MUTOH Rockhopper 3, Spitfire 90, Spitfire 65 Troubleshooting Manual
Troubleshooting
Spitfire 65/90
Rockhopper 3
Troubleshooting
2 AP-74700 – Rev. 1.0 – 10/03/2008
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Troubleshooting
3 AP-74700 – Rev. 1.0 – 10/03/2008
Table of content
1 TROUBLESHOOTING PROCEDURE WHEN A MESSAGE IS DISPLAYED ..............5
1.1 OPERATING CONDITION DISPLAY ..................................................................................6
1.2 MESSAGE TYPE ERRORS .............................................................................................8
1.3 HEATING SYSTEM ERROR ..........................................................................................14
1.4 DATA ERROR............................................................................................................15
1.5 COMMAND ERRORS ..................................................................................................16
2 TROUBLESHOOTING WITH ERROR CODES...........................................................17
2.1 DRAM
ERRORS.......................................................................................................17
2.2 CPU
ERRORS..........................................................................................................18
2.2.1 E 016 error CPU Err(03) ..................................................................................18
2.3 PF - PAPER FEED ERRORS .......................................................................................19
2.4 CARRIAGE RELATED ERRORS.....................................................................................21
2.4.1 E066 - CR Motor Err ........................................................................................21
2.4.2 E068 - CR Encoder Err ....................................................................................21
2.4.3 E072 - CR OverCurrent ...................................................................................21
2.4.4 E070 - CR Timeout Error .................................................................................23
2.4.5 E073 - CR Origin Error.....................................................................................24
2.4.6 E074 - Cover Sensor Error...............................................................................24
2.4.7 E076 - PG Origin Err........................................................................................24
2.4.8 E078 - Head Cable Error .................................................................................25
2.5 LEVER & PRESSURE ROLLER ERRORS........................................................................26
2.5.1 E079 - Lever OverCurrent................................................................................26
2.5.2 E080 - Lever Sensor Err ..................................................................................26
2.6 CAPPING STATION ERRORS.......................................................................................27
2.6.1 E081 - Cap Sensor Err.....................................................................................27
2.6.2 Sensor diagnostics...........................................................................................27
2.6.3 Capping - Motor diagnostics ............................................................................27
2.6.4 E082 - Wiper Sensor Err..................................................................................27
2.6.5 Sensor diagnostics...........................................................................................28
2.6.6 Wiper - Motor diagnostics ................................................................................28
2.6.7 E097 - NVRAM Error .......................................................................................29
2.7 HEAD AND FLATCABLE RELATED ERRORS ....................................................................30
2.8 ETHERNET CARD ERRORS .........................................................................................31
2.9 M
AINBOARD RELATED ERRORS ..................................................................................31
2.9.1 E211 – Incompatible hardware ........................................................................31
2.9.2 E256 – Mode not found....................................................................................31
2.9.3 E257 – Mode not available ..............................................................................31
2.9.4 E258 – Mode Init problem................................................................................31
2.9.5 A259 – Hardware not found .............................................................................32
2.9.6 E260 – Incompatible Firmware ........................................................................33
2.9.7 E261 – Firmware Init Problem..........................................................................33
2.10 W
ALLET-SIMM-CARD ERRORS..................................................................................33
Troubleshooting
4 AP-74700 – Rev. 1.0 – 10/03/2008
3 TROUBLESHOOTING WITHOUT ERROR CODE......................................................35
3.1 PARAMETER & PRINTING RELATED ISSUES .................................................................35
3.1.1 Parameters are not being saved during shutdown...........................................35
3.1.2 Unstable machine behaviour (CPU errors, machine crashes) .........................35
3.1.3 Printer doesn’t start printing, interrupts or intermittently stops during printing..36
3.1.4 Ink drops falling on media from heads during printing......................................37
3.2 PRINTING RELATED PROBLEMS ..................................................................................38
3.2.1 Complete nozzle-row (A or B-channel) is missing............................................38
3.2.2 Head is firing continuously ...............................................................................39
3.3 INITIAL MACHINE STARTUP-RELATED PROBLEMS ..........................................................40
3.3.1 Ink and cleaning compatibility-Chart ................................................................40
3.3.2 Only applicable 65” – 90” machines.................................................................42
3.4 PUMP INK AND CLEANING SUCTION PROBLEMS.............................................................42
3.4.1 The machine is completely dead – non responding.........................................43
3.4.2 Mainboard replacement procedure ..................................................................44
3.4.3 Media Feed – Distance adjustment basic principles ........................................44
3.4.3.1 Mechanical toleration: ...................................................................................44
3.4.3.2 Media toleration ............................................................................................45
Troubleshooting
5 AP-74700 – Rev. 1.0 – 10/03/2008
Introduction
This chapter explains the procedures for troubleshooting this product.
When the product indicates a failure and an error message is also displayed on the control panel, refer to
"Troubleshooting procedures when a message has been displayed" and implement treatment. When the
product indicates failure but an error message has not been displayed, refer to "Troubleshooting procedures
when an error message has not been displayed" and implement treatment.
1 TROUBLESHOOTING PROCEDURE
WHEN A MESSAGE IS DISPLAYED
This chapter explains the messages displayed when the product is operating normally and when an error
occurs.
There are the following types of messages.
Priority level Message Type Description
1
Operating condition
display
Displayed when the product is operating normally
2 Heating system error Displayed when heating element errors occurs during operation.
3
Message type errors Message type errors are displayed when trouble occurs during
operation.
4
Data error Displayed when data communication trouble occurs between the
computer and this product.
5
Command errors Displayed when trouble occurs during analysis of the command
data that is sent to this product from the computer.
Troubleshooting
6 AP-74700 – Rev. 1.0 – 10/03/2008
1.1 OPERATING CONDITION DISPLAY
This chapter explains how to proceed, when the following messages are displayed on your LCD-display.
No. Message Phenomenon Check point Action
(1) Verify the L/R cover sensor
via diagnostics:
Diagnostics Æ Test Æ Sensor
Æ Cover SW
• Replace the cover sensor
if the sensor is not
responding
(2) Open and close the cover,
check if all sensors are
“clicking”.
Ensure the sensor is properly
adjusted:
Adjust the sensor-bracket
or sensor-cam when
necessary
The cover-switch is a twoway switch. Or pin 1 and
2 or pin 2 and 3 are
closed.
Malfunction of the switch
might also result in the
following error:
“E068 CR Encoder Error”
Sensor state:
Pin 1 and 2 on the sensor
are closed, Pin 3 is open
(floating)
1 Cover Open The LCD indicates:
- The front cover is
open.
- One of the coverswitches is not
properly activated or
connected
Pin 2 and 3 on the sensor
are closed, Pin 1 is open
(floating)
!Attention!
Be careful when
adjusting the sensorbracket, the sensor-lip is
not fully stressed. This
will decrease life and
possibly damage the
sensor!
Adjust the sensor and
make sure there is a 0,5
to 1mm gap as
illustrated.
Troubleshooting
7 AP-74700 – Rev. 1.0 – 10/03/2008
(3) If the cover switches are ok,
and the error persists
(4) The cover switch circuit IC’s
on the mainboard assembly
may have a problem
Verify the cover switch
connectors on the
mainboard, (J155 and
J156)
If no spare cover switches
are available, temporary
bypass on own risk is
possible, short circuiting
pins 1 and 2 for both
switches.
Replace the mainboard
assembly if after
bypassing the cover
switches, the mainboard is
still not recognizing a
closed cover switch.
(1) Try to put the lever down:
- Via the foot pedal
- Via the LCD display
If the lever is not
responding, try to short
circuit the 2 pins of the
lever foot pedal.
(2) Check the 2 sensors of the
lever UP / DOWN via
diagnostics:
Diagnostics Æ Test Æ Sensor
Æ Lever Sensor
If sensors are responding:
- Remove A heater platen.
Check if nothing is broken
in de Up/Down mechanism
- Replace the photo
sensor / sensor bracket if
the sensor is not
responding
(3) Verify if the 2 U-photo
sensors on the lever motor are
properly mounted.
• If the photo sensor is
detached or broken, fix or
replace when necessary.
(4) Check the 2 U-photo
sensors for dust or
contamination
• Clean the photo sensor
blowing compressed air
(5) Check if the sensors are
properly connected
• Check the connections
on the Mainboard assy at
connectors J123 and
J124.
2 Set Paper Indicates the lever—
sensor is in the UP
position.
The lever motor
should be the UP
position when
having this
message.
(7) If after replacement of the
sensors, the sensor still doesn’t
respond in diagnostics, the
Mainboard assembly may have
a problem.
• Replace the Mainboard
assembly.
(1) Check if both the
P_REAR_R and P_REAR_L
sensors are properly working:
Diagnostics Æ Test Æ Sensor
Æ PaperRear R and L.
When you cover the
sensor with paper, the
P_REAR sensor should
switch ON.
If the sensor is not
responding, check the
sensor alignment.
Replace if necessary.
3 Paper End There is no media
inside the printer.
The roll of media
has ended
(2) Check if the sensors are not
obstructed by dust, dirt or
media
Clean when necessary
Blow dirt and dust away
from sensor with
compressed air
Troubleshooting
8 AP-74700 – Rev. 1.0 – 10/03/2008
(3) Check if both P_REAR
sensors are properly
connected.
Verify connections on
Mainboard assembly,
connectors J128 and
J129.
(4) The P_REAR sensor
assembly may be broken.
• Replace the P_REAR
sensor assembly.
(5) If after sensor replacement,
the problem still persists, the
Mainboard assembly may have
a problem.
• Replace the Mainboard
assembly.
1.2 MESSAGE TYPE ERRORS
Message type errors are displayed when trouble occurs during operation.
When message type errors occur, this product displays the following error messages on the operation panel
and stops the operation.
When the causes of errors are removed, message type errors are restored and the printing operation will be
restarted.
No. Message Phenomenon Check point Action Refer to
(1) Check the
operation of the
P_EDGE sensor via
“Test: Sensor” of the
self-diagnostic
function.
• If the sensor
responds to the
presence of the
paper, adjust the
sensor volume.
• If the sensor does
not respond to the
presence of the
paper, replace the
P_EDGE sensor
assembly
• Media sensor
sensitivity
adjustment
• Replacing the
P_EDGE
sensor
assembly.
(2) Make sure the
P_EDGE sensor
assembly connector
at the cursor is
securely connected.
• Securely connect
it to CR board
assembly
connector J234.
• Replacing the
Mainboard
assembly,
HDD_Extensio
n board
assembly,
HEAD_DRV
board
assembly and
cooling fan
assembly.
Undefined paper The printer failed to
detect the media.
(3) Make sure the
R_REAR sensor
assembly cables
underneath paper
guide R are securely
connected.
• Securely connect
the cables to
Mainboard
assembly
connectors J128
and J129.
• Replacing the
Mainboard
assembly,
HDD_Extensio
n board
assembly,
HEAD_DRV
board
assembly and
cooling fan
assembly.
Troubleshooting
9 AP-74700 – Rev. 1.0 – 10/03/2008
(4) Check the
Flatcables for
skewed insertion.
• Redo the
connections of
the following
connectors :
• CR board : J201
– J216
• Mainboard : J137
– J152
• Replacing the
Mainboard
assembly,
HDD_Extensio
n board
assembly,
HEAD_DRV
board
assembly and
cooling fan
assembly.
(5) The Flatcables
from the mainboard
to the head board
may be damaged.
• Replace the
Flatcables.
• Replacing the
steel bearer,
tube guide,
Flatcable and
ink tube.
(6) The CR board
assembly may be
damaged.
• Replace the CR
board assembly.
• Replacing the
CR board
assembly.
(7) The Mainboard
assembly may be
damaged.
• Replace the
Mainboard
assembly.
• Replacing the
Mainboard
assembly,
HDD_Extensio
n board
assembly,
HEAD_DRV
board
assembly and
cooling fan
assembly.
2 Paper Slant The paper is fed
askew.
(1) Reset the paper
and check if the
condition recurs.
• If this is caused
by incorrect paper
setup, explain the
correct paper
setup procedure.
-
(1) Check the cutter
grooves for
accumulated paper
dust and slip.
• Remove the
accumulated
paper dust along
the direction of
the grooves.
• Please refer to
the User’s
Guide.
(2) Has the cutter
cap securely been
installed?
• Reset the cutter
cap securely
• Please refer to
the User’s
Guide.
(3) Check the
cutter’s up and down
sliding operation.
• If it does not rise
Go to step (4)
• If it rises : Go to
step (5)
3 Paper Cut Error Even though cutting
operation was
performed, the paper
was not completely cut
and removed.
(4) Check if the
cutter drops to the
bottom end under its
own weight when the
cutter has been
installed without the
cutter spring.
• If it drops: The
cutter spring may
have a problem.
Replace the
cutter spring while
referring to the
unfolded view.
• If it does not drop:
The cutter may
have a problem.
Replace the
cutter. If the
cutter does not
drop after
replaced, replace
the cutter holder.
→ Replacing the
cutter holder, cutter
spring, cutter cap,
solenoid assembly
and solenoid
spring.
Troubleshooting
10 AP-74700 – Rev. 1.0 – 10/03/2008
(5) Check the up and
down operation of
the solenoid via
“Life/Cutter” of the
self-diagnostic
function.
a) The solenoid
moves up and down:
Check the cutter’s
down position
relative to the cutter
groove.
b) It does not move
up and down.
• OK: The cutter’s
service life is
reached or it is
damaged.
Replace the
cutter.
NG: Adjust the
position of the cutter
holder.
• The connectors
may have poor
contacts.
• Check the
connections of
the following
connectors :
CR board : J235
CR board : J201 –
J216
Mainboard : J137 –
J152
→ Please refer to
the User’s Guide
→ Cutter
adjustment
→ Replacing the
CR board
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
(6) Open CR cable,
faulty solenoid
assembly, faulty
board assembly,
etc., may be the
cause.
• Replace the
Flatcables.
• Replace the
solenoid
assembly
• Replace the CR
board assembly
• Replace the
Mainboard
assembly.
• Replacing the
steel bearer,
tube guide, CR
tapes power
cable and ink
tube.
• Replacing the
cutter holder,
cutter spring,
cutter cap,
solenoid
assembly and
solenoid spring
• Replacing the
CR board
assembly
• Replacing the
Mainboard
assembly,
HDD_Extensio
n board
assembly,
HEAD_DRV
board
assembly and
cooling fan
assembly.
4 End of Roll Displayed when the
end of the roll paper is
detected during the
use of roll paper. This
is released when the
lever has been set to
(1) Check if the
message is still
displayed after
turning the power off
and then back on
again.
If the message is
displayed : go to
step (2)
Troubleshooting
11 AP-74700 – Rev. 1.0 – 10/03/2008
(2) Check the
P_REAR sensor
assembly for the
contact condition.
• Redo the
connections of
Mainboard
assembly
connectors J128
and J129. If the
paper is not
initialized, the
sensor may be
damaged.
• Replace the
P_REAR sensor
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
→ Replacing the
P_REAR_R sensor
assembly and
P_REAR_L sensor
assembly.
the up position.
(3) The Mainboard
may be damaged.
• Replace the
Mainboard
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
(1) Check the ink
end via “Test:
Sensor” of the selfdiagnostic function.
• Operate the lever
at the end
detecting element
of the ink sensor
assembly to
check if the ink
end indication
changes. (At this
time, the sensor
for detecting the
presence of
cartridges is set
to Yes.) If there is
no response,
replace the ink
sensor assembly.
→ Sensor menu
→ Replacing the I/H
(ink holder)
assembly
5
6
[ ] Near End
[ ] Ink End
The remaining amount
of ink is low. Printing
is still possible.
There is no more ink
left. Printing in
progress is interrupted
immediately.
(2) Check the ink
sensor connector for
the contact
conditions.
• Redo the
connections of
the following
connectors.
• Junction board :
J401 – J418
• Mainboard : J133
– J134
• Replacing the
Junction board
assembly.
(1) Check the ink
end ID via “Test:
Sensor” of the selfdiagnostic function.
(This is limited to
when smart chips
are set.)
• If the type of the
installed cartridge
does not match
the displayed
type, the ink ID
sensor may be
damaged.
• Sensor menu
7 Not Original Ink
(2) Check the ink ID
sensor connector for
the contact
conditions.
• Redo the
connections of
the following
connectors
• Junction board :
J401 – J418
• Mainboard : J133
– J134
→ Replacing the
JUNCTION board
assembly.
Troubleshooting
12 AP-74700 – Rev. 1.0 – 10/03/2008
(3) The Mainboard
may be damaged.
• Replace the
Mainboard
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
(1) Check if the
message is still
displayed after
turning the power off
and then back on
again.
• When a message
is displayed : Go
to step (2)
-
(2) The amount of
waste ink inside the
tank reached the
specified level.
• Dispose of the
waste ink in the
waste bottle.
-
8 Warning Waste
INK Tank
The waste tank will
soon be full.
(3) If initialization
does take effect
when the waste ink
is disposed of and
waste ink history is
initialized, the
Mainboard may be
damaged.
• Replace the
Mainboard
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
(1) Check if the
message is still
displayed after
turning the power off
and then back on
again.
• When a message
is displayed : Go
to step (2)
-
(2) The number of
times the ink tube
was used reached
the maximum
allowable times.
• Replace the ink
tube.
• Initializing CR
motor history.
→ Replacing the
steel bearer, tube
guide, Flatcable
and ink tube.
9 Warning Waste
INK Tank
The service life of the
ink tube will soon be
reached.
(3) If initialization
does take effect
when the CR motor
history is initialized
after the ink tube is
replaced, the
Mainboard may be
damaged.
• Replace the
Mainboard
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
(1) Check if the
message is still
displayed after
turning the power off
and then back on
again.
• When a message
is displayed :
refer to step (2)
10 (Warning Head
Life)
The service life of the
print head will soon be
reached.
(2) The number of
times the print head
was used reached
the maximum
allowable times.
• Replace the print
head assembly.
• Initialize the head
unit.
→ Replacing the
print head
assembly and head
tape power cable.
→ Counter
initialization menu.
Troubleshooting
13 AP-74700 – Rev. 1.0 – 10/03/2008
(3) If initialization
does not take effect
when the head unit is
initialized, the
Mainboard assembly
may be damaged.
• Replace the
Mainboard
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly
(1) Check the
connections of
connectors.
• Redo the
connections of
the following
connectors.
• Mainboard : J102
• power source
board (small)
assembly : CN51
– CN52
(2) The
HDD_MOTHER
board assembly may
be damaged.
• Replace the ink
tube.
• Initializing CR
motor history.
(3) Hard disk may be
damaged.
• Replace the hard
disks.
11 Hard disk status
connect error
There is a problem in
the hard disk
connections.
(4) The Mainboard
assembly may be
damaged.
• Replace the
Mainboard
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
→ Replacing the
power source board
assembly.
(1) The PCI_LINUX
board assembly may
be damaged.
• Replace the
PCI_LINUX board
assembly.
12 Network
initialize error
There is a problem in
the network board.
(2) The Mainboard
assembly may be
damaged.
• Replace the
Mainboard
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
(1) Check if the
waste bottle has
been installed.
• Install the waste
bottle correctly.
-
(2) Check the
operation of the
waste box sensor
assembly via
“Sensor/Waste Bin”
of the self-diagnostic
function.
• Replace the
waste box sensor
assembly.
-
(3) Check the
connections of the
connectors.
• Check if the
waste box sensor
connectors are
connected to the
rear side cap R.
• Redo the
connections of
the following
connectors.
• Mainboard : J120
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
13 Waste ink tank
sts. No
The waste tank is not
installed.
(4) The Mainboard
assembly may be
damaged.
• Replace the
Mainboard
assembly.
→ Replacing the
Mainboard
assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
Troubleshooting
14 AP-74700 – Rev. 1.0 – 10/03/2008
1.3 HEATING SYSTEM ERROR
Heating system errors are displayed when communication trouble occurs between the heater strips and this
product.
If heating system error occurs, the following error messages are displayed and the printer stops.
Solve the problem to delete the error message and restart the printer.
No Message Check point Action
1 AC not present AC connector. Check AC connector
2 Error sensors A Sensors A Check if the sensors are connected properly.
3 Error sensor A Sensor A Check if the sensors are connected properly.
4 Conn. err. Left A Sensor A Check if the left sensor is connected properly.
5 Conn. err. Right A Sensor A Check if the right sensor is connected properly.
6 Error sensors D1 Sensors D1 Check if the sensors are connected properly.
7 Error sensor D1 Sensor D1 Check if the sensors are connected properly.
8 Conn. err. Left D1 Sensor D1 Check if the left sensor is connected properly.
9 Conn. err. Right D1 Sensor D1 Check if the right sensor is connected properly.
10 Error sensors D2 Sensors D2 Check if the sensors are connected properly.
11 Error sensor D2 Sensor D2 Check if the sensors are connected properly.
12 Conn. err. Left D2 Sensor D2 Check if the left sensor is connected properly.
13 Conn. err. Right D2 Sensor D2 Check if the right sensor is connected properly.
14 Couldn't reach temp Heater strip After 10 minutes, temperature is not reached. Check
the heater strips.
15 Err: Temp > 85°C! Heater strip Temperature comes higher then the limit. Check the
heater strips.
16 Connection err. A Rear Heater (A) Check the connector of the rear heater.
17 Connection err. D1 Dryer (D1) Check the connector of the front heater (D1).
18 Connection err. D2 Dryer (D2) Check the connector of the front heater (D2).
19 Error sensor B1 Fixer (B1) Check the sensor of the fixer 1 (B1).
20 Error sensor C Post fixer (C) Check the sensor of the fixer (C).
21 Connection err. B1 Fixer (B1) Check the connector of the fixer 1 (B1).
22 Connection err. C Post fixer (C) Check the connector of the post fixer (c).
23 Error sensor B2 Fixer (B2) Check the sensor of the fixer 2 (B2)
24 Connection err. B2 Fixer (B2) Check the connector of the fixer 2 (B2).
25 Error D group Heaters D Temperature difference higher than 15°C between
the sensors of the D heaters.
26 Error A group Heaters A Temperature difference higher then 15°C between
the sensors of the A heaters.
27 Error B group Heaters B Temperature difference higher then 15°C between
the sensors of the B heaters.
Important
• Before checking the connectors, please power off the unit and remove the power cable.
Notes
• Check if the connectors are properly connected to the power board.
• Check if the sensors are connected onto the right connector.
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