MUTOH Falcon RJ-4100 Maintenance Manual

1

Full Color Inkjet Printer

RJ-4100

RJ41-A-01

MAINTENANCE

MANUAL

2

CON1000Model Name: RJ–4100

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, RJ-4100, MH-GL, MH-GL/2, MH-RTL, ESC/P2 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.

• EPSON ESC/P is a trademark or trade name of the Seiko-Epson 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 RJ-4100 printer.

RJ-4100 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 Industries Ltd., 1-3 Ikejiri 3-chome, Setagaya-ku, Tokyo

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.

CON1010Model Name: RJ–4100

Some Thoughts on Maintenance Work

1. Some ideas about maintenance work

Maintenance work falls into two major categories, fault maintenance and protective main-

tenance, both of which are aimed at stable operation of the equipment that has been deliv-

ered to the user.

The profitability of maintenance work must also be considered.

• 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

Periodic maintenance is designed to provide the user with more stable 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.

• Don’t press preventive maintenance on the user.

3. Fault maintenance work

A fault will hold up the user’s work and must be remedied quickly. The following are some

basic ideas on fault maintenance:

3-1 Use the user/operator to obtain a more detailed grasp of the fault.

• Conduct a primary consultation by “inquiry sheet”, “fax” and “telephone”

• Select applicable symptoms from the trouble-shooting lists and make inquiries in

accordance with the primary consultation form. (Check error messages, check the

user’s operating conditions, test again with changed settings, output test patterns,

etc.)

3-2 If it is not solved by the primary consultation, take the necessary maintenance items

and make an on-site visit.

• Assemble the necessary maintenance parts from the matrix map

• At the user’s premises, first check the symptoms.

• Proceed with maintenance work in accordance with the fault tracing procedure.

• After the repair work is finished, be sure to check again by testing in accordance

with the test procedure.

3-3 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 Graphics Sales Section or Data Equipment

Sales Section of the Data Imaging Operations Division.

4. The need for user/operator cooperation

! CAUTION: The user can not 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 user’s cooperation, instead of a simple acknowl-

edgement you will usually get doubts and quibbles such as “I’m paying for maintenance”,

“I’m not familiar with the equipment” and “it only benefits the manufacturer.”

However, you must try to persuade the user/operator to cooperate by explaining that doing

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 user’s usage conditions

• Output from diagnostic pattern

• Output from setup lists

• Retest after changing settings

• Probability of recovery by implementing daily inspections.

3

4

CON2000Model Name: RJ–4100

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 jig’s 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 Box Replacement

When the following tasks have been carried out, install a new waste fluid box and

clear the waste fluid counter.

1. After head cleaning and initial filling.

2. When it was not possible to capture main board 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 don’t 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 head board 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 cables or connectors 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.

CON3000Model Name: RJ–4100

Contents 1

History of Amendments CON0000

Introduction CON1000

Some Thoughts on Maintenance Work CON1010

Precautions For Maintaining This Printer CON2000

Contents CON3000

How to use the Maintenance Manual CON4000

Daily Care CON5000

How to Move the Printer Main Unit CON6000

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, Other TRB2001

Primary Consultation ENT0000

• When Message is Displayed

• Printer Status Messages ENT1000~

• Data Errors ENT1200~

• Command Errors ENT1250~

• CPU System Faults ENT1500~

• Mechanical System Faults ENT1700~

• When Message is not Displayed

• Trouble with Initialization ENT2000~

• Trouble with Media Feed ENT3000~

• Trouble with Printing ENT4000~

• Problem Involving Noise ENT5000~

• Trouble with Media Cutting ENT6000~

• Online/Function Problems ENT7000~

• Other ENT8000~

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~

• Other EXA8000~

5

CON3001Model Name: RJ–4100

Contents 2

Replacement and Adjustment Procedures

Right and Left Covers REP 1010

Front Cover REP 1020

Panel Cover REP 1030

Y Rail Cover REP 1030

Front Paper Guide and Right Paper Guide REP 1040

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 Detector Switch Assembly REP 1120

Switch Cable Assembly REP 1130

DC Cable Assembly REP 1130

Main Board Assembly REP 1140

Power Supply Board and Fuse REP 1150

Panel Board Assembly REP 1160

Panel Cable REP 1170

Mother Board Assembly REP 1180

Front Paper Sensor Assembly REP 1190

Rear Paper Sensor Assembly REP 1200

Grid Roller Assembly and Coupling Assembly REP 1210

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 GA Assembly REP 1270

Y Motor Assembly REP 1280

Steel Belt (A0) REP 1290

T Fence Assembly (A0) REP 1300

Cursor Plate Spring REP 1310

Steel Flexible Guide A0 Assembly REP 1310

Y Return Pulley Assembly REP 1320

Cartridge Frame Assembly REP 1330

Ink ID Sensor Assembly (Black) (Yellow) (Magenta) (Cyan) REP 1340

Detector Assembly (Black) (Yellow) (Magenta) (Cyan) REP 1350

Y Cable (A0) REP 1360

Ink Tubes (A0) REP 1370

Cutter Solenoid Assembly REP 1380

Print Head Assembly(Black) REP 1390

Print Head Assembly (Color) REP 1400

Head Cable (Black) REP 1390

Head Cable (Color) REP 1400

Y Paper Sensor Assembly REP 1410

Head Board Assembly REP 1420

Dampers (Black) REP 1430

Dampers (Color) REP 1430

Cursor Assembly REP 1440

Origin Sensor Assembly REP 1450

Waste Fluid Box REP 1460

Junction Board Assembly REP 1470

Network Interface Board REP 1480

Extended Memory (8 MB) (16 MB) (32MB) REP 1490

A0 Scroller REP 1500

Cutter Holder REP 1510

How to Adjust the Platen Height REP 1520

O-rings (Small) and (Large) REP 1530

Tubes Guides A0 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 (Black) REP 1570

How to Adjust the Tilt of the Print Head (Color) REP 1580

How to Capture and Install Backup Parameters REP 1590

How to Install a Program (Software Upgrade) REP 1600

How to Measure the Y Rail Fitting Precision REP 1610

Head Cleaning Procedure REP 1620

How to Check the Power Supply Voltages/100 V AC REP 1630

How to Check the Power Supply Voltages/5 V DC REP 1640

How to Check the Power Supply Voltages/24 V DC and 42 V DC REP 1650

How to Clean the Head Nozzle Face REP 1660

Ink ID Sensor REP 1670

6

CON3002Model Name: RJ–4100

Contents 3

Test Procedures TST0000

• Test 1 Printing from User's Host Computer TST1000

• Test 2 Print a Test Print TST1000

• Test 3 Skew Check TST1000

• Test 4 Head Movement Aging Test TST1001

• Test 5 Media Feed Aging Test TST1001

• Test 6 Cutter Aging Test TST1001

• Test 7 Maintenance Unit Aging Test TST1002

• Test 8 Head (Black/Color) Aging Test TST1002

• Test 9 Sensor Test TST1002

• Test 10 Panel Test TST1003

• Test 11 Fan Operating Test TST1003

Fundamental Knowledge GID0000

Basic Specifications GID1000

Interface Specifications GID1010

Name of Parts GID1100

Explanation of Operating Principles and Mechanisms GID2000

Explanation of Printing Operation GID2100

System Block Diagram GID3000

Explanation of Boards GID3010

Connector Layout Diagram GID3020

Operating Sequence GID4000

• 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

• Monochrome Printing Sequence (Including Flushing) GID4080

• Color Printing Sequence (Including Flushing) GID4090

Stored Test Patterns PAT0000

• Presentation Pattern PAT1000

• Color palette PAT2000

• Print quality adjustment pattern PAT3000

• Setup List PAT4000

Self-Diagnosis Functions BAC0000

• Examination BAC1000

• Memory Capacity BAC1010

• Version BAC1020

• Panel BAC1030

• Sensors BAC1040

• Encoders BAC1050

• Fans BAC1060

• History: Last error message BAC1070

• History: Head nozzle ejection count check BAC1070

• Adjustment BAC2000

• Capping Position Adjustment BAC2010

• Skew Verification BAC2030

• Head Rank Input (Include Initial filling) BAC2040

• Head Nozzle Verification BAC2050

• Black Head Tilt Verification BAC2060

• Color Head Tilt Verification BAC2070

• Reciprocal Printing Positioning BAC2080

• CW Adjustment BAC2090

• Flush Pointer Adjustment BAC2110

• Media Feed Distance Compensation BAC2120

• Front-to-Head, Cutter-to-Head Distances Adjustment BAC2130

• Rear Sensor Position Adjustment BAC2140

• Test Print BAC2150

• Head Cleaning BAC2160

7

CON3003Model Name: RJ–4100

Contents 4

• 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

Adhesives and Tapes CAT3000

Lubrication Points CAT4000

Exploded View Drawing CAT5000

8

9

CON4000Model Name: RJ–4100

How to use the Maintenance Manual

How to use the Maintenance Manual CON4010

How to use the Trouble-Shooting Lists (TRB) CON4020

How to use Primary Consultation (ENT) CON4030

How to use the Matrix Map (MAP) CON4040

How to use the Fault-Tracing Procedure (EXA) CON4050

How to use Replacement and Adjustment Procedure (REP) CON4060

How to use Test Procedure (TST) CON4070

10

CON4010Model Name: RJ–4100

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.

Primary Consultation

ENT❉❉❉❉

Operation Manual, basic

knowledge, daily care, periodic maintenance/

inspection/cleaning

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 Test Procedures

TST❉❉❉❉

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.

11

CON4020Model Name: RJ–4100

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 Plotting: 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.

Plotting precision problems are grouped here.

•

Problem Involving Noise: Troubles that produce abnormal noise from the driving section.

• Online/Function Problems: Online plotting 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.

12

CON4030Model Name: RJ–4100

How to use Primary Consultation (ENT)

■ When a user has reported a fault, first select the applicable details from the trouble-shooting lists (TRB) and then check the conditions in detail by asking questions in

accordance with the primary consultation (ENT) shown below.

• Ask the questions in order, beginning with 1-1, and move to the next question if there is nothing abnormal. If an abnormality is revealed, carry out the task indicated by

the arrow [→].

• If all questions produce nothing abnormal, then jump to the specified matrix map (MAP).

ENT2000Model Name: RJ–4100

Trouble with Initialization

When No Error is Displayed on the Printer's Liquid Crystal Display

1

2

• No power

• Faulty liquid crystal display (no dis-

play/unstable display)

1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

1-9

• Has the power plug come away from the outlet?

→ Plug the cord all the way into the socket.

• Has the cord come away from the printer inlet?

→ Plug the cord all the way into the printer socket and try again.

• Is power available at the power outlet?

→ Check the power supply.

• Is the AC power supply securely earthed? (grounding)

→ Make sure it is connected to a 100 V or 200 V ground and confirm by testing the display again.

• With the cord inserted into the power outlet, is the prescribed voltage available at the end of the cord?

→ Switch off the printer, leave it for ten minutes then try switching on again.

• The overcurrent detector circuit in the printer's power supply may have tripped.

→ Leave it for 10 minutes then try switching on again.

• Are there any large power-consuming peripheral devices, such as a copier, on the same outlet?

→ Take power from a separate power source.

• Is there any equipment near the printer that is producing strong noise?

→ Separate the power supplies of nearby equipment and try increasing their distance from the printer.

• Is the power cable broken?

→ It's no good connecting a broken cable. Replace the power cable.

• Is the LCD unit damaged?

→ It needs to be repaired by the Serviceman.

Please request repair.

❈ If the above procedures do not improve the symptoms, the main unit has probably developed a fault for

some reason.

Go to MAP2000

No. Symptom

Sequence

Items to be Confirmed

When No Error is Displayed on the Printer's Liquid Crystal Display

Trouble with Initialization

Whether an error message is displayed

Fault details

Questioning sequence

If all questions

produce no

abnormality,

jump to the

specified matric

map (MAP)

Major classification of fault details

Page specified by

trouble-shooting

list (TRB)

Page specified by

trouble-shooting

list (TRB)

13

CON4040Model Name: RJ–4100

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

ENT number

selected from

trouble-shooting

list (TRB)

Whether an error message is displayed

Major classification

of fault details and

range of ENT numbers

Fault

details

Replacement

and adjustment

procedure page

Names and drawing numbers of

required parts

Page specified

by primary

consultation (ENT)

Page specified

by primary

consultation (ENT)

Fault-tracing

procedure

(EXA) page

When Message is Not Displayed Trouble with Initialization Model Name: RJ-4100 MAP2000

Trouble with Initialization Model Name: RJ-4100 MAP2000

When Message is Not Displayed

Trouble with Initialization

ENT2000 to ENT2070

Trouble-

Shooting

List

ENT. No.

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-41524 Main Board Assembly

DF-40097 Panel Board Assembly

DF-40114 Panel Cable

DF-40100 Cover Switch Assembly

DF-40099 Lever Sensor Assembly

DF-40108 Paper Sensor Y Assembly

DF-41525 Head Board Assembly

DF-40102 Paper Sensor F Assembly

DF-40103 Paper Sensor R Assembly

DF-40118 Y Cable (A0) x 1

DF-40115 Switch Cable Assembly

DF-40095 Power Board Assembly

DF-41535 DC Cable Assembly

RJ8-ETH13 Network Interface Board (Supply item)

DF-40106 Detector Assembly (Black)

DF-40107 Detector Assembly (Y)

DF-40146 Detector Assembly (M)

DF-40147 Detector Assembly (C)

DF-40123 Cap Assembly

DF-40124 Pump Assembly

DF-40126 Maintenance Station Assembly

DF-40119 Head Cable (Black)

DF-40120 Head Cable (Color)

DF-40121 Print Head Assembly (Black)

DF-40122 Print Head Assembly (Color)

DF-40488 O-rings (Large)

DF-40487 O-rings (Small)

DF-40101 Waste Fluid Box Detector Switch Assembly

SIM8M, SIM16M, SIM32M Extended Memory (32 MB)(Supply item)

DF-40173 Vacuum Fan Assembly

DF-40174 Fan Cable A Assembly

DF-40132 Fan Cable B Assembly

DF-40133 Fan Cable C Assembly

1140

1160

1170

1110

1100

1410

1420

1190

1200

1360

1130

1150

1130

1480

1350

1240

1260

1270

1400

1390

1530

1120

1490

1080

Fault-Tracing Procedure EXA No.

2000

2010

2020

2030

2040

2050

2060

2070

2000

2010

2020

2030

2040

2050

2060

2070

14

CON4050Model Name: RJ–4100

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 [→].

EXA2000Model Name: RJ–4100

Trouble with Initialization

When No Error is Displayed on the Printer's Liquid Crystal Display

1

2

• No power

• Faulty liquid crystal display (no dis-

play/unstable display)

1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

• Is there a broken or shorted lead in the switch cable assembly (between the switch and

power supply board)?

Use a tester to check for broken or shorted leads.

→ Replace the switch cable assembly.

• Do the "Power supply voltage check 100 V AC"

• Do the "Power supply voltage check 5 V DC"

• Do the "Power supply voltage check 24, 42 V DC"

• Check the panel cable connectors on the panel board and main board.

Are they inserted obliquely? Are they securely locked?

Check Main board J113 (PANEL), panel board J301 (MAIN)

→ Reconnect the connectors.

• The panel cable may be faulty.

→ Replace it.

• Is there a fault in the panel board assembly liquid crystal display?

→ Replace the panel board assembly.

• The main board assembly may be damaged.

→ Replace it.

No. Symptom

Sequence

Items to be Confirmed

When No Error is Displayed on the Printer's Liquid Crystal Display

Trouble with Initialization

1130

1630

1640

1650

1170

1160

1140

REP BAC

GO TO Ref. Pages

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

15

CON4060Model Name: RJ–4100

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 don’t know how to go about the removal of covers involved in replacing a part, refer to REP1010 to REP1060.

• If there is a page listed in the top right “GO TO TEST No.” column, you must jump to the test page and carry out a final check.

Y Motor Assembly

Screws

Screw

REP1280Model Name: RJ–4100

How to replace the Y Motor Assembly

GO TO

TEST NO

1001

TEST4

Item Replacement and Adjustment Procedure

1. Replacement

Procedure

2. Adjustment

and

Examination

Procedure

Replace the Y Motor Assembly

1. Remove the Left and Right Covers. (Refer to REP1010)

2. Remove the Rear Paper Guide. (Refer to REP1040)

3. Remove the Steel Belt. (Refer to REP1290)

4. Open the Control Box. (Refer to REP1050)

5. Disconnect connector J119 (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 passes below

the Cartridge Unit, the work will be easier if you

remove the two Cartridge Base screws and push

it back.

1. Carry out the Steel Belt Tensioning Adjustment. (Refer to

REP1550)

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)

Test procedure (TST) page.

You must go to this page

16

CON4070Model Name: RJ–4100

How to use Test Procedure (TST)

■ After completing replacement and adjustment in accordance with the replacement and adjustment procedure (REP), if “GO TO TEST No.” is specified, carry out a final

check in accordance with the following test procedure.

• If you do not understand how to go about the testing operation, refer to the reference pages in the text.

TST1000Model Name: RJ–4100

Test Procedures (Test 1 to Test 3)

Item Test Procedure

Test 1:

Printing from User's Host

Computer

Test 2 :

Print a Test Print

Test 3:

Skew Check

1. With the cooperation of the user/operator, have the user's data printed in the user's operating environment.

2. Check that the printing is normal.

1. Load A3 size media in the printer.

2. Print a “Test Print”. Press the [Resolution] key while you hold down the [Shift] key.

3. Check that the printing is normal. (Refer to PAT1000 for checking printing quality)

1. Load roll media in the printer (thick coated paper).

2. Select “Adjustments/Skew Verification” from the self-diagnostics menu. (Refer to BAC2030)

3. When “Please input paper feed length [m] (default 1.0 m)” is displayed, set the paper feed length

using the “Setting Value +” key to increase the setting or “Setting Value -” key to decrease the setting.

4. End if “Measurement result ± ✼.✼✼✼, ± ✼.✼✼✼” (skew values on left and right sides of the media) are both within

the standard values shown below.

5. Switch off the power when the test is completed.

Standard values

Within ±1.5 mm

Within ±2.5 mm

Within ±10 mm

Roll Media

Cut Media

Conditions

7m

50m

Standard values

Specified Media

Thick

coated

paper

Test number

and name of

test

Test procedure

and items to be

checked

Page specified by replacement

and adjustment procedure (REP)

Page specified by

replacement and

adjustment procedure

(REP)

17

CON5000Model Name: RJ–4100

Daily Care

This section explains the details of daily maintenance (including cleaning, ink cartridge replacement, cutter replacement, etc.)

How to Clean the Printer Main Unit CON5010

How to Clean the Printer Main Unit CON5011

How to Replace Ink Cartridges CON5020

How to Replace the Cutter CON5030

How to Replace the Waste Fluid Box CON5040

18

CON5010Model Name: RJ–4100

How to Clean the Printer Main Unit

RJ-4100 printer should be wiped free of dirt with a dry

soft cloth.

Plotting Board

Cutting Groove

Use a soft damp cloth to wipe away

any paper fluff adhering to the print-

ing board and cutting groove.

♦ The power switch of the RJ-4000 series printer should be switched off

during cleaning.

♦ Don’t use solvents such as thinners or benzene that will damage the finish.

♦ Covers that are fixed with screws contain electrical components and

must not be opened during cleaning.

♦ Paper dust which is produced when the printer is working should be

removed periodically. Make sure that it does not get blown around.

♦ Stubborn dirt that is difficult to remove may be removed with a lint-free

cloth dampened with alcohol.

CAUTION:

♦ Paper dust and fluff will accumulate with long term use and stick to

the plotting board and cutter groove and may cause printing quality and

cutting performance to deteriorate.

They must be cleaned periodically.

IMPORTANT:

Brush

Grid Roller

Use a soft damp cloth to wipe away

any paper dust sticking to the pres-

sure roller.

Clean the grid roller with a nylon

brush.

♦ Paper fluff sticking to the pressure roller and movable roller may prevent

normal feeding of the media and produce a “Skew Check Error”.

They must be cleaned periodically.

IMPORTANT:

19

CON5011Model Name: RJ–4100

How to Clean the Printer Main Unit

Use a cotton bud to wipe away any dust and paper fluff from the front and back

paper sensor covers in two places.

Paper Sensor Cover

♦ Progressive soiling will affect the sensitivity of the sensors and faulty

detection of the media in the initial operation may cause a “Skew Check

Error”. They must be cleaned periodically.

IMPORTANT:

20

When a RJ-4100 Series printer is displaying “No ink” or “No cartridge”, the cartridge

should be replaced or filled without delay. Also, ink cartridges should be prepared

when “[YMCK] Ink Near End” is displayed.

Step 1

If “No ink” appears in the message display sec-

tion, when there is no printing operation in

progress, from the back of the printer, pull out

the ink cartridge whose color is indicated.

Step 2

Open the new ink cartridge packet.

[YMCK] cartridge

♦ Each letter Y, M, C, K in the display indicates a color: “Y” (yellow),

“M” (magenta), “C” (cyan), “K” (black).

♦ Colors for “no ink” are expressed as colors 1 to 4.

Reference:

CON5020Model Name: RJ–4100

How to Replace Ink Cartridges

Step 3

Insert the new cartridge in the slot at the

back of the printer.

Step 4

Check that the display has reverted to its

permanent display.

Reference:

♦ Only specific cartridges can be used. They also have a particular place and

orientation. Be careful not to confuse the location and orientation.

♦ Don’t open the sealed package until you are ready to insert the cartridge in the slot.

If a cartridge is stored for a long period with the seal opened, the printing may be

patchy.

♦ Cartridges should be used within two years of the date printed on the package.

An ink cartridge that has been mounted in the printer for two years should be

replaced.

♦ A cartridge that has been mounted in the printer should be replaced within six months.

Plot OK

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MUTOH Falcon RJ-4100 Maintenance Manual

MUTOH Falcon RJ-4100 Maintenance Manual

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