MUTOH Rockhopper II, Rockhopper II 2H, Rockhopper II 4H Maintance Manual

Maintenance Manual

MUTOH EUROPE N.V.

AP-74065, Rev 1.2: , 27/09/2004

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AP-74065, Rev. 1.2, 27/09/04

MUTOH INDUSTRIES LTD.
Tel.:[phone]
Fax.:[phone]
E-mail:[e-mail]
http://www.mutoh.co.jp

MUTOH EUROPE N.V.
Tel.:[phone]
Fax:[phone]
E-mail:[e-mail]
http://www.mutoh.be

MUTOH DEUTSCHLAND GmbH.
Tel.:[phone]
Fax.:[phone]
E-mail:[e-mail]

MUTOH AMERICA INC.
Tel.: [phone]
Fax: [phone]
E-mail:[e-mail]
http://www.mutoh.com

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AP-74065, Rev. 1.2, 27/09/04

COPYRIGHT NOTICE

COPYRIGHT © 2004 Mutoh Europe N.V. All rights reserved.

This document may not be reproduced by any means, in whole or in part, without written permission of the
copyright owner.

This document is furnished to support the Mutoh’s Rockhopper II series Printer. In consideration of the
furnishing of the information contained in this document, the party to whom it is given, assumes its custody
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.

September 2004
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, Rockhopper II, Eco-Solvent Plus, 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 Note .............................................................................................. 15

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

1.3.1. Warning......................................................................................................................................... 15

1.3.2. Caution.......................................................................................................................................... 16

1.4. Warning labels ..................................................................................................................... 17

1.4.1. Handling the operation procedure labels...................................................................................... 17

1.4.2. Locations and types of operation procedure labels ...................................................................... 17

1.5. Operation procedure labels.................................................................................................. 20

2. Product Overview ........................................................................................................21

2.1. Introduction .......................................................................................................................... 21

2.2. Features............................................................................................................................... 21

2.3. Part names and functions .................................................................................................... 22

2.3.1. Front.............................................................................................................................................. 22

2.3.2. Back .............................................................................................................................................. 23

2.3.3. Operation panel ............................................................................................................................ 24

2.4. Printer status........................................................................................................................ 26

2.4.1. Normal........................................................................................................................................... 26

2.4.2. Setup menu display ...................................................................................................................... 26

2.4.3. Self-diagnosis Function Display.................................................................................................... 26

2.4.4. Maintenance Mode Display .......................................................................................................... 26

2.4.5. Selecting Language ...................................................................................................................... 27

2.5. Position and function of the heating elements ..................................................................... 28

2.5.1. Rockhopper II 2 heater printers .................................................................................................... 28

2.5.2. Rockhopper II 4 heater printers .................................................................................................... 28

2.5.3. 2 or 4 heater.................................................................................................................................. 29

3. Specifications ..............................................................................................................31

3.1. Introduction .......................................................................................................................... 31

3.2. Product Specifications ......................................................................................................... 31

3.3. Interface Specifications........................................................................................................ 33

3.3.1. Centronics Bidirection Parallel Interface:IEEE1284) .................................................................... 33

3.3.2. Network Interface (Optional) Specifications.................................................................................. 34

3.4. Installation............................................................................................................................ 35

3.4.1. Conditions of the installation environment.................................................................................... 35

4. Parts Replacement ......................................................................................................37

4.1. Introduction .......................................................................................................................... 37

4.2. Removing the cover ............................................................................................................. 38

4.2.1. Removing the I/H cover ................................................................................................................ 39

4.2.2. Removing side cover R................................................................................................................. 40

4.2.3. Removing side cover L ................................................................................................................. 42

4.2.4. Removing the front cover.............................................................................................................. 44

4.2.5. Removing the carriage cover........................................................................................................ 46

4.2.6. Removing the panel unit assembly............................................................................................... 47

4.2.7. Removing the Y rail cover............................................................................................................. 48

4.2.8. Removing front paper guide ......................................................................................................... 50

4.2.9. Removing rear paper guide .......................................................................................................... 52

4.2.10. Removing the head cover........................................................................................................... 53

4.2.11. Removing the maintenance cover .............................................................................................. 54

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4.3. Replacement of the heater element..................................................................................... 55

4.3.1. Rockhopper II 2 heaters : Heater elements.................................................................................. 55

4.3.2. Rockhopper II 4 heaters : Heater elements.................................................................................. 59

4.4. Replacing Board Bases........................................................................................................ 65

4.4.1 Replacing the Mainboard assembly, HDD_Extension board assembly, HEAD_DRV board

assembly, PCI_Linux board assembly and cooling fan assembly.......................................................... 65

4.4.2. Replacing the power source board assembly............................................................................... 70

4.4.3. Replacing the inlet assembly, inlet board assembly and lever foot SW cable assembly............. 72

4.4.4. Replacing the JUNCTION board assembly .................................................................................. 73

4.5. Replacing the PF Actuator ................................................................................................... 74

4.5.1. Replacing the PF motor assembly................................................................................................ 74

4.5.2. Replacing the PF_ENC assembly and PF scale assembly.......................................................... 75

4.5.3. Replacing the PF deceleration pulley assembly........................................................................... 76

4.5.4. Replacing the PF deceleration belt............................................................................................... 77

4.5.5. Replacing the P_REAR_R sensor assembly and P_REAR_L sensor assembly ......................... 78

4.5.6. Replacing the suction fan assembly ............................................................................................. 79

4.5.7. Replacing the lever motor assembly and the arm motor installation board.................................. 80

4.5.8. Replacing the transmission photosensor...................................................................................... 82

4.5.9. Replacing the flushing box assembly ........................................................................................... 84

4.6. Replacing the CR Actuator................................................................................................... 85

4.6.1. Replacing the CR motor assembly ............................................................................................... 85

4.6.2. Replacing the steel belt................................................................................................................. 86

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

board ....................................................................................................................................................... 88

4.6.4. Replacing the T fence................................................................................................................... 89

4.6.5. Replacing the CR slave pulley assembly...................................................................................... 91

4.6.6. Replacing the CR actuator pulley and the CR deceleration belt .................................................. 92

4.6.7. Replacing the steel bearer, tube guide, CR tape power cable and ink tube ................................ 93

4.6.8. Replace the cover R sensor assembly and the cover L sensor assembly................................... 95

4.7. Replacing the Cursor ........................................................................................................... 96

4.7.1. Replacing the cutter holder, cutter spring, cutter cap, solenoid assembly and solenoid spring... 96

4.7.2. Replacing the print head assembly and head tape power cable.................................................. 98

4.7.3. Replacing the H ink tube, tube branch and damper assembly................................................... 100

4.7.4. Replacing the CR board assembly ............................................................................................. 101

4.7.5. Replacing the CR_ENC assembly.............................................................................................. 103

4.7.6. Replacing the P_EDGE sensor assembly .................................................................................. 104

4.7.7 Replacing black tape on platform ............................................................................................... 105

4.7.8. Replacing the CR cursor assembly ............................................................................................ 107

4.7.9. Replacing the cursor roller assembly.......................................................................................... 108

4.8. Replacing the Maintenance Area....................................................................................... 112

4.8.1. Replacing the maintenance assembly ........................................................................................ 112

4.8.2. Replacing the wiper and wiperarm ............................................................................................. 115

4.8.3. Replacing the SLIDE motor assembly (wiper arm)..................................................................... 118

4.8.4. Replacing the transmission photosensor (wiper home position and maintenance home position)

.............................................................................................................................................................. 119

4.9. Replacing the Pump Area .................................................................................................. 120

4.9.1. Replacing the pump assembly.................................................................................................... 120

4.9.2. Replacing the pump assembly.................................................................................................... 121

4.9.3. Replacing the pump motor assembly ......................................................................................... 122

4.10. Replacing the Cartridge Area........................................................................................... 123

4.10.1. Replacing the I/H (ink holder) assembly ................................................................................... 123

4.11. Replacing Supports and Scroller...................................................................................... 127

4.11.1. Replacing the waste fluid bottle assembly (Rockhopper II 2H) ................................................ 127

4.11.2. Replacing the waste fluid bottle assembly (Rockhopper II 4H) ................................................ 128

4.11.3. Replacing the waste bottle box sensor assembly (RH II 2H) ................................................... 129

4.11.4. Replacing the waste bottle box sensor assembly (RH II 4H) ................................................... 131

4.11.5. Replacing the scroller R assembly ........................................................................................... 133

4.10.6. Replacing the scroller L assembly ............................................................................................ 135

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5. Self-Diagnosis Function............................................................................................137

5.1. Introduction ........................................................................................................................ 137

5.2. Preparation ........................................................................................................................ 137

5.2.1. Preparations on Machine............................................................................................................ 137

5.2.2. Starting Up .................................................................................................................................. 138

5.3. Operations in Self-Diagnosis Mode.................................................................................... 139

5.3.1. Operating Self-Diagnosis Mode.................................................................................................. 139

5.3.2. Diagnosis Items in Self-Diagnosis Menu .................................................................................... 141

5.4. Test / Inspection Menu....................................................................................................... 142

5.4.1. RAM Capacity Menu ................................................................................................................... 143

5.4.2. Version Menu.............................................................................................................................. 143

5.4.3. Operation Panel Menu................................................................................................................ 144

5.4.4. Sensor Menu............................................................................................................................... 145

5.4.5. Encoder Menu............................................................................................................................. 146

5.4.6. Fan Menu.................................................................................................................................... 147

5.4.7. History Menu............................................................................................................................... 147

5.4.8. Head Signal Menu ...................................................................................................................... 149

5.5. Adjustment Menu ............................................................................................................... 150

5.5.1. Skew Check Menu ...................................................................................................................... 151

5.5.2. Head rank input menu................................................................................................................. 152

5.5.3 Head Nozzle Check Menu .......................................................................................................... 153

5.5.4. Head Slant Check Menu............................................................................................................. 155

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 ................................................................................................. 185

5.9.1. CR Motor Endurance Menu ........................................................................................................ 186

5.9.2. PF Motor Endurance Menu......................................................................................................... 187

5.9.3. Cutter Endurance menu.............................................................................................................. 188

5.9.4. Head Up/Down Endurance Menu............................................................................................... 189

5.9.5. Head Lock Endurance menu ...................................................................................................... 190

5.9.6. Pump Endurance menu .............................................................................................................. 191

5.9.7. Lever Motor Endurance Menu .................................................................................................... 192

5.9.8. Sequential Printing Endurance Menu ......................................................................................... 193

5.9.9. General Endurance Menu........................................................................................................... 194

5.9.10. Endurance Running Check Menu............................................................................................. 195

5.10. Head Lock Menu.............................................................................................................. 196

5.11. Heater System menu ....................................................................................................... 197

5.11.1. Heater Status Menu.................................................................................................................. 197

5.11.2. Heater Temperature Menu ....................................................................................................... 197

5.11.3. Heater Test 30 Menu ................................................................................................................ 198

5.11.4. Heater Test 50 Menu ................................................................................................................ 198

5.11.5. Heater Test Max Menu ............................................................................................................. 198

5.11.6. Heater Version Menu................................................................................................................ 199

5.11.7. Heater Adjust Menu .................................................................................................................. 199

5.12. Eco Prepare menu ........................................................................................................... 200

5.13. Machine size select menu................................................................................................ 201

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6. Maintenance Mode.....................................................................................................203

6.1. Introduction ........................................................................................................................ 203

6.2. Operating Maintenance Mode............................................................................................ 203

6.2.1. Starting Up Maintenance Mode .................................................................................................. 203

6.2.2. Operating Maintenance Mode .................................................................................................... 203

6.3. Maintenance Menu ............................................................................................................ 204

6.3.1. Counter Display Menu ................................................................................................................ 204

6.3.2. Counter Initialization Menu ......................................................................................................... 206

6.3.3. MAC address write enable menu................................................................................................ 207

6.3.4 Head Voltage ............................................................................................................................... 208

7. Adjustments ...............................................................................................................209

7.1. Introduction ........................................................................................................................ 209

7.2. Adjustment ......................................................................................................................... 209

7.3. Parameter backup.............................................................................................................. 212

7.3.1. Tools required for work ............................................................................................................... 212

7.3.2. Procedure for creating backup parameters ................................................................................ 213

7.3.3. Backup parameter installation procedure ................................................................................... 214

7.4. Firmware installation .......................................................................................................... 215

7.4.1. Tools required for work ............................................................................................................... 215

7.4.2. Installation procedure.................................................................................................................. 215

7.5. Steel belt tension adjustment............................................................................................. 218

7.5.1. Tools required for work ............................................................................................................... 218

7.5.2. Adjustment Procedure ................................................................................................................ 218

7.6. PF deceleration belt tension adjustment............................................................................ 220

7.6.1. Tools required for work ............................................................................................................... 220

7.6.2. Adjustment Procedure ................................................................................................................ 220

7.7. Head precision adjustment (slant)...................................................................................... 221

7.7.1 Head slant adjustment ................................................................................................................. 221

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

7.8. Repeatability Adjustment (Bi-Directional)........................................................................... 230

7.9. CW adjustments (Uni-Directional)...................................................................................... 231

7.10. CR deceleration belt tension adjustment ......................................................................... 232

7.10.1. Tools required for work ............................................................................................................. 232

7.10.2. Adjustment Procedure .............................................................................................................. 232

7.11. Cover sensor adjustment ................................................................................................. 233

7.12. Head height adjustment ................................................................................................... 234

7.12.1. Tools required for work ............................................................................................................. 234

7.12.2. Adjustment Procedure .............................................................................................................. 234

7.13. Media sensor sensitivity adjustment ................................................................................ 236

7.13.1. Tools required for work ............................................................................................................. 236

7.13.2. Adjustment Procedure .............................................................................................................. 236

7.14. Cutter adjustment............................................................................................................. 239

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

7.15.1 Pump tubing layout - Rockhopper 4 heater ............................................................................... 240

7.15.2. Pump tubing layout - Rockhopper 2 heater .............................................................................. 243

7.16. Board checklist................................................................................................................. 248

7.16.1. Power supply board. ................................................................................................................. 248

7.16.2. Control board. ........................................................................................................................... 249

7.16.3. Power board.............................................................................................................................. 250

7.16.4. Heater Elements ....................................................................................................................... 250

7.16.5. Checklist ................................................................................................................................... 252

7.17 Flushing box height position adjustment........................................................................... 253

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8. Maintenance ...............................................................................................................257

8.1. Introduction...................................................................................................................................... 257

8.2. Cleaning............................................................................................................................. 258

8.3. Periodical Services ............................................................................................................ 259

8.3.1. Service by end-user .................................................................................................................... 259

8.3.2. Service by authorised Mutoh technician ..................................................................................... 260

8.4. Part Life Information........................................................................................................... 261

8.5. Jig and Tool List................................................................................................................. 262

8.5.1. Required Tools............................................................................................................................ 262

8.6. Lubrication/Bonding ........................................................................................................... 263

8.7. Transportation of Machine ................................................................................................. 265

9. Troubleshooting ........................................................................................................267

9.1. Introduction ........................................................................................................................ 267

9.2. Troubleshooting procedures when a message has been displayed .................................. 267

9.2.1. Operating condition display ........................................................................................................ 268

9.2.2. Message type errors ................................................................................................................... 270

9.2.3. Heating system error................................................................................................................... 277

9.2.4. Data error.................................................................................................................................... 278

9.2.5. Command errors......................................................................................................................... 279

9.2.6. Errors requiring restart................................................................................................................ 280

9.3. Troubleshooting procedures when errors are not displayed.............................................. 291

9.3.1. Problems relating to initial operation........................................................................................... 291

9.3.2. Problems relating to paper feed.................................................................................................. 296

9.3.3. Problems relating to the printing operation................................................................................. 297

9.3.4. Problems relating to noise .......................................................................................................... 309

9.3.5. Problems relating to the paper cutting operation........................................................................ 311

9.3.6. Problems relating to online and functions................................................................................... 314

9.3.7. Other problems ........................................................................................................................... 316

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

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

10.2. Wiring Diagram Rockhopper II 2H ................................................................................... 317

10.3. Wiring Diagram Rockhopper II 4H ................................................................................... 318

10.4. Rockhopper II : Service Parts List/Exploded Views/Configuration Diagrams .................. 318

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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 NOTE

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.

Note 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.

1.3.1. Warning

¾ Do not place the printer in following areas. Doing so may result in the printer falling over and causing

injury.

 Angled place.
 Areas subject to vibration by other equipment.
 Do not stand on the printer or place heavy objects on the printer.

¾ Do not sit on the printer. Doing so may cause the printer to fall and injure people.

¾ Do not cover the ventilation hole of the 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 Be sure that the following is performed before replacing parts.

 Turn the printer off.
 Disconnect the power cable from the electric outlet. Not doing so may cause electric shock or

damage to the electric circuit.

 Unplug the cables connected to the printer.

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1.3.2. Caution

¾ Assembling and disassembling the printer are possible only for the parts shown in the operation manual.

Do not disassemble any frame parts or parts of which disassembling procedures are not shown in the
manual. Doing so may cause trouble that cannot be restored, as the printer is originally assembled in
the factory with a high accuracy of 1/100 mm.

¾ Do not touch the elements on the circuit board with bare hands. Doing so may cause static electricity

and break the elements.

¾ Do not press down the transparent film on the sides of the damper assembly with your hands. The

damper assembly is filled with ink and pressing on the film will make the ink spurt out.

¾ Be careful not to scratch the transparent film on the sides of the damper assembly.

¾ Be careful not to touch the surface of the print head’s nozzles or to let dirt adhere to them.

¾ There is some remaining ink in the tubes. Be careful that the ink is not spilled from the tube onto the

printer or objects close to the printer.

¾ If you need to operate the printer with the cover removed for maintenance, be careful not to get hurt by

the moving parts.

¾ Do not oil the printer mechanism with oil other than the oil designated by MUTOH. Doing so may

damage the parts or shorten the lifetime.

¾ If the power substrate assembly needs to be removed, disconnect the power cable and wait for at least 5

minutes before taking it out. This will discharge the residual electrical charge of the electrolytic capacitor.
Touching the substrate before the capacitor discharges may cause electric shock.

¾ When connecting or disconnecting the FFC type cable from the connector of the main substrate

assembly, be sure to connect or disconnect the cable straight out from the connector. Connecting or
disconnecting at a slant angle may damage, break or short-circuit the inner terminal of the connector.
That may damage the elements on the substrate.

¾ When connecting or disconnecting the FFC type cable from the connector of the CR substrate, be sure

to connect or disconnect the cable straight out from the connector. Connecting or disconnecting at a
slant angle may damage, break or short-circuit the inner terminal of the connector. That may damage
the elements on the substrate.

¾ Before replacing parts, be sure to adjust the capping position. When the capping position adjustment

has not been implemented, the cleaning position and other operational positions can exit the alignment
and normal operations become impossible.

¾ Pay attention to the following points when performing the cutter endurance operation.

 Install an available ink cartridge.
 Make sure that media initialization has been completed.

¾ Make sure that the power of the printer is OFF before performing the parameter backup. Performing the

parameter backup with the power ON may damage the main substrate or data may not be properly
installed.

¾ Make sure that the power of the printer is OFF before installing the firmware. Installing the firmware with

the power ON may damage the main substrate assembly or data may not be properly installed.

¾ Ensure there is sufficient space around the printer when performing maintenance work.

¾ Maintenance must be done by more than one person for :

 detaching the printer from the stand or attaching it.
 packing the printer for transportation.

¾ Be sure to directly clean when spoiling RH Cleaning Liquid. Because this liquid could damage the paint.

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1.4. WARNING LABELS

The handling, attachment locations, and types of warning labels are explained below.
Warning labels are attached to areas to which attention should be paid. Read and understand the positions
and contents thoroughly.

1.4.1. Handling the operation procedure labels

Notes :

¾ Make sure that all labels can be recognized. If text or illustrations are invisible,

clean or replace the label.

¾ When cleaning labels, use a cloth with water or neutral detergent. Do not use a

solvent or gasoline.

¾ If a warning label has been damaged, lost or cannot be recognized, replace the

label.

1.4.2. Locations and types of operation procedure labels

The locations of warning labels are shown below.

(1) Front Part

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No. Type

1

CAUTION VORSICHT ATTENTION

> Do not open the front cover or touch the media during printing.This will result in poor image quality.

> If no printing is to be done for some time, remove the media and put the hold lever in the up

 position. Otherwise the media may lift up and become wrinkled and you will not be able to obtain

 good printing results.


> Öffnen Sie wärhend des Druckens die Frontabdeckung nicht und berü hren Sie das

 Druckmaterial nicht.

> Wenn Sie wärhend lä ngere Zeit den Drucker nicht benutzen, nehmen Sie das Druckmaterial

 heraus und stellen Sie den Halthebel in die obersten Position. Sonst kann sich das Druckmaterial

 aufheben und zerknittern und demzufolge erzielen Sie keine gute Druckergebnisse mehr.



> N'ouvrez pas le couvercle quand l'imprimante est en train d'imprimer. Ne touchez pas non plus

le papier afin d'éviter que la qualité  s'aggrave.

> Si vous ne comptez pas imprimer pendant un certain temps, retirez le papier et mettez le levier

en position levé e. Sinon, le support risque de se soulever et de se froisser et vous n'obtiendrez
pas de bonne qualité d'impression.

2 Only on a Rockhopper II 2H printer

CAUTION VORSICHT ATTENTION

> To avoid injury, keep fingers away from the

 cutter blade.


> Um Verletzungen zu vermeiden, berü rhen Sie das

 Schneidemesser nicht.



> Ne touchez pas la lame afin d'éviter des blessures.

> To avoid injury, do not touch the edge of the

 steel belt.


> Um Verletzungen zu vermeiden, berü hren Sie den

 Stahl-Antriebsriemen nicht .



> Ne touchez pas la courroie de transmission en

acier afin d'éviter des blessures.

A Only on a Rockhopper II 4H printer

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(2) Back Part

No. Type

3

CAUTION

THIS UNIT HAS TWO POWER SUPPLY CORDS
STANDARD. TO REDUCE THE RISK OF ELECTRICAL
SHOCK, DISCONNECT ALL POWER SUPPLY CORDS
BEFORE SERVICING.

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1.5. OPERATION PROCEDURE LABELS

The handling, attachment locations and types of operation procedure labels are explained below.
Your printer has labels, which give simple explanations of operations that require particular care. Read and
understand the locations and contents of these labels thoroughly before performing your work.

No. Type Refer to

6

Yellow

Magenta

Cyan

Black

Transition

Magenta

Liquid

 Light

Magenta

Light

Cyan

Magenta

Cyan

Yellow

Yellow

Black

Ink Type

Slot Number of Ink Cartridge

1

2

3

4

56

7

8



Number



of the
Colours

4

6

Eco Solvent

2x4 colours

Eco Solvent

1x6 colours

Black

Transition

Liquid

Cyan

Æ Refer to the User’s
Guide “Installing ink
cartridges”

Please note that ink
cassettes order is different
for 87” printers versus 50”
and 64” printers.

(Label 50” and 64” printer)

6

Yellow

Black

Magenta

Cyan

Black

Transition

Magenta

Liquid



Light
Magenta



Light
Cyan

Cyan

Cyan

Yellow

Yellow

Black

Ink Type

Slot Number of Ink Cartridge

1

2

3

4

56

7

8

Number

 of the

Colours

4

6



Eco Solvent
2x4 colours



Eco Solvent
1x6 colours

Transition

Liquid

Magenta

Æ Refer to the User’s
Guide “Installing ink
cartridges”

Please note that ink
cassettes order is different
for 87” printers versus 50”
and 64” printers.

(Label 87” printer)

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2. PRODUCT OVERVIEW

2.1. INTRODUCTION

This chapter explains the features, part names, and functions of the printer.

2.2. FEATURES

The features of the printer are explained below.

(1) High speed output

Both models feature new print heads and achieve high speed printing.
They also offer printing widths up to 1263 mm in 50-inch, 1643 mm in 64-inch and 2230 mm in 87-inch spec
possible.

(2) Wide variety of compatible media

Adjustable head height can adapt to various media thickness from 0.08 up to 1.1 mm.

(3) Vibrant Colour Reproduction

To reproduce sharp and vivid colour, 4, 6 and 8 ink colours are used for printing. The 220ml large
capacity ink tank is equipped with an IC chip. This unit can automatically detect the ink quantity,
significantly improving productivity.

(4) Effective usage of media

A JOG feature is provided to allow setting of the printing position as required. Because printing
can be performed on media on which was already printed, excess space can be used effectively.

(5) RIP

Software Starter Pack included in-the-box. (To be defined with the order.)

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2.3. PART NAMES AND FUNCTIONS

Part names and functions are explained below.

2.3.1. Front

No. Name Function

1 Operation panel This panel is used to set operational conditions, the status of the printer,

and other functions.
2 Ink compartment This is the place for installing ink cartridges.
3 Front cover This cover keeps the operator safe from the drive parts of the printer

while it is operating. Only open and/or close the cover to perform

following operations:

¾ Media setting and replacement

¾ Cutter blade replacement

¾ Cleaning the cleaning wiper

¾ In case of media jam.

4 Pressure rollers This roller is used to press the media from above and keep it flat when

printing.
5 Maintenance cover This protects users from electric shocks caused by touching the internal

electrical parts. The cover is opened when expansion memory

(optional) has to be installed, and is closed for normal use.
6 Stand This stand is used to install the printer on a surface flat floor.

The following options are available for installation.

¾ Take-up system + scroller receiver

¾ Motorized roll-off / roll-up system

7 Media cut groove Only onto the Rockhopper II 4H printer !

Used to cut the media straight when it is cut manually.
8 Carriage cover Only onto the Rockhopper II printer !

This is a cover to protect the user from the internal components of the

unit. This is opened during following operation :

¾ When cleaning the cleaning wiper
9 Foot switch This switch is used to raise and lower the pressure rollers.
10 Paper Guide Support the media during printing

In the Rockhopper II it houses post-heater (dryer).

In the Rockhopper II 4H it houses the fixer, post-fixer and dryer.

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2.3.2. Back

No. Name Function

1 AC inlet This is the inlet interface to which the power plug is connected.
2 Interface connector This is the connector to which the interface cable is connected.
3 Foot switch connector This is the connector to which the foot switch cable is attached.
4 Insertion slot This is the slot for inserting media when loading it.
5 Interface slot 1 The network interface board attaches here.
6 Interface slot 2
7 Interface slot 3

This is not used for this printer.

Close it with the cover.

8 Hard disk slot The hard disk attaches here. When not using a hard disk, keep the

cover closed.

9 Nameplate rating The type, name, serial number, rating and other details of the printer are

labelled here.

10 Rear Heater Supports the media during printing and houses the pre-heaters.

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2.3.3. Operation panel

The operation panel is used to set operation conditions, display the status of the printer and set other
functions.
The names and functions of the operation keys and status lamps are explained below.

(1) Operation Keys.

No. Name Normal Setup menu display

1 [POWER] key Turns the printer on and off. Turns the printer on and off.
2 [F1] key Executes the function assigned to F1. Executes the function assigned to F1.
3 [F2] key Executes the function assigned to F2. Executes the function assigned to F2.
4 [F3] key Executes the function assigned to F3. Executes the function assigned to F3.
5 [F4] key Executes the function assigned to F4. Executes the function assigned to F4.
6

[MENU ↑] key

Changes the LCD monitor display to
setup menu status.

Changes the menu in reverse order.

7

[MENU ↓] key

Changes the LCD monitor display to
setup menu status.

Changes the menu in forward order.

8 [ENTER] key Displays the print mode currently set. Determines the new parameter value and

changes the LCD monitor display to the
next menu. Sets the parameter value and
changes the LCD monitor display to the
next menu.

9 [CANCEL] key - Cancels the new parameter value and

changes the LCD monitor display to the
next menu. Clears the parameter value
and changes the LCD monitor display to
the next menu.

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(2) LCD monitor and status lamps.

No. Name Colour Status Function

10 LCD monitor - - The monitor displays the operation status and error

messages of the printer.
ON The printer is on. 11 POWER lamp Green
OFF The printer is off.
Flashing An error has occurred. The contents will be displayed on

the LCD monitor.

12 ERROR lamp Red

OFF Either there is no error or the power is off.
ON The printer is receiving print data.
Flashing The printer is analysing receiving data.

13 DATA lamp Orange

OFF The printer is waiting to receive print data.
ON ¾ The pressure rollers are in the release position.

¾ Media is not set.

14 MEDIA SET lamp Orange

OFF ¾ The pressure rollers are in secured position.

¾ The media is set.
ON The media type is set to roll media. 15 ROLL lamp Orange
OFF The media type is set to sheet media.
ON The media type is set to sheet media. 16 SHEET lamp Orange
OFF The media type is set to roll media.
ON The temperature of the heating elements is the requested

temperature.

The real temperature is the same as the requested

temperature.
Flashing The heating elements are warming up.

The real temperature is different as the requested

temperature.

17 HEATER lamp Orange

OFF The heating elements are powered OFF.

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2.4. PRINTER STATUS

The status of the printer is explained below.

2.4.1. Normal

Indicates that the printer can print when media is loaded.
You can also make settings using the operation panel.

Notes :

¾ Refer to the User’s Guide.

2.4.2. Setup menu display

Indicates that you can make settings using the operation panel.
Operations for printing can be conducted with the operation panel.

Notes :

¾ Refer to the User’s Guide.

2.4.3. Self-diagnosis Function Display

Indicates that you can make settings concerning adjusting the printer using the operation panel. Keys of the
operation panel have the same names and functions as the display status of the setup menu.

Notes :

¾ Refer to the chapter “Self-Diagnosis function”.

2.4.4. Maintenance Mode Display

Indicates that you can make settings concerning the life of the printer. Keys of the operation panel have the
same names and functions as the display status of the setup menu.

Notes :

¾ Refer to the chapter “Maintenance mode”.

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2.4.5. Selecting Language

This chapter explains how to select the language on the display.
Japanese or English is selectable for the display language of the printer.

Follow the steps below to select the display language.

Step 1 : Press the [POWER] key while pressing the [CANCEL] key on the operation panel.

Step 2 : Press the [F1] key or [F2] key on the operation panel to change the parameter.

Step 3 : Press the [POWER] key, and then press the [POWER] key again.

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2.5. POSITION AND FUNCTION OF THE HEATING ELEMENTS

2.5.1. Rockhopper II 2 heater printers

Heater element Temperature Function

Pre-heater (Heater A) 20 – 50°C

→ Open the pores to make the media more receptive
for eco-solvent or eco-solvent plus™ ink.

Dryer (Heater D) 20 – 50°C

→ Applying heating immediately after printing
improves ink/media anchorage.
→ The dryer helps to make the media touch-dry before
it reaches the automatic take-up system.

2.5.2. Rockhopper II 4 heater printers

Heater element Temperature Function

Pre-heater (Heater A) 20 – 50°C

→ Open the pores to make the media more receptive
for eco-solvent or eco-solvent plus™ ink.

Fixer (Heater B) 20 – 70°C

→ To establish optimum fixation onto the media
(coated and uncoated).
→ Optimizes the dot gain control.

Post-Fixer (Heater C) 20 – 70°C

→ The post-fixer finalizes the fixation process and
helps to make the prints touch-dry.

Dryer (Heater D) 20 – 50°C

→ The dryer completes the drying for compatibility
with the take-up in combination with higher output
speeds.
→ Stickiness of printed banner materials is improved.

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2.5.3. 2 or 4 heater

To verify if your printer is equipped with 2 or 4 heaters, please refer to the photo’s mentioned below.

Rockhopper II 2 heater printer

Rockhopper II 4 heater printer

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3. SPECIFICATIONS

3.1. INTRODUCTION

This section explains the specifications, optional parts and supplies, installation
procedures for optional parts, and user support for this printer.

3.2. PRODUCT SPECIFICATIONS

Printers 50”- model 64”- model 87”- model

Technology Drop-on-demand Micro Piezo Inkjet Technology.

Variable drop mass output between 5.4 ng and 41.5 ng

Media Thickness Compensation Automatic media thickness compensation.

Variable – RIP controlled – Head Height
Maximum Media Widths 1273 mm 1653 mm 2240 mm
Maximum Print Widths 1263 mm 1643 mm 2230 mm
Media Thickness

Diameter / Core
Weight

Range: 0.08 mm – 1.1 mm

Maximum: 150 mm / 2” & 3” for 50,64 and 3” for 87

Maximum: 50 kg
Colour Channels 8 colour channels – 4 or 6 process colour output

Inks

Eco-Solvent Plus 2xCMYK speed set-up

Eco-Solvent Plus CMYKLcLm photo tone rendering set-up
Ink Cassette Capacity / Type 220 ml / smart chip ink type & order sensing
Print Modes & Panel Control Options Uni & Bi-directional output, Interweaving, Mirror Output, Multi

Copy, Ink Status, Origin Control
Speed Overview Table ( * )
914mm (36”) wide output

50 & 64 87

Ink Set-Up 2 x 4 Colours 6 Colours 2 x 4 Colours 6 Colours

360 x 360

{{{ {

5.7 – 37.7 2.9 – 19.6 5.7 – 37.7 3.9 – 27.7

720 x 360

{

5.8 – 22.8 2.9 – 11.5 5.9 – 23.1 5.3 – 20.6

720 x 720

{{{ {

2.9 – 11.4 1.4 – 5.6 2.9 – 11.5 2.6 – 10.2

1440 x 720

{

2.9 – 5.9 1.4 – 2.8 3.0 – 6.0 2.6 – 5.2

1440 x 1440

{

1.4 – 2.9 0.7 – 1.5 1.5 – 3.0 1.3 – 2.6

Output speeds are given for 914 mm (36”) output.
50” output is 7 % faster, 64” output is 12 % faster and 87” output is 18 % faster.
For each mode, the minimum (Super High Quality) and maximum speed (Super Draft) are given.
Mode dependent, there are between 2 and 6 speed levels per mode, accessible via print direction selection
and interweave control from the RIP software.
Top speeds indicated are super draft modes and do not guarantee production output quality on all media
types.

{{{ Variable Drop Compatible { Fixed Drop Compatible

LCD Display Backlight LED – 4 lines x 20 characters
Take-up System (standard) Automated
Roll Media Core 2” & 3” for 50 & 64 and 3”” for 87
Interface Centronics, IEEE 1284 compatible / Network, High Speed

Interface (standard high-speed interface card – 4 Mb/s).
Graphics Command Language RTL-PASS, MH-GL, MH-GL/2

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Printers 50”- model 64”- model 87”- model

Power Consumption 1100 VA

80 VA in stand-by

mode

1300 VA
80 VA in stand-by
mode

1400 VA
100 VA in stand-by
mode

External Dimensions in mm (W x D x H)

Weight

2700 x 750 x 1250

170 kg

3100 x 750 x 1250

195 kg

3700 x 750 x 1250

215 kg
Noise Level Operating: 54 dB or less
Standard VCCI (Class A), FCC (Class A), UL, CE, CCIB
Standard Items Hard Disk: 20.3 GB – Stores 16 jobs – Up to 99 copies/job –

PostScript RIP included

Optional Item Extra Scroller Bars – Take-up System – Roll-off / roll-up system

50” model 11.7 m² or larger. Frontage of 4.3 m or greater.
64” model 12.7 m² or larger. Frontage of 4.7 m or greater.

Area

87” model 14.3 m² or larger. Frontage of 5.3 m or greater.

Floor loading capability 2490Pa (300kg/m²) or over

Voltage AC100V - 120V or AC220V – 240V
Frequency 50/60Hz±1Hz

Electrical

Capacity AC100V - 120V: 3A or more

AC220V - 240V: 1.5A or more
Recommended
working environment

Temperature: 25°C

Humidity: 40% to 60%, without condensation
Operational
conditions

Temperature: 18°C to 35°C

Humidity: 40% to 60%, without condensation
Rate of change Temperature: No more than 2°C per hour

Humidity: No more than 5% per hour

Environmental

Storage environment Temperature: -20°C to 60°C

Humidity: 5％ to 85%, without condensation (When ink has been

discharged.)

Specifications are liable to changes without prior notice. All trademarks mentioned are property of their
respective owners.

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3.3. INTERFACE SPECIFICATIONS

This section explains the specifications for the interfaces supported by this product.

3.3.1. Centronics Bidirection Parallel Interface:IEEE1284)

(1) Interface Specifications

Item Specifications

Transmission modes Compatible , Nibble , ECP Mode
Data length 8 bits
Transmission direction Unidirectional (receiving only), Bidirectional
Connector pin number

(2) Table of parallel interface pin numbers and signals

Pin
number

Connection
signal

Signal direction Pin

number

Connection signal Signal

direction

1 STROBE To printer Å 19 SG
2 DATA1 To and from printer Å Æ 20 SG
3 DATA2 To and from printer Å Æ 21 SG
4 DATA3 To and from printer Å Æ 22 SG
5 DATA4 To and from printer Å Æ 23 SG
6 DATA5 To and from printer Å Æ 24 SG
7 DATA6 To and from printer Å Æ 25 SG
8 DATA7 To and from printer Å Æ 26 SG
9 DATA8 To and from printer Å Æ 27 SG
10 ACK From printer Æ 28 SG
11 BUSY From printer Æ 29 SG
12 P ERROR From printer Æ 30 SG
13 SELECTED From printer Æ 31 INIT To printer Å
14 AUTOFD To printer Å 32 FAULT From printer Æ
15 Not connected 33 Not connected
16 SG 34 Not connected
17 FG 35 Not connected
18 +5V 36 SELECTIN To printer Å

(3) Recommended Centronics cable specifications

Item Specifications

Interface Dual-direction Parallel Interface:IEEE1284
Structure AWG28×18 (twisted pair wiring)
Shield construction Metallic tape + weaving (double shielded cable)
Characteristic impedance

62 Ω

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3.3.2. Network Interface (Optional) Specifications

Item Specifications

Network Type Ethernet IEEE802.3
Network I/F 10 Base-T,100 Base-TX

(RJ-45 connector, twisted pair cable)

* Automatic switching
Protocol TCP/IP
Mode

• ftp

• lpr

• socket

Functions

• Automatic protocol recognition

• Transmission speed up to 4 MB/s

• Network environment setting by Web.

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3.4. INSTALLATION

The Installation of the unit is explained below.

3.4.1. Conditions of the installation environment

Important :

Do not place the printer in following areas. Doing so may result in the printer
falling over and causing injury.
Unstable surfaces
Slanted place
Where vibration of other machines is transmitted.

Do not sit on the printer or put heavy things on the printer. Doing so may cause
the printer to fall and injure people.

Do not cover the ventilation hole of the printer with cloth, such as a blanket or
table cloth. Doing so could obstruct ventilation and cause fire.

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

(1) Conditions of the installation environment

Select the place to install this unit according to the environmental condition in the table below.

50” model 11.7 m² or larger. Frontage of 4.3 m or greater.
64” model 12.7 m² or larger. Frontage of 4.7 m or greater.

Area

87” model 14.3 m² or larger. Frontage of 5.3 m or greater.

Floor loading capability 2490Pa (300kg/m²) or over

Voltage AC100V - 120V or AC220V – 240V
Frequency 50/60Hz±1Hz

Electrical

Capacity AC100V - 120V: 3A or more

AC220V - 240V: 1.5A or more
Recommended
working environment

Temperature: 25°C

Humidity: 40% to 60%, without condensation
Operational conditions Temperature: 18°C to 35°C

Humidity: 40% to 60%, without condensation
Rate of change Temperature: No more than 2°C per hour

Humidity: No more than 5% per hour

Environmental

Storage environment Temperature: -20°C to 60°C

Humidity: 5％ to 85%, without condensation (When ink has

been discharged.)

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Notes :

Avoid the following places with regard to temperature or humidity. If doing so, it may
affect the printing result.
Places where the temperature of humidity may rapidly change even though it is within
the correct range.
Places where there is direct sunlight or strong light.
Places where there is direct air from the air conditioner.

It is recommended to install the printer in an environment where the air conditioning is
adjustable for temperature and humidity.

(2) Installation space

Install on a horizontal place that satisfies following conditions.
The floor has the sufficient strength to sustain the weight of the printer and the stand.

Notes :

Refer to ‘product specifications’.

a = 1500 mm
b = 1500 mm
c = 2500 mm
d = 600 mm
e = 1250 mm

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4. PARTS REPLACEMENT

4.1. INTRODUCTION

This chapter explains the procedures for replacing and removing maintenance parts.

Important :

¾ Before replacing parts, be sure to perform following operations.

 Turn the power OFF.
 Remove the electrical cable from the socket. Otherwise, you may

suffer electric shock or the machine’s electric circuits may be
damaged.

 Disconnect all cables from the machine. Not doing so could cause

damage to the printer.

Caution :

¾ Assembling and disassembling the printer is only allowed for the parts for which

disassembling procedures are shown in the operation manual.

¾ Do not disassemble any frame parts or parts for which disassembling procedures

are not shown in the manual.

¾ Doing so may cause trouble that cannot be restored, as the printer is originally

assembled in the factory with a high accuracy of 1/100 mm.

Notes :

¾ After replacing the parts, perform necessary lubrication/bonding according to

"Lubrication/Bonding".

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4.2. REMOVING THE COVER

When replacing any of the parts inside the printer, it is necessary to remove all covers.
The procedures for removing the covers are given below.

1 = I/H cover 5 = Panel unit assembly
2 = Side cover R 6 = Y-rail cover
3 = side Cover L 7 = Front paper guide
4 = Front cover

8 = Rear paper guide

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4.2.1. Removing the I/H cover

Step 1 : Remove the ink cartridge.

Step 2 : Open the I/H cover lid.

Step 3 : Remove the 4 screws fixing the I/H cover.

Step 4 : Remove the I/H cover and I/H cover lid.

1 = Screws (M3x12) fixing the I/H cover

Step 5 :

Remove the 2 screws fixing the ink cover sensor.

Step 6 :

Remove the ink cover sensor.

1 = Ink cover sensor 2 = Screws (M2x10) fixing the ink cover sensor

Step 7 :

Replace the parts inside the printer.

Step 8 :

Reinstall all parts in the opposite order of the removal procedure.

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4.2.2. Removing side cover R

Step 1 : Remove the screw from the upper part of the side cover R.

1 = Screws (M4x12) on the upper part of the side cover R

Step 2 : Remove the 2 screws from the bottom of side cover R.

1 = Screws (M4x16) on the side of the bottom of side cover R

Step 3 : Remove the 3 screws from the back of the bottom of side cover R.

1 = Screws (M4x16) on the back of the bottom of side cover R

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Step 4 : Remove the top of the side cover R.

Step 5 : Remove the 4 bolts from the front and back of the inner surface on the bottom of side cover R

and the front cover nut.

1 = Hexagon socket head cap screws (M4x16) 2 = Cover nut

Step 6 : Remove the 6 bolts from the front and back of the bottom surface on the bottom of the side cover

R.

Step 7 : Remove the bottom of side cover R.

1 = Hexagon socket head cap screws (M5x18)

Step 8 : Replace the parts inside the printer.

Step 9 : Reinstall all parts in the opposite order of the removal procedure.

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4.2.3. Removing side cover L

Step 1 : Remove the screw from the side of the upper part of side cover L.

1 = Screws (M4x12) on the side of the upper part of the side cover L

Step 2 : Remove the 2 screws from the front of the bottom of side cover L.

1 = Screws (4x16) on the back of the bottom of side cover L

Step 3 : Remove the 3 screws from the back of the bottom of side cover L.

1 = Screws (M4x16) on the rear of the bottom part of the side cover L

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Step 4 : Remove the 4 bolts and cover nut from the front and back of the inner surface on the bottom of

side cover L.

1 = Hexagon socket head cap screws (M4x16) 2 = Cover nut

Step 5 : Remove the 6 bolts from the front and back of the bottom surface on the bottom of side cover L.

1 = Hexagon socket head cap screws (M5x18)

Step 6 : Remove the bottom of side cover L.

Step 7 : Replace the parts inside the printer.

Step 8 : Reinstall all parts in the opposite order of the removal procedure.

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4.2.4. Removing the front cover

Step 1 : Open the front cover.

Step 2 : Remove the E ring on the left side.

Step 3 : Remove the 4 screws on the left and right cover spindles.

1 = E ring 2 = Screws (M3x8) on the left and right cover spindles

Step 4 : If the machine is a 50-inch model, remove cover spindle L, and then slide and remove the front

cover.

1 = Cover spindle L

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Step 5 : If the machine is 64 or 87-inch model, remove the E ring and the sensor cam, push the cover

spindle L to the origin side and then slide and remove the front cover.

1 = Cover spindle L 2 = Sensor cam
3 = E ring

Step 6 : Reinstall all parts in the opposite order of the removal procedure.

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4.2.5. Removing the carriage cover

Caution :

Please note that this cover is only on a Rockhopper II (2 heaters) printer.

Step 1 : Remove the I/H cover.

Step 2 : Remove side cover R.

Step 3 : Remove side cover L.

Step 4 : Remove the front cover.

Step 5 : Remove the 4 screws fixing the carriage cover.

Step 6 : Remove the carriage cover.

1 = Carriage cover 2 = Screws (M3x6) fixing the carriage cover

Step 7 : Reinstall all parts in the opposite order of the removal procedure.

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4.2.6. Removing the panel unit assembly

Step 1 : Remove side cover R.

Step 2 : Remove the panel tape power cord.

Step 3 : Remove the 4 screws fixing the panel base.

1 = Panel unit assembly 2 = Screws (M3x6) fixing the panel unit assembly
3 = Tape wire

Step 4 : Remove the panel unit assembly.

Step 5 : Remove the 6 screws fixing the panel board assembly and the panel cover.

1 = Screws (M3x8) fixing the panel cover

Step 6 : Remove the panel cover.

Step 7 : Remove the 4 screws fixing the panel bracket and the panel board assembly.

1 = Screws (M3x8) fixing the panel board assembly

Step 8 : Replace the panel board assembly.

Step 9 : Reinstall all parts in the opposite order of the removal procedure.

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4.2.7. Removing the Y rail cover

Caution :

Removing the Y rail cover, should be performed by at least two persons.
Otherwise the Y rail cover may be deformed.

Step 1 : Remove side cover R.

Step 2 : Remove side cover L.

Step 3 : Remove the front cover.

Step 4 : Remove the carriage cover.

Caution :

Please note that this cover is only on a Rockhopper II (2 heaters) printer.

Step 5 : Remove the 3 screws fixing the Y rail cover and the Y rail cover FG.

1 = Y rail cover FG 2 = Screws (M3x6) fixing the Y rail cover and the Y rail cover FG

Step 6 : Remove the 6 screws from the front of the Y rail cover.

1 = Screws (M4x8) on the front of the Y rail cover

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Step 7 : Remove the 5 screws from the rear of the Y rail cover.

¾ If the machine is an 87-inch model, there are 8 screws on the rear Y rail cover.

1 = Screws (M4x8) on the rear of the Y rail cover

Step 8 : Remove the Y rail cover.

Step 9 : Replace the parts inside the printer.

Step 10 : Reinstall all parts in the opposite order of the removal procedure.

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4.2.8. Removing front paper guide

Step 1 : Remove side cover L.

Step 2 : Remove side cover R.

Step 3 : Remove the front cover.

Step 4 : Remove the carriage cover.

Caution :

Please note that this cover is only on a Rockhopper II (2 heaters) printer.

Step 5 : Remove the Y rail cover.

Step 6 : Remove the screws from the top of front media guide.

Notes :

¾ Please note that the amount of screws is size dependent.

Rockhopper II 2 heater

1 = Screws on the top of front media guide

Rockhopper II 4 heater

1 = Screws on the top of front media guide

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Step 7 : Remove the screws from the front of front media guide.

Notes :

¾ Please note that the amount of screws is size dependent.

Rockhopper II 2 heater

1 = Screws on the front of front media guide

Rockhopper II 4 heater

1 = Screws on the front of front media guide

Step 8 : Standing before the unit move the front paper guide towards you.

Step 9 : Loosen the cables from their cable clamps.

Step 10 : Carefully loosen the connectors

Notes :

¾ Be sure not to damage the cables or connectors.

Step 11 : Remove the front paper guide.

Step 12 : Replace the parts inside the printer.

Step 13 : Reinstall all parts in the opposite order of the removal procedure.

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4.2.9. Removing rear paper guide

Step 1 : Remove side cover L.

Step 2 : Remove side cover R.

Step 3 : Remove the front cover.

Step 4 : Remove the Y rail cover.

Step 5 : Remove the screws from the top of the rear media guide.

Notes :

¾ Please note that the amount of screws is size dependent.

1 = Screws on the rear paper guide

Step 6 : Remove the screws from the rear of rear paper guide.

Notes :

¾ Please note that the amount of screws is size dependent.

Step 7 : Standing at the rear of the unit move the rear paper guide towards you.

Step 8 : Loosen the cables from their cable clamps.

Step 9 : Carefully loosen the connectors

Notes :

¾ Be sure not to damage the cables or connectors.

Step 10 : Remove the rear paper guide.

Step 11 : Replace the parts inside the printer.

Step 12 : Reinstall all parts in the opposite order of the removal procedure.

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4.2.10. Removing the head cover

Step 1 : Remove the I/H cover.

Step 2 : Remove side cover R.

Step 3 : Remove side cover L.

Step 4 : Remove the front cover.

Step 5 : Remove the carriage cover.

Caution :

Please note that this cover is only on a Rockhopper II (2 heaters) printer.

Step 6 : Remove the Y rail cover.

Step 7 : Unlock the head.

Notes :

¾ Please refer to the ‘Head lock menu’.

Step 8 : Pull the head out to the left of the maintenance station.

Caution :

When pulling the head out, do not press on the cutter cap. Doing so could damage the
cutter blade.

Step 9 : Remove the 2 screws fixing the head cover.

1 = Screws (M3x8) fixing the head cover

Step 10 : Remove the head cover.

Step 11 : Replace the parts inside the printer.

Step 12 : Reinstall all parts in the opposite order of the removal procedure.

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4.2.11. Removing the maintenance cover

Step 1 : Remove the I/H cover.

Step 2 : Remove side cover R.

Step 3 : Remove side cover L.

Step 4 : Remove the front cover.

Step 5 : Remove the carriage cover.

Caution :

Please note that this cover is only on a Rockhopper II (2 heaters) printer.

Step 6 : Remove the 6 screws fixing the maintenance cover.

Rockhopper II 2 heater Rockhopper II 4 heater

1 = Screws (M3x8) 1 = Screws (M3x8)

Step 7 : Remove the maintenance cover.

Step 8 : Replace the parts inside the printer.

Step 9 : Reinstall all parts in the opposite order of the removal procedure.

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4.3. REPLACEMENT OF THE HEATER ELEMENT

To replace a heater element of the Rockhopper II series printer, please follow the instructions mentioned in
the explanation of the appropriate heater element.

1. Rockhopper II :

o 1. Replacing the front heater (Heater D) on a Rockhopper II printer
o 2. Replacing the rear heater (Heater A) on a Rockhopper II printer

2. Rockhopper II 4H :

o 1. Replacing the dryer (Heater D) on a Rockhopper II 4H printer
o 2. Replacing the post-fixer (Heater C) on a Rockhopper II 4H printer
o 3. Replacing the fixer (Heater B) on a Rockhopper II 4H printer
o 4. Replacing the heater (Heater A) on a Rockhopper II 4H printer

Caution :

¾ In case the fuse of the heating element is locked, do not replace the fuse but replace

the appropriate heater element. Installation of a fuse of the heater element needs to
be done in a special production environment.

Important :

Before replacing parts, be sure to perform the following operations.

¾ Turn the machine power OFF.
¾ Remove the product's electrical plug from the socket. Otherwise, you may

suffer electric shock or the machine’s electric circuits may be damaged.

¾ Disconnect all cables from the machine. Not doing so could cause damage to

the printer.

4.3.1. Rockhopper II 2 heaters : Heater elements

4.3.1.1. Replacing the front heater (Heater D) on a Rockhopper II printer

Before replacing the front heater, make sure to have following items:

¾ 50” model : Heat Strip Assy Front 1 50 and Heat Strip Assy Front 2 50
¾ 64” model : Heat Strip Assy Front 1 64 and Heat Strip Assy Front 2 64
¾ 87” model : Heat Strip Assy Front 1 87 and Heat Strip Assy Front 2 87
¾ 4 x sensor insul. Patch

To replace the front heater on a Rockhopper II printer, please follow the instructions mentioned below.

Step 1 : Remove side cover L.

Step 2 : Remove side cover R.

Step 3 : Remove the front cover.

Step 4 : Remove the carriage cover.

Step 5 : Remove the Y rail cover.

Step 6 : Remove the front paper guide.

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Step 7 : Remove the front heater strip(s).

Step 8 : Degrease the plate.

Notes :

¾ Make sure the plate is cleaned properly. Dust, glue and other parts must be

removed.

Step 9 : Stick the front heater strip(s) onto the plate.

Notes :

¾ Make sure that the strips connect properly.
¾ Please make sure that the sensor (blue blocks) are positioned on the flat surface of

the front paper guide.

Notes :

¾ Please make sure that there are no air bubbles under the heater strip. Air bubbles

below the heater strip could cause overheating of the heater strip.

Step 10 : Stick onto the sensor an isolation strip.

Step 11 : Reinstall all parts in the opposite order of the removal procedure.

Notes :

¾ During reinstallation of the plate, make sure there are no cables stuck.

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4.3.1.2. Replacing the rear heater on a Rockhopper II printer

Before replacing the post fixer, make sure to have following items:

¾ 50” model : Heater strip assy rear 50
¾ 64” model : Heater strip assy rear 64
¾ 87” model : Heater strip assy rear 87
¾ 2 x press plate
¾ Silicone glue

To replace the rear heater on a Rockhopper II printer, please follow the instructions mentioned below.

Step 1 : Remove side cover L.

Step 2 : Remove side cover R.

Step 3 : Remove the front cover.

Step 4 : Remove the Y rail cover.

Step 5 : Remove the rear paper guide.

Step 6 : Remove the rear heater strip.

Step 7 : Degrease the plate.

Notes :

¾ Make sure the plate is cleaned properly. Dust, glue and other parts must be

removed.

Step 8 : Stick the rear heater strip onto the plate.

Step 9 : Stick (with silicone glue) the two press plates onto the heater strip.

¾ 50” model : X = 380 mm
¾ 64” model : X = 380 mm / Y = 1060 mm
¾ 87” model : X = 660 mm / Y = 1200 mm / Z = 1750 mm

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Notes :

¾ It will take ± 1 hour to let the glue dry.

Step 10 : Reinstall all parts in the opposite order of the removal procedure.

Notes :

¾ During reinstallation of the plate, make sure there are no cables stuck.

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4.3.2. Rockhopper II 4 heaters : Heater elements

4.3.2.1. Replacing the dryer (Heater D) on a Rockhopper II 4H printer

Before replacing the dryer, make sure to have following items:

¾ 50” model : Dryer D1 50 and Dryer D2 50
¾ 64” model : Dryer D1 64 and Dryer D2 64
¾ 87” model : Dryer D1 87 and Dryer D2 872 x sensor insul. Patch

To replace the dryer on a Rockhopper II 4H printer, please follow the instructions mentioned below.

Step 1 : Remove side cover L.

Step 2 : Remove side cover R.

Step 3 : Remove the front cover.

Step 4 : Remove the Y rail cover.

Step 5 : Remove the front paper guide.

Step 6 : Remove the dryer strip(s).

Step 7 : Degrease the plate.

Notes :

¾ Make sure the plate is cleaned properly. Dust, glue and other parts must be

removed.

Step 8 : Stick the dryer strip(s) onto the plate.

Notes :

¾ Make sure that the strips connect properly.
¾ Please make sure that the sensor (blue blocks) are positioned on the flat surface of

the front paper guide.

¾ Stick it as close as possible to the assembly holes. Make sure it does not touch the

assembly holes.

Notes :

¾ Please make sure that there are no air bubbles under the heater strip. Air bubbles

below the heater strip could cause overheating of the heater strip.

Step 9 : Stick onto the sensors a sensor insul. patch.

1 = sensor insul. patch 2 = assembly hole

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Step 10 : Reinstall all parts in the opposite order of the removal procedure.

Notes :

¾ During reinstallation of the plate, make sure there are no cables stuck.

4.3.2.2. Replacing the post fixer (Heater C) on a Rockhopper II 4H printer

Before replacing the heater, make sure to have following items:

¾ 50” model : Post Fixer C 50
¾ 64” model : Post Fixer C 64
¾ 87” model : Post Fixer C 87
¾ 1 x sensor insul. Patch

To replace the post fixer on a Rockhopper II 4H printer, please follow the instructions mentioned below.

Step 1 : Remove side cover L.

Step 2 : Remove side cover R.

Step 3 : Remove the front cover.

Step 4 : Remove the Y rail cover.

Step 5 : Remove the front paper guide.

Step 6 : Remove the post fixer strip.

Step 7 : Degrease the plate.

Notes :

¾ Make sure the plate is cleaned properly. Dust, glue and other parts must be

removed.

Step 8 : Stick the post fixer strip onto the plate.

Notes :

¾ Make sure that the strips connect properly.
¾ Stick it as close as possible to the assembly holes. Make sure it does not touch the

assembly holes.

Notes :

¾ Please make sure that there are no air bubbles under the heater strip. Air bubbles

below the heater strip could cause overheating of the heater strip.

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Step 9 : Stick onto the sensor a sensor insul. patch.

1 = sensor insul. patch 2 = assembly hole

Step 10 : Reinstall all parts in the opposite order of the removal procedure.

Notes :

¾ During reinstallation of the plate, make sure there are no cables stuck.

4.3.2.3. Replacing the fixer (Heater B1 and Heater B2) on a Rockhopper II 4H printer

Before replacing the fixer, make sure to have following items:

¾ 50” model : Fixer B1 50 and Fixer B2 50
¾ 64” model : Fixer B1 64 and Fixer B2 64
¾ 87” model : Fixer B1 87 and Fixer B2 87
¾ Isolation tape
¾ Plot platform calibre

To replace the fixer on a Rockhopper II 4H printer, please follow the instructions mentioned below.

Step 1 : Remove side cover L.

Step 2 : Remove side cover R.

Step 3 : Remove the front cover.

Step 4 : Remove the Y rail cover.

Step 5 : Remove the front paper guide.

Step 6 : Place the plot platform calibre onto the plot platforms.

1 = plot platforms 2 = plot platform calibre onto the plot platforms

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Step 7 : Fix the plot platform calibre onto the plot platform.

1 = Fix plot platform caliber 2 = reachable screws of plot platform

Notes :

¾ Make sure the screws of the plot platform are reachable.

Step 8 : Remove the screws of the plot platform.

1 = screws plot platform

Step 9 : Pull upwards the plot platform calibre and so remove the plot platform with fixer.

Step 10 : Remove the fixer.

Step 11 : Degrease the plot platform.

Notes :

¾ Make sure the plate is cleaned properly. Dust, glue and other parts must be

removed.

Step 12 : Stick the two fixer strips onto the plot platform.

Notes :

¾ Please make sure that there are no air bubbles under the heater strip. Air bubbles

below the heater strip could cause overheating of the heater strip.

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Step 13 : Stick the isolation tape onto the heater strips.

1 = plot platform 2 = fixer heater strip
3 = isolation tape

Step 14 : Reinstall all parts in the opposite order of the removal procedure.

Notes :

¾ During reinstallation of the plate, make sure there are no cables stuck.

4.3.2.4. Replacing the heater (Heater A) on a Rockhopper II 4H printer

Before replacing the post fixer, make sure to have following items:

¾ 50” model : Heater A 50
¾ 64” model : Heater A 64
¾ 87” model : Heater A 87
¾ 2 x press plate
¾ Silicone glue

To replace the heater on a Rockhopper II 4H printer, please follow the instructions mentioned below.

Step 1 : Remove side cover L.

Step 2 : Remove side cover R.

Step 3 : Remove the front cover.

Step 4 : Remove the Y rail cover.

Step 5 : Remove the rear paper guide.

Step 6 : Remove the heater strip.

Step 7 : Degrease the plate.

Notes :

¾ Make sure the plate is cleaned properly. Dust, glue and other parts must be

removed.

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Step 8 : Stick the heater strip onto the plate.

Notes :

¾ Please make sure that there are no air bubbles under the heater strip. Air bubbles

below the heater strip could cause overheating of the heater strip.

Step 9 : Stick (with silicone glue) the two press plates onto the heater strip.

¾ 50” model : X = 380 mm
¾ 64” model : X = 380 mm / Y = 1060 mm
¾ 87” model : X = 660 mm / Y = 1200 mm / Z = 1750 mm

Notes :

¾ It will take ± 1 hour to let the glue dry.

Step 10 : Reinstall all parts in the opposite order of the removal procedure.

Notes :

¾ During reinstallation of the plate, make sure there are no cables stuck.

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4.4. REPLACING BOARD BASES

This chapter explains the procedures for replacing the power source board assembly, mainboard assembly,
PCI_Linux board assembly and cooling fan assembly.

Caution :

When handling circuit boards, do not touch the elements on the board with your bare
hands. Doing so may cause static electricity and break the elements.

4.4.1 Replacing the Mainboard assembly, HDD_Extension board
assembly,

HEAD_DRV board assembly, PCI_Linux board assembly

and

cooling fan assembly

Notes :

¾ To replace the board and connect or disconnect the FFC type cable, you should

leave the plug disconnected from the power socket for a while. Otherwise, over­current could be generated and damage the board.

¾ When changing the main substrate assembly, follow "Parameter backup" to backup

the parameter. Failure to do so could cause the life span counters for the waste
fluid tank and tube not to reset, resulting in an overflow of ink inside the printer.
See "Adjustment" for details of other adjustment.

¾ Remove the following parts before replacing the Mainboard assembly,

HDD_Extension board assembly, HEAD_DRV board assembly, PCI_Linux board
assembly and cooling fan assembly:

 Panel unit assembly: "Removing the panel unit assembly"
 Hard disk: "User’s Guide”

Step 1 : Remove the 20 screws fixing the Mainboard cover 3.

1 = 2 Screws (M3x6) fixing the Mainboard cover 2 = Mainboard cover 3

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Step 2 : Remove the Mainboard cover 3.

Step 3 : Follow the instructions in “Removing the panel unit assembly” to remove the panel unit assembly.

Step 4 : Remove the connector between the cooling fan cable and the cooling fan assembly.

Step 5 : Remove the 2 top and 2 bottom screws fixing the cooling fan assembly.

Step 6 : Replace the cooling fan assembly.

Step 7 : Remove the 15 screws fixing the Mainboard cover.

1 = Panel unit assembly 2 = Cooling fan assembly
3 = Screws (M3x25) fixing the cooling fan assembly 4 = Screws (M3x20) fixing the cooling fan assembly
5 = Mainboard cover 6 = Screws (M3x6) fixing the Mainboard cover

Step 8 : Remove the 4 screws fixing the HEAD_DRV board assembly.

1 = HEAD_DRV board assembly 2 = Screws (M3x6) fixing the HEAD_DRV board

assembly

Step 9 : Replace the HEAD_DRV board assembly.

Step 10 : Remove FFC protection material between HEAD_DRV board assembly and Mainboard

assembly.

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Step 11 : Remove following connectors from the Mainboard assembly.

N° Connector N° # of pins Colour Connected to Remarks

1 J101 12 White Mainboard Lock type
2 J102 6 White Power Lock type
3 J103 168 DIMM
4 J104 68
5 J105 28 White or black Lock type
6 J106 120 PCI_LINUX board
7 J107 120 PCI_LINUX board
8 J108 120 PCI_LINUX board
9 J109 39
10 J110 96 White HD_MOTHER board
11 J111 3 White Adhesion FAN 1 Free
12 J112 2 Blue Adhesion FAN 2 For 50, 64, 87 inch

spec

13 J113 2 Red Adhesion FAN 3 For 50, 64, 87 inch

spec

14 J114 2 Yellow Adhesion FAN 4 For 50, 64, 87 inch

spec

15 J115 2 Black Adhesion FAN 5 For 50, 64, 87 inch

spec.
16 J116 2 White Adhesion FAN 6 For 87 inch spec.
17 J117 3 Yellow Free
18 J118 3 Black DRV_FAN 1
19 J119 No preparation
20 J120 3 Red Waste fluid BOX sensor cable
21 J121 4 White Ink cover sensor
22 J122 5 White Lever foot SW cable
23 J123 4 Black Lever up sensor Transmission

photosensor
24 J124 4 Yellow Lever down sensor Transmission

photosensor
25 J125 6 White Maintenance origin sensor

cable

Transmission

photosensor
26 J126 No preparation
27 J127 5 Red Head slide sensor
28 J128 5 Yellow P_REAR_L sensor
29 J129 4 Blue P_REAR_R sensor
30 J130 4 CR origin sensor Transmission

photosensor
31 J131 5 Black Wiper origin sensor Transmission

photosensor
32 J132 No preparation
33 J133 30 White or black JUNCTION board Lock type
34 J134 30 White or black JUNCTION board Lock type
35 J135 HEAD_DRV board
36 J136 HEAD_DRV board
37 J137 30 White or black CR board Lock type
38 J138 30 White or black CR board Lock type
39 J139 30 White or black CR board Lock type
40 J140 30 White or black CR board Lock type
41 J141 30 White or black CR board Lock type
42 J142 30 White or black CR board Lock type
43 J143 30 White or black CR board Lock type
44 J144 30 White or black CR board Lock type
45 J145 (87) 30 White or black CR board Lock type

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46 J146 (87) 30 White or black CR board Lock type
47 J147 (87) 30 White or black CR board Lock type
48 J148 (87) 30 White or black CR board Lock type
49 J149 (87) 30 White or black CR board Lock type
50 J150 (87) 30 White or black CR board Lock type
51 J151 (87) 30 White or black CR board Lock type
52 J152 (87) 30 White or black CR board Lock type
53 J153 5 Black Free
54 J154 5 White PF_ENC
55 J155 3 White Cover R sensor
56 J156 3 Black Cover L sensor
57 J157 2 White PF motor Lock type
58 J158 3 White CR motor Lock type
59 J159 4 White Lever motor Lock type
60 J160 4 White Pump 1 motor
61 J161 5 White Pump 2 motor
62 J162 6 White HEAD U/D motor
63 J163 7 White Maintenance U/D motor
64 J164 4 White Wiper motor
65 J165
66 J167 7 White Interf. Cable Db9-Jst

1 = PCI_Linux board assembly 2 = Screws fixing the PCI_Linux board assembly (M3x6)

Step 12 : Remove the 2 screws fixing the PCI_Linux board assembly.

Step 13 : Replace the PCI_Linux board assembly.

Step 14 : Remove the 2 screws fixing the cooling fan assembly.

Step 15 : Replace the cooling fan assembly.

Step 16 : Remove the 4 screws fixing the I/F guide.

Step 17 : Remove I/F guide.

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Step 18 : Remove the 6 screws and 4 hexagon spacers fixing the Mainboard assembly.

1 = Mainboard assembly 2 = HDD_Extension board assembly
3 = Hexagon spacer 4 = Screws (M3x6)
5 = Cooling fan assembly 6 = Screws (M3x20) fixing the cooling fan assembly
7 = I/F guide 8 = Screws (M3x8) fixing the I/F guide

Step 19 : Replace the HDD_Extension board assembly.

Step 20 : Replace the Mainboard assembly.

Step 21 : Reinstall all parts in the opposite order of the removal procedure.

Step 22 : Perform media sensor sensitivity adjustment following the "Media sensor sensitivity adjustment"

procedure.

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4.4.2. Replacing the power source board assembly

Caution :

When removing the power source board assembly, remove the power cable and set it
aside for at least 5 minutes in order to completely discharge the electric charge
remaining in the electrolytic capacitor before continuing with the procedure.
Touching the substrate before discharging the capacitor causes electric shock.

Step 1 : Follow the instructions in "Replacing the Mainboard assembly, HDD_Extension board assembly,

HEAD_DRV board assembly, PCI_Linux board assembly and cooling fan assembly" to remove
the Mainboard assembly.

Step 2 : Remove the 2 screws fixing the PS board cover.

1 = PS board cover 2 = Screws (M3x6) fixing the PS board cover

Step 3 : Remove the 5 screws fixing the Mainboard base.

1 = Screws (M3x8) fixing the Mainboard base 2 = Mainboard base

Step 4 : Remove the Mainboard base.

Step 5 : Remove the following connectors from the power source board assembly.

N° Connector N° # of pins Colour Connected to Remarks

1 CN2 3 White Mainboard J101
2 CN3 4 White + 5V adhesion FAN Output four adhesion FAN
3 CN4 12 White Mainboard J101

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Step 6 : Remove the 4 screws fixing the power source.

1 = Power source board assembly 2 = Screws (M4x8) fixing the power board assembly
3 = Hexagon nut fixing the power board assembly 4 = Power source
5 = Screws (M3x6) fixing the power source

Step 7 : Replace the power source.

Step 8 : Remove the 2 screws and 2 hexagon nuts fixing the power source board assembly.

Step 9 : Remove the power source board assembly.

Step 10 : Reinstall all parts in the opposite order of the removal procedure.

Notes :

¾ When installing the mainboard assembly, be careful not to pinch the foot SW cables

by the mainboard base.

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

SW

cable assembly

Step 1 : Follow the instructions in "Replacing the Mainboard assembly, HDD_Extension board assembly,

HEAD_DRV board assembly, PCI_Linux board assembly and cooling fan assembly" to remove
the Mainboard assembly.

Step 2 : Follow step 2 to 4 in "Replacing the power source board assembly" to remove the Mainboard

assembly.

Step 3 : Remove the connector between the inlet board assembly and the inlet assembly.

Step 4 : Remove the 4 screws fixing the inlet board assembly.

1 = Inlet board assembly 2 = Screws (M3x6) fixing the inlet board assembly
3 = Inlet assembly 4 = Screws (M3x6) fixing the inlet assembly and

lever foot SW cable assembly

5 = Screw (M4x8) fixing the inlet assembly 6 = Lever foot SW cable assembly

Step 5 : Replace the inlet board assembly.

Step 6 : Remove the 3 screws fixing the inlet assembly.

Step 7 : Replace the inlet assembly.

Step 8 : Remove the 3 screws fixing the lever foot SW cable assembly.

Step 9 : Replace the lever foot SW cable assembly.

Step 10 : Reinstall all parts in the opposite order of the removal procedure.

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4.4.4. Replacing the JUNCTION board assembly

Notes :

¾ To replace board and connect or disconnect the FFC type cable, you should leave

the plug disconnected from the power socket for a while. Otherwise, over-current
could be generated and damage the board.

¾ Remove the following parts before replacing the JUNCTION board assembly.

 I/H cover: refer to "Removing the I/H cover"
 Side cover R: refer to "Removing side cover R"

Step 1 : Remove following connectors from the JUNCTION board assembly.

N° Connector N° # of pins Colour Connected to Remarks

1 J401 30 White Mainboard Lock type or Plug-in
2 J402 30 White Mainboard Lock type or Plug-in
3 J403 4 White Ink sensor K Cartridge 1
4 J404 4 Black Ink sensor C Cartridge 2
5 J405 4 Red Ink sensor M Cartridge 3
6 J406 4 Yellow Ink sensor Y Cartridge 4
7 J407 4 Blue Ink sensor LC Cartridge 5
8 J408 5 White Ink sensor LM Cartridge 6
9 J409 5 Black Ink sensor O Cartridge 7
10 J410 5 Red Ink sensor G Cartridge 8
11 J411 5 Yellow SC cable K Cartridge 1
12 J412 5 Blue SC cable C Cartridge 2
13 J413 6 White SC cable M Cartridge 3
14 J414 6 Black SC cable Y Cartridge 4
15 J415 6 SC cable LC Cartridge 5
16 J416 6 Yellow SC cable LM Cartridge 6
17 J417 6 Blue SC cable O Cartridge 7
18 J418 7 White SC cable G Cartridge 8

Step 2 : Remove the 4 screws fixing the JUNCTION board assembly.

1 = JUNCTION board assembly 2 = Screws (M3x6) fixing the JUNCTION board assembly

Step 3 : Replace the JUNCTION board assembly.

Step 4 : Reinstall all parts in the opposite order of the removal procedure.

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4.5. REPLACING THE PF ACTUATOR

4.5.1. Replacing the PF motor assembly

Caution :

The motor is hot after the product has been operated, so be careful not to burn yourself.

Notes :

¾ Remove following covers before replacing the parts in the PF motor assembly.

 Side cover R: refer to "Removing side cover R"
 Side cover L: refer to "Removing side cover L"
 Front cover: refer to "Removing the front cover"
 Carriage cover: refer to "Removing the carriage cover"
 Y rail cover: refer to "Removing the Y rail cover"
 Media guide F: refer to "Removing media guide F"

Step 1 : Remove the PF motor assembly connector from the PF motor cable assembly.

Step 2 : Remove the 2 screws fixing the X motor installation board to the side of the L side frame.

1 = Screws (M4x10) fixing the X motor installation
board to the side of the L side frame.

2 = Screws (M4x10) fixing the PF motor assembly to
the X motor installation board.

3 = PF deceleration belt

Step 3 : Remove the 2 screws fixing the PF motor assembly to the X motor installation board.

Step 4 : Replace the PF motor assembly.

Notes :

¾ When installing the PF motor assembly, move the PF deceleration pulley manually

and confirm that the PF deceleration belt is set equally in the center of the PF motor
assembly pulley.

Step 5 : Reinstall all parts in the opposite order of the removal procedure.

Step 6 : Adjust the tension of the PF deceleration belt according to "PF deceleration belt tension

adjustment".

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4.5.2. Replacing the PF_ENC assembly and PF scale assembly

Notes :

¾ Remove the following covers before replacing the PF_ENC assembly.

 Side cover L: refer to "Removing side cover L"

Step 1 : Remove the PF_ENC assembly connector.

Step 2 : Remove the 2 screws fixing the PF encoder installation board.

1 = Bearing 2 = Screws (M3x6) fixing the PF scale installation board
3 = PF scale 4 = Screws (M4x10) fixing the PF encoder installation board

Step 3 : Remove the PF encoder installation board.

Step 4 : Remove the bearing.

Step 5 : Remove the 4 screws fixing the PF scale installation board.

Step 6 : Remove the PF scale installation board.

Step 7 : Replace the PF scale assembly.

Step 8 : Remove the screws fixing the PF_ENC assembly to the PF encoder installation board.

1 = PF_ENC assembly 2 = Screws (M2x6) fixing the PF_ENC assembly to

the PF encoder installation board

3 = PF encoder installation board

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Step 9 : Replace the PF_ENC assembly.

Notes :

¾ When installing the PF_ENC assembly and the PF encoder installation board, make

sure they are aligned with the locating bosses.

Step 10 : Reinstall all parts in the opposite order of the removal procedure.

Step 11 : Adjust the tension of the PF deceleration belt according to "PF deceleration belt tension

adjustment".

4.5.3. Replacing the PF deceleration pulley assembly

Notes :

¾ Remove following covers before replacing the parts in the PF motor assembly.

 Side cover R: refer to "Removing side cover R"
 Side cover L: refer to "Removing side cover L"
 Front cover: refer to "Removing the front cover"
 Carriage cover: refer to "Removing the carriage cover"
 Y rail cover: refer to "Removing the Y rail cover"
 Media guide F: refer to "Removing media guide F"

Step 1 : Follow step 1 to 6 in "Replacing the PF_ENC assembly and PF scale assembly" to remove the

PF scale installation board.

Step 2 : Loosen the set screw fixing the coupling.

1 = Coupling 2 = Set screw fixing the coupling
3 = Y deceleration pulley axis

Step 3 : Pull the Y deceleration pulley to the opposite side of the origin and then remove the deceleration

pulley assembly.

Step 4 : Reinstall all parts in the opposite order of the removal procedure.

Step 5 : Adjust the tension of the PF deceleration belt according to "PF deceleration belt tension

adjustment".

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4.5.4. Replacing the PF deceleration belt

Notes :

¾ Remove following covers before replacing the parts in the PF motor assembly.

 Side cover R: refer to "Removing side cover R"
 Side cover L: refer to "Removing side cover L"
 Front cover: refer to "Removing the front cover"
 Carriage cover: refer to "Removing the carriage cover"
 Y rail cover: refer to "Removing the Y rail cover"
 Media guide F: refer to "Removing media guide F"

Step 1 : Follow the instructions in "Replacing the PF motor assembly" to remove the PF motor.

Step 2 : Follow the instructions in "Replacing the PF_ENC assembly and PF scale assembly" to remove

the PF_ENC assembly and the PF scale assembly.

Step 3 : Replace the PF deceleration belt.

1 = PF deceleration belt

Step 4 :

Reinstall all parts in the opposite order of the removal procedure.

Step 5 : Adjust the tension of the PF deceleration belt according to "PF deceleration belt tension

adjustment".

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4.5.5. Replacing the P_REAR_R sensor assembly and P_REAR_L

sensor

assembly

Notes :

¾ Remove following covers before replacing the P_REAR_R sensor assembly and

P_REAR_L sensor assembly.

 Side cover R: refer to "Removing side cover R"
 Side cover L: refer to "Removing side cover L"
 Front cover: refer to "Removing the front cover"
 Carriage cover: refer to "Removing the carriage cover"
 Y rail cover: refer to "Removing the Y rail cover"
 Media guide F: refer to "Removing media guide F"

Step 1 : Remove the connectors for the P_REAR_R sensor assembly and P_REAR_L sensor assembly

from the Mainboard assembly.

Step 2 : Remove the screw fixing the media sensor installation board.

1 = Media sensor installation board 2 = Screw (M3x8) fixing the media sensor installation board

Step 3 : Remove the media sensor installation board.

Step 4 : Remove the 2 screws fixing the P_REAR_R sensor assembly.

1 = P_REAR_R sensor assembly 2 = Screws (M2x5) fixing the P_REAR_R sensor assembly

Step 5 : Replace the P_REAR_R sensor assembly.

Step 6 : Use the same procedure to replace the P_REAR_L sensor assembly.

Step 7 : Reinstall all parts in the opposite order of the removal procedure.

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4.5.6. Replacing the suction fan assembly

Notes :

¾ Remove following covers before replacing the suction fan assembly.

 Side cover R: refer to "Removing side cover R"
 Side cover L: refer to "Removing side cover L"
 Front cover: refer to "Removing the front cover"
 Carriage cover: refer to "Removing the carriage cover"
 Y rail cover: refer to "Removing the Y rail cover"
 Media guide F: refer to "Removing media guide F"

Step 1 : Remove the suction fan assembly connector from the suction fan cable assembly.

Step 2 : When replacing the suction fan cable assembly, first remove the connector from the Mainboard

assembly.

Step 3 : Remove the 2 screws fixing the suction fan assembly.

1 = Suction fan assembly 2 = Screws (M3x12) fixing the suction fan assembly

Step 4 : Replace the suction fan assembly.

Step 5 : Reinstall all parts in the opposite order of the removal procedure.

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4.5.7. Replacing the lever motor assembly and the arm motor

installation

board

Caution :

The motor is hot after the product has been operated, so be careful not to burn yourself.

Notes :

¾ Remove following covers before replacing the lever motor.

 Side cover R: refer to "Removing side cover R"
 Side cover L: refer to "Removing side cover L"
 Front cover: refer to "Removing the front cover"
 Carriage cover: refer to "Removing the carriage cover"
 Y rail cover: refer to "Removing the Y rail cover"
 Media guide F: refer to "Removing media guide F"

Step 1 : Remove the lever motor assembly connector.

Step 2 : Remove the screw fixing the sensor installation board.

1 = Sensor installation board 2 = Screw (M3x8) fixing the sensor installation board

Step 3 : Remove the sensor installation board.

Step 4 : Remove the hexagon socket head screws with spring washers (3) fixing the CR motor assembly

to the arm motor installation board.

1 = Lever motor assembly 2 = Hexagon socket head screws with spring

washers (M4x10)

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Step 5 : Replace the CR motor assembly.

Step 6 : Remove the hexagon socket head screws with spring washers (2) fixing the arm motor

installation board.

1 = Arm motor installation board 2 = Hexagon socket head screws with spring

washers (M4x10)

Step 7 : Replace the arm motor installation board.

Step 8 : Reinstall all parts in the opposite order of the removal procedure.

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4.5.8. Replacing the transmission photosensor

Notes :

¾ Remove following covers before replacing the transmission photosensor.

 Side cover R: refer to "Removing side cover R"
 Side cover L: refer to "Removing side cover L"
 Front cover: refer to "Removing the front cover"
 Carriage cover: refer to "Removing the carriage cover"
 Y rail cover: refer to "Removing the Y rail cover"

(1) Replacing the transmission photosensor (lever motor side)

Step 1 : Remove the screw fixing the sensor installation board.

1 = Sensor installation board 2 = Screw (M3x8) fixing the sensor installation board

Step 2 : Remove the sensor installation board.

Step 3 : Remove the transmission photosensor from the sensor installation board.

1 = Sensor installation board 2 = Connector
3 = Transmission photosensor

Step 4 : Remove the connector from the transmission photosensor.

Step 5 : Remove the transmission photosensor.

Step 6 : Apply the screw lock to the tab portions of the transmission photosensors to be installed.

Step 7 : Reinstall all parts in the opposite order of the removal procedure.

Notes :

¾ When installing the U/D cable assembly onto the transmission photosensor, be

careful not to confuse the connectors.

 Lever up cable assembly (white): front
 Lever down cable assembly (blue): rear

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(2) Replacing the transmission photosensor (CR origin side)

Notes :

¾ Refer to ‘Head Lock Menu’

Step 1 : Unlock the head.

Step 2 : Move the carriage from the capping position to the left.

Step 3 : Remove the transmission photosensor from the ORG sensor installation board.

1 = ORG sensor installation board 2 = Connector
3 = Transmission photosensor

Notes :

¾ The ORG sensor installation board has been adjusted at the origin in factory. Do

not loosen the fixed screws.

Step 4 : Remove the connector from the transmission photosensor.

Step 5 : Remove the transmission photosensor.

Step 6 : Apply the screw lock to the tab portions of the transmission photosensors to be installed.

Step 7 : Reinstall all parts in the opposite order of the removal procedure.

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4.5.9. Replacing the flushing box assembly

Notes :

¾ Remove following covers before replacing the flushing box assembly.

 Side cover R: refer to "Removing side cover R"
 Side cover L: refer to "Removing side cover L"
 Front cover: refer to "Removing the front cover"
 Carriage cover: refer to "Removing the carriage cover"
 Y rail cover: refer to "Removing the Y rail cover"

Step 1 : Unlock the head.

Notes :

¾ Refer to ‘Head Lock Menu’

Step 2 : Move the carriage from the capping position to the left.

Step 3 : Remove the screw fixing the flushing box assembly.

1 = Flushing box assembly 2 = Screw (M3x8) fixing the flushing box assembly

Step 4 : Remove the tube from the flushing box assembly.

Step 5 : Replace the flushing box assembly.

Step 6 : Reinstall all parts in the opposite order of the removal procedure.

Step 7 : Adjust the head and flushing box assembly so that they do not come into contact.

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4.6. REPLACING THE CR ACTUATOR

4.6.1. Replacing the CR motor assembly

Caution :

The motor is hot after the product has been operated, so be careful not to burn yourself.

Notes :

¾ Remove following covers before replacing the CR motor assembly.

 Side cover R: refer to "Removing side cover R"
 Side cover L: refer to "Removing side cover L"
 Front cover: refer to "Removing the front cover"
 Carriage cover: refer to "Removing the carriage cover"
 Y rail cover: refer to "Removing the Y rail cover"
 Media guide F: refer to "Removing media guide F"

Step 1 : Remove the CR motor cable assembly connector from the CR motor assembly.

Step 2 : Remove the 4 hexagon socket head cap screws fixing the CR motor assembly.

Step 3 : Replace the CR motor assembly.

1 = CR motor assembly 2 = Connector
3 = Hexagon socket head cap screws (M3x6)

Step 4 : Reinstall all parts in the opposite order of the removal procedure.

Step 5 : Adjust the tension of the CR deceleration belt according to "CR deceleration belt tension

adjustment".

Notes :

¾ When installing the CR motor cable assembly connector, install the white cable on

the right side as shown in the previous figure.

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4.6.2. Replacing the steel belt

Caution :

When replacing the steel belt, be careful not to cut your hands by the belt.

Notes :

¾ Do not damage the steel belt.

¾ Remove following covers before replacing the steel belt.

 Side cover R: refer to "Removing side cover R"
 Side cover L: refer to "Removing side cover L"
 Front cover: refer to "Removing the front cover"
 Carriage cover: refer to "Removing the carriage cover"
 Y rail cover: refer to "Removing the Y rail cover"

Step 1 : Unlock the head.

Notes :

¾ Refer to ‘Head Lock Menu’

Step 2 : Move the carriage from the capping position to the left.

Step 3 : Rotate the 2 steel belt adjustment screws counterclockwisely to loosen the steel belt.

1 = Steel belt adjustment screws 2 = Steel belt

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Step 4 : Remove the 2 screws fixing the steel belt.

1 = Screws fixing the steel belt 2 = Steel belt

Step 5 : Replace the steel belt.

Notes :

¾ Be careful when handling the steel belt. The steel belt may be cut off when

accreting dust to it or creasing it.

Step 6 : Reinstall all parts in the opposite order of the removal procedure.

Step 7 : Perform steel belt tension adjustment according to "Steel belt tension adjustment".

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4.6.3. Replacing the SLIDE motor assembly, HD_SLIDE sensor

assembly,

and slide motor installation board

Caution :

The motor is hot after the product has been operated, so be careful not to burn yourself.

Notes :

¾ Remove following covers before replacing the SLIDE motor assembly, HD_SLIDE

sensor assembly, and slide motor installation board.

 Side cover R: refer to "Removing side cover R"
 Side cover L: refer to "Removing side cover L"
 Front cover: refer to "Removing the front cover"
 Carriage cover: refer to "Removing the carriage cover"
 Y rail cover: refer to "Removing the Y rail cover"

Step 1 : Remove the connectors on the SLIDE motor assembly and HD_SLIDE sensor assembly.

Step 2 : Remove the 2 screws fixing the SLIDE motor assembly.

1 = SLIDE motor assembly 2 = Screws (M3x6) fixing the SLIDE motor assembly
3 = HD_SLIDE sensor assembly 4 = Screws (M2x8) fixing the HD_SLIDE sensor

assembly

5 = Slide motor installation board 6 = Screws (M4x6) fixing the slide motor installation

board

Step 3 : Replace the SLIDE motor assembly.

Step 4 : Remove the 2 screws fixing the HD_SLIDE sensor assembly.

Step 5 : Replace the HD_SLIDE sensor assembly.

Step 6 : Remove the 2 screws fixing the slide motor installation board.

Step 7 : Replace the slide motor installation board.

Step 8 : Reinstall all parts in the opposite order of the removal procedure.

Step 9 : Make sure that the Idler moves smoothly.

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4.6.4. Replacing the T fence

Notes :

¾ Remove following covers before replacing the T fence.

 Side cover R: refer to "Removing side cover R"
 Side cover L: refer to "Removing side cover L"
 Front cover: refer to "Removing the front cover"
 Carriage cover: refer to "Removing the carriage cover"
 Y rail cover: refer to "Removing the Y rail cover"

Step 1 : Remove the T fence from the T fence spring hook on the side of the L side frame.

Rockhopper II 2 heater Rockhopper II 4 heater

1 = T fence spring 2 = T fence spring hook
3 = T fence

Step 2 : Remove the screw fixing the T fence push plate.

1 = T fence push plate 2 = Screw (M3x6) fixing the T fence push plate
3 = T fence

Step 3 : Remove the T fence from the hook.

Step 4 : Remove the screw fixing the T fence stationary plate.

1 = T fence stationary plate 2 = T fence
3 = Screw (M3x6) fixing the T fence stationary plate

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Step 5 : Remove the T fence from the hook.

Step 6 : Pull out the T fence in the direction of the arrow as shown in the previous figure while being

careful not to damage the CR_ENC assembly.

Step 7 : Reinstall all parts in the opposite order of the removal procedure.

Notes :

¾ When installing the T fence, pay attention to the following :

 When there is a film on the T fence, remove the film and install the T fence.
 Properly install the T fence to the hooks on the T fence stationary plate.

Refer to the figure in step 2.

 The T fence and the hooks on the stationary plate must have a loose fit.
 When securing the stationary plate with screws, it must be loosened

enough so the T fence can be moved.

 Insert the T fence into the hooks on the T fence push plate and the

CR_ENC assembly. Refer to the following figure.

 Fix the T fence spring hook so that distance A of following diagram is about

1mm.

1 = T fence push plate 2 = T fence
3 = CR_ENC assembly 4 = T fence spring hook

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4.6.5. Replacing the CR slave pulley assembly

Notes :

¾ Remove following covers before replacing the CR slave pulley assembly.

 Side cover R: refer to "Removing side cover R"
 Side cover L: refer to "Removing side cover L"
 Front cover: refer to "Removing the front cover"
 Carriage cover: refer to "Removing the carriage cover"
 Y rail cover: refer to "Removing the Y rail cover"

Step 1 : Follow the instructions in "Replacing the steel belt" to remove the steel belt.

Step 2 : Replace the CR slave pulley assembly.

1 = CR slave pulley assembly 2 = Steel belt
3 = Bearing stopper

Step 3 : Reinstall all parts in the opposite order of the removal procedure.

Step 4 : Perform steel belt tension adjustment according to "Steel belt tension adjustment".

Notes :

¾ Be careful when handling the steel belt. The steel belt may be cut off when

accreting dust to it or creasing it.

¾ The driven pulley shaft is installed one way only. Refer to "Service Parts

List/Exploded Views/Configuration Diagrams", to install it correctly so that the
bearing stoppers are on top.

¾ After installing the CR slave pulley assembly, move the carriage to the left and right

manually to confirm that the steel belt has been set equally in the center of the CR
actuator pulley and the CR slave pulley assembly.

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

Notes :

¾ Remove following covers before replacing the CR slave pulley.

 Side cover R: refer to "Removing side cover R"
 Side cover L: refer to "Removing side cover L"
 Front cover: refer to "Removing the front cover"
 Carriage cover: refer to "Removing the carriage cover"
 Y rail cover: refer to "Removing the Y rail cover"

Step 1 : Follow the instructions in "Replacing the CR motor assembly" to remove the CR motor assembly.

Step 2 : Follow the instructions in "Replacing the steel belt" to remove the steel belt.

Step 3 : Replace the CR actuator pulley.

Step 4 : Replace the CR deceleration belt.

1 = CR slave pulley 2 = CR deceleration belt

Step 5 : Reinstall all parts in the opposite order of the removal procedure.

Step 6 : Adjust the tension of the CR deceleration belt according to "CR deceleration belt tension

adjustment".

Notes :

¾ After installing the CR actuator pulley assembly, move the carriage to the left and

right manually to confirm that the steel belt has been set equally in the center of the
CR actuator pulley and the CR slave pulley assembly.

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

ink

tube

Notes :

¾ To replace the board and connect or disconnect the FFC type cable, you should

leave the plug disconnected from the power socket for a while. Otherwise, over­current could be generated and damage board.

¾ Remove following covers before replacing the steel bearer, tube guide, CR tape

power cable, and ink tube.

 Side cover R: refer to "Removing side cover R"
 Side cover L: refer to "Removing side cover L"
 Front cover: refer to "Removing the front cover"
 Carriage cover: refer to "Removing the carriage cover"
 Y rail cover: refer to "Removing the Y rail cover"

Step 1 : Remove the 8 screws fixing the CR cover.

1 = CR cover 2 = Screws (M3x8) fixing the CR cover

Step 2 : Remove the CR tape power cable connector from the CR board assembly and Mainboard

assembly.

Step 3 : Remove the 2 screws fixing cable push plate.

Step 4 : Remove the 2 screws fixing the tube clamp.

1 = CR tape power cable 2 = Steel bearer
3 = Cable push plate 4 = Screws fixing cable push plate (M3x8)
5 = Screws fixing tube clamp (M3x8)

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Step 5 : Completely remove tube bundles 1 and 2.

1 = Tube bundle 2 = Tube bundle 2

Step 6 : Remove the 4 screws fixing the tube clamp.

Step 7 : Remove the tube clamp.

Step 8 : Remove the coupling screws, O-ring and ink tube from the coupling.

Step 9 : Replace the ink tube.

Step 10 : Remove the 2 screws fixing the cable clamp.

Step 11 : Replace the steel bearing.

Step 12 : Replace the tube guide.

Step 13 : Remove the pipe clamp.

Step 14 : Replace the CR tape power cable.

1 = Tube push plate 2 = Cable clamp
2 = Pipe clamp 3 = Coupling, O-ring, coupling screws
4 = Screws fixing tube push plate (M3x8) 4 = Screws fixing tube cramp (M3x20)

Step 15 : Reinstall all parts in the opposite order of the removal procedure.

Notes :

¾ The CR tape power cables must be bundled during installation so that they can not

move.

¾ The edge of the tube push plate must be upside when installed.
¾ You should soak the O-ring in cleaning liquid once gain before installing it.

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

assembly

Notes :

¾ Remove following covers before replacing the cover R sensor assembly and the

cover L sensor assembly.

 Side cover R: refer to "Removing side cover R"
 Side cover L: refer to "Removing side cover L"
 Front cover: refer to "Removing the front cover"
 Carriage cover: refer to "Removing the carriage cover"
 Y rail cover: refer to "Removing the Y rail cover"

(1) Replacing the cover R sensor assembly

Step 1 : Remove the cover R sensor assembly connector from the Mainboard assembly.

Step 2 : Remove the 2 screws fixing the cover R sensor assembly.

1 = Cover R sensor assembly 2 = Screws (M2x8) fixing the cover R sensor assembly

Step 3 : Replace the cover R sensor assembly.

Step 4 : Reinstall all parts in the opposite order of the removal procedure.

Step 5 : Perform cover sensor adjustment according to "Cover sensor adjustment".

(2) Replacing the cover L sensor assembly

Step 1 : Remove media guide F.

Step 2 : Remove the cover L sensor assembly connector from the cover L cable.

Step 3 : Remove the 2 screws fixing the cover L sensor assembly.

1 = Cover L sensor assembly 2 = Screws (M2x8) fixing the cover L sensor assembly

Step 4 : Replace the cover L sensor assembly.

Step 5 : Reinstall all parts in the opposite order of the removal procedure.

Step 6 : Perform cover sensor adjustment according to "Cover sensor adjustment".

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4.7. REPLACING THE CURSOR

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

assembly

and solenoid spring

(1) Replacing the cutter spring

Step 1 : Open the front cover.

Step 2 : Remove the cutter blade from the cutter holder.

Step 3 : Remove the cutter spring from the cutter holder.

1 = Cutter spring 2 = Cutter holder

Step 4 : Replace the cutter spring.

Step 5 : Reinstall all parts in the opposite order of the removal procedure.

(2) Replacing the cutter holder, cutter cap, solenoid assembly and solenoid spring

Notes :

¾ Remove following covers before replacing the cutter holder, cutter cap, solenoid

assembly, and solenoid spring.

 Side cover R: refer to "Removing side cover R"
 Side cover L: refer to "Removing side cover L"
 Front cover: refer to "Removing the front cover"
 Carriage cover: refer to "Removing the carriage cover"
 Y rail cover: refer to "Removing the Y rail cover"
 Head cover: refer to "Removing the head cover"

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Step 1 : Remove the 2 screws fixing the cutter holder and holder support.

1 = Holder support 2 = Cutter holder
3 = Screws (M3x6) fixing the cutter holder and holder support

Step 2 : Remove the cutter holder.

Step 3 : Remove the cutter blade and cutter spring from the cutter holder.

Step 4 : Remove the cutter cap and Solenoid spring.

Step 5 : Remove the screw fixing the solenoid assembly to the cutter cap.

1 = Cutter cap 2 = Screws (M3x6) fixing the solenoid assembly to

the cutter cap
3 = Solenoid spring 4 = Solenoid assembly
5 = Screws (M2x4) fixing the solenoid assembly to
the cutter holder

6 = Cutter holder

Step 6 : Replace the cutter cap and solenoid spring.

Step 7 : Remove the 2 screws fixing the solenoid assembly to the cutter holder.

Step 8 : Use a screwdriver to push the solenoid assembly up from the hole on the cutter holder side.

Step 9 : Replace the solenoid assembly.

Step 10 : Reinstall all parts in the opposite order of the removal procedure.

Step 11 : Adjust the cutter according to "Cutter adjustment".

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

Notes :

¾ To replace the board and connect or disconnect the FFC type cable, you should

leave the plug disconnected from the power socket for a while. Otherwise, over­current could be generated and damage board.

¾ Remove following covers before replacing the print head assembly and head tape

power cable.

 Side cover R: refer to "Removing side cover R"
 Side cover L: refer to "Removing side cover L"
 Front cover: refer to "Removing the front cover"
 Carriage cover: refer to "Removing the carriage cover"
 Y rail cover: refer to "Removing the Y rail cover"
 Head cover: refer to "Removing the head cover"

¾ The print head assembly has been pre-adjusted. Do not disassemble it.

Step 1 : Drain the ink from all ink paths according to "Head wash menu".

Step 2 : Loosen the 2 screws fixing the damper clamp.

1 = Damper clamp 2 = Screws (M3x6) fixing the damper clamp

Step 3 : Remove the damper clamp.

Step 4 : Remove the head tape power cable.

1 = Head tape power cable 2 = Damper assembly
3 = Head stationary plate / head spacer 4 = Step-bore screw
5 = Screws (M2.6x5) fixing the head stationary plate 6 = Print head assembly

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Step 5 : Remove the damper assembly from the print head assembly.

Step 6 : Remove the screw and step-bore screw fixing the head stationary plate.

Step 7 : Remove the rotation adjustment spring under the head with small flat-head driver or another tool.

Step 8 : Replace the print head assembly.

Step 9 : Reinstall all parts in the opposite order of the removal procedure.

Notes :

¾ Place the removed damper assembly facing upward and fix with tape or place it in a

container to prevent the ink from leaking. Ink adhesion on board may cause faulty
print head.

¾ Align the head tape power cables one by one to each head and paste together with

double-faced tape.

¾ Make sure that the head does not float when installing the head.

 A : Insert the concave portion of the head base in the rear of the cursor convex portion of the

cursor.

 B : Insert the rotation adjustment spring into the convex portion of the head base on the right

front.

Step 10 : Perform head precision adjustment according to "Head precision adjustment".

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

Notes :

¾ Remove following covers before replacing the H ink tube, tube branch, and damper

assembly.

 Side cover R: refer to "Removing side cover R"
 Side cover L: refer to "Removing side cover L"
 Front cover: refer to "Removing the front cover"
 Carriage cover: refer to "Removing the carriage cover"
 Y rail cover: refer to "Removing the Y rail cover"
 Head cover: refer to "Removing the head cover"

Step 1 : Drain the ink from all ink paths according to "Head wash menu".

Step 2 : Follow step 1 in "Replacing the print head assembly and head tape power cable" to remove the

damper clamp.

Step 3 : Remove the ink tube and tube branch from the branch fixing material.

1 = Branch fixing material 2 = Tube branch
3 = Ink tube 4 = H ink tube
5 = Coupling screw, O-ring

Step 4 : Remove the coupling screw and O-ring on the ink tube and the H ink tube sides from the tube

branch.

Step 5 : Replace the tube branch.

Step 6 : Remove the damper assembly from the print head assembly.

1 = Head tape power cable 2 = Damper assembly
3 = Print head assembly 4 = H ink tube, O-ring

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Step 7 : Remove the H ink tube, coupling screw and O-ring from the damper assembly.

Step 8 : Replace the damper assembly.

Step 9 : Replace the H ink tube and O-ring.

Notes :

¾ Please soak the O-ring in cleaning liquid before installation.

Step 10 : Reinstall all parts in the opposite order of the removal procedure.

Notes :

¾ When tightening coupling screws, finger-tighten those. If using tools, it may result

in cracking where the screws fix damper and fail to fill the ink.

¾ Do not grasp the film area of the damper strongly. Doing so may cause faulty

damper and print failure.

4.7.4. Replacing the CR board assembly

Notes :

¾ To replace the board and connect or disconnect the FFC type cable, you should

leave the plug disconnected from the power socket for a while. Otherwise, over­current could be generated and damage the board

¾ Remove following covers before replacing the CR board assembly.

 Side cover R: refer to "Removing side cover R"
 Side cover L: refer to "Removing side cover L"
 Front cover: refer to "Removing the front cover"
 Carriage cover: refer to "Removing the carriage cover"
 Y rail cover: refer to "Removing the Y rail cover"

Step 1 : Remove the 8 screws fixing the CR cover.

1 = CR cover 2 = Screws (M3x8) fixing the CR cover