MUTOH Rockhopper 38 Maintenance Manual
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MUTOH Rockhopper 38 Maintenance Manual

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Maintenance Manual

MUTOH EUROPE N.V.
AP-74038, Rev 1.1 : , 25/01/2005

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Summary of Contents for MUTOH Rockhopper 38

  • Page 1: Maintenance Manual

    Maintenance Manual MUTOH EUROPE N.V. AP-74038, Rev 1.1 : , 25/01/2005...
  • Page 2 Rockhopper 38 – Maintenance Manual AP-74038, Rev. 1.1, 25/01/05...

  • Page 3: Copyright Notice

    This document may not be reproduced by any means, in whole or in part, without written permission of the copyright owner. This document is furnished to support the Mutoh’s Rockhopper 38 Printer. In consideration of the furnishing of the information contained in this document, the party to whom it is given, assumes its custody and control...
  • Page 4 Rockhopper 38 – Maintenance Manual AP-74038, Rev. 1.1, 25/01/05...

  • Page 5: Important Notice

    The product and the contents of this publication may be changed without prior notification. MUTOH EUROPE N.V. has made the best efforts to keep this publication free from error, but if you find any uncertainties or misprints, please call us or the shop where you bought this equipment.
  • Page 6 Rockhopper 38 – Maintenance Manual AP-74038, Rev. 1.1, 25/01/05...

  • Page 7: Table Of Contents

    Rockhopper 38 – Maintenance Manual Table of contents 1. Safety Instructions....................... 11 1.1. Introduction .......................... 11 1.2. Warnings, Cautions and Notes .................... 11 1.3. Important safety instructions ....................11 1.4. Warning labels ........................14 2. Product Overview ......................17 2.1. Getting to know the Printer parts and components .............. 17 2.1.1 Explanation of fixer and dryer ......................
  • Page 8 Rockhopper 38 – Maintenance Manual 4.4. Replacement of PF Driving Section Components..............51 4.4.1 Replacing the X Motor Assembly....................51 4.4.2 Replacing the Fan Assembly and Fan Cables................52 4.4.3 Replacing the Speed Reduction Belt ..................... 54 4.4.4. Replacing the Lever Sensor Assembly..................55 4.4.5 Replacing the Cover Switch Assembly ..................
  • Page 9 Rockhopper 38 – Maintenance Manual 5. Self-Diagnosis Function.................... 113 5.1 Introduction ......................... 113 5.2 Preparation ......................... 114 5.2.1 Preparation on machine....................... 114 5.2.2 Starting up............................ 114 5.3 Examination ........................115 5.3.1 Memory Capacity ......................... 115 5.3.2 Version ............................115 5.3.4 Sensors ............................116 5.3.5 Encoders...
  • Page 10 9.4 Heater Error Messages ....................... 245 9.4.1 Automatic Check.......................... 245 9.4.2 Error Messages..........................246 10. Appendix........................247 10.1. Introduction ........................247 10.2. Wiring Diagram Rockhopper 38 ..................247 10.3. Rockhopper 38 : Service Parts List/Exploded Views/Configuration Diagrams....248 AP-74038, Rev. 1.1, 25/01/05...

  • Page 11: Safety Instructions

    Rockhopper 38 – Maintenance Manual 1. SAFETY INSTRUCTIONS 1.1. INTRODUCTION This chapter explains the meaning of safety terms for personnel who operate this equipment, important safety instructions and the positions of the warning labels. Important : Be sure to follow all instructions and warnings on this manual when using the equipment.
  • Page 12 Stop using your printer if a liquid is spilled into it. This may cause electrical shock or fire. Turn the printer off as soon as possible, unplug the power cord, contact your local MUTOH dealer. Be sure to use the attached cable. Otherwise, electrical shock or fire may occur.
  • Page 13 Rockhopper 38 – Maintenance Manual Do not cut hard objects or drop the cutter. Doing so may damage or chip the cutter blade. Do not bend or pull the waste fluid tube. Doing so may cause that the waste fluid will leak out and malfunction in the product.

  • Page 14: Warning Labels

    If a warning label is damaged, lost or cannot be recognized, replace the label. When replacing warning labels, contact your local MUTOH dealer. Safety Labels are attached to the internal and external area of the printer to alert you to potentially hazardous situations or conditions.
  • Page 15 Rockhopper 38 – Maintenance Manual AP-74038, Rev. 1.1, 25/01/05...
  • Page 16 Rockhopper 38 – Maintenance Manual AP-74038, Rev. 1.1, 25/01/05...

  • Page 17: Product Overview

    Rockhopper 38 – Maintenance Manual 2. PRODUCT OVERVIEW 2.1. GETTING TO KNOW THE PRINTER PARTS AND COMPONENTS AP-74038, Rev. 1.1, 25/01/05...

  • Page 18: Explanation Of Fixer And Dryer

    Rockhopper 38 – Maintenance Manual N° Part Description The protective cover protects the action environment. Opening the cover Cover immediately pauses printing which resumes when the cover is closed. Positive touch keyboard with integrated LCD-Display. Operation Panel Lowers / releases pressure rolls to load / unload media.

  • Page 19: Guided Tour Around The Operation Panel

    Rockhopper 38 – Maintenance Manual 2.2. GUIDED TOUR AROUND THE OPERATION PANEL Your printer is equipped with a direct access operation panel; meaning that all frequently used functions can be addressed directly from the keyboard. Description Data LED : The DATA LED monitors DATA status : LED ON indicates data is being received.
  • Page 20 Rockhopper 38 – Maintenance Manual Cleaning : Pressing for 2 seconds initiates the cleaning procedure. When pressed together with the [SHIFT] key, (9) it initiates the head adjustment procedure. Go to the Previous Menu, when in menu-mode operation. For advanced Cleaning Control, enter the menu system and select submenu [Utility] –...
  • Page 21 Rockhopper 38 – Maintenance Manual Media: Allows selection among roll, cut-sheet or media take-up system support. When pressed together with the [shift] key (9), generates a nozzle check print. Accept a new setting when in menu mode or enter a lower menu level.
  • Page 22 Rockhopper 38 – Maintenance Manual Vacuum : The Vacuum key allows you to reduce the fan power when using very light media such as synthetic paper or uncoated paper lighter than 70 g/m². When pressed together with the [SHIFT] key, (9) it initiates a Set-up List and an adjustment parameter plot.

  • Page 23: Keyboard Concept

    Rockhopper 38 – Maintenance Manual 2.2.1. Keyboard Concept The Menu Mode Operation is used to access settings which cannot be controlled via the direct access keys. As soon as media is loaded, the printer is ONLINE and ready to receive data.

  • Page 24: Menu Structure - Overview

    Rockhopper 38 – Maintenance Manual 2.2.2. Menu Structure – overview MH-GL2 / MHGL, GL2 / Printer command language Command RTL-PASS selection Set-up hard clip area PlotArea Normal / Expend depending of media size. Set-up initial pen position in Position P1 / Full / LL MH-GL, GL2 and MH-GL2.

  • Page 25: Heater System Operation Panel

    Rockhopper 38 – Maintenance Manual 2.3. HEATER SYSTEM OPERATION PANEL 1 = Controls Direct Heater / Fixer 2 = Controls Post Heater / Dryer Controls Direct Heater / Fixer: Set temperature for the direct heater / fixer. Real (RT) and set (ST) temperature are displayed on the LCD screen.
  • Page 26 Rockhopper 38 – Maintenance Manual AP-74038, Rev. 1.1, 25/01/05...

  • Page 27: Specifications

    Rockhopper 38 – Maintenance Manual 3. SPECIFICATIONS 3.1. INTRODUCTION This section explains the specifications, optional parts and supplies, installation procedures for optional parts, and user support for this printer. 3.2. PRODUCT SPECIFICATIONS Specifications are liable to changes without prior notice. All trademarks mentioned are property of their respective owners.

  • Page 28: Interface Specifications

    Rockhopper 38 – Maintenance Manual 3.3. INTERFACE SPECIFICATIONS This section explains the specifications for the interfaces supported by this product. 3.3.1. Centronics Bidirection Parallel Interface:IEEE1284) (1) Interface Specifications Item Specifications Transmission modes Compatible , Nibble , ECP Mode Data length...
  • Page 29 Rockhopper 38 – Maintenance Manual 3.3.2. Network Interface (Optional) Specifications Item Specifications Network Type Ethernet IEEE802.3 Network I/F 10 Base-T,100 Base-TX (RJ-45 connector, twisted pair cable) * Automatic switching Protocol TCP/IP Mode • • • socket Functions • Automatic protocol recognition •...

  • Page 30: Installation

    Rockhopper 38 – Maintenance Manual 3.4. INSTALLATION The Installation of the unit is explained below. 3.4.1. Conditions of the installation environment Important : Do not place the printer in following areas. Doing so may result in the printer falling over and causing injury.
  • Page 31 Rockhopper 38 – Maintenance Manual (2) Installation space Install on a horizontal place that satisfies following conditions. The floor has the sufficient strength to sustain the weight of the printer and the stand. Notes : Refer to ‘product specifications’. AP-74038, Rev. 1.1, 25/01/05...
  • Page 32 Rockhopper 38 – Maintenance Manual AP-74038, Rev. 1.1, 25/01/05...

  • Page 33: Parts Replacement

    Rockhopper 38 – Maintenance Manual 4. PARTS REPLACEMENT 4.1. INTRODUCTION This chapter explains the procedures for replacing and removing maintenance parts. Important : Before replacing parts, be sure to perform following operations. Turn the power OFF. Remove the electrical cable from the socket. Otherwise, you may suffer electric shock or the machine’s electric circuits may be...

  • Page 34: Removal Of Covers

    Rockhopper 38 – Maintenance Manual 4.2. REMOVAL OF COVERS When replacing any of the parts inside the printer, it is necessary to remove all covers. The procedures for removing the covers are given below. Description Right Cover Left Cover Front Cover...

  • Page 35: Removing Right Cover

    Rockhopper 38 – Maintenance Manual 4.2.1 Removing right cover Remove the four screws. Step 1 : The cover is tightened shown by arrow A. Step 2 : Remove the cover while lifting in the direction of arrow B. Reinstall all parts in the opposite order of Step 3 : the removal procedure.

  • Page 36: Removing The Unit Panel Cover

    Rockhopper 38 – Maintenance Manual 4.2.4 Removing the Unit Panel Cover Loosen the two screws on the Front Step 1 : Cover Right Cover Shaft and push the Front Cover to the left. Loosen the Unit Panel Cover Screw by 3 Step 2 : mm or remove it.

  • Page 37: Removing The Front Paper Guide

    Rockhopper 38 – Maintenance Manual 4.2.7 Removing the Front Paper Guide Open the Front Cover. Step 1 : Remove the eight screws on the Step 2 : Front Paper Guide. Lift the Front Paper Guide and Step 3 : pull it out towards you.

  • Page 38: Removing The Left Side Cap

    Rockhopper 38 – Maintenance Manual 4.2.10 Removing the Left Side Cap Remove the Front Paper Guide. Step 1 : Refer to “Removing the Front Paper Guide” Remove the three screws from the Left Side Step 2 : Cover. Remove the two screws from the Side Cap.

  • Page 39: Removing The Head Cover

    Rockhopper 38 – Maintenance Manual 4.2.12 Removing the Head Cover Open the Front Cover. Step 1 : Slide the Head out from the Maintenance Station. Step 2 : Caution : When pull the Head, don’t press the cutter cap ,or the cutter blade will be damaged.

  • Page 40: Replacement Of Board Assemblies

    Rockhopper 38 – Maintenance Manual 4.3 REPLACEMENT OF BOARD ASSEMBLIES 4.3.1 Replacing the Switch Cable Assembly / DC Cable Assembly Caution : The power cable connector must be disconnected before this operation. 4.3.1.1 Replacing the Switch Cable Assembly Open the Control Box. Refer to “Opening and Closing Control Box”...
  • Page 41 Rockhopper 38 – Maintenance Manual 4.3.1.2 Replacing the DC Cable Assembly Open the Control Box. Refer to “Opening and Closing Control Box” Step 1 : Remove the power supply cover. (2 screws). Step 2 : Disconnect connector J001 from the Power Board.

  • Page 42: Replacing The Main Board Assembly

    Rockhopper 38 – Maintenance Manual 4.3.2 Replacing the Main Board Assembly The Main Board is constructed so that backup parameters (“user parameters” and “adjustment parameters”) can be captured by a flash memory card. Caution : Be sure to capture these backup parameters before the board is replaced.
  • Page 43 Rockhopper 38 – Maintenance Manual Remove the Mother Board Assembly (4 fastening screws). Step 4 : Remove the Main Board Assembly (5 fastening screws). Step 5 : Assembling is the reverse of the removal procedure. Step 6 : 3. Set DIP Switches The DIP Switches on the Main Board Assembly are for board testing, not for making settings.

  • Page 44: Replacing The Power Supply Board

    Rockhopper 38 – Maintenance Manual 4.3.3 Replacing the Power Supply Board. 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.

  • Page 45: Replacing The Control Panel Board Assembly

    Rockhopper 38 – Maintenance Manual 4.3.4 Replacing the Control Panel Board Assembly Remove the Unit Panel Cover. Refer to “Removing the Panel Cover” Step 1 : Disconnect connectors J301 from the Panel Board. Step 2 : Remove the Panel Board Assembly (4 fastening screws).

  • Page 46: Replacing The Control Panel Cable

    Rockhopper 38 – Maintenance Manual 4.3.5 Replacing the Control Panel Cable Open the Control Box. Refer to “Opening and Closing Control Box” Step 1 : Remove the Front Paper Guide. Refer to “Removing Front Paper Guide” Step 2 : Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover”...

  • Page 47: Replacing The Heater Board Assembly

    Rockhopper 38 – Maintenance Manual 4.3.6 Replacing the Heater Board Assembly Remove the Front Cover. Refer to “Removing Front Cover”. Step 1 : Remove the Unit Panel Cover. Refer to “Removing the Unit Panel Cover”. Step 2 : Remove the Heater Panel Cover. Refer to “Removing the Heater Panel Cover”...

  • Page 48: Replacing The Heater Panel Cable

    Rockhopper 38 – Maintenance Manual 4.3.7 Replacing the Heater Panel Cable Open the Control Box. Refer to “Opening and Closing Control Box” Step 1 : Remove the Front Paper Guide. Refer to “Removing Front Paper Guide” Step 2 : Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover”...

  • Page 49: Replacing The Mother Board Assembly

    Rockhopper 38 – Maintenance Manual 4.3.8 Replacing the Mother Board Assembly Disconnect all communication connectors. Step 1 : Open the Control Box. Refer to “Opening and Closing Control Box” Step 2 : Remove the Mother Board Assembly (7 fastening screws).

  • Page 50: Replacing The Extended Memory (8Mb) (16Mb) (32 Mb)

    Rockhopper 38 – Maintenance Manual 4.3.9 Replacing the extended memory (8Mb) (16Mb) (32 Mb) Caution: Switch off the power before performing this operation. Open the Control Box. Step 1 : While pulling the stop pins at both ends of the SIMM slot on the Main Board to left and right, push Step 2 : the SIMM over towards the rear and remove it from the slot.

  • Page 51: Replacement Of Pf Driving Section Components

    Rockhopper 38 – Maintenance Manual 4.4. REPLACEMENT OF PF DRIVING SECTION COMPONENTS 4.4.1 Replacing the X Motor Assembly Remove the Front Paper Guide. Refer to “Removing the Front Paper Guide” Step 1 : Remove the Left Cover. Refer to “Removing the Left Cover”...

  • Page 52: Replacing The Fan Assembly And Fan Cables

    Rockhopper 38 – Maintenance Manual 4.4.2 Replacing the Fan Assembly and Fan Cables 4.4.2.1 Replacing the Fan Assembly Remove the Front Paper Guide. Refer to “Removing the Front Paper Guide” Step 1 : Remove the Fan Duct. Step 2 : Remove the Fan Cable Connector.
  • Page 53 Rockhopper 38 – Maintenance Manual Disconnect connectors (J115, J116 and J117) from the Main Board Assembly and remove the Step 8 : cables. Reinstall all parts in the opposite order of the removal procedure. Step 9 : AP-74038, Rev. 1.1, 25/01/05...

  • Page 54: Replacing The Speed Reduction Belt

    Rockhopper 38 – Maintenance Manual 4.4.3 Replacing the Speed Reduction Belt Loosen the four screws that fasten the X Motor Assembly to loosen the belt tension. Step 1 : “Replacing X Motor Assembly” Remove the X Motor (2 fastening screws) from the X Motor Mounting Plate and take off the X Step 2 : Speed Reduction Belt.

  • Page 55: Replacing The Lever Sensor Assembly

    Rockhopper 38 – Maintenance Manual 4.4.4. Replacing the Lever Sensor Assembly Remove the Front Paper Guide. Refer to “Removing Front Paper Guide” Step 1 : Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover” Step 2 : Remove the Right Cover. Refer to “Removing Right Cover”...
  • Page 56 Rockhopper 38 – Maintenance Manual Remove the Lever Sensor Mounting Plate (1 fastening screw). Step 9 : Remove the Lever Sensor (2 fastening screws). Step 10 : Reinstall all parts in the opposite order of the removal procedure. Step 11 : Adjustments : Open the Lever and confirm that “Lever Up is displayed”...

  • Page 57: Replacing The Cover Switch Assembly

    Rockhopper 38 – Maintenance Manual 4.4.5 Replacing the Cover Switch Assembly Remove the Right Cover. Refer to “Removing Right Cover” Step 1 : Disconnect connector J106 from the Main Board. Step 2 : Remove the Sensor Mounting Plate (1 fastening screw).

  • Page 58: Replacing The Waste Bottle Fluid Sensor Assembly

    Rockhopper 38 – Maintenance Manual 4.4.6 Replacing the Waste Bottle Fluid Sensor Assembly Remove the waste fluid bottle Step 1 : Disconnect connector Step 2 : Remove the Waste Fluid Bottle Sensor Assembly. (2 fastening screws) Step 3 : Assembling is the reverse of the removal procedure.

  • Page 59: Replacing The Front Paper Sensor Assembly

    Rockhopper 38 – Maintenance Manual 4.4.7 Replacing the Front Paper Sensor Assembly Open the Control Box. Refer to “Opening and Closing Control Box” Step 1 : Remove the Front Paper Guide. Refer to “Removing Front Paper Guide” Step 2 : Undo the Cable Clamp attached to the front X Reinforcement.

  • Page 60: Replacing The Rear Paper Sensor Assembly

    Rockhopper 38 – Maintenance Manual 4.4.8 Replacing the Rear Paper Sensor Assembly Open the Control Box. Refer to “Opening and Closing Control Box” Step 1 : Remove connector J107 (XR) from the Main Board. Step 2 : Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover”...
  • Page 61 Rockhopper 38 – Maintenance Manual Adjustments : Adjust the bundle of Y Cable, N cable and ink tubes. (Make sure the pressure arm is lowered then move the head left and right and fasten flexible cable fitting C so that there is no twisting) Carry out Front Head and Cutter Head distance adjustment.

  • Page 62: Replacing The Grid Roller Assembly And Coupling Assembly

    Rockhopper 38 – Maintenance Manual 4.4.9 Replacing the Grid Roller Assembly and Coupling Assembly Remove the Pressure Unit. Refer to “Removing Pressure Unit”. Step 1 : Remove the self-tapping screws from the Grid Roller Keeper. Step 2 : Description Bearing keeper...

  • Page 63: Replacing The Pressure Assembly

    Rockhopper 38 – Maintenance Manual 4.4.10 Replacing the Pressure Assembly Remove the right and left covers. Refer to “Removing Right and Left Covers” Step 1 : Remove Unit Panel Cover. Refer to “Removing Unit Panel Cover” Step 2 : Remove Front Cover. Refer to “Removing Front Cover”...
  • Page 64 Rockhopper 38 – Maintenance Manual With the pressure lever down, loosen the stepped screws on the pressured transfer plate. Step 12 : Raise the pressure lever as you remove the pressure transfer plate and pressure link. Step 13 : Pull out the pressure shaft from the right side of the frame.
  • Page 65 Rockhopper 38 – Maintenance Manual Remove the Y cable guide fastening screws (5 screws). Step 15 : Remove the screw holding the Y rail reinforcement plate and take out the pressure assemblies. Step 16 : Caution : You will need a special tool such as a ratchet for the fastening screw on the bottom of the Y rail reinforcement plate (a 4 x 10 mm hexagonal double SEMS).

  • Page 66: Replacing The Blade

    Rockhopper 38 – Maintenance Manual 4.4.11 Replacing the Blade Open the front cover. Step 1 : Use a fine straight screwdriver to slightly prize apart the blade attachment and remove the blade. Step 2 : Description Pressure arm Open this with screwdriver...

  • Page 67: Platen Height Adjustment

    Rockhopper 38 – Maintenance Manual 4.4.13 Platen Height Adjustment Adjust the rail height jig. Refer to “Measuring the Y Rail Fitting Precision” Step 1 : Mount the rail height jig on the standard base and set the dial gauge to “0”...

  • Page 68: Replacement Of Cr Driving Section Components

    Rockhopper 38 – Maintenance Manual 4.5 REPLACEMENT OF CR DRIVING SECTION COMPONENTS 4.5.1 Replacing the Y Motor Assembly Remove the Left and Right Covers. Refer to “Removing Left and Right Covers” Step 1 : Remove the Rear Paper Guide. Refer to “Removing Rear Paper Guide”...

  • Page 69: Replacing The Steel Belt

    Rockhopper 38 – Maintenance Manual 4.5.2 Replacing the Steel Belt Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover” Step 1 : Remove the Front cover. Refer to “Removing Front Cover” Step 2 : Remove the Y Rail Cover. Refer to “Removing Y Rail Cover”...
  • Page 70 Rockhopper 38 – Maintenance Manual Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover” Step 1 : Remove the Front Cover. Refer to “Removing Front Cover” Step 2 : Remove the Y Rail Cover. Refer to “Removing Y Rail Cover”...

  • Page 71: Replacing The Steel Flexible Guide Assembly

    Rockhopper 38 – Maintenance Manual 4.5.4 Replacing the Steel Flexible Guide Assembly Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover” Step 1 : Remove the Front Cover. Refer to “Removing Front Cover” Step 2 : Remove the Y Rail Cover. Refer to “Removing Y Rail Cover”...

  • Page 72: Replacing The Cursor Plate Spring

    Rockhopper 38 – Maintenance Manual 4.5.5 Replacing the Cursor Plate Spring Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover” Step 1 : Remove the Front Cover. Refer to “Removing Front Cover” Step 2 : Remove the Y Rail Cover. Refer to “Removing Y Rail Cover”...

  • Page 73: Replacing The Y Return Pulley Assembly

    Rockhopper 38 – Maintenance Manual 4.5.6 Replacing the Y Return Pulley Assembly Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover” Step 1 : Remove the Front Cover. Refer to “Removing Front Cover” Step 2 : Remove the Y Rail Cover. Refer to “Removing Y Rail Cover”...

  • Page 74: Replacing The Maintenance Area

    Rockhopper 38 – Maintenance Manual 4.6 REPLACING THE MAINTENANCE AREA 4.6.1 Replacing the Pump Motor Assembly Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover” Step 1 : Remove the Front cover. Refer to “Removing Front Cover” Step 2 : Remove the Front Paper Guide.

  • Page 75: Replacing The Cap Assembly

    Rockhopper 38 – Maintenance Manual 4.6.2 Replacing the Cap Assembly Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover” Step 1 : Remove the Front Cover. Refer to “Removing Front Cover” Step 2 : Remove the Y Rail Cover. Refer to “Removing Y Rail Cover”...

  • Page 76: Replacing The Wiper

    Rockhopper 38 – Maintenance Manual Caution : When screwing the cap assembly to the maintenance frame, push it right back before fastening. 4.6.3 Replacing the Wiper Remove the Panel Mounting Plate. Refer to “Replacing Pump Motor Assembly 1-6” Step 1 : Move the Wiper back and, with the wiper rack disconnected, pull the Wiper up and remove it.

  • Page 77: Replacing The Pump Assembly

    Rockhopper 38 – Maintenance Manual 4.6.4 Replacing the Pump Assembly Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover” Step 1 : Remove the Front Cover. Refer to “Removing Front Cover” Step 2 : Remove the Y rail Cover. Refer to “Removing Y Rail Cover”...
  • Page 78 Rockhopper 38 – Maintenance Manual Adjustments: 1. Carry out the Capping Position Adjustment. Please refer to “How to Adjust the Capping Station”. 2. Initialize the wiper count Please refer to “How To Initialize Parameters”. Caution : When inserting tubes on the Cap Assembly, turn the tubes clockwise trough 45 to 90 degrees.

  • Page 79: Replacing The Maintenance Station Assembly

    Rockhopper 38 – Maintenance Manual 4.6.5 Replacing the Maintenance Station Assembly Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover” Step 1 : Remove the Front Cover. Refer to “Removing Front Cover” Step 2 : Remove the Y Rail Cover. Refer to “Removing Y Rail Cover”...

  • Page 80: Replacement Of Ink Supply Section Components

    Rockhopper 38 – Maintenance Manual 4.7 REPLACEMENT OF INK SUPPLY SECTION COMPONENTS 4.7.1 Replacing the Cartridge Frame Assembly Carry out Head Cleaning. Refer to “Head Cleaning Procedure 1” Step 1 : Take out all Cartridges. Step 2 : Remove the right paper guide. Refer to “Removing Right Paper Guide”...
  • Page 81 Rockhopper 38 – Maintenance Manual Remove the cartridge mounting plate from the X reinforcement R. (2 fastening screws on upper Step 10 : surface). Slide the cartridge unit a little way in the direction of Arrow A, then hold it there while you remove Step 11 : it from the cartridge base by lifting it out in the direction of Arrow B.
  • Page 82 Rockhopper 38 – Maintenance Manual Undo the screw joints on each cartridge pipe and the cartridge frame assembly. Step 15 : Remove the cartridge unit by pulling it forward. Step 16 : Remove the cartridge frame assembly for each ink (Two fastening screws x four colours).
  • Page 83 Rockhopper 38 – Maintenance Manual Move the Cartridge Slide in the direction shown by Arrow B. Step 19 : Remove the Cartridge Slide from the Cartridge Frame Assembly. Step 20 : To install removed components, reverse removal procedure. Step 21 : Caution: Don’t use a tool to tighten the coupling screws but get them as tight as possible with...

  • Page 84: Replacing The Ink Id Assembly (Black, Yellow, Magenta, Cyan)

    Rockhopper 38 – Maintenance Manual 4.7.2 Replacing the Ink ID assembly (Black, Yellow, Magenta, Cyan) Remove cartridge. Step 1 : Remove Front Cover. Refer to “Removing Front Cover” Step 2 : Remove Unit Panel Cover. Refer to “Removing Unit Panel Cover”...

  • Page 85: Replacing The Detector Assembly (Black, Yellow, Magenta And Cyan)

    Rockhopper 38 – Maintenance Manual 4.7.3 Replacing the Detector Assembly (Black, Yellow, Magenta and Cyan) Remove the Cartridge Frame Assembly. Refer to “Replacing Cartridge Frame Assembly” Step 1 : Remove paper guide R. Refer to “Removing Paper Guide R” Step 2 :...
  • Page 86 Rockhopper 38 – Maintenance Manual Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover” Step 1 : Remove the Front Cover. Refer to “Removing Front Cover” Step 2 : Remove the Y Rail Cover. Refer to “Removing Y Rail Cover”...
  • Page 87 Rockhopper 38 – Maintenance Manual Take out the Y cable. Step 11 : To install removed components, reverse the removal procedure. Step 12 : Caution: The new Y cable has no fold crease. Make a fold crease in the new cable to match the old cable.

  • Page 88: Replacing The Ink Tubes

    Rockhopper 38 – Maintenance Manual 4.7.5 Replacing the Ink Tubes Carry out Head Cleaning and empty the ink inside the tubes. Refer to “Head Cleaning Procedure” Step 1 : Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover”...

  • Page 89: Replacing The O-Rings (Small) And (Large)

    Rockhopper 38 – Maintenance Manual Adjustments: 1. Carry out the initial filling. Please refer to “How to enter Head Rank” CAUTION : Wait at lease 30 minutes after the initial filling before printing. Otherwise the printing quality can not be assured.
  • Page 90 Rockhopper 38 – Maintenance Manual For replacement of Flexible Cable Guide Unit O-Rings, refer to… Step 3 : For replacement of Cartridge Frame Unit O-Rings, refer to… Step 4 : Caution: Be careful not to lose the O-rings, Initial filling and printing can not be done if the O- rings are missing.

  • Page 91: Replacing The Tube Guide Assembly

    Rockhopper 38 – Maintenance Manual 4.7.7 Replacing the Tube Guide Assembly Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover” Step 1 : Remove the Front Cover. Refer to “Removing Front Cover” Step 2 : Remove the Y Rail Cover. Refer to “Removing Y Rail Cover”...

  • Page 92: Replacement Of Cartridge Area

    Rockhopper 38 – Maintenance Manual 4.8 REPLACEMENT OF CARTRIDGE AREA 4.8.1 Replacing the Cutter Solenoid Assembly Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover” Step 1 : Remove the Front Cover. Refer to “Removing Front Cover” Step 2 : Remove the Y Rail Cover.

  • Page 93: Replacing The Print Head Assembly And Head Cable (Black)

    Rockhopper 38 – Maintenance Manual 4.8.2 Replacing the Print Head Assembly and Head Cable (Black) Carry out Head Cleaning. Refer to “Head Cleaning Procedure 1” Step 1 : Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover” Step 2 : Remove the Front Cover.
  • Page 94 Rockhopper 38 – Maintenance Manual Description Head (Black) Fastening screw Transparent Film Surface Remove the Cable by disconnecting it from the Cursor. Step 11 : Remove the Head an disconnect the Head Cable. Step 12 : Remove the Cable from the Head.
  • Page 95 Rockhopper 38 – Maintenance Manual 4. Carry out the Print Head (Colour) Tilt Adjustment Please refer to “Adjusting the Tilt of the Print Head(Colour)” 5. Carry out a test print Please refer to “Test Procedures, Test 2”. Fit a new Waste Fluid Box Pleas refer to “How to enter Head Rank”...

  • Page 96: Replacing The Print Head Assembly And Head Cable (Color)

    Rockhopper 38 – Maintenance Manual 4.8.3 Replacing the Print Head Assembly and Head Cable (color) Carry out Head Cleaning. Refer to “Head Cleaning Procedure 1” Step 1 : Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover” Step 2 : Remove the Front Cover.
  • Page 97 Rockhopper 38 – Maintenance Manual Remove the Head an disconnect the Head Cable. Step 12 : Remove the Cable from the Head. Step 13 : To install removed components, reverse the removal procedure. Step 14 : Caution: Before the new head is fitted, check the head rank (the five digits of the number on...

  • Page 98: Replacing The Y Paper Sensor Assembly

    Rockhopper 38 – Maintenance Manual 4.8.4 Replacing the Y Paper Sensor Assembly Remove the Front Cover. Refer to “Removing Front Cover” Step 1 : Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover” Step 2 : Remove the Y Rail Cover. Refer to “Removing Y Rail Cover”...

  • Page 99: Replacing The Head Board Assembly

    Rockhopper 38 – Maintenance Manual 4.8.5 Replacing the Head Board Assembly Remove the Front cover. Refer to “Removing Front Cover” Step 1 : Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover” Step 2 : Remove the Y Rail Cover. Refer to “Removing Y Rail Cover”...

  • Page 100: Replacing The Dampers (Black And Colour)

    Rockhopper 38 – Maintenance Manual 4.8.6 Replacing the Dampers (Black and Colour) Carry out Head Cleaning. Refer to “Head Cleaning Procedure 1” Step 1 : Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover” Step 2 : Remove the Front Cover. Refer to “Removing Front cover”...
  • Page 101 Rockhopper 38 – Maintenance Manual Adjustments: 1. Carry out the initial filling. Please refer to “How to enter Head Rank” CAUTION : Wait at lease 30 minutes after the initial filling before printing. Otherwise the printing quality can not be assured.

  • Page 102: Replacing The Cursor Assembly

    Rockhopper 38 – Maintenance Manual 4.8.7 Replacing the Cursor Assembly Remove the Front Cover. Refer to “Removing Front Cover” Step 1 : Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover” Step 2 : Remove the Y Rail Cover. Refer to “Removing Y Rail Cover”...

  • Page 103: Replacing The Origin Sensor Assembly

    Rockhopper 38 – Maintenance Manual 4.8.8 Replacing the Origin Sensor Assembly Remove the Front Cover. Refer to “Removing Front Cover” Step 1 : Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover” Step 2 : Remove the Y Rail Cover. Refer to “Removing Y Rail Cover”...

  • Page 104: Removing The Scroller From The Printer

    Rockhopper 38 – Maintenance Manual 4.8.9 Removing the Scroller from the printer 4.2.58.1 Remove the scroller from the printer Go to the back of the printer and push the Scroller Lock Lever while you lift the right end of the Step 1 : Scroller and slide the Scroller to the right to remove it.
  • Page 105 Rockhopper 38 – Maintenance Manual Caution: Before starting work, be sure to disconnect the power supply cable connector. Pull the Head to the left Step 1 : Lift the Cutter Cap and slide it towards you Step 2 : Lift out the Cutter Blade Step 3 : To install the removed components, reverse removal procedure.

  • Page 106: Replacement Of Support And Scrollers

    Rockhopper 38 – Maintenance Manual 4.9 REPLACEMENT OF SUPPORT AND SCROLLERS 4.9.1 Replacing the head height sensor. Remove the Front Cover. Refer to “Removing Front Cover” Step 1 : Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover”...

  • Page 107: Replacing The Junction Board Assembly

    Rockhopper 38 – Maintenance Manual 4.9.2 Replacing the Junction Board Assembly Remove the Front Cover. Refer to “Removing Front Cover” Step 1 : Remove the Unit Panel Cover. Refer to “Removing Unit Panel Cover” Step 2 : Remove the Y Rail Cover. Refer to “Removing Y Rail Cover”...

  • Page 108: Replacing The Network Interface Board (Optional Item)

    Rockhopper 38 – Maintenance Manual 4.9.3 Replacing the Network Interface Board (Optional Item) Caution: Before starting work, be sure to disconnect the power supply cable connector. Disconnect all Ethernet communications cables. Step 1 : Remove the 2 screws holding the Ethernet board and pull out the board towards you.

  • Page 109: Replacement Of Heater System

    Rockhopper 38 – Maintenance Manual 4.10 REPLACEMENT OF HEATER SYSTEM 4.10.1 Replacing the fixer heater strip Remove the power cable. Step 1 : Remove the heater cable cover. Step 2 : Disconnect the fixer power cable. Step 3 : Remove the two partitions.
  • Page 110 Rockhopper 38 – Maintenance Manual Remove the 4 screws. Step 5 : Remove the heater strip. Step 6 : Degrease the platform. Step 7 : To install removed components, please reverse removal procedure. Step 8 : AP-74038, Rev. 1.1, 25/01/05...

  • Page 111: Replacing The Dryer Heater Strip

    Rockhopper 38 – Maintenance Manual 4.10.2 Replacing the dryer heater strip. Remove the power cable Step 1 : Remove the four screws of the front paper guide Step 2 : Disconnect the dryer power cable, grounding and sensor cable Step 3 :...
  • Page 112 Rockhopper 38 – Maintenance Manual AP-74038, Rev. 1.1, 25/01/05...

  • Page 113: Self-Diagnosis Function

    Rockhopper 38 – Maintenance Manual 5. SELF-DIAGNOSIS FUNCTION 5.1 INTRODUCTION These pages deal with the hidden diagnostic functions of the Inkjet Printer. These hidden diagnostics are mainly intended for examining boards and determining mechanical and firmware adjustment parameters. These functions are incorporated into the printer firmware but they are not disclosed to end users. They are enabled by applying power to the printer while holding down several special panel keys.

  • Page 114: Preparation

    Rockhopper 38 – Maintenance Manual 5.2 PREPARATION Before you can use the self-diagnostic function, you should make the machine ready and display the self- diagnosis menu. 5.2.1 Preparation on machine Before starting up the self-diagnosis function, perform following preparations. (1) Setting printing media...

  • Page 115: Examination

    Rockhopper 38 – Maintenance Manual 5.3 EXAMINATION This is intended for board checking. X and Y excitation is not turned on by selecting “Examination” from the Diagnostics Menu. The X and Y excitation condition will be preserved as it is at the time you select an item to be examined.

  • Page 116: Sensors

    Rockhopper 38 – Maintenance Manual 5.3.3 Panel This procedure is used to check panel keys, LCD, LEDs and buzzer. EXAM: Panel Press [ENTER] to shift to “Exam: Sensor” or [BACK] to shift to “EXAM: Panel” 5.3.4 Sensors This procedure is used for checking, from displays on panel or terminal, the status of sensors for XF (the X...

  • Page 117: Encoders

    Rockhopper 38 – Maintenance Manual 5.3.5 Encoders This procedure is used to verify the values of X-axis (media feed) and Y-axis (carriage) from displays on the panel or the terminal. Press [ENTER] to shift to “EXAM: Fan” or [Back] to shift to “EXAM: Encoder”.

  • Page 118: History

    Rockhopper 38 – Maintenance Manual 5.3.8 History 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).

  • Page 119: Head Waveform

    Rockhopper 38 – Maintenance Manual [Serious Failure History] This procedure is used to verify the history of serious failures. CPU Errors are not included in thee serious failure history. The history displays a maximum of seven events. Panel displays are shown below.

  • Page 120: Adjustment

    Rockhopper 38 – Maintenance Manual 5.4 ADJUSTMENT 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.

  • Page 121: Check Media Skew

    Rockhopper 38 – Maintenance Manual 5.4.2 Check Media Skew This procedure will feed a specific amount of paper (a single pass band feed) and the sensors will read the position of the edge of the media before and after feeding and check for any discrepancy. If no media is loaded when this item is selected, you will be asked to load the media.

  • Page 122: How To Enter Head Rank

    Rockhopper 38 – Maintenance Manual 5.4.3 How to Enter Head Rank This procedure is for entering back or colour head rank. It is used for determining the head drive voltage and for temperature compensation. The panel has a range setting range and an out of range rank entry on the terminal will be ignored.

  • Page 123: How To Check Head Nozzles

    Rockhopper 38 – Maintenance Manual 5.4.4 How to Check Head Nozzles After filling the inks, this procedure uses printing results to check whether the head nozzles are ejecting the ink properly. If the nozzles are ejecting ink badly, implement the cleaning treatment in this procedure. If there is no media, the printer will request media.
  • Page 124 Rockhopper 38 – Maintenance Manual Lettering is not printed in the Head Nozzle Check Pattern. AP-74038, Rev. 1.1, 25/01/05...

  • Page 125: How To Check Black Head Tilt

    Rockhopper 38 – Maintenance Manual 5.4.5 How to Check Black Head Tilt This procedure uses printing results to check whether the black head is tilted. If it is tilted, it needs to be adjusted mechanically. Press [ENTER] while “End: Check Tilt” is displayed to move to “AJST: Colour Tilt”...

  • Page 126: How To Check Colour Head Tilt

    Rockhopper 38 – Maintenance Manual 5.4.6 How to Check Colour Head Tilt This procedure uses printing results to check whether the black head is tilted. If it is tilted, it needs to be adjusted mechanically. Press [ENTER] while “END: Check Tilt” is displayed to move to “AJST: CW”.

  • Page 127: How To Align Repeatability Printing Position

    Rockhopper 38 – Maintenance Manual 5.4.7 How to Align Repeatability Printing Position This procedure is used to align black and color 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 firmware the differences between the CW printing position and the CCW printing position.
  • Page 128 Rockhopper 38 – Maintenance Manual Repeatability printing position alignment pattern Adjustment items Black and colour reciprocal printing position alignment Printing method Single-pass, bidirectional Black X 180 dpi, Y 360 dpi Colour X 180 dpi, Y 360 dpi AP-74038, Rev. 1.1, 25/01/05...

  • Page 129: How To Adjust Cw

    Rockhopper 38 – Maintenance Manual 5.4.8 How to Adjust CW This procedure is used for adjusting the left side (capping side) edge position for plotting and for axial alignment of the black and color heads. The adjustment of the edge sensor position in the firmware, the...
  • Page 130 Rockhopper 38 – Maintenance Manual CW Adjustment Pattern Adjustment Items Adjust position of left edge of plot (on the capping position side) Black and colour head axial alignment Printing method Single-pass, uni-directional Black X 180 dpi, Y 360 dpi Colour X 180 dpi, Y 360 dpi...

  • Page 131: How To Adjust The Flush Pointer

    Rockhopper 38 – Maintenance Manual 5.4.9 How to Adjust the Flush Pointer This procedure is used to adjust the position of black or color flushing into the flushing box. The adjustment causes flushing into the flushing box and from the results the position for black or color flushing will be entered in 720 dpi units.

  • Page 132: How To Adjust The Media Transport Distance

    Rockhopper 38 – Maintenance Manual 5.4.10 How to Adjust the Media Transport Distance This procedure is used to adjust the position of black or color flushing into the flushing box. The adjustment causes flushing into the flushing box and from the results the position for black or color flushing will be entered in 720 dpi units.

  • Page 133: How To Adjust Front-To-Head, Cutter-To-Head Distances

    Rockhopper 38 – Maintenance Manual 5.4.11 How to Adjust Front-to-Head, Cutter-to-Head Distances This procedure is used to adjust the distances between the front sensor and the head and between the cutter and head which affect printing and media cutting by entering top and bottom margins.

  • Page 134: How To Adjust The Rear Sensor Position

    Rockhopper 38 – Maintenance Manual 5.4.12 How to Adjust the Rear Sensor Position 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.

  • Page 135: How To Make A Test Print

    Rockhopper 38 – Maintenance Manual 5.4.13 How to make a Test Print 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.

  • Page 136: Head Cleaning

    Rockhopper 38 – Maintenance Manual 5.4.14 Head Cleaning This procedure is used at the end of the production process or before prior to head replacement. Note: For color head cleaning, you will be asked to confirm that all color cartridges have been removed and to install the cleaning jig.

  • Page 137: Cleaning

    Rockhopper 38 – Maintenance Manual 5.5 CLEANING This procedure is used for head nozzle cleaning. The items are as follows. Item Details Normal Normal Cleaning (wiping) Powerful Powerful Cleaning (wiping and rubbing) Operations for selecting cleaning by panel and terminal are shown below.

  • Page 138: Test Printing

    Rockhopper 38 – Maintenance Manual 5.6 TEST PRINTING This procedure is used for test printing. The items are as shown below. For adjustment parameter prints, if no serial number has been entered, a serial number will be requested. Online data signal reception is always enabled but no signals are transmitted during the processing of a hidden diagnostic sequence.

  • Page 139: Parameters

    Rockhopper 38 – Maintenance Manual 5.7 PARAMETERS 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.

  • Page 140: How To Update Parameters

    Rockhopper 38 – Maintenance Manual 5.7.2 How to Update Parameters. This procedure will update adjustment parameters. Note: The actual writing to flash memory is done when diagnostics are completed or power is switched off. Press [ENTER] to input the adjustment parameter.

  • Page 141: How To Update The Head Rank Parameter

    Rockhopper 38 – Maintenance Manual 5.7.4 How to Update the Head Rank Parameter This procedure will update the head rank parameter. If [Back] was pressed, a message that the parameter is not updated will appear and the display will move to “UPDATE: Head Rank”.

  • Page 142: How To Update The Media Transport Distance Parameter

    Rockhopper 38 – Maintenance Manual 5.7.6 How to Update the Media Transport Distance Parameter This procedure will update the media transport distance parameter. If [Back] was pressed, a message that the parameter is not updated will appear and the display will move to “UPDATE: X Length”.

  • Page 143: Aging

    Rockhopper 38 – Maintenance Manual 5.8 AGING This procedure concerns the aging of the mechanism and head. Details of the items are as follows. Item Details Carriage Motor Reciprocal scanning Media Feed Motor Media feed roller drive Cutter Media Cutting...

  • Page 144: Media Feed

    Rockhopper 38 – Maintenance Manual 5.8.2 Media Feed This procedure is used for aging the media feed motor. Repeatability operation is carried out for a specified number of times. 5.8.3 Cutter This procedure is used for aging the cutter. Media is cut a specified number of times.

  • Page 145: Head

    Rockhopper 38 – Maintenance Manual 5.8.5 Head This procedure is used for aging the cutter. Select black or color and carry out in-fill printing a specified number of times. Press [ENTER] to specify a number of times to carry out aging in the same way as the carriage motor and return to “AGING: Head”...
  • Page 146 Rockhopper 38 – Maintenance Manual AP-74038, Rev. 1.1, 25/01/05...

  • Page 147: Maintenance Mode

    Rockhopper 38 – Maintenance Manual 6. MAINTENANCE MODE 6.1. INTRODUCTION This chapter provides information on the maintenance mode. The maintenance mode provides the user with functions of displaying and initializing the life counters. It is used in the manufacturing process, adjustment and maintenance.

  • Page 148: Maintenance Menu

    Rockhopper 38 – Maintenance Manual 6.3. MAINTENANCE MENU The maintenance menu includes the following diagnosis items. Initialization item Description Refer to Counter Display Menu This menu displays the life counters. Counter Display Menu Counter Initialization Initializes the service life counter.
  • Page 149 Rockhopper 38 – Maintenance Manual * Counter Display * Ink remain 1 00000000 Ink remain 2 00000000 (1/11) * Counter Display * Ink remain 3 00000000 Ink remain 4 00000000 (2/11) * Counter Display * Ink remain 5 00000000 Ink remain 6...

  • Page 150: Counter Initialization Menu

    Rockhopper 38 – Maintenance Manual 6.3.2. Counter Initialization Menu This menu initializes the life counters. The parameters that can be initialized in this menu are as follows. Diagnosis item Description Number of prints Initializes the total number of printing counter.
  • Page 151 Step 3 : Notes : Write down this number ‘FM0 xxxxxx’. Important are the 6 digits ‘x’. Based on this number Mutoh Europe’s service department can provide you the correct MAC Step 4 : address for your printer. Reinstall the covers.
  • Page 152 Rockhopper 38 – Maintenance Manual AP-74038, Rev. 1.1, 25/01/05...

  • Page 153: Adjustments

    Rockhopper 38 – Maintenance Manual 7. ADJUSTMENTS 7.1. INTRODUCTION Adjustments and adjustments procedures required when replacing parts are explained in this chapter. Notes: Refer to “Jig and tool list” 7.2 ADJUSTMENTS 7.2.1 Steel Belt Tension Adjustment Caution: Steel belt are highly susceptible to breakage and end damage must e handled...

  • Page 154: How To Adjust X Speed Reduction Belt Tension

    Rockhopper 38 – Maintenance Manual When the belt adjustment is completed, use a belt tensioning jig to adjust the tension. Move the Step 3 : cursor to the capping position and measure the deflection of the belt at the centre of the Y rail.

  • Page 155: Tilt Of The Print Head Adjustment (Black)

    Rockhopper 38 – Maintenance Manual 7.2.3 Tilt of the Print Head Adjustment (Black) Caution: When the Print Head Assembly is to be replaced, the Head must first be cleaned. Otherwise air bubbles and clogged ink will prevent proper printing. Caution: Avoid touching, knocking or rubbing the nozzle face of the Print Head Assembly.
  • Page 156 Rockhopper 38 – Maintenance Manual Implement the “Head Rank Input”. (Refer to “Adjusting the Capping Position”) Step 5 : Implement the “Head Nozzle Verification”. (Refer to “Check Head Nozzles”) Step 6 : Enter the rank of Black. (Refer to “Enter Head Rank”) Step 7 : (The rank of Color will be registered as it is.)
  • Page 157 Rockhopper 38 – Maintenance Manual Implement the “Color Head Tilt Verification”. (Refer to “Check Color Head Tilt”) Step 14 : This will run unidirectional printing with four colors. Here, Head Adjuster A is used to adjust the depth of the Color Head relative to the Black Head.
  • Page 158 Rockhopper 38 – Maintenance Manual After completing Repeatability Printing Positioning, return to the previous level. Step 20 : Implement the “CW Adjustment”. (Refer to “Adjusting CW”) Step 21 : This will compensate for any difference between the printing start position (5 mm from the edge of the media) and the Color printing position relative to Black (pitch between heads).

  • Page 159: Tilt Of The Print Head Adjustment (Colour)

    Rockhopper 38 – Maintenance Manual 7.2.4 Tilt of the Print Head Adjustment (colour) Caution: When the Print Head Assembly is to be replaced, the Head must first be cleaned. Otherwise air bubbles and clogged ink will prevent proper printing. Caution: Avoid touching, knocking or rubbing the nozzle face of the Print Head Assembly.
  • Page 160 Rockhopper 38 – Maintenance Manual Implement the “Capping Position Adjustment”. (Refer to “Adjusting the Capping Position) Step 4 : Implement the “Head Rank Input”. (Refer to “Enter Head Rank”) Step 5 : Implement the “Head Nozzle Verification”. (Refer to ”Check Head Nozzles”) Step 6 : Enter the rank of Black as it is and register the Colour rank.
  • Page 161 Rockhopper 38 – Maintenance Manual Check the printing and enter a positive value to move the second line (CCW printing) towards the Step 15 : Cap, or a negative value to move it in the opposite direction. Register first for Black, then for Color.

  • Page 162: Capturing And Installing Backup Parameters

    Rockhopper 38 – Maintenance Manual 7.2.5 Capturing and installing Backup Parameters 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.

  • Page 163: Install A Program (Software Upgrade)

    Rockhopper 38 – Maintenance Manual 7.2.6 Install a Program (Software Upgrade) 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.

  • Page 164: Y Rail Fitting Precision Measurement

    Rockhopper 38 – Maintenance Manual 7.2.7 Y Rail Fitting Precision measurement Caution: The Y Rail fitting precision affects picture quality and rectangular accuracy. If, for any reason, you think the precision has altered or the frame and XY rails have been removed and readjustment is necessary, special jigs are available for taking measurements.
  • Page 165 Rockhopper 38 – Maintenance Manual 7.2.7.2 How to control precision and specifications value In fitting the Y Rail, the height is fixed by pressing on frame guide pins (left and right in each of Step 1 : two places) and parallelism is fixed by the inserting the Y Rail fitting control jig (JD-42051) between the Y Rail and the Frame.

  • Page 166: Head Cleaning Procedure 1

    Rockhopper 38 – Maintenance Manual 7.2.8 Head Cleaning Procedure 1 Caution: When to Clean the Head “Head Cleaning” must be carried out whenever this printer is moved by truck (refer to “Transporting the printer”) or when the parts shown below are replaced. (Refer to “Head Cleaning Procedure”) When this operation is performed, there is a risk that the inks...
  • Page 167 Rockhopper 38 – Maintenance Manual Caution: If Black & Color is selected, first remove the black cartridge and carry out Steps 4 to 8 shown below, the take out the color cartridge and similarly carry out Steps 4 to 8.

  • Page 168: How To Check The Power Supply Voltages/ 100 V Ac, 200 V Ac

    Rockhopper 38 – Maintenance Manual 7.2.9 How to check the Power Supply Voltages/ 100 V AC, 200 V AC Turn off the Power Switch and open the Control Box. Step 1 : (The Power Cable may remain connected.) With the Power Switch off, check that 100 to 120 V AC or 200 to 240 V AC is being output Step 2 : between pins 2 and 3 of connector J001 on the Power Board.

  • Page 169: How To Check The Power Supply Voltages / 5 V Dc

    Rockhopper 38 – Maintenance Manual 7.2.10 How to check the Power Supply Voltages / 5 V DC Turn off the power switch and open the Control Box. Step 1 : (The power cable may remain connected.) With Power Board connector J001 disconnected, turn on the Power Switch and check that Step 2 : +5 V ±...

  • Page 170: How To Check The Power Supply Voltages/24 V Dc And 42 V Dc

    Rockhopper 38 – Maintenance Manual 7.2.11 How to Check the Power Supply Voltages/24 V DC and 42 V DC 24 V DC Check Turn off the power switch and open the Control Box. Step 1 : (The power cable may remain connected.)
  • Page 171 Rockhopper 38 – Maintenance Manual 42 V DC Check Turn off the power switch and open the Control Box. Step 1 : (The power cable may remain connected.) With Power Board connector J001 disconnected, turn on the Power Switch and check that +42 V Step 2 : ±0.5 V is being output between pins 10 and 11 of J001.

  • Page 172: Cleaning The Head Nozzle Face

    Rockhopper 38 – Maintenance Manual 7.2.12 Cleaning the Head Nozzle Face If the nozzles are clogged by paper dust or foreign matter clinging to the Head Nozzle Face, use the following procedure to remove it. Caution: Be careful not to touch the nozzle face directly with your fingers otherwise normal ejection may not be possible.

  • Page 173: Replacing X Speed Reduction Pulley Assembly

    Rockhopper 38 – Maintenance Manual 7.2.13 Replacing X Speed Reduction Pulley Assembly Remove left and right covers. Step 1 : Remove the front cover. Step 2 : Remove the Y rail cover. Step 3 : Remove the Front Plate. Step 4 : Loosen the four screws holding the X motor assembly and loosen the belt tension.
  • Page 174 Rockhopper 38 – Maintenance Manual Slide and remove the X speed reduction pulley assembly. Step 9 : Assembly is the reverse of the removal procedure. Step 10 : AP-74038, Rev. 1.1, 25/01/05...

  • Page 175: Maintenance

    Rockhopper 38 – Maintenance Manual 8. MAINTENANCE 8.1 TRANSPORTING THE PRINTER This section explains the procedure for moving a printer which is in use to another floor in the same building or to another building. 8.1.1 How to move on the same floor or by elevator to another floor A serviceman need not be present but the following procedure should be explained to the user.

  • Page 176: How To Move To A Different Building By Vehicle

    Rockhopper 38 – Maintenance Manual 8.1.2 How to move to a different building by vehicle A serviceman must bring the following items and follow the procedure set out below. • Main unit packing box • Vinyl bag • Head fastening plate (ME-24632) and wing bolt (DE-48262) •...

  • Page 177: Daily Maintenance

    8.2.1 How to clean the printer unit Rockhopper 38 printer should be wiped free of dirt with a dry soft cloth. Caution : The power switch of the RJ-4000 series printer should be switched off during cleaning.
  • Page 178 Rockhopper 38 – Maintenance Manual Important: Paper dust sticking to the pressure roller and movable roller may prevent normal feeding of the media and produce a “Skew check error”. They must be cleaned periodically. Use a cotton bud to wipe away any dust and paper dust from the front and back paper sensor covers in two places.

  • Page 179: Replacing The Ink Cassettes

    Rockhopper 38 – Maintenance Manual 8.2.2 Replacing the ink Cassettes When a Rockhopper 38 series Printer displays “No ink” or “No Cartridge”, the cartridge should be replaced or filled without delay. Also, ink cartridges should be prepared when “[YCMK] Ink Near End” is displayed.

  • Page 180: Replacing The Cutting Blade

    Rockhopper 38 – Maintenance Manual 8.2.3 Replacing the cutting blade Depending on the kind of roll media used, paper dust gathers in the cutter slot and on the cutter blade edge. This may cause bad sheet off quality. In this case, replace or clean the cutting blade or/and clean the cutter slot.
  • Page 181 Rockhopper 38 – Maintenance Manual Put the head manually back into its capping position, and turn the power switch ON. Step 4 : Note: Durability of the cutting blade may differ depending on the kind or thickness of the media and used environment. We recommend purchasing a spare cutting blade so that you always have a spare blade at hand.

  • Page 182: Emptying The Waste Bottle

    Rockhopper 38 – Maintenance Manual 8.2.4 Emptying the waste bottle When printing A0 size or larger widths, very small amounts of ink will be ejected on the left edge for stable printing quality. The waste ink ejected on the left side in that way is collected in a translucent bottle under the main unit (the waste ink bottle).

  • Page 183: Replacing The Blades

    8.2.5. Replacing the blades Please follow the procedure below to install the new blades, which has to be done every year as part of the periodical services done by an authorised Mutoh technician. Step 1 : Put the lever up.

  • Page 184: Periodical Services

    Caution: There are two parts of periodical service, namely the parts that can be replaced by the end-user and the parts that need to be done by authorized Mutoh technicians. 8.3.1. Service by end-user Perform periodical inspections according to the table below.

  • Page 185: Troubleshooting

    Rockhopper 38 – Maintenance Manual 9. TROUBLESHOOTING 9.1. INTRODUCTION This chapter explains the procedures for troubleshooting this product. When the product indicates a failure and an error message is also displayed on the control panel, refer to "Troubleshooting procedures when a message has been displayed" and implement treatment. When the product indicates failure but an error message has not been displayed, refer to "Troubleshooting procedures...

  • Page 186: Errors When Message Is Displayed

    Rockhopper 38 – Maintenance Manual 9.2 ERRORS WHEN MESSAGE IS DISPLAYED 9.2.1 Printer Status Messages Message Explanation N° Checkpoint Action Cover open The front • Is the cover sensor arm loose? → Tighten the cover sensor cover is open arm screw •...
  • Page 187 Rockhopper 38 – Maintenance Manual Message Explanation N° Checkpoint Action Undefined This message • Is the paper sensor Y assy cable → Connect it securely to Media means that that is attached to the head unit connector J204 (P EDGE)
  • Page 188 Rockhopper 38 – Maintenance Manual Message Explanation N° Checkpoint Action Media Skew • Reload media and confirm its → If the problem is simply Error status. due to poor loading, explain to the user how to load the media properly •...
  • Page 189 Rockhopper 38 – Maintenance Manual Message Explanation N° Checkpoint Action [User 1] This message is • Is the paper sensor Y assy cable → Connect it securely to Media End displayed when that is attached to the head unit connector J204 (P EDGE)
  • Page 190 Rockhopper 38 – Maintenance Manual Message Explanation N° Checkpoint Action Remove This message is • Switch off the printer temporarily Media displayed if, after and check that the message is raising the lever displayed when you switch on during printing again.
  • Page 191 Rockhopper 38 – Maintenance Manual Message Explanation N° Checkpoint Action Media Cut Error This message • Check how the cutter cap is fitted → Fit the cutter cap is displayed securely when the • Check the up and down → If it rises, go to 1.4 media is not movement of the cutter.
  • Page 192 Rockhopper 38 – Maintenance Manual Message Explanation N° Checkpoint Action → The capacity without Not enough When this printer • Check RAM capacity with the memory has insufficient printer’s self-diagnostic optional extended memory SIMM**MB memory for the “Examination: RAM capacity”.
  • Page 193 Rockhopper 38 – Maintenance Manual Message Explanation N° Checkpoint Action Insert special This • Switch off the printer temporarily cartridge message is and check that the message is displayed displayed when you switch on when a again. cartridge • Use the printer’s self-diagnostic other than a “Sensor: Cartridge”...
  • Page 194 Rockhopper 38 – Maintenance Manual Message Explanation N° Checkpoint Action [KCMY] Ink Low This • Check the no ink cartridge with → Remove all cartridges message is the printer’s self diagnostic “Sensor: and gently switch the displayed No ink”. detector assemblies (K, C,...
  • Page 195 Rockhopper 38 – Maintenance Manual Message Explanation N° Checkpoint Action [KCMY] This message • Switch off the printer indicates that the temporarily and check that cartridge ink cartridge that is the message is displayed shown on the when you switch on again.
  • Page 196 Rockhopper 38 – Maintenance Manual Message Explanation N° Checkpoint Action → For checking, use the Not filled This message • With genuine Mutoh Cartridge means “Initial filling properly inserted, start self- [KCMY] “No Ink” procedure has not been diagnostic mode and check that After adjustment and done”...
  • Page 197 Rockhopper 38 – Maintenance Manual Message Explanation N° Checkpoint Action → Install all cartridges and Ink type This message is • Use the printer’s self diagnostic error displayed when the “Sensor: Cartridge” to check the check that al four colours wrong type of ink ink type.

  • Page 198: Data Errors

    Rockhopper 38 – Maintenance Manual 9.2.2 Data Errors Message Explanation N° Checkpoint Action Network The optional • The main board assy may be → Replace it Detection network board can damaged Error not be detected • The Ethernet Board assy may →...

  • Page 199: Command Errors

    Rockhopper 38 – Maintenance Manual 9.2.3 Command Errors Message Explanation N° Checkpoint Action MH01 Error A command that is • Try communicating with → Contact your Mutoh local (undefined not defined in any the available computer and dealer. command) command mode cable.

  • Page 200: Cpu System Faults

    Rockhopper 38 – Maintenance Manual 9.2.4 CPU system faults Message Explanation N° Checkpoint Action → Replace it E001 Error This error display • The mainboard assy may be DRAM means that a fault damaged Standard has occurred in DRAM Error...
  • Page 201 Rockhopper 38 – Maintenance Manual Message Explanation N° Checkpoint Action → Contact your Mutoh E016 CPU Indicates that • Check AC power supply and Err [00] handling an printer peripheral devices Local Dealer (Interrupt interrupt has been → Contact your Mutoh •...
  • Page 202 Rockhopper 38 – Maintenance Manual Message Explanation N° Checkpoint Action → Contact your Mutoh E016 CPU Err Indicates that a • Check AC power supply and [10] reserved printer peripheral devices Local Dealer (Indicates that a command has → Contact your Mutoh •...
  • Page 203 Rockhopper 38 – Maintenance Manual Message Explanation N° Checkpoint Action E065 This message • Use the self-diagnostic Error X indicates that a “Examination/History” to check the Motor fault has history of faults occurred in the • Use the self-diagnostic → Check connectors J119 (X media feed “Aging/Media Feed Motor”...
  • Page 204 Rockhopper 38 – Maintenance Manual Message Explanation N° Checkpoint Action E066 Error Y This message indicates that a • Use the self- Motor fault has occurred in the head diagnostic movement motor (Y axis) while “Examination/Hist the printer was working.
  • Page 205 Rockhopper 38 – Maintenance Manual Message Explanation N° Checkpoint Action E075 Error Sensor This message indicates • Use the self- Fault that condition has diagnostic occurred in which the “Sensor/Origin” and origin cannot be carry out the origin detected. sensor test.

  • Page 206: Heater Errors

    Rockhopper 38 – Maintenance Manual 9.2.5 Heater Errors Errors caused by the heater system. 9.2.5.1 Automatic Check The heater system has been equipped with an automated diagnostics system to determine if it is safe to activate the heaters or to determine if there is a problem.
  • Page 207 Rockhopper 38 – Maintenance Manual 9.5.2.2 Error Messages Error Message Description + action to take Connect Error D1 sensor D1 has connection problem, please check connection Connect Error D2 sensor D2 has connection problem, please check connection Connect Error A1...

  • Page 208: Errors When Message Is Not Displayed

    Rockhopper 38 – Maintenance Manual 9.3 ERRORS WHEN MESSAGE IS NOT DISPLAYED 9.3.1 Trouble with Initialization. Message Explanation N° Checkpoint Action No Power • Is there a broken or shorted lead → Replace the switch cable in the switch cable assy (between assy.
  • Page 209 Rockhopper 38 – Maintenance Manual Message Explanation N° Checkpoint Action → Adjust cover switch Initial filling This symptom • With the printer cover closed, is of inks means that the liquid crystal display showing height. failed when new cover open? →...
  • Page 210 Rockhopper 38 – Maintenance Manual Message Explanation N° Checkpoint Action → If it has fallen out, refit it. Initial filling is Initial filling Is the cap assy spring fallen out or completed means to fill the broken? If it is broken, replace the...
  • Page 211 Rockhopper 38 – Maintenance Manual Message Explanation N° Checkpoint Action Initial Initial filling 1.10 • Are there any breaks, cuts or air → Change each ink tube, filling is means to leaks in the ink tubes? cleaning each time and...
  • Page 212 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • After power is • With the printer cover closed, is the → Adjust cover switch height. switched on, liquid crystal display showing cover Check cover switch assy nothing works open?
  • Page 213 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action Ink cartridges • With genuine Mutoh cartridges properly → For checking, use the are installed inserted, use the self-diagnostic “Sensor: [KCMY] “No Ink” procedure but not No Ink” → After adjustment and recognized and “Sensor: No Cartridge”...
  • Page 214 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action Media is not • Are the media suction fans turning? → If they are not turning, go to suction consultation 1-4. • Are XF/XR detecting normally → Check the connections of paper sensor according to the self-diagnostic F and paper sensor R connectors.

  • Page 215: Trouble With Media Feed

    Rockhopper 38 – Maintenance Manual 9.3.2 Trouble with Media Feed. Message N° Checkpoint Action • The media • Do paper sensors XF/XR → Check the connections of paper comes off when it detect normally with the self- sensor F and paper sensor R...
  • Page 216 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • The media • Is the media mounted recommended → If it is not media recommended by size is by Mutoh? Mutoh (especially thin tracing paper, different etc.), the paper sensors may read...

  • Page 217: Trouble With Printing

    Rockhopper 38 – Maintenance Manual 9.3.3 Trouble with printing. Message N° Checkpoint Action • Does not print • Is there a problem with the printer →Upgrade the printer driver continuously driver software? version. • Is there a problem with the remote →Upgrade the RPU version.
  • Page 218 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • Dots are missing from the • Clean twice in succession. printing • Are the ink tubes filled with ink? CAUTION: Wait at least 30 minutes after initial filling before Bad Example printing.
  • Page 219 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • Does not print • Check “24, 42 V DC Power Supply at all. Check” • Is the cap assy spring fallen out or → If it has fallen out, refit it.
  • Page 220 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • Does not print • With genuine Mutoh cartridges → Use the [KCMY] “No Cartridge” at all. properly inserted, use the printer’s procedure shown in EXA1100 for self-diagnostic “Sensor: No Ink” or checking.
  • Page 221 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • The entire surface is • Check the connections for head → Reconnect the connectors. printed black cables 1 and 2. Are they inserted → Replace head cables 1 and 2.
  • Page 222 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • Printing becomes shaded. • Was the printing done → Wait at least 30 minutes • The image contains blurs. immediately after initial after initial filling before • Transverse lines appear to be split.
  • Page 223 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • Printing becomes shaded. 1.11 • Are all the pressure → If there is paper dust or • The image contains blurs. rollers (15) pressurizing scraps near the pressure • Transverse lines appear to be split.
  • Page 224 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • Printing becomes shaded. 1.19 • Has ink dried on the → Use the self-diagnostic • The image contains blurs. surface of the print head “Adjustment/Head Cleaning” • Transverse lines appear to be split.
  • Page 225 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • Edges of printing are blurred • Does cleaning restore →Carry out three successive normal operation? cleanings. • Is media →If the media is causing the recommended by symptoms, and it is not...
  • Page 226 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • Many satellites (unwanted dots) • Do three cleanings in • The printing has whiskers succession. • Printed lines appear blurred (printing • Have the Test Print → If the nozzle check pattern is dirty) printed.
  • Page 227 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • Many satellites (unwanted dots) 1.11 • Does the head that is → Re-enter the rank of the • The printing has whiskers fitted have a rank that black head correctly.
  • Page 228 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action Mixed colour lines do not overlap. • Is the steel belt 150 g ± 20 g tension adjusted properly? • Is the Y drive pulley →Re-tighten the set screw set screw loose? securely.
  • Page 229 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • Inaccurate line length in the • Are environmental →After checking compliance direction of head movement conditions within the range with the range (Main scanning direction) recommended for assured recommended for assured...
  • Page 230 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • Inaccurate straight line in • Are the fans working normally → Check the connectors the direction of head according to the self-diagnostic between fan assy, fan cable movement (straightness) “Examination/Fans”? assy and main board assy.
  • Page 231 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • Inaccurate line distance in the • Are environmental →After checking compliance with direction of media feed conditions within the range the range recommended for (Subsidiary scanning distance) recommended for assured...
  • Page 232 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • Inaccurate straight line in the • Is there any mistake →Enter the rank correctly. direction in the rank of the head of media feed (joining precision Y) that is actually...

  • Page 233: Problem Involving Noise

    Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • Bad right angle • Are the fans working →Check the connectors between precision normally according to the fan assy, fan cable assy and main self-diagnostic board assy. “Examination/Fans”? Fan cable A assy is J115 (FAN1)
  • Page 234 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • Abnormal noise • Is there something touching or some →Remove the obstruction or when media is foreign matter at the place producing foreign matter. sucked down the abnormal noise? • It a board producing the noise? →Replace the board in question.
  • Page 235 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • Abnormal noise • Is the abnormal noise due to →Replace them. Also, explain the when media is fed. pressure roller deformation? need to raise the lever, as shown in the caution label, when the printer is not printing •...

  • Page 236: Trouble With Media Cutting

    Rockhopper 38 – Maintenance Manual 9.3.5 Trouble with Media Cutting Message N° Checkpoint Action • Does not cut • Is the cutter blade chipped or → Replace the cutter. normally (Since deteriorated as checked in the there is no cutting...
  • Page 237 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • Cutting occurs during printing • Is there a problem with the →Upgrade the printer driver (Since there is no cutting of printer driver software? version cut sheet • Is there a problem with the →Upgrade the RPU version.
  • Page 238 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • The cutting • Are the paper guide surfaces being →Clean the surfaces. operation is maintained as a result of the primary normal but consultation? the media does • Is the cutter blade chipped or →Replace the cutter.

  • Page 239: Online/Function Problems

    Rockhopper 38 – Maintenance Manual 9.3.6 Online/Function Problems. Message N° Checkpoint Action • Cannot connect • Try communicating with the → Contact your Mutoh local dealer. normally with RS- available computer and cable. 232C Confirm: Does the error occur → There may be a broken lead in...
  • Page 240 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action Printing position • Is there a problem with the CW →Adjust it. is offset. adjustment? • Is the front-sensor-to-head distance →Adjust them. or the cutter-to-head distance causing a problem for top and bottom margin distance adjustments? •...

  • Page 241: Other

    Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • There is an • Are the printing position and location →Set them to suitable values. extra feed after method settings suitable? printing is finished • Is there a problem with the printer →Upgrade the printer driver...
  • Page 242 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • Mounting the • Is there a problem with the →Apply grease (G501) and adjust the media is difficult movement of the pressure pressure transfer plate. lever? • Is there a problem with the →Replace pressure assy.
  • Page 243 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • Ink has overflowed • Check inside the waste fluid from the waste fluid box. If it is full of ink, explain to the customer as you replace the waste fluid box.
  • Page 244 Rockhopper 38 – Maintenance Manual Message N° Checkpoint Action • Trouble related to • The ink cartridge may be →Return it to the dealer and request ink (consumable damaged. that it be checked. item) • The media (consumable item) →Return it to the dealer and request •...

  • Page 245: Heater Error Messages

    Rockhopper 38 – Maintenance Manual 9.4 HEATER ERROR MESSAGES Errors caused by the heater system. 9.4.1 Automatic Check The heater system has been equipped with an automated diagnostics system to determine if it is safe to activate the heaters or to determine if there is a problem.

  • Page 246: Error Messages

    Rockhopper 38 – Maintenance Manual 9.4.2 Error Messages Error Description Connect Error D1 sensor D1 has connection problem, please check connection Connect Error D2 sensor D2 has connection problem, please check connection Connect Error A1 sensor A1 has connection problem, please check connection...

  • Page 247: Appendix

    Rockhopper 38 – Maintenance Manual 10. APPENDIX 10.1. INTRODUCTION This chapter provides referential information such as service data and exploded views. 10.2. WIRING DIAGRAM ROCKHOPPER 38 AP-74038, Rev. 1.1, 25/01/05...

  • Page 248: Rockhopper 38: Service Parts List/Exploded Views/Configuration Diagrams

    Rockhopper 38 – Maintenance Manual 10.3. ROCKHOPPER 38: SERVICE PARTS LIST/EXPLODED VIEWS/CONFIGURATION DIAGRAMS This section includes the service parts list, exploded views of respective units and configuration diagrams. Notes : For the latest ‘exploded views’ and ‘part description’, please refer to the spare part lists of the printer.
  • Page 249 Rockhopper 38 – Maintenance Manual LB-10031 LB-45171 LB-45170 LB-24602 LB-45805 EY-24603 ME-24615 ME-24605 ME-24614 ME-24124 EY-24502 ME-24613 ME-24612 ME-24609 DF-43737 LB-10250 LB-24600 NS-05030081 MY-24612 UNIT-SDMP38 ME-24236 ME-24237 CAT5001-00 REV./ DR-4001-43993 DF-41461 AP-74038, Rev. 1.1, 25/01/05...
  • Page 250 Rockhopper 38 – Maintenance Manual AP-85011 ME-24617 (3x) NS-05030081 (8x) MY-41793 ME-24606 ME-24626 ME-23046(5x) ME-24631 ME-24618 NS-06030061(4x) UNIT-SDMP38 CAT5002-00 REV./ AP-74038, Rev. 1.1, 25/01/05...
  • Page 251 Rockhopper 38 – Maintenance Manual DF-41792 MY-41792 MY-40469 (3x) MK-24207 DE-49812 DE-46552 ME-24239 DF-40469 DE-46552 DF-40470 NS-05040101 ME-24240 NS-06030061 ME-24608 MY-24146 ME-24128(0,7 m) DE-49738(2x0,44 m) DE-49891(8x0,02 m) ME-24100 ME-24101 NS-04030061 (2x) DE-48958 (2x) NS-04030061 (4x) DE-44113 ME-24103 NS-04030061 (4x) ME-24102...
  • Page 252 Rockhopper 38 – Maintenance Manual ME-24138 MY-24114 MY-34776 ME-24600 ME-20926 ME-24138 ME-24627 ME-20925 MY-34776 ME-24616 ME-24601 ME-24138 MY-34776 ME-24601 ME-24138 EY-24623 ME-24601 ME-24128 ME-24628 ME-24604 ME-24621 UNIT-SDMP38 CAT5004-00 REV./ AP-74038, Rev. 1.1, 25/01/05...
  • Page 253 Rockhopper 38 – Maintenance Manual DE-21303 (3") RJ41-SR03 DF-40980 ME-27065 DP-3022-40153 DE-49780 DE-21303(3") LB-45000 DP-3022-40153 AP-74038, Rev. 1.1, 25/01/05...
  • Page 254 Rockhopper 38 – Maintenance Manual MY-33945B DF-44766 UNIT-SDMP38 CAT5006-00 REV./ AP-74038, Rev. 1.1, 25/01/05...
  • Page 255 Rockhopper 38 – Maintenance Manual ME-40856 UNIT-SDMP38 CAT5007-00 REV./ AP-74038, Rev. 1.1, 25/01/05...
  • Page 256 Rockhopper 38 – Maintenance Manual DRYER MK-24600 MK-24603(220V) MK-24602(110V) FIXER MK-51622(220V) MK-51621(110V) EY-24320 (RJ8-ETH14) MK-24601 MK-24604 ME-24610 ME-24238 DE-11165 EY-24600 MC-7002 AE-91025 (3x) ME-24607 PCB Layout + cables UNIT-SDMP38 refer to drawing AP-76130 CAT5008-00 REV./ AP-76131 AP-74038, Rev. 1.1, 25/01/05...
  • Page 257 Rockhopper 38 – Maintenance Manual DE-10875B UNIT-SDMP38 CAT5009-00 REV./ AP-74038, Rev. 1.1, 25/01/05...
  • Page 258 Rockhopper 38 – Maintenance Manual AP-74038, Rev. 1.1, 25/01/05...

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