MM Spitfire 65-90 and Rockhopper 3 Rev 2.3

Maintenance
Manual
Spitfire 65/90
Rockhopper 3
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Spitfire 65/90 & Rockhopper 3
Service Manual
COPYRIGHT NOTICE
COPYRIGHT © 20-Oct-11 Mutoh Belgium nv. 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 Mutoh’s Spitfire 65/90 and Rockhopper 3. 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 Belgium nv
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.
20 October 2011
Published: Mutoh Belgium nv, 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:
• Change the direction of your radio and TV reception antenna or feeder.
• Change the direction of the product.
• Move either the product or the receiving antenna so there is more distance between them.
• Be sure the product and the receiving antenna are on separate power lines.
2. Trademark mentioned in this manual.
• MUTOH, Spitfire 65/90, Spitfire Mild Solvent, Rockhopper 3, Eco Solvent Ultra and Eco Solvent
Plus, MH-GL, MH-GL2, MH-RTL are registered trademarks or product names of MUTOH
INDUSTRIES LTD.
• Centronics and Bitronics are registered trademarks or product names of Centronics Data Computer
Corporation.
• Windows 95, Windows 98, Windows Me, Windows XP, Windows NT4.0, Windows2000, and MSDOS
are registered trademarks or product names of Microsoft Corporation.
• DOS/V is registered trademark and product name of International Business Machine Corporation
(IBM).
• 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 BELGIUM nv.
The product and the contents of this publication may be changed without prior notification.
MUTOH BELGIUM nv 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 BELGIUM nv 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 ....................................................................................................................... 11

1.1 INTRODUCTION .................................................................................................................................... 12
1.2 WARNINGS, CAUTIONS AND NOTES ...................................................................................................... 12
1.3 IMPORTANT SAFETY INSTRUCTIONS....................................................................................................... 12
1.4 WARNING LABELS ................................................................................................................................ 15
1.5 MAINTENANCE AND OPERATION LABELS ................................................................................................ 17
1.6 LABELS IN FUNCTION OF TRANSPORTATION ........................................................................................... 18
2 PRODUCT OVERVIEW ........................................................................................................................... 19
2.1 INTRODUCTION .................................................................................................................................... 20
2.2 FEATURES........................................................................................................................................... 20
2.3 PART NAMES AND FUNCTIONS............................................................................................................... 21
2.4 PRINTER STATUS ................................................................................................................................. 26
3 SPECIFICATIONS ................................................................................................................................... 29
3.1 INTRODUCTION .................................................................................................................................... 30
3.2 PRODUCT SPECIFICATIONS .................................................................................................................. 30
3.3 INTERFACE SPECIFICATIONS ................................................................................................................ 31
3.4 INSTALLATION ...................................................................................................................................... 33
4 PARTS REPLACEMENT ......................................................................................................................... 35
4.1 INTRODUCTION .................................................................................................................................... 37
4.2 SWITCHING INK TYPES ......................................................................................................................... 41
4.3 REMOVING THE COVER ........................................................................................................................ 49
4.4 INSTALLING AND ACTIVATING THE SERVICE CHIP. ................................................................................... 66
4.5 HEATER ELEMENTS .............................................................................................................................. 69
4.6 BOARD ASSEMBLIES............................................................................................................................. 75
4.7 REPLACING THE PF ACTUATOR ............................................................................................................ 84
4.8 REPLACING THE CR ACTUATOR ........................................................................................................... 97
4.9 REPLACING THE CURSOR ................................................................................................................... 107
4.10 REPLACING THE MAINTENANCE STATION AREA .................................................................................... 121
4.11 REPLACING THE PUMP AREA .............................................................................................................. 136
4.12 REPLACING THE CARTRIDGE AREA ..................................................................................................... 140
4.13 REPLACING THE WASTE BOTTLE ......................................................................................................... 144
4.14 REPLACING / INSTALLING THE SMART CHIP MANAGEMENT SYSTEM. ....................................................... 145
4.15 REPLACING THE WASTE BOTTLE BOX SENSOR ASSEMBLY ..................................................................... 150
5 DIAGNOSTICS MODE ........................................................................................................................... 151
5.1 INTRODUCTION .................................................................................................................................. 153
5.2 PREPARATIONS ON THE PRINTER BEFORE OPERATING ......................................................................... 153
5.3 OPERATIONS IN DIAGNOTICS MODE .................................................................................................... 154
5.4 TEST / INSPECTION MENU .................................................................................................................. 158
5.5 ADJUSTMENT MENU........................................................................................................................... 166
5.6 CLEANING MENU ............................................................................................................................... 186
5.7 SAMPLE PRINTING MENU ................................................................................................................... 186
5.8 PARAMETER MENU ............................................................................................................................ 187
5.9 ENDURANCE RUNNING MENU ............................................................................................................. 193
5.10 HEAD LOCK MENU ............................................................................................................................. 203
5.11 HEATER SYSTEM MENU ...................................................................................................................... 204
5.12 SOL PREPARE MENU .......................................................................................................................... 206
5.13 SMS MENU ...................................................................................................................................... 206
5.14 MACHINE SIZE SELECT MENU .............................................................................................................. 207
5.15 CHIPMGR MENU ................................................................................................................................ 208
5.16 SMS HTEMP MENU ............................................................................................................................ 208
6 MAINTENANCE MODE ......................................................................................................................... 209
6.1 INTRODUCTION .................................................................................................................................. 210
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6.2 START UP .......................................................................................................................................... 210

6.3 MAINTENANCE MENU ......................................................................................................................... 211
7 ADJUSTMENTS..................................................................................................................................... 215
7.1 INTRODUCTION .................................................................................................................................. 216
7.2 DIFFERENT ADJUSTMENTS ................................................................................................................. 216
7.3 PARAMETER BACKUP ......................................................................................................................... 219
7.4 FIRMWARE INSTALLATION ................................................................................................................... 224
7.5 STEEL BELT TENSION ADJUSTMENT ..................................................................................................... 231
7.6 PF DECELERATION BELT TENSION ADJUSTMENT .................................................................................. 233
7.7 HEAD PRECISION ADJUSTMENT (SLANT) .............................................................................................. 234
7.8 REPEATABILITY ADJUSTMENT (BI-DIRECTIONAL) ................................................................................. 245
7.9 CW ADJUSTMENTS (UNI-DIRECTIONAL) .............................................................................................. 249
7.10 CR DECELERATION BELT TENSION ADJUSTMENT .................................................................................. 250
7.11 COVER SENSOR ADJUSTMENT ............................................................................................................ 251
7.12 HEAD HEIGHT ADJUSTMENT ................................................................................................................ 252
7.13 MEDIA SENSOR SENSITIVITY ADJUSTMENT ........................................................................................... 254
7.14 CUTTER ADJUSTMENT ........................................................................................................................ 257
7.15 PUMP TUBING LAYOUT FOR PUMP ASSEMBLY ....................................................................................... 258
7.16 BOARD CHECKLIST............................................................................................................................. 259
7.17 FLUSHING BOX HEIGHT POSITION ADJUSTMENT .................................................................................... 264
7.18 STEP ADJUST .................................................................................................................................... 266
8 MAINTENANCE ..................................................................................................................................... 273
8.1 INTRODUCTION .................................................................................................................................. 274
8.2 CLEANING ......................................................................................................................................... 274
8.3 PERIODICAL SERVICES ...................................................................................................................... 275
8.4 PART LIFE INFORMATION .................................................................................................................... 279
8.5 JIG AND TOOL LIST ............................................................................................................................ 280
8.6 LUBRICATION/BONDING...................................................................................................................... 281
8.7 TRANSPORTATION OF THE PRINTER .................................................................................................... 283
9 APPENDIX ............................................................................................................................................. 285
9.1 INTRODUCTION .................................................................................................................................. 285
9.2 WIRING DIAGRAM .............................................................................................................................. 285
9.3 SERVICE PARTS LIST/EXPLODED VIEWS/CONFIGURATION DIAGRAMS ................................................... 285
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1 SAFETY INSTRUCTIONS
1.1 INTRODUCTION ......................................................................................................... 12
1.2 WARNINGS, CAUTIONS AND NOTES ............................................................................ 12
1.3 IMPORTANT SAFETY INSTRUCTIONS ............................................................................ 12
1.4 WARNING LABELS ..................................................................................................... 15

1.4.1 Handling the warning labels ............................................................................. 15
1.4.2 Locations and types of warning labels ............................................................. 15
1.4.2.1 Location and types of warning labels on front part. ....................................... 15
1.4.2.2 Location and types of warning labels on back part. ...................................... 17
1.5 MAINTENANCE AND OPERATION LABELS ...................................................................... 17
1.6 LABELS IN FUNCTION OF TRANSPORTATION ................................................................. 18
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1.1 INTRODUCTION
This chapter explains the meaning of safety terms for personnel who operate this equipment, important
safety instructions, and the positions of the warning labels.
Important
• Be sure to follow all instructions and warnings in this manual when using the equipment.
1.2 WARNINGS, CAUTIONS AND NOTES

Safety terms in this manual and the contents of warning labels attached to the printer are categorized into
the following three types depending on the degree of risk (or the scale of accident).
Read the following explanations carefully and follow the instructions in this manual.
Safety terms Details

Important Must be followed carefully to avoid death or serious bodily injury
Must be observed to avoid bodily injury (moderately or lightly) or damage to your
Caution
equipment
Notes Contains important information and useful tips on the operation of your printer
1.3 IMPORTANT SAFETY INSTRUCTIONS

General safety instructions that must be observed to use the equipment safely are explained below.
 Do not place the printer in the following areas. Doing so may result in the printer tipping or falling over
and causing injury.
• Unstable surfaces
• Sloping floors
• Areas subject to vibration by other equipment
 Do not stand on or place heavy objects on your printer. Doing so may result in the printer tipping or
falling over and causing injury.
 Do not cover the ventilation hole of your printer with cloth, such as a blanket or table cloth. Doing so
could obstruct ventilation and cause fire.
 Do not place the printer in humid and dusty areas. Doing so may result in electrical shock or fire.
 Do not use a damaged power cable. Doing so may result in electrical shock.
 Do not attempt to plug in electrical plugs with wet hands. Doing so may result in electrical shock.
 Do not connect earth cables in the following areas.
• Gas pipes → Doing so may cause fire or an explosion.
• Earth terminals for telephone line or lightening rod → Doing so may cause a large flow of voltage if
lightening occurs.
• Water pipes or faucets → If there is a plastic part in the pipe, the earth will not work properly.
 Do not insert or drop metal or inflammable objects into openings, such as ventilation outlets. Doing so
may result in electrical shock and fire.
 Stop using your printer if a liquid is spilled into it. This may cause electrical shock or fire. Turn the
printer off as soon as possible, unplug the power cord, and contact your local MUTOH dealer.
 Be sure to use the attached cable. Otherwise, electrical shock or fire may occur.
 Be sure to use the specified voltage (AC 100 V to 120V, or AC 220V to 240V). Otherwise, electrical
shock or fire may occur.
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 Use electricity directly from a power outlet (AC 100 V to 120V, or AC 220V to 240V). Do not put many
loads on one electrical output. Otherwise, heat may be generated and cause fire.
 Be sure to use an outlet with an earth terminal and use the terminal correctly. Otherwise, electrical
shock or fire may occur.
 Follow the instructions below when handling the power cable.
• Do not modify the cable.
• Do not put heavy objects on the cable.
• Do not bend, twist or pull the cable.
• Do not wire the cable near equipment that generates heat.
 Follow the instructions below when handling the power plug. Otherwise, fire may occur.
• Wipe away dust and any other residue before inserting the plug.
• Ensure that the plug is firmly inserted as far as it will go.
 When handling the foot switch, be aware of the following:
• Do not place anything heavy on the foot switch.
• Do not bend the cable of the foot switch with force and do not pull.
• Do not place the foot switch near thermal devices.
 When handling ink cassettes, be careful that ink does not get in your eyes or on your skin. However, if
this happens, flush immediately with water and wash skin with soap. Otherwise, your eyes may become
congested or inflamed slightly. If you feel discomfort, consult a doctor immediately.
 Do not disassemble ink cassettes. Otherwise, ink may get in your eyes or on your skin.
 Spitfire Mild Solvent Inks
• General information:
Symptoms of poisoning may even occur after several hours; therefore medical observation for at
least 48 hours after the accident.
• After inhalation:
Supply fresh air. If required, provide artificial respiration. Keep patient warm. Consult doctor if
symptoms persist.
In case of unconsciousness place patient stably in side position for transportation.
• After skin contact: Generally the product does not irritate the skin.
• After eye contact: Rinse opened eye for several minutes under running water.
• After swallowing: Seek medical advice or consult doctor.
 Eco Solvent Ultra
• General information:
Symptoms of poisoning may even occur after several hours; therefore medical observation for at
least 48 hours after the accident.
• After inhalation:
remove person to ventilated fresh air. If not breathing, give artificial respiration right away. If
breathing is difficult, give oxygen. Seek immediate medical attention.
• After skin contact: wash surface areas with soap and water. Wash soiled clothing before wearing.
Consult a physician if irritation continues.
• After eye contact: immediately flush with room temperature, low pressure, and clean water for at
least 15 minutes. Seek medical attention if eye irritation continues.
• After swallowing: Seem medical advice or consult doctor.
 Be careful not to pinch your fingers when opening and closing the cover of the ink compartment.
 Be careful not to pinch your fingers when opening and closing the front cover.
 Follow the instructions below when connecting the network interface cable. Otherwise, electrical shock
or fire may occur.
• Do not touch the connector.
• Do not connect the network cable connector that is not the same specification to the interface board.
 When cutting the roll media, be careful of the following. Incorrect handling can result in injury to the
hands and fingers from the razor blade.
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• When holding the media, do not place fingers over the media cut groove.
• Move the razor blade slowly along the media cutting groove.
 Do not use thinner, benzene, alcohol or other active agents. Doing so may result in damage or paint
peeling from the casing.
 Be careful not to spill water inside the printer. Doing so may result in a short circuit.
 Be careful not to touch the heaters during or after operation. Doing so may result in burns.
 With the Spitfire 65/90 printer, only use Spitfire Mild Solvent Ink and appropriate cleaning liquid. With the
Rockhopper 3 printer, only use Eco Solvent Ultra ink and appropriate cleaning liquid.
 Never open the covers fixed with screws, except the left cover. Doing so may result in electrical shock
or a malfunctioning in the printer.
 Do not touch the cutter blade. Doing so may result in bodily injury.
 Do not cut hard objects or drop the cutter. Doing so may damage or chip the cutter blade.
 Do not bend or pull the waste fluid tube. Doing so may cause that the waste fluid will leak out and
malfunction in the product.
 Do not touch the cleaning wiper or the head cap unit whit bear hands. Use a dust free cloth and gloves
to clean.
 Do not tilt the printer, stand it against a wall or turn it upside down. Doing so may cause ink to leak
inside the printer. Movement after transport is also not covered by the warranty.
 When installing options, do not touch the elements on the circuit board. The elements on the boards can
be very hot and can cause burns.
 Have four or more people unpack and assemble the printer.
 When lifting the printer out of the packing box, be sure to remove the vinyl cover first, and then grab the
holding grips on the sides of the printer. Lifting the printer with the vinyl cover on may cause your hands
to slip and drop or damage the printer.
 Have two or more people transport the printer.
 Ensure that the plug has been disconnected from the power socket when it is not to be used for a long
time.
 Earth wires must be connected to wires or terminals that fulfil the conditions below.
• Earth terminals of power sockets
• Earth wires with copper morsel that is at least 650 mm under the ground
 Earth wires must be connected to wires or terminals that fulfil the conditions below.
 Keep the printer horizontal during transportation.
 Be sure to do the following before attaching options.
• Switch the printer OFF.
• Unplug the power cord from the socket.
• Unplug cables connected to the printer. Otherwise, damage to the printer or your computer may
occur.
• Remove electrostatic charge from your clothes and body by touching the metal parts of the printer.
• Electronic components such as the memory may malfunction if exposed to an electrostatic charge.
 The equipment that you bought has required the extraction and use of natural resources for its
production. It may content hazardous substances for the health and the environment.
In order to avoid the dissemination of those substances in our environment and to diminish the pressure
on the natural resources, we encourage you to use the appropriate take-back system. Those systems
will reuse or recycle most of the materials of your end life equipment in a sound way.
If you need more information on the collection, reuse and recycling systems, please contact your local or
regional waste administration.
 Do not replace the battery on the mainboard with an incorrect type. There will be a risk of explosion
otherwise.
Dispose the used batteries according to the local or regional waste regulations.
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1.4 WARNING LABELS

The handling, attachment locations, and types of warning labels are explained below.
Warning labels are attached on areas which require attention. Read and understand the positions and
contents thoroughly before performing your work.
1.4.1 Handling the warning labels
Be sure to note the following when handling the labels.
Notes
• Make sure that all labels can be recognized. If text or illustrations cannot be seen clearly, either clean
or replace the label.
• When cleaning labels, use a cloth with water or neutral detergent. Do not use a solvent or gasoline.
• If a warning label is damaged, lost or cannot be recognized, replace the label. When replacing warning
labels, contact your local MUTOH dealer.
1.4.2 Locations and types of warning labels
The locations of warning labels are shown below.
1.4.2.1 Location and types of warning labels on front part.
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N° Type
4,7
5,6
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1.4.2.2 Location and types of warning labels on back part.
N° Type
CAUTION
THIS UNIT HAS TWO POWER SUPPLY CORDS, WHEN WiNDING
3 UNIT IS PROVIDED. TO REDUCE THE RISK OF ELECTRICAL
SHOCK, DISCONNECT ALL POWER SUPPLY CORDS
BEFORE SERVICING.
1.5 MAINTENANCE AND OPERATION LABELS
Rockhopper 3
Spitfire 65/90
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1.6 LABELS IN FUNCTION OF TRANSPORTATION
N° Description
1 BEFORE powering on printer,
REMOVE dummy cartridges.
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2 PRODUCT OVERVIEW
2.1 INTRODUCTION ......................................................................................................... 20
2.2 FEATURES ............................................................................................................... 20
2.3 PART NAMES AND FUNCTIONS .................................................................................... 21

2.3.1 Front ................................................................................................................ 21
2.3.2 Connections on the back ................................................................................. 22
2.3.3 Position and function of the heating elements ................................................. 23
2.3.4 Operation panel ............................................................................................... 24
2.4 PRINTER STATUS ...................................................................................................... 26

2.4.1 Normal ............................................................................................................. 26
2.4.2 Setting menu display ........................................................................................ 26
2.4.3 Changing the printer status .............................................................................. 27
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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
2 models feature new print heads and achieve high speed printing.
They also offer printing widths up to 1643mm in Spitfire-65 and Rockhopper-65 (65 inch) and 2250 mm in
Spitfire-90 and Rockhopper-90 (90 inch).
Machine Media Width Printing Width

Spitfire 65 and Rockhopper 65 1653 mm 1643 mm
Spitfire 90 and Rockhopper 90 2280 mm 2250 mm
(2) Wide variety of compatible media
Adjustable head height can be adapted to various media thickness from 0.08 up to 1.1 mm.
(3) Vibrant Colour Reproduction
To reproduce sharp and vivid colour, 4 ink colours are used for printing. On the Spitfire 65/90 uses 220ml of
large capacity Spitfire Mild Solvent cassettes equipped with an IC chip. The Rockhopper 3 uses 220ml of
large capacity Eco Solvent Ultra cassettes equipped with an IC chip. This IC chip can automatically detect
the correct ink type, the correct colour, ink configuration and the ink quantity, significantly improving
productivity.
(4) Effective usage of media
A JOG feature is provided allowing the user to set the printing position. Because printing can be performed
on media on which there has already been 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
N° Name Function
1 Heater plate Supports and heats the media during printing.
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:
2 Front cover
Media setting and replacement
Cutter blade replacement
Cleaning the cleaning wiper
3 Carriage Drives and holds the print heads.
4 Operation panel To control the printer.
5 Ink compartment cover Covers the ink compartment.
6 Stand Carries the main body.
7 Waste bottle assembly Collects the waste fluid.
8 Winder Rolls up the roll media.
9 Front tension system Keeps the media under tension.
10 Left maintenance covers. Covers the maintenance areas.
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2.3.2 Connections on the back
N° Connection
1 Ethernet connector
2 Card reader slot
3 Smartchip label
4 Harddisk bracket cover
5 Centronics connector
6 Foot switch connector
7 Power inlet
8 Environmental label
9 Bulk ink connector
10 ID label
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2.3.3 Position and function of the heating elements
Heater element Temperature Function

→ Open the pores to make the media more receptive
Pre-heater (Heater A) 20 – 50°C
for the Ink.
→ To establish optimum fixation onto the media
Spitfire 65/90: 20 – 40°C
Fixer (Heater B) (coated and uncoated).
Rockhopper 3: 20 – 70°C
→ Optimizes the dot gain control.
→ The post-fixer finalizes the fixation process and
Post-Fixer (Heater C) 20 – 70°C
helps to make the prints touch-dry.
→ The dryer completes the drying for compatibility
with the take-up in combination with higher output
Dryer (Heater D) 20 – 50°C
speeds.
→ Stickiness of printed banner materials is improved.
There have been a number of requests from the field, asking the heaters to be on by default for a few user
settings. This has now been implemented as follows:
(1) On the Spitfire 65/90, user 1 and user 8 default settings are as follows:
Pre heater A: 50°C
Fixer B: 40°C
Post Fixer C: 50°C
Dryer D: 50°C
(2) On the Rockhopper 3, user 1 and user 8 default settings are as follows:
Pre heater A: 50°C
Fixer B: 55°C
Post Fixer C: 50°C
Dryer D: 50°C
(3) On both the Spitfire 65/90 and the Rockhopper 3, users 2  7, by default the heaters are still OFF.
Notes
• Please note some RIP software do not allow selection of the user from software side. In some cases,
however, they do automatically activate user 8.
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2.3.4 Operation panel
The operation panel is used to set operational 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
N° Name Normal Setup menu display

1 [POWER] key Powers the printer on and off. Powers the printer on and off.
2 [F1] key Executes the function assigned to F1. Executes the function assigned to F1.
Changes the LCD monitor display to Changes the menu in reverse order.
6 [MENU ↑] key
the setup menu status.
Changes the LCD monitor display to Changes the menu in forward order.
7 [MENU ↓] key
setup menu status.
Determines the new parameter value and
changes the LCD monitor display to the
8 [ENTER] key Displays the print mode currently set. next menu. Sets the parameter value and
next menu.
Cancels the new parameter value and
9 [CANCEL] key - next menu. Clears the parameter value
and changes the LCD monitor display to
the next menu.
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(1) LCD monitor and light indicators.
N° Name Colour Status Function

The monitor displays the operation status and error
10 LCD monitor - -
messages of the printer.
ON The printer is ON.
11 POWER lamp Green
OFF The printer is OFF.
An error has occurred. The contents will be displayed on
Flashing
12 ERROR lamp Red the LCD monitor.
OFF Either there is no error or the power is OFF.
ON The printer is receiving print data.
13 DATA lamp Orange Flashing The printer is analyzing received data.
OFF The printer is waiting to receive print data.
The pressure roller is in the release position.
ON
Media has not been loaded.
14 MEDIA SET lamp Orange
The pressure roller is in the secured position.
OFF
The media has not been loaded.
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.
The temperature of the heating elements is the requested
temperature.
ON
The real temperature is the same as the requested
temperature.
17 HEATER lamp Orange
The heating elements are warming up.
Flashing The real temperature is different as the requested
temperature.
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 receive print data when media is loaded.
You can also change printer settings using the operation panel.
The contents displayed on the LCD monitor of the operation panel is as follows:
1→
2→ ←3
4→ ←5
6→ ←7
N° Position Description
Displays the current status of the printer. Depending on the status, the
1 1st line
contents may be displayed in 2 to 4 lines.
2 Left of 2nd line Displays the function assigned to [F1] key.
3 Right of 2nd line Displays the function assigned to [F2] key.
4 Left of 3rd line Displays the function assigned to [F3] key.
5 Right of 3rd line Displays the function assigned to [F4] key.
6 Left of 4th line Displays the currently set media type.
Displays the approximate amount of remaining media that is currently
set. (Units: m)
7 Right of 4th line However, the amount is displayed only when either "Roll media 1",
"Roll media 2", or "Roll media 3" is selected in the Roll media setting
menu.
2.4.2 Setting menu display

In the SetupMenu, changes can be made to the printer settings.
The contents displayed on the LCD monitor of the operation panel is as follows:
1→
2→ ←3
4→ ←5
←6
N° Position Description
1 1st line Displays the setting menu name currently set.
2 Left of 2nd line Displays the function assigned to [F1] key.
3 Right of 2nd line Displays the function assigned to [F2] key.
4 Left of 3rd line Displays the function assigned to [F3] key.
5 Right of 3rd line Displays the function assigned to [F4] key.
Displays the currently available functions of the [F1] key to the [F4]
key.
6 4th line
Displays the page status if there are multiple pages for the currently
displayed setting menu.
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2.4.3 Changing the printer status
To change the printer status, follow the steps below.
(1) Changing the status from normal to the setting menu display
Press either [MENU ] or [MENU ] on the operation panel when the printer is in normal status.
The display of the operation panel changes to the Setting menu display.
Notes
• Refer to "Setup menu" for details of the setting menu.
(2) Changing the status from the setting menu display to normal
Take one of the following actions when the printer is in the setting menu display to change the operation
panel display to normal one.
Press the [CANCEL] key on the operation panel.

Leave the printer for 3 minutes when the status is in the setting menu display.
[MENU ↑] or [MENU ↓] ↓ ↑ [CANCEL] or leave the printer as it is

↓ ↑ for 3 minutes
Notes
• Refer to ’Status messages" for details of displaying the printer status.
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3 SPECIFICATIONS
3.1 INTRODUCTION ......................................................................................................... 30
3.2 PRODUCT SPECIFICATIONS ....................................................................................... 30
3.3 INTERFACE SPECIFICATIONS ...................................................................................... 31

3.3.1 Centronics Bidirection Parallel Interface:IEEE1284 Specifications .................. 31
3.3.2 Network Interface Specifications ...................................................................... 32
3.4 INSTALLATION .......................................................................................................... 33

3.4.1 Choosing a place for the printer ....................................................................... 33
3.4.1.1 Installation environment Requirements ......................................................... 33
3.4.1.2 Required space ............................................................................................. 34
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3.1 INTRODUCTION
This section explains the specifications and installation procedures for optional parts.
3.2 PRODUCT SPECIFICATIONS
Printers 65”- model 90”- model

Drop-on-demand Micro Piezo Inkjet Technology.
Technology
Variable drop mass output between 5.4 ng and 41.5 ng
Automatic media thickness compensation.
Media Thickness Compensation
Variable – RIP controlled – Head Height
Maximum Media Widths 1651 mm 2280 mm
Maximum Print Widths 1641 mm 2250 mm
Thickness Range: 0.08 mm – 1.1 mm
Media Diameter / Core Maximum: 300 mm / 2” or 3”
Weight Maximum: 100 kg
Colour Channels 8 colour channels – 4 process colour output
Spitfire Mild Solvent 2xCMYK speed set-up
Spitfire Mild Solvent CMYKLcLm photo tone rendering set-up
Inks
Eco Solvent Ultra 2xCMYK speed set-up
Eco Solvent Ultra CMYKLcLm photo tone rendering set-up
Ink Cassette Capacity / Type 220 ml / smart chip ink type & order sensing
Uni & Bi-directional output, Interweaving, Mirror Output, Multi
Print Modes & Panel Control Options
Copy, Ink Status, Origin Control
LCD Display Backlight LED – 4 lines x 20 characters
Take-up System (standard) Automated
Roll Media Core 2” & 3”
IEEE Standard / Network Topology 10Base-T, 100Base-TX,
Interface
1000Base-T
Graphics Command Language RTL-PASS, MH-GL, MH-GL/2
1300 VA 1400 VA
Power Consumption
80 VA in stand-by mode 100 VA in stand-by mode
External Dimensions in mm (W x D x H) 3100 x 750 x 1250 3700 x 750 x 1250
Weight ± 360 kg ± 400 kg

Power Supply AC 100 – 120 V / AC 220 – 240 V auto-switching
Temperature: 18 – 28 °C
Working Environment Humidity: 40 – 80 % (no condensation)
The recommended humidity is 55%.
Noise Level Operating: 54 dB or less
Standard CE
Hard Disk: 20.3 GB – Stores 16 jobs – Up to 99 copies/job –
Standard Items
PostScript RIP included
Optional Item Air Purification System
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 Specifications

(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 Connection Signal direction Pin Connection signal Signal

number signal number direction
1 STROBE To printer  19 SG
2 DATA1 To and from printer   20 SG
10 ACK From printer  28 SG
11 BUSY From printer  29 SG
12 P ERROR From printer  30 SG
13 SELECTED From printer  31 INIT To printer 
14 AUTOFD To printer  32 FAULT From printer 
15 Not connected 33 Not connected
16 SG 34 Not connected
17 FG 35 Not connected
18 +5V 36 SELECTIN To printer 
(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 Specifications
Item Specifications
NetWork Type Intel 82541 gigabit controller
10 Base-T,100 Base-TX 1000 base- T.
NetWork I/F
(RJ-45 connector, category 5E or higher 4 pair)
Protocol TCP/IP
ftp
Mode lpr
socket
Automatic protocol recognition
Functions
Transmission speed up to 4 MB/s
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3.4 INSTALLATION
Product installation is explained below.
3.4.1 Choosing a place for the printer

Install the unit on a proper location referring to the following.
Important
• Do not place the printer on an unstable or slanted surface, or places that are subject to
vibration. Doing so may cause the product to fall, become damaged, or cause injury.
• Do not stand on the printer or place any heavy objects on it. Doing so may cause it to fall over,
become damaged, or cause injury.
• Do not cover the ventilation hole of the printer with cloth, such as a blanket or table cloth.
Doing so could prevent the printer from ventilating and cause fire.
• Keep the printer away from humid and dusty areas. Humidity may result in electrical shock or
fire.
3.4.1.1 Installation environment Requirements
Choose a place for printer installation following the requirements in the table below.
65” model 12.7m² (144ft²) or larger. Frontage of 4.7m (15.7ft) or greater.

Area
90” model 14.3m² (162ft²) or larger. Frontage of 5.3m (17.7ft) or greater.
Floor loading capability 2490Pa (300kg/m²) or over
65” 90”
AC 100-120V AC 100-120V
Voltage
AC 220-240V AC 220-240V
Electrical Frequency 60/50Hz±1Hz 60/50Hz±1Hz
AC100V-120V : 12A AC100V-120V : 13A
Capacity
AC220V-240V : 6A AC220V-240V : 7A
In order to protect the printer for over currents, short circuits and earth faults, the building
installation should be equipped with an automatic breaker double pole of 20 A and an earth leakage
switch of 300 mA.
Recommended Temperature: 23°C

working Humidity: 55%, without condensation
environment
Operational Temperature: 18°C-27°C
conditions Humidity: 40% to 65%, without condensation
Environmental
Temperature: No more than 2°C per hour
Rate of change
Humidity: No more than 5% per hour
Temperature: 4°C to 50°C
Storage
Humidity: 40% to 80%, without condensation (When ink has been
environment
discharged.)
Notes
• Avoid places where sudden changes in temperature and humidity are expected, even though the
condition is within the range written above. Otherwise, printed images may appear differently from
what you expect:
• Also avoid places where direct sunlight or excessive lighting are expected, or places where air
conditioners blow directly.
• MUTOH recommends that the printer should be installed where air conditioning can be adjusted easily.
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3.4.1.2 Required space
Install the product on a flat surface that fulfils the following conditions.
Notes
• Refer to “Product Specifications” of the User's Guide for the information of the product.
a 1500mm
b 1500mm
c 2500mm
d 600mm
e 1250mm
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4 PARTS REPLACEMENT
4.1 INTRODUCTION .................................................................................................................................... 37
4.1.1 Cautions and notes .................................................................................................................... 37
4.1.2 Flat cable treatment ................................................................................................................... 38
4.2 SWITCHING INK TYPES ......................................................................................................................... 41
4.2.1 Switching from Eco-Solvent Ultra to Spitfire Mild Solvent ......................................................... 41
4.2.1.1 Consequences ...................................................................................................................................... 41
4.2.1.2 Conversion procedure ........................................................................................................................... 43
4.2.2 Switching from Spitfire Mild Solvent to Eco-Solvent Ultra ......................................................... 45
4.2.2.1 Consequences ...................................................................................................................................... 45
4.2.2.2 Conversion ............................................................................................................................................ 47
4.3 REMOVING THE COVER ........................................................................................................................ 49
4.3.1 Removing the I/H cover ............................................................................................................. 50
4.3.2 Removing side cover R .............................................................................................................. 51
4.3.3 Removing side cover L .............................................................................................................. 53
4.3.4 Removing the front cover ........................................................................................................... 55
4.3.5 Removing the panel unit assembly ............................................................................................ 59
4.3.6 Removing the Y rail cover .......................................................................................................... 60
4.3.7 Removing front paper guide....................................................................................................... 61
4.3.8 Removing rear paper guide ....................................................................................................... 63
4.3.9 Removing the head cover .......................................................................................................... 64
4.3.10 Removing the maintenance cover ............................................................................................. 65
4.4 INSTALLING AND ACTIVATING THE SERVICE CHIP. ................................................................................... 66
4.5 HEATER ELEMENTS .............................................................................................................................. 69
4.5.1 Pre Heater .................................................................................................................................. 69
4.5.2 Fixer ........................................................................................................................................... 71
4.5.3 Post Fixer ................................................................................................................................... 73
4.5.4 Drier ........................................................................................................................................... 73
4.6 BOARD ASSEMBLIES............................................................................................................................. 75
4.6.1 Replacing the Mainboard assembly, HDD_Extension board assembly, HEAD_DRV board
assembly and cooling fan assembly......................................................................................................... 75
4.6.2 Replacing the power supply boards ........................................................................................... 80
4.6.3 Replacing the inlet assembly, inlet board assembly and foot SW cable assembly .................. 82
4.6.4 Replacing the JUNCTION board assembly ............................................................................... 83
4.7 REPLACING THE PF ACTUATOR ............................................................................................................ 84
4.7.1 Replacing the PF motor assembly ............................................................................................. 84
4.7.2 Replacing the PF_ENC assembly and PF scale assembly ....................................................... 85
4.7.3 Replacing the PF deceleration pulley assembly ........................................................................ 86
4.7.4 Replacing the PF deceleration belt ............................................................................................ 86
4.7.5 Replacing the P_REAR_R sensor assembly and P_REAR_L sensor assembly ...................... 87
4.7.6 Replacing the suction fan assembly .......................................................................................... 88
4.7.7 Replacing the lever motor assembly and the arm motor installation board............................... 89
4.7.8 Replacing the transmission photo sensor .................................................................................. 90
4.7.9 Replacing the flushing box assembly ........................................................................................ 92
4.8 REPLACING THE CR ACTUATOR ........................................................................................................... 97
4.8.1 Replacing the CR motor assembly ............................................................................................ 97
4.8.2 Replacing the steel belt.............................................................................................................. 98
4.8.3 Replacing the SLIDE motor assembly, HD_SLIDE sensor assembly, and slide motor
installation board ...................................................................................................................................... 99
4.8.4 Replacing the T fence (Timing fence or Linear Y-Axis Encoder)............................................. 100
4.8.5 Replacing the CR slave pulley assembly................................................................................. 102
4.8.6 Replacing the CR actuator pulley and the CR deceleration belt ............................................. 103
4.8.7 Replacing the steel bearer, tube guide, CR tape power cable and ink tube ........................... 104
4.8.8 Replace the cover R sensor assembly and the cover L sensor assembly .............................. 106
4.9 REPLACING THE CURSOR ................................................................................................................... 107
4.9.1 Replacing the cutter holder, cutter spring, cutter cap, solenoid assembly and solenoid spring
107
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4.9.2 Replacing the print head assembly and head tape power cable ............................................. 109
4.9.3 Replacing the H ink tube, tube branch and damper assembly ................................................ 110
4.9.4 Replacing the CR board assembly .......................................................................................... 112
4.9.5 Replacing the CR_ENC assembly ........................................................................................... 114
4.9.6 Replacing the P_EDGE sensor assembly ............................................................................... 115
4.9.7 Replacing the CR cursor assembly ......................................................................................... 116
4.9.8 Replacing the cursor roller assembly ....................................................................................... 117
4.9.8.1 Replacing the cursor roller assembly (upper 2 cursor rollers) ............................................................. 117
4.9.8.2 Replacing the cursor roller assembly (6 high-load bearings) : Large bearing type .............................. 117
4.9.9 Y-rail roller strips ...................................................................................................................... 119
4.10 REPLACING THE MAINTENANCE STATION AREA .................................................................................... 121
4.10.1 Replacing the Capping Station Assembly (Maintenance Assembly) ...................................... 121
4.10.2 Assembling the Capping Station .............................................................................................. 124
4.10.3 Replacing the cap(s) ................................................................................................................ 127
4.10.4 Replacing the wiper and wiperarm and replace the sponge.................................................... 130
4.10.4.1 Replacing the wipers in the wiperarm .............................................................................................. 130
4.10.4.2 Replacing the wiperarm ................................................................................................................... 131
4.10.5 Replacing the SLIDE motor assembly (wiper arm) .................................................................. 132
4.10.6 Replacing the transmission photo sensor (wiper home position and maintenance home
position) 133
4.11 REPLACING THE PUMP AREA .............................................................................................................. 136
4.11.1 Replacing the pump assembly ................................................................................................. 136
4.11.2 Replacing the pump ................................................................................................................. 138
4.11.3 Replacing the pump motor assembly ...................................................................................... 139
4.12 REPLACING THE CARTRIDGE AREA ..................................................................................................... 140
4.12.1 Replacing the I/H (ink holder) assembly .................................................................................. 140
4.13 REPLACING THE WASTE BOTTLE ......................................................................................................... 144
4.13.1 Replacing the waste fluid bottle assembly ............................................................................... 144
4.14 REPLACING / INSTALLING THE SMART CHIP MANAGEMENT SYSTEM. ....................................................... 145
4.15 REPLACING THE WASTE BOTTLE BOX SENSOR ASSEMBLY ..................................................................... 150
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4.1 INTRODUCTION
This chapter explains the procedures for replacing and removing maintenance parts.
4.1.1 Cautions and notes

Important
• Before replacing parts, be sure to perform following operations.
o Switch the power OFF.
o Remove the electrical cable from the socket. Otherwise, you may suffer electric shock or
the machine’s electric circuits may be damaged.
o Press the power button again to release all the rest tension in the capacitors.
o Disconnect all cables from the machine. Not doing so could cause damage to the printer
Caution
• Assembling and disassembling the printer is only allowed for the parts for which disassembling
procedures are shown in the operation manual.
• Do not disassemble any frame parts or parts for 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.
Notes
• After replacing the parts, perform necessary lubrication/bonding according to "Lubrication/Bonding".
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4.1.2 Flat cable treatment

Caution
• Misuse of flat cables can cause errors like constant printing of 1 head and illegal printing.
• Bad connections may cause short circuits which will lead to damage of the mainboard or
carriage board.
Point of interest 1: Insertion of flat cables
A flatcable fits precisely in its insertion slot, although it is possible to insert it in the wrong way because of its
flexibility. Please refer to the picture below for more visual support.
V X
Push the flatcable in the slot with the same pressure on the whole surface.
Be sure that the flatcable is inserted straight.
V X
Make sure that the contacts of the flat cable touch the contacts of the connector.
Make sure there is no damage done to the sides of the flat cables.
Point of interest 2: Removal of flat cables
In case the flatcable should be reused, be careful when removing it. Do not pull at the end of the cable but at
the left and right side just above the slot.
A flatcable can be pulled out and inserted a maximum amount of 20 times.
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Point of interest 3: Storage of flat cables
When ordering flatcables smaller than 700 mm, they are shipped in a plastic bag because of the difficulty to
ship them flat. Be sure to remove them and store them on a flat surface.
When the flat cables are longer than 700 mm, they can be stored wound up (as they are shipped)
Point of interest 4: Damage to flat cables
Before reusing a flatcable, check if the cable is not damaged.
Several types of damages can occur.
1. The cables are damaged at the sides
2. The contacts on the cable are not parallel and straight
3. The contact points of the connector are not positioned in the centre of the cable contacts.
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4. The contacts became loose.
Point of interest 5: Folding of flatcables
Mutoh used to fold the flatcables (from the carriage board to the heads) in production. Because of the
fragility, the final folding should be done by the Mutoh Technician.
The numbers in the procedure correspond with the ones on the picture.
1. Measure off 11 mm.
2. Fold to approximately 60°. Do NOT push the cable completely flat. This could damage the cable.
3. The flatcable will spring back to 90°
4. Insert the cable in the slot as explained.
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4.2 SWITCHING INK TYPES

4.2.1 Switching from Eco-Solvent Ultra to Spitfire Mild Solvent
When performing the following procedure, it is possible to convert a Rockhopper 3 (Extreme) to a Spitfire
65/90 (Extreme).
For this conversion, you will need AT LEAST the following parts:
1 2 3 4 5 6 7 8 9 10
Quantity
N° Part number Part Description
2x4 config 1x6 config
1 RJ80U-22-CLN Eco-Solvent Ultra cleaning cassette 220 ml 16 16
2 RJ80MS-22-CLN Spitfire Mild Solvent cleaning cassette 220 ml 8 10
3 RJ80MS-22-BK Black Spitfire Mild Solvent ink cassette 220 ml 2 1
4 RJ80MS-22-CY Cyan Spitfire Mild Solvent ink cassette 220 ml 2 1
5 RJ80MS-22-MA Magenta Spitfire Mild Solvent ink cassette 220 ml 2 1
6 RJ80MS-22-YE Yellow Spitfire Mild Solvent ink cassette 220 ml 2 1
Light Cyan Spitfire Mild Solvent ink cassette 220
7 RJ80MS-22-Lc 0 1
ml
Light Magenta Spitfire Mild Solvent ink cassette
8 RJ80MS-22-Lm 0 1
220 ml
9 MY-42110 Damper 8 8
10 ME-80077 Cap 4 4
4.2.1.1 Consequences
Transforming your Rockhopper 3 (Extreme) to a Spitfire 65/90 (Extreme) has following consequences:
► Different ink and cleaning

► Different maintenance necessary
► Different User and Maintenance kits 6 months
► Different User’s Guides and other documentation
► Different labels
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It is possible to only perform the ink conversion and to replace the dampers and caps, but if you want to be
totally up to date (cosmetics, documentation, kits) it is necessary to order a Spitfire Extreme starter kit:
(part number: M2x4MS or M1x6MS)
The following items are included in M2x4MS or M1x6MS
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4.2.1.2 Conversion procedure
The complete conversion takes about 45 minutes
Please follow the instructions below to switch from Eco-Solvent Ultra to Spitfire Mild Solvent Ink.
Step 1 : Power ON the printer.
Step 2 : Set printer to printer mode in the ChipMgr menu.
SetupMenu 5/7 ► InkManager 2/2 [F2] ► ChipMgr [F3] ► Printer [F2]
NO CREDIT HAS TO BE LOADED TO PERFORM THE ACTIONS LISTED BELOW
Step 3 : Insert 8 NEW Eco-Solvent Ultra cleaning cassettes.
Step 4 : Perform an InkLoad with Eco-Solvent Ultra cleaning.
SetupMenu 5/7 ► InkManager 1/2 [F3] ► InkLoad [F2] ► ALL [F3] ►YES [F2]
Step 5 : Check if the consumed cleaning in each cassette is approximately the same, if not, find its cause.
Important
BE SURE THAT CLEANING IS CONSUMED FROM THE CLEANING CASSETTES!! ECO-SOLVENT
ULTRA CLEANING AND SPITFIRE MILD SOLVENT INKS ARE NOT COMPATIBLE WITH EACH
OTHER.
IF NOT, FIND THE CAUSE OF THE PROBLEM!
Step 7 : Perform a second head wash with Eco-Solvent Ultra cleaning.
Step 8 : Check the cleaning liquid consumption once again.
Step 9 : Insert 8 NEW Spitfire Mild Solvent cleaning cassettes.
Step 10 : Perform an InkLoad with Spitfire Mild Solvent cleaning.
Step 12 : Replace the dampers as described in the Service Manual.
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Step 13 : Insert 8 NEW Spitfire Mild Solvent Ink cassettes as follows.
Step 14 : Perform an InkLoad with Spitfire Mild Solvent ink.
Step 15 : Check the ink consumption once again.
Step 16 : Replace the caps as described in the Service Manual.
Step 17 : Switch OFF the printer.
Step 18 : Power ON in diagnostics mode.
Step 19 : Set the SMS flag.
Check Menu 3/3 ► SMS [F2] ► Set ► ENTER ►ENTER
Notes
• The SMS flag lets the firmware know that there is MS ink loaded in the printer.
Step 20 : Power OFF the printer.
Step 21 : Power ON the printer in user mode.
Step 22 : Switch to Cassette-Mode in the ChipMgr. Menu.
Step 23 : Perform a NozzleCheck and necessary cleanings until all nozzles are present.
Step 24 : Ready To Print
Step 25 : Perform the necessary cosmetic upgrades such as dome labels, keyboard sheet…
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4.2.2 Switching from Spitfire Mild Solvent to Eco-Solvent Ultra
When performing the following procedure, it is possible to convert a Spitfire 65/90 (Extreme) to a
Rockhopper 3 (Extreme)
For this conversion, you will need AT LEAST the following parts:
1 2 3 4 5 6 7 8 9 10
Quantity
N° Part number Part Description
2x4 config 1x6 config
1 RJ80MS-22-CLN Spitfire Mild Solvent cleaning cassette 220 ml 16 16
2 RJ80U-22-CLN Eco-Solvent Ultra cleaning cassette 220 ml 8 10
3 RJ80U-22-BK Black Eco-Solvent Ultra ink cassette 220 ml 2 1
4 RJ80U-22-CY Cyan Eco-Solvent Ultra ink cassette 220 ml 2 1
5 RJ80U-22-MA Magenta Eco-Solvent Ultra ink cassette 220 ml 2 1
6 RJ80U-22-YE Yellow Eco-Solvent Ultra ink cassette 220 ml 2 1
Light Cyan Eco-Solvent Ultra ink cassette 220
7 RJ80U-22-Lc 0 1
ml
Light Magenta Eco-Solvent Ultra ink cassette
8 RJ80U-22-Lm 0 1
220 ml
9 MY-42110 Damper 8 8
10 ME-80077 Cap 4 4
4.2.2.1 Consequences
Transforming your Spitfire 65/90 (Extreme) to a Rockhopper 3 (Extreme) has following consequences:
► Different ink and cleaning

► Different maintenance necessary
► Different User and Maintenance kits 6 months
► Different User’s Guides and other documentation
► Different labels
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It is possible to only perform the ink conversion and to replace the dampers and caps, but if you want to be
totally up to date (cosmetics, documentation, kits) it is necessary to order a Rockhopper 3 Extreme starter
kit: (part number: M2x4U or M1x6U)
The following items are included in M2x4U or M1x6U:
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4.2.2.2 Conversion
The conversion procedure takes about 45 minutes
Please follow the instructions below to switch Spitfire Mild Solvent from to Eco-Solvent Ultra Ink.
Step 2 : Set printer to printer mode in the ChipMgr menu.
SetupMenu 5/7 ► InkManager 2/2 [F2] ► ChipMgr [F3] ► Printer [F2]
NO CREDIT HAS TO BE LOADED TO PERFORM THE ACTIONS LISTED BELOW
Step 4 : Perform an InkLoad with Spitfire Mild Solvent cleaning.
SetupMenu 5/7 ► InkManager 1/2 [F3] ► InkLoad [F2] ► ALL [F3] ►YES [F2]
Step 5 : Check if the consumed cleaning in each cassette is approximately the same, if not, find its cause.
Important
BE SURE THAT CLEANING IS CONSUMED FROM THE CLEANING CASSETTES!! ECO-
SOLVENT ULTRA CLEANING AND SPITFIRE MILD SOLVENT INKS ARE NOT
COMPATIBLE WITH EACH OTHER.
IF NOT, FIND THE CAUSE OF THE PROBLEM!
Step 7 : Perform a second head wash with Spitfire Mild Solvent cleaning.
Step 10 : Perform an InkLoad with Eco-Solvent Ultra cleaning.
Step 12 : Replace the dampers as described in the Service Manual.
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Step 13 : Insert 8 NEW Eco-Solvent Ultra Ink cassettes as follows.
Step 14 : Perform an InkLoad with Eco-Solvent Ultra ink.
Step 15 : Check the ink consumption once again.
Step 16 : Replace the caps as described in the Service Manual.
Step 17 : Switch OFF the printer.
Step 18 : Power ON in diagnostics mode.
Step 19 : Reset the SMS flag
Check Menu 3/3 ► SMS [F2] ► Reset ► ENTER ►ENTER
Step 21 : Power ON the printer in user mode.
Step 22 : Switch to Cassette-Mode in the ChipMgr. Menu.
Step 24 : Ready To Print
Step 25 : Perform the necessary cosmetic upgrades such as dome labels, keyboard sheet…
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4.3 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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4.3.1 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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4.3.2 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)
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4.3.3 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.
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4.3.4 Removing the front cover

Step 1 : Open the front cover.
Step 2 : Remove the Support containing the slow running wheel (Left side of the printer)
1 = Support with slow running wheel
Step 3 : Remove the E-ring (Left side of the printer)
1 = E ring 2 = Grip tool
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Step 4 : Remove the 2 screws on the left cover spindles.
2 = Screws (M3x8) right cover spindles
Step 5 : Loose (not remove!) the 2 screws of the right spindle a little.
1 = E ring 2 = Screws (M3x8) left cover spindles
Step 6 : Remove the sensor assy.
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Step 7 : Remove the left cover spindle with the wheel in once.
1 = Spindle left with wheel
Step 8 : Remove the front cover
Step 9 : Reinstall all components in the opposite way
Notes
• Make sure the spindle is oriented in the right direction when fixing the front cover to it. The spindle is
fixed to the front cover in the open position. The ridge of the wheel on the spindle must point in the
forward direction (see photo below)
1 = Flat (top) side of the spindle 3 = Front Cover

2 = Ridge on the wheel 4 = Screws for fixing the cover to the spindle (LEFT)
Step 10 : Alignment of the sensor (height adjust)
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Step 11 : The sensor assy has to be aligned when (re)assembling it.
Caution
• Height adjust of the sensor is necessary! In order to make the sensor well function and
keeping it, the pressure of the wheel-cam on the lever of the sensor may not be too high. A
little margin must be contained when the front cover is in the most downwards position. In this
position make sure the sensor is switched (!), but that there is still a little margin so the sensor
lever can be pushed even further.
1 = Holes / Screws for fixing and adjusting the sensor assy
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4.3.5 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.
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4.3.6 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 2 : Remove side cover L.
Step 3 : Remove the front cover.
Step 4 : 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 5 : 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 6 : Remove the 5 screws from the rear of the Y rail cover.
• If the machine is a 90-inch model, there are 8 screws on the rear Y rail cover.
1 = Screws (M4x8) on the rear of the Y rail cover
Step 7 : Remove the Y rail cover.
4.3.7 Removing front paper guide

Step 5 : Remove the screws from the top of front media guide.
Notes
• Please note that the amount of screws is size dependent.
Spitfire 65/90 and Rockhopper 3
1 = Screws on the top of front media guide
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Step 6 : Remove the screws from the front of front media guide.
Notes
1 = Screws on the front of front media guide
Step 7 : Standing before the unit move the front paper guide towards you.
Step 8 : Loosen the cables from their cable clamps.
Step 9 : Carefully loosen the connectors
Notes
• Be sure not to damage the cables or connectors.
Step 10 : Remove the front paper guide.
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4.3.8 Removing rear paper guide
Step 5 : Remove the screws from the top of the rear media guide.
Notes
1 = Screws on the rear paper guide
Step 6 : Remove the screws from the rear of rear paper guide.
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
• Be sure not to damage the cables or connectors.
Step 10 : Remove the rear paper guide.
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4.3.9 Removing the head cover
Step 1 : Remove the I/H cover.
Step 6 : Unlock the head.
Notes
• Please refer to the ‘Head lock menu’.
Step 7 : 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 8 : Remove the 2 screws fixing the head cover.
1 = Screws (M3x8) fixing the head cover
Step 9 : Remove the head cover.
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4.3.10 Removing the maintenance cover

Step 1 : Remove the 6 screws fixing the maintenance cover.
1 = Screws (M3x8)
Step 2 : Remove the maintenance cover.
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4.4 INSTALLING AND ACTIVATING THE SERVICE CHIP.

When a SIM card access problem occurs, a spare SIM card (service chip) is available. This chip needs to be
installed and activated. The activation code can be obtained via Mutoh’s service department as described
further in the replacement and installation procedure.
To optimize the SIM cards based on direct field feedback, we would like you to send back the SIM card to
our Service department.
SIM card details
Part number: AE-40080001

Compatible with: ► Rockhopper 3 (Extreme)
► Spitfire 65/90 (Extreme)
Notes
• It is recommended to have some spare SIM cards in stock
SIM card errors and solutions
As from the latest firmware versions, SIM card error messages have been integrated. Please find below a list
of errors which can be displayed. For more details about these errors, please refer to TIB220 and TIB225.
Error # Service Instruction Solution

[E1] Printer chip is broken Install a service chip
[E2] Printer chip is broken Install a service chip
[E10] Invalid chip Install a service chip
[E32] Invalid chip operation occurred Restart machine
Step 1 : Remove all cartridges with smart chips
Step 2 : Check flat cables between mainboard and
cassette led interface board (CLIB)
Other Step 3 : Check all connections on the CLIB board
errors
Check all chip connections Step 4 : Check all connections on Smart Chip
[E … ] Management System assembly
Step 5 : Check all connections on the CLIB expander
board (Spitfire 100 only!)
Step 6 : If none of above helps, install a service chip.
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Service chip installation
Important
• Be sure to have the latest firmware installed before replacing the SIM card. Check for the latest
version on our firmware download FTP. Please refer to TIB117 for login details.
Follow the instructions below when one of the above errors occurs and the SIM card needs to be replaced.
Step 2 : Remove the power cable.
Step 3 : Power ON the printer to remove the rest voltage from the capacitors and main supply.
The display and LED’s will light up for a second and rest voltage will be removed.
Step 4 : GENTLY push open the little lip of the smart chip holder because it is very fragile. Remove the
SIM card and replace it with a new one.
Step 5 : Insert the power cable.
Step 6 : Power ON the printer in diagnostics mode.
Step 7 : Go to the ChipMgr. Menu and press [F4] ► Activate

* C h i p M g r P r i n t e r *
L o g s S t a t u s
E r a s e A c t i v a t e
( 1 / 1 )
Step 8 : Press the [ENTER] key to confirm the activation.

* C h i p M g r P r i n t e r *
A c t i v a t e ?
[ E N T E R ] o r [ C A N C E L ]
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Step 9 : If a correct chip has been inserted, a challenge code will appear. For example:
C h a l l e n g e c o d e :
A 0 1 C B A B E 1 2 3 4 F E D C
4 3 B 2 9 7 A 6 C A F E B B 5 8
[ E N T E R ] o r [ C A N C E L ]
Important
• Do not power OFF the machine until the activation is done! If you do so, another code will be
needed
Step 10 : Contact Mutoh’s Service Department giving them following information

► Machine type e.g. Spitfire 65 Extreme
► Full firmware version information e.g. sx3.02,mA M
► Machine serial number e.g. MS2E-123456
► Amount of ink on the ChipMgr left e.g. 1337 ml
► Challenge code e.g. A01C BABE 1234 FEDC 43B2 97A6 CAFE BB58
Step 11 : You will receive the activation code.
Step 12 : Press the [ENTER]-key.
Step 13 : Enter the activation code.
Change the character at the cursor using the [F2]-key to increase the value and [F4]-key to
decrease. Go to the next character by pressing the arrow-down or [ENTER]-key. Return to the
previous character by pressing the arrow-up key.
* A c t i v a t i o n c o d e *
+
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 -
Step 14 : Press the [ENTER] key when the cursor is at the last character to finish the code entry.
Step 15 : If the entered activation code is wrong, the message “Activation Error!” appears and you will go
back to the activation code entry screen. If it is still wrong after three attempts, you have to apply
a new code.
After entering the activation code correctly, the following will appear:
* S e r v i c e C h i p M g r *
A c t i v a t i o n O K
A d d e d 1 3 3 7 m l
P r e s s [ E N T E R ]
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4.5 HEATER ELEMENTS

To replace a heater element of the Spitfire 65/90 or Rockhopper 3 printer, please follow the instructions
mentioned in the explanation of the appropriate heater element.
1. Replacing the dryer (Heater D)
2. Replacing the post-fixer (Heater C)
3. Replacing the fixer (Heater B)
4. Replacing the heater (Heater A)
Caution
• 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.
• Switch the power OFF.
• Remove the product's electrical plug 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.
4.5.1 Pre Heater
Before replacing the post fixer, make sure to have following items:
• 65” model: Heater A 64
• 90” model: Heater A 87
• 2 x press plate
• Silicone glue
To replace the heater on a Spitfire 65/90 or Rockhopper 3, please follow the instructions mentioned below.
Step 5 : Remove the rear paper guide.
Step 6 : Remove the heater strip.
Step 7 : Degrease the plate.
Notes
• 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
• 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.
• 65” model : X = 380 mm / Y = 1060 mm

• 90” model : X = 660 mm / Y = 1200 mm / Z = 1750 mm
Notes
• It will take ± 1 hour to let the glue dry.
Notes
• During reinstallation of the plate, make sure there are no cables stuck.
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4.5.2 Fixer
Before replacing the fixer, make sure to have following items:

• 65” model: Fixer B1 64 and Fixer B2 64
• 90” model: Fixer B1 87 and Fixer B2 87
• Isolation tape
• Plot platform calibre
To replace the fixer on a Spitfire 65/90 or Rockhopper 3, please follow the instructions mentioned below.
Step 6 : Place the plot platform calibre onto the plot platforms.
1 = plot platforms 2 = plot platform calibre onto the plot platforms
Step 7 : Fix the plot platform calibre (heater tool) onto the plot platform.
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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
Step 12 : Stick the two fixer strips onto the plot platform.
Notes
Step 13 : Stick the isolation tape onto the heater strips.
1 = plot platform 2 = fixer heater strip

3 = isolation tape
Notes
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4.5.3 Post Fixer

Before replacing the heater, make sure to have following items:
• 65” model : Post Fixer C 64
• 90” model : Post Fixer C 87
• 1 x sensor insul. Patch
To replace the post fixer on a Spitfire 65/90 or Rockhopper 3, please follow the instructions mentioned
below.
Step 6 : Remove the post fixer strip.
Notes
Step 8 : Stick the post fixer strip (1) onto the plate.
1 = Post fixer strip
4.5.4 Drier
Before replacing the dryer, make sure to have following items:
• 65” model: Dryer D1 64 and Dryer D2 64
• 90” model: Dryer D1 87 and Dryer D2 872 x sensor insul. Patch
To replace the dryer on a Spitfire 65/90 or Rockhopper 3, please follow the instructions mentioned below.
Step 6 : Remove the dryer strip(s).
Notes
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Step 8 : Stick the dryer strip(s) onto the plate.
1 = Dryer strip
Notes
• Make sure that the strips connect properly.
• Please make sure that the sensor (blue blocks) are positioned on the flat surface of the front paper
guide.
• Stick it as close as possible to the assembly holes. Make sure it does not touch the assembly holes.
Notes
Notes
Notes
• Make sure that the strips connect properly.
• Stick it as close as possible to the assembly holes. Make sure it does not touch the assembly holes.
Notes
Notes
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4.6 BOARD ASSEMBLIES

This chapter explains the procedures for replacing the power source board assembly, mainboard 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.
4.6.1 Replacing the Mainboard assembly, HDD_Extension board

assembly, HEAD_DRV board assembly and cooling fan assembly
Important
• Do not replace the battery on the mainboard with an incorrect type. There will be a risk of
explosion otherwise.
Dispose the used batteries according to the local or regional waste regulations.
Notes
• Before replacing the mainboard, discharging the capacitors on the power supply is needed.
• Follow these instructions :
o Switch off the device (Push Power ON/OFF key)

o Unplug the power cable
o Push the Power ON/OFF key again
→ The Display of the device lights up once more for a short time and goes out.
→ The Capacitors of the power supply are now discharged.
o Push the Power ON/OFF key again
→ The switch is now in the OFF position (and safe to plug the power cord again after the repair).
• Now it’s safe to open the machine and replace boards.
Notes
• Before replacing the mainboard, be sure to backup your parameters with a flashcard. Please follow the
instructions in the maintenance manual.
Notes
• Be aware that there are different types of mainboards available. There are RoHS and non-RoHS type
mainboards.
• RoHS is often referred to as the lead-free directive, but it restricts the use of the following 6 substances:
o Lead
o Mercury
o Cadmium
o Hexavalent chromium
o Polybrominated biphensyls (PBB)
o Polybrominated diphenyl ether (PBDE)
PBB and PBDE are flame retardants used in several plastics
As from firmware sp2.03 the firmware will support the new RJ8000 RoHS compliant mainboard including the
new PMC 400 MHz processor, and the new RoHS compliant network interface card. These new mainboards
will offer the user higher performance and full Rohs compliancy.
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Step 1 : Remove the power cable
Step 2 : Power ON the machine, this to remove the rest voltage from the capacitors and main supply.
The display and LED’s will light up for a second and rest voltage will be removed
Step 3 : Remove the right side cover.
Step 4 : Remove the mainboard cover 3 by loosening the 20 screws.
Step 5 : Disconnect the cooling fan cables.
Step 6 : Remove the display panel (4screws) and flatcable.
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Step 7 : Remove the mainboard cover by loosening the 16 screws.
Step 8 : Remove the bracket by loosening the 2 screws, this to have more accessibility to the mainboard
Step 9 : Remove the network card assembly by loosening the 2 screws.
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Step 10 : Remove the hard disk assembly by loosening the 3 screws.
Step 11 : Remove the HEAD_DRV board and FCC protection by loosening the 4 screws.
Step 12 : Remove the hard disk brackets and FCC protection by loosening the 4 screws.
Step 13 : Remove the RAM out of the slot and put it in the new mainboard.
Remove the Centronics interface by loosening the two screws.
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Step 14 : Disconnect following cables.

N° Connector N° # of pins Colour Connected to Remarks
1 J101 12 White Main Power Lock type
2 J102 6 White 12 V Power Lock type
3 J103 168 DIMM
4 J104 68
5 J105 28 White /black Display Panel Lock type
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 65, 90 inch spec
13 J113 2 Red Adhesion FAN 3 For 65, 90 inch spec
14 J114 2 Yellow Adhesion FAN 4 For 65, 90 inch spec
15 J115 2 Black Adhesion FAN 5 For 65, 90 inch spec.
16 J116 2 White Adhesion FAN 6 For 90 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 photo sensor
24 J124 4 Yellow Lever down sensor Transmission photo sensor
25 J125 6 White Maintenance origin sensor cable Transmission photo sensor
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 photo sensor
31 J131 5 Black Wiper origin sensor Transmission photo sensor
33 J133 30 White / black JUNCTION board Lock type
34 J134 30 White / black JUNCTION board Lock type
35 J135 HEAD_DRV board
36 J136 HEAD_DRV board
37 J137 30 White / black CR board Lock type
45 J145 (87) 30 White / black CR board Lock type
46 J146 (87) 30 White / black CR board Lock type
47 J147 (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
Step 15 : Remove the mainboard assembly by loosening the 6 screws and 4 hexagon spacers.
Step 16 : To install new mainboard, please follow the procedure backwards.
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4.6.2 Replacing the power supply boards

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.
Follow the instructions in "Replacing the Mainboard assembly, HDD_Extension board assembly,
HEAD_DRV board assembly and cooling fan assembly" to remove the Mainboard assembly.
Step 1 : Remove the 2 screws fixing the PS board cover.
1 = PS board cover 2 = Screws (M3x6) fixing the PS board cover
Step 2 : Remove the 5 screws fixing the Mainboard base.
1 = Screws (M3x8) fixing the Mainboard base 2 = Mainboard base
Step 3 : Remove the Mainboard base.
Step 4 : Remove the following connectors from the power source board assembly.

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 5 : 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 6 : Replace the power source.
Step 7 : Remove the 2 screws and 2 hexagon nuts fixing the power source board assembly.
Step 8 : Remove the power source board assembly.
Notes
• When installing the mainboard assembly, be careful not to pinch the foot SW cables by the mainboard
base.
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4.6.3 Replacing the inlet assembly, inlet board assembly and foot SW
cable assembly
Follow the instructions in "Replacing the Mainboard assembly, HDD_Extension board assembly,
HEAD_DRV board assembly and cooling fan assembly" to remove the Mainboard assembly.
Follow step 2 to 4 in "Replacing the power source board assembly" to remove the Mainboard assembly.
Step 1 : Remove the connector between the inlet board assembly and the inlet assembly.
Step 2 : 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 3 : Replace the inlet board assembly.
Step 4 : Remove the 3 screws fixing the inlet assembly.
Step 5 : Replace the inlet assembly.
Step 6 : Remove the 3 screws fixing the lever foot SW cable assembly.
Step 7 : Replace the lever foot SW cable assembly.
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4.6.4 Replacing the JUNCTION board assembly
Notes
• 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.
• Remove the following parts before replacing the JUNCTION board assembly.
o I/H cover: refer to "Removing the I/H cover"
o Side cover R: refer to "Removing side cover R"
Step 1 : Remove following connectors from the JUNCTION board assembly.

1 J401 30 White Mainboard – J134 Lock type or Plug-in
2 J402 30 White Mainboard – J133 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 Red 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.
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4.7 REPLACING THE PF ACTUATOR

4.7.1 Replacing the PF motor assembly
Caution
• The motor is hot after the product has been operated, so be careful not to burn yourself
Notes
• Remove following covers before replacing the parts in the PF motor assembly.
o Side cover L: refer to "Removing side cover L"
o Front cover: refer to "Removing the front cover"
o Y rail cover: refer to "Removing the Y rail cover"
o 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 2 = Screws (M4x10) fixing the PF motor assembly to
board to the side of the L side frame. 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
• When installing the PF motor assembly, move the PF deceleration pulley manually and confirm that the
PF deceleration belt is set equally in the centre of the PF motor assembly pulley.
Step 6 : Adjust the tension of the PF deceleration belt according to "PF deceleration belt tension
adjustment".
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4.7.2 Replacing the PF_ENC assembly and PF scale assembly

Notes
• Remove the following covers before replacing the PF_ENC assembly.
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
Step 9 : Replace the PF_ENC assembly.
Notes
• When installing the PF_ENC assembly and the PF encoder installation board, make sure they are
aligned with the locating bosses.
adjustment".
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4.7.3 Replacing the PF deceleration pulley assembly

Notes
Follow steps in "Replacing the PF_ENC assembly and PF scale assembly" to remove the PF scale
installation board.
Step 1 : Loosen the set screw fixing the coupling.
1 = Coupling 2 = Set screw fixing the coupling

3 = Y deceleration pulley axis
Step 2 : Pull the Y deceleration pulley to the opposite side of the origin and then remove the deceleration
pulley assembly.
adjustment".
4.7.4 Replacing the PF deceleration belt

Notes
Follow the instructions in "Replacing the PF motor assembly" to remove the PF motor.
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 1 : Replace the PF deceleration belt.
1 = PF deceleration belt
adjustment".
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4.7.5 Replacing the P_REAR_R sensor assembly and P_REAR_L sensor

assembly
Notes
• Remove following covers before replacing the P_REAR_R sensor assembly and P_REAR_L sensor
assembly.
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.
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4.7.6 Replacing the suction fan assembly
Notes
• Remove following covers before replacing the suction fan assembly.
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.
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4.7.7 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
• Remove following covers before replacing the lever motor.
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)
Step 5 : Replace the CR motor assembly.
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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.
4.7.8 Replacing the transmission photo sensor
Notes
• Remove following covers before replacing the transmission photo sensor.
(1) Replacing the transmission photo sensor (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 photo sensor from the sensor installation board.
1 = Sensor installation board 2 = Connector

3 = Transmission photo sensor
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Step 4 : Remove the connector from the transmission photo sensor.
Step 5 : Remove the transmission photo sensor.
Step 6 : Apply the screw lock to the tab portions of the transmission photo sensors to be installed.
Notes
• When installing the U/D cable assembly onto the transmission photo sensor, be careful not to confuse
the connectors.
• Lever up cable assembly (white): front
• Lever down cable assembly (blue): rear
(2) Replacing the transmission photo sensor (CR origin side)
Notes
• Refer to ‘Head Lock Menu’
Step 2 : Move the carriage from the capping position to the left.
Step 3 : Remove the transmission photo sensor from the ORG sensor installation board.
1 = ORG sensor installation board 2 = Connector

3 = Transmission photo sensor
Notes
• 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 photo sensor.
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4.7.9 Replacing the flushing box assembly

1) Installing the bracket
Step 1 : Unlock the head (In User mode > SetupMenu 6/7)
*WiperClean*
F1 → No Yes ← F2
(1/1)
Notes
Following display will appear.
*WiperClean*
Changed Wiper?
→ Press ENTER
After job is done, press the ENTER key, and the head will lock again.
Step 3 : Remove the screw fixing the old flushing box assembly
Step 4 : Remove the tube from the flushing box assembly
Step 5 : Connect the tube to the new flushing box assembly
Step 6 : Replace the flushing box assembly
Step 7 : Adjust the head and flushing box assembly.
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Step 8 : Check in headheight low if the heads does not interfere with the backside of the bracket. If there
is interference, you have to lower the spittingbox.
7.17. Flushing box height position adjustment.
Step 1 : When the carriage passes both intervals, move the carriage to the left. Loosen the adjustment
screw of the flushing box a bit and put the flushing box on the correct height.
Step 2 : tighten the screw
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2) Replacing the sponge
Notes
• Replace the sponge in these situations:
o After one month (periodical service by end user)

o The sponge bends or is saturated
o Ink drops on the media can be caused by a saturated or bended sponge
Notes
• Use gloves and tweezers to change the absorbent in the flushing box.
Step 1 : Unlock the head (In User mode > SetupMenu 6/7)
*WiperClean*
(1/1)
Notes
*WiperClean*
Changed Wiper?
→ Press ENTER
Step 2 : The carriage moves to the waiting position for replacing the flushing sponge.
Step 3 : Remove the old absorbents with tweezers.
Notes
• USE GLOVES TO CHANGE THE ABSORBENT
N° Part Description
1 Sponge
2 Tweezers
3 Gloves
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Step 4 : Install the new absorbents in the flushing box. Make sure that the 2 holes are on the right side of
the flushing box and that the pins of the black box are in the holes of the absorbent.
1 Two holes
2 Pin of black box
Step 5 : Lock the head
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3) Replacing the spitting box
Notes
• Replacing the black box is a part of the periodical services done by the end user. It should be done
every 6 months.
Step 1 : Unlock the head
*WiperClean*
(1/1)
Notes
*WiperClean*
Changed Wiper?
→ Press ENTER
Step 2 : The carriage moves to the waiting position for replacing the black box.
Step 3 : Loosen the screw tightening the black box to the bracket and replace the black box.
1 Black Box
2 Bracket
3 Screw
Step 4 : Tighten the screw and lock the head.
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4.8 REPLACING THE CR ACTUATOR

4.8.1 Replacing the CR motor assembly
Caution
Notes
• Remove following covers before replacing the CR motor assembly.
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.
Step 4 : Connect the white wire to the connector indicated whit the red label.
1 = Red label 2 = Connector

3 = White wire
Step 5 : Adjust the tension of the CR deceleration belt according to "CR deceleration belt tension
adjustment".
Notes
• 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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4.8.2 Replacing the steel belt

Caution
• When replacing the steel belt, be careful not to cut your hands by the belt.
Notes
• Do not damage the steel belt.
o Remove following covers before replacing the steel belt.

Notes
• Refer to ‘Head Lock Menu’
Step 3 : Rotate the 2 steel belt adjustment screws counter clockwise to loosen the steel belt.
1 = Steel belt adjustment screws 2 = Steel belt
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
• Be careful when handling the steel belt. The steel belt may be cut off when accreting dust to it or
creasing it.
Step 7 : Perform steel belt tension adjustment according to "Steel belt tension adjustment".
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4.8.3 Replacing the SLIDE motor assembly, HD_SLIDE sensor

assembly, and slide motor installation board
Caution
Notes
• Remove following covers before replacing the SLIDE motor assembly, HD_SLIDE sensor assembly,
and slide motor installation board.
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 9 : Make sure that the Idler moves smoothly.
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4.8.4 Replacing the T fence (Timing fence or Linear Y-Axis Encoder)
Notes
• Remove following covers before replacing the T fence.
Step 1 : Remove the T fence from the T fence spring hook on the side of the L side frame.
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
Step 5 : Remove the T fence from the hook.
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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.
Notes
• When installing the T fence, pay attention to the following :
o When there is a protective film on the T fence, remove the film and install the T fence.
o Properly install the T fence to the hooks on the T fence stationary plate. Refer to the figure in step
2.
o The T fence and the hooks on the stationary plate must have a loose fit.
o When securing the stationary plate with screws, it must be loosened enough so the T fence can be
moved.
o Insert the T fence into the hooks on the T fence push plate and the CR_ENC assembly. Refer to
the following figure.
1 = T fence push plate 2 = T fence

3 = CR_ENC assembly
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4.8.5 Replacing the CR slave pulley assembly
Notes
• Remove following covers before replacing the CR slave pulley assembly.
Follow the instructions in "Replacing the steel belt" to remove the steel belt.
Step 1 : Replace the CR slave pulley assembly.
1 = CR slave pulley assembly 2 = Steel belt

3 = Bearing stopper
Step 3 : Perform steel belt tension adjustment according to "Steel belt tension adjustment".
Notes
• Be careful when handling the steel belt. The steel belt may be cut off when accreting dust to it or
creasing it.
• 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.
• 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 centre of the CR actuator pulley and the CR slave pulley
assembly.
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4.8.6 Replacing the CR actuator pulley and the CR deceleration belt
Notes
• Remove following covers before replacing the CR slave pulley.
Follow the instructions in "Replacing the CR motor assembly" to remove the CR motor assembly.
Follow the instructions in "Replacing the steel belt" to remove the steel belt.
Step 1 : Replace the CR actuator pulley.
Step 2 : Replace the CR deceleration belt.
1 = CR slave pulley 2 = CR deceleration belt
Step 4 : Adjust the tension of the CR deceleration belt according to "CR deceleration belt tension
adjustment".
Notes
• 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 centre of the CR actuator pulley and the CR slave
pulley assembly.
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4.8.7 Replacing the steel bearer, tube guide, CR tape power cable and
ink tube
Notes
• To replace the board and connect or disconnect the FFC type cable, you should leave the plug
damage board.
• Remove following covers before replacing the steel bearer, tube guide, CR tape power cable, and ink
tube.
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)
Notes
• The CR tape power cables must be bundled during installation so that they cannot move.
• The edge of the tube push plate must be upside when installed.
• You should soak the O-ring in cleaning liquid once again before installing it.
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4.8.8 Replace the cover R sensor assembly and the cover L sensor
assembly
Notes
• Remove following covers before replacing the cover R sensor assembly and the cover L sensor
assembly.
(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 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 6 : Perform cover sensor adjustment according to "Cover sensor adjustment".
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4.9 REPLACING THE CURSOR

4.9.1 Replacing the cutter holder, cutter spring, cutter cap, solenoid
assembly and solenoid spring
(1) Replacing the cutter spring
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.
(2) Replacing the cutter holder, cutter cap, solenoid assembly and solenoid spring
Notes
• Remove following covers before replacing the cutter holder, cutter cap, solenoid assembly, and
solenoid spring.
o 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 6 = Cutter holder
the 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 11 : Adjust the cutter according to "Cutter adjustment".
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4.9.2 Replacing the print head assembly and head tape power cable
Notes
damage board.
• Remove following covers before replacing the print head assembly and head tape power cable.
• 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
Step 5 : Remove the damper assembly from the print head assembly.
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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.
Notes
• 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.
• Align the head tape power cables one by one to each head and paste together with double-faced tape.
• 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.
Perform head precision adjustment according to "Head precision adjustment".
4.9.3 Replacing the H ink tube, tube branch and damper assembly
Notes
• Remove following covers before replacing the H ink tube, tube branch, and damper assembly.
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.
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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
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
• Please soak the O-ring in cleaning liquid before installation.
Notes
• 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.
• Do not grasp the film area of the damper strongly. Doing so may cause faulty damper and print failure.
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4.9.4 Replacing the CR board assembly
Notes
damage the board
• Remove following covers before replacing the CR board assembly.

Step 1 : Remove the 8 screws fixing the CR cover.
1 = CR cover 2 = Screws (M3x8) fixing the CR cover
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Step 2 : Remove following connectors from the CR board.

1 J201 30 White or Black Mainboard Lock type or Plug-in
17 J217 21 White or Black I160B head
33 J233 5 White CR_ENC
34 J234 5 Black P_EDGE sensor
35 J235 2 White Solenoid
Step 3 : Remove the 2 screws and 2 hexagon spacers fixing the CR board assembly.
Step 4 : Replace the CR board assembly.
1 = CR board assembly 2 = Screws fixing the CR board assembly (M3x6)

3 = Hexagon spacers fixing the CR boar
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4.9.5 Replacing the CR_ENC assembly
Notes
• Remove following cover before replacing the CR_ENC assembly.
• Side cover L: refer to "Removing side cover L"
Follow the steps in "Replacing the flushing box assembly" to slide the CR cursor to the left.
Step 1 : Remove the CR_ENC assembly connector from the CR board assembly.
Step 2 : Remove the T fence from the T fence spring, and then from the CR_ENC assembly.
Step 3 : Remove the 2 screws fixing the CR_ENC assembly.
1 = CR_ENC assembly 2 = Screws (M2x12) fixing the CR_ENC assembly
Step 4 : Replace the CR_ENC assembly.
Notes
• When removing the T fence from the CR_ENC assembly, be careful not to damage the T fence.
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4.9.6 Replacing the P_EDGE sensor assembly
Notes
• Remove following covers before replacing the P_EDGE sensor Assembly.
Step 1 : Remove the P_EDGE sensor assembly connector from the CR board assembly.
Step 2 : Remove the screw fixing the P_EDGE sensor assembly.
Step 3 : Replace the P_EDGE sensor assembly.
1 = P_EDGE sensor assembly 2 = Screw (M2x12) fixing the P_EDGE sensor

assembly
Step 5 : Perform media sensor sensitivity adjustment according to "Media sensor sensitivity adjustment".
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4.9.7 Replacing the CR cursor assembly

Notes
• Remove following covers before replacing the CR cursor assembly.
Follow the instructions in "Replacing the cutter holder, cutter spring, cutter cap, solenoid assembly, and
solenoid spring" to "Replacing the P_EDGE sensor assembly " to remove the parts in cursor components.
Slide the CR cursor assembly to the opposite side of the home position.
Follow the instructions in "Replacing the steel belt" to remove the steel belt from the CR cursor.
Step 1 : Remove the 4 screws fixing the CR board installation board.
Step 2 : Remove the CR board installation board.
1 = CR board installation board 2 = Screws (M3x8) fixing the CR board installation board
Step 3 : Remove the T fence.
Step 4 : Remove the CR blade spring.
1 = CR cursor assembly 2 = CR blade spring
Step 5 : Replace CR cursor assembly.
Step 7 : Perform head height adjustment according to "Head height adjustment".
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4.9.8 Replacing the cursor roller assembly
Notes
• Remove following cover before replacing the Cursor roller assembly.
4.9.8.1 Replacing the cursor roller assembly (upper 2 cursor rollers)
Follow the instructions in "Replacing the CR cursor assembly” to remove the CR cursor assembly.
Step 1 : Remove the E ring fixing the cursor roller assembly.
1 = CR cursor assembly 2 = E ring fixing the cursor roller assembly.

Step 2 : Replace the cursor roller assembly.
4.9.8.2 Replacing the cursor roller assembly (6 high-load bearings) : Large bearing type
Follow the instructions in "Replacing the CR cursor assembly” to remove the CR cursor assembly.
Step 1 : Remove the side cursor roller assemblies and B cursor axis together with flat-head driver or
another tool.
1 = CR cursor assembly 2 = B cursor axis
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Step 2 : Remove the E ring fixing the cursor roller assembly of downside.
1 = CR cursor assembly 2 = E ring fixing the cursor roller assembly.
Step 3 : Replace the cursor roller assembly.
Step 4 : Install the spacers and the other parts as shown in the following figure.
1 = E ring fixing the side cursor roller assy 2 = High-load bearing of the side cursor roller assy
3 = Brass spacer of the side cursor roller assy 4 = E ring of the cursor roller assy
5 = High-load bearing of the cursor roller assy of downside 6 = Brass spacer of the cursor roller assy
Step 5 : Apply the screw lock to the cursor axis, and install the cursor roller assembly with the axis at the
lower position.
Notes
• Be sure that the screw lock does not contaminate the cursor roller or the spacer.
1 = Applying position of the screw lock
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4.9.9 Y-rail roller strips
In each Y-rail, 4 roller strips are installed to guide the carriage smoothly.
There is a difference between the straight strips and the ones installed under 45°. The ones installed under
45° have been redesigned. Therefore, some new kits have been made; as well as for the 65”, 90” as 100”
printers. Do not switch among them to guarantee a smooth movement of the carriage.
Please find below all the necessary information on how to order, recognize and install them.
1. New kit numbers
For 65” machines KY-80168 (includes 2 x ME-80268 + 2 x DF-42875)

For 90” machines KY-80169 (includes 2 x ME-80269 + 2 x DF-42569)
2. Recognition points
The redesigned strips are a little bit thinner. This is impossible to see with the bare eye. Though, there are
two recognition points:
1. The new strip has a sharper chamfer (3x45°) compared to the former ones.
2. The kits exist out of two bags, a set of new and a set of old ones. On each bag, the part number is
written.
new part numbers for 65” machines ME-80268
for 90” machines ME-80269
3. Installation procedure
Step 1 : Remove all necessary covers to have access to the y-rail and carriage.
Step 2 : Open the steel belt.
Step 3 : Remove the 2 leaf springs (left and right) of the carriage; this to remove the tension between
roller strips and bearings.
Caution
• Be careful not to damage the linear encoder strip.
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Step 4 : Remove the return pulley plate by loosening the 4 screws.
Step 5 : Remove the roller strips.
Step 6 : Grease the new roller strips on both sides and install them on the correct positions.
► Old ones straight, new ones under 45°.
◄ Redesigned strips ► installed under 45°
◄ Former strips ►installed straight
Step 7 : Reinstall all parts and adjust the tension of the steel belt.
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4.10 REPLACING THE MAINTENANCE STATION AREA

4.10.1 Replacing the Capping Station Assembly
(Maintenance Assembly)
Notes
• When replacing the parts inside the maintenance assembly, be sure to perform following operation to
clear the counter.
• "High ink initialization" or " Cleaning initialization": refer to "Counter Display Menu"
• Remove following covers before replacing the parts inside the maintenance assembly.
Follow step 1 in "Replacing the flushing box assembly" to move the CR cursor to the left.
Step 1 : Remove the 4 screws fixing the Wiper Arm Assy.
1 = screws 2 = wiper arm assy
Step 2 : Remove the wiper arm assy.
Step 3 : Remove the cover from the pump assembly.
Step 4 : Remove the screw fixing the flushing box installation board.
Step 5 : Remove the flushing box installation board.
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Step 6 : Remove the tubes from the pump station
Notes
Be careful when removing the tubing from the nipple. Hold the tubing as close to the nipple as possible.
Turn the tubing left and right until it is coming off. Otherwise the tubing will stretch and the inner coating
layer will be damaged.
(1) Turn the tubing left right and pull gently (2) Stretched and damaged tubing
Notes
• There is some remaining ink in the tubes. Be careful that the ink is not spilled from the tube onto the
printer or items close to the printer.
Step 7 : Disconnect the electrical wires.
Step 8 : Cut the 3 rock-ties (DF-41410)
Step 9 : Unplug the wires (on the connectors)
1 = rock ties 2 = connectors
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Step 10 : Remove the 6 screws fixing the maintenance assembly.
1= screws (M3x8) fixing the maintenance assembly Position of the holes
Step 11 : Replace the maintenance assembly.
Notes
• Secure the maintenance assembly so that it abuts against the rear right portion.
• The connection sequence for the tubes is as follows: Numbers in brackets ( ) are the cap numbers from
left to right as viewed from the front of the main body.
Step 12 : Move the cursor to the opposite side of the origin.
Step 13 : Cap once.
Step 14 : Move the CR Cursor to the left side of the printer.
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Step 15 : Use the build-in mirror (in the left maintenance cover) to check that the cap does not impinge on
the nozzle.
1 = Print head (nozzle face) 2 = Nozzle

3 = Cap trace 4 = Mirror
Step 16 : Reinstall the rest of the parts in the opposite order of the removal procedure. Make sure that both
cam and gears in the capping station assy are sufficient applied with grease (KY-80050)
4.10.2 Assembling the Capping Station
Step 1 : Hook the lever of the plastic sub assy with the head caps to the hook on the basic plate. There’s
one lever and one hook on the basic plate.
Notes
• Turn the wheel on the basic plate until the hook is a little in the up position.
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Step 2 : Attach the 2 side supports of the basic plate to the black plastic station
Step 3 : Place the plate with the axes in this position under the basic plate of the capping / maintenance
station and put the cap unit (black plastic part) over the axes. Make sure that all hooked parts
stay hooked. Press the spring and attach two screws (NS-05030061) to the ends of the axes. At
the left side (this means the side of the tin) a round piece is needed between the screw and the
axis.
Plate with Axes
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Step 4 : Attach both plates with 4x NS-05030051. Determine the position by using the nipples on the
basic plate.
Step 5 : Adjust the ridge so that you aren’t able anymore to put a sheet of paper between the ridge
Step 6 : Put the 4 black tubes on the nipples as on the pictures below.
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4.10.3 Replacing the cap(s)

Because of the new springs it is possible to replace one cap at a time. Please follow the instructions below to
replace one or more caps.
Step 2 : To prevent ink is dripping out of the tubings, please perform a TubingFlush first.
*CutterChange*
(1/1)
Step 4 : Move the carriage away from the maintenance area.
Step 5 : Remove the wiper arm assembly by loosening the four screws.
Step 6 : Turn the gear counter clockwise until the cap assembly is in its highest position.
Step 7 : Remove the ‘cap assembly top cover’ (1) with a flat screwdriver (2).
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Step 8 : Disconnect the tubing(s) and remove the old cap as shown below.
Step 9 : Replace the cap(s) and connect the tubings again. Please refer to the image below to be sure the
correct pump layout is used.
1 = bearing
2 = black spot on cap
3 = tube at the back of the cap
Notes
• Make sure when mounting the caps that with the bearing at the right side the caps black spot is on the
underside and the tube at the back at the upper side.
Step 10 : Replace the ‘cap assy front cover’ (1) as shown below. Otherwise the caps (2) will not be guided
correctly.
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Step 11 : Turn the gear clockwise until the cap assembly is in its lowest position.
Step 12 : Reinstall the wiper arm assembly and tighten the four screws.
Step 13 : Press the [ENTER] key. The carriage will go back to its home position.
*CutterChange*
Changed Cutter?
→ Press ENTER
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4.10.4 Replacing the wiper and wiperarm and replace the sponge
4.10.4.1 Replacing the wipers in the wiperarm
One of the items falling under periodical service is the wiper. According to the periodical service of the
Rockhopper 3 or Spitfire 65/90 printer, wipers should be replaced every 6 months. The periodical services
ensure a stable printout quality of the machine.
Caution
• Do not touch the cleaning wiper or the head cap unit with your hands while cleaning the
cleaning wiper. Doing so may result in poor head cleaning because of oil on your hands.
• Wear protective gloves.
Step 1 : To replace the wipers, please follow the instructions mentioned below.
Step 2 : Remove the old wiper from the wiper arm as shown in the picture below.
Step 3 : Before inserting a new wiper, moisten the wiper with Eco Solvent cleaning liquid. Or with spitfire
cleaning liquid.
Step 4 : Click the new wipers in the wiper arm in the manner shown in the pictures below.
Be sure to insert the wiper Be sure that the wiper clicks in the wiper
correctly as shown below: holder!
When standing in front of

the machine.
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4.10.4.2 Replacing the wiperarm
Step 1 : Power ON the printer and go to the “WiperClean-Menu”. This will cause the unlocking of the
carriage.
* WiperClean *
Changed wiper?
→ ENTER
Step 2 : Automatically move the carriage to the left side of the machine so you can remove the four
screws of the wiperarm assembly.
N° Part
1 Screws
Step 3 : Remove the wiperarm assembly as shown on the picture below.
Notes
Be careful when removing the wiperarm assembly, so you do not break the sensor located close to the
wiper.
N° Part
1 Sensor
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Step 4 : Remove the wiperarm assembly cover (see picture below) and reinstall the new one.
N° Part
1 Wiperarm assembly
2 Wiperarm assembly cover
Step 5 : To reinstall the wiper assembly, please reverse the removal procedure.
Step 6 : After complete reinstallation, clean the wipers using Isopropanol.
4.10.5 Replacing the SLIDE motor assembly (wiper arm)
Caution
Follow the instructions in "Replacing the maintenance assembly" to remove the maintenance assembly.
Step 1 : Remove the 2 screws fixing the SLIDE motor assembly.
1 = SLIDE motor assembly 2 = Screws (M3x6) fixing the SLIDE motor assembly
Step 2 : Replace the SLIDE motor assembly.
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4.10.6 Replacing the transmission photo sensor (wiper home

position and maintenance home position)
Step 1 : Remove the transmission photo sensor from the side plate R.
1 = Transmission photo sensor 2 = cable assembly
Step 2 : Remove each origin cable assembly from the transmission photo sensor.
Notes
• When installing the origin cable assembly onto the transmission photo sensor, be careful to not confuse
the connectors.
• Wiper origin cable assembly (black): front
• Maintenance origin cable assembly (white): rear
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In case of having a wiper sensor error, follow the instructions below to solve it.
(1) Check if the screws of the wiper sensor assembly is well tightened
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(2) The flag attached to the wiper sensor assembly does not fit perfectly in between the sensor poles.
When the wiper arm assembly is not pulled back completely by the stepper motor, the flag will not activate
the sensor and an error will occur.
Solve this by doing the following:
Step 2 : Remove the wiper arm assembly (1). (4 screws)
Step 3 : Bend the sensor plate up (1) and backwards (2) for ± 0,5 – 1 mm so the flag (attached to the
wiper arm assembly) fits perfectly in between the sensor poles.
Step 4 : Reinstall the wiper arm assembly and tighten the screws firmly.
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4.11 REPLACING THE PUMP AREA

4.11.1 Replacing the pump assembly
Notes
• Maintenance cover: refer to "Removing the maintenance cover"
Step 1 : Remove the tubes on the maintenance station and those to the waste bottle.
1 = tube connections on the maintenance station 2 = tube connections on the underside of the pump
(Connections of the Tubes of the pump station station (Connections of the tubes going to the waste
connected on the maintenance station) bottle)
Notes
Concerning the tube connections on the maintenance station :
Be careful when removing the tubing from the nipple. Hold the tubing as close to the nipple as possible.
Turn the tubing left and right until it is coming off. Otherwise the tubing will stretch and the inner coating
layer will be damaged.
(1) Turn the tubing left right and pull gently (2) Stretched and damaged tubing
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Notes
• There is some remaining ink in the tubes. Be careful that the ink is not spilled from the tube onto the
printer or items close to the printer.
Notes
• Concerning the tube connections on the underside of the pump assy :
• When reconnecting the tubes going to the waste bottle, cut off approximately 5mm of each tube before
putting it on the nipple. This provides a good connection of the tubes on the nipples.
Step 2 : Disconnect the electrical wires of the pump motors on the connectors.
Step 3 : Remove the 4 screws fixing the pump assembly
1 = Pump assembly 2 = Screws (M3x8) fixing the pump assembly
Step 4 : Replace the pump assembly.
Notes
• Follow the instructions in "Pump tubing layout for pump assembly" to connect the tube.
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4.11.2 Replacing the pump
Follow the instructions in "Replacing the pump assembly” to remove the pump assembly.
Step 1 : Remove the screw fixing the pump assembly.
1 = Pump assembly 2 = Screws (M3x6) fixing the pump assembly
Step 2 : Replace the pump
Notes
• Follow the instructions in "Pump tubing layout for pump assembly" to connect the tube.
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4.11.3 Replacing the pump motor assembly
Caution
Follow the instructions in "Replacing the pump assembly” to remove the pump assembly.
Step 1 : Remove the 2 screws fixing the pump motor assembly.
1 = Pump motor assembly 2 = Screws (M3x6) fixing the pump motor assembly
Step 2 : Replace the pump motor assembly.
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4.12 REPLACING THE CARTRIDGE AREA

4.12.1 Replacing the I/H (ink holder) assembly
There are 8 I/H assembly’s installed in this printer. Following procedure is for the removal of 1 I/H assembly.
Notes
• Remove following covers before replacing the parts in the I/H assembly.
o I/H cover: refer to "Removing the I/H cover"
o Panel unit assembly: refer to "Removing the panel unit assembly"
(1) Removing the I/H assembly
Step 1 : Perform the ink discharge operation to discharge the ink from the inside of all ink paths.
Notes
• For ink draining procedure, refer to "Head wash menu".
Step 2 : Remove the following connectors from the JUNCTION board assembly.
• Ink sensor assembly connectors (8)
• SC cable assembly connectors (8)
Notes
• For more details of the JUNCTION board assembly connector, refer to "Table Connectors connected to
the JUNCTION board assembly" in "Replacing the JUNCTION board assembly".
Step 3 : Remove the sensor assembly harnesses removed in step 2 from their clamps.
Step 4 : Pull the harnesses out of the grommets on the board base fixing plate.
Step 5 : Follow the step 1 to 3 in "Replacing the power source board assembly" to remove the Mainboard
base.
Step 6 : Remove the 3 screws fixing the P/S board installation board.
Step 7 : Remove the P/S board installation board.
Step 8 : Remove the coupling screws and O-ring from the I/H assembly.
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Step 9 : Remove the 4 screws fixing I/C slide 2 and the I/H assembly.
1 = I/H assembly 2 = I/C slide 2

3 = Screws (M3x8) fixing I/C slide 2 and the I/H
assembly
Step 10 : Remove the I/H assembly.
Notes
• Please soak the O-ring in cleaning liquid before installation.
(2) Replacing the ink ID board assembly and the holder pressure spring
Step 2 : Remove the 2 screws fixing the holder pressure spring.
1 = Holder pressure spring (two-ply use) 2 = Screws (M3x6) fixing the holder pressure spring
3 = Ink ID board assembly 4 = SC cable assembly
Step 3 : Replace the holder pressure spring.
Step 4 : Remove the SC cable assembly connector from the ink ID board assembly.
Step 5 : Replace the ink ID board assembly.
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(3) Replacing the cartridge frame assembly
Step 2 : Remove the cables from the I/H assembly clamp.
Step 3 : Disengage the hook fixing the cartridge frame assembly, and then slide the cartridge frame
assembly in the direction of the arrow to remove it.
Step 4 : Slide the cartridge frame assembly in the direction of the arrow to remove it.
1 = Cartridge frame assembly 2 = Hook
Step 5 : Replace the cartridge frame assembly.
(4) Replacing the ink sensor assembly (ink NOT sensor, ink END sensor)
Step 2 : Remove the cables from the I/H assembly clamp.
Step 3 : Remove the cartridge frame assembly.
Step 4 : Remove the screw fixing the ink END sensor.
1 = Ink END sensor 2 = Screw (M3x10) fixing the ink END sensor
Step 5 : Remove the ink END sensor.
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Step 6 : Remove the screw fixing the Ink NOT sensor to the Cartridge frame assembly.
1 = Ink NOT sensor 2 = Screw (M2x8) fixing the ink NOT sensor
Step 7 : Remove the ink NOT sensor.
Step 8 : Replace the ink sensor assembly.
Notes
• When installing the ink NOT sensor, do not tighten the screw firmly. Otherwise, the switch may not
come out.
Make sure that the Ink NOT sensor switch moves.
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4.13 REPLACING THE WASTE BOTTLE

4.13.1 Replacing the waste fluid bottle assembly
Notes
• When replacing the waste fluid bottle assembly, be sure to perform following operation to clear the
counter. "High ink initialization" or " Cleaning initialization": refer to "Counter Initialization Menu"
Step 1 : Remove the waste fluid bottle assembly.
Caution
• Waste ink will remain inside the tubes. Be careful that the ink is not spilled from the tube onto
the printer or items close to the printer.
Step 2 : Confirm on the operation bottle that the waste bottle has been removed.
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4.14 REPLACING / INSTALLING THE SMART CHIP

MANAGEMENT SYSTEM.
To install / replace the smart chip management system onto your printer, please follow the procedure below.
All necessary parts are combined in a kit (KY-81260).
1. Content of the kit
KY- 81260 Smart chip management system update kit

PartN° Description Quantity
MY-81260 Rear inlet assembly 1
EY-80230 Smart chip junction board 1
AE-91025 Cable guide 4
NS-11030061 Screw M3x6 4
2. Installation procedure
PART 1: Installing the rear inlet assembly into the printer.
Step 1 : Remove the protecting cover.
Step 2 : Remove the plastic cover.
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Step 3 : Remove the screws of the network device and the 2 metal covers.
Step 4 : Remove the network device and the 2 metal covers.
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Step 5 : Install the rear inlet assembly at the location previously used by the 2 metal covers using the 4
screws M3x6 , included in the kit
Step 6 : Guide the electrical cables of the assembly through the left cable outlet to the outside of the
printer.
Step 7 : Fasten the electrical cables with the cable guide included in the kit, in such a way the cables
cannot tangle up into the fan.
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Step 8 : Reinstall the network device, the plastic cover and the protecting cover.
Step 9 : Fix the electrical cables of the rear inlet to the machine as shown on the images below.
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PART 2: Replacing the print at the side of the pcb tower with the smart chip junction board (EY-
80230)
Step 1 : Disconnect all wires from the print at the side of the pcb tower
Step 2 : Remove the print.
Step 3 : Replace the print by the smart chip junction board included in the kit.
Step 4 : Reconnect all electrical wires to the smart chip junction board.
Step 5 : Connect the 2 electrical wires of the rear inlet assembly to the new print, the black connector on
the black connector of the pcb, the white connector on the white one.
Step 6 : Load the latest Spitfire firmware (at least version 1.02).
Notes
• For more information on the operation of the smart chip management system, refer to the Smart chip
Management System instruction sheet.
Notes
• It might be possible that there are SIM card access problems. If this is the case, please refer to
installing and activating the service chip.
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4.15 REPLACING THE WASTE BOTTLE BOX SENSOR

ASSEMBLY
Follow the instructions in "Replacing the waste fluid bottle assembly" to remove the waste fluid bottle
assembly.
Caution
• Waste ink will remain inside the tubes. Be careful that the ink is not spilled from the tube onto
the printer or items close to the printer.
Step 1 : Remove the waste liquid BOX sensor assembly connector from the rear side cap R.
1 = Rear side cap R 2 = Waste liquid BOX sensor assembly connector
Step 2 : Remove the waste liquid box assy from the stand.
Step 3 : Remove the screws fixing the waste liquid sensor assembly.
Notes
• When installing the waste liquid BOX sensor assembly, pay attention to following points :
• Adjust the waste liquid BOX sensor assembly before installing the waste liquid bottle cover.
• Position and install it so that "Sensor: Waste liquid tank" is properly switched in "Sensor Menu".
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5 DIAGNOSTICS MODE
5.1 INTRODUCTION ....................................................................................................... 153
5.2 PREPARATIONS ON THE PRINTER BEFORE OPERATING................................................ 153
5.3 OPERATIONS IN DIAGNOTICS MODE ......................................................................... 154

5.3.1 Operating Diagnostics Mode .......................................................................... 154
5.3.2 Diagnosis Items in Diagnostics Menu ............................................................ 157
5.4 TEST / INSPECTION MENU ....................................................................................... 158

5.4.1 RAM Capacity Menu ...................................................................................... 159
5.4.2 Version Menu ................................................................................................. 159
5.4.3 Operation Panel Menu ................................................................................... 160
5.4.4 Sensor Menu.................................................................................................. 161
5.4.5 Encoder Menu................................................................................................ 162
5.4.6 Fan Menu ....................................................................................................... 162
5.4.7 History Menu .................................................................................................. 163
5.4.8 Head Signal Menu ......................................................................................... 165
5.4.9 NVRAM menu ................................................................................................ 165
5.5 ADJUSTMENT MENU ............................................................................................... 166

5.5.1 Skew Check Menu ......................................................................................... 167
5.5.2 Head rank input menu .................................................................................... 168
5.5.3 Head Nozzle Check Menu ............................................................................. 169
5.5.4 Head Slant Check Menu ................................................................................ 171
5.5.4.1 Head slant adjustment ................................................................................ 171
5.5.4.2 Front and back ............................................................................................ 173
5.5.5 Repeatability Adjustment (Bi-Directional) ....................................................... 175
5.5.6 CW adjustments (Uni-Directional) .................................................................. 176
5.5.7 Band Feed Correction Menu (X Length) ........................................................ 177
5.5.8 Top & bottom adjustment menu ..................................................................... 179
5.5.9 P_REAR sensor position adjustment menu ................................................... 180
5.5.10 Test print menu .............................................................................................. 181
5.5.11 Head wash menu ........................................................................................... 182
5.5.12 Software Counter Initialization Menu ............................................................. 184
5.5.13 Feed Pitch Check Menu ................................................................................. 185
5.5.14 Fill printing menu............................................................................................ 185
5.6 CLEANING MENU .................................................................................................... 186
5.7 SAMPLE PRINTING MENU ........................................................................................ 186
5.8 PARAMETER MENU ................................................................................................. 187

5.8.1 Parameter Initialization Menu......................................................................... 187
5.8.2 Parameter Update Menu ................................................................................ 188
5.9 ENDURANCE RUNNING MENU .................................................................................. 193
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5.9.1 CR Motor Endurance Menu ........................................................................... 194

5.9.2 PF Motor Endurance Menu ............................................................................ 195
5.9.3 Cutter Endurance menu ................................................................................. 196
5.9.4 Head Up/Down Endurance Menu .................................................................. 197
5.9.5 Head Lock Endurance menu.......................................................................... 198
5.9.6 Pump Endurance menu ................................................................................. 199
5.9.7 Lever Motor Endurance Menu........................................................................ 200
5.9.8 Sequential Printing Endurance Menu............................................................. 201
5.9.9 General Endurance Menu .............................................................................. 202
5.9.10 Endurance Running Check Menu .................................................................. 203
5.10 HEAD LOCK MENU .................................................................................................. 203
5.11 HEATER SYSTEM MENU ........................................................................................... 204

5.11.1 Heater Status Menu ....................................................................................... 204
5.11.2 Heater Temperature Menu ............................................................................. 204
5.11.3 Heater Test 30 Menu ..................................................................................... 205
5.11.4 Heater Test 50 Menu ..................................................................................... 205
5.11.5 Heater Test Max Menu .................................................................................. 205
5.11.6 Test Aging Menu ............................................................................................ 206
5.11.7 Heater Version Menu ..................................................................................... 206
5.12 SOL PREPARE MENU ............................................................................................... 206
5.13 SMS MENU ........................................................................................................... 206
5.14 MACHINE SIZE SELECT MENU ................................................................................... 207
5.15 CHIPMGR MENU ..................................................................................................... 208
5.16 SMS HTEMP MENU ................................................................................................. 208
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5.1 INTRODUCTION
When having problems with the Spitfire 65/90 – Rockhopper 3, for example, bad print quality, broken items,
malfunctioning of sensors, the diagnostics mode can help to solve these problems.
This mode is implemented in the firmware and all operations can be done from the display.
Notes
• Refer to “Part names and functions ".
5.2 PREPARATIONS ON THE PRINTER BEFORE OPERATING

Before working in the diagnostics mode, some actions should be done before working on the printer.
1. Load media for adjustments
Be sure to load a roll of media in case of adjusting the heads, printing the parameters, etc…
Only use coated paper to be sure that the printed patterns are representative.
2. Plug in the power cable
Notes
• Do not connect three or more power plugs to one outlet.
3. Start up in Diagnostics mode

Power OFF the printer in case it is in User Mode.
Power ON the printer and hold the [F2] key, [F4] key, and [MENU ↓] key simultaneously.
The system will enter the Diagnostics mode and display the Diagnostics menu.
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5.3 OPERATIONS IN DIAGNOTICS MODE

This section explains how to operate in the Diagnostics mode and provides the list of available diagnosis
items.
5.3.1 Operating Diagnostics Mode

Follow the operation flow shown below to operate the Diagnostics mode.
For more detailed operation steps, refer to the flow chart of the applicable diagnosis item.
Step 1 : Make sure the printer is in the diagnostic mode
Step 2 : Press the [MENU ↑] key or the [MENU ↓] key on the operation panel to change over in the
diagnosis menu.
Step 3 : Press the [F1] key, [F2] key, [F3] key or [F4] key to select the applicable diagnosis item.
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Step 4 : Press the [F2] key or the [F4] key on the operation panel to modify the set value.
Step 5 : To save the modified value, press the [ENTER] key on the operation panel.
The modified set value is stored and a next item is displayed.
Notes
• If you press the [CANCEL] key instead of the [ENTER] key, the modification will not be stored.
Notes
• Modifications will be stored definitely when the machine’s memory has been powered off once. If the
machine is not powered off properly, all changes made will be ignored!
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Step 6 : To quit the diagnosis menu, press the [CANCEL] key on the operation panel.
The system returns to an upper hierarchy of the diagnosis menu.
Step 7 : To exit the Diagnostics menu, press the [POWER] key.
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5.3.2 Diagnosis Items in Diagnostics Menu

The Diagnostics menu includes following diagnosis items.
Initialization item Description Reference

Inspection Menu Performs various inspections on the circuit boards, Refer to Inspection Menu
sensors, and fans.
Adjustment Menu Performs various adjustments for the printer mechanism. Refer to Adjustment Menu
Cleaning Menu Performs mode-specified purge. Refer to Purge Menu
Sample Printing Performs sample printing necessary for adjustment. Sample Printing Menu
Menu
Parameter Menu Configures various adjustment parameters. Refer to Parameter Menu
Endurance Performs endurance running of the printer mechanism. Refer to Endurance
Running Menu Running Menu
Head Lock Menu Performs lock and release of the print head. Refer to Head Lock Menu
Heater System Performs various inspections and tests on the heater
-
Menu system
Sol Prepare Menu Configures the automatic start-up sequence for initial
-
inkload procedure after shipping
SMS Menu Ink Type configuration menu Do not use
ChipMgr. Performs various inspections on the ChipMgr printer
-
system
SMS HTemp Leave this setting to auto when there is no colour mixing Refer to SMS HTemp
or nozzle drop out.
* Check *
F1 → Test Adjustment ← F2
F3 → Cleaning Print ← F4
(1/3)
* Check *
F1 → Parameter Life ← F2
F3 → Head lock Heat Syst ← F4
(2/3)
* Check *
F1 → Sol Prepare SMS  F2
F3 → ChipMgr. SMS HTemp  F4
(3/3)
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5.4 TEST / INSPECTION MENU

In the Inspection menu, you can perform various inspections on the circuit boards, sensors and fans.
The Inspection menu includes the following diagnosis items.
Initialization item Description Refer to

RamCapacity This menu displays the memory size. → Ram Capacity Menu
Ver Displays the versions of the firmware and mainboard → Version Menu
assembly.
Firmware version
Backup parameter version
Setting of dip switches
Revision of mainboard assembly
Panel Used to check the functions of the operation panel keys, → Operation Panel Menu
LCD, and LED.
Sensor This menu displays the sensor status in the operation → Sensor Menu
panel.
CR_HP sensor
Cover sensor
Lever sensor
P_EDGE sensor
P_REAR sensor
HD_SLIDE sensor
Thermistor sensor
Ink ID sensor
Ink NOT sensor
Ink END sensor
Encoder Displays the detected values from the following encoders. → Encoder Menu
CR (Carriage)
PF (Media feed)
Fan This menu is used to check if the fan operates normally by → Fan Menu
switching ON and OFF the fan.
Elec. Used to check the following records. → History Menu
• Maintenance history
• Serious error history
Head Signal This menu is used to check the head-driving signal. → Head Signal Menu
Features
NVRAM This menu is used to check the available free space → NVRAM menu
* Test *
F1 → RamCapacity Version ← F2
F3 → Panel Sensor ← F4
(1/3)
* Test *
F1 → Encoder Fan ← F2
F3 → Elec. Head Signal ← F4
(2/3)
* Test *
F1 → Features NVRAM ← F2
(3/3)
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5.4.1 RAM Capacity Menu

This menu displays the memory size.
* RamCapacity *
RamCapacity 256 MB
Notes
• The Memory Size menu displays the size of the memory installed on the mainboard (128 MB or 256
MB).
5.4.2 Version Menu

This menu displays following contents about the firmware and mainboard assembly.
• Firmware version
• Backup parameter version
• Setting of dip switches of mainboard assembly
• Revision of mainboard assembly
Notes
• The details of the dipswitch setting of mainboard assembly are as follows.
o Switch 1: OFF
o Switch 2: OFF
* Ver *
Firm Sp1.03,mA
Parameter 1.00
(1/2)
* Ver *
DipSW 0x03
Board Rev 10
(2/2)
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5.4.3 Operation Panel Menu

This menu is used to check the functions of the operation panel keys, LCD, and LEDs.
(1) Operation panel key check

When you press a key on the operation panel, the name of the key is displayed on the LCD. To exit the
operation panel key check, press the [CANCEL] key twice.
(2) LCD check

The entire LCD screen is filled in black. You can check for any missing dots.
(3) LED check

The following LEDs light up in order. The LCD displays the name of the LED that is currently illuminated.
• Power lamp
• Error lamp
• Data lamp
• Media set lamp
• Heater lamp
• Roll media lamp
• Sheet/Cut paper
* Panel *
F1 → Key LCD ← F2
F3 → LED
* Panel *
Key ??????
███████████████
███████████████
███████████████
███████████████
* Panel *
LED Origin
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5.4.4 Sensor Menu

This menu displays the sensor status in the operation panel.
If the displayed sensor status does not match the actual machine status, replace or adjust the relevant
sensor referring to "Table Inspection Items in Sensor Menu".
N° Sensor name Status in display Refer to

CR_HP sensor ON/OFF Replacing the transmission photo sensor
Waste fluid sensor ON/OFF Replacing the waste liquid BOX sensor assembly
Wiper sensor On/Off
Cap sensor On/Off
Cover sensor Open/Close Replace the cover R sensor assembly and the
cover L sensor assembly
Ink cover sensor Open/Close Removing the I/H cover
Lever Up ON/OFF Replacing the transmission photo sensor
Lever Down ON/OFF Replacing the transmission photo sensor
Foot lever SW sensor ON/OFF
P_EDDE sensor 0 to FF (0 to 255) Replacing the P_EDGE sensor assembly
P_REAR-R sensor ON/OFF Replacing the P_REAR_R sensor assembly and
P_REAR_L sensor assembly
P_REAR-L sensor ON/OFF Replacing the P_REAR_R sensor assembly and
P_REAR_L sensor assembly
HD_SLIDE sensor ON/OFF Replacing the SLIDE motor assembly, HD_SLIDE
sensor assembly and slide motor installation board
Head Thermistor **°C
Ink ID sensor Pig, Dye, WASH Replacing the Cartridge Area
Ink NOT sensor 12345678 Replacing the Cartridge Area
Ink END sensor 12345678 Replacing the Cartridge Area
Notes
• The ink ID sensor indicates the type of ink cartridge installed
• The ink NOT sensor indicates the number where a cartridge is missing.
• For the ink end sensor, the colour of the ink that has run out is displayed.
* Sensor *
CR Origin Off CR_HP sensor
Waste Bin On Waste fluid sensor
(1/9)
* Sensor *
Wiper On Wiper sensor
Cap Off Cap sensor
(2/9)
* Sensor *
Cover Open Cover sensor
InkCover Open Ink cover sensor
(3/9)
* Sensor *
LeverUp On Lever up sensor
LeverDown On Lever down sensor
(4/9)
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* Sensor *
FootLever On Foot lever SW sensor
PaperEdgeAD 04e P_EDGE sensor
(5/9)
* Sensor *
PaperRear R Off P_REAR_R sensor
PaperRear L Off P_REAR_L sensor
(6/9)
* Sensor *
Headslide On HD_SLIDE sensor
Temp 25°C Head Thermistor
(7/9)
* Sensor *
Ink ID 12 34 5678 Ink ID Sensors
(8/9)
* Sensor *
Ink Not Ink NOT sensor
Ink End Ink END sensor
(9/9)
5.4.5 Encoder Menu

This menu displays the detected values from the following encoders.
• CR_ENC (Carriage)
• PF_ENC (Media feed)
Notes
• For the encoder-detected values, the encoder pulse numbers are displayed in hexadecimal number.
* Encoder *
CR 0000 CR_ENC
PF 0000 PF_ENC
5.4.6 Fan Menu
This menu is used to check if the fan operates normally by switching it ON and OFF
As soon as you select this menu, the fan will be activated.
When you press the [CANCEL] key, the fan is off and the operation panel displays "Inspection: Fan".
* Fan *
[Cancel] End
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5.4.7 History Menu
This menu is used to check the maintenance history and serious error history.
* Elec. *
F1 → Maintenance Error ← F2
(1) Maintenance history
Maintenance history for the following parts is displayed.

• Waste liquid tank capacity (#)
• Number of cuts (#)
• Number of wipes of the cleaner head (#)
• Number of rubs of the cleaner head (#)
• Number of drives of the CR motor (#)
• Number of drives of the PF motor (#)
• Number of printing copies (#)
• Number of cleanings (#)
• Discharge amount of head ink 1 (A, B nozzles), M dot
• Cutter solenoid down times (#)
• Pump A life
• Pump B life
Notes
• For the CR motor drive count, 1 pass becomes 1 count.
• For the PF motor drive count, 10 meters travel becomes 1 count.
* Maintenance *
WasteInk 00000000 Waste liquid tank capacity
Cut 00000000 Number of cuts
(1/10)
* Maintenance *
Wiper 00000000 Number of wipes of the cleaner head
Rubbing 00000000 Number of rubs of the cleaner head
(2/10)
* Maintenance *
CR Motor 00000000 Number of drives of the CR motor
PF Motor 00000000 Number of drives of the PF motor
(3/10)
* Maintenance *
PrintingNumber 00000000 Number of printing copies
Cleaning 00000000 Number of cleanings
(4/10)
* Maintenance *
Fire 1-A 00000000Mdot Discharge amount of head 1-A nozzle ink
Fire 1-B 00000000Mdot Discharge amount of head 1-B nozzle ink
(5/10)
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* Maintenance *
Fire 2-B 00000000Mdot Discharge amount of head 2-A nozzle ink
(6/10)
* Maintenance *
Fire 3-B 00000000Mdot Discharge amount of head 3-B nozzle ink
(7/10)
* Maintenance *
Fire 4-B 00000000Mdot Discharge amount of head 4-A nozzle ink
(8/10)
* Maintenance *
Pump A 24926 Number of cycles of Pump A
Pump B 24980 Number of cycles of Pump B
(9/10)
* Maintenance *
Cut Sole. 00000000 Cutter solenoid down time
(10/10)
(2) Serious error history
This menu displays the serious errors that have occurred so far.
Notes
• A serious error history does not include any CPU errors.
• A serious error history can contain up to 32 error events.
* Error *
Error0 Y current
Error1 X motor
(1/16)
* Error *
Error2 X motor
Error3 X motor
(2/16)
* Error *
Error30 Y Current
Error31 No Error
(16/16)
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5.4.8 Head Signal Menu
This menu is used to check the head-driving signal.
* Head Signal *
F1 → Flush Mode1 ← F2
F3 → Mode2 Mode3 ← F4
(1/2)
* Head Signal *
F1 → Mode5 Mode7 ← F2
(2/2)
Select:
* Head Signal *
ENTER:
* Flush *
Drive
5.4.9 NVRAM menu
Notes
• Be careful when initializing NVRAM. This will permanently delete all parameters of your printer.
Diagnostics ==> Test ==> NVRAM
* NVRAM *
F1 → Free Space: xxx
F3 → Max Block: xxx
(1/1)
Free space: bytes free

Max block: largest block free (bytes)
If an error occurs while checking the NVRAM, following screen will appear.
* NVRAM *
F1 → Free problem
F3 → ERROR ID: *
(1/1)
If you experience parameter problems and max block and/or free space is low (<100), try to set:
Diagnostics ==> Param ==> Mod level to 0 and restart the printer.
If this doesn’t help: try to reset NVRAM via: Maintenance ==> Initialize ==> NVRAM.
Be aware that all parameters will be lost if doing so.
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5.5 ADJUSTMENT MENU

In this menu, you can align the printing position and correct the media feed operation.
The Adjustment menu includes following diagnosis menus:

Skew check In this menu, you can perform media feed and check Skew Check Menu
the degree of skew in the media feed operation by
means of the sensors.
Head rank input Inputs the characteristic value of the installed print Head rank input menu
head. Ink is replenished after this input.
Head nozzle check Prints out a printing to check the ink discharge Head Nozzle Check Menu
performance of the head nozzles.
Head angle check Prints out a print to check for printer head slant. Head Slant Check Menu
Mechanical adjustment should be performed as
necessary.
Repeatability Prints out a print to align the two-way printing Repeatability Adjustment
adjustment position. Menu
CW adjustment Prints out a print to adjust any gaps between the CW Adjustment Menu
heads.
Band feed correction Prints out a print to correct the media feed amount Band Feed Correction
for each pass. Menu (X Length)
Top & bottom Sets the top and bottom margins. Top & bottom adjustment
adjustment menu
P_REAR sensor Adjusts the position of the P_REAR sensor using P_REAR sensor position
position adjustment sheet media. adjustment menu
Test Print Prints out a nozzle check pattern and the adjustment Test print menu
variables.
Head Wash Cleans the tubes and heads using cleaning fluid. Head wash menu
Software counter Clears various software counters. Software Counter
initialization Initialization Menu
Feed amount check Used to check the media feed amount for one band. Feed Pitch Check Menu
Fill pattern A fill printing pattern is printed by both ends of the Fill printing menu
head.
* Adj *
F1 → CheckSkew Input Rank ← F2
F3 → ChkNozzle HeadSlant ← F4
(1/4)
* Adj *
F1 → Bi-D Uni-D ← F2
F3 → Feed Adj. Top&Bottom ← F4
(2/4)
* Adj *
F1 → R. Sns. Pos. TestPrint ← F2
F3 → CleanHead CountClear ← F4
(3/4)
* Adj *
F1 → SendPitch
F3 → FillPattern BI-D400
(4/4)
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5.5.1 Skew Check Menu

In this menu, you can perform media feed and check the degree of skew in the media feed operation by
means of the sensors.
When you select this item from the Adjustment menu, the machine feeds the length specified by the
operation panel and checks for media feed skew by comparing the media edge positions before and after the
media feed detected by the sensors.
Notes
• Before performing skew check, ensure that the media is set correctly.
• Since the reference position where media has been set is determined the first time the media left edge
is detected, errors may result as follows if the media is not setup correctly.
• Media errors occur during skew check and the operation stops.
• "Undefined Media" occurs frequently during media initialization when the power is turned on or media
is cut.
* Check Skew *
0.1 m – 10.0 m +
1.0 m - Set per 0.1 m
↓ ENTER
* Check Skew *
Set Paper When media is not set
↓ Media set
* Check Skew *
Paper Initial
↓ Finishing media initialization
* Check Skew *
Exc. Skew
↓ Finishing media edge detection normally
* Check Skew *
SkewResult + 0.010 mm
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5.5.2 Head rank input menu

Inputs the head rank.
The head rank is used to determine the operation voltage of the head and compensate the temperature.
Input head rank following the steps below.
(1) Selecting input method
When inputting head rank, select one of the following methods.
• Input using the QR code
• Input from the operation panel
(2) When input using the QR code has been selected
Make sure that the operation panel displays "Input HEAD1 QR code".
Input the QR code from the QR code reader.
* QRcode * * QRcode *
Input Head1 QRcode Head ID input
↓ ENTER Incorrectly entered : Error

Correctly entered : Initial charge menu Press “ENTER” to re-enter
(3) When input from the operation panel is selected
Input the parameters of the upper and lower sections of the head rank using the operation panel keys.
* Panel * * QRcode *
ID1 - H + Head ID input
7BZ3E3CVXUWVWQQ 21 -

Press “ENTER” to re-enter
* Panel *
ID1 – L +
00Y012VTTR 40UWJB -
↓ ENTER
Correctly entered : Initial charge menu
(4) Initial ink charge menu
When the input head rank has been confirmed, initial ink charge is performed.
* Charge *
Ink charge [enter] → [CANCEL] Initial charge is not executed.
Voltage input value is updated.
↓ ENTER
* Charge *
[1] No Cartridge
↓ Set cartridge
* Charge *
Ink Charge
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5.5.3 Head Nozzle Check Menu

In this menu, you can check if the head nozzles, after refilling, can discharge ink correctly by printing a
sample print.
To print out head nozzle check patterns, follow the steps below.
Step 1 : Set media as necessary.
Notes
• Refer to the User’s Guide.
• Pressing the [ENTER] key in the Diagnosis menu in self-diagnostic mode moves the lever up and
down.
After media has been set, the machine prints out head nozzle check patterns in the following modes.
1 pass Single way
Step 2 : Check the printed head nozzle check patterns for the following points.
• Ink nozzle discharge amount (omission, discontinuity, meandering)
• Satellite
• T fence
• Nozzle alignment in vertical direction
• Nozzle alignment in horizontal direction
Nozzle check: Prints out patterns in the order of 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B.
Nozzle alignment in vertical direction: Prints out patterns in the order of 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B.
Nozzle alignment in horizontal direction (CW): Prints out patterns in the order of 1A, 1B, 2A, 2B, 3A, 3B, 4A,
4B.
Nozzle alignment in horizontal direction (CCW): Prints out patterns in the order of 1A, 1B, 2A, 2B, 3A, 3B,
4A, 4B.
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Step 3 : If any abnormal conditions are found in the ink discharge status of the head nozzles, perform ink
purge on the relevant heads.
Step 4 : After the ink purge, the system returns to the purge selection menu.
* ChkNozzle *
Set Paper If media is not set
↓ Media set
* ChkNozzle *
Paper Initial
↓ End Media initialization
* ChkNozzle *
F1 → End Output Pattern ← F2
(1/2)
* ChkNozzle *
F1 → Normal Powerful ← F2
F3 → Little
(2/2)
If Normal cleaning is selected
* Normal *
Cleaning
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5.5.4 Head Slant Check Menu

This menu prints out a sample printing to check for head slant.
Item Description
Slant All head slant check.
Front and back Front and back position and slant of each head relative to the reference head check.
All Confirmation of the forward and rear positions for all nozzle rows and all heads.
end Check complete.
5.5.4.1 Head slant adjustment
Step 1 : Start the self-diagnostic function.
Notes
• Refer to “Diagnostics Function”
Step 2 : Select "Adj:HeadSlant".
Step 3 : Print "Slant" pattern.

If dotted lines on pattern CW and CCW are not a straight line, which you can check with a
magnifying glass (enlargement of at least 10), please go to step 4.
Notes
• When the printing pattern is printed, you will only see lines, and no notifications of ink channels. The
head sequence shown below.
• 4 head model: 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B
Step 4 : Loosen the screw (with one turn) fixing the head stationary plate.
N° Part
1 Screw (M2.5x5) fixing the head stationary plate
2 Angle adjustment screw
3 Front and back adjustment screw
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Step 5 : Make adjustments until amount of CW and CCW offset are identical.
Notes
• In theory, the alignment of CW and CCW should be identical. But in practice, it is almost impossible to
become a perfect alignment. When there is a slight difference between CW and CCW, be sure the
heads are well seated.
• In case you only print uni directional, adjust the CW till it is aligned perfectly.
• In case you print bi-directional, and CW and CCW cannot be aligned more perfectly. Divide the fault
equally.
• When printing the pattern, the head identifications 1A, 1B etc, are not printed. Analyse the pattern as
shown below. Be sure to have five lines for each colour.
How to adjust What to become
N° Part
Step 6 : Tighten the screw fixing the head stationary plate.
Step 7 : Repeat step 1 to 6 until the adjustment is correct for all heads.
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5.5.4.2 Front and back
To perform a Head Front/Back Adjustment, please follow the steps below.
Step 1 : In diagnostic mode, go to [Adjust: Head Slant].
Step 2 : Press the [F2] key for F&B (front and back) adjustment.
* HeadSlant *
F1 → Slant F&B ← F2
F3 → Check End ← F4
Step 3 : Print out [Front/Back] pattern. First pattern A with 1A as reference is printed, then pattern B with
4B as reference and finally A+B.
A+B
4B is the
reference
head
1A is the
reference
head
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Notes
To help you identify the print heads on the test pattern please refer to the diagram below.
Know you see, 1A is Black, 1B is Yellow, etc (in our colour combination).
Step 4 : Check if all nozzles are in 1 row by using a magnifying glass with an enlargement of at least 10.
If not, please proceed to step 5.
Step 5 : Loosen the screw with 1 turn, which secures the Head Fixing Plate.
N° Part
1 Head Fixing plate securing screw
2 Front/Back Adjustment Screw
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When the nozzles are not in one row, adjust the head front/back position by moving the Head Front/Back
Adjustment Screw the manner shown below.
First adjust nozzle row A (1A, 2A, 3A, 4A)... When you determine a small misalignment after adjusting A,
readjust again until all nozzles of row A and B are perfectly aligned.
Notes
• We only give an example for one colour combination. Please refer to “Operation Procedure Labels”
in the Maintenance Manual where you can find the other possible colour combinations.
Step 6 : Tighten the screw which secures the Head Fixing Plate.
Step 7 : Repeat step 1 to 7 until the adjustment is correct.
5.5.5 Repeatability Adjustment (Bi-Directional)
To perform a Repeatability Adjustment, please follow the steps below.
Notes
• Refer to “Diagnostics Function".
Step 2 : Select "Adj:Bi-D".
Step 3 : Print a repeatability pattern.
The odd rows (with each 5 dots) are the references.

So the even rows should be adjusted (use a magnifying with an enlargement of at least 10)
When you want to move the even rows (with dots) to the right, you have to increase (+) the value.
For example: The value is 20, adjust it to 30 for example
The value is -20, adjust it to -10 for example
When you want to move the even rows (with dots) to the left, you have to decrease (-) the value.
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the value is -20, and adjust it to 30 for example
4B 4A 3B 3A 2B 2A 1B 1A
Step 4 : Adjust reciprocation per head height.
• #1: Head height LOW

• #2: Head height MIDDLE
• #3: Head height HIGH
Notes
• In the event that all parts of unit do not line up due to part or assembly precision error, make
adjustments until everything in the area around centre lines up in a straight line.
5.5.6 CW adjustments (Uni-Directional)

To perform CW adjustments, please follow the steps below.
Notes
Step 2 : Select "Adj:Uni-D".
Step 3 : Print a CW adjustment pattern.
The odd rows (alternately 1A and 1B) are the references. So the even rows (2A, 2B, 3A, 3B, 4 A and 4B)
should be adjusted (use a magnifying with an enlargement of at least 10)
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1B 1A 1B 1A 1B 1A
4B 4A 3B 3A 2B 2A
Notes
5.5.7 Band Feed Correction Menu (X Length)
To correct the media feed distance, you must first print out check patterns and measure the distance
between lines drawn in the media feed direction. Then enter the measured value in this menu.
The system uses the entered value to determine the PF encoder resolution parameter in the firmware.
To perform an X-length Adjustment, please follow the steps below.
• Go to Feed Adjustment.
• Set the parameter value to 900 mm.
• Print out the Feed Adjustment pattern.
• Measure the printed Band Feed Correction pattern.
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• Enter the measured value as the Media Feed Distance parameter.
* Feed Adj. *
X Length 300 – 1000 +
500 mm -
↓ ENTER
CANCEL * Feed Adj. *

←← ←← Enter Print Start
↓
↓
↓
↓ ↓ ENTER
↓
↓ * Feed Adj. *
↓ Set paper A media is not set
↓
↓
↓
↓ ↓ Media setting
↓
↓ * Feed Adj. *
↓ Paper Initial
↓
↓
↓
↓ →→ →→→→→ ↓ Finish media initialization
↓ ↑
↓ ↑ * Feed Adj. *
↓ ↑ Adjustment Print Display during adjustment printing
↓ ↑
↓ ↑
↓ ↑
→ ↑ →→ →→→→→ ↓ Finish printing
↑
↑ * Feed Adj. *
↑ X Length 300 – 1010 +
↑ 500.0 mm -
↑
↑
↑ ↓ ENTER
↑
↑ * Feed Adj. *
←← Enter Print Start
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5.5.8 Top & bottom adjustment menu

Sets printing margins.
Step 2 : After the media has been set, pattern printing with band feed compensation and media cutting
are performed.
Measure the following adjustment items for the results of the printing of the top & bottom adjustment pattern.
Measurements are carried out at the centre of the media. The adjustment items are as follows.
• Top distance
• Bottom distance
• Side margin
1: Top distance
2: Bottom distance
3: Side margin
4: Media feed direction
Step 3 : Input each measurement as a parameter.
* Top&Bottom *
Set Paper If media is not set
↓ Set media
* Top&Bottom *
Paper Initial
↓ End Media Initialization

* Top&Bottom *
Adjustment Print Display during adjustment printing
* Top&Bottom *
Top Length 0 – 40.0 +
5.0 mm -
* Top&Bottom *
5.0 mm -
* Top&Bottom *
Side 0 – 20.0 +
5.0 mm -
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5.5.9 P_REAR sensor position adjustment menu

Adjust the P_REAR sensor position in order to accurately detect the length of the cut media.
During this adjustment, the P_REAR sensor position can be adjusted inside the firmware by referring to the
nozzle, in order to obtain a maximum printable area starting from the ends of the media.
Notes
• Use cutting media for adjusting the P_REAR sensor. Set A3 cutting media in portrait orientation.
• P_REAR sensor position adjustment is a process necessary during manufacturing. This does not need
to be done when band feed is compensated.
After the media has been set, a pattern printing with the P_REAR sensor position adjustment is performed.
Step 2 : Draws a horizontal line (black 1 dot line) 17 mm away from the media end.
Step 3 : Measure the distance from the media end to the line just drawn.
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Step 4 : Input the measurement as the parameter of the P_REAR sensor position.
* Rear Sensor *
Set Cutting Paper
↓ Set media
* Rear Sensor *
Paper Initial If media is not set
↓ End media initialization
* Rear Sensor *
Paper Width 297.0 mm Check media width
↓ ENTER
* Rear Sensor *
Rear Sensor 7.0 – 27.0 +
17.0 mm -
5.5.10 Test print menu

In this menu, you can print out adjustment patterns.
After media has been set, the machine prints out the following test Printings.
• Nozzle check: Head nozzle check pattern
• Adjustment variables: Set values of various adjustment variables
Step 2 : Perform selected test print.
*Print*
NOZZLE CheckAdj.Vari.
*Thickness*
50µm-1500µm +
120µm -
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5.5.11 Head wash menu

This menu is used to purge ink and clean the heads before print head replacement.
Step 1 : Initialize the waste ink history.

• Refer to ‘Parameter Initialization Menu’
Step 2 : Discharge the waste fluid from the waste fluid bottle.
Step 3 : Press the [ENTER] key in the operation panel to confirm the head cleaning menu.
Step 4 : Remove all ink cartridges.
Step 5 : Press the [ENTER] key in the operation panel to drain the ink.
Step 6 : After the ink has been drained, install the head cleaning fixture.
Step 7 : Press the [ENTER] key in the operation panel to supply the cleaning fluid.
Step 8 : After the cleaning fluid has been supplied, remove the head cleaning fixture.
Step 9 : Drain the cleaning fluid by pressing the [ENTER] key in the operation panel.
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Step 10 : Initialize the waste ink history.
Notes
• When performing the ink cleaning, always initialize the waste ink history then start a head cleaning.
Otherwise, during cleaning, the waste ink tank becomes full and cleaning is interrupted.
• After the head cleaning, always initialize the waste ink history. Otherwise, during filling, the waste ink
tank becomes full, and filling is interrupted.
• Before ink filling, discharge the cleaning fluid, and wait for at least 30 minutes. Otherwise, the printing
may be unstable.
* Clean Head *
Remove cartridge
↓ Eject all cartridge and press the [ENTER] key to drain ink
* Clean Head *
Ink Discharge
↓ End Ink draining
* Clean Head *
Set Cleaning jig
↓ Set the head cleaning jig and press the [ENTER] key to charge
the cleaning liquid.
* Clean Head *
Head Cleaning
↓ Charge cleaning liquid
* Clean Head *
Remove cleaning jig
↓ Remove the head cleaning jig and press the [ENTER] key to
drain the cleaning liquid.
* Clean Head *
Head Cleaning
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5.5.12 Software Counter Initialization Menu

This menu initializes the software counters such as the ink amount counter.
Notes
• Before delivery, always initialize the software counters.
The software counters that can be initialized through this menu are as follows.
Counter Initial value

Ink amount counter 0
Ink consumption counter 1 0
Cumulative printout timer 0
Waste ink counter 0
Initial ink charge flag Set
Pressing the [ENTER] key in the operation panel performs the software counter initialization. Pressing the
[CANCEL] key cancels the initialization.
* CountClear *
Counter reset?
↓ ENTER
* CountClear *
Wait little time
↓ End initialization
* CountClear *
R. Sns. Pos. Testprint
CleanHead CountClear
(3/4)
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5.5.13 Feed Pitch Check Menu
To check the feed pitch, follow the steps below.
Step 2 : Select "Adj: SendPitch".
Step 3 : Select "Pattern 1" or "Pattern 2" to print feed pitch check patterns.
• "Pattern 1": Drawn with 1 inch (2.54 cm) intervals
• "Pattern 2": Draw a repetitive pattern with 1/4 inch (0.635 cm) intervals every 4 lines and 0.63 cm
intervals between each of the 4 lines.
Step 4 : Confirm that it is drawn at 1 inch intervals as shown in the following drawing.
A = Media feed direction
5.5.14 Fill printing menu

A fill printing pattern is printed by both ends of the head.
• A: Media feed direction

• B: 100% print
65-inch specifications are pattern printed in the sequence 1A&4B, 1A&4B, 1A&4B
90-inch specifications are printed in the sequence 1A&8B, 1A&4B, 5A&8B.
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5.6 CLEANING MENU

The Purge menu includes the following diagnosis items.
Diagnosis item Description

Normal Performs normal purge.
Powerful Performs powerful purge.
Little Performs minimum purge.
Initial ink charge Performs initial ink charge.
* Cleaning *
F1 → Normal Powerful ← F2
F3 → Little Ink charge ← F4
↓ Select item (Normal cleaning)
* Normal *
Cleaning
5.7 SAMPLE PRINTING MENU

The Sample printing menu includes the following items.

Nozzle Check Prints the head nozzle check pattern.
Adjustment variables Prints out the set values of various adjustment items.
Notes
• When serial numbers are not input to this product, the serial numbers become blank spaces.
* Print *
F1 → Nozzle Adj. Variable ← F2
↓ Select item (Nozzle check)
* Check Nozzle *
Adjustment Print
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5.8 PARAMETER MENU

In this menu, you can modify the values of various adjustment items (adjustment parameter).
The Parameter menu includes the following items.

Initialize. Initializes the adjustment parameters. Parameter Initialization
Menu
Update Updates the adjustment parameters. Parameter Update Menu
* Parameter *
F1 → Initialize Update ← F2
5.8.1 Parameter Initialization Menu

This menu initializes the adjustment parameters. The parameters that can be initialized in this menu are as
follows.
• Capping position
• Media feed distance
• Serial number
• Head history
• Wiper history
• Waste ink history
• CR motor history
• PF motor history
• Pumps
• Waste tank
• Initialization of all items
* Initialize *
F1 → P. FeedLen serialNo. ← F2
F3 → Head Wiper ← F4
(1/3)
*Initialize*
F1 → CR Motor PF Motor ← F2
F3 → Pump A Pump B ← F4
(2/3)
*Initialize*
F1 → WasteInk All ← F2
(3/3)
↓ Select item (P. FeedLen.)
* P. FeedLen. *
Initialize OK?
↓ ENTER
* P. FeedLen. *
Initialize Parameter
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5.8.2 Parameter Update Menu

This menu updates the adjustment parameters. The parameters that can be updated through this menu are
as follows.
• Head voltage
• Printing position alignment
• CW adjustment
• Mechanical parameter
• Ink parameter
• Serial number
Notes
• If you update any parameter in the Parameter Update menu, always turn the power OFF after quitting
the menu. The updated parameters will not be stored in the flash memory unless the system power is
switched OFF.
* Update *
F1 → HeadRank PrintPos. ← F2
F3 → CW Adj. P. FeedLen. ← F4
(1/3)
* Update *
F1 → Mechparm Inparm ← F2
F3 → PrintP400 serialNo. ← F4
(2/3)
*Update*
F1 → MOD Level
(3/3)
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(1) Head ID
The head ID is used to determine the printer head-driving voltage and perform temperature correction.
After a head ID has been entered, the system shifts to the Ink Charge menu.
* HeadRank * * HeadRank *
ID1 – H + Head ID input
1BZ3E3ECVXUWWQQ -

Press “ENTER” to re-enter
* HeadRank *
ID1 - L +
00Y0IZVTTR 40UWJB -
↓ ENTER
* HeadRank *
Update Parameter
↓ ENTER
* HeadRank *
Updating Parameter
↓
* HeadRank * CANCEL
Ink charge [ENTER] →→→→ Initial charge is not performed
Rank input value is updated
↓ ENTER
* Charge *
[1] No Cartridge
↓
* Charge *
Ink Charge
(2) Printing position alignment

This updates the printing position alignment parameters.
* PrintPos Adj.*
# 1 Head 1A +
-28 -
* PrintPos Adj. *
#1 Head 1B +
-28 -
If the parameter is updated

* PrintPos Adj. * * PrintPos Adj. *
#1 Head 4B + ENTER Update Parameter?
-48 - →→→→→
↓ ENTER
* PrintPos Adj. *
Updating parameter
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(3) CW
This updates the CW adjustment parameters.
* CW Adj. *
Gap 1 - 2 -400→ 400 +
0 -
* CW Adj. *
Gap 1 - 3 -400→ 400 +
0 -
If the parameter is updated
* CW Adj. * * CW Adj. *
Gap 1 - 4 -400→ 400 + ENTER Update Parameter?
0 - →→→→→
↓ ENTER
* CW Adj. *
Updating Parameter
(4) Media feed distance

This updates the media feed distance parameters.
* PaperFeedLen. *
X Length 290 – 1010 +
500.0 mm -
↓ ENTER
* PaperFeedLen. *
Update Parameter?
↓ ENTER
* Update *
Updating Parameter
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(5) Mechanical parameter

Update the mechanical position parameters. The setup items are as follows.
• Top distance
• Bottom distance
• Side margin
• P_REAR sensor position
* Mechparm *
5.0 mm -
* Mechparm *
Bottom 0 – 40.0 +
5.0 mm -
* Mechparm *
Side 0 – 20.0 +
5.0 mm -
* Mechparm *
Rear Sensor 0 – 27.0 +
17.0 mm -
↓ ENTER
* Mechparm *
Update Parameter
↓ ENTER
* Mechparm *
Updating Parameter
(6) Ink parameter

• Set: Ink not filled
• Reset: Ink filled
Notes
• When "set" has been selected on the ink parameter update menu, the product implements initial filling
operations at the next start up.
* InkParameter *
Init. Fill Flag +
Set -
↓ ENTER
* InkParameter *
Update Parameter? If the parameter is changed
↓ ENTER
* InkParameter *
Updating Parameter
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(7) Serial number entry
* SerialNo. *
+
DD6*000001 -
* SerialNo. *
+
DD6C*00001 -
* SerialNo. *
+
DD6C1*0001 -
* SerialNo. *
+
DD6C12*001 -
* SerialNo. *
+
DD6C123*01 -
* SerialNo. *
+
DD6C1234*1 -
* SerialNo. *
+
DD6C12345* -
Notes
• The third figure of a serial number differs with the machine size.
• 6: 65 inch
• 8: 90 inch
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5.9 ENDURANCE RUNNING MENU

In this menu, you can perform endurance running on the printer heads.
The Endurance Running menu includes the following items.

CR Motor Performs carriage stroke. CR Motor Endurance Menu
PF motor Drives the PF motor. PF Motor Endurance Menu
Razor Blade Cuts media. Cutter Endurance menu
Head up/down Changes over the head height repeatedly. Head Up/Down Endurance
Menu
Head lock Tests head lock operation. Head Lock Endurance
Performs wiper up/down operation via the selecting menu
menu.
Pump Drives the positive/negative pressure pump motor. Pump Endurance menu
Lever motor Drives the lever motor. Sequential Printing
Endurance Menu
Nozzle print Prints out a printing by printer heads repeatedly. Sequential Printing
Endurance Menu
General endurance Performs endurance running on the CR, PF and General Endurance Menu
head up/down concurrently.
Confirmation Check the number of endurance running cycles. Endurance Running Check
Menu
* Life *
F1 → CR motor PF motor ← F2
F3 → Cutter Head U/D ← F4
(1/3)
* Life *
F1 → Head Lock Pump ← F2
F3 → Lever Motor Nozzle ← F4
(2/3)
* Life *
F1 → Total Life Check ← F2
(3/3)
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5.9.1 CR Motor Endurance Menu

You can perform carriage stroke according to your desired setting. The available settings are shown below.
Setup item Description Parameters Remarks

Operation speed (CW, Sets carriage operation speed (CW and CCW). 240, 300 Unit: cps
CCW)
Number of endurance Set the number of endurance running cycles -1 to 10000
running cycles
Notes
• If the number of endurance running cycles has been set to -1, the units continuously repeat endurance
running until a key input is given from the operation panel.
• The maximum counter value for endurance running cycles is 99999999 (up to 8-digit number). If the
number of cycles exceeds the maximum value, the counter is reset to 0.
* Speed CW *
Speed 240 / 300 + Speed (CW)
240 cps -
↓ ENTER
* Speed CCW *
Speed 240 / 300 + Speed (CCW)
240 cps -
↓ ENTER
* Aging Count *
Count -1 → 10000 + Number of endurance running cycles
50 -
↓ ENTER
* CR Motor *
Count 5 Perform endurance running
↓ ENTER
* CR Motor *
End 50
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5.9.2 PF Motor Endurance Menu

You can drive the PF motor according to your desired settings. The available settings are shown below.

Media feed amount Sets amount of media feeds per endurance 0 to 100 Unit: mm
operation.
running cycles
Notes
• The motor drive parameters are determined as follows depending on the media feed amount.
Speed 54 cps
Acceleration 0.1 G
Deceleration 0.1 G
• If the number of endurance running cycles is set to -1, the units continuously repeat endurance
* FeedAmount *
0 – 100.0 mm + Media feed amount
0.1 mm -
↓ ENTER
* LifeCount *
50 -
↓ ENTER
* PFmotor *
↓ ENTER
* PFmotor *
End 50
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5.9.3 Cutter Endurance menu

You can perform the cutting operation according to the settings.
Caution
• Pay attention to the following points when performing the cutter endurance operation.
• Install usable ink cartridges.
• Make sure that media initialization is complete.
• Performing the cutter endurance operation without ink cartridges could result in damage to the
product if the cutter fails outside the cutting range.
The available settings are shown below.

Page size Sets amount of media feeds per endurance 30 to 3000 Unit: mm
operation.
running cycles
Waiting time Set the waiting time after one cycle of 40 Unit: second
endurance running
Notes
• The waiting time is not modifiable.
* Page size *
30 – 3000 mm + Page size
30 mm -
↓ ENTER
* Cutter *
Count -1 → 10000 + Count Endurance
50 -
↓ ENTER
* Cutter *
Time Wait (sec) 40 Check Waiting time
↓ ENTER
* Cutter *
Count 5 Perform endurance
↓ ENTER
* Cutter *
End 50
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5.9.4 Head Up/Down Endurance Menu

This menu performs endurance running for the head up/down operation.

Waiting time Set the waiting time after one cycle of 10 Unit: second
endurance running
running cycles
Notes
• The waiting time is not modifiable.
* LifeCount *
50 -
↓ ENTER
* Head U/D *
Time Wait (sec) 10 Check wait time
↓ ENTER or CANCEL
* Head U/D *
↓ ENTER or CANCEL
* Head U/D *
End 50
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5.9.5 Head Lock Endurance menu

Test endurance of head lock.
In the Head Lock Endurance menu, you can perform head lock operation according to the set items.
Notes
• Refer to "Head Up/Down Endurance Menu"
• The wait time for head lock endurance is set to 10 seconds.
* Head lock *
Wiper U/D Yes/No + Wiper up and down
Yes -
↓ ENTER
* LifeCount *
50 -
↓ ENTER
* Head Lock *
Time Wait (sec) 10 Check wait time
↓ ENTER to perform endurance
* Head Lock *
↓ End
* Head Lock *
End 50
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5.9.6 Pump Endurance menu

This menu performs endurance running for the pump.
In the Pump Endurance menu, you can perform the pump motor assembly endurance operation according to
the settings.

Operation speed Sets the operation speed of the High/Normal/Low
pump motor assembly.
Number of endurance running cycles Set the number of endurance -1 to 10000
running cycles
Notes
* Aging pump *
F1 → High Normal ← F2
F3 → Low
↓ Select speed (high)
* LifeCount *
50 -
↓ ENTER
* High *
↓ ENTER or CANCEL
* High *
End 50
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5.9.7 Lever Motor Endurance Menu

This menu performs endurance running for the lever motor.
You can drive the lever motor according to your desired settings. The available settings are shown below.

running cycles
Notes
* LifeCount *
50 -
↓ ENTER
* LeverMotor *
↓ ENTER or CANCEL
* LeverMotor *
End 50
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5.9.8 Sequential Printing Endurance Menu

This menu performs endurance running for the printer heads.
You can operate the printer heads according to your desired settings. The available settings are shown
below.
Setup item Description Parameters

Printing mode Set printing mode. MODE 1, MODE 2, MODE 3,
MODE 5, MODE 6, MODE 7
Media Cut Sets whether to cut media each time one Yes, No
printing is printed out or not.
running cycles
Notes
* Print Mode *
F1 → MODE1 MODE2 ← F2
(1/2)
* Print Mode *
(2/2)
↓ Select mode
* Cut *
Cut Yes/No +
Yes -
↓ ENTER
* Nozzle *
50 -
↓ ENTER
* Nozzle *
↓ ENTER or CANCEL
* Nozzle *
End 50
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5.9.9 General Endurance Menu

This menu performs the general endurance running.

Operation speed (CW, Sets carriage operation speed (CW and CCW). 240/300 Unit: cps
CCW)
Media feed amount Set the media feed amount per cycle 0 to 100 Unit: mm
running cycles
Notes
* Speed CW *
Speed 240 / 300 + Speed (CW)
240 cps -
↓ ENTER
* Speed CCW *
Speed 240 / 300 + Speed (CCW)
240 cps -
↓ ENTER
* Feed Amount *
0 – 100.0 mm + Media feed amount
0.1 mm -
↓ ENTER
* Life Count *
Count -1 → 10000 + Number of total endurance running cycles
50 -
↓ ENTER
* Total Life *
↓ ENTER or CANCEL
* Total Life *
End 50
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5.9.10 Endurance Running Check Menu

In this menu, you can confirm the number of endurance running cycles that have been already finished.
The number of endurance running cycles is stored in NVRAM in the system. Therefore, even if a serious
error occurs during endurance running, you can confirm the number of finished cycles just before the
occurrence of the serious error.
* Check *
CR Motor 50 Number of endurance running cycles (CR Motor)
PF Motor 0 Number of endurance running cycles (PF Motor)
(1/5)
* Check *
Cutter 33 Number of endurance running cycles (Cutter)
Head U/D 55 Number of endurance running cycles (Head
(2/5) up/down)
* Check *
Head lock 77 Number of endurance running cycles (head lock)
Wiper 77 Number of endurance running cycles (wiper)
(3/5)
* Check *
Pump 77 Number of endurance running cycles (pump mot)
Lever Motor 77 Number of endurance running cycles (sequential
(4/5) Printing)
* Check *
Nozzle 77
Total Life 88 Number of endurance running cycles (All)
(5/5)
5.10 HEAD LOCK MENU

Lock and unlock the head lock.
• Lock: Locks the head.

• Unlock: Releases the head lock.
* Head lock *
F1 → Lock Unlock ← F2
(1/1)
↓ Select (unlock)
* Unlock *
Wait Little time
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5.11 HEATER SYSTEM MENU

This menu is used to evaluate the heating elements of the printer.

Status This menu displays the status of the heating system. → Heater Status Menu
Temperature This menu displays the real temperature of the heating → Heater Temperature
elements. Menu
Test 30 This menu heats the temperature up to 30°C. → Heater Test 30 Menu
Test 50 This menu heats the temperature up to 50°C. → Heater Test 50 Menu
Test Max This menu heats the temperature up to the maximum → Heater Test Max Menu
temperature.
Version This menu displays the version of the control heater → Heater Version Menu
board.
Adjust For calibration of the heaters. → Heater Adjust Menu
For future use only!
* Heating System *
F1 → Status Temperature ← F2
F3 → Test 30 Test 50 ← F4
(1/2)
* Heating System *
F1 → Test Max Test Aging ← F2
F3 → Version
(2/2)
5.11.1 Heater Status Menu
This menu displays the status of the heating system.
* Status *
Heater Standby
No errors
5.11.2 Heater Temperature Menu
This menu displays the real temperature of the heating elements.
* Temperature *
A : R25
B1 : R24 B2 : R24 C : R25
D1 : R26 D2 : R26
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5.11.3 Heater Test 30 Menu
This menu heats the temperature up to 30°C.
* Test 30 *
Sending to heat system
The display will mention de current temperature. You can follow the heating of the heater elements on the
display up to 30°C.
* Temperature *
A : R30
B1 : R30 B2 : R30 C : R31
D1 : R31 D2 : R31
5.11.4 Heater Test 50 Menu
This menu heats the temperature up to 50°C.
* Test 50 *
* Temperature *
A : R50
B1 : R50 B2 : R50 C : R51
D1 : R50 D2 : R50
5.11.5 Heater Test Max Menu
This menu heats the temperature up to maximum temperature.
* Test MAX *
* Temperature *
A : R50
B1 : R70 B2 : R70 C : R70
D1 : R50 D2 : R50
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5.11.6 Test Aging Menu
Display:
* TestHeaterAging *
# 20 12mins ON+FAN
A:45 B1:60 B2:60
C:50 D1:40 D2:40
Explanation of the above screen:
• # 20: Indicates the index number of the current cycle.

When going to the next cycle, this number is increased with 1.
This number will also be displayed when an error occurs, so you know the moment when the error
occurred.
• 12mins : minutes remaining in the current cycle
• ON+FAN: ON = heating, OFF = cooling down, FAN = fans ON.
Cycles:
Heating to max temps with fans on: 20min #0,4,8,12,16…
Cooling down with fans on: 10min #1,5,9,13,17…
Heating to max temps with fans off: 20min #2,6,10,14,18…
Cooling down with fans off: 10min #3,7,11,15,19…
5.11.7 Heater Version Menu

This menu displays the version of the control heater board.
* Version *
Ver = 2.07
5.12 SOL PREPARE MENU

Loading ink for the first time. Please refer to the User’s Guide.
* SOL prepare*
Init.SOL flag +  F2
Reset -  F4
5.13 SMS MENU

*SMS ink support *
Init.SMS flag +  F2
Set -  F4
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Service Manual
5.14 MACHINE SIZE SELECT MENU

Used when the Mainboard is exchanged, etc.
If the system is in the operation mode or the Diagnostics menu mode, press the [POWER] key to power OFF
the unit.
Step 1 : Press the [POWER] key while simultaneously pressing and holding the [MENU ↑] key and the
[MENU ↓] key.
Step 2 : Select the machine size.
* MachineSize *
F1 → 65inch 90inch ← F2
- 65inch - (1/1)
↓ Select item
*Head*
F1 → 4 Head 8 Head ← F2
-4 Head- (1/1)
↓ Select item
Select Finish!
Please re-starting
Step 3 : Power OFF the unit.
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Service Manual
5.15 CHIPMGR MENU

Via the chip mgr menu, printer error numbers are also displayed.
For example
ChipMgr ==> status
Write error: able to read the ml status.
*ChipMgr Printer*
Write Error [E7]
Xxxxxx ml
Read error: not able to read ml status from chip
*ChipMgr Printer*
Read Error [E9]
No errors concerning ml status.
*ChipMgr Printer*
Status
Xxxxx ml
5.16 SMS HTEMP MENU

Leave this setting to auto when there is no colour mixing or nozzle drop out. In case there is, change the
value to 38. After changing the value, always perform the bi-directional adjustment procedure again.
* Check *
SolPrepare SMS
ChipMgr SMS HTemp ← F4
(3/3)
↓ Select item
*SMS HTemp*
+
38° C -
F2, F4 > ENTER
This value can be set as follows:
Default: AUTO
Minimum: 10
Maximum: 45
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6 MAINTENANCE MODE
6.1 INTRODUCTION .................................................................................................................................. 210
6.2 START UP .......................................................................................................................................... 210
6.2.1 Operating Maintenance Mode ................................................................................................. 210
6.3 MAINTENANCE MENU ......................................................................................................................... 211
6.3.1 Counter Display Menu ............................................................................................................. 211
6.3.2 Counter Initialization Menu ...................................................................................................... 213
6.3.3 Head Voltage ........................................................................................................................... 214
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6.1 INTRODUCTION
In the maintenance mode, different life counters can be checked and head voltage can be set. This mode is
implemented in the firmware and all operations can be done from the display.
Notes
• Refer to “Operation Panel ".
6.2 START UP
Please follow the steps below to start up in maintenance mode.
Step 1 : Power OFF the printer in case it stands in the User mode
Step 2 : Power ON the printer while holding the [F1] key, [F3] key and [MENU ↑] key.
The system will enter the maintenance mode and display the maintenance menu.
6.2.1 Operating Maintenance Mode

For operating the maintenance mode, refer to "Operations in Diagnostics Mode".
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6.3 MAINTENANCE MENU

The maintenance menu includes the following diagnosis items.

Counter Display Menu This menu displays the life counters. Counter Display Menu
Counter Initialization Initializes the service life counter. Counter Initialization Menu
Menu
* Counter *
F1 → Indication InitMenu ← F2
Head VLT ← F4
6.3.1 Counter Display Menu

Displaying the life counters.

Rest ink 1 Displays ink consumption counter (1).
Cutter service life Displays the cutter service life counter.
Number of prints Displays the counter for the total number of prints.
Waste ink Displays the service life counter for the waste liquid tank (right).
Cleaner Displays the cleaning unit life counter.
CR motor Displays the CR motor service life counter.
PF motor Displays the PF motor service life counter.
Pump A Displays the number of pump cycles of pump A
Pump B Displays the number of pump cycles of pump B
Head 1 A Displays the service life counter for nozzle A of head unit 1.
Head 1 B Displays the service life counter for nozzle B of head unit 1.
Notes
• All life counters are displayed in decimal number.
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* INDICATION *
RestInk 1 00000000
RestInk 2 00000000
(1/12)
* INDICATION *
RestInk 3 00000000
RestInk 4 00000000
(2/12)
* INDICATION *
RestInk 5 00000000
RestInk 6 00000000
(3/12)
* INDICATION *
RestInk 7 00000000
RestInk 8 00000000
(4/12)
* INDICATION *
CutterLife 00000000
PrintNumber 00000000
(5/12)
* INDICATION *
WasteInk 00000000
Cleaner 00000000
(6/12)
* INDICATION *
CR Motor 00000000Mdot
PF Motor 00000000Mdot
(7/12)
* INDICATION *
Pump A 00000000
Pump B 00000000
(8/12)
* INDICATION *
Head 1A 00000000Mdot
Head 1B 00000000Mdot
(9/12)
* INDICATION *
(10/12)
* INDICATION *
(11/12)
* INDICATION *
(12/12)
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6.3.2 Counter Initialization Menu

This menu initializes the life counters. The parameters that can be initialized in this menu are as follows.

Number of prints Initializes the total number of printing counter.
initialization
Ink initialization Initializes the ink capacity counter.
Waste ink initialization Initializes the waste fluid tank service life counter.
Head error reset Resets critical trouble errors due to over-current flowing to the head.
Total initialization Initializes the service life counter.
NVRAM initialization Initializes NVRAM.
Notes
• Be careful when initializing the NVRAM, you will permanently delete all
parameters.
Timer initialization Initializes the timer.

Cutter initialization Initializes the cutter cumulative counter.
CR motor initialization Initializes the CR motor service life counter.
PF motor initialization Initializes the PF motor service life counter.
Cleaning initialization Initializes the cleaning wiper service life counter.
Pump A Initializes the head pump life service counter for heads 1 and 2
Pump B Initializes the head pump life service counter for heads 3 and 4
Head unit 1 Initializes the head 1 nozzle service life counter.
initialization
initialization
initialization
initialization
* Init*
PrintNumber Ink ID
WasteInk Head error
(1/5)
* Init*
Ink All
NVRAM Timer
(2/5)
* Init*
TotalCut CR motor
PF motor Cleaning
(3/5)
* Init*
Pump A Pump B
Head Unit 1 Head Unit 2
(4/5)
Head Unit 3 Head Unit 4
(4/5)
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Service Manual
6.3.3 Head Voltage

In this menu, you can change the head voltage compensation value from -9 to +2.5. The default value is 0.
If your Spitfire 65/90 / Rockhopper 3 does not print perfectly in 360x360, change the value to optimize your
print quality.
* Head VLT *
0.0 +
-
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7 ADJUSTMENTS
7.1 INTRODUCTION .................................................................................................................................. 216
7.2 DIFFERENT ADJUSTMENTS ................................................................................................................. 216
7.3 PARAMETER BACKUP ......................................................................................................................... 219
7.3.1 Procedure for creating backup parameters ............................................................................. 220
7.3.2 Backup parameter installation procedure ................................................................................ 221
7.3.3 Parameter update .................................................................................................................... 222
7.3.4 Memory card explorer .............................................................................................................. 223
7.4 FIRMWARE INSTALLATION ................................................................................................................... 224
7.4.1 Installation procedure when using a flash memory card ......................................................... 224
7.4.2 Installation procedure when using a computer ........................................................................ 225
7.4.2.1 When using a printer cable................................................................................................... 225
7.4.2.2 When using the Firmware Update Wizard ........................................................................... 226
7.5 STEEL BELT TENSION ADJUSTMENT ..................................................................................................... 231
7.5.1 Tools required for work ............................................................................................................ 231
7.5.2 Adjustment Procedure ............................................................................................................. 231
7.6 PF DECELERATION BELT TENSION ADJUSTMENT .................................................................................. 233
7.7 HEAD PRECISION ADJUSTMENT (SLANT) .............................................................................................. 234
7.7.1 Head slant adjustment ............................................................................................................. 234
7.7.2 Front and back of head adjustment ......................................................................................... 236
7.7.3 Fine tuning the Front and back head adjustment .................................................................... 238
7.8 REPEATABILITY ADJUSTMENT (BI-DIRECTIONAL) ................................................................................. 245
7.8.1 Fine tuning the Bi-directional adjustment................................................................................. 246
7.9 CW ADJUSTMENTS (UNI-DIRECTIONAL) .............................................................................................. 249
7.10 CR DECELERATION BELT TENSION ADJUSTMENT .................................................................................. 250
7.11 COVER SENSOR ADJUSTMENT ............................................................................................................ 251
7.12 HEAD HEIGHT ADJUSTMENT ................................................................................................................ 252
7.13 MEDIA SENSOR SENSITIVITY ADJUSTMENT ........................................................................................... 254
7.14 CUTTER ADJUSTMENT ........................................................................................................................ 257
7.15 PUMP TUBING LAYOUT FOR PUMP ASSEMBLY ....................................................................................... 258
7.15.1 Pump tubing layout .................................................................................................................. 258
7.16 BOARD CHECKLIST............................................................................................................................. 259
7.16.1 Power supply board. ................................................................................................................ 259
7.16.2 Control board. .......................................................................................................................... 260
7.16.3 Power board. ............................................................................................................................ 261
7.16.4 Heater Elements ...................................................................................................................... 261
7.16.5 Checklist................................................................................................................................... 263
7.17 FLUSHING BOX HEIGHT POSITION ADJUSTMENT .................................................................................... 264
7.18 STEP ADJUST .................................................................................................................................... 266
7.18.1 Basics about the step............................................................................................................... 266
7.18.2 How to change the step ........................................................................................................... 267
7.18.3 Questions and answers on step adjust .................................................................................... 271
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7.1 INTRODUCTION
Adjustments and adjustment procedures required when replacing parts are explained in this chapter.
Notes
• Refer to “Jig and tool list "
7.2 DIFFERENT ADJUSTMENTS

The required adjustments after replacing some parts are schemed below.
When adjusting or replacing maintenance parts, a printing adjustment is required using the auto-diagnostic
function on the printer. Refer to the table below while making adjustments.
Replaced or Adjustment Adjustment Refer to

adjusted part order
1 Head rank input (including initial filling) → Head rank input menu
Head nozzle check → Head Nozzle Check
2
Menu
Head angle check → Head Slant Check
3
Menu
Head precision adjustment → Head precision
4
Print head adjustment
Repeatability adjustment → Repeatability
5
Adjustment Menu
6 CW adjustment → CW Adjustment Menu
7 Test Print → Test print menu
Head unit lifespan count reset → Parameter
8
Initialization Menu
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1 Parameter backup → Parameter backup

2 Firmware installation → Firmware installation
Machine size select → Machine size select
3
menu
Backup parameter installation → Backup parameter
4
installation procedure
Media sensor sensitivity adjustment → Media sensor
5
sensitivity adjustment
6 Head rank input → Head rank input menu
7
Menu
Mainboard Head angle check → Head Slant Check
8
assembly Menu
9
Adjustment Menu
10 CW adjustment → CW Adjustment Menu
Band feed correction → Band Feed Correction
11
Menu (X Length)
Top and bottom adjustment → Top & bottom
12
adjustment menu
Rear sensor position adjustment → P_REAR sensor
13 position adjustment
menu
CR deceleration belt tension adjustment → Steel belt tension
1
adjustment
2
Adjustment Menu
CR motor
assembly 3
adjustment menu
Initializing CR motor history → Parameter
5
Initialization Menu
PF deceleration belt tension adjustment → PF deceleration belt
1
tension adjustment
2
Menu (X Length)
3
PF motor adjustment menu
assembly Rear sensor position adjustment → P_REAR sensor
menu
Initializing PF motor history → Parameter
6
Initialization Menu
1
P_EDGE sensor sensitivity adjustment
assembly Top and bottom adjustment → Top & bottom
2
adjustment menu
Cover sensor Cover sensor assembly position adjustment → Cover sensor
1
assembly adjustment
1 PF_ENC inspection → Encoder Menu
2
PF_ENC Menu (X Length)
assembly Top and bottom adjustment → Top & bottom
3
adjustment menu
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1 Cutter adjustment → Cutter adjustment

Sub-platen
2 Cutter endurance operation check → Cutter Endurance menu
1 CR encoder inspection → Encoder Menu
2
Adjustment Menu
T fence
3
adjustment menu
Steel belt tension adjustment → Steel belt tension
CR slave pulley 1
adjustment
1 Cutter adjustment → Cutter adjustment
Cutter holder
Cutter endurance operation check → Cutter Endurance
assembly 2
menu
Head height adjustment → Head height
1
adjustment
2
sensitivity adjustment
Continuous printing endurance operation → Head Nozzle Check
check Menu
3
→ Sequential Printing
Endurance Menu
4
Menu
Carriage Head angle check → Head Slant Check
5
assembly Menu
Head precision adjustment → Head precision
6
adjustment
7
adjustment Menu
CW adjustment → Repeatability
8
Adjustment Menu
Top and bottom adjustment → P_REAR sensor
menu
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7.3 PARAMETER BACKUP

During the lifetime of a printer, different parameters will be stored on the NVRAM (Flash-ROM or EEPROM)
installed on the mainboard. When replacing this mainboard, all parameters will be lost. Therefore, a
parameter backup is very helpful.
There are different types of parameters

• Panel setting values
• Mechanism adjustment values
• Mainboard adjustment values
Tools needed.
Flash memory card (AF-10063)
Notes
• For the backup parameter, the Mainboard adjustment values cannot be changed or deleted.
If it is necessary to replace the Mainboard while performing maintenance work, make a parameter backup.
You can shorten some of the adjustment procedures by matching the printer mechanism with the new
Mainboard.
Caution
• Before making a parameter backup, make sure that the power source to the printer is OFF. If
the operation is performed with the power source on, the Mainboard could be damaged and
the data may not be installed correctly.
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7.3.1 Procedure for creating backup parameters
Use the following procedure to create backup parameters.
Important
• Before replacing parts, be sure to perform the following operations.
• Power OFF the machine.
• Remove the product's electrical plug from the socket. Otherwise, you may suffer electric
shock or the machine’s electric circuits may be damaged.
Step 1 : Remove the memory cover.
Step 2 : Install the memory card for parameter backup into the memory card connector slot (J104) on the
mainboard assembly.
Notes
• Install the memory card so that its front is toward the inside of the printer.

After all of the lamps on the operation panel light up, the LED display on the panel displays
"PRINTER→CARD".
Step 4 : Press the [ENTER] key on the operation panel.

The LED display on the operation panel displays "P→C Started".
Backup parameter creation begins.
If the backup parameter has been created correctly, "P→C Completed" is displayed on the operation panel.
Step 5 : Switch OFF the power source to the printer.
Step 6 : Remove the memory card for parameter backup.
Notes
• If you do not have backup memory card, output "Adj. Variable" in "Sample Printing Menu". Required
parameter is output.
• For the panel setting value, output "Setup" in the Operation Manual. Maintenance history is not
printed.
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7.3.2 Backup parameter installation procedure

The following is the procedure for installing the backup parameter from the memory card into the new
Mainboard assembly.
Use the following procedure to install backup parameters.
(1) When using a flash memory card
Step 1 : Install the memory card for the backup into the memory card connector slot for the new
Mainboard assembly.
Notes
• Install the memory card so that its front is toward the inside of the printer.
Step 2 : Switch the power to the printer ON.

After all of the lamps on the operation panel come on, the LED display on the panel displays
"PRINTER→CARD".
Step 3 : Press either the [MENU ↑] key or [MENU ↓] key on the operation panel.
"CARD→PRINTER" is displayed on the LED display on the operation panel.
Step 4 : Press the [ENTER] key on the operation panel.

The LED display on the operation panel displays "C→P Started".
Backup parameter creation begins.
Step 5 : If the backup parameter has been created correctly, "C→P Completed" is displayed on the
operation panel.
Step 6 : Switch OFF the power source to the printer.
Step 7 : Remove the memory card for parameter backup.
Step 8 : Reinstall the memory cover
There are two kinds of backup procedures. The first one is the manual procedure as described below. A
second procedure is the automatic procedure. The automatic procedure consists out of installing the memory
card and wait for a while. The procedure will automatically start. The manual procedure is described below.
(2) When not using a flash memory card

The settings should be input by the panel.
Step 1 : Install the firmware according to "Firmware installation".
Step 2 : Follow the instructions in "Machine size select menu" to select the machine size.
Step 3 : Initialize NVRAM according to "Counter Initialization Menu".
Step 4 : Follow the instructions in "Parameter Update Menu" and refer to the printed adjustment variable
to enter following setting value.
• Head voltage
• Printing position alignment (Bi-D)
• CW adjustment
• Mechanical parameter (Top margin, Bottom margin, Side margin, P_REAR sensor position)
• Ink parameter (Initial ink charge flag)
• Serial number
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7.3.3 Parameter update
Step 1 : Restart the printer

At first start-up of the new firmware, the parameter configuration will be updated.
* Updating settings. *
Will auto reboot
Do not power down!
Please wait
Caution
• Don’t push the [Cancel] button!
• Cancelling the parameter update process will result in incorrect printer behaviour.
Step 2 : Set the printer in “Printer mode” if you want to use the printer in this mode.
It is necessary to set the printer in printer mode and to set the colormode in the chipmgr menu when you
want to use the printer in printermode.
Caution
• The printer is set to “cassette mode” after a firmware update. This will cause the “not original
ink” message when the printer was used in “printer mode” before the update.
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7.3.4 Memory card explorer
There is third party software available to program and read flash cards. Concrete; it is possible to copy
firmware and store parameters to a flashcard or to download them to your workstation.
1. Advantages
• Only 1 flash card is needed.

• Program your flashcard yourself: Download the *.pcc files form Mutoh’s firmware download FTP, copy it
to the flash card with the program and update your Mutoh printer(s)
Be sure to program the flash card as well, when you want to take a parameter back up.
• Possibility to centralize all parameter backups in one folder.
• Parameters can be exchanged.
2. Memory Card Explorer software
Memory Card Explorer ("MCE" & "MCE/NT")

is a graphical Windows software package
which provides direct access to the data
stored in flash, SRAM and ATA PCMCIA
memory PC Cards. It allows the binary
"image" of the card data to be saved to or
loaded from the hard disk drive in simple and
fast operations. Data between any two
address blocks can be copied and edited.
MCE is compatible with Windows 95, 98, ME,
NT4, 2000 and XP
For more information, please refer to TIB 213
3. Method of working
Using only 1 flashcard
Step 1 : Install parameter back up firmware via software on flash card.

Step 2 : Backup parameters of printer / cutter with flashcard.
Step 3 : Store parameters from flashcard on the PC using the new software.
Step 4 : Copy new firmware from Mutoh’s Firmware FTP site via software to flash card.
Step 5 : Install new firmware on printer / cutter.
Step 6 : Copy parameter backup via software to flash card.
Step 7 : Install parameters from flashcard on printer / cutter.
Using parallel / USB cable and parameter backup card
Step 1 : Install parameter back up firmware via software on flash card.

Step 2 : Backup parameters of printer / cutter with flashcard.
Step 3 : Store parameters from flashcard on the PC using the new software.
Step 4 : Download new firmware from Mutoh’s Firmware FTP site.
Step 5 : Update firmware via parallel / USB cable.
Step 6 : Install parameters on printer / cutter.
Step 7 : Install parameters from flashcard on printer / cutter.
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7.4 FIRMWARE INSTALLATION

The procedure for installing firmware is explained below.
Install firmware when performing the following maintenance operations.

• When replacing the Mainboard assembly
• When upgrading firmware
Caution
• Before installing firmware, be sure that the power to the printer is turned off.
• Performing these operations with the power on could result in damage to the Mainboard
assembly or cause the data to not be installed correctly.
Notes
• Refer to “Jig and Tool list”.
7.4.1 Installation procedure when using a flash memory card

The procedure for installing firmware is explained below.
Important
• Switch the power OFF.
• Remove the product's electrical plug from the socket. Otherwise, you may suffer electric
(1) When using a flash memory card

Step 1 : Remove the memory cover.
Step 2 : Install the memory card for the installation of firmware into the memory card connector slot
(J104) of the Mainboard assembly.
Notes
• Install the memory card so that its front points towards the inside of the printer.
Step 3 : Switch the power ON.
Step 4 : Firmware installation starts.
Step 5 : Check if the buzzer sounded and whether the firmware was installed correctly.
Step 6 : Switch off the power source to the printer.
Step 7 : Remove the memory card for firmware installation.
Step 8 : Reinstall the memory cover.
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7.4.2 Installation procedure when using a computer
7.4.2.1 When using a printer cable
Step 1 : Using a printer cable, connect the PC to the printer.
Step 3 : All lamps will flash for an instant.
Step 4 : Press the [F2] key on the operation panel within 1 second.
The message "Ready to load" is displayed and the firmware install mode takes effect.
Step 5 : Send new firmware data by MS-DOS copy command etc. (e.g. "COPY /B rh2.04.jfl LPT1")
Step 6 : Firmware installation will take about 60 seconds. The following messages will appear in order on
the LED display on the operation panel during installation.
• “Loading"
• "Erasing"
• "Copying"
• "Comparing"
• "End"
Step 7 : Check if the buzzer sounded and whether the firmware was installed correctly.
Important
• After installation of the firmware onto the Spitfire 65/90 / Rockhopper 3, you must upgrade the
heater system board.
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7.4.2.2 When using the Firmware Update Wizard
For more information, please refer to TIB 251
Necessities
• The new FW Update Wizard V1.00

• Personal Computer
• Normal IEEE-1284 cable (=Centronics cable) or USB to IEEE-1284 converter cable.
Step 1 : Be sure that the Printer is powered OFF.
Step 2 : Connect the printer to the PC with the centronics cable or the USB to centronics cable.
Step 3 : Open the firmware update wizard and press next.
Step 4 : If you agree to the disclaimer, press the next button.
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Step 5 : Browse to the place where you have downloaded the new FW and click next.
Step 6 : Choose the type of cable you are using.

• Are you using a normal IEEE 1284 (=centronics) cable
Or
• Are you using a USB to IEEE 1284 converter cable.
Step 7 : Power ON the printer
• All indication LEDs will go ON

• When the LEDs go OFF, press F2
• The display will show, “Ready to load”.
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Step 8 : When the display shows the message, press the next button.
Step 9 : Choose the correct printer port and click next.

Depending on which kind of cable you are using you will get figure1 or figure2.
Option1: Using a normal IEEE 1284 (=centronics) cable
Figure 1
Option2: Using a USB to IEEE 1284 converter cable.
Figure 2
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Step 10 : You are now ready to update to the latest FW. Check if all settings are correct and press Install.
Step 11 : The firmware installation takes about 60 seconds. The following messages will appear on the
LCD of the operation panel according to the process status:
“Loading” ► Receiving ROM data.

“Erasing” ► Erasing old firmware.
“Copying” ► Copying new firmware to ROM.
“Comparing” ► Comparing copy to source.
“End” ► End
Step 12 : The new firmware has been transferred. A buzzer sound indicates that the firmware installation
has been correctly completed.
Important
• Do not close the wizard before the complete installation is performed.
Step 13 : Switch OFF the printer and restart it to activate the new Firmware.
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(3) Updating the heater system board
To update the heater system board of a Spitfire 65/90 / Rockhopper 3, please follow the instructions
mentioned below.
Important
• Before updating the heater system board, make sure you already installed the firmware into the
Spitfire 65/90 / Rockhopper 3.
Step 1 : Make sure the printer is OFF.
Step 2 : Press simultaneously the [CANCEL] and the [ENTER] key while switching the printer ON.
Step 3 : The display will mention the following message.
* User Setting *
Rem Update
F3 → CRD Update
(1/1)
Step 4 : Press the [F3] key.
The heater system board is now being updated. The display will mention the following messages.
Erasing sectors
Wait flash programming
Step 5 : At the end the display will mention the following message.
Card Update
DO NOT POWER DOWN
Version Installed
Step 6 : Press the [CANCEL] key.
Step 8 : Updating the heater system board is completed.
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7.5 STEEL BELT TENSION ADJUSTMENT

The procedure to adjust the steel belt tension is explained below.
7.5.1 Tools required for work

The following tools are required.
• Tension gauge: max. 2.0 N (200 g)
• Steel belt tension attachment 2: for gauge diameter 2mm (0.08in.) or less
Notes
• Refer to “jig and Tool list”.
7.5.2 Adjustment Procedure
Step 1 : Place the tension gauge at the centre of the steel belt.
1 = steel belt 2 = Tension gauge
Notes
• The regulation values for the tension of the steel belt are shown below.
o 65 inch specifications: 1.0 N ± 0.1 N (100 g ± 10 g)
o 90 inch specifications: 0.9 N ± 0.1 N (90 g ± 10 g)
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Step 2 : If the tension of the steel belt is not within the range of regulated values, adjust the steel belt
tension screws.
1 = Steel belt 2 = Steel belt tension screw

3 = CR slave pulley
Step 3 : Move the CR cursor to the left and right once or twice. Adjust the CR driven pulley until the
upper and lower margins are identical.
Caution
• If the tension is not equivalent across the entire belt, it could snap during operation.
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7.6 PF DECELERATION BELT TENSION ADJUSTMENT

When removing the PF motor or removing/installing the PF deceleration belt, adjust the tension of the PF
deceleration belt.
The following tools are required to adjust the tension of the PF deceleration belt.
• Tension gauge: max. 50 N (5 kgf)
Notes
• Refer to “Jig and tool list”
Step 1 : Loosen the 2 screws fixing the PF motor installation board.
Step 2 : Install the tension gauge on the PF motor installation board and pull it in the direction shown on
the figure below.
1 = PF deceleration belt 2 = Screws (M3x6) fixing the PF motor installation

board
3 = PF motor installation board 4 = Tension gauge
Notes
• The regulated value of the tension for the PF deceleration belt is 34.32 N ±10 % (3,5 kgf ±10 %).
Step 3 : Tighten the 2 screws fixing the PF motor installation board.
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7.7 HEAD PRECISION ADJUSTMENT (SLANT)

When replacing the head assembly, use the following procedure to adjust the head angle and head
forward/rear position.
Before starting with the head adjustment, following actions needs to be fulfilled:
• Perform a nozzle check, and if necessary a cleaning to make sure all nozzles are present.
• Switch OFF the heaters
• Disable i²
• Control and remember the IP address of the printer
• Make sure you have adjustment paper available
• Make sure the media is loaded correctly.
7.7.1 Head slant adjustment
Notes
• Refer to “Diagnostics Function”
Step 2 : Select "Adj:HeadSlant".
Step 3 : Print "Slant" pattern.

If dotted lines on pattern CW and CCW are not a straight line, which you can check with a
magnifying glass (enlargement of at least 10), please go to step 4.
Notes
• When the printing pattern is printed, you will only see lines, and no notifications of ink channels. The
head sequence shown below.
• 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B
Step 4 : Loosen the screw (with one turn) fixing the head stationary plate.
N° Part
1 Screw (M2.5x5) fixing the head stationary plate
3 Front and back adjustment screw
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Step 5 : Make adjustments until amount of CW and CCW offset are identical.
Notes
• In theory, the alignment of CW and CCW should be identical. But in practice, it is almost impossible to
become a perfect alignment. When there is a slight difference between CW and CCW, be sure the
heads are well seated.
• In case you only print uni directional, adjust the CW till it is aligned perfectly.
• In case you print bi-directional, and CW and CCW cannot be aligned more perfectly. Divide the fault
equally.
Notes
• When printing the pattern, the head identifications 1A, 1B etc, are not printed. Analyse the pattern as
shown below. Be sure to have five lines for each colour.
How to adjust What to become
N° Part
Step 6 : Tighten the screw fixing the head stationary plate.
Step 7 : Repeat step 1 to 6 until the adjustment is correct for all heads.
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7.7.2 Front and back of head adjustment
Step 1 : In diagnostic mode, go to [Adjust: Head Slant].
Step 2 : Press the [F2] key for F&B (front and back) adjustment.
* HeadSlant *
F1 → Slant F&B ← F2
F3 → Check End ← F4
Step 3 : Print out [Front/Back] pattern. First pattern A with 1A as reference is printed, then pattern B with
4B as reference and finally A+B.
A+B
1B 4A+1B 4A 2B 3A+2B 3A 3B 2A+3B 2A 4B 1A+4B 1A
4B is the
reference head
1B 4B 2B 4B 3B 4B 1B 4B 2B 4B 3B 4B
1A is the
4A 1A 3A 1A 2A 1A 4A 1A 3A 1A 2A 1A reference head
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Notes
To help you identify the print heads on the test pattern please refer to the diagram below.
Know you see, 1A is Black, 1B is Yellow, etc (in our colour combination).
Step 4 : Check if all nozzles are in 1 row by using a magnifying glass with an enlargement of at least 10. If
not, please proceed to step 5.
Step 5 : Loosen the screw with 1 turn, which secures the Head Fixing Plate.
N° Part
1 Head Fixing plate securing screw
2 Front/Back Adjustment Screw
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When the nozzles are not in one row, adjust the head front/back position by moving the Head Front/Back
Adjustment Screw the manner shown below. First adjust nozzle row A (1A, 2A, 3A, 4A). When adjusted
perfectly, nozzle row B should automatically be adjusted. But in practice this isn’t always a fact. When you
determine a small misalignment after adjusting A well, readjust again until all nozzles of row A and B are
perfectly aligned.
Notes
• We only give an example for one colour combination. Please refer to “Operation Procedure Labels” in
the Maintenance Manual where you can find the other possible colour combinations.
Step 6 : Tighten the screw which secures the Head Fixing Plate.
Step 7 : Repeat step 1 to 7 until the adjustment is correct.
7.7.3 Fine tuning the Front and back head adjustment

The adjustment exists out of printing 3 files. The meaning of this pattern is to adjust the heads more precisely
then with the F&B adjustment. It remains important to perform the front and back adjustment in diagnostic
mode, this adjustment is a means of fine tuning the printheads.
The big advantage of this pattern is that it is fast and easy to evaluate.
Background information
Every head exist out of 2 nozzle rows. Nozzle row A and B. These A B
are shifted 1/360th dpi (please refer to the picture on the right). This
is the basic thought of this adjustment. The purpose of this 1/180 inch 1/360 inch
adjustment is to calibrate the “B” nozzle row of each head exactly
in the centre of two “A” nozzle rows of the reference head. After the
adjustment, all heads should be in the same line.
To adjust all heads, a reference head is chosen. (3A – Magenta)
The new pattern prints the A nozzle row from the reference head
and the B nozzle row of the head which needs to be adjusted in
front and back direction.
Head 1
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In the example below nozzle row B of head 1 is adjusted until it is exactly in the centre of two nozzle rows A
of the reference head 3.
Head Nozzle Rows

1 2 3 4
a b a b a b a b
A B A B
Head 1 Head 3
To Adjust Reference
After this calibration head 1, compared to head 3, are in one line. The next head can be adjusted.
Please follow the instructions below for the complete procedure to print the patterns and to evaluate and
adjust.
This adjustment solves quality problems like below. What you see is an example of a black solid colour
plane.
Before head adjustment After head adjustment
To adjust the heads of this ink configuration, head 3 is chosen as reference. NEVER ADJUST THE
REFERENCE HEAD! For every other head (1, 2 a 4) a print file is sent to the printer and the front/back
adjustment is done. Please be sure before performing these adjustments that the front and back adjustment
is diagnostics mode is done as good as possible.
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Ink configuration
Head Nozzle Rows
1 2 3 4
a b a b a b a b
To perform this adjustment, you will need to have the print files which are located on the firmware download
FTP: ftp://firmware@ftp.mutoh.be/firmware_download (please refer to TIB117bis to log in)
Step 1 : Power ON the printer in user mode (no diagnostics mode needed)
Step 2 : Switch OFF all heaters and make sure head height is low in user 1.
Step 3 : Load media.
Step 4 : Edit the IP-address in the PRINT.BAT file in Notepad or Ultra-edit 32.
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Step 5 : Drag the first file (RH64_2x4_3AM_1BY_small_head_1.prn) into the PRINT.BAT file.
Notes
Analysis of the file name:
1 2 3 4 5 6 7
RH64 _ 2x4 _ 3AM _ 1BY _ small _ head_1 . prn
1: Machine type
2: Ink configuration
3: Reference Nozzle row + colour (Nozzle row 3A + Magenta)
4: Nozzle row + colour (Nozzle row 1B + Yellow)
5: Smallest dot size (5.4pl) for better visualization.
6: Head number
7: File extension
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Step 6 : Following pattern will be printed. Use a magnifying glass of at least x25 to evaluate the print.
NEVER adjust the reference head! Begin the evaluation at the bottom of the print to be sure that
the bottom line is printed by a B nozzle row. Then go up and take the average, this because it
can occur that there are some misfiring nozzles which are not representative.
Nozzle row 1B (yellow) is too close to the reference Nozzle row 1B (yellow) is too close to the reference
(magenta). It should be perfectly in the middle (refer to (magenta). It should be perfectly in the middle (refer to
picture below). So head 1 should come lower. picture below). So head 1 should come higher.
Step 7 : After evaluation, adjust head 1 by turning the adjustment screw clockwise or counter clockwise.
Head 1 must come down, so the adjustment screws Head 1 must go up, so the adjustment screws should
should be turned counter clockwise. be turned clockwise.
Caution
• When the magnifying glass gives a mirror view, the screws should be adjusted the other way
around.
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Step 8 : After adjusting the head, print the same pattern until the nozzles are perfectly in between the
nozzles of the reference. (picture 1)
Caution
• Be sure that the “B” nozzle row is the bottom line of the swat. Otherwise the head is shifted
more then 1/360th inch according to the reference head which also means that the F&B
adjustment is not performed correctly. (picture 2)
Picture 1
Picture 2
Step 9 : Perform the same adjustments for the rest of the heads. Please follow the order of the files to
adjust the heads.
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What you should see when the complete adjustment is done properly.
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7.8 REPEATABILITY ADJUSTMENT (BI-DIRECTIONAL)

Purpose of this check.
To check if each head fires the ink at the same position when printing from left to right and right to left.
The check needs to be done for all head heights

# 1 = low
# 2 = middle
# 3 = high
This check needs to be done 3 times
Bi-D = Standard check

Di-D400 = extra check for printing in FAST 540
Bi-D480 = extra check for printing in FAST 360
Notes
Step 2 : Select "Adj:Bi-D".
Step 3 : Print a repeatability pattern.
The odd rows (with each 5 dots) are the references. So the even rows should be adjusted (use a magnifying
with an enlargement of at least 10)
4B 4A 3B 3A 2B 2A 1B 1A
Adjust reciprocation per head height.
• #1: Head height LOW

• #2: Head height MIDDLE
• #3: Head height HIGH
Notes
When you performed the first Bi-D alignment, perform the same operation for as well Bi-D400 and Bi-D450.
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7.8.1 Fine tuning the Bi-directional adjustment

1. Tools necessary
• Network connection
• The 3 print files + batch file on the CD.
• Magnifier (x10) + blue light
• Adjustment paper with a known thickness value.

INFO: Mutoh standard adjustment paper has a thickness of 120µm.
2. How to print the files
Step 1 : Power ON the printer in diagnostics mode → [F2]+[F4]+[▼] and Power ON
Step 2 : Load the adjustment media.
Step 4 : Go to Adjustment → Bi-D and set the correct thickness.
Step 5 : Press enter
Step 6 : Press the [CANCEL] key when following message is displayed.
Step 7 : Go to Adjustment → Bi-D: The panel displays the correct thickness value.
Step 8 : Leave the panel on this display to continue. The print data (head height) will be wrong
when standing on another display.
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Step 9 : Copy the four files to your hard disk and edit the batch file from the CD and fill in the IP address
of the printer.
Step 10 : Drag first file (“01_BiDir_LOW.prn”) into the batch file (“print.bat”).
Step 11 : The adjustment file will be printed, with head height LOW.
3. How to evaluate the files
Step 1 : Every block (1A-8B) should be checked for stair case effects. In case of this symptom, the bi-
direction value should be adjusted.
Step 2 : The arrows are the direction of the print direction of the pass. When standing in front of the
printer, looking at the output, the first pass is always printed from Left to Right
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Step 3 : To adjust the values for LOW (#1) from 1A – 8B press ENTER
Step 4 : Press the [CANCEL] key
Step 5 : Adjust the values for LOW (#1) from 1A – 8B.
Step 6 : After editing the values a small pattern will be printed. No need to look at it.
Step 7 : Following is displayed. Press F4 to END. (You need to go out of the Bi-Directional adjustment
menu to activate the new settings)
Step 8 : Choose Bi-D: The panel displays the correct thickness value.
Step 9 : Leave the panel on this display to print. The print data (head height) will be wrong when
standing on another display.
Step 10 : Reprint the file until no stair case effects are visible anymore with a magnifying glass.
(Ignore satellites)
Step 11 : If the adjustment for headheight LOW is finished, the same steps should be followed for
headheight MIDDLE (#2) and HIGH (#3).
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7.9 CW ADJUSTMENTS (UNI-DIRECTIONAL)

To perform CW adjustments, please follow the steps mentioned below.
Notes
Step 2 : Select "Adj:Uni-D".
Step 3 : Print a CW adjustment pattern.
The odd rows (alternately 1A and 1B) are the references. So the even rows (2A, 2B, 3A, 3B, 4 A and 4B)
should be adjusted (use a magnifying with an enlargement of at least 10)


1B 1A 1B 1A 1B 1A
4B 4A 3B 3A 2B 2A
Notes
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7.10 CR DECELERATION BELT TENSION ADJUSTMENT

When removing/installing the CR deceleration belt, such as when removing the CR motor, adjust the tension
of the CR deceleration belt.

• Tension gauge: max. 50 N (5 kgf)
Notes
• Refer to “Jig and Tool List ".

Use the following procedure to adjust the tension of the CR deceleration belt.
Step 1 : Loosen the 4 hexagon socket head cap screws fixing the CR motor installation board.
1 = CR motor installation board 2 = Hexagon socket head cap screw

3 = CR motor assembly 4 = Tension gauge
Step 2 : Install the tension gauge on the PF motor installation board.
Step 3 : Pull the tension gauge in the direction of the arrow shown on the figure above.
Notes
• The regulated value of the tension for the CR deceleration belt is 34.32 N ± 10 % (3,5 kgf ± 10 %).
Step 4 : Tighten the 4 hexagon socket head cap screws fixing the CR motor installation board.
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7.11 COVER SENSOR ADJUSTMENT

When replacing the cover sensor assembly or removing/installing the front cover, use this procedure to
adjust the cover sensor.
Notes
• Refer to “Diagnostics Function ".
Step 2 : Select "Check:Test" on the self-diagnostic menu.
Step 3 : In the inspection menu, select "Check: Check".
Step 4 : Select "Sensor:Etc." on the sensor menu.
Step 5 : Open and close the front cover assembly and make sure the dimension between the media guide
and the front cover end is 21 mm, and the display in the operation panel is switched as follows.
Front cover Operation panel display

Open Sensor: open
Closed Sensor: closed
Notes
• Use a block gauge to measure the height of the front cover when opening it.
• If the opening height of the front cover and the information displayed on the operation panel are different,
adjust the installation position of the sensor cam.
• A better way to adjust the position of the sensor is to adjust the height of the bracket holding the sensor.
This way you will not damage the screw of the sensor-cam.
1 = Sensor cam 2 = Set screw
Step 6 : Use step 5 to check the display on the operation panel once more.
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7.12 HEAD HEIGHT ADJUSTMENT

If CR cursor assembly is changed, adjust head height.

• CR gap check jig
• spacers
Notes
• Refer to “Jig and Tool List".

Perform the head height adjustment following the procedures below.
Step 1 : Unlock the head lock according to "Head Lock Menu".
Step 2 : Move the CR cursor on the platen.
Step 3 : Remove the head cover according to "Removing the head cover".
Step 4 : Point slide gear mark down so that heads move into low position.
Step 5 : Loosen the screws (2, one on the right, one on the left) that fasten the head U/D eccentric shaft
lever.
1 = Head U/D eccentric shaft lever 2 = Screws fixing the head U/D eccentric shaft lever
3 = Slide gear 4 = Slide gear triangular mark
Step 6 : Put the CR gap adjusting jig on the platen.
Step 7 : Move the CR cursor so that 1.2mm side of adjustment jig makes contact with the side of head.
Step 8 : Adjust head U/D eccentric shaft lever so that CR gap adjustment jig can move freely.
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Step 9 : Perform CR cursor right/left adjustment.
1 = Platen 2 = CR gap check jig

3 = Print head 4 = CR cursor
5 = Height 1.2 mm 6 = Height 1.3 mm
7 = CR gap adjustment jig 1.2 mm side
Step 10 : Fasten the screws (2, one on the right, one on the left) that fasten the head U/D eccentric shaft
lever.
Step 11 : Apply non reflective tape to the head U/D eccentric shaft lever as shown in the following printing:
Notes
• Completely cover the screw heads with non reflective tape. If non-reflective tape cannot be applied to
chosen location, the head slide sensor may not detect screw head properly.
1 = Head U/D eccentric shaft cover 2 = Non reflective tape

3 = Screw fixing the head U/D eccentric shaft cover
Notes
• It may happen that the range to adjust the head height is TOO high. If this happens, install the spacers.
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7.13 MEDIA SENSOR SENSITIVITY ADJUSTMENT

When replacing the P_EDGE sensor assembly or Mainboard assembly, adjust the media sensor.
Notes
• Pay attention to the following points when adjusting the media sensor.
This should be performed in an area where sun light and illumination do not influence the sensor.
The front cover and Y rail cover should be installed when performing the work.
When making adjustments, hold the media by hand or the media hold lever so that the media stays
still on the sensor.
• If the media is lifted off, the accuracy of the sensor may be affected.
A non-conductive type screw driver should be used when adjusting the control on the Mainboard
assembly.
• Otherwise, a short circuit may result if the driver contacts the metal parts, such as electronics parts on
the Mainboard assembly or the frame.

• Reference media: Double coated media (recommended media)
Notes
• Refer to “Jig and Tool List".
Notes
• The adjustment values are as follows.
o HIGH level (with media) A/D value
o In decimal number : 216 to 223 (H)
o LOW level (without media) A/D value
o In decimal number : 48 to 0 (H)
(1) HIGH level (with media) adjustment of the A/D value
Step 1 : Set the standard media.
Step 2 : Select "Check: Head Lock" in the Diagnostics menu.
Notes
Refer to “Diagnostics Function ".
Step 3 : Release the head lock.
Step 4 : Check if the installation angle of the P_EDGE sensor is 15°.
Step 5 : In the inspection menu, select "Check: Check".
Step 6 : Display "Sensor: PaperEdgeAD".
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Step 8 : Move the carriage so that the dimension between the right edge of the standard media and the
cutter is 5 to 10 cm.
1 = Razor Blade 2 = Carriage
Step 9 : Adjust the P_EDGE sensor control shown in the following figure so that the values displayed in
the operation panel become the adjustment value.
• Control R693: Rough adjustment
• Control R694: Fine adjustment
Location of the
Potentiometers
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(2) LOW level (without media) A/D value check
Step 1 : Adjust the A/D value of the HIGH level following the "(1) HIGH level A/D value adjustment"
procedure.
Step 2 : Align the cutter and the right edge of the standard media by moving the carriage.
1 = Razor Blade
Notes
• Perform the following if the A/D values of the edge sensor are not the adjustment value.
o Checking the installation angle (about 15°) of the P_EDGE sensor assembly
o Replacing the P_EDGE sensor assembly
o Re-inspecting the Mainboard assembly
Step 3 : Make sure that the values displayed in the operation panel are as shown below.
• In hexadecimal number: 30 to 0
• In decimal number: 48 to 0
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7.14 CUTTER ADJUSTMENT

This section explains the procedure for adjusting the cutter.
When replacing the sub-platen, replacing the solenoid assembly, or removing/installing media guide F, use
this procedure to adjust the cutter.
Confirm if the media has been cut correctly.
Notes
• Refer to “Cutter Endurance menu".
If media guide F has been installed at an angle, adjust it.
Notes
• Refer to “Removing media guide F".
Loosen the screw fixing the cutter holder.
1 = Cutter holder 2 = Screws (M3x6) fixing the cutter holder
Slide the cutter holder forward and backward as shown in the following figure so that the dimension between
the cutter blade and the cutter groove of the sub-platen is 0.2 to 0.7 mm.
1 = Cutter holder 2 = Cutter groove of the sub-platen
Tighten the screw fixing the cutter holder.
Insert paper into unit. Manually place an indentation into paper.
Confirm that the distance between paper indentation and cutter groove is between 0.2 and 0.7mm.
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7.15 PUMP TUBING LAYOUT FOR PUMP ASSEMBLY

7.15.1 Pump tubing layout
1 = waste tube connection 2 = connection to the head caps
Spitfire 65-90 and Rockhopper 3
Notes
Please be careful, when replacing the tubings, it is possible to have kinks in the tubings. Please avoid this
by turning the tubing to the left or the right at the head connection and/or waste tube connection.
Also be careful the tubings do not touch or get stuck in the gears.
1 Critical tubings
2 Gears
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7.16 BOARD CHECKLIST

7.16.1 Power supply board.
Green LED on Power ON OFF Flashing

Supply Power supply works ok Power supply is not Power supply is not
working. starting.
→ 220V/110V? → Load connected?
→ Load connected to → Restart machine (wait
PS? 10 sec after power off)
→ Error message on → Error message “Heat
Spitfire 65/90 / System Not Found” (*)
Rockhopper 3: “Heat → Damaged power
system not found”(*) supply → replace
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7.16.2 Control board.
LED D8 POWER ON OFF

GREEN Board has 5V => ok Board has no 5V
Power cable connected?
→ Power supply green led ON?
→ Bad cable
LED D2 ALIVE Blinking: OK Fatal error: lockup
LED D1 ERROR Error occurred No error
LED D5 8000 RX/TX Communication ok No communication
LED D7 8000 RX/TX Communication ok No communication
LED D3 Programming led Not used for user!!
LED D6 Programming led Not used for user!!
SMD L11, L2,L6,L13 Coil OK Burned
No problem Temperature sensor cable shorted
to chassis, indication which cable
has a problem.
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7.16.3 Power board.
D2 RED/GREEN(rev. C) ON OFF
From rev C on, it will be OK NO +24V present
a green led → PS ok?
→ Power cable ok?
D1 RED ON OFF
110/220V indicator Should be on in a 110V Should be off in a 220V
grid. grid.
D23, 21,19,13,6,4 RED ON OFF
Heater is on Heater is off
During cold start-up, the self test will run.
All LEDs should go on, one at a time, for a short period.
After a warm start-up, the self test will not run.
During normal operation: LEDs can go on in a random manner.
7.16.4 Heater Elements

Resistance (Ω) 65” 90”
A 2 x 32,3 2 x 24,2
B1/B2 2 x 65,5 2 x 44
C 2 x 32,3 2 x 22,5
D1/ D2 2 x 22,5 2 x 22,5
Thermal Sensor 10k 10k
When checking the thermal sensors, also measure them with the chassis as a reference. If the resistance is
not infinite, the sensor has a short circuit, mostly due to a damaged cable.
If the resistance is infinite, the thermal fuse might be blown. Or in minor cases, check for bad connections at
heater elements and connector.
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Connector:
Tips
Safety relay
On the power board is a safety relay that will switch 220 or 110V to the solid state relays whenever the
Spitfire 65/90 / Rockhopper 3 is powered off. This is to prevent that defective solid state relays can make the
heat strips overheat and melt its fuses.
Buzzer:
1 small beep for each heater that reached the desired temperature.
3 short beeps when heater accepts new data coming from the Spitfire 65/90 / Rockhopper 3.
4 seconds beep => error.
Heater D
In case of a defective fuse on a D-heater, check for isolation on the temperature sensors. Some machines
were released without isolation patches on the temperature sensors and cause the strips to overheat.
Heater A
In earlier machines strips were mounted with a fuse with a critical, narrow margin. Please do not pass 48°C
in the menu setting. This will be solved in successive firmware releases after 1.04.
FLAT Strip
In case of a DIY replacement of a heat strip, make sure that the strip is flatly mounted! Air gaps between
strip and plate can cause overheating and cause fire!
Firmware Bugs
Check the firmware division for these.
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7.16.5 Checklist
Product information :
Serial Number : ________________________________________________
Firmware Version : ________________________________________________
Firmware Version Heater Control Board : ________________________________________________
Basic diagnostics :
Grid power 110V 220V
Grid frequency 50Hz 60Hz
Fuse 1 OK NOK (OPEN)
Power Supply :
LED (Green) ON : OFF : Flashes :
Control Board :
LEDS : ON OFF Flashes
LED D8
LED D1
LED D2
LED D5
LED D7
LED D3
LED D6
Filters OK Bad (visual)

SMD L11
SMD L2
SMD L6
SMD L8
Power Board :
D2 Red/Green (rev. C) Power ON : OFF :
D1 110V/220V ON : OFF :
D23, 21,19,13,6,4 Heater On Flashes?
Cold Start up :
Operation :
Heater elements :
Resistance (Ω) 65” 90”
A 2 x 32,3 2 x 24,2
B1/B2 2 x 65,5 2 x 44
C 2 x 32,3 2 x 22,5
D1/ D2 2 x 22,5 2 x 22,5
Thermal Sensor 10k 10k
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7.17 FLUSHING BOX HEIGHT POSITION ADJUSTMENT

Notes
• Incorrect position of the flushing box height will cause large ink drops on the printout.
Before adjustment of the flushing box height position, please make sure to have:
• The “Flush Box Height Jig Tool” (JD-80001)
Step 1 : Remove the I/H cover.
Step 5 : Start up in Diagnostic Mode and Unlock the Head
* Head lock *
F1 → Lock Unlock ← F2
(1/1)
↓ Select (unlock)
* Unlock *
Wait Little time
Step 6 : Place the flushing box height jig tool on the flushing sponge as shown below:
Step 7 : Turn the wheel of the carriage until the arrow is on the bottom so the carriage is in the lowest
position.
1 Carriage wheel
2 Arrow
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Step 8 : Carefully move the carriage to the right. The carriage should pass the first interval but not the
second.
1 Interval 1
2 Interval 2
3 Reference of the head
Step 9 : When the carriage passes both intervals, move the carriage to the left. Loosen the adjustment
screw of the flushing box a bit and put the flushing box on the correct height and then tighten the
screw.
Notes
Check in head height low if the heads does not interfere with the backside of the bracket. If there is
interference, you have to lower the spitting box.
1 Heads
2 Spitting box
3 Bracket
4 Crucial point where heads pass the bracket
Step 10 : Lock the head
Step 11 : The flushing box is now height adjusted.
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7.18 STEP ADJUST

Obtaining constant printing quality on a wide-format Piezo inkjet printer is not only determined by the working
environment, the RIP, the profiles, the inks and the media which are used. One of the key factors for
obtaining constant output quality is the correct distance adjustment, also called “step”, on your Mutoh inkjet
printer.
7.18.1 Basics about the step
Every image is printed in several print passes. After every pass, the media is fed an amount of millimetres.
When the step is not set correctly, the passes will overlap each other or will not be printed precisely next to
each other which results in white bands between two print passes.
Therefore a function, distance adjust (or step), is added to the menu to control this feed operation.
Refer to the table below for visual support
The passes overlap each other The passes are printed too far from each other
► step between the print passes is too small ► step between the print passes is too large
Notes
It is recommended to start printing with a step of 100.00% and to adjust it afterwards. Once a step is set for
a particular media it will not change on following conditions:
• The step is only applicable on the printer in question and not interchangeable.
• The media manufacturer does not change any specifications (especially backing) of the media.
• The standard take-up system is used in combination with the I² technology.
• The optional unwinder/winder 100 is used.
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7.18.2 How to change the step
Perform a nozzle check to be sure all nozzles are present. If not, perform the necessary cleanings.
1) Via the status screen
Step 1 : Press in the Ready to print screen
Step 2 : Press
Step 3 : Press or to change the step
2) While printing
Step 1 : Press while printing.
Step 2 : Press or to change the step
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3) Via the printer interface
It is also possible to print a pattern via the firmware.
Step 2 : Load the media to print on
Step 3 : Perform a nozzle check to be sure all nozzles are present. If not, perform the necessary
cleanings.
Step 4 : Set the step to 100%
Step 5 : Print the test pattern.
F3
▼
Step 6 : To evaluate the print, you should look for gaps or overlaps between the different passes (1-4).
The direction of the adjustment (increase or decrease the step adjust value) is the easiest to
check in the X-rows. To check the quality, the Y rows should be the standard.
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Step 7 : Step is too small ► overlap visible between passes
Step is too big ► gap visible between passes
Step 8 : Change the step if necessary.
Step 9 : Print the test pattern again until no gap or overlap is visible anymore.
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An alternative way to determine and change the step via the printer interface is as follows.
Step 2 : Load the media to print on
Step 3 : Perform a nozzle check to be sure all nozzles are present. If not, perform the necessary
cleanings.
Step 4 : Print the pattern.
Setup items Parameters Description

Dist.Adj. Print 1 Print the test file with intervals of ± 0.10%
Change Change the step (90.00 % - 110.00 %)
Print 2 Print the test file with intervals of ± 0.20%
- [CANCEL] key: to shift to the previous hierarchy menu.
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Step 1 : Set the step to 100.00%.
Step 2 : Print pattern 1 or 2.
Step 3 : Adjust the step with the or key
Reprint the patterns until step is set correctly.
7.18.3 Questions and answers on step adjust
Q: What if the step cannot be adjusted properly?
A: Send the complete print to our Service department.
Q: Once the step is set, is it always the same?
A: Yes, condition that:

The same media is loaded (step is media dependent)
The media developer hasn’t changed the media (backing for example)
The gridroll has not been changed.
The mainboard has not been changed.
Q: What if the step is different on the left and right side of the print.
A: This means that the media is not running straight. The solution is to recalibrate the winding system.
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8 MAINTENANCE
8.1 INTRODUCTION .................................................................................................................................. 274
8.2 CLEANING ......................................................................................................................................... 274
8.3 PERIODICAL SERVICES ...................................................................................................................... 275
8.3.1 Maintenance on a Spitfire 65/90 done by the end-user ........................................................... 275
8.3.2 Maintenance on a Rockhopper 3 done by the end-user.......................................................... 275
8.3.3 Maintenance on a Spitfire 65/90 done by a authorised Mutoh technician ............................... 276
8.3.4 Maintenance on a Rockhopper 3 done by a authorised Mutoh technician.............................. 276
8.4 PART LIFE INFORMATION .................................................................................................................... 279
8.5 JIG AND TOOL LIST ............................................................................................................................ 280
8.5.1 Required Tools ......................................................................................................................... 280
8.6 LUBRICATION/BONDING...................................................................................................................... 281
8.7 TRANSPORTATION OF THE PRINTER .................................................................................................... 283
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8.1 INTRODUCTION
This chapter provides information about the periodical services and part life.
Important
o Power OFF the printer.
o Remove the product's electrical plug from the socket. Otherwise, you may suffer electric
o Disconnect all cables from the machine. Not doing so could cause damage to the printer.
Caution
• Ensure there is sufficient space around the printer when performing maintenance work.
• If you need to operate the printer with the cover removed for maintenance, be careful not to get
hurt by the moving parts.
• In the periodical services, the following work must be performed with one or more assistant
worker.
• Removing/attaching the unit and the stand
• Packaging the machine for transport
8.2 CLEANING
You need to clean the printer periodically to keep it in best working condition.
Notes
• Make sure to remove all dust every time you clean the printer.
Notes
• Refer to “Exploded Views/Service Parts List”.
Part Timing Check point Action

Platen surface Several times per year Media dust accumulation Clean it.
Media guide F Foreign objects
Pressure rollers Damages Please note: If ink
deposits are present,
remove them with a
dampened cloth and
wipe the area with a
clean dry cloth.
Timing fence Several times per year Media dust accumulation Clean it.
(CR encoder detection Foreign objects If any damages are
slit plate) Damages found, replace the part.
P_REAR sensor surface Several times per year Media dust accumulation Clean it.
Foreign objects
Cleaner head (Cleaning Several times per year Ink deposits Clean it.
wiper) Damages
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8.3 PERIODICAL SERVICES

The periodical services ensure stable printout quality of the machine.
Caution
• There are two parts of periodical service, namely the parts that can be replaced by the end-user
and the parts that need to be done by authorized Mutoh technicians.
8.3.1 Maintenance on a Spitfire 65/90 done by the end-user

Perform periodical inspections according to the table below.
Maint. Month
Cycle 1 2 3 4 5 6 7 8 9 10 11 12
1 x x x x x X X X X X
2 X X
3 x x x x x X X X X X X X
4 2 2 2 2 2 2 2 2 2 2 2 2
weekly weekly weekly weekly weekly weekly weekly weekly weekly weekly weekly weekly
5 daily daily daily daily daily daily daily daily daily daily daily daily
8 weekly weekly weekly weekly weekly weekly weekly weekly weekly weekly weekly weekly
8.3.2 Maintenance on a Rockhopper 3 done by the end-user
Maint. Month
Cycle 1 2 3 4 5 6 7 8 9 10 11 12
1 x x x x x x X X X X X x
2 X X
3 x x x x x X X X X X X X
4 2 2 2 2 2 2 2 2 2 2 2 2
weekly weekly weekly weekly weekly weekly weekly weekly weekly weekly weekly weekly
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8.3.3 Maintenance on a Spitfire 65/90 done by a authorised Mutoh

technician
Maint. Month
Cycle 1 2 3 4 5 6 7 8 9 10 11 12
1 X X
2 X X
3 X X
4 X
5 X
6 x
7 X X
8 X X
9 X X
10 X X
11 X X
8.3.4 Maintenance on a Rockhopper 3 done by a authorised Mutoh

technician
Maint. Month
Cycle 1 2 3 4 5 6 7 8 9 10 11 12
1 X X
2 X X
3 X
4 X
5 X
6 x
7 X X
8 X X
9 X X
10 X X
11 X X
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8.3.5 Available maintenance kits when using classic dampers

8.3.5.1 In case your printer is currently loaded with Eco ink
maintenance cycle Kit 6 months (KY-80301)

Description Part nr.
1 Dampers MY-42110
2 Tubing pumps KY-80035
3 Spitting box tubing KY-80036
4 Spitting box MY-35085
5 L connection ME-60014
6 Grease for maintenance cycle KY-80050
8.3.5.2 In case your printer is currently loaded with Mild Solvent ink

1 Dampers MY-42110
2 Pump MY-80300L
4 Spitting box DE-35085
7 Cap assy MY-80622
8.3.5.3 Maintenance cycle kit 12 months (for both MS and Eco ink)
maintenance cycle kit 12 months (KY-80227)

1 Dampers MY-42110
2 Pumps MY-80300L
5 Tubing KY-80036
7 Capping station KY-80627
9 Wiper assy MY-80385
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8.3.6 Available maintenance kits when using valve dampers

8.3.6.1 In case your printer is currently loaded with Eco / MSU or Bio-lactite ink

1 Dampers ME-60810
8.3.6.2 In case your printer is currently loaded with MS or MS+ ink

1 Dampers ME-60810
2 Pump MY-80300L
7 Cap assy MY-80622
8.3.6.3 Maintenance cycle kit 12 months (for MS, MS+, MSU, Bio-Lactite and Eco ink)
maintenance cycle kit 12 months (KY-81708)

1 Dampers ME-60810
2 Pumps MY-80300L
6 Thumb screw BM-5800-003008
8 Maintenance station assy MY-80627
10 Wiper assy MY-80385
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Service Manual
8.4 PART LIFE INFORMATION

To know the life of a service part, check the maintenance counter from the counter display menu in the
maintenance mode.
Notes
• Refer to "Counter Display Menu" for more details of the counter display menu.
Name Life expectancy Warning display

Print head 28 x 109 dots Warning at 95%
(Warning Head Life)
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Service Manual
8.5 JIG AND TOOL LIST

This section provides lists of jigs and tools required for service operations.
8.5.1 Required Tools

(1) Tools for part replacement
N° Name Part code Remarks
1 Philips driver No.2 Generic product Shaft length should be 250 mm or more.
2 Philips driver No.2 Generic product Shaft length should be 50 mm or less.
3 Philips driver No.1 Generic product Generic product For head adjustment, shaft length
150 mm or more
4 Flat-head driver Generic product
5 Pliers Generic product
6 Tweezers Generic product
7 Hexagon wrench (1.5 mm to Generic product For head adjustment, etc.
6.0 mm)
8 Box driver (5.5 mm) Generic product For exchanging the mainboard
9 Box driver (7.0 mm) Generic product For exchanging the power board
10 E ring holder (E-2.5) Generic product JIS E-2.5
IWATA DENKO Co., Ltd.
11 E ring holder (E-4) Generic product JIS E-5
IWATA DENKO Co., Ltd.
12 Head cleaning jig JD-30410 Exclusive rubber bush, including mini fitting
4 set required per a main unit
13 Rubber bush JD-42052 Expendable supplies (exchange per using 20 times)
14 Mini fitting JD-42053 / Maker: Iuchi Seieido Co., Ltd.
Generic product
15 Mild Solvent Cleaning liquid (1l) RJ80MS- 1 litre of cleaning liquid Eco-Ultra
100_CLN
16 Bottle for cleaning liquid (500 JD-42054 /
ml) Generic product
(2) Tools for adjustment
N° Name Part code Remarks
1 Personal computer Generic product Printer port mounted parts
2 Printer cable Generic product Amphenol 36P, male connector
3 Tension gauge Generic product For measuring 5,000g Max.
Reference maker: Oba Keiki Seisakusho
4 Tension gauge Generic product Max. capacity should be 200 to 500g.
Reference maker: Oba Keiki Seisakusho
5 Y-axis tension attachment JD-42050 For steel belt tension adjustment
Gauge diameter: 4 mm (0.16in.) or less
6 Y-axis tension attachment 2 JD-42435 For steel belt tension adjustment
Gauge diameter: 2 mm (0.08in.) or less
7 CR gap check jig JD-42177 For head height adjustment
8 Flash memory card Generic product Spec.:
4MB Flash Memory Card
Type-II (PCMCIARel.2.1/JEIDAVer.4.2)
5V unique driving spec.
9 Loupe (equivalent to 10x) Generic product Generic product For head precision adjustment
10 Block gauge (21 mm) Generic product Generic product For cover sensor adjustment
11 Hand glass Generic product Generic product For checking the cap trace
12 Double coated media Exclusive For adjusting printing accuracy and sensor sensitivity
specified media Maker: Mitsubishi inkjet media
Product number: IJ-MatteCort 143
Other similar media
RJ6-THCCPAPE 137 (MUTOH)
13 Straight scale (1000 mm) Generic product
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Service Manual
8.6 LUBRICATION/BONDING
After disassembling/assembling this machine, always perform necessary lubrication/bonding according to the
table below.
Caution
• Do not oil the printer mechanism with oil other than designated by MUTOH. Doing so may
damage the parts or shorten the lifetime.
Parts Item Manufacturer Type

PF Driving U/D gear of the Apply to the gear Kanto Kasei Co., FLOIL G-MK-1
Components pressurizing arm components Ltd.
Arm motor mounting plate Coating the Kanto Kasei Co., FLOIL G-MK-1
and intermediate gear intermediate gear Ltd.
boar diameter part boar part
Deceleration pulley Apply to the driving Kanto Kasei Co., FLOIL G-MK-1
pulley Ltd.
X-axis deceleration belt Coating the Kanto Kasei Co., FLOIL G-MK-1
deceleration belt Ltd.
gear intermesh part
CR Driving Y rail machining drawing Coating the hole Kanto Kasei Co., FLOIL G-MK-1
Components that fastens the Y Ltd.
drive base
Coating the hole Kanto Kasei Co., FLOIL G-MK-1
that fastens the Ltd.
return pulley
mounting plate
Y rail and Roller guide When inserting the Kanto Kasei Co., FLOIL G-MK-1
Y rail, apply to the Ltd.
lower face of the
roller guide.
Pressurizing axis bearing Coating the upper Kanto Kasei Co., FLOIL G-MK-1
part and shaft Ltd.
insertion part
Pressurizing cam Apply to the cam Kanto Kasei Co., FLOIL G-MK-1
components Ltd.
Roller guide Apply to the roller Kanto Kasei Co., FLOIL G-MK-1
guide surface. Ltd.
Slide idler gear Apply to the gear Kanto Kasei Co., FLOIL G-MK-1
components Ltd.
Driving pulley Apply to the driving Kanto Kasei Co., FLOIL G-MK-1
pulley Ltd.
CR deceleration belt Coating the Kanto Kasei Co., FLOIL G-MK-1
deceleration belt Ltd.
gear intermesh part
Cursor Head U/D colour Apply to the head Kanto Kasei Co., FLOIL G-MK-1
Components U/D colour Ltd.
Head U/D cam Apply to the head Kanto Kasei Co., FLOIL G-MK-1
U/D cam Ltd.
Slide gear Apply to the gear Kanto Kasei Co., FLOIL G-MK-1
components Ltd.
Head base Head installation board Apply to the screw Kanto Kasei Co., FLOIL G-MK-1
components hole position which Ltd.
fastens the shoulder
screw
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Service Manual
Maintenance Maintenance assembly Apply to the gear Kanto Kasei Co., FLOIL G-MK-1
components and cam Ltd.
components
Pump Combined gear Apply to the gear Kanto Kasei Co., FLOIL G-MK-1
Components components Ltd.
Deceleration gear Apply to the gear Kanto Kasei Co., FLOIL G-MK-1
components Ltd.
Idler gear Apply to the gear Kanto Kasei Co., FLOIL G-MK-1
components Ltd.
Idler gear axis Apply between the Kanto Kasei Co., FLOIL G-MK-1
pump base and the Ltd.
idler gear axis.
Winding Winding assembly (gear Apply to the gear Kanto Kasei Co., FLOIL G-MK-1
components components) components Ltd.
PF Driving Set screw Apply the screw lock Loctite 243
Components to the coupling set
screw.
CR Driving Adjusting screw of the CR After adjusting the Loctite 243
Components slave pulley steel belt, apply the
screw lock.
Cursor Step-bore screw Screw lock applying Loctite 243
Components to the shoulder
screw that fastens
the cursor and head
mounting plate
Maintenance E ring Apply to each of the Loctite 243
components E-rings (prevents
noise due to
vibration).
Scroller Set screw Apply the screw lock Loctite 243
receptacle R to the adjusting
components knob set screw.
Others Screw Apply to the position Loctite 243
of the screw lock.
PF Driving CR tape power cable Stick double-sided Not specified
Components tape to the CR tape
power cables
(locating).
Head base Head 2 tape wire Stick double-sided Not specified
components tape to the head 2
tape power cables
(locating and
preventing
floatation).
Pump Pump assembly Acetate tape is fixed Not specified
Components to the pump
assembly tube
(prevents dislodging
of tube).
Others Locations where sharp Acetate tape is fixed Not specified
edges are likely to occur to tape electrical
wires and
harnesses, where
sharp edges are
likely to occur
(sharp edge
protection).
Mutoh part nr. FLOIL G-MK-1: KY-80050
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Service Manual
8.7 TRANSPORTATION OF THE PRINTER

When you transport the printer, the printer should be repackaged using the original box and packing
materials, to protect it from vibration or impact.
(1) Task before transportation
Step 2 : Verify if the product is at a normal status.
Step 3 : Start the auto-diagnostic function.
Notes
• Refer to “Diagnostics Function”.
Step 4 : Select "Adj:CleanHead".

Step 5 : Select "CleanHead" menu.
Notes
• Refer to “Head wash menu”.
Step 6 : When the head cleaning has been finished, power OFF the printer.
Step 7 : Remove the scroller.
Step 8 : Disconnect the power cable and all other cables.
Step 9 : Remove the winding system installed.
Notes
• Refer to Users Guide of the Winding Systems.
Step 10 : Install the protective materials.
Notes
Step 11 : Remove the product from the stand.
Notes
Step 12 : Pack the printer.

(2) Task after transportation
Step 1 : Unpack, assemble, and install the printer.
Step 2 : Reinstall the winding system.
Notes
• Do not forget to align the winding system after installation. Please refer to the user’s guide of your
winding system.
Step 3 : Make the machine ready for operation.

Notes
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Service Manual
9 APPENDIX
9.1 INTRODUCTION
This chapter provides referential information such as service data and exploded views.
9.2 WIRING DIAGRAM
9.3 SERVICE PARTS LIST/EXPLODED

VIEWS/CONFIGURATION DIAGRAMS
This section includes the service parts list, exploded views of respective units and configuration diagrams.
Notes
• For the latest ‘exploded views’ and ‘part description’, please refer to the spare part lists of the printer.
• The latest exploded views are available separately from the manual.
• For spare parts, please refer to the latest spare part list.
• Specifications are liable to changes without prior notice.
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Maintenance

COPYRIGHT © 20-Oct-11 Mutoh Belgium nv. All rights reserved.

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

• Change the direction of the product.

2. Trademark mentioned in this manual.

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1 SAFETY INSTRUCTIONS ....................................................................................................................... 11

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6.2 START UP .......................................................................................................................................... 210

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1.2 WARNINGS, CAUTIONS AND NOTES ............................................................................ 12

1.3 IMPORTANT SAFETY INSTRUCTIONS ............................................................................ 12

1.4 WARNING LABELS ..................................................................................................... 15

1.5 MAINTENANCE AND OPERATION LABELS ...................................................................... 17

1.6 LABELS IN FUNCTION OF TRANSPORTATION ................................................................. 18

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1.2 WARNINGS, CAUTIONS AND NOTES

Safety terms Details

1.3 IMPORTANT SAFETY INSTRUCTIONS

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1.4 WARNING LABELS

1.4.1 Handling the warning labels

Be sure to note the following when handling the labels.

1.4.2 Locations and types of warning labels

The locations of warning labels are shown below.

1.4.2.1 Location and types of warning labels on front part.

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1.4.2.2 Location and types of warning labels on back part.

1.5 MAINTENANCE AND OPERATION LABELS

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1.6 LABELS IN FUNCTION OF TRANSPORTATION

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2.2 FEATURES ............................................................................................................... 20

2.3 PART NAMES AND FUNCTIONS .................................................................................... 21

2.4 PRINTER STATUS ...................................................................................................... 26

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(1) High speed output

Machine Media Width Printing Width

(2) Wide variety of compatible media

(3) Vibrant Colour Reproduction

(4) Effective usage of media

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2.3 PART NAMES AND FUNCTIONS

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2.3.2 Connections on the back

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2.3.3 Position and function of the heating elements

Heater element Temperature Function

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2.3.4 Operation panel

(1) Operation keys

N° Name Normal Setup menu display

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(1) LCD monitor and light indicators.

N° Name Colour Status Function

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