy PVC Power Supply (Frequency) 50 Hz ±1 Hz / 60 Hz ±1 Hz Auto Change
tac film (Media other than the above and new media are based on OEM assessment.)
Power Standby 60 W or less
Roll Media Tube Diameter Standard 2-inch & 3- inch Consumption Printing 110 W or less
Maximum Media Width 1574.8 mm (62 inch)
Cleaning 75 W or less
Media Sizes 1554.8 mm (61.2 inch)
External Height 1163.5 mm
Maximum Roll Media Length 50 m (maximum size roll that can be mounted) Dimensions
Width 2350 mm
Maximum Cutting Media Length 1300 mm
Depth 650 mm (680 mm)
Media longer than this can be loaded but media size cannot be detected and
Weight Body 85 kg (833 N)
it is handled as roll media.
Legs 17.5 kg (171.5 N)
Rockhopper-62 Basic Specifications Model Name: Rockhopper-62 GID1000-3

Names of Parts Model Name: Rockhopper-46/62 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 Take-up System

1. Exterior parts of the Main Unit (Rear)
Cartridge Cover 6 Ink Slots
Rear Paper
Guide
Waste
Bottle
Scroller
Scroller
Adjusting
Screw Scroller Slip Ring

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

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 Pressure Relay Plate Lever sensor Assembly

4. Head Section
Head pipes (6) Origin Sensor Head Board Assembly
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

5. Maintenance Station Parts
Pump Motor Assembly P Motor Flange
Pump Motor Gear

Pump Motor Plate
Damper CR
Cap Assembly Flat Washer
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
Speed Reduction
Maintenance Unit Gear Bearer

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

System Block Diagram Model Name: Rockhopper-46/62 GID3000
System Block Diagram Model Name: Rockhopper-46/62 GID3000

System Block Diagram - Heater System Model Name: Rockhopper-46 GID3001
MK-24200
MK-24201
MK-41314
MK-24210
MK-24204
MK-24209
MK-21000
MK-24205
MK-41461


Power On Sequence Model Name: Rockhopper-46/62 GID4010
error occurs
Power Switch ON [Checks Standard DRAM] Serious Error (StdDRAM)
error occurs
[Checks Optional DRAM] Serious Error (OptDRAM)
error occurs
[Checks NVRAM] [Write initial values to NVRAM]
error occurs
[Read 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)
Origin position not set
< Is capping position registered? > Error Display
No
< Carriage not at capping position on startup > Strong Cleaning
Normal Standby
Power On Sequence Model Name: Rockhopper-46/62 GID4010

Power Off Sequence Model Name: Rockhopper-46/62 GID4020
Power Switch Off < Origin detection in progress > [Servo slows and stops]
< Media initialization in progress > [Servo slows and stops]
< Media cutting in progress > [Servo slows and stops]
< Open Cover >

< Lever up and location other than capping position >
< Cleaning in progress >

< Printing in progress > [Servo slows and stops]
< 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 Model Name: Rockhopper-46/62 GID4020

Media Detection Sequence Model Name: Rockhopper-46/62 GID4030
Media Detection Sequence
< Panel setting: cut sheet >
YES
No [Media trailing edge detection]
[Media width detection at trailing edge detection position]
Media feed Media rewind

[Media width detection]
[Media leading edge detection]
[End]

(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]
Yes
< Reflection sensor reading <= 0 x 56 ? > [Sets media edge gain to normal]
[Waits 2 ms]
[Base value χ = ad2]
No
[Base value χ = ad1]

(2) Media Leading Edge Detection 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 > Yes

[Media detection error]
No < Roll media moved 3010 mm >
< Reflective sensor value became Z >
Yes No
[Moves forward 7 mm]
[Moves media slowly back to a position where reflective sensor value becomes Z]
Yes
< Media moved 10 mm > [Media detection error]
No
< Reflective sensor value became Z > No
Yes
[End]

(3) Media width detection
Carriage
Maintenance unit
Media width No
< Is the carriage over the maintenance unit? > [Move carriage to maintenance unit]
detection 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) = (χ + (a+b+c)÷ 3) ÷2]
[Moves the carriage slowly towards B to a position where the reflection sensor becomes equal to the Z value]
Yes
< Moved 144.875 mm > [Media detection error]
No
Right edge No
[Quick detection] < Reflection sensor reached Z >
144.875mm detection Yes
[Slow detection]
50.0mm [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 >
Yes
[Quick detection] Left edge No
< 62 inch: Moved 1555.425 mm >
46 inch: 1098.125mm detection
No
62 inch: 1555.425mm Yes
< Reflection sensor reached Z >
[Slow detection] [e2 = encoder count]
50.0mm
[Media width = e2-e1 : move carriage to the position of e1]

Head
Rear sensor
(XR)
[Move media forward until XR sensor goes "off" status]
< Media moved 1300 mm > Yes [Recognizes that

No
roll media is loaded]
< XR sensor becomes No
Yes
"off" status >
[Move forward 7 mm]
[Move media slowly back until XR sensor goes "off" status]
Yes
< Media moved 30 mm > [Media detection error]
No
No
< XR sensor becomes
Yes "off" status >
[End]

Normal Standby Sequence Model Name: Rockhopper-46/62 GID4040
Normal Standby Condition < 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]
Normal Standby Sequence Model Name: Rockhopper-46/62 GID4040

Encoder Disconnected Check Sequence Model Name: Rockhopper-46/62 GID4050
Compete check for [Initializes PWM gate array]

disconnected encoder
[Checks X-axis + direction]
< Origin sensor ? >

OFF
ON
[Check Y-axis + direction] [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 [PWM output on]
for disconnection
[PWM torque output]
No
< Move 5 pulses ? >
Yes
No
< 20 msec elapsed ? >
Yes
[Increases PWM torque]
No
< Moves 5 pulses ? >
Yes < 20 msec elapsed ? > No
Yes
[End] [Encoder error]
Encoder Disconnected Check Sequence Model Name: Rockhopper-46/62 GID4050

Origin Detection Sequence Model Name: Rockhopper-46/62 GID4060
Origin Detection
Machine Origin Flag

Origin
Yes
Origin < Inside origin flag ? > [Move (200 mm) towards A while monitoring Origin sensor off]
Detection No
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]

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

Yes
< Origin sensor on ? >
(Go to next page)

[Moves 10 mm towards B]
[Moves (50 mm) towards A until origin sensor goes off]

Yes
< Moved 50 mm without sensor going off ? > [Faulty sensor error]
No
[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]

Media Cutting Sequence Model Name: Rockhopper-46/62 GID4070
Detects trailing edge of media
(2) (3) (1)
Maintenance Unit
Media Cutting < Printing in progress ? >

No
Yes
< Manual cutting requested ? > If media has just been initialized, feed 10 mm
No
No
< XR sensor is "off" status ? > [Wait ink drying period]
Yes
< Is ink drying period finished ? >
Yes
< Manual cutting requested ? > [Moves forward 186 mm]
Yes
[Moves to a point 1/3 of media from right edge] < Manual cut finished key entry occurred >
[Cut towards (1)]
[ End ] [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)
No
Yes < Tried 3 times ? >
[Moves 5 mm forward]
[Moves 5 mm back]
No
< Tried 3 times ? >
Yes
Retry once if media can not be shaken out

No
< There is media at the position detected by [Media cutting error]
Yes the edge sensor >
[ End ]
Media Cutting Sequence Model Name: Rockhopper-46/62 GID4070

Printing Sequence (Including Flushing) Model Name: Rockhopper-46/62 GID4080
Yes
Colour Printing < Are you printing with media already mounted when power was switched on ?> [Pull media 300 mm forward]
Sequence No
Yes
< Did you wait for 20 minutes after initialization ? > [Pull media 250 mm forward]
No
[Pull media 150 mm forward]
[Move to position for starting to plot]
< Printing Mode ?>
360dpi High Speed 360dpi Standard 360dpi High Quality
360 × 360: 2-pass bidirectional 360 × 360: 4-pass bidirectional 360 × 360: 4-pass unidirectional
[Moves carriage and prints] [Moves carriage and prints] [Moves carriage and prints]
[Moves media 4.3 mm forward] [Moves media 2.18 mm forward] [Moves media 2.18 mm forward]
No No No
< Printing finished ? > < Printing finished ? > < Printing finished ? >
Yes Yes Yes
[End] [End] [End]
< Printing Mode ?>

720 × 720: 4-pass bidirectional 720 × 720: 4-pass unidirectional 720 × 720: 8-pass unidirectional
[Moves media 2.15 mm forward] [Moves media 2.15 mm forward] [Moves media 1.09 mm forward]
No No No
Yes Yes Yes
[End] [End] [End]

< Printing Mode ?>
1440 × 720: 4-pass bidirectional 1440 × 720: 8-pass unidirectional 1440 × 720: 8-pass unidirectional
[Moves media 1.13 mm forward] [Moves media1.13 mm forward] [Moves media 1.13 mm forward]
No No No
Yes Yes Yes
[End] [End] [End]
Note: Flushing occurs each time. • 46-inch: Flushes on right side
• 62-inch: Flushes on right side (for bidirectional printing with pigment inks, flush left & right)
Printing Sequence (Including Flushing) Model Name: Rockhopper-46/62 GID4080

Rockhopper-46
3 Stored Test Patterns Model Name: Rockhopper-46 PAT 0 0 0 0
Stored Test Patterns

< Stored Test Patterns >
These are patterns that are stored in the printer and can be output by the user or the serviceman when required without using a host computer.
The printer contains the following three stored test patterns, any of which can be output directly by keys.
No. Name of Stored Test Pattern Name of Direct Keys Purpose and Details Reference Page
1. Test Pattern [Shift]+[PRINT LAYOUT] When trouble related to printing (such as picture quality or printing precision) PAT1000
has occurred, having this pattern output in the field can become the basis for
identifying the cause of the problem from the maintenance manual.
In A3 size, it is a 7-colour pattern showing picture quality and printing precision.
When printing with A0 media mounted, in addition to the A3 size pattern,
the J line pattern will be printed over the entire width in the Y direction.
• Printing will be in accordance with the printing mode set on the panel.
2.
3. Print Quality Adjustment Pattern [Shift]+[CLEANING] Print quality adjustment pattern for obtaining the best printing quality. PAT3000
Mount A3 or bigger cut media or roll media.
Pattern A is for adjusting the Repeatability printing position of the left head.
Pattern B is for adjusting the Repeatability printing position of the right head.
Pattern C is for aligning the printing positions of the left and right heads.
• The printing mode set on the panel will be ignored.
4. Setup List [Shift]+[MEDIA] Outputs the user information currently set in the printer PAT4000
A4 size, settings are output as test.
Rockhopper-46
3 Stored Test Patterns Model Name: Rockhopper-46 PAT 0 0 0 0
Rockhopper-62 Stored Test Patterns Model Name: Rockhopper-62 PAT 0 0 0 0 - 3
Stored Test Patterns

< Stored Test Patterns >
These are patterns that are stored in the printer and can be output by the user or the serviceman when required without using a host computer.
The printer contains the following three stored test patterns, any of which can be output directly by keys.
No. Name of Stored Test Pattern Name of Direct Keys Purpose and Details Reference Page
1. Test Pattern [Shift]+[PRINT LAYOUT] When trouble related to printing (such as picture quality or printing precision) PAT1000
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.
2.
3. Print Quality Adjustment Pattern [Shift]+[CLEANING] Print quality adjustment pattern for obtaining the best printing quality. PAT3000
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.
4. Setup List [Shift]+[MEDIA] Outputs the user information currently set in the printer PAT4000
A4 size, settings are output as test.
Rockhopper-62 Stored Test Patterns Model Name: Rockhopper-62 PAT 0 0 0 0 - 3

Stored Test Patterns/Test Pattern Model Name: Rockhopper-46/62 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 Location for Confirmation
• Printed result differs from other machines Whole
• No printing at all Whole
• Entire surface printed black Whole
• Printing density varies Rows C, D, E, H
• Black and white stripes appear in the printing Rows C, D, E, H, J
• Edges of printing are blurred Rows C, D, E, G
• Dots missing from printing Row Row G
• Many satellites (unwanted dots) Whole
• Whiskers on the printing Rows A, B, I
• Lines are blurred Frame and Frame, Row I
• Mixed colour lines do not overlap Rows A, B, I
• Black and colour positions are offset Row I
• Printed length is abnormal Frame
Plotted over the entire width of the media

that is loaded
Stored Test Patterns/Test Pattern Model Name: Rockhopper-46/62 PAT 1 0 0 0

Stored Test Patterns/Print quality adjustment pattern Model Name: Rockhopper-46/62 PAT 3 0 0 0
Print quality adjustment pattern
This prints patterns shown in the diagram on the right for making fine adjustments of printing Alignment Print
quality.
• Pattern A is for adjusting the Repeatability printing position of the left head.
• Pattern B is for adjusting the Repeatability printing position of the right head.
• Pattern C is for aligning the printing positions of the left and right heads.
1. Make sure no data are being received then mount an A3 or larger sheet of cut media 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 adjust-
ments using the following procedures.
4. [Pattern A: 4] is displayed.
Use the setting Value + and - keys to enter the number of the best image and press
[ENTER].
5. [Pattern B: 4] is displayed.
[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 Model Name: Rockhopper-46/62 PAT 3 0 0 0
Stored Test Patterns/Setup List Model Name: Rockhopper-46/62 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 Model Name: Rockhopper-46/62 PAT 4 0 0 0

Rockhopper-46
3 Self-Diagnostic Functions Model Name: Rockhopper-46 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 Flush Pointer Adjustment ------------------------------------------------------------BAC2110

How to Start Self-Diagnosis ---------------------------------------------------------------BAC0020 Media Feed Distance Compensation ---------------------------------------------BAC2120
Margin Adjustment ---------------------------------------------------------------------BAC2130
1. Examination ----------------------------------------------------------------------------------BAC1000 Rear Sensor Position Adjustment--------------------------------------------------BAC2140
Memory Capacity-----------------------------------------------------------------------BAC1010 Test Print ---------------------------------------------------------------------------------BAC2150
Version ------------------------------------------------------------------------------------BAC1020 Head Wash ------------------------------------------------------------------------------BAC2160
Panel --------------------------------------------------------------------------------------BAC1030
Sensors -----------------------------------------------------------------------------------BAC1040 3. Cleaning ---------------------------------------------------------------------------------------BAC3000
Encoders ---------------------------------------------------------------------------------BAC1050 Normal, Powerful
Fans ---------------------------------------------------------------------------------------BAC1060
Ethernet Board --------------------------------------------------------------------------BAC1065 4. Test Printing ---------------------------------------------------------------------------------BAC4000
History: Last error message ---------------------------------------------------------BAC1070 Head Printing Verification
History: Head nozzle ejection count check --------------------------------------BAC1070 Check Black In-filling
Head Drive Waveform ----------------------------------------------------------------BAC1080 Adjustment Parameters
2. Adjustment -----------------------------------------------------------------------------------BAC2000 5. Parameters -----------------------------------------------------------------------------------BAC5000

Capping Position Adjustment -------------------------------------------------------BAC2010 Initialize -----------------------------------------------------------------------------------BAC5010
Skew Verification -----------------------------------------------------------------------BAC2030 Update ------------------------------------------------------------------------------------BAC5020
Head Rank Input (Initial Filling)-----------------------------------------------------BAC2040
Head Nozzle Verification -------------------------------------------------------------BAC2050 6. Aging -------------------------------------------------------------------------------------------BAC6000
Left Head Tilt Verification ------------------------------------------------------------BAC2060 Carriage Motor --------------------------------------------------------------------------BAC6010
Right Head Tilt Verification ----------------------------------------------------------BAC2070 Media Feed Motor----------------------------------------------------------------------BAC6020
Repeatability Printing Positioning (Normal dot, Micro dot) ------------------BAC2080 Cutter --------------------------------------------------------------------------------------BAC6030
CW Adjustment (Normal dot, Micro dot) -----------------------------------------BAC2090 Maintenance Unit-----------------------------------------------------------------------BAC6040
Head ---------------------------------------------------------------------------------------BAC6050
Rockhopper-46
3 Self-Diagnostic Functions Model Name: Rockhopper-46 BAC0000
Rockhopper-62 Self-Diagnostic Functions Model Name: Rockhopper-62 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 Flush Pointer Adjustment ------------------------------------------------------------BAC2110

How to Start Self-Diagnosis ---------------------------------------------------------------BAC0020 Media Feed Distance Compensation ---------------------------------------------BAC2120
Margin Adjustment ---------------------------------------------------------------------BAC2130
1. Examination ----------------------------------------------------------------------------------BAC1000 Rear Sensor Position Adjustment--------------------------------------------------BAC2140
Memory Capacity-----------------------------------------------------------------------BAC1010 Test Print ---------------------------------------------------------------------------------BAC2150
Version ------------------------------------------------------------------------------------BAC1020 Head Wash ------------------------------------------------------------------------------BAC2160
Panel --------------------------------------------------------------------------------------BAC1030
Sensors -----------------------------------------------------------------------------------BAC1040 3. Cleaning ---------------------------------------------------------------------------------------BAC3000
Encoders ---------------------------------------------------------------------------------BAC1050 Normal, Powerful
Fans ---------------------------------------------------------------------------------------BAC1060
Ethernet Board --------------------------------------------------------------------------BAC1065 4. Test Printing ---------------------------------------------------------------------------------BAC4000
History: Last error message ---------------------------------------------------------BAC1070 Head Printing Verification
History: Head nozzle ejection count check --------------------------------------BAC1070 Check Black In-filling
Head Drive Waveform ----------------------------------------------------------------BAC1080 Adjustment Parameters
2. Adjustment -----------------------------------------------------------------------------------BAC2000 5. Parameters -----------------------------------------------------------------------------------BAC5000

Capping Position Adjustment -------------------------------------------------------BAC2010 Initialize -----------------------------------------------------------------------------------BAC5010
Skew Verification -----------------------------------------------------------------------BAC2030 Update ------------------------------------------------------------------------------------BAC5020
Head Rank Input (Initial Filling)-----------------------------------------------------BAC2040
Head Nozzle Verification -------------------------------------------------------------BAC2050 6. Aging -------------------------------------------------------------------------------------------BAC6000
Left Head Tilt Verification ------------------------------------------------------------BAC2060 Carriage Motor --------------------------------------------------------------------------BAC6010
Right Head Tilt Verification ----------------------------------------------------------BAC2070 Media Feed Motor----------------------------------------------------------------------BAC6020
Repeatability Printing Positioning (Normal dot, Micro dot) ------------------BAC2080 Cutter --------------------------------------------------------------------------------------BAC6030
CW Adjustment (Normal dot, Micro dot) -----------------------------------------BAC2090 Maintenance Unit-----------------------------------------------------------------------BAC6040
Head ---------------------------------------------------------------------------------------BAC6050
Rockhopper-62 Self-Diagnostic Functions Model Name: Rockhopper-62 BAC0000-3

Self-Diagnosis Tree 1 Model Name: Rockhopper-46/62 BAC0010
1. Examination BAC1000
1.1 Memory Capacity Memory Capacity BAC1010

1.2 Versions Firmware BAC1020
Parameters
DIP Switches
1.3 Panel Keys BAC1030
LCD
LEDs and Buzzer
1.4 Sensors X Front, X Rear, Cover, Lever BAC1040
Origin, No Ink, No Cartridge, Ink ID, Media Edge
Temperature, Waste Fluid Tank
1.5 Encoder Encoder X BAC1050
Encoder Y
1.6 Fan Fan Check On BAC1060
Fan Check Off
1.7 Ethernet Board BAC1065
1.8 History Maintenance L Head Ejections: ❉❉mdot BAC1070
(Head Nozzle Ejection Count) L Wiping Count: ❉❉
L Rubbing Count: ❉❉
R Head Ejections: ❉❉mdot
R Wiping Count: ❉❉
R Rubbing Count: ❉❉
W Wiping Count: ❉❉
W Rubbing Count: ❉❉
Quantity of Ink in Waste Fluid Tank
Black Ink Remaining
Cyan Ink Remaining
Magenta Ink Remaining
Yellow Ink Remaining
G Ink Remaining
O Ink Remaining
CPU System and Mechanical System Errors Failure Error 1 ~ 7 BAC1070
(Last error message display)
1.9 Head Drive Waveform Head Waveform VK BAC1080
KC1
CHG
ND2
ND1
TR1
FLUSH

2. Adjustments
2.1 Capping Position Adjustment BAC2010

2.2 Skew Verification BAC2030
2.3 Head Rank Input (including Initial Filling) Left Rank: ❉❉❉ BAC2040
Right Rank: ❉❉❉
Filling
2.4 Head Nozzle Verification Printing BAC2050

Normal Cleaning
Powerful Cleaning
2.5 Left Head Tilt Verification Printing BAC2060
2.6 Right Head Tilt Verification Printing BAC2070
2.7 Repeatability Printing Positioning (Normal dot) Left Differential BAC2080
Right Differential
2.8 Repeatability Printing Positioning (Micro dot) Left Differential BAC2080
Right Differential
2.9 CW Adjustment (Normal dot) Gap adjustment BAC2090
2.10 CW Adjustment (Micro dot) Gap adjustment BAC2090
2.11 Flush Pointer Adjustment Left Pointer BAC2110
Right Pointer
Left Pointer (left flushing)
Right Pointer (right flushing)
2.12 Media Feed Distance Compensation BAC2120
2.13 Front-to-Head, Cutter-to-Head Distance Adjustment Top Distance BAC2130
Bottom Distance
Distance
Distance
2.14 Rear Sensor Position Adjustment BAC2140
2.15 Test Print Head Printing Verification BAC2150
Black in-filling
Adjustment Parameters
2.16 Head Wash BAC2160

3. Cleaning BAC3000
3.1 Normal
3.2 Powerful
4. Test Printing BAC4000

4.1 Head Printing Verification
4.2 Black infill printing
4.3 Adjustment Parameters
5. Parameters BAC5000
5.1 Initialization Capping Position BAC5010
X Encoder Resolution
Maintenance History Left Head
Error History Right Head
Serial Number Wiper
Complete
5.2 Updating Capping Position BAC5020
Head Rank Left
Right
Print Positioning L Delay
R Delay
Gap
Print Positioning (Micro dot) L Delay
R Delay
Gap
Media Transport Distance
Mechanical Parameters 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
6. Aging PaperWidAdj
6.1 Carriage Motor BAC6000
6.2 Media Feed Motor BAC6010
6.3 Cutter BAC6020
6.4 Maintenance Unit BAC6030
6.5 Head Left BAC6040
Right BAC6050

How to Start Self-Diagnosis Model Name: Rockhopper-46/62 BAC0020
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 spe-
cial 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 adjust-
ment. The printer will be reset on exiting diagnostic mode. Diagnostic functions are
as follows.
Operations for selecting Diagnostics items are shown below.
Table 1: Hidden diagnostic functions
Item Details DIAG: Exam ❈ To terminate self-diagnostics, switch off the power.
Examination Verification of RAM capacity, version, panel, sensors, encoders, fans,
network board, history and waveform Menu Up
ENTER
Adjustment Manufacturing processes, adjustments on head replacement and DIAG: Exam Examination Menu
adjustments to media feed system Back
Cleaning Mode specified head cleaning Menu Down Menu Up
ENTER
Test printing Head nozzle verification printing, black in-filling and adjustment parameters DIAG: Adjustment Adjustment Menu
Parameters Initialization, updating Back
Menu Down Menu Up
Aging Carriage motor, media feed, cutter, maintenance unit, head ENTER
DIAG: Cleaning Cleaning Menu
Back
Menu Down Menu Up
1. Power supply to the printer is off. ENTER
2. Switch on the power with the [Head Cleaning] + [Menu Display] + [Shift] keys DIAG: Test Print Test Print Menu
Back
held down. Menu Down Menu Up
3. The panel LCD will display “DIAG: EXAM”. X and Y excitation remains off. ENTER
DIAG: Parameter Parameter Menu
Note 1: The system will not revert to normal mode even if there is no key entry for three minutes. Back
Note 2: Roll media mode is set automatically. Menu Down Menu Up
ENTER
Note 3: Panel keys that can be operated are [CANCEL] and the keys for menu display (Menu Up
DIAG: Aging Aging Menu
and Down, Back, Value + and –, ENTER) Back
Note 4: To terminate self-diagnostics, switch off the power. Menu Down
Note 5: To feed media, press [MENU] while holding down the [Shift] key when the Diagnostics Menu
is displayed.
How to Start Self-Diagnosis Model Name: Rockhopper-46/62 BAC0020

Examination Model Name: Rockhopper-46/62 BAC1000
This is intended for board checking. X and Y excitation is not turned on by selecting To return to the Diagnostics Menu from the Examination Menu, press [Back].
“Examination” from the Diagnostics Menu.
EXAM:
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. Menu Up
ENTER
EXAM: Ram Capacity Memory Capacity Display
Back
Table 1-1: Board examination items Menu Down Menu Up
ENTER
Item Details EXAM: Version Version Display
Memory Capacity Check memory capacity Back
Versions Programs, Backup parameters, DIP Switches Menu Down Menu Up
Panel Keys, LCD, LEDs, Buzzer ENTER
Sensors XF, XR, Covers, Levers, Origin, Ink out, No cartridge, Ink ID, EXAM: Panel Panel Check
Media edge, Thermistor, Waste fluid tank Back
Menu Down Menu Up
Encoders X-axis (media feed), Y-axis (carriage) ENTER
Fans Check on/off EXAM: Sensor Sensor Check
Network Initializing, None, Error, Initialization Error, Initialization OK Back
History Maintenance, Major failure Menu Down Menu Up
Head Waveform Check head drive waveform ENTER
EXAM: Encoder Encoder Check
Back
Menu Down Menu Up
ENTER
EXAM: Fan Fan Check
Back
Menu Down Menu Up
ENTER
EXAM: Option Board Initialize Data Display
Back
Menu Down Menu Up
ENTER
EXAM: Record History Display
Back
Menu Down Menu Up
ENTER
EXAM: Head Drive Waveform Check
Back
Menu Down
Examination Model Name: Rockhopper-46/62 BAC1000

Examination: Memory Capacity Model Name: Rockhopper-46/62 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 Model Name: Rockhopper-46/62 BAC1010

Examination: Version Model Name: Rockhopper-46/62 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 1.00 Program version display
Menu Down Menu Up
VER: Param 1.00 Backup parameter version display
Menu Down Menu Up
VER: Dip SW 0xFF Verify DIP switches
Menu Down
« Reference »
DIP switch
1 Off 2 Off : 0 X 03
1 On 2 Off : 0 X 02
1 Off 2 On : 0 X 01
1 On 2 On : 0 X 00
Press [ENTER] to shift to “EXAM: Panel” or [Back] to shift to “EXAM: Version”.
Examination: Version Model Name: Rockhopper-46/62 BAC1020

Examination: Panel Model Name: Rockhopper-46/62 BAC1030
This procedure is used to check panel keys, LCD, LEDs and buzzer.
EXAM: Panel
PANEL: Key Panel key check Under key check, when each key is pressed that
key is shown on the LCD. Press the [ENTER] key
Menu Up ENTER to shift to LCD check after 2 seconds.
PANEL: L c d ■■■■■■ Panel LCD check Under LCD check, the screen is repeatedly filled
with black from the right edge.
Menu Up Menu Down
PANEL: L e d • B u z z e r Panel LED and buzzer check Under LED and buzzer check, LEDs are lit in
sequence from Data, Error, Standard, Thin,
Menu Down High Quality, Normal, High Speed, Low, High
Roll Media, Cut Sheet and finally the sounding of
the buzzer is checked.
Press [ENTER] to shift to “EXAM: Sensor” or [Back] to shift to “EXAM: Panel”.
Examination: Panel Model Name: Rockhopper-46/62 BAC1030

Examination: Sensors Model Name: Rockhopper-46/62 BAC1040
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 Menu Up
(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: K D C D G D M P Y W O N Ink type check
EXAM: Sensor Menu Down Menu Up
SENS: Edge 004e Media edge sensor check

Menu Up
Menu Down Menu Up
SENS: Xf Paper Off X Front sensor check
SENS: TEMP 25, 25°C Temperature sensor check
Menu Down Menu Up
Menu Down Menu Up
SENS: Xr Paper Off X Rear sensor check
SENS: Tank Exist Waste fluid tank sensor check
Menu Down Menu Up
Menu Down
SENS: Cover Open Cover sensor check
Menu Down Menu Up
No Cart. means No Cartridge.
SENS: Lever Down Lever sensor check Colour is expressed by an alphabetical letter.
Cartridge indicates the Special Cartridge sensor.
Menu Down Menu Up
SENS: Origin On Origin sensor check KCGMYO ink ID display

D = dye, P = pigment, W = cleaning liquid, N = other brand, = no cartridge
Menu Down Menu Up
SENS: No Ink KCGMYO No Ink sensor check Press [ENTER] to shift to [EXAM: Encoder] or [Back] to shift to [EXAM: Sensor].
Menu Down Menu Up
SENS: No Car KCGMYO Cartridge sensor check
Menu Down
Examination: Sensors Model Name: Rockhopper-46/62 BAC1040

Examination: Encoders Model Name: Rockhopper-46/62 BAC1050
This procedure is used to verify the values of X-axis (media feed) and Y-axis (car-
riage) from displays on the panel or the terminal.
EXAM: Encoder
Menu Up
ENCODER : X 0000 X encoder check
Menu Down 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 Model Name: Rockhopper-46/62 BAC1050

Examination: Fans Model Name: Rockhopper-46/62 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 Model Name: Rockhopper-46/62 BAC1060

Examination: Ethernet Board Model Name: Rockhopper-46/62 BAC1065
This procedure is used to verify the initialization of Ethernet board data.
EXAM: Option Board

Ethernet board initialization is in progress.
OptBoard: Initialize
Wait until the next message is displayed.
OptBoard: No There is no Ethernet board.
OptBoard: Wrong The Ethernet board is wrong.
An error has occured during

OptBoard: Error
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 Model Name: Rockhopper-46/62 BAC1065

Examination: History Model Name: Rockhopper-46/62 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: Mainte Verify maintenance history
Menu Down Menu Up
RECORD: Error Verify error history
Menu Down
If [Back] is pressed while the History menu is displayed, the display will shift to
“EXAM: Record”.

Maintenance History
Panel and Terminal displays are shown below.

Menu Up
EXAM: Mainte
Waste-Ink: 120 cc Volume of ink waste fluid
Menu Up Menu Down Menu Up

Number of Black head ejections
L Head Count: 0M (Unit 1 Mdot) KRemainder: Full Number of ejections remaining to end of black ink
Menu Down Menu Up Menu Down Menu Up
L Wiping: 2 Number of times Black head wipings CRemainder: Full Number of ejections remaining to end of cyan ink
L Rubbing: 2 Number of times Black head rubbings MRemainder: Full Number of ejections remaining to end of magenta ink
Number of Colour head ejections
R Head Count: 0M (Unit 1 Mdot) YRemainder: Full Number of ejections remaining to end of yellow ink
R Wiping: 2 Number of times Colour head wipings Number of ejections remaining to end of G ink
GRemainder: Full
R Rubbing: 2 Number of times Colour head rubbings
ORemainder: Full Number of ejections remaining to end of O ink
Menu Down Menu Up Menu Down
W Wiping: 4 Number of times Wiper wipings
Menu Down Menu Up
W Rubbing: 4 Number of times Wiper rubbings 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
Menu Down to “RECORD: Mainte”.

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 CURRENT Y over-current error
Menu Down Menu Up
Err1 : X MOTOR X motor error
Menu Down Menu Up
Err2 : 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 Model Name: Rockhopper-46/62 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. [Terminal]
Therefore the cables connected to the head board should be disconnected. Left Head VK voltage TP17
Left Head COM Q5E
EXAM: Head Drive Right Head VK voltage TP15
Right Head COM Q3E
Menu Up
ENTER
Head Driver: VK PullOut Head Cable
Menu Down Menu Up ENTER
Head Driver: KC1 ENTER KEY to END
Menu Down 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 Model Name: Rockhopper-46/62 BAC1080

Adjustment Model Name: Rockhopper-46/62 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 Details
Capping Position Adjustment To adjust capping position parameters in the firmware
Skew Verification To use sensor results to check for media skew
Head Rank Input To enter a specific value for a specific head and fill inks
Head Nozzle Verification After filling inks, to check head nozzle ejection by print results
Black Head Tilt Verification To check left head tilt by printing (mechanical adjustment)
Colour Head Tilt Verification To check right head tilt by printing (mechanical adjustment)
Repeatability Printing Positioning To align reciprocal printing position by printing
CW Adjustment To align the shafts of the two heads by printing and adjust left
margin
Flush Pointer Adjustment To adjust the position for flushing into the flushing box
Media Feed Distance Compensation To print a line in the X direction and enter its distance (X resolu-
tion adjustment)
XF-XR Sensor Distance To measure the distance XF and XR sensors with cut media
XF, Cutter-to-Head Distance To adjust top, bottom, left and right margins
Test Print To check head nozzles and adjust parameters (enter serial num-
bers)
Head Wash Done after manufacturing and before head replacement

Press [Back] to return to the self-diagnostics Menu from the Adjustment Menu.
DIAG: Adjustment
Menu Up
Menu Up
ENTER
AJST: UniDir Print
AJST: Home Capping Position Adjustment
Back Menu Down Menu Up
Menu Down Menu Up
AJST: Chk Paper Mov AJST: Flash Point

Menu Down Menu Up
Menu Down Menu Up
AJST: Head Rank AJST: X Length
Menu Down Menu Down Menu Up

Menu Up
AJST: ChkNozzles AJST: Margin
AJST: Left Tilt AJST: Rear Sns Posi
AJST: Right Tilt AJST: Test Print

AJST: BiDir Print AJST: Head Wash
Menu Down Menu Up
AJST: UniDir (MD)
Menu Down Menu Up
AJST: UniDir Print
Note: MD = Microdot

Adjustment: Capping Position Model Name: Rockhopper-46/62 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 Model Name: Rockhopper-46/62 BAC2010

Adjustment: Media Skew Model Name: Rockhopper-46/62 BAC2030
This procedure will feed a specific amount of paper (a single pass band feed) and the sen- Press [ENTER] to move to “Adjustment: Rank Input” or [Back] to move to
sors will read the position of the edge of the media before and after feeding and check for “AJST: ChkPaperMov”. Other panel keys are ignored during processing.
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 Standard values
feeding the specified amount, the edge sensors will again detect the left and right edges of
Condition A0 Media
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 Cut Sheet ±1.5 mm or less
Thick
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 pro- 7m ±2.5 mm or less coated
cessing is in progress. Roll Media paper
CAUTION: Make sure media is properly loaded. 50 m ±10 mm or less
The first time this adjustment is made, the reference position for media skew will be deter-
mined by detecting the right edge (origin side). If the adjustment is made with a bad 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
After media initialization has been completed
Paper Feed 1.0 m Setting can be specified in units of
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 + for cap side, - for opposite side
Non-origin side Capping position side
Adjustment: Media Skew Model Name: Rockhopper-46/62 BAC2030

Adjustment: Head Rank Model Name: Rockhopper-46/62 BAC2040
This is to enter the rank for the left or right head. This is used to determine CAUTION:
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 The following operations must not be performed during ink filling.
is invalid. When the right rank is set, pressing the [ENTER] key will switch to Printing will not work properly if ink filling is stopped or interrupted.
the ink filling menu. • Switching off the power
• Opening the front cover
AJST: Head Rank • Raising the pressure lever
Settings are changed by + and -, from
Left Rank: 21117 the left normal rank, frequency ID, • Removing an ink cartridge
Menu Down Menu Up micro-rank are all displayed when
everything is confirmed. CAUTION:
Right Rank: 26■■■ Parameters are updated by setting the
Press [ENTER] to entire right rank. The ink filling operation will not proceed unless all six ink cartridges are
move to the following item 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 Model Name: Rockhopper-46/62 BAC2040

Adjustment: Head Nozzles Model Name: Rockhopper-46/62 BAC2050
After filling the inks, this procedure uses printing results to check whether the head If [ENTER] is pressed while “Nozzle check completed” is displayed, the “AJST:
nozzles are ejecting the ink properly. If the nozzles are ejecting ink badly, imple- BlackTilt” menu will be appear. If [Back] is pressed while no processing is in
ment the cleaning treatment in this procedure. If there is no media, the printer will progress, “AJST: ChkNozzles” will be restored.
request media. If it is out of ink, it will ask for an ink cartridge. If there is media and
Head Nozzle Check Pattern (6 colours)
ink, the Head Nozzle Check Pattern will be printed.
Check Items Nozzle ink eject check (missing, discontinuous, meandering)
This and subsequent items that require printing for adjustment or checking include
Satellite
requests for media and inks. If the [CANCEL] key is pressed during printing, the
Timing fence
printer will stop printing.
Printing method Single-pass, bidirectional
AJST: ChkNozzles X 180 dpi Y 360 dpi
Set Paper If media is not loaded
After media has been loaded
Paper Initial
Media initialization in progress
[C] no ink If there is no cyan ink for instance
After installing a cyan ink cartridge
Adjustment Print Adjustment print is displayed
Printing is finished o y m
END: ChkNozzles Menu Up is output

g c k
Menu Down Menu Up
CLEAN: Normal
Menu Down Menu Up 5
CLEAN: Powerful 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
Menu Down Menu Up
START: ChkNozzles [Menu Down] completed
25
Select cleaning [Enter] to move to the following
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 Model Name: Rockhopper-46/62 BAC2050

Adjustment: Left Head Tilt Model Name: Rockhopper-46/62 BAC2060
This procedure uses printing results to check whether the left head is tilted. If it is Left Head Tilt Check Pattern
tilted, it needs to be adjusted mechanically.
Check Items Left head tilt
AJST: Left Tilt
Adjustment Print Displayed during printing Print Method Single-pass, uni-direction
Printing finished X 180 dpi, Y 720 dpi
END: Check Tilt [Menu Down] is output
Menu Down Menu Up
Press [ENTER] to print again,
START: Check Tilt
next menu is end
Width 4.5
Press [ENTER] while “END: Check Tilt” is displayed to move to “AJST: 5
Right Tilt”. c k c k g k g k c k c k g k g k c k c k g k g k
Paint Vertical width 6
25
30 µm or less
k g k g
30 µm or less
k k
Right side (g side) is Right side (g side) is

too far forward. too far back.
Adjustment: Left Head Tilt Model Name: Rockhopper-46/62 BAC2060

Adjustment: Right Head Tilt Model Name: Rockhopper-46/62 BAC2070
This procedure uses printing results to check whether the right head is tilted. If it is Right Head Tilt Check Pattern
tilted, it needs to be adjusted mechanically.
Check Items Right head tilt (based on Left head)
AJST: Right Tilt
Adjustment Print Displayed during printing Print Method Single-pass, uni-directional
Printing finished
X 180 dpi, Y 360 dpi
END: Check Tilt [Menu Down] is output
Menu Down Menu Up
Press [ENTER] to print again, The center of the right head
START: Check Tilt
next menu is end Width 9
Press [ENTER] while “END: Check Tilt” is displayed to move to 5
“AJST: BiDirPrint”. k y c y g m o k g o m k
Paint Vertical width 6

The center of the left head
25
Standard values
y y c
c y y
30 µm or less 30 µm or less
Adjustment: Right Head Tilt Model Name: Rockhopper-46/62 BAC2070

Adjustment: Repeatability Printing Position Model Name: Rockhopper-46/62 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 Displayed during printing Adjustment Print Displayed during printing
ENTER ENTER
Setting can be specified in units of Setting can be specified in units of
KCG Err: -250 µm KCG Err: -250 µm
10 µm using the VALUE + and - keys 10 µm using the VALUE + and - keys
Menu Down Menu Up Press [ENTER] to update reciprocal difference Menu Down Menu Up Press [ENTER] to update reciprocal difference
Setting can be specified in units of Setting can be specified in units of
MYO Err: -250 µm 10 µm using the VALUE + and - keys MYO Err: -250 µm 10 µm using the VALUE + and - keys
Press [ENTER] Press [ENTER] Press [ENTER] to update the reciprocal difference Press [ENTER] Press [ENTER] Press [ENTER] to update the reciprocal
after correction without correction after correction without correction difference
Print Start? Print Start?
ENTER ENTER
If [ENTER] is pressed at “MYO Err:” and the parameter has been changed, 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 the left and right CCW printing delays (position and timing) will each be updated
in the firmware and another adjustment print will be made. in the firmware and another adjustment print will be made.
If the parameter was not changed, “Print Start?” will be displayed. If the parameter was not changed, “Print Start?” will be displayed.
If [ENTER] is pressed, another adjustment print will be made. If [ENTER] is pressed, another print will be made.
If [Back] is pressed, the display will move to “AJST: BiDir (MD)”. If [Back] is pressed, the display will move to “AJST: UniDirPrint”. (BAC2090)
→ Continued next page

Repeatability printing position alignment pattern (6 colours)
Adjustment items Left and right repeatability printing position alignment
Printing method Single-pass, bidirectional

CW printing – +
CCW printing
CW printing
Standard values
50 µm or less 70 µm or less

Adjustment: CW Model Name: Rockhopper-46/62 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 ENTER
Adjustment Print Displayed during printing Adjustment Print Displayed during printing
ENTER ENTER
Setting can be specified in units of 5 µm Setting can be specified in units of ±5 µm
Head Gap: -34765µm Head Gap: -34765 µm
Press [ENTER] to update gap Press [ENTER] to update gap
Press [ENTER] Press [ENTER]
after correction after correction
Set values are updated by [ENTER]. In the case where [ENTER] was pressed 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 under "Head Gap:", if the parameter change is changed another adjustment print
will be made. will be made.
If [ENTER] is pressed without the parameter being changed, control shifts to If [ENTER] is pressed without the parameter being changed, control shifts to "Flush
"Adjust: CW (MD)". Pointer adjustment".

CW Adjustment Pattern (6 colours)
Adjustment Items Left and right head axial alignment
Printing method Single-pass, uni-directional

0.7
g c k
o y m o y m o y m
9
k
5
25
Standard value
- +
Enter this distance
50 µm or less

Adjustment: Flush Pointer Model Name: Rockhopper-46/62 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
Cap unit side flushing box ejection finished

Setting can be specified in 1 pulse units
Left Point: 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 Model Name: Rockhopper-46/62 BAC2110

Adjustment: Media Feed Distance Model Name: Rockhopper-46/62 BAC2120
This procedure is used to adjust the distance for media transport. The adjustment Media feed distance adjustment pattern
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. Adjustment items Adjust the distance for media transport
Printing method Four-pass, bidirectional 360 dpi
AJST: X Length
Adjustment Print Displayed during adjustment printing
Printing finished
Setting can be specified in 0.1 mm units
XLine Len: 300.0 mm
using the VALUE + and - keys
When parameter is changed and [ENTER] is pressed k m c y
k
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. k r g y bmc
300
150
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 Model Name: Rockhopper-46/62 BAC2120

Adjustment: Top and Bottom, Left and Right Margins Model Name: Rockhopper-46/62 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.
AJST: Margin Front/Cutter to Head Distance Adjustment Pattern

An adjustment print is made after the leading edge of the media is cut.
Adjustment Items Top and bottom margins, left and right margins
Adjustment Print Displayed during adjustment printing Printing Method Black, single-pass, uni-directional 360 dpi
After print finished and the media was cut
T Margin: 25.0 mm Setting can be specified in 0.1 mm units
using the VALUE + and - keys Bottom distance 20
Menu Down Menu Up
Setting can be specified in 0.1 mm units
B Margin: 20.0 mm using the VALUE + and - keys 5 5
Menu Down Menu Up
> Margin: 5.0 mm Black paint, vertical width 9
Menu Down Menu Up Top distance 25

< Margin: 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 Model Name: Rockhopper-46/62 BAC2130
Adjustment: Rear Sensor Position Model Name: Rockhopper-46/62 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
Setting can be specified in ±0.1 mm units
Paper Y: 840.0 mm
using the VALUE + and - keys
Press [ENTER] to update the setting, and move to “AJST: Test Print”.
Adjustment: Rear Sensor Position Model Name: Rockhopper-46/62 BAC2140

Adjustment: Test Print Model Name: Rockhopper-46/62 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 Print
Printing finished
Menu Up Menu Down ENTER
PRINT: Black Fill Print
Printing finished
Menu Up Menu Down ENTER
PRINT: Parameters Print
Printing finished
On [ENTER], if no serial number is registered
Register Serial Number Back
Parameter is printed but serial
ENTER number is not printed.
Digits to be entered will blink from the left.
1 BZ400001 Use the VALUE + and - keys to change the
settings
Use [ENTER], [Menu Up] and [Menu Down]
Adjustment parameter printing to move between digits
begins
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 Model Name: Rockhopper-46/62 BAC2150

Adjustment: Head Wash Model Name: Rockhopper-46/62 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 follow-
ing procedure by pressing the [ENTER] key.
AJST: Head Wash

Rm All Cartridge
After all cartridges are removed
Set Wash Jig
After withdrawing a specified amount of ink
Ink Absorb
After all cleaning jigs are installed
Washing
After cleaning fluid has been extracted
Rm Wash Jig
After cleaning jig has been removed
Washing
After head cleaning has been completed, the display will move to “AJST: Home”.
Adjustment: Head Wash Model Name: Rockhopper-46/62 BAC2160

Cleaning: Normal, Powerful Model Name: Rockhopper-46/62 BAC3000
This procedure is used for head nozzle cleaning. The items are as follows. Normal
Normal cleaning (wiping). It moves to next menu, “CLEAN: Powerful” when
Item Details Normal cleaning is finished.
Normal Normal cleaning (wiping)
Powerful Powerful cleaning (wiping and rubbing)
Cleaning selection operation is shown below.

Powerful
Press [Back] to return to the Diagnostics Menu This procedure carries out powerful cleaning (wiping and rubbing). The operation
is the same as for normal cleaning.
ENTER
CLEAN: Normal Printing finished To next menu
when Normal
Menu Down Menu Up cleaning is finished
CLEAN: Powerful
Menu Down
Cleaning: Normal, Powerful Model Name: Rockhopper-46/62 BAC3000

Test Printing: Head Printing, Black in-filling, Parameters Model Name: Rockhopper-46/62 BAC4000
This procedure is used for test printing. The items are as shown below. For adjust- 1. Head Printing Verification
ment parameter prints, if no serial number has been entered, a serial number will To check that the head prints and print an adjustment pattern.
be requested. Online data signal reception is always enabled but no signals are
transmitted during the processing of a diagnostic sequence. Panel
Item Details Adjustment Print

Head Printing Verification Adjustment pattern printing
After the adjustment pattern printing has been finished, “PRINT: ChkNozzles” will
Check in-filling Black in-filling appear.
Adjustment Parameters Display firmware adjustment parameters
2. Check black in-filling

Procedures for the selection of items from panel are shown below. To print by filling an area with black colour.
Press [Back] to return to the Diagnostics Menu.
Panel
DIAG: Test Print Adjustment Print
Menu Up After the adjustment pattern printing has finished, "Print: black in-fill" appears.
ENTER
PRINT: ChkNozzles End Print
3. Adjustment Parameters
Menu Down Menu Up This procedure is used to print firmware adjustment parameters.
ENTER
PRINT: Black Fill End Black infill printing
Panel
Menu Down Menu Up
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 Model Name: Rockhopper-46/62 BAC4000
Parameters Model Name: Rockhopper-46/62 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 Details
Initialize Initalize adjustment parameters
Update Input adjustment parameter values
DIAG: Parameter
Menu Up
ENTER
Parameter
PARAM: Initial initialization
Back
Menu Down Menu Up
PARAM: Update
Menu Down
Parameters Model Name: Rockhopper-46/62 BAC5000

Parameters: Initialize Model Name: Rockhopper-46/62 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
ENTER
INIT: Maintenance INIT: Left Head
Menu Down Menu Up
INIT: ErrorRecord INIT: Right Head
Menu Down Menu Up
INIT: Serial No. INIT: Wiper
Menu Down Menu Up
INIT: All
Menu Down Menu Up
Press [ENTER] to display “Param Initial?”. Press [ENTER] again to initialize.

After initialization, “INIT: Parameter” is restored.
Press the [BACK] key to restore “PARM: Initial” without initializing.
Parameters: Initialize Model Name: Rockhopper-46/62 BAC5010

Parameters: Update Model Name: Rockhopper-46/62 BAC5020
Update
This procedure will update adjustment parameters.

Note: The actual writing to flash memory is done when diagnostics are com-
pleted or power is switched off.
PARAM: Update
UPDATE: Home Previou menu is "UPDATE: Mech Param"
Menu Down Menu Up
UPDATE: Head Rank
Menu Down Menu Up
UPDATE: Print Posi
Menu Down Menu Up
UPDATE: Microdot
Menu Down Menu Up
UPDATE: X Length
Menu Down Menu Up
UPDATE: Mech Param Next menu is "UPDATE: Home"
Press [ENTER] to input the adjustment parameter.

Press [BACK] to return to “PARM: Update”.
Parameters: Update Model Name: Rockhopper-46/62 BAC5020

Update: Capping Position Parameter Model Name: Rockhopper-46/62 BAC5021
This procedure will update the capping position parameter.
UPDATE: Home
Use the VALUE + and - keys to change
Home: -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

Update Parameter
appear
The update message will appear when you press [ENTER]
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 Model Name: Rockhopper-46/62 BAC5021

Update: Head Rank Parameter Model Name: Rockhopper-46/62 BAC5022
This procedure will update the head rank parameter.
UPDATE: Head Rank
Use the VALUE + and - keys to change the
Left Rank: 21117 setting and press [ENTER] to confirm the change.
Menu Down Menu Up
Right Rank: 21117
setting and press [ENTER] to confirm the change.
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 Model Name: Rockhopper-46/62 BAC5022

Update: Print Positioning Parameter Model Name: Rockhopper-46/62 BAC5023
This procedure will update the print positioning parameter.
UPDATE: PrintPosi (and Micro-Dot)
DelayL: -0.250 mm setting and press [ENTER] to confirm the change.
Menu Down Menu Up
Use the Setting + and - keys to change the
DelayR: -0.250 mm
setting and press [ENTER] to confirm the change.
Menu Down Menu Up
Use the Setting + and - keys to change the
L-RGap: -34.290 mm setting and press [ENTER] to confirm the change.
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: PrintPosi”.
Update: Print Positioning Parameter Model Name: Rockhopper-46/62 BAC5023

Update: Media Transport Distance Parameter Model Name: Rockhopper-46/62 BAC5024
This procedure will update the media transport distance parameter.
UPDATE: X Length
Xlength: 300.0 mm
the setting
Param Update?
Update Param 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: X Length”.
Update: Media Transport Distance Parameter Model Name: Rockhopper-46/62 BAC5024

Update: Mechanical Parameters Model Name: Rockhopper-46/62 BAC5025
This procedure will update the mechanical parameters.
UPDATE: Mech Param
Use the VALUE + and - keys to change the setting
HtoEdge: 25.180 mm and press [ENTER] to confirm the change.
Menu Down Menu Up
XFtoH: 30.890 mm
and press [ENTER] to confirm the change.
Menu Down Menu Up

HtoCut: 15.390 mm and press [ENTER] to confirm the change.
Menu Down Menu Up
XFtoXR: 123.700 mm and press [ENTER] to confirm the change.
Menu Down Menu Up
Paper Edge: 2809
Menu Down Menu Up
LeftFlushP: 2424 and press [ENTER] to confirm the change.
Menu Down Menu Up
RightFlushP: 3699 and press [ENTER] to confirm the change.
Menu Down Menu Up
AnotherLFP: 38700
Menu Down Menu Up
AnotherRFP: 40000 and press [ENTER] to confirm the change.
Menu Down Menu Up
PaperWidAdj: -5 and press [ENTER] to confirm the change.
Param Update?
Update Param 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: Mech Param”.
Update: Mechanical Parameters Model Name: Rockhopper-46/62 BAC5025

Aging Model Name: Rockhopper-46/62 BAC6000
This procedure concerns the aging of the mechanism and head. Details of the items
are as follows.
Item Details
Carriage Motor Reciprocal carriage scanning
Media Feed Motor Media feed roller drive
Cutter Media cutting
Maintenance Capping
Head In-fill printing
Selection of items from the panel is shown below.
DIAG: Aging
Menu Up
ENTER
AGING: Y Motor Carriage motor aging
Back
Menu Down Menu Up
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 Model Name: Rockhopper-46/62 BAC6000

Aging: Carriage Motor Model Name: Rockhopper-46/62 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
Terminate endurance with [ENTER], [Back] or
AGING: 10
[CANCEL]
End
AGING END: 50 Escape with [ENTER] or [Back]
Aging: Carriage Motor Model Name: Rockhopper-46/62 BAC6010

Aging: Media Feed Model Name: Rockhopper-46/62 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
Press [ENTER], [Back] or [CANCEL]
AGING: 10
to end aging.
End
AGING END: 50
Aging: Media Feed Model Name: Rockhopper-46/62 BAC6020

Aging: Cutter Model Name: Rockhopper-46/62 BAC6030
This procedure is used for aging the cutter. Media is cut a specified number of
times.
AGING: Cutter
AGING: 10
to end aging
End
AGING END: 50
Aging: Cutter Model Name: Rockhopper-46/62 BAC6030

Aging: Maintenance Unit Model Name: Rockhopper-46/62 BAC6040
This procedure is used for aging the capping. Capping is carried out a specified
number of times.
AGING: Mainte Unit

AGING: 10
to end aging.
End
AGING END: 50
Aging: Maintenance Unit Model Name: Rockhopper-46/62 BAC6040

Aging: Head Model Name: Rockhopper-46/62 BAC6050
This procedure is used for aging the print head. Select left or right and carry out in-
fill printing a specified number of times.
AGING: Head
AGING HEAD: Left
Menu Down 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 Model Name: Rockhopper-46/62 BAC6050

Rockhopper-46
3 Maintenance Parts Model Name: Rockhopper-46 C AT 0 0 0 0
Maintenance Parts Still Under Construction
Maintenance Parts List CAT1000

Maintenance Tool List CAT2000
Lubrication Points CAT4000
Exploded Drawings CAT5000
Periodical Maintenance
s CAT7000
Rockhopper-46
Rockhopper-62 Maintenance Parts Model Name: Rockhopper-62 C AT 0 0 0 0 - 3
Maintenance Parts Still Under Construction
Maintenance Parts List CAT1000-3

Maintenance Tool List CAT2000
Lubrication Points CAT4000
Exploded Drawings (Not yet available) CAT6000
Periodical Maintenance
s CAT8000
Rockhopper-62 Maintenance Parts Model Name: Rockhopper-62 C AT 0 0 0 0 - 3

Rockhopper-46
3 Maintenance Parts List Model Name: Rrockhopper-46 C AT 1 0 0 0
Description Technical
Description Technical Preferred Reference
Reference Order N°
Panel Cable Assy DF-41617 DF-41461
Main Board Assy DF-41586 DE-34498
SW Cable Assy DE-41619 DF-41477
Power Supply Board Assy DF-41587 DE-34535
DC Cable Assy DF-41468 DF-41464
Head Board Assy DF-41588 DE-34456
Y Cable Assy (46") DF-41600 DF-41460
Panel Board Assy DF-40097 DE-33585
Head Cable (Colour) DF-41601 DF-41462
Mother Board Assy DF-40098 DE-48667
Print Head (Colour) DF-40690 DE-49732
Lever Sensor Assy DF-41589 DF-41469
Cap Assy DF-41602 DF-41406
Cover Sw. R. Assy DF-41590 DF-41478
Pump Assy DF-41603 DF-41603
Paper Sensor XR cable Assy DF-41592 DF-41468
Wiper DF-40125 DE-49771
Detection Unit Assy (Black) DF-40106 DF-40011
Maintenance Station Assy DF-41604 MY-21474
Detection Unit Assy (Yellow) DF-40107 DF-40012
Cartridge Frame Assy MY-44051 MY-44051
Detection Unit Assy (Magenta) DF-40146 DF-40013
Damper (Colour) DF-40129 DE-49734
Detection Unit Assy (Cyan) DF-40147 DF-40014
Ink Tube (2.0 BK) 46" DF-42726 DF-42726
Detection Unit Assy (LC/Orange) DF-41593 DF-41480
Grid Roller Assy DF-41840 DE-34525
Detection Unit Assy (LM/Green) DF-41594 DF-41481
Pressure Assy DF-42727 MY-33987P
Paper Sensor Y Assy DF-41595 DF-41470
Pressure Roller Assy DF-41530 DF-40982
Origin Sensor Assy DF-40109 DE-49921
Blade DF-42728 DE-21612
X Motor Assy DF-41597 MY-34558
X Speed Reduction Belt DF-40137 DE-49802
Y Motor Assy DF-41598 MY-34087
Steel Belt 46" DF-41606 DE-49764C
DE-34187 +
Pump Motor Assy PE DF-41599 DF-41060 T Fence (46") DF-41607 DE-34516
Cutter Solenoid Assy DF-40113 DE-33659 Cursor Assy DF-42729 MY-34986
Vacuum Fan Assy DF-40173 DE-33353 Y Return Pulley Assy DF-40144 MY-49761
Fan extension cable RH 46” MK-24210 Fuse DF-40345 DF-40317
Fan extension cable 2 assy DF-41621 DF-41483 Flange(2") DF-40446 DE-33602
Fan extension cable 3 assy DF-41622 DF-41484 Flange(3") DF-40447 DE-21303
2” Core flange set MY-33602 MY-33602
Rockhopper-46
3 Maintenance Parts List Model Name: Rockhopper-46 C AT 1 0 0 0
Rockhopper-46
3 Maintenance Parts List Model Name: Rrockhopper-46 C AT 1 0 0 0
Description Technical Preferred Description Technical Preferred

Reference Order N° Reference Order N°
3” Core flange set MY-40447 MY-40447 Cartridge Pipe slot 1 DE-34514A DE-34514A
O Ring (Small) 100 pcs. DF-40487 DF-40487 Cartridge Pipe slot 2 DE-34514B DE-34514B
O Ring (Large) 100 pcs. DF-40488 DF-40488 Cartridge Pipe slot 3 DE-34514C DE-34514C
Tube Guide 46" DF-41677 MY-34517 Cartridge Pipe slot 4 DE-34515A DE-34515A
Cursor Plate Spring DF-40854 DF-40854 Cartridge Pipe slot 5 DE-34515B DE-34515B
Steel Bare (46") DF-41616 DE-33943C Cartridge Pipe slot 6 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 Power AC-inlet schutter 10A MC-7001
Spring Plunger Magnet DE-49194 DE-49194 External waste bottle system SDMP
V2 MY-24146
Bearing Grid Roller DE-48846 DE-48846
Cleaning bottle 500ml JD-42054
Encoder reader (incl. Cable) DF-41626 DF-41465
Keyboard assy for SDMP 46” EY-24502
Media Distance Pieces (10 pcs) MY-40650 MY-40650
Panel cable DF-41461
X motor extension cable assy DF-41623 DF-41485
Keyboard sheet SDMP V2 LB-242000
X ENC extension cable assy DF-41624 DF-41486
Heater PCB for SDMP 46” EY-24501
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
3 Maintenance Parts List Model Name: Rockhopper-46 C AT 1 0 0 0
Rockhopper-62 Maintenance Parts List Model Name: Rockhopper-62 C AT 1 0 0 0 - 3

Main Board Assy DF-42010 DE-34719 Fan extension cable 3 assy DF-41622 DF-41484
Power Supply Board Assy DF-41587 DE-34535 Fan extension cable 4 assy DF-41993 DF-41773
Head Board Assy DF-41588 DE-34456 Panel Cable Assy DF-41617 DF-41461
Panel Board Assy DF-40097 DE-33585 SW Cable Assy DE-41619 DF-41477
Mother Board Assy 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 MY-34087 Pressure Assy DF-42727 MY-33987P
DE-34187 +
Pump Motor Assy PE DF-41599 DF-41060 Pressure Roller Assy DF-41530 DF-40982
Cutter Solenoid Assy DF-40113 DE-33659 Blade DF-42728 DE-21612
Vacuum Fan Assy DF-40173 DE-33353 X Speed Reduction Belt DF-40137 DE-49802
Fan extension cable 1/3 assy DF-41620 DF-41482 Steel Belt 62" DF-42001 DE-41754
Fan extension cable 2/3 assy MK-42403 MK-42403 T Fence (62") DF-42002 DE-34698
Fan extension cable 3/3 assy MK-42401 MK-42401 Cursor Assy DF-42729 MY-34986
Fan extension cable 2 assy DF-41621 DF-41483 Y Return Pulley Assy DF-40144 MY-49761
Fuse DF-40345 DF-40317


Flange(2") DF-40446 DE-33602 Switch Head Height DF-42733 DF-42340
Flange(3") DF-40447 DE-21303 N Belt 62" DF-42737 DE-34700
2” Core flange set MY-33602 MY-33602 Head fixing assy DF-42734 DE-34987 +
DF-42345 +
3” Core flange set MY-40447 MY-40447 DF-42344 +
O Ring (Small) 100 pcs. DF-40487 DF-40487 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
Junction Board Assy DE-34540 DE-34540 Y-motor cable assy DF-41625 DF-41466
Ink ID Sensor 1 Assy (Blk) DF-41609 DF-41471 Waste ink bottle RJ-6100 54 & 62 DF-42008 DF-42008
DE-34776 +
Ink ID Sensor 2 Assy (Cy) DF-41610 DF-41472
Coupling assy DF-40693 3x NS-21040031
Ink ID Sensor 3 Assy (Mg) DF-41611 DF-41473
Cartridge Pipe slot 1 DE-34702 DE-34702
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
Hooked screw driver Rockhopper TL-24000
Bearing Grid Roller DE-48846 DE-48846
Waste tank sensor plate ME-24124
Encoder reader (incl. Cable) DF-41626 DF-41465
Waste tank sensor MS-24000
Media Distance Pieces (10 pcs) MY-40650 MY-40650
Waste tank sensor Cable MK-24208
Flange set roll tubs ZMY-46040 ZMY-46040
Waste connection tube small ME-24115
E-HEDS- E-HEDS-
Linear encoder 180 LPI 9200#Q00 9200#Q00 Flush box spare part MY-24115
X motor extension cable assy DF-41994 DF-41771 Paper guide assy F 62" SDMP MY-11249
X ENC extension cable assy DF-41995 DF-41772

Description Technical Preferred

Reference Order N°
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

Maintenance Tool List Model Name: Rockhopper-46/62 C AT 2 0 0 0
No. Drawing No. Name Appearance Remarks No. Drawing No. Name Appearance Remarks
1 Personal Computer Commercial 5 Bar tension gauge Commercial

item 49 N (5 kgf) item
(made by Ooba S/S)
2 JD-30410 Head cleaning jig Special item, 6 JD-30395 Rail height jig Special item
assembly includes rubber assembly
(6 sets required) bush and
mini-fitting
2.1 JD-42052 Rubber bushing Special item 7 JD-30432 Rail height reference Special item
❉ Replace after (consumable) base assembly
using 20 times
2.2 JD-42053 Mini-fitting Special item

(made by Inaiseieido) (commercial
item)
3 JD-42050 Belt tension Special item 8 Phillips screwdriver Commercial

attachment No. 1 item
9 Phillips screwdriver Commercial

4 Bar tension gauge Commercial No. 2 item
4.9 N (500 gf) item
(made by Ooba S/S)
10 Hex nut driver 5.5 mm Commercial
item

11 Standard screwdriver Commercial 20 Multimeter Commercial
item item
12 Allen key 1.5 mm Commercial

item
13 21 JD-41844 Cleaning fluid A-29 Special item

Allen key 2 mm Commercial
(18-liter)
item
14 Allen key 2.5 mm Commercial

item
15 22 JD-42054 Cleaning fluid bottle, Special item

Allen key 3 mm Commercial
500 ml (Commercial
item
item)
16 Spanner 5.5 mm Commercial

item
17 23 Ball driver 1.5 mm Commercial

Spanner 17 mm Commercial
item
item
18 Tweezers Commercial 24 Ball driver 2.5 mm Commercial

item item
19 Jeweller's screwdriver Commercial 25 Hexagon ratchet Commercial

item spanner item

26 M-block (Height: 20) Commercial
item
27 JD-42145 Head height jig Special item
28 Pocket microscope Commercial

(Magnification: 25x to 50x) item
29 TL-24000 Hooked screwdriver Commercial

For Rockhopper 62" item

Lubrication Points Model Name: Rockhopper-46/62 C AT 4 0 0 0
No. Name of Unit Lubrication Point Brand, Product Number Application Remarks
1 Pressurization Pressure cam Shin-Etsu Chemical Co., Ltd., To improve sliding or similar
Unit Silicone Grease G501
2 Maintenance Unit Transfer gear bearings Shin-Etsu Chemical Co., Ltd., To improve durability or similar
Silicone Grease G501
3 R Frame Sliding parts around pressurizing Shin-Etsu Chemical Co., Ltd., To improve sliding or similar
relay plate Silicone Grease G501
4 X Drive X speed reduction belt parts Shin-Etsu Chemical Co., Ltd., To improve durability
Silicone Grease G501
5 Y Rail Back of roller track Shin-Etsu Chemical Co., Ltd., For inserting roller, reducing or similar
Silicone Grease G501 cursor noise
6 Y Rail Cursor track Sumiko Lubricants Co., Ltd To prevent burning Soak a cloth and
Sumi Grease Spray apply lightly
7 Covers Cover pins and frame holes Shin-Etsu Chemical Co., Ltd., For cover opening/closing or similar
Silicone Grease G501 action and noise
Lubrication Points Model Name: Rockhopper-46/62 C AT 4 0 0 0

ROCKHOPPER 46
UNIT-SDMP46 CAT5001-00
REV. /
DE-10873
NS-11040081
LB-10080(2x)
DE-21469 DF-40027
LB-10031
DE-21470
DE-33950C
LB-10082
NS-05030081
DF-41386
NS-05030081
DE-11174
NS-05030081
NS-11040081 DE-34501
NS-11030061 DF-41388
NS-51040101
NS-05030081 NS-05030081
DE-21467
DF-40650
DF-40411C NS-11040081
ME-24233 DE-10872
NS-05030081
NS-05040081
DE-10973
NS-11030061 NS-21030031
NS-51040101
DE-31567
DF-40521C DE-47066
NS-05030081
NS-05030081
DF-41387
NS-05030081
DE-21469
DF-41376 NS-11030061 DR-4014-43315
NS-11040081
DF-41490(A/E)
DE-11159
NS-11030061 ME-24206
ME-24205 MY-24217
NS-05030081
NS-11030061
ME-24232 DF-41429 NS-05030081
NS-11040081
DR-4001-43993(4x)
DR-4001-43993(2x) ME-24124
NS-11030061
DE-10972
ME-24236 NS-05030081 LB-10250
DF-41375
ME-24237(2x)
MY-24218=
EY-24502
NS-06030061(4x) ME-24227+AP-52128+ME-24218
LB-24200 DF-41461
MY-24205
NS-11030061
ROCKHOPPER 46
REV. /
ME-23046(5x)
NS-05040101
DE-33609
DF-41384
DE-49815
NS-11040041 DE-11170
NS-05040081
DE-49814
NS-04040101
DS-1074-41211K NS-06040061(3x)
DP-3022-40153
NS-35040201 DF-49828
NS-05040081(3x) ME-24231 DE-33992
NS-05040081
NS-21030031
E-P-20
DE-49811 DE-47866X(1,5x)
DE-49796
DE-49812
DE-33991
DE-49801
NS-05040081 E-P-20
DF-40981 DE-49904
DF-41378
DF-40091
DF-41793
ME-24211
DE-49651
DF-40470
DE-46552
DF-40469
DF-41428 DE-49813
NS-21030031 DE-46552
DE-49796 DE-49651
MY-41793
DE-49810
DE-49811 E-NAD-06
NS-05030401 E-P-25
DE-40321
DF-40470 DE-49812
DE-46552 NS-05030061 NS-05040081
DF-40520 DF-40469 DE-47866F

NS-05030061
NS-05040101 DE-46552 DE-40615
DE-33608 NS-05030401
NS-05030401
NS-05030081
DE-33608
DE-33608
DF-40137
DE-49804 DE-49802 NS-05030101

NS-05030101
E-NAD-06
DE-46562
DE-49803 DF-41622
N-40202C DF-41484 NS-05030101 NS-05030061

DE-34558
DE-41597
DE-33353
DE-33353
DF-41483 DF-40173
DF-40173
DF-41621
DE-33353
DF-41485
DF-41486 MK-24210
DF-41623 DF-40173
DF-41624
ROCKHOPPER 46
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)
NS-05040101
DE-48958 (2x) DF-40469 DE-46552
MY-24146 NS-04030061 (4x)

DF-40470
MY-40469 (3x)
DE-44113 ME-24103 MY-41792 ME-24240
DE-49827
DF-40561 DP-3022-40153
NS-04030061 (4x) NS-06030061
ME-24102
NS-51030051
DR-4010-41280
AE-91025 (3x)
JD-42054
NS-05040101 NS-04040101 DE-49142
BM-1301-003006 DE-49947
NS-04030061
ME-24104 E-P-25
NS-04030061 (4x) DF-42340
DF-42733 NS-11040041
DE-45115 MK-24208
DF-42342
DF-41536
NS-01020081
DE-34540 DF-42341
DE-49826
DE-49782 NS-11040041
NS-05030081 DE-10868 DE-49781
NS-01020081
NS-06020051 NS-06020051
NS-51030051 DF-41590
DF-41469 DF-41478
DF-41592
DF-41433 DF-41589 DF-40553
DF-41468 DE-47071
DE-45115 DF-41615 DF-40562
DR-4014-43892
DF-41463 DE-47046 DF-41374
ME-24234 DF-41329
DF-40564
NS-35040201
E-P-25 DF-41931
NS-05040101
NS-05040121 DE-48931
NS-05030061
NS-05040101
DR-4010-41280
E-NAD-06 DE-49948
NS-05040401 DF-41329
DE-49950
NS-05040121
DE-33999
DF-41425
DE-47866E DF-40081
DE-47866H
NS-05040081 DE-49949
DE-32692 NS-06030061
E-NAD-06
DF-40556
DF-41581
DE-49651(3x)
ROCKHOPPER 46
UNIT-SDMP 46 CAT5004-00
REV. /
DF-41602
DF-41400
NS-41030061 DF-41406
DF-42725
DE-34187 NS-11030061
ME-24138
DF-41403
NS-35030101 DE-40176
NS-05030061 DF-41401
DF-41060
NS-21030031
DE-49771 DF-41599 DE-34508
DF-40514
DE-48846 DF-40125 DE-34069
DF-40522 DE-34525
NS-05030061
DF-40682
NS-41030061
DE-21394 NS-35030061
NS-05030121 DP-3022-40153
DF-41405
ME-24138 DE-48918C DF-40681
DF-40523
DE-21465
NS-35030101 DF-41603
DE-34068
DF-41582
DE-48846
NS-21030031
DE-34521 DF-41840
DF-40514
ME-24118
DE-21394 DE-34525
NS-05030061
DE-21608
DE-48846 NS-05030061
NS-05030061
DF-40522 NS-35030061 NS-41030061
DE-34999
DF-40523 ME-24138
DE-21465
NS-35030101
DF-40693
DE-48846 NS-21030031
DF-40514
ME-24118
DE-48846
DE-21394 NS-41030061
NS-05030061 NS-35030061
DF-40522 ME-24138
DE-34525
DF-40523 DE-21465
E-P-25 NS-35030101 NS-35030101
DF-42007
DE-48846 DF-41326
NS-05030081
DF-41327
DF-41382
ME-24118
DE-21394
(t=0.1) DF-41578A NS-05030061 ME-24128

(t=0.2) 〃 B
(t=0.3) 〃 C DF-40523 DF-40522 DF-44183
DE-34521
DE-11158
ROCKHOPPER 46
REV. /
DE-11172
NS-05030061 NS-05030081
DE-21303 (3")
DR-4010-43353 DE-33602 (2")
NS-01030301
DE-49763
DF-40447 (3")
NS-05030061 DF-41427 DF-40446 (2")
DE-47091
DE-34519 DF-41435
DE-47040
DF-41607 DE-34500
NS-21030061
DE-44181 DE-34516
DR-4010-43353
DP-3022-40153
DF-41259
DE-49780
DE-44181
DF-41460
DS-4104-40904 DE-35084
DF-41600
DE-33602
DF-42735
NS-05030061
DF-40144 DE-34521
DE-11171 DF-40559 DE-34499 DP-3022-40153

NS-04030061
DE-34520
DE-11173 NS-05030081 ME-27065
NS-05030061
DF-40641
DE-21479
NS-05040101 DF-40558
NS-05030081 NS-05040081
DF-40555 DE-42544
NS-35040101
DE-49752C DE-33598
DE-21395
NS-04030061
NS-05040081
DF-40551
NS-05040101
DR-7032-41990
DR-7032-41990
DF-40510
DE-49753C DE-47092
DF-40555
MY-33987P DE-49760
DF-40550
NS-35040201
DE-21395
DF-41422
DE-33987 NS-05030081 DF-40551
DR-7032-41990
DE-34521 NS-51040101
DF-40982 NS-35040101 NS-23040041
DF-40510 DE-49753C
DF-41530 NS-04030061
DE-21612
DF-42728 DE-33987
DF-40550 DF-41424
DE-49883
DF-40982 DF-40552C
N-40202C
DF-40360
DE-21612 DE-34087
NS-05030081
DE-49764C DF-41625
DR-7032-41990
DF-41606 DF-41466
DF-41518
DF-41598
ROCKHOPPER 46
REV. /
DE-34979 DF-41392
DF-41393
誤挿入防止板M
DF-41394
DF-41460
誤挿入防止板Y
DE-35084 DF-41395 誤挿入防止板LC
DF-41398
ﾅﾍﾞ小ﾈｼﾞM3×8(W)
DF-41460 NS-05030081
誤挿入防止板LM
DF-42731
DE-33943C DF-41399
DE-34978 DF-41616
I/Cｽﾗｲﾄﾞ2
DF-41609 DE-21537
DF-41471 I/Cｶﾞｲﾄﾞﾍﾞｰｽ
DE-21473
DF-40011 DE-49772
DE-49738G
DF-40106 ｶﾞﾀ取りﾊﾞﾈ
DF-42726 DF-40978
DF-41610
DF-41472 ﾅﾍﾞ小ﾈｼﾞM3×8(W)
NS-05030081
DF-40014
DF-40147
DF-41611
DE-49778
DE-49778 DF-41473
DE-49993 DF-40013
DE-49992
ｶｰﾄﾘｯｼﾞﾍﾞｰｽ
DF-40146 DE-11166
DE-48950 ∼ﾌﾚｰﾑｱｾﾝﾌﾞﾘ,針
DF-41612
DE-49777
DF-41474
DF-40488
DE-49777 DF-40012
DF-40488 DF-40107 吸収材

DE-48949 DE-34746
DF-41613
DF-41475
DF-40487
DE-34513 DF-41614
DF-41480
DF-41593 DF-41476
DE-34514A
(SLOT1) DE-33600
DE-21477A DE-34514B
(SLOT2) NS-41030061
DE-21477B DE-21477D DE-34514C

(SLOT3) NS-05030081
DF-41410 NS-05030081
DE-21477C DE-34515A
DE-21477E DF-40488 DF-41481
(SLOT4)
DE-34515B
DE-21477F (SLOT5)
DE-49777 DF-41594
DE-34515C
(SLOT6)
DE-21300
NS-41030121
DF-44051
DE-49778 NS-41020081
+
DE-49892
ROCKHOPPER 46
REV. /
DF-40129
DE-41588
DE-48950
DF-41426
DE-49734 NS-05030101
DE-34456
DF-41626
NS-05030081
DF-40129 DF-41465
DE-48950
DF-41462 DE-49734 DE-33943C
NS-11030061 DF-41601
DF-40853 DF-41430
DE-48949
NS-06020121
DF-40487
NS-05030081
NS-11030061 E-HEDS-9200#Q00
180LPI
DF-40820 DE-48949
DE-49194 DF-40487
NS-11030061 DF-40934 NS-05030081
DF-41462
DF-40690 NS-11030061
DE-33659 DF-41601 DE-49921
DF-41669
DF-40613 DE-40109
DF-40113
DF-41404
DF-40934
DF-40936 DF-40836
DF-40690
NS-05030081 Rev.1
DE-21478
DF-40613 DF-41439A
NS-11030061
DF-41404
NS-05030081
DF-41409
DF-41416
DE-21476 DF-42344 DF-41443
DF-40854
DF-41595 NS-41020041
DF-42332
NS-05030061
DF-41470 DE-34513
DE-34067 DE-49744 DF-41444

DF-42343
DF-42729
DR-4010-43353 DR-7032-41990 DE-49746 DE-44197 NS-41030051
NS-05030061
DF-41411 DE-42051 DF-42337

DE-49879 DE-44197
DF-40685 DF-42345 DF-41445 DF-42335 DF-41444

DE-34065 DE-44197 DP-3022-40153
DF-40683 DF-42336
DE-44197
DE-47014
DE-42051 DE-42051
NS-11030061
DF-42734 DR-7032-41990 DF-41445
DE-34986
DE-44197
DF-41432
DE-34987
DE-34066 DE-42051
DE-49744
DP-5005-40189
DF-40951
DF-42339 DE-44197
DF-40718 DF-42333
NS-11030061 DE-49746
NS-41030061
DE-49879 DR-7032-41990
NS-05040081
NS-06020051
DR-7032-41990
DF-42334
DE-11167 DE-47014 DF-42331

DR-7032-41990
DE-47014 DE-44197 DF-42330 DF-40683

NS-11030061 DF-42338
DR-7032-41990 DE-42051 DF-42330

DP-3022-40153 DP-3022-40153
ROCKHOPPER 46
REV. /
SENSORS
MK-24200
J11
DF-41439A
DF-41437 DR-4001-43993 (3x)
ME-24230
DE-48958
2
DF-41439B
1
DE-48667
ME-24238
NS-06030061 (DF-40098)
1
2
E-MSFC-6KEX
J09
DE-33641 DF-41391 POWER
DF-41439C (3x) MK-24201
NS-06030061
DE-34505 DE-46951 NS-05040081
DF-41494 NS-11040041
E-SSC-58-12-F DE-11165
E-MTFC231114
MK
-24
209
DF-41464
MK
-21
000
J0
(DF-41618)
7
NS-11030061 SIMM(16MB)
MAIN PCB
J2
DF-41340B NS-05030081
DE-34498
(DF-41586) EY-24501
DF-41439A
NS-06030041 DE-33585 DE-10871

DE-49832 DF-41439B J02
(DF-40097)
J1
MK-24204
DF-41439C (7x)
MK-24204
NS-11030061
J000
DE-34535 NS-05030081
(DF-41587)
NS-51030061
NS-05040081
NS-05030081
NS-11040041 MK-41314
MC-7001
AE-91025 (3x)
DF-41461
NS-05030081 DF-41617
DE-49749
PCB Layout + cables

ME-24200
NS-35030061 refer to drawing AP-76128
DF-41619
DF-41477
E-SL10K2-5
Rockhopper-46
You have to change some parts of the Rockhopper printer to obtain a good quality. Please refer to the
tables for an overview of periodical maintenance.
You will notice that the X-marks indicate a renewal of the mentioned part(s) after this many months.
You have to change the absorbents every week.
IMPORTANT :
Note that the x-marks in month 6 and month 12 are only to be done by authorised Mutoh
technicians.
Maintenance cycle on Rockhopper 46 “

Monthly
Description Qty
1 2 3 4 5 6 7 8 9 10 11 12
Print Head 2 X
Flush Box Spare Part 1 X X
Wiper 1 X X
Sensor on ext. Waste Bottle syst. 1 X
Maint. Station GA Assy RJ-6100 1 X X
Waste Connection tube small 2 X X
Dust removal in fan area - X
Cleaning maintenance Station - X X
Cleaning bottle 1 X X
Blade on press roller 4100/6100P 18 X
F-absorbent 1 RJ-4100 4 WEEKLY
Rockhopper-46
Rockhopper-62 Maintenance Parts Model Name: Rockhopper-62 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 “

Monthly
Description Qty
1 2 3 4 5 6 7 8 9 10 11 12
Print Head 2 X
Flush Box Spare Part 1 X X
Wiper 1 X X
Sensor on ext. Waste Bottle syst. 1 X
Maint. Station GA Assy RJ-6100 1 X X
Waste Connection tube small 2 X X
Dust removal in fan area - X
Cleaning maintenance Station - X X
Cleaning bottle 1 X X
Blade on press roller 4100/6100P 24 X
F-absorbent 1 RJ-4100 4 WEEKLY
Rockhopper-62 Maintenance Parts Model Name: Rockhopper-62 C AT 8 0 0 0

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MAINTENANCE

Eco-Solvent Inkjet Printer

Rockhopper: AP-74016, Rev:1.0

Published by Mutoh Europe,

Copyright February 2002, Mutoh Europe All rights reserved.

Introduction Model Name:Rockhopper-46/62 CON1000

Some Thoughts on Maintenance Work Model Name:Rockhopper-46/62 CON1010

PRECAUTION 1 Head Cleaning PRECAUTION 5 Maintenance Unit Tubes

PRECAUTION 4 Thorough Waste Fluid Bottle Replacement

1. After head cleaning and initial filling.

Precautions For Maintaining This Printer Model Name:Rockhopper-46/62 CON2000

Introduction CON 1000 CON 1000

Contents Model Name:Rockhopper-46/62 CON3000

Trouble-Shooting Lists TRB0000 Fault-Tracing Procedure EXA0000

Replacement and Adjustment Procedures

Speed Reduction Pulley Assembly REP 1680

Trouble-Shooting Lists TRB0000-3 Fault-Tracing Procedure EXA0000-3

Rockhopper-62 Contents 1 Model Name: Rockhopper-62 CON3007

Replacement and Adjustment Procedures REP0000-2

Speed Reduction Pulley Assembly REP 1680

Rockhopper-62 Contents 2 Model Name: Rockhopper-62 CON3008

Rockhopper-62 Contents 3 Model Name: Rockhopper-62 CON3009

How to use the Maintenance Manual

Como usar el Manual de Mantenimiento

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

How to use the Maintenance Manual Model Name: Rockhopper-46/62 CON4000

Task Page Details Reference Materials

Check circumstances by “fax” or “telephone”. Check error

Manual de Operaciones, Conocimiento

Task Page Details Reference Materials

How to use the Maintenance Manual Model Name: Rockhopper-46/62 CON4010

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

When Message is Displayed TRB1000

• Printer Status Messages, Data Errors, Command Errors

When Message is Not Displayed TRB2000 to TRB2001

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

• Online/Function Problems: Online printing function problems.

Name and Diagram Number of

DF-41592 XR Cable Assembly (Paper Sensor R)

DF-41620 Fan Extension Cable 1 Assembly

DF-41604 Maintenance Station Assembly

DF-41609 INK ID Sensor 1 Assembly

DF-41536 Junction Board Assembly

DF-41619 Switch Cable Assembly

DF-41587 Power Board Assembly

DF-40173 Vacuum Fan Assembly

DF-40147 Detector Assembly (C)

DF-41615 INK ID Sensor Cable

DF-41603 Pump Assembly

DF-41601 Head Cable

When Message is Not Displayed Trouble with Initializatio Model Name: 46

Whether an error message is displayed Major classification of fault details

1-12 • Is there a broken lead in head cables? Hidden diagnostic

1-16 • Is there a broken lead in Y cables?

1-17 • The main board assembly may be damaged.

How to replace the Y Motor Assembly Model Name: Rockhopper-46/62 REP1280

« REFERENCE » If there is to be no replacement that

1. Replacement Replace the Y Motor Assembly

« REFERENCE » Since the Y Motor Assembly Cable pass-

2. Adjustment 1. Carry out the Steel Belt Tensioning Adjustment.