Page 1: Maintenance Manual
Maintenance Manual MUTOH EUROPE N.V. AP-74065, Rev 1.2: , 27/09/2004...
Page 2 Rockhopper II series printers – Maintenance Manual MUTOH INDUSTRIES LTD. MUTOH EUROPE N.V. MUTOH DEUTSCHLAND GmbH. MUTOH AMERICA INC. Tel.:81-(0)3-54867145 Tel.:32-(0)59-561400 Tel.:49-(0)2159 913430 Tel.: (480) 968-7772 Fax.:81-(0)3-54867163 Fax:32-(0)59-807117 Fax.:49-(0)2159 913456 Fax: (480) 968-7990 E-mail:ibd@mutoh.co.jp E-mail:mutoh@mutoh.be E-mail:Mutoh-Sales@t-online.de E-mail:Sales@mutoh.com http://www.mutoh.co.jp http://www.mutoh.be http://www.mutoh.com...
Page 3 Rockhopper II series printers – Maintenance Manual AP-74065, Rev. 1.2, 27/09/04...
Page 4: 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 II series Printer. In consideration of the furnishing of the information contained in this document, the party to whom it is given, assumes its custody...
Page 5 Rockhopper II series printers – Maintenance Manual AP-74065, Rev. 1.2, 27/09/04...
Page 6: 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 7 Rockhopper II series printers – Maintenance Manual AP-74065, Rev. 1.2, 27/09/04...
Page 8: Table Of Contents
Rockhopper II series printers – Maintenance Manual TABLE OF CONTENTS 1. Safety Instructions.......................15 1.1. Introduction .......................... 15 1.2. Warnings, Cautions and Note ....................15 1.3. Important safety instructions ....................15 1.3.1. Warning............................15 1.3.2. Caution............................16 1.4. Warning labels ........................17 1.4.1.
Page 9 Rockhopper II series printers – Maintenance Manual 4.3. Replacement of the heater element ..................55 4.3.1. Rockhopper II 2 heaters : Heater elements .................. 55 4.3.2. Rockhopper II 4 heaters : Heater elements .................. 59 4.4. Replacing Board Bases......................65 4.4.1 Replacing the Mainboard assembly, HDD_Extension board assembly, HEAD_DRV board...
Page 10 Rockhopper II series printers – Maintenance Manual 5. Self-Diagnosis Function....................137 5.1. Introduction ........................137 5.2. Preparation ........................137 5.2.1. Preparations on Machine ......................137 5.2.2. Starting Up ..........................138 5.3. Operations in Self-Diagnosis Mode..................139 5.3.1. Operating Self-Diagnosis Mode....................139 5.3.2.
Page 11 Rockhopper II series printers – Maintenance Manual 6. Maintenance Mode.....................203 6.1. Introduction ........................203 6.2. Operating Maintenance Mode.................... 203 6.2.1. Starting Up Maintenance Mode ....................203 6.2.2. Operating Maintenance Mode ....................203 6.3. Maintenance Menu ......................204 6.3.1. Counter Display Menu ........................ 204 6.3.2.
Page 12 Rockhopper II series printers – Maintenance Manual 8. Maintenance .......................257 8.1. Introduction ............................257 8.2. Cleaning ..........................258 8.3. Periodical Services ......................259 8.3.1. Service by end-user ........................259 8.3.2. Service by authorised Mutoh technician ..................260 8.4. Part Life Information......................261 8.5.
Page 13 Rockhopper II series printers – Maintenance Manual AP-74065, Rev. 1.2, 27/09/04...
Page 14: Safety Instructions
Rockhopper II series printers – Maintenance Manual 1. SAFETY INSTRUCTIONS 1.1. INTRODUCTION This chapter explains the meaning of safety terms for personnel who operate this equipment, important safety instructions and the positions of the warning labels. Important : • Be sure to follow all instructions and warnings in this manual when using the equipment.
Page 15: Caution
If you need to operate the printer with the cover removed for maintenance, be careful not to get hurt by the moving parts. Do not oil the printer mechanism with oil other than the oil designated by MUTOH. Doing so may damage the parts or shorten the lifetime.
Page 16: Warning Labels
Rockhopper II series printers – Maintenance Manual 1.4. WARNING LABELS The handling, attachment locations, and types of warning labels are explained below. Warning labels are attached to areas to which attention should be paid. Read and understand the positions and contents thoroughly.
Page 17 Rockhopper II series printers – Maintenance Manual Type CAUTION VORSICHT ATTENTION > Do not open the front cover or touch the media during printing.This will result in poor image quality. > If no printing is to be done for some time, remove the media and put the hold lever in the up position.
Page 18 Rockhopper II series printers – Maintenance Manual (2) Back Part Type CAUTION THIS UNIT HAS TWO POWER SUPPLY CORDS STANDARD. TO REDUCE THE RISK OF ELECTRICAL SHOCK, DISCONNECT ALL POWER SUPPLY CORDS BEFORE SERVICING. AP-74065, Rev. 1.2, 27/09/04...
Page 19: Operation Procedure Labels
Rockhopper II series printers – Maintenance Manual 1.5. OPERATION PROCEDURE LABELS The handling, attachment locations and types of operation procedure labels are explained below. Your printer has labels, which give simple explanations of operations that require particular care. Read and understand the locations and contents of these labels thoroughly before performing your work.
Page 20: Product Overview
Rockhopper II series printers – Maintenance Manual 2. PRODUCT OVERVIEW 2.1. INTRODUCTION This chapter explains the features, part names, and functions of the printer. 2.2. FEATURES The features of the printer are explained below. (1) High speed output Both models feature new print heads and achieve high speed printing.
Page 21: Part Names And Functions
Rockhopper II series printers – Maintenance Manual 2.3. PART NAMES AND FUNCTIONS Part names and functions are explained below. 2.3.1. Front Name Function Operation panel This panel is used to set operational conditions, the status of the printer, and other functions.
Page 22: Back
Rockhopper II series printers – Maintenance Manual 2.3.2. Back Name Function AC inlet This is the inlet interface to which the power plug is connected. Interface connector This is the connector to which the interface cable is connected. Foot switch connector This is the connector to which the foot switch cable is attached.
Page 23: Operation Panel
Rockhopper II series printers – Maintenance Manual 2.3.3. Operation panel The operation panel is used to set operation conditions, display the status of the printer and set other functions. The names and functions of the operation keys and status lamps are explained below.
Page 24 Rockhopper II series printers – Maintenance Manual (2) LCD monitor and status lamps. Name Colour Status Function LCD monitor The monitor displays the operation status and error messages of the printer. POWER lamp Green The printer is on. The printer is off.
Page 25: Printer Status
Rockhopper II series printers – Maintenance Manual 2.4. PRINTER STATUS The status of the printer is explained below. 2.4.1. Normal Indicates that the printer can print when media is loaded. You can also make settings using the operation panel. Notes : Refer to the User’s Guide.
Page 26: Selecting Language
Rockhopper II series printers – Maintenance Manual 2.4.5. Selecting Language This chapter explains how to select the language on the display. Japanese or English is selectable for the display language of the printer. Follow the steps below to select the display language.
Page 27: Position And Function Of The Heating Elements
Rockhopper II series printers – Maintenance Manual 2.5. POSITION AND FUNCTION OF THE HEATING ELEMENTS 2.5.1. Rockhopper II 2 heater printers Heater element Temperature Function → Open the pores to make the media more receptive Pre-heater (Heater A) 20 – 50°C for eco-solvent or eco-solvent plus™...
Page 28: Or 4 Heater
Rockhopper II series printers – Maintenance Manual 2.5.3. 2 or 4 heater To verify if your printer is equipped with 2 or 4 heaters, please refer to the photo’s mentioned below. Rockhopper II 2 heater printer Rockhopper II 4 heater printer...
Page 29 Rockhopper II series printers – Maintenance Manual AP-74065, Rev. 1.2, 27/09/04...
Page 30: Specifications
Rockhopper II series printers – 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 Printers 50”- model 64”- model 87”- model Technology Drop-on-demand Micro Piezo Inkjet Technology.
Page 31 Rockhopper II series printers – Maintenance Manual Printers 50”- model 64”- model 87”- model Power Consumption 1100 VA 1300 VA 1400 VA 80 VA in stand-by 80 VA in stand-by 100 VA in stand-by mode mode mode External Dimensions in mm (W x D x H)
Page 32: Interface Specifications
Rockhopper II series printers – 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...
Page 33: Network Interface (Optional) Specifications
Rockhopper II series printers – 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 34: Installation
Rockhopper II series printers – 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 35 Rockhopper II series printers – Maintenance Manual Notes : Avoid the following places with regard to temperature or humidity. If doing so, it may affect the printing result. Places where the temperature of humidity may rapidly change even though it is within the correct range.
Page 36: Parts Replacement
Rockhopper II series printers – 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 37: Removing The Cover
Rockhopper II series printers – Maintenance Manual 4.2. REMOVING THE COVER When replacing any of the parts inside the printer, it is necessary to remove all covers. The procedures for removing the covers are given below. 1 = I/H cover...
Page 38: Removing The I/H Cover
Rockhopper II series printers – Maintenance Manual 4.2.1. Removing the I/H cover Step 1 : Remove the ink cartridge. Step 2 : Open the I/H cover lid. Step 3 : Remove the 4 screws fixing the I/H cover. Step 4 : Remove the I/H cover and I/H cover lid.
Page 39: Removing Side Cover R
Rockhopper II series printers – Maintenance Manual 4.2.2. Removing side cover R Step 1 : Remove the screw from the upper part of the side cover R. 1 = Screws (M4x12) on the upper part of the side cover R Step 2 : Remove the 2 screws from the bottom of side cover R.
Page 40 Rockhopper II series printers – Maintenance Manual Step 4 : Remove the top of the side cover R. Step 5 : Remove the 4 bolts from the front and back of the inner surface on the bottom of side cover R and the front cover nut.
Page 41: Removing Side Cover L
Rockhopper II series printers – Maintenance Manual 4.2.3. Removing side cover L Step 1 : Remove the screw from the side of the upper part of side cover L. 1 = Screws (M4x12) on the side of the upper part of the side cover L Step 2 : Remove the 2 screws from the front of the bottom of side cover L.
Page 42 Rockhopper II series printers – Maintenance Manual Step 4 : Remove the 4 bolts and cover nut from the front and back of the inner surface on the bottom of side cover L. 1 = Hexagon socket head cap screws (M4x16)
Page 43: Removing The
Rockhopper II series printers – Maintenance Manual 4.2.4. Removing the front cover Step 1 : Open the front cover. Step 2 : Remove the E ring on the left side. Step 3 : Remove the 4 screws on the left and right cover spindles.
Page 44 Rockhopper II series printers – Maintenance Manual Step 5 : If the machine is 64 or 87-inch model, remove the E ring and the sensor cam, push the cover spindle L to the origin side and then slide and remove the front cover.
Page 45: Removing The Carriage Cover
Rockhopper II series printers – Maintenance Manual 4.2.5. Removing the carriage cover Caution : Please note that this cover is only on a Rockhopper II (2 heaters) printer. Step 1 : Remove the I/H cover. Step 2 : Remove side cover R.
Page 46: Removing The Panel Unit Assembly
Rockhopper II series printers – Maintenance Manual 4.2.6. Removing the panel unit assembly Step 1 : Remove side cover R. Step 2 : Remove the panel tape power cord. Step 3 : Remove the 4 screws fixing the panel base.
Page 47: Removing The Y Rail Cover
Rockhopper II series printers – Maintenance Manual 4.2.7. Removing the Y rail cover Caution : Removing the Y rail cover, should be performed by at least two persons. Otherwise the Y rail cover may be deformed. Step 1 : Remove side cover R.
Page 48 Rockhopper II series printers – Maintenance Manual Step 7 : Remove the 5 screws from the rear of the Y rail cover. If the machine is an 87-inch model, there are 8 screws on the rear Y rail cover. 1 = Screws (M4x8) on the rear of the Y rail cover Step 8 : Remove the Y rail cover.
Page 49: Removing Front Paper Guide
Rockhopper II series printers – Maintenance Manual 4.2.8. Removing front paper guide Step 1 : Remove side cover L. Step 2 : Remove side cover R. Step 3 : Remove the front cover. Step 4 : Remove the carriage cover.
Page 50 Rockhopper II series printers – Maintenance Manual Step 7 : Remove the screws from the front of front media guide. Notes : Please note that the amount of screws is size dependent. Rockhopper II 2 heater 1 = Screws on the front of front media guide...
Page 51: Removing Rear Paper Guide
Rockhopper II series printers – Maintenance Manual 4.2.9. Removing rear paper guide Step 1 : Remove side cover L. Step 2 : Remove side cover R. Step 3 : Remove the front cover. Step 4 : Remove the Y rail cover.
Page 52: Removing The Head Cover
Rockhopper II series printers – Maintenance Manual 4.2.10. Removing the head cover Step 1 : Remove the I/H cover. Step 2 : Remove side cover R. Step 3 : Remove side cover L. Step 4 : Remove the front cover.
Page 53: Removing The Maintenance Cover
Rockhopper II series printers – Maintenance Manual 4.2.11. Removing the maintenance cover Step 1 : Remove the I/H cover. Step 2 : Remove side cover R. Step 3 : Remove side cover L. Step 4 : Remove the front cover.
Page 54: Replacement Of The Heater Element
Rockhopper II series printers – Maintenance Manual 4.3. REPLACEMENT OF THE HEATER ELEMENT To replace a heater element of the Rockhopper II series printer, please follow the instructions mentioned in the explanation of the appropriate heater element. 1. Rockhopper II : 1.
Page 55 Rockhopper II series printers – Maintenance Manual Step 7 : Remove the front heater strip(s). Step 8 : Degrease the plate. Notes : Make sure the plate is cleaned properly. Dust, glue and other parts must be removed. Step 9 : Stick the front heater strip(s) onto the plate.
Page 56 Rockhopper II series printers – Maintenance Manual 4.3.1.2. Replacing the rear heater on a Rockhopper II printer Before replacing the post fixer, make sure to have following items: 50” model : Heater strip assy rear 50 64” model : Heater strip assy rear 64 87”...
Page 57 Rockhopper II series printers – Maintenance Manual Notes : It will take ± 1 hour to let the glue dry. Step 10 : Reinstall all parts in the opposite order of the removal procedure. Notes : During reinstallation of the plate, make sure there are no cables stuck.
Page 58: Rockhopper Ii 4 Heaters : Heater Elements
Rockhopper II series printers – Maintenance Manual 4.3.2. Rockhopper II 4 heaters : Heater elements 4.3.2.1. Replacing the dryer (Heater D) on a Rockhopper II 4H printer Before replacing the dryer, make sure to have following items: 50” model : Dryer D1 50 and Dryer D2 50 64”...
Page 59 Rockhopper II series printers – Maintenance Manual Step 10 : Reinstall all parts in the opposite order of the removal procedure. Notes : During reinstallation of the plate, make sure there are no cables stuck. 4.3.2.2. Replacing the post fixer (Heater C) on a Rockhopper II 4H printer Before replacing the heater, make sure to have following items: 50”...
Page 60 Rockhopper II series printers – Maintenance Manual Step 9 : Stick onto the sensor a sensor insul. patch. 1 = sensor insul. patch 2 = assembly hole Step 10 : Reinstall all parts in the opposite order of the removal procedure.
Page 61 Rockhopper II series printers – Maintenance Manual Step 7 : Fix the plot platform calibre onto the plot platform. 1 = Fix plot platform caliber 2 = reachable screws of plot platform Notes : Make sure the screws of the plot platform are reachable.
Page 62 Rockhopper II series printers – Maintenance Manual Step 13 : Stick the isolation tape onto the heater strips. 1 = plot platform 2 = fixer heater strip 3 = isolation tape Step 14 : Reinstall all parts in the opposite order of the removal procedure.
Page 63 Rockhopper II series printers – Maintenance Manual Step 8 : Stick the heater strip onto the plate. Notes : Please make sure that there are no air bubbles under the heater strip. Air bubbles below the heater strip could cause overheating of the heater strip.
Page 64: Replacing Board Bases
Rockhopper II series printers – Maintenance Manual 4.4. REPLACING BOARD BASES This chapter explains the procedures for replacing the power source board assembly, mainboard assembly, PCI_Linux board assembly and cooling fan assembly. Caution : When handling circuit boards, do not touch the elements on the board with your bare hands.
Page 65 Rockhopper II series printers – Maintenance Manual Step 2 : Remove the Mainboard cover 3. Step 3 : Follow the instructions in “Removing the panel unit assembly” to remove the panel unit assembly. Step 4 : Remove the connector between the cooling fan cable and the cooling fan assembly.
Page 66 Rockhopper II series printers – Maintenance Manual Step 11 : Remove following connectors from the Mainboard assembly. N° Connector N° # of pins Colour Connected to Remarks J101 White Mainboard Lock type J102 White Power Lock type J103 DIMM J104...
Page 67 Rockhopper II series printers – Maintenance Manual J146 (87) White or black CR board Lock type J147 (87) White or black CR board Lock type J148 (87) White or black CR board Lock type J149 (87) White or black CR board...
Page 68 Rockhopper II series printers – Maintenance Manual Step 18 : Remove the 6 screws and 4 hexagon spacers fixing the Mainboard assembly. 1 = Mainboard assembly 2 = HDD_Extension board assembly 3 = Hexagon spacer 4 = Screws (M3x6) 5 = Cooling fan assembly...
Page 69: Replacing The Power Source Board Assembly
Rockhopper II series printers – Maintenance Manual 4.4.2. Replacing the power source board assembly Caution : When removing the power source board assembly, remove the power cable and set it aside for at least 5 minutes in order to completely discharge the electric charge remaining in the electrolytic capacitor before continuing with the procedure.
Page 70 Rockhopper II series printers – Maintenance Manual Step 6 : Remove the 4 screws fixing the power source. 1 = Power source board assembly 2 = Screws (M4x8) fixing the power board assembly 3 = Hexagon nut fixing the power board assembly...
Page 71: Replacing The Inlet Assembly, Inlet Board Assembly And Lever Foot Sw Cable Assembly
Rockhopper II series printers – Maintenance Manual 4.4.3. Replacing the inlet assembly, inlet board assembly and lever foot SW cable assembly Step 1 : Follow the instructions in "Replacing the Mainboard assembly, HDD_Extension board assembly, HEAD_DRV board assembly, PCI_Linux board assembly and cooling fan assembly" to remove the Mainboard assembly.
Page 72: Replacing The Junction Board Assembly
Rockhopper II series printers – Maintenance Manual 4.4.4. Replacing the JUNCTION board assembly Notes : To replace board and connect or disconnect the FFC type cable, you should leave the plug disconnected from the power socket for a while. Otherwise, over-current could be generated and damage the board.
Page 73: Replacing The Pf Actuator
Rockhopper II series printers – Maintenance Manual 4.5. REPLACING THE PF ACTUATOR 4.5.1. Replacing the PF motor assembly Caution : The motor is hot after the product has been operated, so be careful not to burn yourself. Notes : Remove following covers before replacing the parts in the PF motor assembly.
Page 74: Replacing The Pf_Enc Assembly And Pf Scale Assembly
Rockhopper II series printers – Maintenance Manual 4.5.2. Replacing the PF_ENC assembly and PF scale assembly Notes : Remove the following covers before replacing the PF_ENC assembly. Side cover L: refer to "Removing side cover L" Step 1 : Remove the PF_ENC assembly connector.
Page 75: Replacing The Pf Deceleration Pulley Assembly
Rockhopper II series printers – Maintenance Manual Step 9 : Replace the PF_ENC assembly. Notes : When installing the PF_ENC assembly and the PF encoder installation board, make sure they are aligned with the locating bosses. Step 10 : Reinstall all parts in the opposite order of the removal procedure.
Page 76: Replacing The Pf Deceleration Belt
Rockhopper II series printers – Maintenance Manual 4.5.4. Replacing the PF deceleration belt Notes : Remove following covers before replacing the parts in the PF motor assembly. Side cover R: refer to "Removing side cover R" Side cover L: refer to "Removing side cover L"...
Page 77: Replacing The P_Rear_R Sensor Assembly And P_Rear_L Sensor Assembly
Rockhopper II series printers – Maintenance Manual 4.5.5. Replacing the P_REAR_R sensor assembly and P_REAR_L sensor assembly Notes : Remove following covers before replacing the P_REAR_R sensor assembly and P_REAR_L sensor assembly. Side cover R: refer to "Removing side cover R"...
Page 78: Replacing The Suction Fan Assembly
Rockhopper II series printers – Maintenance Manual 4.5.6. Replacing the suction fan assembly Notes : Remove following covers before replacing the suction fan assembly. Side cover R: refer to "Removing side cover R" Side cover L: refer to "Removing side cover L"...
Page 79: Replacing The Lever Motor Assembly And The Arm Motor Installation Board
Rockhopper II series printers – Maintenance Manual 4.5.7. Replacing the lever motor assembly and the arm motor installation board Caution : The motor is hot after the product has been operated, so be careful not to burn yourself. Notes : Remove following covers before replacing the lever motor.
Page 80 Rockhopper II series printers – Maintenance Manual Step 5 : Replace the CR motor assembly. Step 6 : Remove the hexagon socket head screws with spring washers (2) fixing the arm motor installation board. 1 = Arm motor installation board...
Page 81: Replacing The Transmission Photosensor
Rockhopper II series printers – Maintenance Manual 4.5.8. Replacing the transmission photosensor Notes : Remove following covers before replacing the transmission photosensor. Side cover R: refer to "Removing side cover R" Side cover L: refer to "Removing side cover L"...
Page 82 Rockhopper II series printers – Maintenance Manual (2) Replacing the transmission photosensor (CR origin side) Notes : Refer to ‘Head Lock Menu’ Step 1 : Unlock the head. Step 2 : Move the carriage from the capping position to the left.
Page 83: Replacing The Flushing Box Assembly
Rockhopper II series printers – Maintenance Manual 4.5.9. Replacing the flushing box assembly Notes : Remove following covers before replacing the flushing box assembly. Side cover R: refer to "Removing side cover R" Side cover L: refer to "Removing side cover L"...
Page 84: Replacing The Cr Actuator
Rockhopper II series printers – Maintenance Manual 4.6. REPLACING THE CR ACTUATOR 4.6.1. Replacing the CR motor assembly Caution : The motor is hot after the product has been operated, so be careful not to burn yourself. Notes : Remove following covers before replacing the CR motor assembly.
Page 85: Replacing The Steel Belt
Rockhopper II series printers – Maintenance Manual 4.6.2. Replacing the steel belt Caution : When replacing the steel belt, be careful not to cut your hands by the belt. Notes : Do not damage the steel belt. Remove following covers before replacing the steel belt.
Page 86 Rockhopper II series printers – Maintenance Manual Step 4 : Remove the 2 screws fixing the steel belt. 1 = Screws fixing the steel belt 2 = Steel belt Step 5 : Replace the steel belt. Notes : Be careful when handling the steel belt. The steel belt may be cut off when accreting dust to it or creasing it.
Page 87: Board
Rockhopper II series printers – Maintenance Manual 4.6.3. Replacing the SLIDE motor assembly, HD_SLIDE sensor assembly, and slide motor installation board Caution : The motor is hot after the product has been operated, so be careful not to burn yourself.
Page 88: Replacing The T Fence
Rockhopper II series printers – Maintenance Manual 4.6.4. Replacing the T fence Notes : Remove following covers before replacing the T fence. Side cover R: refer to "Removing side cover R" Side cover L: refer to "Removing side cover L"...
Page 89 Rockhopper II series printers – Maintenance Manual Step 5 : Remove the T fence from the hook. Step 6 : Pull out the T fence in the direction of the arrow as shown in the previous figure while being careful not to damage the CR_ENC assembly.
Page 90: Replacing The Cr Slave Pulley Assembly
Rockhopper II series printers – Maintenance Manual 4.6.5. Replacing the CR slave pulley assembly Notes : Remove following covers before replacing the CR slave pulley assembly. Side cover R: refer to "Removing side cover R" Side cover L: refer to "Removing side cover L"...
Page 91: Replacing The Cr Actuator Pulley And The Cr Deceleration Belt
Rockhopper II series printers – Maintenance Manual 4.6.6. Replacing the CR actuator pulley and the CR deceleration belt Notes : Remove following covers before replacing the CR slave pulley. Side cover R: refer to "Removing side cover R" Side cover L: refer to "Removing side cover L"...
Page 92: Replacing The Steel Bearer, Tube Guide, Cr Tape Power Cable And Ink Tube
Rockhopper II series printers – Maintenance Manual 4.6.7. Replacing the steel bearer, tube guide, CR tape power cable and ink tube Notes : To replace the board and connect or disconnect the FFC type cable, you should leave the plug disconnected from the power socket for a while. Otherwise, over- current could be generated and damage board.
Page 93 Rockhopper II series printers – Maintenance Manual Step 5 : Completely remove tube bundles 1 and 2. 1 = Tube bundle 2 = Tube bundle 2 Step 6 : Remove the 4 screws fixing the tube clamp. Step 7 : Remove the tube clamp.
Page 94: Replace The Cover R Sensor Assembly And The Cover L Sensor Assembly
Rockhopper II series printers – Maintenance Manual 4.6.8. Replace the cover R sensor assembly and the cover L sensor assembly Notes : Remove following covers before replacing the cover R sensor assembly and the cover L sensor assembly. Side cover R: refer to "Removing side cover R"...
Page 95: Replacing The Cursor
Rockhopper II series printers – Maintenance Manual 4.7. REPLACING THE CURSOR 4.7.1. Replacing the cutter holder, cutter spring, cutter cap, solenoid assembly and solenoid spring (1) Replacing the cutter spring Step 1 : Open the front cover. Step 2 : Remove the cutter blade from the cutter holder.
Page 96 Rockhopper II series printers – Maintenance Manual Step 1 : Remove the 2 screws fixing the cutter holder and holder support. 1 = Holder support 2 = Cutter holder 3 = Screws (M3x6) fixing the cutter holder and holder support Step 2 : Remove the cutter holder.
Page 97: Replacing The Print Head Assembly And Head Tape Power Cable
Rockhopper II series printers – Maintenance Manual 4.7.2. Replacing the print head assembly and head tape power cable Notes : To replace the board and connect or disconnect the FFC type cable, you should leave the plug disconnected from the power socket for a while. Otherwise, over- current could be generated and damage board.
Page 98 Rockhopper II series printers – Maintenance Manual Step 5 : Remove the damper assembly from the print head assembly. Step 6 : Remove the screw and step-bore screw fixing the head stationary plate. Step 7 : Remove the rotation adjustment spring under the head with small flat-head driver or another tool.
Page 99: Replacing The H Ink Tube, Tube Branch And Damper Assembly
Rockhopper II series printers – Maintenance Manual 4.7.3. Replacing the H ink tube, tube branch and damper assembly Notes : Remove following covers before replacing the H ink tube, tube branch, and damper assembly. Side cover R: refer to "Removing side cover R"...
Page 100: Replacing The Cr Board Assembly
Rockhopper II series printers – Maintenance Manual Step 7 : Remove the H ink tube, coupling screw and O-ring from the damper assembly. Step 8 : Replace the damper assembly. Step 9 : Replace the H ink tube and O-ring.
Page 101 Rockhopper II series printers – Maintenance Manual Step 2 : Remove following connectors from the CR board. N° Connector N° # of pins Colour Connected to Remarks J201 White or Black Mainboard Lock type or Plug-in J202 White or Black...
Page 102: Replacing The Cr_Enc Assembly
Rockhopper II series printers – Maintenance Manual 4.7.5. Replacing the CR_ENC assembly Notes : Remove following cover before replacing the CR_ENC assembly. Side cover L: refer to "Removing side cover L" Step 1 : Follow step 1 in "Replacing the flushing box assembly" to slide the CR cursor to the left.
Page 103: Replacing The P_Edge Sensor Assembly
Rockhopper II series printers – Maintenance Manual 4.7.6. Replacing the P_EDGE sensor assembly Notes : Remove following covers before replacing the P_EDGE sensor Assembly. Side cover R: refer to "Removing side cover R" Side cover L: refer to "Removing side cover L"...
Page 104: Replacing Black Tape On Platform
In case of a damaged or faded black tape, you have to stick a new black tape onto the print platform. This black tape can be ordered with Mutoh Europe’s order entry department. To stick the black tape onto the print platform, please follow the instructions mentioned below.
Page 105 Rockhopper II series printers – Maintenance Manual Notes : Make sure that the black tape connects properly. Please make sure that there are no air bubbles under the black tape. Air bubbles below the black tape could cause the black tape to come loose.
Page 106: Replacing The Cr Cursor Assembly
Rockhopper II series printers – Maintenance Manual 4.7.8. Replacing the CR cursor assembly Notes : Remove following covers before replacing the CR cursor assembly. Side cover R: refer to "Removing side cover R" Side cover L: refer to "Removing side cover L"...
Page 107: Replacing The Cursor Roller Assembly
Rockhopper II series printers – Maintenance Manual 4.7.9. Replacing the cursor roller assembly Notes : Remove following cover before replacing the Cursor roller assembly. Side cover R: refer to "Removing side cover R" Side cover L: refer to "Removing side cover L"...
Page 108 Rockhopper II series printers – Maintenance Manual 1 = CR cursor assembly 2 = E ring fixing the cursor roller assembly. Step 4 : Replace the cursor roller assembly. Step 5 : Install the spacers and the other parts as shown in the following figure.
Page 109 Rockhopper II series printers – Maintenance Manual 4.7.9.3. B. Replacing the cursor roller assembly (6 high-load bearings) : open bearing type Step 1 : Follow the instructions in "Replacing the CR cursor assembly " to remove the CR cursor assembly.
Page 110 Rockhopper II series printers – Maintenance Manual Step 6 : Apply the screw lock to the cursor axis, and install the cursor roller assembly with the axis at the lower position. Notes : Be sure that the screw lock does not contaminate the cursor roller or the spacer.
Page 111: Replacing The Maintenance Area
Rockhopper II series printers – Maintenance Manual 4.8. REPLACING THE MAINTENANCE AREA 4.8.1. Replacing the maintenance assembly Notes : When replacing the parts inside the maintenance assembly, be sure to perform following operation to clear the counter. "High ink initialization" or " Cleaning initialization": refer to "Counter Display Menu"...
Page 112 Rockhopper II series printers – Maintenance Manual Step 8 : Remove the connector and tube from the maintenance assembly. 1 = tube connections Notes : There is some remaining ink in the tubes. Be careful that the ink is not spilled from the tube onto the printer or items close to the printer.
Page 113 Rockhopper II series printers – Maintenance Manual 50 or 64 inch model: Cap (a) and Pump (1), Cap (b) and Pump (3), Cap (c) and Pump (2), Cap (d) and Pump (4) 87 inch model 2 heater: Cap (a) and Pump (1), Cap (b) and Pump (3), Cap (c) and...
Page 114: Replacing The Wiper And Wiperarm
Rockhopper II series printers – Maintenance Manual 4.8.2. Replacing the wiper and wiperarm 4.8.2.1 Installing the new wipers in the wiperarm. Please follow the procedure mentioned below. Step 1 : Click the new wipers in the new wiperarm on the positions and manor shown in the pictures.
Page 115 Rockhopper II series printers – Maintenance Manual Step 2 : Push the carriage to the left side of the machine so you can remove the four screws of the wiper assembly. Part Screws Step 3 : Remove the wiper assembly Notes : Be careful removing the wiper assembly, so you don’t break the sensor located...
Page 116 Rockhopper II series printers – Maintenance Manual Step 4 : Remove the wiperarm and reinstall the new one. Part Wiperarm assembly T plate Step 5 : To reinstall the wiper assembly, please reverse the removal procedure. Step 6 : After complete reinstallation, clean the wipers using Isopropanol.
Page 117: Replacing The Slide Motor Assembly (Wiper Arm)
Rockhopper II series printers – Maintenance Manual 4.8.3. Replacing the SLIDE motor assembly (wiper arm) Caution : The motor is hot after the product has been operated, so be careful not to burn yourself. Step 1 : Follow the instructions in "Replacing the maintenance assembly" to remove the maintenance assembly.
Page 118: Replacing The Transmission Photosensor (Wiper Home Position And Maintenance Home Position)
Rockhopper II series printers – Maintenance Manual 4.8.4. Replacing the transmission photosensor (wiper home position and maintenance home position) Step 1 : Remove the transmission photosensor from the side plate R. 1 = Transmission photosensor (wiper origin side) 2 = Transmission photosensor (maintenance origin...
Page 119: Replacing The Pump Area
Rockhopper II series printers – Maintenance Manual 4.9. REPLACING THE PUMP AREA 4.9.1. Replacing the pump assembly Notes : Remove following covers before replacing the parts in the PF motor assembly. Side cover R: refer to "Removing side cover R"...
Page 120: Replacing The Pump Assembly
Rockhopper II series printers – Maintenance Manual Step 2 : Remove the 4 screws fixing the pump assembly. Rockhopper II 2 heater Rockhopper II 2 heater 1 = Pump assembly 2 = Screws (M3x8) fixing the pump assembly Step 3 : Replace the pump assembly.
Page 121: Replacing The Pump Motor Assembly
Rockhopper II series printers – Maintenance Manual 4.9.3. Replacing the pump motor assembly Caution : The motor is hot after the product has been operated, so be careful not to burn yourself. Step 1 : Follow the instructions in "Replacing the pump assembly " to remove the pump assembly.
Page 122: Replacing The Cartridge Area
Rockhopper II series printers – Maintenance Manual 4.10. REPLACING THE CARTRIDGE AREA 4.10.1. Replacing the I/H (ink holder) assembly There are 8 I/H assembly 's installed in this printer. Following procedure is for the removal of 1 I/H assembly. Notes : Remove following covers before replacing the parts in the I/H assembly.
Page 123 Rockhopper II series printers – Maintenance Manual Step 6 : Remove the 3 screws fixing the P/S board installation board. Step 7 : Remove the P/S board installation board. Step 8 : Remove the coupling screws and O-ring from the I/H assembly.
Page 124 Rockhopper II series printers – Maintenance Manual (2) Replacing the ink ID board assembly and the holder pressure spring Step 1 : Remove the I/H assembly. Step 2 : Remove the 2 screws fixing the holder pressure spring. 1 = Holder pressure spring (two-ply use)
Page 125 Rockhopper II series printers – Maintenance Manual (4) Replacing the ink sensor assembly (ink NOT sensor, ink END sensor) Step 1 : Remove the I/H assembly. Step 2 : Remove the cables from the I/H assembly clamp. Step 3 : Remove the cartridge frame assembly.
Page 126: Replacing Supports And Scroller
Rockhopper II series printers – Maintenance Manual 4.11. REPLACING SUPPORTS AND SCROLLER 4.11.1. Replacing the waste fluid bottle assembly (Rockhopper II 2H) Notes : When replacing the waste fluid bottle assembly, be sure to perform following operation to clear the counter. "High ink initialization" or " Cleaning initialization": refer to "Counter Initialization Menu"...
Page 127: Replacing The Waste Fluid Bottle Assembly (Rockhopper Ii 4H)
Rockhopper II series printers – Maintenance Manual 4.11.2. Replacing the waste fluid bottle assembly (Rockhopper II 4H) Notes : When replacing the waste fluid bottle assembly, be sure to perform following operation to clear the counter. "High ink initialization" or " Cleaning initialization": refer to "Counter Initialization Menu"...
Page 128: Replacing The Waste Bottle Box Sensor Assembly (Rh Ii 2H)
Rockhopper II series printers – Maintenance Manual 4.11.3. Replacing the waste bottle box sensor assembly (RH II 2H) Step 1 : Follow the instructions in "Replacing the waste fluid bottle assembly" to remove the waste fluid bottle assembly. Step 2 : Remove the waste liquid BOX sensor assembly connector from the rear side cap R.
Page 129 Rockhopper II series printers – Maintenance Manual Step 6 : Remove the waste liquid sensor installation board. Step 7 : Remove the screws (M2x8) fixing the waste liquid BOX sensor assembly. 1 = Waste liquid sensor installation board 2 = Waste liquid BOX sensor assembly...
Page 130: Replacing The Waste Bottle Box Sensor Assembly (Rh Ii 4H)
Rockhopper II series printers – Maintenance Manual 4.11.4. Replacing the waste bottle box sensor assembly (RH II 4H) Step 1 : Follow the instructions in "Replacing the waste fluid bottle assembly" to remove the waste fluid bottle assembly. Caution : Waste ink will remain inside the tubes.
Page 131 Rockhopper II series printers – Maintenance Manual Step 4 : Remove the screws fixing the waste liquid sensor assembly. Step 5 : Reinstall all parts in the opposite order of the removal procedure. Notes : When installing the waste liquid BOX sensor assembly, pay attention to following...
Page 132: Replacing The Scroller R Assembly
Rockhopper II series printers – Maintenance Manual 4.11.5. Replacing the scroller R assembly (1) Replacing the scroller R assembly Step 1 : Remove the 4 hexagon socket head springs fixing the scroller R assembly. 1 = Scroller R assembly 2 = Hexagon socket head springs Step 2 : Replace the scroller R assembly.
Page 133 Rockhopper II series printers – Maintenance Manual Step 3 : Remove the E ring fixing the axes of the rollers to be replaced. 1 = Pressure roller 2 = Roller 1 3 = Roller 2 4 = E ring (E-3)
Page 134: Replacing The Scroller L Assembly
Rockhopper II series printers – Maintenance Manual 4.10.6. Replacing the scroller L assembly (1) Replacing the scroller L assembly Step 1 : Remove the 4 hexagon socket head springs fixing the scroller L assembly. 1 = Scroller L assembly 2 = Hexagon socket head springs Step 2 : Replace the scroller L assembly.
Page 135 Rockhopper II series printers – Maintenance Manual Step 3 : Remove the E ring fixing the axes of the rollers to be replaced. 1 = Pressure roller 2 = Roller 1 3 = E ring (E-3) 4 = E ring (E-4) Step 4 : Replace the rollers.
Page 136: Self-Diagnosis Function
Rockhopper II series printers – Maintenance Manual 5. SELF-DIAGNOSIS FUNCTION 5.1. INTRODUCTION This chapter provides information on the self-diagnosis function. The self-diagnosis function adjusts the printing accuracy. It is used in the manufacturing process, adjustment and maintenance. The self-diagnosis function is implemented in the system firmware. All functions are available from the operation panel.
Page 137: Starting Up
Rockhopper II series printers – Maintenance Manual 5.2.2. Starting Up To use the self-diagnosis function, you should first display the self-diagnosis menu on the operation panel. The self-diagnosis menu is completely independent of the normal operation mode and self-diagnosis display mode.
Page 138: Operations In Self-Diagnosis Mode
Rockhopper II series printers – Maintenance Manual 5.3. OPERATIONS IN SELF-DIAGNOSIS MODE This section explains how to operate in the self-diagnosis mode and provides the list of available diagnosis items. 5.3.1. Operating Self-Diagnosis Mode Follow the operation flow shown below to operate the self-diagnosis mode.
Page 139 Rockhopper II series printers – Maintenance Manual Step 3 : Press the [F2] key or the [F4] key on the operation panel to modify the set value. Step 4 : To save the modified value, press the [ENTER] key on the operation panel.
Page 140: Diagnosis Items In Self-Diagnosis Menu
Rockhopper II series printers – Maintenance Manual Step 5 : To quit the diagnosis menu, press the [CANCEL] key on the operation panel. The system returns to an upper hierarchy of the diagnosis menu. Step 6 : To exit the self-diagnosis menu, press the [POWER] key.
Page 141: Test / Inspection Menu
Rockhopper II series printers – Maintenance Manual 5.4. TEST / INSPECTION MENU In the Inspection menu, you can perform various inspections on the circuit boards, sensors and fans. The Inspection menu includes the following diagnosis items. Initialization item Description Refer to →...
Page 142: Ram Capacity Menu
Rockhopper II series printers – Maintenance Manual 5.4.1. RAM Capacity Menu This menu displays the memory size. * RamCapacity * RamCapacity 256 MB Notes : The Memory Size menu displays the size of the memory installed on the mainboard (128 MB or 256 MB).
Page 143: Operation Panel Menu
Rockhopper II series printers – Maintenance Manual 5.4.3. Operation Panel Menu This menu is used to check the functions of the operation panel keys, LCD, and LEDs. (1) Operation panel key check When you press a key on the operation panel, the name of the key is displayed on the LCD. To exit the operation panel key check, press the [CANCEL] key twice.
Page 144: Sensor Menu
Rockhopper II series printers – Maintenance Manual 5.4.4. Sensor Menu This menu displays the sensor status in the operation panel. If the displayed sensor status does not match the actual machine status, replace or adjust the relevant sensor referring to "Table Inspection Items in Sensor Menu".
Page 145: Encoder Menu
Rockhopper II series printers – Maintenance Manual * Sensor * FootLever Foot lever SW sensor PaperEdgeAD P_EDGE sensor (5/9) * Sensor * PaperRear R P_REAR_R sensor PaperRear L P_REAR_L sensor (6/9) * Sensor * Headslide HD_SLIDE sensor Temp 25°C Head thermistor...
Page 146: Fan Menu
Rockhopper II series printers – Maintenance Manual 5.4.6. Fan Menu This menu is used to check if the fan operates normally by turning it ON and OFF the fan. As soon as you select this menu, the fan will be activated.
Page 147 Rockhopper II series printers – Maintenance Manual * Maintenance * PrintingNumber 00000000 Number of printing copies Cleaning 00000000 Number of cleanings (4/10) * Maintenance * Fire 1-A 00000000Mdot Discharge amount of head 1-A nozzle ink Fire 1-B 00000000Mdot Discharge amount of head 1-B nozzle ink...
Page 148: Head Signal Menu
Rockhopper II series printers – Maintenance Manual 5.4.8. Head Signal Menu This menu is used to check the head-driving signal. * Head Signal * F1 → Flush Mode1 ← F2 F3 → ← F4 Mode2 Mode3 (1/2) * Head Signal * F1 →...
Page 149: Adjustment Menu
Rockhopper II series printers – Maintenance Manual 5.5. ADJUSTMENT MENU In this menu, you can align the printing position and correct the media feed operation. The Adjustment menu includes following diagnosis menus : Initialization item Description Refer to Skew check...
Page 150: Skew Check Menu
Rockhopper II series printers – Maintenance Manual 5.5.1. Skew Check Menu In this menu, you can perform media feed and check the degree of skew in the media feed operation by means of the sensors. When you select this item from the Adjustment menu, the machine feeds the length specified by the operation panel and checks for media feed skew by comparing the media edge positions before and after the media feed detected by the sensors.
Page 151: Head Rank Input Menu
Rockhopper II series printers – Maintenance Manual 5.5.2. Head rank input menu Inputs the head rank. The head rank is used to determine the operation voltage of the head and compensate the temperature. Input head rank following the steps below.
Page 152: Head Nozzle Check Menu
Rockhopper II series printers – Maintenance Manual 5.5.3 Head Nozzle Check Menu In this menu, you can check if the head nozzles, after refilling, can discharge ink correctly by printing a sample print. To print out head nozzle check patterns, follow the steps below. The following is the description of the printing method.
Page 153 Rockhopper II series printers – Maintenance Manual Nozzle alignment in horizontal direction (CCW): Prints out patterns in the order of 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B. Step 4 : If any abnormal conditions are found in the ink discharge status of the head nozzles, perform ink purge on the relevant heads.
Page 154: Head Slant Check Menu
Rockhopper II series printers – Maintenance Manual 5.5.4. Head Slant Check Menu This menu prints out a sample printing to check for head slant. Item Description Slant All head slant check. Front and back Front and back position and slant of each head relative to the reference head check.
Page 155 Rockhopper II series printers – Maintenance Manual Step 5 : Make adjustments until amount of CW and CCW offset are identical. Notes : In theory, the alignment of CW and CCW should be identical. But in practice, it is almost impossible to become a perfect alignment. When there is a slight difference between CW and CCW, be sure the heads are well seated.
Page 156 Rockhopper II series printers – Maintenance Manual For a 8 head machine Step 1 : Start the self-diagnostic function. Notes : Refer to “Self-Diagnosis Function” Step 2 : Select "Adj:HeadSlant". Step 3 : Print "Slant" pattern. If dotted lines on pattern CW and CCW are not a straight line, which you can check with a magnifying glass (enlargement of at least 10), please go to step 4.
Page 157 Rockhopper II series printers – Maintenance Manual Notes : When printing the pattern, the head identifications 1A, 1B etc, are not printed. Analyse the pattern as shown below. Be sure to have five lines for each color. Adjustable head slant...
Page 158 Rockhopper II series printers – Maintenance Manual 5.5.4.2. Front and back For a 4 head machine To perform a Head Front/Back Adjustment, please follow the steps mentioned below. Step 1 : In diagnostic mode, go to [Adjust : Head Slant].
Page 159 Rockhopper II series printers – Maintenance Manual Notes : To help you identify the print heads on the test pattern please refer to the diagram below. Know you see, 1A is Black, 1B is Yellow, etc (in our color combination).
Page 160 Rockhopper II series printers – Maintenance Manual Step 6 : When the nozzles are not in one row, adjust the head front/back position by moving the Head Front/Back Adjustment Screw the manner shown below. First adjust nozzle row A (1A, 2A, 3A, 4A).
Page 161 Rockhopper II series printers – Maintenance Manual For a 8 head machine To perform a Head Front/Back Adjustment, please follow the steps mentioned below. Step 1 : In diagnostic mode, go to [Adjust : Head Slant]. Step 2 : Press the [F2] key for F&B (front and back) adjustment.
Page 162 Rockhopper II series printers – Maintenance Manual If not, please proceed to step 5. Step 5 : Loosen the screw with 1 turn, which secures the Head Fixing Plate. Part Head Fixing plate securing screw Front/Back Adjustment Screw Step 6 : When the nozzles are not in one row, adjust the head front/back position by moving the Head Front/Back Adjustment Screw the manner shown below.
Page 163: Repeatability Adjustment (Bi-Directional)
Rockhopper II series printers – Maintenance Manual 5.5.5. Repeatability Adjustment (Bi-Directional) To perform a Repeatability Adjustment, please follow the steps mentioned below. Step 1 : Start the self-diagnostic function. Notes : Refer to “Self-Diagnosis Function". Step 2 : Select "Adj:Bi-D".
Page 164: Cw Adjustments (Uni-Directional)
Rockhopper II series printers – Maintenance Manual 5.5.6. CW adjustments (Uni-Directional) To perform CW adjustments, please follow the steps mentioned below. Step 1 : Start the self-diagnostic function. Notes : Refer to “Self-Diagnosis Function". Step 2 : Select "Adj:Uni-D". Step 3 : Print a CW adjustment pattern.
Page 165: Band Feed Correction Menu (X Length)
Rockhopper II series printers – Maintenance Manual 5.5.7. Band Feed Correction Menu (X Length) In this menu, you can correct the media feed distance. To correct the media feed distance, you must first print out check patterns and measure the distance between lines drawn in the media feed direction.
Page 166 Rockhopper II series printers – Maintenance Manual * Feed Adj. * X Length 300 – 1000 + 500 mm - ↓ ENTER CANCEL * Feed Adj. * ← ← ← ← Enter Print Start ↓ ↓ ↓ ↓ ↓ ENTER ↓...
Page 167: Top & Bottom Adjustment Menu
Rockhopper II series printers – Maintenance Manual 5.5.8. Top & bottom adjustment menu Sets printing margins. Make adjustments following the steps below. Step 1 : Set media as necessary. Step 2 : After the media has been set, pattern printing with band feed compensation and media cutting are performed.
Page 168: P_Rear Sensor Position Adjustment Menu
Rockhopper II series printers – Maintenance Manual 5.5.9. P_REAR sensor position adjustment menu Adjust the P_REAR sensor position in order to accurately detect the length of the cut media. During this adjustment, the P_REAR sensor position can be adjusted inside the firmware by referring to the nozzle, in order to obtain a maximum printable area starting from the ends of the media.
Page 169: Test Print Menu
Rockhopper II series printers – Maintenance Manual Step 4 : Input the measurement as the parameter of the P_REAR sensor position. * Rear Sensor * Set Cutting Paper ↓ Set media * Rear Sensor * Paper Initial If media is not set ↓...
Page 170: Head Wash Menu
Rockhopper II series printers – Maintenance Manual 5.5.11. Head wash menu In this menu, ink is drained and the head is cleaned at the completion of the manufacturing process and before replacing the print head. Execute a cleaning following the steps below.
Page 171 Rockhopper II series printers – Maintenance Manual * Clean Head * Remove cartridge ↓ Eject all cartridge and press the [ENTER] key to drain ink * Clean Head * Ink Discharge ↓ End Ink draining * Clean Head * Set Cleaning jig ↓...
Page 172: Software Counter Initialization Menu
Rockhopper II series printers – Maintenance Manual 5.5.12. Software Counter Initialization Menu This menu initializes the software counters such as the ink amount counter. Notes : Before delivery, always initialize the software counters. The software counters that can be initialized through this menu are as follows.
Page 173: Feed Pitch Check Menu
Rockhopper II series printers – Maintenance Manual 5.5.13. Feed Pitch Check Menu In this menu, you can check the media feed amount for one band by reviewing a sample printing. There is no adjustment item. To check the feed pitch, follow the steps below.
Page 174: Purge Menu
Rockhopper II series printers – Maintenance Manual 5.6. PURGE MENU In this menu, you can purge ink from the printer heads. The Purge menu includes the following diagnosis items. Diagnosis item Description Normal Performs normal purge. Powerful Performs powerful purge.
Page 175: Sample Printing Menu
Rockhopper II series printers – Maintenance Manual 5.7. SAMPLE PRINTING MENU This menu prints out a sample printing. The Sample printing menu includes the following items. Diagnosis item Description Nozzle Check Prints the head nozzle check pattern. Adjustment variables Prints out the set values of various adjustment items.
Page 176: Parameter Menu
Rockhopper II series printers – Maintenance Manual 5.8. PARAMETER MENU In this menu, you can modify the set values of various adjustment items (adjustment parameter). The Parameter menu includes the following items. Initialization item Description Refer to Initialize. Initializes the adjustment parameters.
Page 177: Parameter Update Menu
Rockhopper II series printers – Maintenance Manual 5.8.2. Parameter Update Menu This menu updates the adjustment parameters. The parameters that can be updated through this menu are as follows. Head voltage Printing position alignment CW adjustment Media feed distance Mechanical parameter...
Page 178 Rockhopper II series printers – Maintenance Manual (1) Head ID In this menu, you can enter a head ID. The head ID is used to determine the printer head-driving voltage and perform temperature correction. After a head ID has been entered, the system shifts to the Ink Charge menu.
Page 179 Rockhopper II series printers – Maintenance Manual (2) Printing position alignment This updates the printing position alignment parameters. * PrintPos Adj.* # 1 Head 1A -28 - * PrintPos Adj. * #1 Head 1B -28 - If the parameter is updated * PrintPos Adj.
Page 180 Rockhopper II series printers – Maintenance Manual (4) Media feed distance This updates the media feed distance parameters. * PaperFeedLen. * X Length 290 – 1010 + 500.0 mm - ↓ ENTER * PaperFeedLen. * Update Parameter ? ↓ ENTER...
Page 181 Rockhopper II series printers – Maintenance Manual (5) Mechanical parameter Update the mechanical position parameters. The setup items are as follows. Top distance Bottom distance Side margin P_REAR sensor position * Mechparm * Top Length 0 – 40.0 + 5.0 mm -...
Page 182 Rockhopper II series printers – Maintenance Manual (6) Ink parameter This updates the ink parameter. The setup items are as follows. Set: Ink not filled Reset: Ink filled Notes : When "set" has been selected on the ink parameter update menu, the product implements initial filling operations at the next start up.
Page 183 Rockhopper II series printers – Maintenance Manual (8) Serial number entry This is for entering the serial number. * SerialNo. * DD5*000001 - * SerialNo. * DD5C*00001 - * SerialNo. * DD5C1*0001 - * SerialNo. * DD5C12*001 - * SerialNo. * DD5C123*01 - * SerialNo.
Page 184: Endurance Running Menu
Rockhopper II series printers – Maintenance Manual 5.9. ENDURANCE RUNNING MENU In this menu, you can perform endurance running on the printer heads. The Endurance Running menu includes the following items. Initialization item Description Refer to CR Motor Performs carriage stroke.
Page 185: Cr Motor Endurance Menu
Rockhopper II series printers – Maintenance Manual 5.9.1. CR Motor Endurance Menu This menu performs endurance running for the CR motor. You can perform carriage stroke according to your desired setting. The available settings are shown below. Setup item Description...
Page 186: Pf Motor Endurance Menu
Rockhopper II series printers – Maintenance Manual 5.9.2. PF Motor Endurance Menu This menu performs endurance running for the PF motor. You can drive the PF motor according to your desired settings. The available settings are shown below. Setup item...
Page 187: Cutter Endurance Menu
Rockhopper II series printers – Maintenance Manual 5.9.3. Cutter Endurance menu This menu performs endurance running for the cutter. You can perform the cutting operation according to the settings. Caution : Pay attention to the following points when performing the cutter endurance operation.
Page 188: Head Up/Down Endurance Menu
Rockhopper II series printers – Maintenance Manual * Cutter * Count Perform endurance ↓ ENTER * Cutter * 5.9.4. Head Up/Down Endurance Menu This menu performs endurance running for the head up/down operation. You can perform the capping operation according to your desired settings. The available settings are shown below.
Page 189: Head Lock Endurance Menu
Rockhopper II series printers – Maintenance Manual 5.9.5. Head Lock Endurance menu Test endurance of head lock. In the Head Lock Endurance menu, you can perform head lock operation according to the set items. Notes : Refer to "Head Up/Down Endurance Menu"...
Page 190: Pump Endurance Menu
Rockhopper II series printers – Maintenance Manual 5.9.6. Pump Endurance menu This menu performs endurance running for the pump. In the Pump Endurance menu, you can perform the pump motor assembly endurance operation according to the settings. The available settings are shown below.
Page 191: Lever Motor Endurance Menu
Rockhopper II series printers – Maintenance Manual 5.9.7. Lever Motor Endurance Menu This menu performs endurance running for the lever motor. You can drive the lever motor according to your desired settings. The available settings are shown below. Setup item...
Page 192: Sequential Printing Endurance Menu
Rockhopper II series printers – Maintenance Manual 5.9.8. Sequential Printing Endurance Menu This menu performs endurance running for the printer heads. You can operate the printer heads according to your desired settings. The available settings are shown below. Setup item...
Page 193: General Endurance Menu
Rockhopper II series printers – Maintenance Manual 5.9.9. General Endurance Menu This menu performs the general endurance running. You can operate various driving systems according to your desired settings. The available settings are shown below. Setup item Description Parameters Remarks...
Page 194: Endurance Running Check Menu
Rockhopper II series printers – Maintenance Manual 5.9.10. Endurance Running Check Menu In this menu, you can confirm the number of endurance running cycles that have been already finished. The number of endurance running cycles is stored in NVRAM in the system. Therefore, even if a serious error occurs during endurance running, you can confirm the number of finished cycles just before the occurrence of the serious error.
Page 195: Head Lock Menu
Rockhopper II series printers – Maintenance Manual 5.10. HEAD LOCK MENU Lock and unlock the head lock. The following items are in the head lock menu. Lock: Locks the head. Unlock: Releases the head lock. * Head lock * F1 →...
Page 196: Heater System Menu
Rockhopper II series printers – Maintenance Manual 5.11. HEATER SYSTEM MENU This section describes the heater system menu. This menu is used to evaluate the heating elements of the printer. Initialization item Description Refer to → Heater Status Menu Status This menu displays the status of the heating system.
Page 197: Heater Test 30 Menu
Rockhopper II series printers – Maintenance Manual 5.11.3. Heater Test 30 Menu This menu heats the temperature up to 30°C. * Test 30 * Sending to heat system The display will mention de current temperature. You can follow the heating of the heater elements on the display up to 30°C.
Page 198: Heater Version Menu
Rockhopper II series printers – Maintenance Manual 5.11.6. Heater Version Menu This menu displays the version of the control heater board. * Version * Ver = 2.03 5.11.7. Heater Adjust Menu Notes : With this menu you can calibrate the heaters. Please note that this function is for future use only.
Page 199: Eco Prepare Menu
Rockhopper II series printers – Maintenance Manual 5.12. ECO PREPARE MENU Loading ink for the first time. Please refer to the User’s Guide. AP-74065, Rev. 1.2, 27/09/04...
Page 200: Machine Size Select Menu
Rockhopper II series printers – Maintenance Manual 5.13. MACHINE SIZE SELECT MENU This section describes the select menu of the machine size. Used when the Mainboard is exchanged, etc. Step 1 : If the system is in the operation mode or the self-diagnosis menu mode, press the [POWER] key to power off the unit.
Page 201 Rockhopper II series printers – Maintenance Manual AP-74065, Rev. 1.2, 27/09/04...
Page 202: Maintenance Mode
Rockhopper II series printers – 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 203: Maintenance Menu
Rockhopper II series printers – 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 204 Rockhopper II series printers – Maintenance Manual Notes : All life counters are displayed in decimal number. For 87-inch specifications, the head 5A, 5B, 6A, 6B, 7A, 7B, 8A, 8B are added. * Counter Display * Ink remain 1 00000000...
Page 205: Counter Initialization Menu
Rockhopper II series printers – 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 206: Mac Address Write Enable Menu
Notes : Write down this number ‘FM0 xxxxxx’. Important are the 6 digits ‘x’. Step 4 : Based on this number Mutoh Europe’s service department can provide you the correct MAC address for your printer. Step 5 : Reinstall the covers.
Page 207: Head Voltage
Rockhopper II series printers – Maintenance Manual Step 5 : Press the [F3] key. Step 6 : Press the [F1] key. Step 7 : Press the [F4] key. Step 8 : The password has been inserted. Use the [F1], [F2], [F3] and [F4] key to insert the MAC address.
Page 208: Adjustments
Rockhopper II series printers – Maintenance Manual 7. ADJUSTMENTS 7.1. INTRODUCTION Adjustments and adjustment procedures required when replacing parts are explained in this chapter. Notes : Refer to “Jig and tool list ". 7.2. ADJUSTMENT The adjustments required when replacing parts are explained below.
Page 209 Rockhopper II series printers – Maintenance Manual Band feed correction → Band Feed Correction Menu (X Length) Top and bottom adjustment → Top & bottom adjustment menu Rear sensor position adjustment → P_REAR sensor position adjustment menu → Test print menu...
Page 210 Rockhopper II series printers – Maintenance Manual Carriage Head height adjustment → Head height assembly adjustment Media sensor sensitivity adjustment → Media sensor sensitivity adjustment Continuous printing endurance operation → Head Nozzle Check check Menu → Sequential Printing Endurance Menu Head nozzle check →...
Page 211: Parameter Backup
Rockhopper II series printers – Maintenance Manual 7.3. PARAMETER BACKUP This chapter explains the different types of parameter backup methods. The different backup parameters related to the operation of the printer are recorded on the NVRAM (Flash- ROM or EEPROM) installed on the Mainboard.
Page 212: Procedure For Creating Backup Parameters
Rockhopper II series printers – Maintenance Manual 7.3.2. Procedure for creating backup parameters This section explains the procedure for recording backup parameters from the Mainboard assembly onto a memory card. Use the following procedure to create backup parameters. Important : Before replacing parts, be sure to perform the following operations.
Page 213: Backup Parameter Installation Procedure
Rockhopper II series printers – Maintenance Manual 7.3.3. Backup parameter installation procedure The following is the procedure for installing the backup parameter from the memory card into the new Mainboard assembly. Use the following procedure to install backup parameters. (1) When using a flash memory card...
Page 214: Firmware Installation
Rockhopper II series printers – Maintenance Manual 7.4. FIRMWARE INSTALLATION The procedure for installing firmware is explained below. The programs (firmware) that control the operation of the printer are recorded on the NVRAM (Flash-ROM) installed on the Mainboard. Install firmware when performing the following maintenance operations.
Page 215 Rockhopper II series printers – Maintenance Manual (1) When using a flash memory card Step 1 : Remove the memory cover. Step 2 : Install the memory card for the installation of firmware into the memory card connector slot (J104) of the Mainboard assembly.
Page 216 Rockhopper II series printers – Maintenance Manual Step 5 : Check if the buzzer sounded and whether the firmware was installed correctly. Step 6 : Power the unit OFF. Important : After installation of the firmware onto the Rockhopper II 4 heater, you must upgrade the heater system board.
Page 217: Steel Belt Tension Adjustment
Rockhopper II series printers – Maintenance Manual 7.5. STEEL BELT TENSION ADJUSTMENT The procedure for adjusting the steel belt tension is explained below. This section explains the procedure for adjusting steel belt tension. When removing/installing the steel belt, adjust its tension.
Page 218 Rockhopper II series printers – Maintenance Manual Step 2 : If the tension of the steel belt is not within the range of regulated values, adjust the steel belt tension screws. 1 = Steel belt 2 = Steel belt tension screw...
Page 219: Pf Deceleration Belt Tension Adjustment
Rockhopper II series printers – Maintenance Manual 7.6. PF DECELERATION BELT TENSION ADJUSTMENT The procedure for adjusting the tension of the PF deceleration belt is explained below. When removing the PF motor or removing/installing the PF deceleration belt, adjust the tension of the PF deceleration belt.
Page 220: Head Precision Adjustment (Slant)
Rockhopper II series printers – Maintenance Manual 7.7. HEAD PRECISION ADJUSTMENT (SLANT) This section explains the procedure for adjusting the head angle. When replacing the head assembly, use the following procedure to adjust the head angle and head forward/rear position.
Page 221 Rockhopper II series printers – Maintenance Manual Notes : In theory, the alignment of CW and CCW should be identical. But in practice, it is almost impossible to become a perfect alignment. When there is a slight difference between CW and CCW, be sure the heads are well seated.
Page 222 Rockhopper II series printers – Maintenance Manual 7.7.1.2 For a 8 head machine Step 1 : Start the self-diagnostic function. Notes : Refer to “Self-Diagnosis Function” Step 2 : Select "Adj:HeadSlant". Step 3 : Print "Slant" pattern. If dotted lines on pattern CW and CCW are not a straight line, which you can check with a magnifying glass (enlargement of at least 10), please go to step 4.
Page 223 Rockhopper II series printers – Maintenance Manual Notes : When printing the pattern, the head identifications 1A, 1B etc, are not printed. Analyse the pattern as shown below. Be sure to have five lines for each color. Adjustable head slant...
Page 224: Front And Back Of Head Adjustment
Rockhopper II series printers – Maintenance Manual 7.7.2. Front and back of head adjustment 7.7.2.1 For a 4 head machine To perform a Head Front/Back Adjustment, please follow the steps mentioned below. Step 1 : In diagnostic mode, go to [Adjust : Head Slant].
Page 225 Rockhopper II series printers – Maintenance Manual Notes : To help you identify the print heads on the test pattern please refer to the diagram below. Know you see, 1A is Black, 1B is Yellow, etc (in our color combination).
Page 226 Rockhopper II series printers – Maintenance Manual Step 6 : When the nozzles are not in one row, adjust the head front/back position by moving the Head Front/Back Adjustment Screw the manner shown below. First adjust nozzle row A (1A, 2A, 3A, 4A).
Page 227 Rockhopper II series printers – Maintenance Manual 7.7.2.2. For a 8 head machine To perform a Head Front/Back Adjustment, please follow the steps mentioned below. Step 1 : In diagnostic mode, go to [Adjust : Head Slant]. Step 2 : Press the [F2] key for F&B (front and back) adjustment.
Page 228 Rockhopper II series printers – Maintenance Manual Step 5 : Loosen the screw with 1 turn, which secures the Head Fixing Plate. Part Head Fixing plate securing screw Front/Back Adjustment Screw Step 6 : When the nozzles are not in one row, adjust the head front/back position by moving the Head Front/Back Adjustment Screw the manner shown below.
Page 229: Repeatability Adjustment (Bi-Directional)
Rockhopper II series printers – Maintenance Manual 7.8. REPEATABILITY ADJUSTMENT (BI-DIRECTIONAL) To perform a Repeatability Adjustment, please follow the steps mentioned below. Step 1 : Start the self-diagnostic function. Notes : Refer to “Self-Diagnosis Function". Step 2 : Select "Adj:Bi-D".
Page 230: Cw Adjustments (Uni-Directional)
Rockhopper II series printers – Maintenance Manual 7.9. CW ADJUSTMENTS (UNI-DIRECTIONAL) To perform CW adjustments, please follow the steps mentioned below. Step 1 : Start the self-diagnostic function. Notes : Refer to “Self-Diagnosis Function". Step 2 : Select "Adj:Uni-D". Step 3 : Print a CW adjustment pattern.
Page 231: Cr Deceleration Belt Tension Adjustment
Rockhopper II series printers – Maintenance Manual 7.10. CR DECELERATION BELT TENSION ADJUSTMENT This section explains the procedure for adjusting the tension of the CR deceleration belt. When removing/installing the CR deceleration belt, such as when removing the CR motor, adjust the tension of the CR deceleration belt.
Page 232: Cover Sensor Adjustment
Rockhopper II series printers – Maintenance Manual 7.11. COVER SENSOR ADJUSTMENT This section explains the procedure for adjusting the cover sensor. When replacing the cover sensor assembly or removing/installing the front cover, use this procedure to adjust the cover sensor.
Page 233: Head Height Adjustment
Rockhopper II series printers – Maintenance Manual 7.12. HEAD HEIGHT ADJUSTMENT This section explains the procedure for adjusting the head height. If CR cursor assembly is changed, adjust head height. 7.12.1. Tools required for work The following tools are required when adjusting the head height.
Page 234 Rockhopper II series printers – Maintenance Manual Step 8 : Adjust head U/D eccentric shaft lever so that CR gap adjustment jig can move freely. Step 9 : Perform CR cursor right/left adjustment. 1 = Platen 2 = CR gap check jig...
Page 235: Media Sensor Sensitivity Adjustment
Rockhopper II series printers – Maintenance Manual 7.13. MEDIA SENSOR SENSITIVITY ADJUSTMENT This section explains the procedure for adjusting the sensitivity of the media sensor. When replacing the P_EDGE sensor assembly or Mainboard assembly, adjust the media sensor. Notes : Pay attention to the following points when adjusting the media sensor.
Page 236 Rockhopper II series printers – Maintenance Manual (1) HIGH level (with media) adjustment of the A/D value Step 1 : Set the standard media. Step 2 : Select "Check : Head Lock" in the self-diagnosis menu. Notes : Refer to “Self-Diagnosis Function ".
Page 237 Rockhopper II series printers – Maintenance Manual (2) LOW level (without media) A/D value check Step 1 : Adjust the A/D value of the HIGH level following the "(1) HIGH level A/D value adjustment" procedure. Step 2 : Align the cutter and the right edge of the standard media by moving the carriage.
Page 238: Cutter Adjustment
Rockhopper II series printers – Maintenance Manual 7.14. CUTTER ADJUSTMENT This section explains the procedure for adjusting the cutter. When replacing the sub-platen, replacing the solenoid assembly, or removing/installing media guide F, use this procedure to adjust the cutter. Step 1 : Confirm if the media has been cut correctly.
Page 239: Pump Tubing Layout For Pump Assembly
Rockhopper II series printers – Maintenance Manual 7.15. PUMP TUBING LAYOUT FOR PUMP ASSEMBLY 7.15.1 Pump tubing layout - Rockhopper 4 heater (1) For 50 or 64 inch spec 1 = connection to the head caps 2 = waste tube connection 50”...
Page 240 Rockhopper II series printers – Maintenance Manual Notes : 1. Please be careful, when replacing the tubings, it is possible to have kinks in the tubings. Please avoid this by turning the tubing to the left or the right at the head connection and/or waste tube connection.
Page 241 Rockhopper II series printers – Maintenance Manual 87” Rockhopper II 4 heater Notes : 1. Please be careful, when replacing the tubings, it is possible to have kinks in the tubings. Please avoid this by turning the tubing to the left or the right at the...
Page 242: Pump Tubing Layout - Rockhopper 2 Heater
Rockhopper II series printers – Maintenance Manual 7.15.2. Pump tubing layout - Rockhopper 2 heater (1) For 50 or 64 inch spec 50” or 64” Rockhopper II 2 heater Step 1 : Connect the tubing in the manner shown in the figure below.
Page 243 Rockhopper II series printers – Maintenance Manual Step 3 : Insert into the waste fluid tubes from the pumps a piece of tube (DF-43951; 15 cm). 1 = piece of tube (15 cm) Step 4 : Bundle the waste fluid tubes in the large waste fluid tube.
Page 244 Rockhopper II series printers – Maintenance Manual (2) For 87 inch spec 87” Rockhopper II 2 heater Step 1 : Waste fluid tube E and an ink tube joining tube are added between fluid tube A and the pump 4 tube fitting that groups together the waste fluid side tubes.
Page 245 Rockhopper II series printers – Maintenance Manual Step 3 : Connect up the tubing for pump 2 in the manner shown in the figure below. 1 = Tube connecting to waste fluid tube 2 = Tube connecting to cap b...
Page 246 Rockhopper II series printers – Maintenance Manual Step 6 : Insert in the waste fluid tubes from the pumps a piece of 15 cm tube (DF-43951). 1 = piece of tube (15 cm) Step 7 : Stick the locking wire saddle onto side plate F.
Page 247: Board Checklist
Rockhopper II series printers – Maintenance Manual 7.16. BOARD CHECKLIST 7.16.1. Power supply board. Green LED on Power Flashing Supply Power supply works ok Power supply is not Power supply is not working. starting. → 220V/110V? → Load connected? → Load connected to →...
Page 248: Control Board
Rockhopper II series printers – Maintenance Manual 7.16.2. Control board. LED D8 POWER GREEN Board has 5V => ok Board has no 5V Power cable connected? → Power supply green led ON? → Bad cable LED D2 ALIVE (*) Blinking: OK Fatal error:µP lockup...
Page 249: Power Board
Rockhopper II series printers – Maintenance Manual 7.16.3. Power board. RED/GREEN(revC) From rev C on, it will be NO +24V present → PS ok? a green led → Power cable ok? 110/220V indicator Should be on in a 110V Should be off in a 220V grid.
Page 250 On the powerboard is a safety relay that will switch 220 or 110V to the solid state relays whenever the Rockhopper II series printer is powered off. This is to prevent that defective solid state relays can make the heatstrips overheat and melt its fuses.
Page 251: Checklist
Rockhopper II series printers – Maintenance Manual 7.16.5. Checklist Product information : Serial Number ________________________________________________ Firmware Version ________________________________________________ Firmware Version Heater Control Board ________________________________________________ Basic diagnostics : Grid power 110V 220V Grid frequency 50Hz 60Hz Fuse 1 NOK (OPEN) Power Supply :...
Page 252: Flushing Box Height Position Adjustment
Rockhopper II series printers – Maintenance Manual 7.17 FLUSHING BOX HEIGHT POSITION ADJUSTMENT Incorrect position of the flushing box height will cause large ink drops on the printout. Please follow the steps below to correctly adjust your flushing box height position.
Page 253 Rockhopper II series printers – Maintenance Manual Step 11 : Turn the wheel of the carriage till the arrow is on the bottom so the carriage is in the lowest position. 1 = Carriage wheel 2 = Arrow Step 12 : Carefully move the carriage to the right.
Page 254 Rockhopper II series printers – Maintenance Manual Note: The “Spacer kit flush box” (KY-80002) consists out of 10 spacers with thickness 0,5 mm and 10 with thickness 1,0 mm. Thickness: 0,5 mm (DF-44237) Thickness: 1,0 mm (DF-44236) Step 14 : Tighten the screw and repeat step 10 to 12 until adjustment is correct.
Page 255 Rockhopper II series printers – Maintenance Manual AP-74065, Rev. 1.2, 27/09/04...
Page 256: Maintenance
Rockhopper II series printers – Maintenance Manual 8. MAINTENANCE 8.1. INTRODUCTION This chapter provides information about the periodical services, part life, lubrication/bonding and transport. Important : Before replacing parts, be sure to perform following operations. Turn the machine power OFF.
Page 257: Cleaning
Rockhopper II series printers – Maintenance Manual 8.2. CLEANING You need to clean the printer periodically to keep it in best working condition. Notes : Refer to the User’s Guide. Refer to “Exploded Views/Service Parts List”. Part Timing Check point...
Page 258: Periodical Services
Caution : There are to parts of periodical service, namely the parts that can be replaced by the end-user and the parts that needs to be done by authorized Mutoh technicians. 8.3.1. Service by end-user Perform periodical inspections according to the table below.
Page 259: Service By Authorised Mutoh Technician
Rockhopper II series printers – Maintenance Manual 8.3.2. Service by authorised Mutoh technician Perform periodical inspections according to the table below. N° Part number Quantity Action MY-42110 Replace the dampers. MY-80300 Replace the pumps. MY-35380 + ME-80771 Replace wiper arm and wipers.
Page 260: Part Life Information
Rockhopper II series printers – Maintenance Manual 8.4. PART LIFE INFORMATION This section shows how to check the life of a service part. To know the life of a service part, check the maintenance counter from the counter display menu in the maintenance mode.
Page 261: Jig And Tool List
Rockhopper II series printers – Maintenance Manual 8.5. JIG AND TOOL LIST This section provides lists of jigs and tools required for service operations. 8.5.1. Required Tools (1) Tools for part replacement Name Part code Remarks Philips driver No.2 Generic product Shaft length should be 250 mm or more.
Page 262: Lubrication/Bonding
After disassembling/assembling this machine, always perform necessary lubrication/bonding according to the table below. Caution : Do not oil the printer mechanism with oil other than designated by MUTOH. Doing so may damage the parts or shorten the lifetime. Parts Item...
Page 263 Rockhopper II series printers – Maintenance Manual Maintenance Maintenance assembly Apply to the gear Kanto Kasei Co., FLOIL G-MK-1 components and cam Ltd. components Pump Combined gear Apply to the gear Kanto Kasei Co., FLOIL G-MK-1 Components components Ltd. Deceleration gear Apply to the gear Kanto Kasei Co.,...
Page 264: Transportation Of Machine
Rockhopper II series printers – Maintenance Manual 8.7. TRANSPORTATION OF MACHINE This section explains transferring and transporting the printer. When you transport the printer, the printer should be repackaged using the original box and packing materials, to protect it from vibration or impact.
Page 265 Rockhopper II series printers – Maintenance Manual Step 11 : Remove the product from the special stand. Notes : Refer to the User’s Guide. Step 12 : Package the machine. (2) Task after transportation Step 1 : Unpack, assemble, and install the machine.
Page 266: Troubleshooting
Rockhopper II series printers – 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 267: Operating Condition Display
Rockhopper II series printers – Maintenance Manual 9.2.1. Operating condition display This chapter explains the messages displayed, the items to be confirmed and the remedy. Message Phenomenon Check point Action Refer to → Cover sensor Cover Open The front cover is (1) Check if the •...
Page 268 Rockhopper II series printers – Maintenance Manual (4) Make sure the • Securely connect → Replacing the transmission the transmission Mainboard photosensor photosensor assembly, cables at the lever cables to HDD_Extension motor have been Mainboard board assembly, securely installed. assembly...
Page 269: Message Type Errors
Rockhopper II series printers – Maintenance Manual 9.2.2. Message type errors The following explains the messages, items to be confirmed and remedies to take when message type errors occur while the product is operating. Message type errors are displayed when trouble occurs during operation.
Page 270 Rockhopper II series printers – Maintenance Manual (7) The Mainboard • Replace the → Replacing the assembly may be Mainboard Mainboard damaged. assembly. assembly, HDD_Extension board assembly, HEAD_DRV board assembly and cooling fan assembly. Paper Slant The paper is fed (1) Reset the •...
Page 271 Rockhopper II series printers – Maintenance Manual (5) Check the up OK : → Please refer to and down The cutter’s the User’s Guide operation of the service life is → Cutter solenoid via reached or it is adjustment “Life/Cutter” of the damaged.
Page 272 Rockhopper II series printers – Maintenance Manual been set to the up (2) Check the •Redo the → Replacing the position. P_REAR sensor connections of Mainboard assembly for the Mainboard assembly, contact condition. assembly HDD_Extension connectors J128 board assembly, and J129. If the...
Page 273 Rockhopper II series printers – Maintenance Manual (2) Check the ink • Redo the → Replacing the ID sensor connections of the JUNCTION board connector for the following assembly. contact conditions. connectors : • Junction board : J401 – J418 •...
Page 274 Rockhopper II series printers – Maintenance Manual (2) The number of • Replace the print → Replacing the times the print head assembly. print head head was used • Initialize the head assembly and reached the unit. head tape power maximum cable.
Page 275 Rockhopper II series printers – Maintenance Manual (3) Check the •Check if the → Replacing the connections of the waste box sensor Mainboard connectors. connectors are assembly, connected to the HDD_Extension rear side cap R. board assembly, • Redo the...
Page 276: Heating System Error
Rockhopper II series printers – Maintenance Manual 9.2.3. Heating system error The following explains the messages, items to be confirmed and remedies to take when errors handling heating system occur while the product is operating. Heating system errors are displayed when communication trouble occurs between the heater strips and this product.
Page 277: Data Error
Rockhopper II series printers – Maintenance Manual 9.2.4. Data error The following explains the messages, items to be confirmed and remedies to take when data errors occur while the product is operating. Data errors are displayed when data communication trouble occurs between the computer and this product.
Page 278: Command Errors
Rockhopper II series printers – Maintenance Manual 9.2.5. Command errors The following explains the messages, items to be confirmed and remedies to take when command errors occur while the product is operating. Command errors are displayed when trouble occurs during analysis of the command data that is sent to this product from the computer.
Page 279: Errors Requiring Restart
Rockhopper II series printers – Maintenance Manual 9.2.6. Errors requiring restart The following explains the messages, items to be confirmed and remedies to take when errors requiring restart occur while the product is operating. Errors requiring restart are displayed when trouble critical to the operation of this product occurs.
Page 280 Rockhopper II series printers – Maintenance Manual E 016 error Interruption (1) Check the AC • Replace → Replacing the CPU Err [00] exception error: power source and Mainboard Mainboard Trouble occurred in the printer assembly assembly, the interrupt process...
Page 281 Rockhopper II series printers – Maintenance Manual E 016 error Floating point CPU Err [15] exception error : trouble occurred in the floating points E 016 error Watch exception CPU Err [22] error : trouble occurred in the watch. E 016 error...
Page 282 Rockhopper II series printers – Maintenance Manual E071 error PF An overload (4) PF motor • Replace PF → Replacing PF over current occurred in the PF assembly may be motor assembly Motor Assembly motor (X-axis) damaged. • Replace → Replacing the during operation.
Page 283 Rockhopper II series printers – Maintenance Manual (4) Check the T- • If contaminated → Replacing the fence for with grease and T fence contamination, dust, wipe off with flows and bends. a dry cloth. • If contaminated with ink, wipe off...
Page 284 Rockhopper II series printers – Maintenance Manual E 073 Error CR_HP cannot be (1) Check the • Check the → Sensor Menu CR Origin detected. transmission connections of the photosensor for transmission CR home position photosensor for detection via “Test: CR home position Sensor”...
Page 285 Rockhopper II series printers – Maintenance Manual (3) The print head •Replace the print → Replacing the may be damaged. head assembly print head assembly and head tape power cable. → Counter initialization menu → Replacing the (4) The CR board •...
Page 286 Rockhopper II series printers – Maintenance Manual E 077 Error Trouble occurred in (1) The • Replace the → Replacing the Head the head driver. HEAD_DRV board HEDA_DRV board Mainboard Overheat assembly may assembly. assembly, have a problem. HDD_Extension board assembly,...
Page 287 Rockhopper II series printers – Maintenance Manual (2) The Mainboard • Replace the → Replacing the assembly may Mainboard Mainboard have a problem. assembly. assembly, HDD_Extension board assembly, HEAD_DRV board assembly and cooling fan assembly. E 080 Error Trouble occurred in (1) Check the •...
Page 288 Rockhopper II series printers – Maintenance Manual (2) Is the • If the → Replacing the transmission transmission transmission photosensor at the photosensor is photosensor. cap securely detached, fix it installed? securely. (3) Is the sensor • Clean the sensor →...
Page 289 Rockhopper II series printers – Maintenance Manual (5) Make sure that • Replace the → Replacing the the connections of SLIDE motor SLIDE motor the SLIDE motor assembly for the assembly (wiper assembly for the wiper SLIDE. arm). WIPER slide are good.
Page 290: Troubleshooting Procedures When Errors Are Not Displayed
Rockhopper II series printers – Maintenance Manual 9.3. TROUBLESHOOTING PROCEDURES WHEN ERRORS ARE NOT DISPLAYED The following explains the messages, items to be confirmed and remedies to take when error messages are not displayed 9.3.1. Problems relating to initial operation This chapter explains the messages displayed, the items to be confirmed and the remedy.
Page 291 Rockhopper II series printers – Maintenance Manual (2) Make sure that • Redo the → Replacing the the connections of connections of the Mainboard the panel cable following assembly, connectors at the connectors. HDD_Extension panel side and the • Mainboard : J109...
Page 292 Rockhopper II series printers – Maintenance Manual (5) The JUNCTION • Replace the → Replacing the board assembly JUNCTION board JUNCTION board may be damaged. assembly. assembly. → Replacing the (6) The Mainboard • Replace the assembly may have Mainboard Mainboard a problem.
Page 293 Rockhopper II series printers – Maintenance Manual (5) The HEAD_DRV • Replace the → Replacing the board assembly HEAD_DRV board Mainboard may have a assembly. assembly, problem. HDD_Extension board assembly, HEAD_DRV board assembly and cooling fan assembly. (6) The Mainboard •...
Page 294 Rockhopper II series printers – Maintenance Manual (4) Check if the • Redo the → Replacing the detection function of connections of Mainboard the P_REAR sensor Mainboard assembly, assembly is proper assembly HDD_Extension via “Test: Sensor” of connectors J128 board assembly, the self-diagnostic and J129.
Page 295: Problems Relating To Paper Feed
Rockhopper II series printers – Maintenance Manual 9.3.2. Problems relating to paper feed Phenomenon Check point Action Refer to → Replacing the The paper comes off at paper (1) Check if the • Check if the set initialization or during the...
Page 296: Problems Relating To The Printing Operation
Rockhopper II series printers – Maintenance Manual 9.3.3. Problems relating to the printing operation Phenomenon Check point Action Refer to → Firmware Continuous printing cannot be (1) The program • Upgrade the performed. ROM may have firmware version. installation. failed.
Page 297 Rockhopper II series printers – Maintenance Manual Cleaning does not fix problems (1) Check the use • Under low → Specifications such as clogging or split nozzle. conditions of the humidity conditions product. in particular, printing is performed poorly. Check the...
Page 298 Rockhopper II series printers – Maintenance Manual (10) The • Replace the → Replacing the maintenance maintenance maintenance assembly may have assembly. assembly a problem. (11) The Mainboard • Replace the → Replacing the assembly may have Mainboard print head assembly a problem.
Page 299 Rockhopper II series printers – Maintenance Manual (10) The Mainboard • Replace the → Replacing the assembly may have Mainboard Mainboard a problem. assembly. assembly, HDD_Extension board assembly, HEAD_DRV board assembly and cooling fan assembly. Drawn black on a full screen (Or (1) Check the head •...
Page 300 Rockhopper II series printers – Maintenance Manual (2) Check if printing • The following → User’s Guide began immediately phenomena may after ink occur for the first replenishment. printing that is processed immediately after ink replenishment. • Faint lines are drawn.
Page 301 Rockhopper II series printers – Maintenance Manual (10) Check the • Using the provided → User’s Guide cleaning wipers for cleaning cloth for → Replacing the contamination. cleaning the wipers, cleaner slightly dampen it with cleaning liquid and wipe the...
Page 302 Rockhopper II series printers – Maintenance Manual (2) Check if the set • Reset the → User’s Guide paper is one of recommended those recommended paper and recheck by MUTOH. the condition. If paper not recommended by MUTOH is used, the...
Page 303 Rockhopper II series printers – Maintenance Manual Fiber tracking is shown in prints. (2) Check if printing • The following → User’s Guide began immediately phenomena may after ink occur for the first replenishment. printing processed immediately after ink replenishment.
Page 304 Rockhopper II series printers – Maintenance Manual (8) Check if the • Using the wiper, → User’s Guide nozzle face is wiped wipe the nozzle face correctly. well. (9) Check the • Using the provided → User’s Guide. cleaning wipers for cleaning cloth for →...
Page 305 Rockhopper II series printers – Maintenance Manual (6) Make sure that • If they are → Replacing the T the CR_ENC interfering with each fence. assembly and the T other, adjust the → Replacing the fence are not installation positions CR_ENC assembly.
Page 306 Rockhopper II series printers – Maintenance Manual A limited line in the paper feed (1) Check if the use • Be sure to use the direction is not accurate ( in the conditions are within product under the sub scanning direction)
Page 307 Rockhopper II series printers – Maintenance Manual Inaccurate squareness (1) Check the Setup the paper → User’s Guide installation method according to the of the paper. User’s Guide. (2) Check the • If the surrounding → User’s Guide rotation of the...
Page 308: Problems Relating To Noise
Rockhopper II series printers – Maintenance Manual 9.3.4. Problems relating to noise Phenomenon Check point Action Refer to → Replacing the There is noise when the paper is (1) Check the • Remove loaded. surroundings of the obstructions and suction fan suction fan foreign material.
Page 309 Rockhopper II series printers – Maintenance Manual (4) Check the CR • Correct the cable’s → Replacing the cables for noise. tendency and fix the steel bearer, tube condition. guide, CR tape • If noise is heard power cable and ink from between the tube.
Page 310: Problems Relating To The Paper Cutting Operation
Rockhopper II series printers – Maintenance Manual 9.3.5. Problems relating to the paper cutting operation Phenomenon Check point Action Refer to → User’s Guide The cutting operation (1) Check the operation panel • Change the is not performing and make sure that the media setting.
Page 311 Rockhopper II series printers – Maintenance Manual b) It does not move up or • The connectors → Replacing the CR down. may have poor board assembly contacts. → Replacing the Check the Mainboard connections of the assembly, following HDD_Extension connectors.
Page 312 Rockhopper II series printers – Maintenance Manual The cutting operation (1) Check the cutter blade for • Replace the cutter. → User’s Guide is in process, but the shipping and deterioration. paper has not been cut. The paper has not (2) Check if the cutter cap is •...
Page 313: Problems Relating To Online And Functions
Rockhopper II series printers – Maintenance Manual 9.3.6. Problems relating to online and functions Phenomenon Check point Action Refer to → User’s Guide Online has not been (1) Check the • Change the setting. properly established Centronics settings in by Centronics.
Page 314 Rockhopper II series printers – Maintenance Manual A portion of the data (1) The program ROM • Upgrade the firmware → Firmware has not been drawn may have failed. version. installation (is missing). Garbled characters or (2) Check the T fence •...
Page 315: Other Problems
Rockhopper II series printers – Maintenance Manual 9.3.7. Other problems Phenomenon Check point Action Refer to → Parameter A hang up occurs (1) The internal • Check the process operation of operation again backup the Mainboard after initializing assembly may be parameters and re- malfunctioning.
Page 316: Appendix
Rockhopper II series printers – Maintenance Manual 10. APPENDIX 10.1. INTRODUCTION This chapter provides referential information such as service data and exploded views. 10.2. WIRING DIAGRAM ROCKHOPPER II 2H AP-74065, Rev. 1.2, 27/09/04...
Page 317: Wiring Diagram Rockhopper Ii 4H
Rockhopper II series printers – Maintenance Manual 10.3. WIRING DIAGRAM ROCKHOPPER II 4H 10.4. ROCKHOPPER II : SERVICE PARTS LIST/EXPLODED VIEWS/CONFIGURATION DIAGRAMS This section includes the service parts list, exploded views of respective units and configuration diagrams. Notes : For the latest ‘exploded views’ and ‘part description’, please refer to the spare part lists of the printer.
Page 318 Rockhopper II series printers – Maintenance Manual AP-74065, Rev. 1.2, 27/09/04...
Page 319 MUTOH INDUSTRIES LTD. MUTOH EUROPE N.V. MUTOH DEUTSCHLAND GmbH. MUTOH AMERICA INC. Tel.:81-(0)3-54867145 Tel.:32-(0)59-561400 Tel.:49-(0)2159 913430 Tel.: (480) 968-7772 Fax.:81-(0)3-54867163 Fax:32-(0)59-807117 Fax.:49-(0)2159 913456 Fax: (480) 968-7990 E-mail:ibd@mutoh.co.jp E-mail:mutoh@mutoh.be E-mail:Mutoh-Sales@t-online.de E-mail:Sales@mutoh.com http://www.mutoh.co.jp http://www.mutoh.be http://www.mutoh.com...

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MUTOH Rockhopper II series Maintenance Manual

1 Safety Instructions

2 Product Overview

3 Specifications

4 Parts Replacement

5 Self-Diagnosis Function

6 Maintenance Mode

7 Adjustments

8 Maintenance

9 Troubleshooting

10 Appendix

Quick Links

Maintenance Manual

Troubleshooting

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