MUTOH spitfire 90 Maintenance Manual

Maintenance

Manual

Spitfire 65/90

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AP-74096, Rev. 1.0, 09/06/05

MUTOH INDUSTRIES LTD.

Tel.:81-(0)3-54867145

Fax.:81-(0)3-54867163

E-mail:[email protected]o.jp

http://www.mutoh.co.jp

MUTOH EUROPE N.V.

Tel.:32-(0)59-561400

Fax:32-(0)59-807117

E-mail:mutoh@mutoh.be

http://www.mutoh.be

MUTOH DEUTSCHLAND GmbH.

Tel.:49-(0)2159 913430

Fax.:49-(0)2159 913456

E-mail:Mutoh-Sales@t-online.de

MUTOH AMERICA INC.

Tel.: (480) 968-7772

Fax: (480) 968-7990

E-mail:[email protected]

http://www.mutoh.com

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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 Mutoh’s Spitfire. In consideration of the furnishing of the information

contained in this document, the party to whom it is given, assumes its custody and control and agrees to the

following:

The information herein contained is given in confidence, and any part thereof shall not be copied or

reproduced without written consent of Mutoh Europe N.V.

This document or the contents herein under no circumstances shall be used in the manufacture or

reproduction of the article shown and the delivery of this document shall not constitute any right or license to

do so.

June 2005

Published: Mutoh Europe N.V., Archimedesstraat 13, B-8400 Oostende, BELGIUM

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Important Notice

This product has been tested and found to comply with the limits for a Class A digital device, pursuant to Part

15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference

when the product is operated in a commercial environment.

This product generates, uses, and can radiate radio frequency energy and if not installed and used in

accordance with this manual, may cause harmful interference to radio communications. Operation of this

product in a residential area is likely to cause harmful interference in which case the user will be required to

correct the interference at his expense.

1. Radio interfere

Product generates weak radio signals and may interfere with television reception and utilities. If a

product does interfere with radio or TV reception, try following:

¾ Change the direction of your radio and TV reception antenna or feeder.

¾ Change the direction of the product.

¾ Move either the product or the receiving antenna so there is more distance between them.

¾ Be sure the product and the receiving antenna are on separate power lines.

2. Trademark mentioned in this manual.

¾ MUTOH, Spitfire, Spitfire Mild Solvent, MH-GL, MH-GL2, MH-RTL are registered trademarks or

product names of MUTOH INDUSTRIES LTD.

¾ Centronics and Bitronics are registered trademarks or product names of Centronics Data Computer

Corporation.

¾ Windows 95, Windows 98, Windows Me, Windows XP, Windows NT4.0, Windows2000, and

MSDOS are registered trademarks or product names of Microsoft Corporation.

¾ DOS/V is registered trademark and product name of International Business Machine Corporation

(IBM).

¾ Other company and product names may be registered trademarks or product names.

No part of this product or publication may be reproduced, copied or transmitted in any form or by any means,

except for personal use, without the permission of MUTOH EUROPE N.V.

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.

MUTOH EUROPE N.V. shall not be liable for any damages or troubles resulting from the use of this

equipment or this manual.

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TABLE OF CONTENTS

1. Safety Instructions.......................................................................................................15

1.1. Introduction .............................................................................................................15

1.2. Warnings, Cautions and Notes................................................................................15

1.3. Important safety instructions ...................................................................................15

1.4. Warning labels ........................................................................................................18

1.5 Labels in function of transportation ..........................................................................21

2. Product Overview ........................................................................................................23

2.1. Introduction .............................................................................................................23

2.2. Features..................................................................................................................23

2.3. Part names and functions........................................................................................24

2.3.1. Front.................................................................................................................24

2.3.2. Back..................................................................................................................26

2.3.3. Position and function of the heating elements ..................................................27

2.3.4. Operation panel................................................................................................28

2.4. Printer status...........................................................................................................30

2.4.1. Normal..............................................................................................................30

2.4.2. Setting menu display ........................................................................................30

2.4.3. Changing the printer status...............................................................................31

3. specifications...............................................................................................................33

3.1. Introduction .............................................................................................................33

3.2. Product Specifications.............................................................................................34

3.3. Interface Specifications...........................................................................................35

3.4. Installation...............................................................................................................37

3.4.1. Choosing a place for the printer........................................................................37

3.4.2. Installing the printer ..........................................................................................39

4. Parts Replacement ......................................................................................................41

4.1. Introduction .............................................................................................................41

4.2. Removing the cover ................................................................................................42

4.2.1. Removing the I/H cover....................................................................................43

4.2.2. Removing side cover R.....................................................................................44

4.2.3. Removing side cover L.....................................................................................46

4.2.4. Removing the front cover..................................................................................48

4.2.5. Removing the panel unit assembly...................................................................52

4.2.6. Removing the Y rail cover.................................................................................53

4.2.7. Removing front paper guide..............................................................................54

4.2.8. Removing rear paper guide ..............................................................................56

4.2.9. Removing the head cover.................................................................................57

4.2.10. Removing the maintenance cover ..................................................................58

4.3. Replacement of the heater element ........................................................................59

4.3.1. Heater elements ...............................................................................................59

4.4. Replacing Board Bases...........................................................................................66

4.4.1 Replacing the Mainboard assembly, HDD_Extension board assembly,

HEAD_DRV board assembly, PCI_Linux board assembly and cooling fan assembly66

4.4.2. Replacing the power source board assembly...................................................72

4.4.3. Replacing the inlet assembly, inlet board assembly and lever foot SW cable

assembly ....................................................................................................................74

4.4.4. Replacing the JUNCTION board assembly ......................................................75

4.5. Replacing the PF Actuator ......................................................................................76

4.5.1. Replacing the PF motor assembly....................................................................76

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4.5.2. Replacing the PF_ENC assembly and PF scale assembly...............................77

4.5.3. Replacing the PF deceleration pulley assembly ...............................................78

4.5.4. Replacing the PF deceleration belt...................................................................79

4.5.5. Replacing the P_REAR_R sensor assembly and P_REAR_L sensor assembly

...................................................................................................................................80

4.5.6. Replacing the suction fan assembly .................................................................81

4.5.7. Replacing the lever motor assembly and the arm motor installation board.......82

4.5.8. Replacing the transmission photosensor..........................................................84

4.5.9. Replacing the flushing box assembly................................................................86

4.6. Replacing the CR Actuator......................................................................................92

4.6.1. Replacing the CR motor assembly ...................................................................92

4.6.2. Replacing the steel belt ....................................................................................93

4.6.3. Replacing the SLIDE motor assembly, HD_SLIDE sensor assembly, and slide

motor installation board ..............................................................................................95

4.6.4. Replacing the T fence (Timing fence or Linear Y-Axis Encoder) ......................96

4.6.5. Replacing the CR slave pulley assembly..........................................................98

4.6.6. Replacing the CR actuator pulley and the CR deceleration belt.......................99

4.6.7. Replacing the steel bearer, tube guide, CR tape power cable and ink tube ...100

4.6.8. Replace the cover R sensor assembly and the cover L sensor assembly......102

4.7. Replacing the Cursor.............................................................................................103

4.7.1. Replacing the cutter holder, cutter spring, cutter cap, solenoid assembly and

solenoid spring .........................................................................................................103

4.7.2. Replacing the print head assembly and head tape power cable.....................105

4.7.3. Replacing the H ink tube, tube branch and damper assembly........................107

4.7.4. Replacing the CR board assembly .................................................................108

4.7.5. Replacing the CR_ENC assembly..................................................................110

4.7.6. Replacing the P_EDGE sensor assembly ......................................................111

4.7.7. Replacing the CR cursor assembly.................................................................112

4.7.8. Replacing the cursor roller assembly..............................................................113

4.8. Replacing the MAINTENANCE station Area.........................................................115

4.8.1. Replacing the Capping Station Assembly (Maintenance Assembly)...............115

4.8.1. Assembling the Capping Station.....................................................................118

4.8.3. Replacing the caps.........................................................................................121

4.8.4. Replacing the wiper and wiperarm and replace the sponge ...........................122

4.8.5. Replacing the SLIDE motor assembly (wiper arm).........................................127

4.8.6. Replacing the transmission photosensor (wiper home position and maintenance

home position)..........................................................................................................128

4.9. Replacing the Pump Area .....................................................................................129

4.9.1. Replacing the pump assembly........................................................................129

4.9.2. Replacing the pump........................................................................................131

4.9.3. Replacing the pump motor assembly..............................................................132

4.10. Replacing the Cartridge Area..............................................................................133

4.10.1. Replacing the I/H (ink holder) assembly.......................................................133

4.11. Replacing Supports and Scroller.........................................................................137

4.11.1. Replacing the waste fluid bottle assembly....................................................137

4.11.2. Replacing the waste bottle box sensor assembly.........................................138

5. Self-Diagnosis Function............................................................................................141

5.1. Introduction ...........................................................................................................141

5.2. Preparation............................................................................................................141

5.2.1. Preparations on Machine................................................................................141

5.2.2. Starting Up......................................................................................................142

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5.3. Operations in Self-Diagnosis Mode.......................................................................143

5.3.1. Operating Self-Diagnosis Mode......................................................................143

5.3.2. Diagnosis Items in Self-Diagnosis Menu ........................................................145

5.4. Test / Inspection Menu..........................................................................................146

5.4.1. RAM Capacity Menu.......................................................................................147

5.4.2. Version Menu..................................................................................................147

5.4.3. Operation Panel Menu....................................................................................148

5.4.4. Sensor Menu ..................................................................................................149

5.4.5. Encoder Menu ................................................................................................150

5.4.6. Fan Menu .......................................................................................................151

5.4.7. History Menu...................................................................................................151

5.4.8. Head Signal Menu..........................................................................................153

5.5. Adjustment Menu ..................................................................................................154

5.5.1. Skew Check Menu..........................................................................................155

5.5.2. Head rank input menu ....................................................................................156

5.5.3 Head Nozzle Check Menu..............................................................................157

5.5.4. Head Slant Check Menu.................................................................................159

5.5.5. Repeatability Adjustment (Bi-Directional) .......................................................164

5.5.6. CW adjustments (Uni-Directional)...................................................................165

5.5.7. Band Feed Correction Menu (X Length).........................................................166

5.5.8. Top & bottom adjustment menu......................................................................168

5.5.9. P_REAR sensor position adjustment menu....................................................169

5.5.10. Test print menu.............................................................................................170

5.5.11. Head wash menu..........................................................................................171

5.5.12. Software Counter Initialization Menu............................................................173

5.5.13. Feed Pitch Check Menu ...............................................................................174

5.5.14. Fill printing menu ..........................................................................................174

5.6. Purge Menu...........................................................................................................175

5.7. Sample Printing Menu...........................................................................................176

5.8. Parameter Menu....................................................................................................177

5.8.1. Parameter Initialization Menu .........................................................................177

5.8.2. Parameter Update Menu ................................................................................178

5.9. Endurance Running Menu.....................................................................................187

5.9.1. CR Motor Endurance Menu............................................................................188

5.9.2. PF Motor Endurance Menu.............................................................................189

5.9.3. Cutter Endurance menu..................................................................................190

5.9.4. Head Up/Down Endurance Menu...................................................................191

5.9.5. Head Lock Endurance menu ..........................................................................192

5.9.6. Pump Endurance menu..................................................................................193

5.9.7. Lever Motor Endurance Menu........................................................................194

5.9.8. Sequential Printing Endurance Menu .............................................................195

5.9.9. General Endurance Menu...............................................................................196

5.9.10. Endurance Running Check Menu.................................................................197

5.10. Head Lock Menu.................................................................................................198

5.11. Heater System menu...........................................................................................199

5.11.1. Heater Status Menu......................................................................................199

5.11.2. Heater Temperature Menu ...........................................................................199

5.11.3. Heater Test 30 Menu....................................................................................200

5.11.4. Heater Test 50 Menu....................................................................................200

5.11.5. Heater Test Max Menu.................................................................................200

5.11.6. Test Aging Menu...........................................................................................201

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5.11.7. Heater Version Menu....................................................................................201

5.12. Sol Prepare menu ...............................................................................................202

5.13. SMS MEnu..........................................................................................................202

5.13. Machine size select menu...................................................................................203

6. Maintenance Mode.....................................................................................................205

6.1. Introduction ...........................................................................................................205

6.2. Operating Maintenance Mode...............................................................................205

6.2.1. Starting Up Maintenance Mode ......................................................................205

6.2.2. Operating Maintenance Mode.........................................................................205

6.3. Maintenance Menu................................................................................................206

6.3.1. Counter Display Menu....................................................................................206

6.3.2. Counter Initialization Menu .............................................................................208

6.3.3. MAC address write enable menu....................................................................209

6.3.4 Head Voltage...................................................................................................210

7. Adjustments...............................................................................................................211

7.1. Introduction ...........................................................................................................211

7.2. Adjustment............................................................................................................211

7.3. Parameter backup.................................................................................................214

7.3.1. Tools required for work...................................................................................214

7.3.2. Procedure for creating backup parameters.....................................................215

7.3.3. Backup parameter installation procedure .......................................................216

7.4. Firmware installation .............................................................................................217

7.4.1. Tools required for work...................................................................................217

7.4.2. Installation procedure .....................................................................................217

7.5. Steel belt tension adjustment................................................................................220

7.5.1. Tools required for work...................................................................................220

7.5.2. Adjustment Procedure....................................................................................220

7.6. PF deceleration belt tension adjustment ...............................................................222

7.6.1. Tools required for work...................................................................................222

7.6.2. Adjustment Procedure....................................................................................222

7.7. Head precision adjustment (slant).........................................................................223

7.7.1 Head slant adjustment.....................................................................................223

7.7.2. Front and back of head adjustment ................................................................225

7.8. Repeatability Adjustment (Bi-Directional)..............................................................228

7.9. CW adjustments (Uni-Directional).........................................................................229

7.10. CR deceleration belt tension adjustment.............................................................230

7.10.1. Tools required for work.................................................................................230

7.10.2. Adjustment Procedure..................................................................................230

7.11. Cover sensor adjustment ....................................................................................231

7.12. Head height adjustment ......................................................................................232

7.12.1. Tools required for work.................................................................................232

7.12.2. Adjustment Procedure..................................................................................232

7.13. Media sensor sensitivity adjustment....................................................................234

7.13.1. Tools required for work.................................................................................234

7.13.2. Adjustment Procedure..................................................................................234

7.14. Cutter adjustment................................................................................................238

7.15. Pump tubing layout for pump assembly ..............................................................240

7.15.1 Pump tubing layout........................................................................................240

7.16. Board checklist....................................................................................................242

7.16.1. Power supply board......................................................................................242

7.16.2. Control board................................................................................................243

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7.16.3. Power board. ................................................................................................244

7.16.4. Heater Elements...........................................................................................244

7.16.5. Checklist.......................................................................................................246

7.17 Flushing box height position adjustment ..............................................................247

8. Maintenance...............................................................................................................251

8.1. Introduction ...........................................................................................................251

8.2. Cleaning................................................................................................................252

8.3. Periodical Services................................................................................................253

8.3.1. Service by end-user........................................................................................253

8.3.2. Service by authorised Mutoh technician.........................................................255

8.4. Part Life Information..............................................................................................258

8.5. Jig and Tool List....................................................................................................259

8.5.1. Required Tools ...............................................................................................259

8.6. Lubrication/Bonding...............................................................................................260

8.7. Transportation of Machine.....................................................................................262

9. Troubleshooting ........................................................................................................265

9.1. Introduction ...........................................................................................................265

9.2. Troubleshooting procedures when a message has been displayed......................265

9.2.1. Operating condition display ............................................................................266

9.2.2. Message type errors.......................................................................................268

9.2.3. Heating system error ......................................................................................275

9.2.4. Data error .......................................................................................................276

9.2.5. Command errors.............................................................................................277

9.2.6. Errors requiring restart....................................................................................278

9.3. Troubleshooting procedures when errors are not displayed..................................289

9.3.1. Problems relating to initial operation...............................................................289

9.3.2. Problems relating to paper feed......................................................................295

9.3.3. Problems relating to the printing operation.....................................................296

9.3.4. Problems relating to noise..............................................................................308

9.3.5. Problems relating to the paper cutting operation ............................................310

9.3.6. Problems relating to online and functions.......................................................313

9.3.7. Other problems...............................................................................................315

10. Appendix...................................................................................................................317

10.1. Introduction .........................................................................................................317

10.2 Wiring Diagram.....................................................................................................317

10.4. Service Parts List/Exploded Views/Configuration Diagrams................................317

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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.

1.2. WARNINGS, CAUTIONS AND NOTES

Safety terms in this manual and the contents of warning labels attached to the printer are categorized into

the following three types depending on the degree of risk (or the scale of accident).

Read the following explanations carefully and follow the instructions in this manual.

Safety terms Details

Important Must be followed carefully to avoid death or serious bodily injury

Caution Must be observed to avoid bodily injury (moderately or lightly) or damage to your

equipment

Notes Contains important information and useful tips on the operation of your printer

1.3. IMPORTANT SAFETY INSTRUCTIONS

General safety instructions that must be observed to use the equipment safely are explained below.

¾ Do not place the printer in the following areas. Doing so may result in the printer tipping or falling

over and causing injury.

• Unstable surfaces

• Angled place

• Areas subject to vibration by other equipment

¾ Do not stand on or place heavy objects on your printer. Doing so may result in the printer tipping

or falling over and causing injury.

¾ Do not cover the ventilation hole of your printer with cloth, such as a blanket or table cloth. Doing

so could obstruct ventilation and cause fire.

¾ Do not place the printer in humid and dusty areas. Doing so may result in electrical shock or fire.

¾ Do not use a damaged power cable. Doing so may result in electrical shock.

¾ Do not attempt to plug in electrical plugs with wet hands. Doing so may result in electrical shock.

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¾ Do not connect earth cables in the following areas.

• Gas pipes → Doing so may cause fire or an explosion.

• Earth terminals for telephone line or lightening rod → Doing so may cause a large flow of

voltage if lightening occurs.

• Water pipes or faucets → If there is a plastic part in the pipe, the earth will not work

properly.

¾ Do not insert or drop metal or inflammable objects into openings, such as ventilation outlets.

Doing so may result in electrical shock and fire.

¾ Stop using your printer if a liquid is spilled into it. This may cause electrical shock or fire. Turn the

printer off as soon as possible, unplug the power cord, and contact your local MUTOH dealer.

¾ Be sure to use the attached cable. Otherwise, electrical shock or fire may occur.

¾ Be sure to use the specified voltage (AC 100 V to 120V, or AC 220V to 240V). Otherwise,

electrical shock or fire may occur.

¾ Use electricity directly from a power outlet (AC 100 V to 120V, or AC 220V to 240V). Do not put

many loads on one electrical output. Otherwise, heat may be generated and cause fire.

¾ Be sure to use an outlet with an earth terminal and use the terminal correctly. Otherwise,

electrical shock or fire may occur.

¾ Follow the instructions below when handling the power cable.

o Do not modify the cable.

o Do not put heavy objects on the cable.

o Do not bend, twist or pull the cable.

o Do not wire the cable near equipment that generates heat.

¾ Follow the instructions below when handling the power plug. Otherwise, fire may occur.

o Wipe away dust and any other residue before inserting the plug.

o Ensure that the plug is firmly inserted as far as it will go.

¾ When handling the foot switch, be aware of the following:

o Do not place anything heavy on the foot switch.

o Do not bend the cable of the foot switch with force and do not pull.

o Do not place the foot switch near thermal devices.

¾ When handling ink cassettes, be careful that ink does not get in your eyes or on your skin.

However, if this happens, flush immediately with water and wash skin with soap. Otherwise, your

eyes may become congested or inflamed slightly. If you feel discomfort, consult a doctor

immediately.

¾ Do not disassemble ink cassettes. Otherwise, ink may get in your eyes or on your skin.

¾ Be careful not to pinch your fingers when opening and closing the cover of the ink compartment.

¾ Be careful not to pinch your fingers when opening and closing the front cover.

¾ Follow the instructions below when connecting the network interface cable. Otherwise, electrical

shock or fire may occur.

o Do not touch the connector.

o

Do not connect the network cable connector that is not the same specification to the

interface board.

¾ When cutting the roll media, be careful of the following. Incorrect handling can result in injury to

the hands and fingers from the razor blade.

o When holding the media, do not place fingers over the media cut groove.

o Move the razor blade slowly along the media cutting groove.

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¾ Do not use thinner, benzene, alcohol or other active agents. Doing so may result in damage or

paint peeling from the casing.

¾ Be careful not to spill water inside the printer. Doing so may result in a short circuit.

¾ Be careful not to touch the heaters during or after operation. Doing so may result in burns.

¾ Only use Spitfire Mild Solvent Ink and appropriate cleaning liquid.

¾ Never open the covers fixed with screws, except the left cover. Doing so may result in electrical

shock or a malfunctioning in the printer.

¾ Do not touch the cutter blade. Doing so may result in bodily injury.

¾ Do not cut hard objects or drop the cutter. Doing so may damage or chip the cutter blade.

¾ Do not bend or pull the waste fluid tube. Doing so may cause that the waste fluid will leak out and

malfunction in the product.

¾ Do not touch the cleaning wiper or the head cap unit whit bear hands. Use a dust free cloth and

gloves to clean.

¾ Do not tilt the printer, stand it against a wall or turn it upside down. Doing so may cause ink to

leak inside the printer. Movement after transport is also not covered by the warranty.

¾ When installing options, do not touch the elements on the circuit board. The elements on the

boards can be very hot and can cause burns.

¾ Have four or more people unpack and assemble the printer.

¾ When lifting the printer out of the packing box, be sure to remove the vinyl cover first, and then

grab the holding grips on the sides of the printer. Lifting the printer with the vinyl cover on may

cause your hands to slip and drop or damage the printer.

¾ Have two or more people transport the printer.

¾ Ensure that the plug has been disconnected from the power socket when it is not to be used for a

long time.

¾ Earth wires must be connected to wires or terminals that fulfill the conditions below.

o Earth terminals of power sockets

o Earth wires with copper morsel that is at least 650 mm under the ground

¾ Earth wires must be connected to wires or terminals that fulfill the conditions below.

¾ Keep the printer horizontal during transportation.

¾ Be sure to do the following before attaching options.

o Turn the printer off.

o Unplug the power cord from the socket.

o Unplug cables connected to the printer. Otherwise, damage to the printer or your computer

may occur.

o Remove electrostatic charge from your clothes and body by touching the metal parts of the

printer.

o Electronic components such as the memory may malfunction if exposed to an electrostatic

charge.

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1.4. WARNING LABELS

The handling, attachment locations, and types of warning labels are explained below.

Warning labels are attached on areas which require attention. Read and understand the positions and

contents thoroughly before performing your work.

1.4.1. Handling the warning labels

Be sure to note the following when handling the labels.

Notes :

• Make sure that all labels can be recognized. If text or illustrations cannot be seen

clearly, either clean or replace the label.

• When cleaning labels, use a cloth with water or neutral detergent. Do not use a

solvent or gasoline.

• If a warning label is damaged, lost or cannot be recognized, replace the label.

When replacing warning labels, contact your local MUTOH dealer.

1.4.2. Locations and types of warning labels

The locations of warning labels are shown below.

1.4.2.1.

Location and types of warning labels on front part.

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No. Type

1

2

3

4,7

5,6

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1.4.2.2.

Location and types of warning labels on back part.

No. Type

3

CAUTION



THIS UNIT HAS TWO POWER SUPPLY CORDS, WHEN WiNDING



UNIT IS PROVIDED. TO REDUCE THE RISK OF ELECTRICAL



SHOCK, DISCONNECT ALL POWER SUPPLY CORDS

BEFORE SERVICING.

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