Falcon Outdoor 46

MUTOH Falcon Outdoor 46, Falcon Outdoor 62, Rockhopper 46, Rockhopper 62 Maintenance Manual

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MAINTENANCE
MANUAL
Eco-Solvent Inkjet Printer
Rockhopper 46/62
Rockhopper: AP-74016, Rev:1.0
CON1000
Model Name: Rockhopper-46/62
CON1000
Model Name:Rockhopper-46/62
Introduction
Introduction
This equipment is Class 1 communications equipment (communications equipment
to be used in commercial and industrial areas) and conforms to Voluntary
Communications Control Institute (VCCI) standards for data processing and other
equipment for the prevention of radio wave interference in commercial and industrial
areas.
Therefore, if it is used in or near a residential area, it may cause interference with
radio and television reception.
It should be used correctly in accordance with the operation manual.
Concerning interference with reception
Since this product emits weak radio waves, if it is not installed and used correctly
and is thought to be causing interference with radio and television reception, this
may be prevented by trying a combination of the following measures:
Try changing the orientation of the receiving antenna and feeder.
Try changing the orientation of this product.
Change the distance between the receiver and this product.
Try using different power supply systems for the receiver and this product.
Trademarks included in this manual
MUTOH, Model Name:Rockhopper-46/62, MH-GL, MH-GL/2, MH-RTL
are trademarks or trade names of Mutoh Industries Ltd.
HP, HP-GL, HP-GL/2, HP-RTL, HP759X, HP758X, C2848 are trademarks or
trade names of the Hewlett Packard Company.
Centronics and Bitronics are trademarks or trade names of the Centronics Data
Computer Company.
Windows 3.1, Windows 95, Windows NT 3.51, Windows NT 4.0, MS-DOS are
trademarks or trade names of the Microsoft Corporation
Other names of products and companies are the trademarks or trade names of
each relevant company.
This manual contains basic technical details necessary for marketplace servicing to
maintain product quality and performance of Model Name:Rockhopper-46/62 printer.
Model Name:Rockhopper-46/62 printer is equipped with a self-diagnostic program
that will be of service for adjusting and checking whenever a fault is detected or
during maintenance.
This manual contains all the basic items but actual maintenance work should be
undertaken only after a thorough understanding of the functions, operations and
movements has been gained from the operation manual and by other means.
Please note that there may be occasions where the name of a part used in the
explanation in this manual differs from the name of that same part that is used in the
operation manual or in the parts list.
Published by Mutoh Europe,
Archimedesstraat 13, 8400 Oostende Belgium
Copyright February 2002, Mutoh Europe All rights reserved.
CAUTION:
The details of this product and the contents of this manual are
protected by copyright held by this Company and, except for
legitimate use by individuals, unauthorized copying, reproduction
or distribution in whole or part is forbidden.
Details contained in this manual may be subject to future alteration
without notice.
Details contained in this manual are believed to be correct but
please contact this Company or a dealer if an error is suspected
or a point is not clear.
In no event will this Company be responsible for the consequences
of using this product or this manual.
CON1010
Model Name:Rockhopper-46/62
CON1010
Model Name:Rockhopper-46/62
Some Thoughts on Maintenance Work
Some Thoughts on Maintenance Work
1. Algunas ideas sobre el trabajo de Mantenciónn
La mantencion cae en dos categorias, Full mantencion y mantencion preventiva
, both of which are aimed at stable operation of the equipment that has been deliv-
ered to the user.
Las posibilidades de mantencion deben considerar.
In principle, fault maintenance and protective maintenance are both carried out by the
one person.
Both fault maintenance and protective maintenance involve the bringing of maintenance
parts.
The cooperation of the user/operator is used effectively.
2. Protective maintenance work
La mantencion periodica esta designed to provide the user con mas estabilidad operation of the
equipment and involves the periodic cleaning and replacement of replacement parts. Basic
ideas on protective maintenance include:
Adhere strictly to preventive maintenance periods.
In a case of carrying out preventive maintenance, gain the approval of the user before-
hand.
Dont press preventive maintenance on the user.
3. Fault maintenance work
A fault will hold up the users work and must be remedied quickly. The following are some
basic ideas on fault maintenance:
3-1 If it is not solved by the primary consultation, take the necessary maintenance items
and make an on-site visit.
Assemble the necessary maintenance parts from the matrix map
At the users premises, first check the symptoms.
Proceed with maintenance work in accordance with the fault tracing procedure.
After the repair work is finished, be sure to check again by testing in accordance
with the test procedure.
3-2 If repair is not possible even though all the work has been done in accordance with
the fault tracing procedure:
Contact the Sales Support Groups in your local distributor.
4. The need for user/operator cooperation
! CAUTION: The user cannot be compelled to do the following!
Asking the user/operator to cooperate is not a matter of having the user do the mainte-
nance for you but it is necessary in order to have the equipment working more efficiently
and for having faults rectified quickly.
Actually, even when you do ask for the users cooperation, instead of a simple acknowl-
edgement you will usually get doubts and quibbles such as Im paying for maintenance,
Im not familiar with the equipment and it only benefits the manufacturer.
However, you must try to persuade the user/operator to cooperate by explaining that doing
daily inspections will give better printing quality and giving you all the fine details of a fault
means that the fault will be rectified quickly.
The following explains the items you need in order to understand fault conditions in detail:
Check error messages
Check users usage conditions
Output from diagnostic pattern
Output from setup lists
Retest after changing settings
Probability of recovery by implementing daily inspections.
CON2000
Model Name:Rockhopper-46/62
CON2000
Model Name:Rockhopper-46/62
Precautions For Maintaining This Printer
Precautions For Maintaining This Printer
PRECAUTION 1 Head Cleaning
Head cleaning (see REP1620) must be carried out when this printer is to be trans-
ported by truck (see CON6000) and when the following parts are to be replaced.
< Replacement parts > Head, Damper, Head Cable, Cartridge Frame Assembly,
Ink Tubes
PRECAUTION 2 Head Cleaning Jig
When the head cleaning jig is to be used, fill the jigs 100 cc bottle with at least 50
cc of cleaning fluid and use it with the cap loosened.
If head cleaning is done with the cap tightened, ink will flow back into the 100 cc
bottle.
When you have finished head cleaning, return the remaining cleaning fluid from the
100 cc bottle to the 500 cc cleaning fluid bottle (JD-42054).
PRECAUTION 3 Printing After Initial Filling
On rare occasions, printing quality may be unstable if printing is carried out immedi-
ately after initial filling.
If this occurs, switch off the power and wait for at least 30 minutes before trying to
print again.
PRECAUTION 4 Thorough Waste Fluid Bottle Replacement
When the following tasks have been carried out,drain the waste fluid bottle.
1. After head cleaning and initial filling.
2. When it was not possible to capture main board assembly backup parameters.
PRECAUTION 6 Take Care When Inserting Head Cable and Y Cable
PRECAUTION 7 Ink and Cleaning Fluid Conduct Electricity
When the print head assembly, head board assembly and main board assembly
have been replaced, be careful to insert the head cable and Y cable straight to the
back and dont forget to lock the connectors.
(The connectors fitted with locks are J207 and J208 on the head board.)
If the cables are inserted obliquely or power is applied without locking the connec-
tors, there is a risk that the main board assembly may be damaged and it will be
impossible for ink to be ejected.
Ink and cleaning fluid will conduct electricity.
If there is ink or cleaning fluid on the connectors of the head or head cables when
power is applied, there will be a short circuit which may lead to all sorts of damage.
If there is ink on the contacts of the connector, wipe it off with alcohol or ethanol and
allow to dry thoroughly before reconnecting.
PRECAUTION 5 Maintenance Unit Tubes
If you can not lower the maintenance unit cap assembly and the cap assembly and
pump assembly have been replaced:
When the two tubes from the pump assembly are being connected to the cap
assembly, turn them clockwise through 45 to 90 degrees as you insert them.
CON3000
Model Name:Rockhopper-46/62
CON3000
Model Name:Rockhopper-46/62
Contents
Contents
Rockhopper-463 Rockhopper-62
Introduction CON 1000 CON 1000
Some Thoughts on Maintenance Work CON 1010 CON 1010
Precautions For Maintaining This Printer CON 2000 CON 2000
Contents CON 3001 ~ 3 CON 3007 ~ 9
How to use the Maintenance Manual CON 4000 CON 4000
Trouble-Shooting Lists TRB 0000 TRB 0000-3
Matrix Map MAP 0000 MAP 0000-3
Fault-Tracing Procedure EXA 0000 EXA 0000-3
Replacement and Adjustment Procedures REP 0000 REP 0000-3
Fundamental Knowledge GID 0000 GI D 0000-3
Stored Test Patterns PAT 0000 PAT 0000-3
Self-Diagnosis Functions BAC 0000 BAC 0000-3
Maintenance Parts CAT 0000 CAT 0000-3
CON3001
Model Name: Rockhopper-46
Model Name: Rockhopper-46
Rockhopper-463 Contents 1
Rockhopper 46 inch
Trouble-Shooting Lists TRB0000
When Message is Displayed TRB1000
- How to Use LEDs to Check CPU System and Mechanical System Faults TRB1001
When Message is not Displayed
- Initialization, Media Feed, Printing TRB2000
- Noise, Media Cutting, Online, Others TRB2001
Matrix Map MAP0000
When Message is Displayed
- Printer Status Messages MAP1000
- Data Errors MAP1200
- Command Errors MAP1250
- CPU System Faults MAP1500
- Mechanical System Faults MAP1700
When Message is not Displayed
- Trouble with Initialization MAP2000
- Trouble with Media Feed MAP3000
- Trouble with Printing MAP4000
- Problem Involving Noise MAP5000
- Trouble with Media Cutting MAP6000
- Online/Function Problems MAP7000
- Other MAP8000
Fault-Tracing Procedure EXA0000
When Message is Displayed
- Printer Status Messages EXA1000~
- Data Errors EXA1200~
- Command Errors EXA1250~
- CPU System Faults EXA1500~
- Mechanical System Faults EXA1700~
When Message is not Displayed
- Trouble with Initialization EXA2000~
- Trouble with Media Feed EXA3000~
- Trouble with Printing EXA4000~
- Problem Involving Noise EXA5000~
- Trouble with Media Cutting EXA6000~
- Online/Function Problems EXA7000~
- Others EXA8000~
Heater System MAP9000
Heater System EXA9000
Heater System Faults EXA1800
CON3002
CON3002
Rockhopper-463 Contents 2
Rockhopper-463 Contents 2
Replacement and Adjustment Procedures
Right and Left Covers REP 1010
Front Cover REP 1020
Panel Cover, Y Rail Cover REP 1030
Front Paper Guide and Rear Paper Guide REP 1040
Left Side Cap and Right Side Cap REP 1041
Control Box REP 1050
Head Cover REP 1060
X Motor Assembly REP 1070
Fan Assembly and Fan Cable REP 1080
X Speed Reduction Belt REP 1090
Lever Sensor Assembly REP 1100
Cover Switch Assembly REP 1110
Waste Fluid Box Sensor Assembly REP 1120
Switch Cable Assembly, DC Cable Assembly REP 1130
Main Board Assembly REP 1140
Power Supply Board Assembly REP 1150
Panel Board Assembly and Heater anel Board Assembly REP 1160
Panel Cable REP 1170
Extension Board Assembly REP 1180
XR Cable Assembly (Rear Paper Sensor) REP 1200
Pressure Assembly, Pressure Roller and Blade REP 1220
Pump Motor Assembly REP 1230
Cap Assembly REP 1240
Wiper REP 1250
Pump Assembly REP 1260
Maintenance Station Assembly REP 1270
Y Motor Assembly REP 1280
Steel Belt REP 1290
T Fence Assembly REP 1300
Cursor Plate Spring, Steel Flexible Guide Assembly REP 1310
Y Return Pulley Assembly REP 1320
Cartridge Frame Assembly REP 1330
Ink ID Sensor Assembly REP 1340
Detector Assembly REP 1350
Y Cable REP 1360
Ink Tubes REP 1370
Cutter Solenoid Assembly REP 1380
Print Head Assembly, Head Cable REP 1390
Edge Sensor Assembly REP 1410
Head Board Assembly REP 1420
Dampers REP 1430
Cursor Assembly REP 1440
Origin Sensor Assembly, Y Encoder REP 1450
Junction Board Assembly REP 1470
How to Adjust the Platen Height REP 1520
Tubes Guides Assemblies REP 1540
How to Adjust Steel Belt Tension REP 1550
How to Adjust X Speed Reduction Belt Tension REP 1560
How to Adjust the Tilt of the Print Head REP 1570
How to Capture and Install Backup Parameters REP 1590
How to Install a Program (Software Upgrade) REP 1600
Head Cleaning Procedure REP 1620
How to Clean the Head Nozzle Face REP 1660
Speed Reduction Pulley Assembly REP 1680
Grid Roller Assembly REP 1690
F Absorbent Assembly REP 1700
Front / Rear Heater (or heater sensors) (refer to)REP 1040
CON3003
Model Name: Rockhopper-46
CON3003
Model Name: Rockhopper-46
Rockhopper-463 Contents 3
Rockhopper-463 Contents 3
Fundamental Knowledge GID0000
Basic Specifications GID1000
System Block Diagram GID3000
Operating Sequence
- Power On Sequence GID4010
- Power Off Sequence GID4020
- Media Detection Sequence GID4030
- Normal Standby Sequence GID4040
- Encoder Disconnected Check Sequence GID4050
- Origin Detection Sequence GID4060
- Media Cutting Sequence GID4070
- Printing Sequence (Including Flushing) GID4080
Stored Test Patterns PAT0000
Presentation Pattern PAT1000
Print quality adjustment pattern PAT3000
Setup List PAT4000
Self-Diagnosis Functions BAC0000
Examination BAC1000
- Memory (RAM) Capacity BAC1010
- Version BAC1020
- Panel BAC1030
- Sensors BAC1040
- Encoders BAC1050
- Fans BAC1060
- Ethernet Board BAC1065
- History: Last error message BAC1070
- History: Head nozzle ejection count check BAC1070
- Head Waveform BAC1080
Adjustment BAC2000
- Capping Position Adjustment BAC2010
- Skew Verification BAC2030
- Head Rank Input (Include Initial filling) BAC2040
- Head Nozzle Verification BAC2050
- Left Head Tilt Verification BAC2060
- Right Head Tilt Verification BAC2070
- Repeatability Printing Positioning BAC2080
- CW Adjustment BAC2090
- Flush Pointer Adjustment BAC2110
- Media Feed Distance Compensation BAC2120
- Margin Adjustment BAC2130
- Rear Sensor Position Adjustment BAC2140
- Test Print BAC2150
- Head Wash BAC2160
Cleaning BAC3000
- Normal BAC3000
- Powerful BAC3000
Test Printing BAC4000
- Head Printing Verification BAC4000
- Adjustment Parameters BAC4000
Parameters BAC5000
- Initialize BAC5010
- Update BAC5020
Aging BAC6000
- Carriage Motor BAC6010
- Media Feed Motor BAC6020
- Cutter BAC6030
- Maintenance Unit BAC6040
- Head BAC6050
Maintenance Parts CAT0000
Maintenance Parts List CAT1000
Maintenance Tool List CAT2000
Lubrication Points CAT4000
Exploded View Drawing CAT5000
CON3007
Model Name: Rockhopper-62
CON3007
Model Name: Rockhopper-62
Rockhopper-62 Contents 1
Rockhopper-62 Contents 1
Rockhopper 62 inch
Trouble-Shooting Lists TRB0000-3
When Message is Displayed TRB1000
- How to Use LEDs to Check CPU System and Mechanical System Faults TRB1001
When Message is not Displayed
- Initialization, Media Feed, Printing TRB2000
- Noise, Media Cutting, Online, Others TRB2001
Matrix Map MAP0000-3
When Message is Displayed
- Printer Status Messages MAP1000
- Data Errors MAP1200
- Command Errors MAP1250
- CPU System Faults MAP1500
- Mechanical System Faults MAP1700-2
When Message is not Displayed
- Trouble with Initialization MAP2000-2
- Trouble with Media Feed MAP3000-2
- Trouble with Printing MAP4000-2
- Problem Involving Noise MAP5000
- Trouble with Media Cutting MAP6000
- Online/Function Problems MAP7000
- Other MAP8000
Fault-Tracing Procedure EXA0000-3
When Message is Displayed
- Printer Status Messages EXA1000~
(1020-2)
- Data Errors EXA1200~
- Command Errors EXA1250~
- CPU System Faults EXA1500~
- Mechanical System Faults EXA1700~
When Message is not Displayed
- Trouble with Initialization EXA2000~
(2070-2)
- Trouble with Media Feed EXA3000~
(3000-2)
- Trouble with Printing EXA4000~
(4050-2)
(4100-2)
(4130-2)
- Problem Involving Noise EXA5000~
- Trouble with Media Cutting EXA6000~
- Online/Function Problems EXA7000~
- Others EXA8000~
(8050-2)
Heater System  MAP9000
Heater System EXA9000-2
Heater System Faults EXA1800-2
CON3008
Model Name: Rockhopper-62
CON3008
Model Name: Rockhopper-62
Rockhopper-62 Contents 2
Rockhopper-62 Contents 2
Replacement and Adjustment Procedures REP0000-2
Right and Left Covers REP 1010
Front Cover REP 1020
Panel Cover, Y Rail Cover REP 1030
Front Paper Guide and Rear Paper Guide REP 1040-2
Left Side Cap and Right Side Cap REP 1041
Control Box REP 1050
Head Cover REP 1060
X Motor Assembly REP 1070
Fan Assembly and Fan Cable REP 1080-2
X Speed Reduction Belt REP 1090
Lever Sensor Assembly REP 1100
Cover Switch Assembly REP 1110
Waste Fluid Box Sensor Assembly REP 1120
Switch Cable Assembly, DC Cable Assembly REP 1130
Main Board Assembly REP 1140
Power Supply Board Assembly REP 1150
Panel Board Assembly REP 1160
Panel Cable REP 1170
Extension Board Assembly REP 1180
XR Cable Assembly (Rear Paper Sensor) REP 1200
Pressure Assembly, Pressure Roller and Blade REP 1220
Pump Motor Assembly REP 1230
Cap Assembly REP 1240
Wiper REP 1250
Pump Assembly REP 1260
Maintenance Station Assembly REP 1270
Y Motor Assembly REP 1280
Steel Belt REP 1290
T Fence Assembly REP 1300
Cursor Plate Spring, Steel Flexible Guide Assembly REP 1310-2
Y Return Pulley Assembly REP 1320
Cartridge Frame Assembly REP 1330
Ink ID Sensor Assembly REP 1340
Detector Assembly REP 1350
Y Cable REP 1360-2
Ink Tubes REP 1370-2
Cutter Solenoid Assembly REP 1380
Print Head Assembly, Head Cable REP 1390
Edge Sensor Assembly REP 1410
Head Board Assembly REP 1420
Dampers REP 1430
Cursor Assembly REP 1440
Origin Sensor Assembly, Y Encoder REP 1450
Junction Board Assembly REP 1470
How to Adjust the Platen Height REP 1520
Tubes Guides Assemblies REP 1540-2
How to Adjust Steel Belt Tension REP 1550
How to Adjust X Speed Reduction Belt Tension REP 1560
How to Adjust the Tilt of the Print Head REP 1570
How to Capture and Install Backup Parameters REP 1590
How to Install a Program (Software Upgrade) REP 1600
Head Cleaning Procedure REP 1620
How to Clean the Head Nozzle Face REP 1660
Speed Reduction Pulley Assembly REP 1680
Grid Roller Assembly REP 1690
F Absorbent Assembly REP 1700
Waste Fluid Bottle Assembly REP 1710
Front / Rear Heater (or heater sensors) (refer to)REP 1040-2
CON3009
Model Name: Rockhopper-62
CON3009
Model Name: Rockhopper-62
Rockhopper-62 Contents 3
Rockhopper-62 Contents 3
Fundamental Knowledge GID0000-3
Basic Specifications GID1000-3
System Block Diagram GID3000
Operating Sequence
- Power On Sequence GID4010
- Power Off Sequence GID4020
- Media Detection Sequence GID4030
- Normal Standby Sequence GID4040
- Encoder Disconnected Check Sequence GID4050
- Origin Detection Sequence GID4060
- Media Cutting Sequence GID4070
- Printing Sequence (Including Flushing) GID4080
Stored Test Patterns PAT0000-3
Presentation Pattern PAT1000
Print quality adjustment pattern PAT3000
Setup List PAT4000
Self-Diagnosis Functions BAC0000-3
Examination BAC1000
- Memory (RAM) Capacity BAC1010
- Version BAC1020
- Panel BAC1030
- Sensors BAC1040
- Encoders BAC1050
- Fans BAC1060
- Ethernet Board BAC1065
- History: Last error message BAC1070
- History: Head nozzle ejection count check BAC1070
- Head Waveform BAC1080
Adjustment BAC2000
- Capping Position Adjustment BAC2010
- Skew Verification BAC2030
- Head Rank Input (Include Initial filling) BAC2040
- Head Nozzle Verification BAC2050
- Left Head Tilt Verification BAC2060
- Right Head Tilt Verification BAC2070
- Repeatability Printing Positioning BAC2080
- CW Adjustment BAC2090
- Flush Pointer Adjustment BAC2110
- Media Feed Distance Compensation BAC2120
- Margin Adjustment BAC2130
- Rear Sensor Position Adjustment BAC2140
- Test Print BAC2150
- Head Wash BAC2160
Cleaning BAC3000
- Normal BAC3000
- Powerful BAC3000
Test Printing BAC4000
- Head Printing Verification BAC4000
- Adjustment Parameters BAC4000
Parameters BAC5000
- Initialize BAC5010
- Update BAC5020
Aging BAC6000
- Carriage Motor BAC6010
- Media Feed Motor BAC6020
- Cutter BAC6030
- Maintenance Unit BAC6040
- Head BAC6050
Maintenance Parts CAT0000-3
Maintenance Parts List CAT1000-3
Maintenance Tool List CAT2000
Lubrication Points CAT4000
Exploded View Drawing CAT5000
CON4000
CON4000
Model Name: Rockhopper-46/62
How to use the Maintenance Manual
How to use the Maintenance Manual
How to use the Maintenance Manual
Como usar el Manual de Mantenimientol CON4010
How to use the Trouble-Shooting Lists (TRB) CON4020
How to use the Matrix Map (MAP) CON4040
How to use the Fault-Tracing Procedure (EXA) CON4050
Procedimiento de Reemplazo y Ajustes (REP) CON4060
Model Name: Rockhopper-46/62
CON4010
Model Name: Rockhopper-46/62
CON4010
Model Name: Rockhopper-46/62
How to use the Maintenance Manual
How to use the Maintenance Manual
Fault maintenance work procedures and how to use the Maintenance Manual
When a user reports an equipment fault, use the following procedure to carry out fault recovery tasks.
A fault occurs
Task Page Details Reference Materials
Check fault circumstances,
select fault details from
Trouble-Shooting Lists
Trouble-Shooting List
TRB❉❉❉❉
Check circumstances by fax or telephone. Check error
messages, check user usage conditions, retry after changing settings, output
diagnostic pattern, etc. Select fault symptoms produced by user from
the Trouble-Shooting List.
Conduct a consultation by fax or telephone.
Check possibility of user error or recovery by daily inspection. Check error
messages, check user usage conditions, output diagnostic pattern, output
setup list. Retry after changing settings, etc.
Manual de Operaciones, Conocimiento
báasico, Cuidados diarios, Mantencion periodica/
inspeccion/Limpieza
Task Page Details Reference Materials
Gather the necessary
maintenance parts
Matrix Map
MAP❉❉❉❉
Gather the necessary maintenance parts Maintenance Parts list, Maintenance Tools list,
Exploded views
Conduct a tracing inquiry Fault Tracing Procedures
EXA❉❉❉❉
Conduct an inquiry to trace the cause of the fault Basic knowledge
Replace parts and adjust Replacement and Adjustment
Procedures REP❉❉❉❉
Replace or readjust parts suspected to be faulty.
Carry out adjustments after replacing parts.
Basic knowledge
Final check Separate causes of faults and check operation after faults have been
rectified.
Conduct a primary
consultation with the user
If you are unable to resolve the fault at this point, take the necessary maintenance parts and make an on-site visit.
CON4020
Model Name: Rockhopper-46/62
CON4020
Model Name: Rockhopper-46/62
How to use the Trouble-Shooting Lists (TRB)
How to use the Trouble-Shooting Lists (TRB)
1. How to look up trouble-shooting tables
When a user has reported a fault, first select the applicable details from the trouble-shooting lists (TRB) and jump to the specified primary consultation (ENT).
Faults are broadly classified as those which cause a message to appear in the printer LCD and those which do not.
For troubles that cause a message to be displayed, select the message as it is.
Troubles with no message display are classified into the 10 blocks shown below. First select the block then select the appropriate fault details from that block.
2. Definitions of groupings in the case of faults that produce no message display
When Message is Displayed TRB1000
Printer Status Messages, Data Errors, Command Errors
CPU System Faults, Mechanical System Faults
When Message is Not Displayed
TRB2000 to TRB2001
Trouble with Initialization: Troubles that occur when unpacking immediately after delivery are grouped here.
Check this group for a similar trouble occurring other than immediately after delivery.
Troubles concerning the series of operations up to the enabling of printing are grouped here.
Trouble with Printing: This group concerns printing quality problems.
Trouble with Media Feed: This group concerns problems with the media path.
Trouble with Media Cutting: Cutter section problems are grouped here.
Printing precision problems are grouped here.
Problem Involving Noise: Troubles that produce abnormal noise from the driving section.
Online/Function Problems: Online printing function problems.
Troubles involving driver software, consumable items, peripheral devices are grouped here.
Other: Troubles concerning the series of operations up to the enabling of printing are grouped here.
CON4040
Model Name: Rockhopper-46/62
CON4040
Model Name: Rockhopper-46/62
How to use the Matrix Map (MAP)
How to use the Matrix Map (MAP)
When the primary consultation (ENT) has not revealed any anomaly, gather the necessary maintenance parts according to the matrix map (MAP) shown below and visit
the user.
Major classification of fault details
Whether an error message is displayed
Major classification
of fault details and
range of EXA
numbers
Fault
details
Replacement
and adjustment
procedure page
Names and drawing numbers of
required parts
When Message is Not Displayed Trouble with Initialization
Trouble with Initializatio Model Name: 463
MAP2000
When Message is Not Displayed
When Message is Not Displayed
[Trouble with Initialization]
EXA2000 to EXA2070
Problem
- Power supply does not come on
- LCD faulty (no display/erratic display)
- Initial filling of inks failed
- Initial filling is completed but no ink comes out
- After power is switched on, nothing works
- When power is applied, “Initializing” appears and then a reset is executed.
- After mounting media, initial operation fails
- Printer does not work even with the cover closed
- Printer does not stop even with the cover opened
- Ink cartridges are installed but not recognized
- Can not make entries from the operating panel
- Data is received but not plotted
- Media is not suction
Replacement and Adjustment Procedure REP. No.
Name and Diagram Number of
Replacement Part
DF-41586 Main Board Assembly
DF-40097 Panel Board Assembly
DF-41617 Panel Cable
DF-41590 Cover Switch Assembly
DF-41589 Lever Sensor Assembly
DF-41595 Edge Sensor Assembly
DF-41588 Head Board Assembly
DF-41592 XR Cable Assembly (Paper Sensor R)
DF-41600 Y Cable
DF-41619 Switch Cable Assembly
DF-41587 Power Board Assembly
DF-41468 DC Cable Assembly
DF-41593 Detector 1 Assembly
DF-41594 Detector 2 Assembly
DF-40106 Detector Assembly (Black)
DF-40107 Detector Assembly (Y)
DF-40146 Detector Assembly (M)
DF-40147 Detector Assembly (C)
DF-41602 Cap Assembly
DF-41603 Pump Assembly
DF-41604 Maintenance Station Assembly
DF-40690 Print Head Assembly (Colour)
DF-41601 Head Cable
DF-41591 Waste Fluid Box Sensor
DF-40173 Vacuum Fan Assembly
DF-41620 Fan Extension Cable 1 Assembly
DF-41621 Fan Extension Cable 2 Assembly
DF-41622 Fan Extension Cable 3 Assembly
DF-41609 INK ID Sensor 1 Assembly
DF-41610 INK ID Sensor 2 Assembly
DF-41611 INK ID Sensor 3 Assembly
DF-41612 INK ID Sensor 4 Assembly
DF-41613 INK ID Sensor 5 Assembly
DF-41614 INK ID Sensor 6 Assembly
DF-41615 INK ID Sensor Cable
DF-41536 Junction Board Assembly
1140
1160
1170
1110
1100
1410
1420
1200
1360
1130
1150
1130
1350
1350
1350
1350
1350
1350
1240
1260
1270
1390
1390
1120
1080
1080
1080
1080
1340
1340
1340
1340
1340
1340
1470
1470
2000
2000
2010
2020
2030
2030
2030
2030
2030
2040
2050
2060
2070
Fault-
Tracing
Procedure
EXA No.
CON4050
Model Name: Rockhopper-46/62
CON4050
Model Name: Rockhopper-46/62
How to use the Fault-Tracing Procedure (EXA)
How to use the Fault-Tracing Procedure (EXA)
Gather the parts specified by the matrix map (MAP), visit the user and carry out the task of recovery in accordance with the fault-tracing procedure (EXA) shown below.
First, check again on-site that there was no mistake about the primary consultation. (EXA and ENT page numbers are the same)
Carry out the checking tasks in order, beginning with 1-1, and move to the next task if there is nothing abnormal. If an abnormality is revealed, carry out the task indi-
cated by the arrow [].
Whether an error message is displayed
Fault details
Fault-tracing
sequence
Major classification of fault details
Page specified by
matrix map (MAP)
Page specified by
matrix map (MAP)
Replacement and
adjustment procedure
(REP) page reference
Hidden diagnostic
procedure page
reference
CON4060
Model Name: Rockhopper-46/62
CON4060
Model Name: Rockhopper-46/62
How to use Replacement and Adjustment Procedure (REP)
How to use Replacement and Adjustment Procedure (REP)
If the fault-tracing procedure (EXA) has produced a replacement task, carry out the work of replacement and adjustment in accordance with the replacement and adjust-
ment procedure (REP) shown below.
If you dont know how to go about the removal of covers involved in replacing a part, refer to REP1010 to REP1060.
Screws
Y motor cable terminal
Y motor assembly
REP1280
Model Name: Rockhopper-46/62
REP1280
Model Name: Rockhopper-46/62
How to replace the Y Motor Assembly
How to replace the Y Motor Assembly
Item Replacement and Adjustment Procedure
1. Replacement
Procedure
2. Adjustment
and
Examination
Procedure
« REFERENCE » If there is to be no replacement that
includes the Y motor assembly, steps 2, 4
and 5 are not necessary.
Replace the Y Motor Assembly
1. Remove the Left and Right Covers.
2. Remove the Rear Paper Guide.
3. Remove the Steel Belt.
4. Open the Control Box.
5. Disconnect connector J120 (YMOT) from the Main Board
Assembly.
6. Remove the Y Motor Assembly. (3 fastening screws)
7. Assembling is the reverse of the removal procedure.
« REFERENCE » Since the Y Motor Assembly Cable pass-
es below the Cartridge Unit, the work will
be easier if you remove the two Cartridge
Base screws and push it back.
1. Carry out the Steel Belt Tensioning Adjustment.
Replacement and adjustment item
Replacement
procedure
Adjustment
procedure
and items to
be checked
Page specified by
the fault-tracing
procedure (EXA)
Page specified by
the fault-tracing
procedure (EXA)
TRB0000
Model Name: Rockhopper-46
TRB0000
Model Name: Rockhopper-46
Rockhopper-463 Trouble-Shooting Lists
Rockhopper-43 Trouble-Shooting Lists
Trouble-Shooting Lists
When Message is Displayed
Printer Status Messages TRB1000
Data Errors TRB1000
Command Errors TRB1000
CPU System Faults TRB1000
Mechanical System Faults TRB1000
When Message is Not Displayed
Trouble with Initialization TRB2000
Trouble with Printing TRB2000
Trouble with Media Feed TRB2000
Trouble with Media Cutting TRB2001
Problem Involving Noise TRB2001
Online/Function Problems TRB2001
Others TRB2001
Heater System TRB2001
How to Use LEDs to Check CPU System TRB1001
and Mechanical System Faults
Heaters System Faults TRB1000
TRB0000-3
Model Name: Rockhopper-62
TRB0000-3
Model Name: Rockhopper-62
Rockhopper-62 Trouble-Shooting Lists
Rockhopper-62 Trouble-Shooting Lists
Trouble-Shooting Lists
When Message is Displayed
Printer Status Messages TRB1000
Data Errors TRB1000
Command Errors TRB1000
CPU System Faults TRB1000
Mechanical System Faults TRB1000
When Message is Not Displayed
Trouble with Initialization TRB2000
Trouble with Printing TRB2000
Trouble with Media Feed TRB2000
Trouble with Media Cutting TRB2001
Problem Involving Noise TRB2001
Online/Function Problems TRB2001
Others TRB2001
Heater System TRB2001
How to Use LEDs to Check CPU System TRB1001
and Mechanical System Faults
Heaters System Faults TRB1000
When Message is Displayed
When Message is Displayed
TRB1000
Model Name: Rockhopper-46/62
TRB1000
Model Name: Rockhopper-46/62
Trouble-Shooting 1/3 (List of Faults)
Trouble-Shooting 1/3 (List of Faults)
Cases where an error message is displayed on the liquid crystal display of the main printer unit
GO TO EXA No.Minor Faults CPU System/Mechanical System Faults GO TO EXA No.
Printer Status Messages
CPU System Faults
Cover Open
Lever Up
Cover and Lever
Undefined Media
Media Skew Error
[User 1] Media End
Remove Media
Roll Media End
Media Cut Error
Not enough memory SIMM 12 MB
Insert Special Cartridge
[ ] Ink Low
[ ] No Ink
[ ] No Cartridge
Capping position not specified
Not Filled
No Waste Fluid Box
Wrong Ink Type
EXA1000
EXA1000
EXA1000
EXA1010
EXA1020
EXA1030
EXA1040
EXA1050
EXA1060
EXA1070
EXA1080
EXA1090
EXA1090
EXA1100
EXA1110
EXA1120
EXA1130
EXA1150
• E001 Error DRAM (Standard DRAM error)
• E002 Error Opt.DRAM (Optional DRAM error)
•E016CPUErr[00] (Interrupt exception error)
•E016CPUErr[02] (Command boundary exception error)
•E016CPUErr[03] (Data boundary exception error)
•E016CPUErr[04] (Address error exception)
(Load or command fetch)
•E016CPUErr[05] (Address error exception) (Store)
•E016CPUErr[06] (Bus error exception) (Command fetch)
•E016CPUErr[07] (Bus error exception) (Data load)
•E016CPUErr[08] (System call exception error)
•E016CPUErr[09] (Break point exception error)
•E016CPUErr[10] (Reserved command exception error)
•E016CPUErr[11] (Unable to use coprocessor exception error)
•E016CPUErr[12] (Operation overflow exception error)
•E016CPUErr[13] (Trap exception error)
•E016CPUErr[15] (Floating point exception error)
•E016CPUErr[22] (Watch exception error)
•E016CPUErr[32] (Watchdog timeout exception error)
•E016CPUErr[33] (Abort error)
• Error E237 Transfer memory (Transfer memory error/Transfer memory
access error)
• Error E129 NVRAM
EXA1500
EXA1500
EXA1510
EXA1510
EXA1510
EXA1510
EXA1510
EXA1510
EXA1510
EXA1510
EXA1510
EXA1520
EXA1520
EXA1520
EXA1520
EXA1520
EXA1520
EXA1520
EXA1520
EXA1520
EXA1530
Mechanical System Faults
E065 Error X Motor
E069 Error X Encoder
E071 Error X Timeout
E073 Error X Overcurrent
E066 Error Y Motor
E070 Error Y Encoder
E072 Error Y Timeout
E074 Error Y Overcurrent
E075 Error Sensor Fault
EXA1700
EXA1700
EXA1700
EXA1700
EXA1710
EXA1710
EXA1710
EXA1710
EXA1720
Data Errors
Network Detection Error
Network Initialization Error
EXA1230
EXA1230
Command Errors
MH01 Error (Undefined Command)
MH02 Error (Parameter Error)
MH03 Error (Numerical Error)
MH04 Error (Undefined Character Set)
MH07 Error (Buffer Overflow)
EXA1250
EXA1250
EXA1250
EXA1250
EXA1250
Heater System Faults EXA1800
/