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