Mutoh 6000

MAINTENANCE MANUAL
Full-Color Inkjet Printer
RJ-6000 43/54/62
RJ6000-A-01
Introduction
This equipment is Class 1 communications equipment (communications equipment to be used in commercial and industrial areas) and conforms to Voluntary Communications Control Institute (VCCI) standards for data processing and other equipment for the prevention of radio wave interference in commercial and industrial areas. Therefore, if it is used in or near a residential area, it may cause interference with radio and television reception. It should be used correctly in accordance with the operation manual. I Concerning interference with reception Since this product emits weak radio waves, if it is not installed and used correctly and is thought to be causing interference with radio and television reception, this may be prevented by trying a combination of the following measures: Try changing the orientation of the receiving antenna and feeder. Try changing the orientation of this product. Change the distance between the receiver and this product. Try using different power supply systems for the receiver and this product. I Trademarks included in this manual MUTOH, RJ-6000-43/54/62, MH-GL, MH-GL/2, MH-RTL are trademarks or trade names of Mutoh Industries Ltd. HP, HP-GL, HP-GL/2, HP-RTL, HP759X, HP758X, C2848 are trademarks or trade names of the Hewlett Packard Company. Centronics and Bitronics are trademarks or trade names of the Centronics Data Computer Company. Windows 3.1, Windows 95, Windows NT 3.51, Windows NT 4.0, MS-DOS are trademarks or trade names of the Microsoft Corporation Other names of products and companies are the trademarks or trade names of each relevant company.
Model Name: RJ6000-43/54/62
CON1000
This manual contains basic technical details necessary for marketplace servicing to maintain product quality and performance of RJ-6000-43/54/62 printer. RJ-6000-43/54/62 printer is equipped with a self-diagnostic program that will be of service for adjusting and checking whenever a fault is detected or during maintenance. This manual contains all the basic items but actual maintenance work should be undertaken only after a thorough understanding of the functions, operations and movements has been gained from the operation manual and by other means. Please note that there may be occasions where the name of a part used in the explanation in this manual differs from the name of that same part that is used in the operation manual or in the parts list.
CAUTION: The details of this product and the contents of this manual are protected by copyright held by this Company and, except for legitimate use by individuals, unauthorized copying, reproduction or distribution in whole or part is forbidden. Details contained in this manual may be subject to future alteration without notice. Details contained in this manual are believed to be correct but please contact this Company or a dealer if an error is suspected or a point is not clear. In no event will this Company be responsible for the consequences of using this product or this manual.
Published by Mutoh Industries Ltd., 1-3 Ikejiri 3-chome, Setagaya-ku, Tokyo 154-8560 Japan Copyright October 1999, Mutoh Industries Ltd. All rights reserved.
Introduction
CON1000
Some Thoughts on Maintenance Work

1. Some ideas about maintenance work Maintenance work falls into two major categories, fault maintenance and protective maintenance, both of which are aimed at stable operation of the equipment that has been delivered to the user. The profitability of maintenance work must also be considered. In principle, fault maintenance and protective maintenance are both carried out by the one person. Both fault maintenance and protective maintenance involve the bringing of maintenance parts. The cooperation of the user/operator is used effectively. 2. Protective maintenance work Periodic maintenance is designed to provide the user with more stable operation of the equipment and involves the periodic cleaning and replacement of replacement parts. Basic ideas on protective maintenance include: Adhere strictly to preventive maintenance periods. In a case of carrying out preventive maintenance, gain the approval of the user beforehand. Dont press preventive maintenance on the user. 3. Fault maintenance work A fault will hold up the users work and must be remedied quickly. The following are some basic ideas on fault maintenance: 3-1 If it is not solved by the primary consultation, take the necessary maintenance items and make an on-site visit. Assemble the necessary maintenance parts from the matrix map At the users premises, first check the symptoms. Proceed with maintenance work in accordance with the fault tracing procedure. After the repair work is finished, be sure to check again by testing in accordance with the test procedure. If repair is not possible even though all the work has been done in accordance with the fault tracing procedure: Contact the Sales Support Groups in your local distributor.

4. The need for user/operator cooperation ! CAUTION: The user can not be compelled to do the following!
CON1010
Asking the user/operator to cooperate is not a matter of having the user do the maintenance for you but it is necessary in order to have the equipment working more efficiently and for having faults rectified quickly. Actually, even when you do ask for the users cooperation, instead of a simple acknowledgement you will usually get doubts and quibbles such as Im paying for maintenance, Im not familiar with the equipment and it only benefits the manufacturer. However, you must try to persuade the user/operator to cooperate by explaining that doing daily inspections will give better printing quality and giving you all the fine details of a fault means that the fault will be rectified quickly. The following explains the items you need in order to understand fault conditions in detail: Check error messages Check users usage conditions Output from diagnostic pattern Output from setup lists Retest after changing settings Probability of recovery by implementing daily inspections.
3-2
Some Thoughts on Maintenance Work
CON1010
Precautions For Maintaining This Printer

PRECAUTION 1 Head Cleaning PRECAUTION 5
Model Name: RJ6000-43/54/62 Maintenance Unit Tubes
CON2000
Head cleaning (see REP1620) must be carried out when this printer is to be transported by truck (see CON6000) and when the following parts are to be replaced. < Replacement parts > Head, Damper, Head Cable, Cartridge Frame Assembly, Ink Tubes
If you can not lower the maintenance unit cap assembly and the cap assembly and pump assembly have been replaced: When the two tubes from the pump assembly are being connected to the cap assembly, turn them clockwise through 45 to 90 degrees as you insert them.
PRECAUTION 2
Head Cleaning Jig
PRECAUTION 6
Take Care When Inserting Head Cable and Y Cable
When the head cleaning jig is to be used, fill the jigs 100 cc bottle with at least 50 cc of cleaning fluid and use it with the cap loosened. If head cleaning is done with the cap tightened, ink will flow back into the 100 cc bottle. When you have finished head cleaning, return the remaining cleaning fluid from the 100 cc bottle to the 500 cc cleaning fluid bottle (JD-42054).
When the print head assembly, head board assembly and main board assembly have been replaced, be careful to insert the head cable and Y cable straight to the back and dont forget to lock the connectors. (The connectors fitted with locks are J207 and J208 on the head board.) If the cables are inserted obliquely or power is applied without locking the connectors, there is a risk that the main board assembly may be damaged and it will be impossible for ink to be ejected. PRECAUTION 7 Ink and Cleaning Fluid Conduct Electricity
PRECAUTION 3
Printing After Initial Filling
On rare occasions, printing quality may be unstable if printing is carried out immediately after initial filling. If this occurs, switch off the power and wait for at least 30 minutes before trying to print again.
Ink and cleaning fluid will conduct electricity. If there is ink or cleaning fluid on the connectors of the head or head cables when power is applied, there will be a short circuit which may lead to all sorts of damage. If there is ink on the contacts of the connector, wipe it off with alcohol or ethanol and allow to dry thoroughly before reconnecting.
PRECAUTION 4
Thorough Waste Fluid Box Replacement
When the following tasks have been carried out, install a new waste fluid box and clear the waste fluid counter. 1. After head cleaning and initial filling. 2. When it was not possible to capture main board assembly backup parameters.
Precautions For Maintaining This Printer
CON2000
Contents
CON3000
RJ-6000-43 History of Amendments Introduction Some Thoughts on Maintenance Work Precautions For Maintaining This Printer Contents How to use the Maintenance Manual Trouble-Shooting Lists Matrix Map Fault-Tracing Procedure Replacement and Adjustment Procedures Fundamental Knowledge Stored Test Patterns Self-Diagnosis Functions Maintenance Parts CON 0000 CON 1000 CON 1010 CON 2000 CON 3001 ~ 3 CON 4000 TRB 0000 MAP 0000 EXA 0000 REP 0000 GID 0000
RJ-6000-54 CON 0000 CON 1000 CON 1010 CON 2000 CON 3004 ~ 6 CON 4000 TRB 0000-2 MAP 0000-2 EXA 0000-2 REP 0000-2 GID 0000-2
RJ-6000-62 CON 0000 CON 1000 CON 1010 CON 2000 CON 3007 ~ 9 CON 4000 TRB 0000-3 MAP 0000-3 EXA 0000-3 REP 0000-3 GID 0000-3
PAT 0000 BAC 0000 CAT 0000
PAT 0000-2 BAC 0000-2 CAT 0000-2
PAT 0000-3 BAC 0000-3 CAT 0000-3
Contents
CON3000
RJ-6000-43 Contents 1
Model Name: RJ6000-43
CON3001
RJ-6000
43 inch
Trouble-Shooting Lists When Message is Displayed - How to Use LEDs to Check CPU System and Mechanical System Faults When Message is not Displayed - Initialization, Media Feed, Printing - Noise, Media Cutting, Online, Others
TRB0000 TRB1000 TRB1001
TRB2000 TRB2001
Fault-Tracing Procedure When Message is Displayed - Printer Status Messages - Data Errors - Command Errors - CPU System Faults - Mechanical System Faults When Message is not Displayed - Trouble with Initialization - Trouble with Media Feed - Trouble with Printing - Problem Involving Noise - Trouble with Media Cutting - Online/Function Problems - Others
EXA0000 EXA1000~ EXA1200~ EXA1250~ EXA1500~ EXA1700~
Matrix Map When Message is Displayed - Printer Status Messages - Data Errors - Command Errors - CPU System Faults - Mechanical System Faults When Message is not Displayed - Trouble with Initialization - Trouble with Media Feed - Trouble with Printing - Problem Involving Noise - Trouble with Media Cutting - Online/Function Problems - Other
MAP0000 MAP1000 MAP1200 MAP1250 MAP1500 MAP1700
EXA2000~ EXA3000~ EXA4000~ EXA5000~ EXA6000~ EXA7000~ EXA8000~
MAP2000 MAP3000 MAP4000 MAP5000 MAP6000 MAP7000 MAP8000
CON3001
CON3002
Replacement and Adjustment Procedures Right and Left Covers Front Cover Panel Cover, Y Rail Cover Front Paper Guide and Rear Paper Guide Left Side Cap and Right Side Cap Control Box Head Cover X Motor Assembly Fan Assembly and Fan Cable X Speed Reduction Belt Lever Sensor Assembly Cover Switch Assembly Waste Fluid Box Sensor Assembly Switch Cable Assembly, DC Cable Assembly Main Board Assembly Power Supply Board Assembly Panel Board Assembly Panel Cable Extension Board Assembly XR Cable Assembly (Rear Paper Sensor) Pressure Assembly, Pressure Roller and Blade Pump Motor Assembly Cap Assembly Wiper Pump Assembly Maintenance Station Assembly Y Motor Assembly Steel Belt T Fence Assembly REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP 1010 1020 1030 1040 1041 1050 1060 1070 1080 1090 1100 1110 1120 1130 1140 1150 1160 1170 1180 1200 1220 1230 1240 1250 1260 1270 1280 1290 1300 Cursor Plate Spring, Steel Flexible Guide Assembly Y Return Pulley Assembly Cartridge Frame Assembly Ink ID Sensor Assembly Detector Assembly Y Cable Ink Tubes Cutter Solenoid Assembly Print Head Assembly, Head Cable Edge Sensor Assembly Head Board Assembly Dampers Cursor Assembly Origin Sensor Assembly, Y Encoder Junction Board Assembly How to Adjust the Platen Height Tubes Guides Assemblies How to Adjust Steel Belt Tension How to Adjust X Speed Reduction Belt Tension How to Adjust the Tilt of the Print Head How to Capture and Install Backup Parameters How to Install a Program (Software Upgrade) Head Cleaning Procedure How to Clean the Head Nozzle Face Speed Reduction Pulley Assembly Grid Roller Assembly F Absorbent Assembly REP REP REP REP REP REP REP REP REP REP REP REP REP REP 1310 1320 1330 1340 1350 1360 1370 1380 1390 1410 1420 1430 1440 1450
REP 1470 REP 1520 REP REP REP REP 1540 1550 1560 1570
REP 1590 REP 1600 REP 1620 REP 1660 REP 1680 REP 1690 REP 1700
CON3002
Fundamental Knowledge Basic Specifications System Block Diagram Operating Sequence - Power On Sequence - Power Off Sequence - Media Detection Sequence - Normal Standby Sequence - Encoder Disconnected Check Sequence - Origin Detection Sequence - Media Cutting Sequence - Printing Sequence (Including Flushing) GID0000 GID1000 GID3000 GID4010 GID4020 GID4030 GID4040 GID4050 GID4060 GID4070 GID4080 -

Head Rank Input (Include Initial filling) Head Nozzle Verification Left Head Tilt Verification Right Head Tilt Verification Repeatability Printing Positioning CW Adjustment Flush Pointer Adjustment Media Feed Distance Compensation Margin Adjustment Rear Sensor Position Adjustment Test Print Head Wash
CON3003
BAC2040 BAC2050 BAC2060 BAC2070 BAC2080 BAC2090 BAC2110 BAC2120 BAC2130 BAC2140 BAC2150 BAC2160 BAC3000 BAC3000 BAC3000 BAC4000 BAC4000 BAC4000 BAC5000 BAC5010 BAC5020 BAC6000 BAC6010 BAC6020 BAC6030 BAC6040 BAC6050
Stored Test Patterns Presentation Pattern Print quality adjustment pattern Setup List
PAT0000 PAT1000 PAT3000 PAT4000
Cleaning - Normal - Powerful Test Printing - Head Printing Verification - Adjustment Parameters Parameters - Initialize - Update Aging - Carriage Motor - Media Feed Motor - Cutter - Maintenance Unit - Head
Self-Diagnosis Functions Examination - Memory (RAM) Capacity - Version - Panel - Sensors - Encoders - Fans - Ethernet Board - History: Last error message - History: Head nozzle ejection count check - Head Waveform Adjustment - Capping Position Adjustment - Skew Verification
BAC0000 BAC1000 BAC1010 BAC1020 BAC1030 BAC1040 BAC1050 BAC1060 BAC1065 BAC1070 BAC1070 BAC1080 BAC2000 BAC2010 BAC2030
Maintenance Parts Maintenance Parts List Maintenance Tool List Lubrication Points Exploded View Drawing
CAT0000 CAT1000 CAT2000 CAT4000 CAT5000
CON3003
CON3004
RJ-6000
54 inch
TRB0000-2 TRB1000 TRB1001
Fault-Tracing Procedure When Message is Displayed - Printer Status Messages Data Errors Command Errors CPU System Faults Mechanical System Faults
EXA0000-2 EXA1000~ (1020-2) EXA1200~ EXA1250~ EXA1500~ EXA1700~
TRB2000 TRB2001
MAP0000-2 MAP1000 MAP1200 MAP1250 MAP1500 MAP1700-2
When Message is not Displayed - Trouble with Initialization - Trouble with Media Feed - Trouble with Printing
MAP2000-2 MAP3000-2 MAP4000-2 MAP5000 MAP6000 MAP7000 MAP8000
Problem Involving Noise Trouble with Media Cutting Online/Function Problems Others
EXA2000~ (2070-2) EXA3000~ (3000-2) EXA4000~ (4050-2) (4100-2) (4130-2) EXA5000~ EXA6000~ EXA7000~ EXA8000~ (8050-2)
CON3004
10
CON3005
Replacement and Adjustment Procedures Right and Left Covers Front Cover Panel Cover, Y Rail Cover Front Paper Guide and Rear Paper Guide Left Side Cap and Right Side Cap Control Box Head Cover X Motor Assembly Fan Assembly and Fan Cable X Speed Reduction Belt Lever Sensor Assembly Cover Switch Assembly Waste Fluid Box Sensor Assembly Switch Cable Assembly, DC Cable Assembly Main Board Assembly Power Supply Board Assembly Panel Board Assembly Panel Cable Extension Board Assembly XR Cable Assembly (Rear Paper Sensor) Pressure Assembly, Pressure Roller and Blade Pump Motor Assembly Cap Assembly Wiper Pump Assembly Maintenance Station Assembly Y Motor Assembly Steel Belt T Fence Assembly
REP0000-2 REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP 1010 1020 1030 1040 1041 1050 1060 1070 1080-2 1090 1100 1110 1120 1130 1140 1150 1160 1170 1180 1200 1220 1230 1240 1250 1260 1270 1280 1290 1300 Cursor Plate Spring, Steel Flexible Guide Assembly Y Return Pulley Assembly Cartridge Frame Assembly Ink ID Sensor Assembly Detector Assembly Y Cable Ink Tubes Cutter Solenoid Assembly Print Head Assembly, Head Cable Edge Sensor Assembly Head Board Assembly Dampers Cursor Assembly Origin Sensor Assembly, Y Encoder Junction Board Assembly How to Adjust the Platen Height Tubes Guides Assemblies How to Adjust Steel Belt Tension How to Adjust X Speed Reduction Belt Tension How to Adjust the Tilt of the Print Head How to Capture and Install Backup Parameters How to Install a Program (Software Upgrade) Head Cleaning Procedure How to Clean the Head Nozzle Face Speed Reduction Pulley Assembly Grid Roller Assembly F Absorbent Assembly Waste Fluid Bottle Assembly REP REP REP REP REP REP REP REP REP REP REP REP REP REP 1310-2 1320 1330 1340 1350 1360-2 1370-2 1380 1390 1410 1420 1430 1440 1450
REP 1470 REP 1520 REP REP REP REP 1540-2 1550 1560 1570
REP 1590 REP 1600 REP 1620 REP 1660 REP 1680 REP 1690 REP 1700 REP 1710
CON3005
11
Fundamental Knowledge Basic Specifications System Block Diagram Operating Sequence - Power On Sequence - Power Off Sequence - Media Detection Sequence - Normal Standby Sequence - Encoder Disconnected Check Sequence - Origin Detection Sequence - Media Cutting Sequence - Printing Sequence (Including Flushing) GID0000-2 GID1000-2 GID3000 GID4010 GID4020 GID4030 GID4040 GID4050 GID4060 GID4070 GID4080 -

CON3006
PAT0000-2 PAT1000 PAT3000 PAT4000
BAC0000-2 BAC1000 BAC1010 BAC1020 BAC1030 BAC1040 BAC1050 BAC1060 BAC1065 BAC1070 BAC1070 BAC1080 BAC2000 BAC2010 BAC2030
CAT0000-2 CAT1000-2 CAT2000 CAT4000 CAT5000
CON3006
12
CON3007
RJ-6000
62 inch
TRB0000-3 TRB1000 TRB1001
Fault-Tracing Procedure When Message is Displayed - Printer Status Messages Data Errors Command Errors CPU System Faults Mechanical System Faults
EXA0000-3 EXA1000~ (1020-2) EXA1200~ EXA1250~ EXA1500~ EXA1700~
TRB2000 TRB2001
MAP0000-3 MAP1000 MAP1200 MAP1250 MAP1500 MAP1700-2
When Message is not Displayed - Trouble with Initialization - Trouble with Media Feed - Trouble with Printing
MAP2000-2 MAP3000-2 MAP4000-2 MAP5000 MAP6000 MAP7000 MAP8000
Problem Involving Noise Trouble with Media Cutting Online/Function Problems Others
EXA2000~ (2070-2) EXA3000~ (3000-2) EXA4000~ (4050-2) (4100-2) (4130-2) EXA5000~ EXA6000~ EXA7000~ EXA8000~ (8050-2)
CON3007
13
CON3008
Replacement and Adjustment Procedures Right and Left Covers Front Cover Panel Cover, Y Rail Cover Front Paper Guide and Rear Paper Guide Left Side Cap and Right Side Cap Control Box Head Cover X Motor Assembly Fan Assembly and Fan Cable X Speed Reduction Belt Lever Sensor Assembly Cover Switch Assembly Waste Fluid Box Sensor Assembly Switch Cable Assembly, DC Cable Assembly Main Board Assembly Power Supply Board Assembly Panel Board Assembly Panel Cable Extension Board Assembly XR Cable Assembly (Rear Paper Sensor) Pressure Assembly, Pressure Roller and Blade Pump Motor Assembly Cap Assembly Wiper Pump Assembly Maintenance Station Assembly Y Motor Assembly Steel Belt T Fence Assembly
REP0000-2 REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP 1010 1020 1030 1040 1041 1050 1060 1070 1080-2 1090 1100 1110 1120 1130 1140 1150 1160 1170 1180 1200 1220 1230 1240 1250 1260 1270 1280 1290 1300 Cursor Plate Spring, Steel Flexible Guide Assembly Y Return Pulley Assembly Cartridge Frame Assembly Ink ID Sensor Assembly Detector Assembly Y Cable Ink Tubes Cutter Solenoid Assembly Print Head Assembly, Head Cable Edge Sensor Assembly Head Board Assembly Dampers Cursor Assembly Origin Sensor Assembly, Y Encoder Junction Board Assembly How to Adjust the Platen Height Tubes Guides Assemblies How to Adjust Steel Belt Tension How to Adjust X Speed Reduction Belt Tension How to Adjust the Tilt of the Print Head How to Capture and Install Backup Parameters How to Install a Program (Software Upgrade) Head Cleaning Procedure How to Clean the Head Nozzle Face Speed Reduction Pulley Assembly Grid Roller Assembly F Absorbent Assembly Waste Fluid Bottle Assembly REP REP REP REP REP REP REP REP REP REP REP REP REP REP 1310-2 1320 1330 1340 1350 1360-2 1370-2 1380 1390 1410 1420 1430 1440 1450
REP 1470 REP 1520 REP REP REP REP 1540-2 1550 1560 1570
REP 1590 REP 1600 REP 1620 REP 1660 REP 1680 REP 1690 REP 1700 REP 1710
CON3008
14
Fundamental Knowledge Basic Specifications System Block Diagram Operating Sequence - Power On Sequence - Power Off Sequence - Media Detection Sequence - Normal Standby Sequence - Encoder Disconnected Check Sequence - Origin Detection Sequence - Media Cutting Sequence - Printing Sequence (Including Flushing) GID0000-3 GID1000-3 GID3000 GID4010 GID4020 GID4030 GID4040 GID4050 GID4060 GID4070 GID4080 -

CON3009
PAT0000-3 PAT1000 PAT3000 PAT4000
BAC0000-3 BAC1000 BAC1010 BAC1020 BAC1030 BAC1040 BAC1050 BAC1060 BAC1065 BAC1070 BAC1070 BAC1080 BAC2000 BAC2010 BAC2030
CAT0000-3 CAT1000-3 CAT2000 CAT4000 CAT5000
CON3009
15
How to use the Maintenance Manual
CON4000

How to use the Maintenance Manual How to use the Trouble-Shooting Lists (TRB) CON4010 CON4020
How to use the Matrix Map (MAP) How to use the Fault-Tracing Procedure (EXA) How to use Replacement and Adjustment Procedure (REP)
CON4040 CON4050 CON4060
CON4000
16

I Fault maintenance work procedures and how to use the Maintenance Manual When a user reports an equipment fault, use the following procedure to carry out fault recovery tasks.
CON4010
A fault occurs
Task Page Details
Check circumstances by fax or telephone. Check error messages, check user usage conditions, retry after changing settings, output diagnostic pattern, etc. Select fault symptoms produced by user from the Trouble-Shooting List. Operation Manual, basic knowledge, daily care, periodic maintenance/ inspection/cleaning
Reference Materials
Check fault circumstances, Trouble-Shooting List select fault details from TRB Trouble-Shooting Lists
Conduct a primary consultation with the user
Conduct a consultation by fax or telephone. Check possibility of user error or recovery by daily inspection. Check error messages, check user usage conditions, output diagnostic pattern, output setup list. Retry after changing settings, etc.
If you are unable to resolve the fault at this point, take the necessary maintenance parts and make an on-site visit.
Task
Gather the necessary maintenance parts
Page
Matrix Map MAP
Details
Gather the necessary maintenance parts
Reference Materials
Maintenance Parts list, Maintenance Tools list, Exploded views
Conduct a tracing inquiry
Fault Tracing Procedures EXA
Conduct an inquiry to trace the cause of the fault
Basic knowledge
Replace parts and adjust
Replacement and Adjustment Procedures REP
Replace or readjust parts suspected to be faulty. Carry out adjustments after replacing parts.
Basic knowledge
Final check
Separate causes of faults and check operation after faults have been rectified.
CON4010
17
How to use the Trouble-Shooting Lists (TRB)
CON4020
1. How to look up trouble-shooting tables I When a user has reported a fault, first select the applicable details from the trouble-shooting lists (TRB) and jump to the specified primary consultation (ENT). Faults are broadly classified as those which cause a message to appear in the printer LCD and those which do not. For troubles that cause a message to be displayed, select the message as it is. Troubles with no message display are classified into the 10 blocks shown below. First select the block then select the appropriate fault details from that block. 2. Definitions of groupings in the case of faults that produce no message display
When Message is Displayed TRB1000
Printer Status Messages, Data Errors, Command Errors CPU System Faults, Mechanical System Faults When Message is Not Displayed Trouble with Initialization: TRB2000 to TRB2001 Troubles that occur when unpacking immediately after delivery are grouped here. Check this group for a similar trouble occurring other than immediately after delivery. Troubles concerning the series of operations up to the enabling of printing are grouped here. This group concerns problems with the media path. This group concerns printing quality problems. Printing precision problems are grouped here. Troubles that produce abnormal noise from the driving section. Cutter section problems are grouped here. Online printing function problems. Troubles concerning the series of operations up to the enabling of printing are grouped here. Troubles involving driver software, consumable items, peripheral devices are grouped here.
Trouble with Media Feed: Trouble with Printing: Problem Involving Noise: Trouble with Media Cutting: Online/Function Problems: Other:
How to use the Trouble-Shooting Lists (TRB)
CON4020
18
How to use the Matrix Map (MAP)
CON4040
I When the primary consultation (ENT) has not revealed any anomaly, gather the necessary maintenance parts according to the matrix map (MAP) shown below and visit the user.
Whether an error message is displayed Names and drawing numbers of required parts
When Message is Not Displayed
Major classification of fault details

Trouble with Initialization Model Name: RJ-6000-43
MAP2000
When Message is Not Displayed [Trouble with Initialization] EXA2000 to EXA2070
Problem FaultTracing Procedure EXA No.

2000 2000 2010 2020 2030 2030 2030 2030 2030 2040 2050 2060 2070 - Power supply does not come on - LCD faulty (no display/erratic display) - Initial filling of inks failed - Initial filling is completed but no ink comes out - After power is switched on, nothing works - When power is applied, Initializing appears and then a reset is executed. - After mounting media, initial operation fails - Printer does not work even with the cover closed - Printer does not stop even with the cover opened - Ink cartridges are installed but not recognized - Can not make entries from the operating panel - Data is received but not plotted - Media is not suction
Fault details
How to use the Matrix Map (MAP)
1140 1160 1170 1110 1100 1410 1420 1200 1360 1130 1150 1130 1350 1350 1350 1350 1350 1350 1240 1260 1270 1390 1390 1120 1080 1080 1080 1080 1340 1340 1340 1340 1340 1340 1470 1470
Replacement and adjustment procedure page
Replacement and Adjustment Procedure REP. No.
DF-41586 Main Board Assembly DF-40097 Panel Board Assembly DF-41617 Panel Cable DF-41590 Cover Switch Assembly DF-41589 Lever Sensor Assembly DF-41595 Edge Sensor Assembly DF-41588 Head Board Assembly DF-41592 XR Cable Assembly (Paper Sensor R) DF-41600 Y Cable DF-41619 Switch Cable Assembly DF-41587 Power Board Assembly DF-41468 DC Cable Assembly DF-41593 Detector 1 Assembly DF-41594 Detector 2 Assembly DF-40106 Detector Assembly (Black) DF-40107 Detector Assembly (Y) DF-40146 Detector Assembly (M) DF-40147 Detector Assembly (C) DF-41602 Cap Assembly DF-41603 Pump Assembly DF-41604 Maintenance Station Assembly DF-40690 Print Head Assembly (Color) DF-41601 Head Cable DF-41591 Waste Fluid Box Sensor DF-40173 Vacuum Fan Assembly DF-41620 Fan Extension Cable 1 Assembly DF-41621 Fan Extension Cable 2 Assembly DF-41622 Fan Extension Cable 3 Assembly DF-41609 INK ID Sensor 1 Assembly DF-41610 INK ID Sensor 2 Assembly DF-41611 INK ID Sensor 3 Assembly DF-41612 INK ID Sensor 4 Assembly DF-41613 INK ID Sensor 5 Assembly DF-41614 INK ID Sensor 6 Assembly DF-41615 INK ID Sensor Cable DF-41536 Junction Board Assembly
Major classification of fault details and range of EXA numbers
Name and Diagram Number of Replacement Part
Trouble with Initialization
Model Name: RJ-6000-43
MAP2000
CON4040
19
How to use the Fault-Tracing Procedure (EXA)
CON4050
I Gather the parts specified by the matrix map (MAP), visit the user and carry out the task of recovery in accordance with the fault-tracing procedure (EXA) shown below. First, check again on-site that there was no mistake about the primary consultation. (EXA and ENT page numbers are the same) Carry out the checking tasks in order, beginning with 1-1, and move to the next task if there is nothing abnormal. If an abnormality is revealed, carry out the task indicated by the arrow [].
Whether an error message is displayed Major classification of fault details
Items to be Confirmed
Are there any breaks, cuts or air leaks in the ink tubes? Change each ink tube, cleaning each time and checking that ink flows during cleaning. Check that connectors J207 (HEAD C1) and J208 (HEAD C2) on the head board assembly, and head cables on the print head are not inserted obliquely, and they are locked securely. Insert the connectors again. Is there a broken lead in head cables? Replace head cables. Is the print head assembly damaged? Replace the print head assembly. 1390 1-14 1-15 Is the head board assembly damaged? Replace it. Check that the Y cable connector is connected securely and not inserted obliquely. Reconnect head board assembly connectors J201 (MAIN1) and J202 (MAIN2) and main board assembly connectors J111 (HEAD1) and J112 (HEAD 2). Is there a broken lead in Y cables? Replace Y cables. The main board assembly may be damaged. Replace it. 1360 1140 1420 1400
When No Error is Displayed on the Printer's Liquid Crystal Display

No. 1 Symptom Initial filling is completed but no ink comes out (Initial filling means to fill the head with ink to enable it to print.)
Sequence 1-10 1-11
EXA2021
GO TO Ref. Pages R E P B A C
Page specified by matrix map (MAP)
1370
Replacement and adjustment procedure (REP) page reference Hidden diagnostic procedure page reference
Fault details
1-12 1-13
Fault-tracing sequence
1-16 1-17
CAUTION:
Power must be off when connectors are being disconnected or reconnected, otherwise you may be injured or a board may be damaged. The main board assembly will certainly be damaged if power is applied with main board assembly connectors J111 (HEAD) and J112 (HEAD2) and head board connectors J201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP.
Page specified by matrix map (MAP)

EXA2021
How to use the Fault-Tracing Procedure (EXA)
CON4050
20
How to use Replacement and Adjustment Procedure (REP)
CON4060
I If the fault-tracing procedure (EXA) has produced a replacement task, carry out the work of replacement and adjustment in accordance with the replacement and adjustment procedure (REP) shown below. If you dont know how to go about the removal of covers involved in replacing a part, refer to REP1010 to REP1060.
Page specified by the fault-tracing procedure (EXA)
Replacement and adjustment item
How to replace the Y Motor Assembly
REP1280
Replacement procedure
Item
REFERENCE
Replacement and Adjustment Procedure

If there is to be no replacement that includes the Y motor assembly, steps 2, 4 and 5 are not necessary.
Screws
1. Replacement Procedure
Replace the Y Motor Assembly 1. Remove the Left and Right Covers. 2. Remove the Rear Paper Guide. 3. Remove the Steel Belt. 4. Open the Control Box. 5. Disconnect connector J120 (YMOT) from the Main Board Assembly. 6. Remove the Y Motor Assembly. (3 fastening screws) 7. Assembling is the reverse of the removal procedure. REFERENCE Since the Y Motor Assembly Cable passes below the Cartridge Unit, the work will be easier if you remove the two Cartridge Base screws and push it back.
Adjustment procedure and items to be checked
Y motor cable terminal
2. Adjustment and Examination Procedure
1. Carry out the Steel Belt Tensioning Adjustment.
Y motor assembly
REP1280
Page specified by the fault-tracing procedure (EXA)
How to use Replacement and Adjustment Procedure (REP)
CON4060
21
RJ-6000-43 Trouble-Shooting Lists
TRB0000
Trouble-Shooting Lists
When Message is Displayed Printer Status Messages Data Errors Command Errors CPU System Faults Mechanical System Faults How to Use LEDs to Check CPU System and Mechanical System Faults When Message is Not Displayed Trouble with Initialization Trouble with Media Feed Trouble with Printing Problem Involving Noise Trouble with Media Cutting Online/Function Problems Others TRB2000 TRB2000 TRB2000 TRB2001 TRB2001 TRB2001 TRB2001 TRB1000 TRB1000 TRB1000 TRB1000 TRB1000 TRB1001
TRB0000
22
TRB0000-2
TRB0000-2
23
TRB0000-3
TRB0000-3
24
Trouble-Shooting 1/3 (List of Faults)

Minor Faults Cover Open Lever Up Cover and Lever Undefined Media Media Skew Error [User 1] Media End Remove Media Roll Media End Media Cut Error Not enough memory SIMM 12 MB Insert Special Cartridge [ ] Ink Low [ ] No Ink [ ] No Cartridge Capping position not specified Not Filled No Waste Fluid Box Check Waste Fluid Box Waste Fluid Box Full Wrong Ink Type
When Message is Displayed
TRB1000
Cases where an error message is displayed on the liquid crystal display of the main printer unit GO TO EXA No. EXA1000 EXA1000 EXA1000 EXA1010 EXA1020 EXA1030 EXA1040 EXA1050 EXA1060 EXA1070 EXA1080 EXA1090 EXA1090 EXA1100 EXA1110 EXA1120 EXA1130 EXA1140 EXA1140 EXA1150 CPU System/Mechanical System Faults GO TO EXA No. EXA1500 E001 Error DRAM (Standard DRAM error) EXA1500 E002 Error Opt.DRAM (Optional DRAM error) EXA1510 E016CPUErr[00] (Interrupt exception error) EXA1510 E016CPUErr[02] (Command boundary exception error) EXA1510 E016CPUErr[03] (Data boundary exception error) EXA1510 E016CPUErr[04] (Address error exception) (Load or command fetch) EXA1510 E016CPUErr[05] (Address error exception) (Store) EXA1510 E016CPUErr[06] (Bus error exception) (Command fetch) EXA1510 E016CPUErr[07] (Bus error exception) (Data load) EXA1510 E016CPUErr[08] (System call exception error) EXA1510 E016CPUErr[09] (Break point exception error) EXA1520 E016CPUErr[10] (Reserved command exception error) EXA1520 E016CPUErr[11] (Unable to use coprocessor exception error) EXA1520 E016CPUErr[12] (Operation overflow exception error) EXA1520 E016CPUErr[13] (Trap exception error) EXA1520 E016CPUErr[15] (Floating point exception error) EXA1520 E016CPUErr[22] (Watch exception error) EXA1520 E016CPUErr[32] (Watchdog timeout exception error) EXA1520 E016CPUErr[33] (Abort error) Error E237 Transfer memory (Transfer memory error/Transfer memory EXA1520 access error) EXA1530 Error E129 NVRAM
Printer Status Messages
CPU System Faults
Command Errors
MH01 MH02 MH03 MH04 MH07
Error Error Error Error Error
(Undefined Command) (Parameter Error) (Numerical Error) (Undefined Character Set) (Buffer Overflow)
EXA1250 EXA1250 EXA1250 EXA1250 EXA1250
Mechanical System Faults
Network Detection Error Network Initialization Error
EXA1230 EXA1230
E065 E069 E071 E073 E066 E070 E072 E074 E075
Error Error Error Error Error Error Error Error Error
X Motor X Encoder X Timeout X Overcurrent Y Motor Y Encoder Y Timeout Y Overcurrent Sensor Fault
EXA1700 EXA1700 EXA1700 EXA1700 EXA1710 EXA1710 EXA1710 EXA1710 EXA1720
Data Errors
TRB1000
25
How to Use LEDs to Check CPU System and Mechanical System Faults
When the printer stops working and nothing appears on the liquid crystal display (LCD), a fault has probably occurred in the CPU system or the mechanical system. In that case, open the control box and check the error by the LEDs on the main board assembly. LED display 1 2 3 4 5 6 7 8 Details of Error E001 Error DRAM E002 Error Opt.DRAM E002 Error Opt.DRAM E016CPUErr[00] E016CPUErr[02] E016CPUErr[03] E016CPUErr[04] E016CPUErr[05] E016CPUErr[06] E016CPUErr[07] E016CPUErr[08] E016CPUErr[09] E016CPUErr[10] E016CPUErr[11] E016CPUErr[12] E016CPUErr[13] E016CPUErr[15] E016CPUErr[22] E016CPUErr[32] E016CPUErr[33] E237 Error Transfer memory E129 Error NVRAM E065 E069 E071 E073 E066 E070 E072 E074 E075 Error X Motor Error X Encoder Error X Timeout Error X Overcurrent Error Y Motor Error Y Encoder Error Y Timeout Error Y Overcurrent Error Sensor Fault
TRB1001
is on,
is off.
Fault-Tracing Procedure EXA page (Standard DRAM error) (Optional DRAM 1 error) (Optional DRAM 2 error) (Interrupt exception error) (Command boundary exception error) (Data boundary exception error) (Address error exception) (Load or command fetch) (Address error exception) (Store) (Bus error exception) (Command fetch) (Bus error exception) (Data load) (System call exception error) (Break point exception error) (Reserved command exception error) (Unable to use coprocessor exception error) (Operation overflow exception error) (Trap exception error) (Floating point exception error) (Watch exception error) (Watchdog timeout exception error) (Abort error) (Transfer memory error/Transfer memory access error) EXA1500 EXA1500 EXA1500 EXA1510 EXA1510 EXA1510 EXA1510 EXA1510 EXA1510 EXA1510 EXA1510 EXA1510 EXA1520 EXA1520 EXA1520 EXA1520 EXA1520 EXA1520 EXA1520 EXA1520 EXA1520 EXA1530 EXA1700 EXA1700 EXA1700 EXA1700 EXA1710 EXA1710 EXA1710 EXA1710 EXA1720
CPU System Faults
How to Use LEDs to Check CPU System and Mechanical System Faults
TRB1001
26

Cases where no error message is displayed on the liquid crystal display of the main printer unit No power Faulty liquid crystal display (no display/unstable display) Initial filling of inks failed Initial filling is completed but no ink comes out After power is switched on, nothing works When power is applied, Initializing appears and then a reset is executed. Media is mounted but the initialization operation is not done Printer does not work even with the cover closed Printer does not stop even with the cover opened Ink cartridges are installed but not recognized Can not make entries from the operating panel Data is received but not printed Media is not suction

GO TO EXA No. EXA2000 EXA2000 EXA2010 EXA2020 EXA2030 EXA2030 EXA2030 EXA2030 EXA2030 EXA2040 EXA2050 EXA2060 EXA2070
TRB2000
GO TO EXA No. EXA4000 EXA4010 EXA4020 EXA4020 EXA4030 EXA4030 EXA4040 EXA4050 EXA4050 EXA4050 EXA4050 EXA4060 EXA4070 EXA4070 EXA4070 EXA4080 EXA4080 EXA4090 EXA4100 EXA4110 EXA4120 EXA4130
Cases where no error message is displayed on the liquid crystal display of the main printer unit Does not print continuously There is an extra feed after printing is finished Dots are missing from the printing Cleaning does not cure blockage Does not print at all Does not print a specific color The entire surface is printed black Printing becomes shaded The image contains blurs Transverse lines appear to be split Black and white lines appear in the printed image Edges of printing are blurred Many satellites (unwanted dots) The printing has whiskers Printed lines appear blurred (printing is dirty) Mixed color lines do not overlap Black and color positions are offset Inaccurate line length in the direction of head movement (Main scanning direction) Inaccurate straight line in the direction of head movement (straightness) Inaccurate line distance in the direction of media feed (Subsidiary scanning distance) Inaccurate straight line in the direction of media feed (joining precision Y) Bad right angle precision
Trouble with Media Feed
The media comes off when it is initialized or during printing The media is skewed or meanders when it is initialized or during printing The media becomes wrinkled when it is initialized or during printing The media jams when it is initialized or during printing The media tears when it is initialized or during printing The media size is different after media mounting and initialization Tracing paper and thin media cannot be detected
EXA3000 EXA3000 EXA3000 EXA3000 EXA3000 EXA3010 EXA3010
Trouble with Printing
TRB2000
27

Cases where no error message is displayed on the liquid crystal display of the main printer unit Abnormal noise when media is sucked down Abnormal noise when standing by ready to print Abnormal noise when head is moving left and right Abnormal noise when media is fed Abnormal noise when cutting

GO TO EXA No. EXA5000 EXA5010 EXA5020 EXA5030 EXA5040
TRB2001
GO TO EXA No. EXA7000 EXA7000 EXA7020 EXA7020 EXA7020 EXA7020 EXA7030 EXA7040 EXA7050 EXA7060
Cases where no error message is displayed on the liquid crystal display of the main printer unit Cannot connect normally with Centronics Cannot connect normally with Network The scale function does not work correctly The rotate function does not work correctly The mirror function does not work correctly Other functions are not working correctly Printing position is offset Some data are not printed (omitted) Text and printing data are garbled (extra lines appear) There is an extra feed after printing is finished
Online/Function Problems
Problem Involving Noise
Trouble with Media Cutting
Others
Does not cut normally Cutting occurs during printing The cutting operation is normal but the media is not cut The cutting is bad and the media jams The cutting operation is normal but the media does not fall out Inaccurate media cutting Cutting is delayed for some time after printing has ended White paper is cut (Blank print)
EXA6000 EXA6010 EXA6020 EXA6020 EXA6030 EXA6040 EXA6050 EXA6050
The printer hangs up Power shutdown during printing The ink cartridges will not go in Ink has overflowed from the waste fluid box Ink overflows from flushing box Ink is split around the X-rail
EXA8000 EXA8010 EXA8020 EXA8050 EXA8050 EXA8050
TRB2001
28
RJ-6000-43 Matrix Map
MAP0000
Matrix Map
When Message is Displayed Printer Status Messages Data Errors Command Errors CPU System Faults Mechanical System Faults MAP1000 MAP1200 MAP1200 MAP1500 MAP1700
When Message is Not Displayed Trouble with Initialization Trouble with Media Feed Trouble with Printing Problem Involving Noise Trouble with Media Cutting Online/Function Problems Other MAP2000 MAP3000 MAP4000 MAP5000 MAP6000 MAP7000 MAP8000
MAP0000
29
MAP0000-2
Matrix Map
When Message is Displayed Printer Status Messages Data Errors Command Errors CPU System Faults Mechanical System Faults MAP1000-2 MAP1200 MAP1200 MAP1500 MAP1700-2
When Message is Not Displayed Trouble with Initialization Trouble with Media Feed Trouble with Printing Problem Involving Noise Trouble with Media Cutting Online/Function Problems Other MAP2000-2 MAP3000-2 MAP4000-2, 4001-2 MAP5000-2 MAP6000-2 MAP7000-2 MAP8000-2
MAP0000-2
30
MAP0000-3
Matrix Map
When Message is Displayed Printer Status Messages Data Errors Command Errors CPU System Faults Mechanical System Faults MAP1000-3 MAP1200 MAP1200 MAP1500 MAP1700-2
When Message is Not Displayed Trouble with Initialization Trouble with Media Feed Trouble with Printing Problem Involving Noise Trouble with Media Cutting Online/Function Problems Other MAP2000-2 MAP3000-3 MAP4000-2, 4001-3 MAP5000-3 MAP6000-2 MAP7000-2 MAP8000-2
MAP0000-3
31
FaultTracing Procedure EXA No. 1000 1000 1000 1010 1020 1030 1040 1050 1060 1070 1080 1090 1090 1100 1110 1120 1130 1140 1150

EXA1000 to EXA1150 When Message is Displayed [Printer Status Display] Problem
- Cover open - Lever up - Cover & Lever - Undefined Media - Media Skew Error - [User 1] Media End - Remove Media - Roll Media End - Media Cut Error - Not enough memory SIMM12MB - Insert Special Cartridge - [] Ink Low - [] No Ink - [] No Cartridge - Capping position not specified - Not Filled - No Waste Fluid Box - Check Waste Fluid Box - Wrong Ink Type
Replacement and Adjustment Procedure REP. No. Name and Diagram Number of Replacement Part 1140 1160 1110 1170 1100 1410 1420 1200 1360 1380 1350 1350 1350 1350 1350 1350 1120 1220 1220 1330 1340 1340 1340 1340 1340 1340 1470 1470 1690 DF-41586 Main Board Assembly DF-40097 Panel Board Assembly DF-41590 Cover Switch Assembly DF-41617 Panel Cable DF-41589 Lever Sensor Assembly DF-41595 Edge Sensor Assembly DF-41588 Head Board Assembly DF-41592 XR Cable Assembly (Paper Sensor R) DF-41600 Y Cable DF-40113 Cutter Solenoid Assembly DF-41593 Detector1 Assembly DF-41594 Detector2 Assembly DF-40106 Detector Assembly (Black) DF-40107 Detector Assembly (Y) DF-40146 Detector Assembly (M) DF-40147 Detector Assembly (C) DF-41591 Waste Fluid Box Sensor Assembly DF-41529 Pressure Assembly DF-41530 Pressure Roller DF-40127 Cartridge Frame Assembly DF-41609 Ink ID Sensor1 Assembly DF-41610 Ink ID Sensor2 Assembly DF-41611 Ink ID Sensor3 Assembly DF-41612 Ink ID Sensor4 Assembly DF-41613 Ink ID Sensor5 Assembly DF-41614 Ink ID Sensor6 Assembly DF-41615 Ink ID Cable DF-41536 Junction Board Assembly DF-41840 Grid Roller Assembly
Printer Status Messages Model Name: RJ-6000-43
MAP1000
MAP1000
32
FaultTracing Procedure EXA No. 1000 1000 1000 1010 1020-2 1030 1040 1050 1060 1070 1080 1090 1090 1100 1110 1120 1130 1140 1150

Replacement and Adjustment Procedure REP. No. Name and Diagram Number of Replacement Part 1140 1160 1110 1170 1100 1410 1420 1200 1360-2 1380 1350 1350 1350 1350 1350 1350 1120 1220 1220 1330 1340 1340 1340 1340 1340 1340 1470 1470 1690 1690 DF-41586 Main Board Assembly DF-40097 Panel Board Assembly DF-41590 Cover Switch Assembly DF-41617 Panel Cable DF-41589 Lever Sensor Assembly DF-41595 Edge Sensor Assembly DF-41588 Head Board Assembly DF-41592 XR Cable Assembly (Paper Sensor R) DF-41600 Y Cable DF-40113 Cutter Solenoid Assembly DF-41593 Detector1 Assembly DF-41594 Detector2 Assembly DF-40106 Detector Assembly (Black) DF-40107 Detector Assembly (Y) DF-40146 Detector Assembly (M) DF-40147 Detector Assembly (C) DF-41591 Waste Fluid Box Sensor Assembly DF-41529 Pressure Assembly DF-41530 Pressure Roller DF-40127 Cartridge Frame Assembly DF-41609 Ink ID Sensor1 Assembly DF-41610 Ink ID Sensor2 Assembly DF-41611 Ink ID Sensor3 Assembly DF-41612 Ink ID Sensor4 Assembly DF-41613 Ink ID Sensor5 Assembly DF-41614 Ink ID Sensor6 Assembly DF-41615 Ink ID Cable DF-41536 Junction Board Assembly DF-41840 Grid Roller Assembly DF-41989 Grid Roller Assembly (2)
MAP1000-2
MAP1000-2
33
FaultTracing Procedure EXA No. 1000 1000 1000 1010 1020-2 1030 1040 1050 1060 1070 1080 1090 1090 1100 1110 1120 1130 1140 1150

1140 1160 1110 1170 1100 1410 1420 1200 1360-2 1380 1350 1350 1350 1350 1350 1350 1120 1220 1220 1330 1340 1340 1340 1340 1340 1340 1470 1470 1690 1690
Replacement and Adjustment Procedure REP. No. Name and Diagram Number of Replacement Part DF-41586 Main Board Assembly DF-40097 Panel Board Assembly DF-41590 Cover Switch Assembly DF-41617 Panel Cable DF-41589 Lever Sensor Assembly DF-41595 Edge Sensor Assembly DF-41588 Head Board Assembly DF-41592 XR Cable Assembly (Paper Sensor R) DF-41600 Y Cable DF-40113 Cutter Solenoid Assembly DF-41593 Detector1 Assembly DF-41594 Detector2 Assembly DF-40106 Detector Assembly (Black) DF-40107 Detector Assembly (Y) DF-40146 Detector Assembly (M) DF-40147 Detector Assembly (C) DF-41591 Waste Fluid Box Sensor Assembly DF-41529 Pressure Assembly DF-41530 Pressure Roller DF-40127 Cartridge Frame Assembly DF-41609 Ink ID Sensor1 Assembly DF-41610 Ink ID Sensor2 Assembly DF-41611 Ink ID Sensor3 Assembly DF-41612 Ink ID Sensor4 Assembly DF-41613 Ink ID Sensor5 Assembly DF-41614 Ink ID Sensor6 Assembly DF-41615 Ink ID Cable DF-41536 Junction Board Assembly DF-41840 Grid Roller Assembly
Printer Status Messages Model Name: RJ-6000-62 MAP1000-3
Printer Status Messages Model Name: RJ-6000-62 MAP1000-3
34

When Message is Displayed [Data Errors, Command Errors] EXA1230 to EXA1250 Name and Diagram Number of Replacement Part
Data Errors, Command Errors
Model Name: RJ-6000-43/54/62
MAP1200
Problem FaultTracing Procedure EXA No. 1230 1230 1250 1250 1250 1250 1250
- Network Detection Error - Network Initialization Error - MH01 Error (Undefined Command) - MH02 Error (Parameter Error) - MH03 Error (Numerical Error) - MH04 Error (Undefined Character Set) - MH07 Error (Buffer Overflow)
1140
DF-41586 Main Board Assembly
Data Errors, Command Errors
Model Name: RJ-6000-43/54/62
MAP1200
35

When Message is Displayed [CPU System Faults] EXA1500 to EXA1530 Name and Diagram Number of Replacement Part
CPU System Faults
Model Name: RJ-6000-43/54/62
MAP1500
Problem FaultTracing Procedure EXA No. 1500 1500 1510 1510 1510 1510 1510 1510 1510 1510 1510 1520 1520 1520 1520 1520 1520 1520 1520 1520 1530
- E001 Error DRAM (Standard DRAM error) - E002 Error Opt.DRAM (Optional DRAM error) - E016 CPUErr[00] (Interrupt exception error) - E016 CPUErr[02] (Command boundary exception error) - E016 CPUErr[03] (Data boundary exception error) - E016 CPUErr[04] (Address error exception load) - E016 CPUErr[05] (Address error exception store) - E016 CPUErr[06] (Bus error exception check) - E016 CPUErr[07] (Bus error exception load) - E016 CPUErr[08] (System call exception) - E016 CPUErr[09] (Break point exception) - E016 CPUErr[10] (Reserved command exception) - E016 CPUErr[11] (Processor usage denial exception) - E016 CPUErr[12] (Operation overflow exception) - E016 CPUErr[13] (Trap exception) - E016 CPUErr[15] (Floating point exception) - E016 CPUErr[22] (Watch exception) - E016 CPUErr[32] (Watchdog timeout error) - E016 CPUErr[33] (Abort error) - E237 Error Transfer memory (Transfer memory error/access error) - Error E129 NVRAM (Backup memory error)
1140
DF-41586 Main Board Assembly
CPU System Faults
Model Name: RJ-6000-43/54/62
MAP1500
36

MAP1700
EXA1700 to EXA1720

1700 1700 1700 1700 1710 1710 1710 1710 1720 - Error E065 X Motor - Error E069 X Encoder - Error E071 X Timeout - Error E073 X Overcurrent - Error E066 Y Motor - Error E070 Y Encoder - Error E072 Y Timeout - Error E074 Y Overcurrent - Error E075 Sensor Abnormal
1140 1070
1280 1290 1450 1150 1080 1080 1080 1080
DF-41586 Main Board Assembly DF-41597 X Motor Assembly DF-41598 CR Motor Assembly (Y Motor) DF-41607 T Fence DF-40109 Origin Sensor Assembly DF-41587 Power Board Assembly DF-40173 Vacuum Fan Assembly DF-41620 Fan Extension Cable 1 Assembly DF-41621 Fan Extension Cable 2 Assembly DF-41622 Fan Extension Cable 3 Assembly
When Message is Displayed [Mechanical System Faults]
MAP1700
37

Model Name: RJ-6000-54/62
MAP1700-2
EXA1700 to EXA1720

1700 1700 1700 1700 1710 1710 1710 1710 1720 - Error E065 X Motor - Error E069 X Encoder - Error E071 X Timeout - Error E073 X Overcurrent - Error E066 Y Motor - Error E070 Y Encoder - Error E072 Y Timeout - Error E074 Y Overcurrent - Error E075 Sensor Abnormal
1280 1290 1450 1150 1080-2 1080-2 1080-2 1080-2 1080-2
1140 1070
DF-41586 Main Board Assembly DF-41597 X Motor Assembly DF-41598 CR Motor Assembly (Y Motor) DF-41607 T Fence DF-40109 Origin Sensor Assembly DF-41587 Power Board Assembly DF-40173 Vacuum Fan Assembly DF-41620 Fan Extension Cable 1 Assembly DF-41621 Fan Extension Cable 2 Assembly DF-41622 Fan Extension Cable 3 Assembly DF-41993 Fan Extension Cable 4 Assembly
When Message is Displayed [Mechanical System Faults]
MAP1700-2
38
FaultTracing Procedure EXA No. EXA2000 to EXA2070 Problem
2000 2000 2010 2020 2030 2030 2030 2030 2030 2040 2050 2060 2070

- Power supply does not come on - LCD faulty (no display/erratic display) - Initial filling of inks failed - Initial filling is completed but no ink comes out - After power is switched on, nothing works - When power is applied, Initializing appears and then a reset is executed. - After mounting media, initial operation fails - Printer does not work even with the cover closed - Printer does not stop even with the cover opened - Ink cartridges are installed but not recognized - Can not make entries from the operating panel - Data is received but not plotted - Media is not suction

When Message is Not Displayed [Trouble with Initialization]
Replacement and Adjustment Procedure REP. No. Name and Diagram Number of Replacement Part 1140 1160 1170 1110 1100 1410 1420 1200 1360 1130 1150 1130 1350 1350 1350 1350 1350 1350 1240 1260 1270 1390 1390 1120 1080 1080 1080 1080 1340 1340 1340 1340 1340 1340 1470 1470 DF-41586 Main Board Assembly DF-40097 Panel Board Assembly DF-41617 Panel Cable DF-41590 Cover Switch Assembly DF-41589 Lever Sensor Assembly DF-41595 Edge Sensor Assembly DF-41588 Head Board Assembly DF-41592 XR Cable Assembly (Paper Sensor R) DF-41600 Y Cable DF-41619 Switch Cable Assembly DF-41587 Power Board Assembly DF-41468 DC Cable Assembly DF-41593 Detector 1 Assembly DF-41594 Detector 2 Assembly DF-40106 Detector Assembly (Black) DF-40107 Detector Assembly (Y) DF-40146 Detector Assembly (M) DF-40147 Detector Assembly (C) DF-41602 Cap Assembly DF-41603 Pump Assembly DF-41604 Maintenance Station Assembly DF-40690 Print Head Assembly (Color) DF-41601 Head Cable DF-41591 Waste Fluid Box Sensor DF-40173 Vacuum Fan Assembly DF-41620 Fan Extension Cable 1 Assembly DF-41621 Fan Extension Cable 2 Assembly DF-41622 Fan Extension Cable 3 Assembly DF-41609 INK ID Sensor 1 Assembly DF-41610 INK ID Sensor 2 Assembly DF-41611 INK ID Sensor 3 Assembly DF-41612 INK ID Sensor 4 Assembly DF-41613 INK ID Sensor 5 Assembly DF-41614 INK ID Sensor 6 Assembly DF-41615 INK ID Sensor Cable DF-41536 Junction Board Assembly
MAP2000
MAP2000
39
FaultTracing Procedure EXA No. EXA2000 to EXA2070-2 Problem
2000 2000 2010 2020 2030 2030 2030 2030 2030 2040 2050 2060 2070-2

- Power supply does not come on - LCD faulty (no display/erratic display) - Initial filling of inks failed - Initial filling is completed but no ink comes out - After power is switched on, nothing works - When power is applied, Initializing appears and then a reset is executed. - After mounting media, initial operation fails - Printer does not work even with the cover closed - Printer does not stop even with the cover opened - Ink cartridges are installed but not recognized - Can not make entries from the operating panel - Data is received but not plotted - Media is not suction

When Message is Not Displayed [Trouble with Initialization]
Replacement and Adjustment Procedure REP. No. Name and Diagram Number of Replacement Part 1140 1160 1170 1110 1100 1410 1420 1200 1360-2 1130 1150 1130 1350 1350 1350 1350 1350 1350 1240 1260 1270 1390 1390 1120 1080-2 1080-2 1080-2 1080-2 1080-2 1340 1340 1340 1340 1340 1340 1470 1470 DF-41586 Main Board Assembly DF-40097 Panel Board Assembly DF-41617 Panel Cable DF-41590 Cover Switch Assembly DF-41589 Lever Sensor Assembly DF-41595 Edge Sensor Assembly DF-41588 Head Board Assembly DF-41592 XR Cable Assembly (Paper Sensor R) DF-41600 Y Cable DF-41619 Switch Cable Assembly DF-41587 Power Board Assembly DF-41468 DC Cable Assembly DF-41593 Detector 1 Assembly DF-41594 Detector 2 Assembly DF-40106 Detector Assembly (Black) DF-40107 Detector Assembly (Y) DF-40146 Detector Assembly (M) DF-40147 Detector Assembly (C) DF-41602 Cap Assembly DF-41603 Pump Assembly DF-41604 Maintenance Station Assembly DF-40690 Print Head Assembly (Color) DF-41601 Head Cable DF-41591 Waste Fluid Box Sensor DF-40173 Vacuum Fan Assembly DF-41620 Fan Extension Cable 1 Assembly DF-41621 Fan Extension Cable 2 Assembly DF-41622 Fan Extension Cable 3 Assembly DF-41993 Fan Extension Cable 4 Assembly DF-41609 INK ID Sensor 1 Assembly DF-41610 INK ID Sensor 2 Assembly DF-41611 INK ID Sensor 3 Assembly DF-41612 INK ID Sensor 4 Assembly DF-41613 INK ID Sensor 5 Assembly DF-41614 INK ID Sensor 6 Assembly DF-41615 INK ID Sensor Cable DF-41536 Junction Board Assembly
Trouble with Initialization Model Name: RJ-6000-54/62
Trouble with Initialization Model Name: RJ-6000-54/62
MAP2000-2
MAP2000-2
40

Name and Diagram Number of Replacement Part When Message is Not Displayed [Trouble with Media Feed] EXA3000 to EXA3010 DF-41586 Main Board Assembly DF-40173 Vacuum Fan Assembly DF-41620 Fan Extension Cable 1 Assembly DF-41621 Fan Extension Cable 2 Assembly DF-41622 Fan Extension Cable 3 Assembly DF-41529 Pressure Assembly DF-41595 Edge Sensor Assembly DF-41592 XR Cable Assembly (Paper Sensor R) DF-41600 Y Cable DF-41840 Grid Roller Assembly
MAP3000

3000 3000 3000 3000 3000 3010 3010
- The media comes off when it is initialized or during printing - The media is skewed or meanders when it is initialized or during printing - The media becomes wrinkled when it is initialized or during printing - The media jams when it is initialized or during printing - The media tears when it is initialized or during printing - The media size is different after media mounting and initialization - Tracing paper and thin media cannot be detected
1140 1080 1080 1080 1080 1110 1410 1200 1360 1690
MAP3000
41

Name and Diagram Number of Replacement Part When Message is Not Displayed [Trouble with Media Feed] EXA3000-2 to EXA3010

DF-41586 Main Board Assembly DF-40173 Vacuum Fan Assembly DF-41620 Fan Extension Cable 1 Assembly DF-41621 Fan Extension Cable 2 Assembly DF-41622 Fan Extension Cable 3 Assembly DF-41993 Fan Extension Cable 4 Assembly DF-41529 Pressure Assembly DF-41595 Edge Sensor Assembly DF-41592 XR Cable Assembly (Paper Sensor R) DF-41600 Y Cable DF-41840 Grid Roller Assembly DF-41989 Grid Roller Assembly (2)
MAP3000-2

3000-2 3000-2 3000-2 3000-2 3000-2 3010 3010
1140 1080-2 1080-2 1080-2 1080-2 1080-2 1110 1410 1200 1360-2 1690 1690
MAP3000-2
42

Name and Diagram Number of Replacement Part When Message is Not Displayed [Trouble with Media Feed] EXA3000-2 to EXA3010

DF-41586 Main Board Assembly DF-40173 Vacuum Fan Assembly DF-41620 Fan Extension Cable 1 Assembly DF-41621 Fan Extension Cable 2 Assembly DF-41622 Fan Extension Cable 3 Assembly DF-41993 Fan Extension Cable 4 Assembly DF-41529 Pressure Assembly DF-41595 Edge Sensor Assembly DF-41592 XR Cable Assembly (Paper Sensor R) DF-41600 Y Cable DF-41840 Grid Roller Assembly
MAP3000-3

3000-2 3000-2 3000-2 3000-2 3000-2 3010 3010
1140 1080-2 1080-2 1080-2 1080-2 1080-2 1110 1410 1200 1360-2 1690
MAP3000-3
43

Name and Diagram Number of Replacement Part When Message is Not Displayed [Trouble with Printing] EXA4000 to EXA4130
(EXA4110 to EXA4130 See MAP4001)
MAP4000

4000 4010 4020 4020 4030 4040 4050 4050 4050 4050 4060 4070 4070 4070 4080 4080 4090 4100 - Does not print continuously - There is an extra feed after printing is finished - Dots are missing from the printing - Cleaning does not cure blockage - Does not print at all or does not print a specific color - The entire surface is printed black - Printing becomes shaded - The image contains blurs - Transverse lines appear to be split - Black and white lines appear in the printed image - Edges of printing are blurred - Many satellites (unwanted dots) - The printing has whiskers - Printed lines appear blurred - Mixed color lines do not overlap - Black and color positions are offset - Inaccurate line length in the direction of head movement (Main scanning direction) - Inaccurate straight line in the direction of head movement (straightness)
1140 1080 1080 1080 1080 1370 1390 1360 1290 1240 1260 1230 1250 1270 1390 1420 1350 1350 1350 1350 1350 1350 1200 1150
DF-41586 Main Board Assembly DF-40173 Vacuum Fan Assembly DF-41620 Fan Extension Cable 1 Assembly DF-41621 Fan Extension Cable 2 Assembly DF-41622 Fan Extension Cable 3 Assembly DF-41605 Ink Tube DF-41601 Head Cable DF-41600 Y Cable DF-41607 T Fence DF-41602 Cap Assembly DF-41603 Pump Assembly DF-41599 Pump Motor Assembly DF-40125 Wiper DF-41604 Maintenance Station Assembly DF-40690 Print Head Assembly (Color) DF-41588 Head Board Assembly DF-41593 Detector 1 Assembly DF-41594 Detector 2 Assembly DF-40106 Detector Assembly (Black) DF-40107 Detector Assembly (Y) DF-40146 Detector Assembly (M) DF-40147 Detector Assembly (C) DF-41592 XR Cable Assembly (Paper Sensor R) DF-41587 Power Board Assembly
MAP4000
44

Name and Diagram Number of Replacement Part When Message is Not Displayed [Trouble with Printing] EXA4000 to EXA4130-2
(EXA4110 to EXA4130-2 See MAP4001-2)
MAP4000-2

4000 4010 4020 4020 4030 4040 4050-2 4050-2 4050-2 4050-2 4060 4070 4070 4070 4080 4080 4090 4100-2 - Does not print continuously - There is an extra feed after printing is finished - Dots are missing from the printing - Cleaning does not cure blockage - Does not print at all or does not print a specific color - The entire surface is printed black - Printing becomes shaded - The image contains blurs - Transverse lines appear to be split - Black and white lines appear in the printed image - Edges of printing are blurred - Many satellites (unwanted dots) - The printing has whiskers - Printed lines appear blurred - Mixed color lines do not overlap - Black and color positions are offset - Inaccurate line length in the direction of head movement (Main scanning direction) - Inaccurate straight line in the direction of head movement (straightness)
1140 1080-2 1080-2 1080-2 1080-2 1080-2 1370 1390 1360-2 1290 1240 1260 1230 1250 1270 1390 1420 1350 1350 1350 1350 1350 1350 1200 1150
DF-41586 Main Board Assembly DF-40173 Vacuum Fan Assembly DF-41620 Fan Extension Cable 1 Assembly DF-41621 Fan Extension Cable 2 Assembly DF-41622 Fan Extension Cable 3 Assembly DF-41993 Fan Extension Cable 4 Assembly DF-41605 Ink Tube DF-41601 Head Cable DF-41600 Y Cable DF-41607 T Fence DF-41602 Cap Assembly DF-41603 Pump Assembly DF-41599 Pump Motor Assembly DF-40125 Wiper DF-41604 Maintenance Station Assembly DF-40690 Print Head Assembly (Color) DF-41588 Head Board Assembly DF-41593 Detector 1 Assembly DF-41594 Detector 2 Assembly DF-40106 Detector Assembly (Black) DF-40107 Detector Assembly (Y) DF-40146 Detector Assembly (M) DF-40147 Detector Assembly (C) DF-41592 XR Cable Assembly (Paper Sensor R) DF-41587 Power Board Assembly
MAP4000-2
45

DF-41586 Main Board Assembly DF-40173 Vacuum Fan Assembly DF-41620 Fan Extension Cable 1 Assembly DF-41621 Fan Extension Cable 2 Assembly DF-41622 Fan Extension Cable 3 Assembly DF-41529 Pressure Assembly DF-40854 Cursor Plate Spring DF-41616 Steel Flexible Cable Assembly DF-41840 Grid Roller Assembly DF-41841 Speed Reduction Pulley Assembly When Message is Not Displayed [Trouble with Printing] EXA4000 to EXA4130
(EXA4000 to EXA4100 See MAP4000)

MAP4001

4110 4120 4130
- Inaccurate line distance in the direction of media feed (Subsidiary scanning distance) - Inaccurate straight line in the direction of media feed (joining precision Y) - Bad right angle precision
1140 1080 1080 1080 1080 1220 1310 1310 1690 1680
MAP4001
46

When Message is Not Displayed [Trouble with Printing] EXA4000 to EXA4130
(EXA4000 to EXA4100-2 See MAP4000-2)

Name and Diagram Number of Replacement Part DF-41586 Main Board Assembly DF-40173 Vacuum Fan Assembly DF-41620 Fan Extension Cable 1 Assembly DF-41621 Fan Extension Cable 2 Assembly DF-41622 Fan Extension Cable 3 Assembly DF-41993 Fan Extension Cable 4 Assembly DF-41529 Pressure Assembly DF-40854 Cursor Plate Spring DF-41616 Steel Flexible Cable Assembly DF-41840 Grid Roller Assembly DF-41989 Grid Roller Assembly (2) DF-41988 Speed Reduction Pulley Assembly
MAP4001-2

4110 4120 4130-2
1140 1080-2 1080-2 1080-2 1080-2 1080-2 1220 1310-2 1310-2 1690 1690 1680
MAP4001-2
47

When Message is Not Displayed [Trouble with Printing] EXA4000 to EXA4130-2
(EXA4000 to EXA4100-2 See MAP4000-2)

Name and Diagram Number of Replacement Part DF-41586 Main Board Assembly DF-40173 Vacuum Fan Assembly DF-41620 Fan Extension Cable 1 Assembly DF-41621 Fan Extension Cable 2 Assembly DF-41622 Fan Extension Cable 3 Assembly DF-41993 Fan Extension Cable 4 Assembly DF-41529 Pressure Assembly DF-40854 Cursor Plate Spring DF-41616 Steel Flexible Cable Assembly DF-41840 Grid Roller Assembly DF-41988 Speed Reduction Pulley Assembly
MAP4001-3

4110 4120 4130-2
1140 1080-2 1080-2 1080-2 1080-2 1080-2 1220 1310-2 1310-2 1690 1680
MAP4001-3
48

When Message is Not Displayed [Problem Involving Noise] EXA5000 to EXA5040 Name and Diagram Number of Replacement Part
MAP5000

5000 5010 5020 5030 5040 - Abnormal noise when media is sucked down - Abnormal noise when standing by ready to print - Abnormal noise when head is moving left and right - Abnormal noise when media is fed - Abnormal noise when cutting
1140 1080 1150 1390 1420 1320 1280 1220 1090 1070 1360 1540 1690
DF-41586 Main Board Assembly DF-40173 Vacuum Fan Assembly DF-41587 Power Board Assembly DF-40690 Print Head Assembly (Color) DF-41588 Head Board DF-40144 Y Return Pulley Assembly DF-41598 Cursor Motor Assembly (Y Motor) DF-41529 Pressure Assembly DF-40137 X Speed Reduction Belt DF-41597 X Motor Assembly DF-41600 Y Cable DF-41677 Tube Guide Assembly DF-41840 Grid Roller Assembly
MAP5000
49

MAP5000-2

1140 1080-2 1150 1390 1420 1320 1280 1220 1090 1070 1360-2 1540-2 1690 1690
DF-41586 Main Board Assembly DF-40173 Vacuum Fan Assembly DF-41587 Power Board Assembly DF-40690 Print Head Assembly (Color) DF-41588 Head Board DF-40144 Y Return Pulley Assembly DF-41598 Cursor Motor Assembly (Y Motor) DF-41529 Pressure Assembly DF-40137 X Speed Reduction Belt DF-41597 X Motor Assembly DF-41600 Y Cable DF-41677 Tube Guide Assembly DF-41840 Grid Roller Assembly DF-41989 Grid Roller Assembly (2)
MAP5000-2
50

MAP5000-3

1140 1080-2 1150 1390 1420 1320 1280 1220 1090 1070 1360-2 1540-2 1690
DF-41586 Main Board Assembly DF-40173 Vacuum Fan Assembly DF-41587 Power Board Assembly DF-40690 Print Head Assembly (Color) DF-41588 Head Board DF-40144 Y Return Pulley Assembly DF-41598 Cursor Motor Assembly (Y Motor) DF-41529 Pressure Assembly DF-40137 X Speed Reduction Belt DF-41597 X Motor Assembly DF-41600 Y Cable DF-41677 Tube Guide Assembly DF-41840 Grid Roller Assembly
MAP5000-3
51

When Message is Not Displayed [Trouble with Media Cutting] EXA6000 to EXA6050 Name and Diagram Number of Replacement Part
MAP6000

6000 6010 6020 6020 6030 6040 6050 6050 - Does not cut normally - Cutting occurs during printing - The cutting operation is normal but the media is not cut - The cutting is bad and the media jams - The cutting operation is normal but the media does not fall out - Inaccurate media cutting - Cutting is delayed for some time after printing has ended - White paper is cut
1140 1380 1360 1420
DF-41586 Main Board Assembly DF-40113 Cutter Solenoid Assembly DF-41600 Y Cable DF-41588 Head Board Assembly
MAP6000
52

When Message is Not Displayed [Trouble with Media Cutting] EXA6000 to EXA6050 Name and Diagram Number of Replacement Part
MAP6000-2

6000 6010 6020 6020 6030 6040 6050 6050 - Does not cut normally - Cutting occurs during printing - The cutting operation is normal but the media is not cut - The cutting is bad and the media jams - The cutting operation is normal but the media does not fall out - Inaccurate media cutting - Cutting is delayed for some time after printing has ended - White paper is cut
1140 1380 1360-2 1420
DF-41586 Main Board Assembly DF-40113 Cutter Solenoid Assembly DF-41600 Y Cable DF-41588 Head Board Assembly
MAP6000-2
53

When Message is Not Displayed [Online/Function Problems] EXA7000 to EXA7060 Name and Diagram Number of Replacement Part
MAP7000

7000 7000 7000 7020 7020 7020 7020 7030 7040 7050 7060 - Cannot connect normally with RS-232C - Cannot connect normally with Centronics - Cannot connect normally with Network - The scale function does not work correctly - The rotate function does not work correctly - The mirror function does not work correctly - Other functions are not working correctly - Printing position is offset - Some data are not printed (omitted) - Text and printing data are garbled (extra lines appear) - There is an extra feed after printing is finished
1140 1360 1420 1290
DF-41586 Main Board Assemblym) DF-41600 Y Cable DF-41588 Head Board Assembly DF-41607 T Fence
MAP7000
54

When Message is Not Displayed [Online/Function Problems] EXA7000 to EXA7060 Name and Diagram Number of Replacement Part
MAP7000-2

7000 7000 7000 7020 7020 7020 7020 7030 7040 7050 7060 - Cannot connect normally with RS-232C - Cannot connect normally with Centronics - Cannot connect normally with Network - The scale function does not work correctly - The rotate function does not work correctly - The mirror function does not work correctly - Other functions are not working correctly - Printing position is offset - Some data are not printed (omitted) - Text and printing data are garbled (extra lines appear) - There is an extra feed after printing is finished
1140 1360-2 1420 1290
DF-41586 Main Board Assemblym) DF-41600 Y Cable DF-41588 Head Board Assembly DF-41607 T Fence
MAP7000-2
55

Name and Diagram Number of Replacement Part When Message is Not Displayed [Other] EXA8000 to EXA8050
Other
DF-41586 Main Board Assembly DF-40127 Cartridge Frame Assembly DF-41593 Detector 1 Assembly DF-41594 Detector 2 Assembly DF-40106 Detector Assembly (Black) DF-40107 Detector Assembly (Y) DF-40146 Detector Assembly (M) DF-40147 Detector Assembly (C) DF-41587 Power Board Assembly DF-41591 Waste Fluid Box Sensor Assembly DF-42007 F Absorbent Material Assembly
MAP8000

8000 8010 8020 8030 8040 8050 - The printer hangs up - Power shutdown during printing - The ink cartridges will not go in - Ink has overflowed from the waste fluid box - Ink overflows from flushing box - Ink is split around the X-rail
1140 1330 1350 1350 1350 1350 1350 1350 1150 1120 1700
Other
MAP8000
56

Name and Diagram Number of Replacement Part When Message is Not Displayed [Other] EXA8000 to EXA8050-2
Other
DF-41586 Main Board Assembly DF-40127 Cartridge Frame Assembly DF-41593 Detector 1 Assembly DF-41594 Detector 2 Assembly DF-40106 Detector Assembly (Black) DF-40107 Detector Assembly (Y) DF-40146 Detector Assembly (M) DF-40147 Detector Assembly (C) DF-41587 Power Board Assembly DF-41591 Waste Fluid Box Sensor Assembly DF-42007 F Absorbent Material Assembly DF-42008 Waste Fluid Bottle Assembly
MAP8000-2

8000 8010 8020 8050-2 8050-2 8050-2 8050-2 - The printer hangs up - Power shutdown during printing - The ink cartridges will not go in - Ink has overflowed from the waste fluid box - Ink overflows from flushing box - Ink is split around the X-rail - Ink has overflowed from the waste fluid bottle
1140 1330 1350 1350 1350 1350 1350 1350 1150 1120 1700 1710
Other
MAP8000-2
57
RJ-6000-43 Fault-Tracing Procedure
Model Name:
RJ6000-43
EXA0000
Fault-Tracing Procedure
When Message is Displayed Printer Status Messages Data Errors Command Errors CPU System Faults Mechanical System Faults EXA1000 EXA1200 EXA1250 EXA1500 EXA1700
When Message is Not Displayed Trouble with Initialization Trouble with Media Feed Trouble with Printing Problem Involving Noise Trouble with Media Cutting Online/Function Problems Other EXA2000 EXA3000 EXA4000 EXA5000 EXA6000 EXA7000 EXA8000
Model Name:
RJ6000-43
EXA0000
58
EXA0000-2
When Message is Displayed Printer Status Messages Data Errors Command Errors CPU System Faults Mechanical System Faults EXA1000 EXA1200 EXA1250 EXA1500 EXA1700 (Difference between RJ-6000-43 and 54) ( 1020-2 )
When Message is Not Displayed Trouble with Initialization Trouble with Media Feed Trouble with Printing Problem Involving Noise Trouble with Media Cutting Online/Function Problems Other EXA2000 EXA3000 EXA4000 EXA5000 EXA6000 EXA7000 EXA8000 ( 2070-2 ) ( 3000-2 ) ( 4050-2, 4100-2, 4130-2 )
Model Name:
RJ6000-54
EXA0000-2
59
EXA0000-3
When Message is Displayed Printer Status Messages Data Errors Command Errors CPU System Faults Mechanical System Faults EXA1000 EXA1200 EXA1250 EXA1500 EXA1700 (Difference between RJ-6000-43 and 62) ( 1020-2 )
When Message is Not Displayed Trouble with Initialization Trouble with Media Feed Trouble with Printing Problem Involving Noise Trouble with Media Cutting Online/Function Problems Other EXA2000 EXA3000 EXA4000 EXA5000 EXA6000 EXA7000 EXA8000 ( 2070-2 ) ( 3000-2 ) ( 4050-2, 4100-2, 4130-2 )
Model Name:
RJ6000-62
EXA0000-3
60

No. 1 Symptom Cover Open This message means that the Front Cover is open Lever Up This message means that the Pressure Lever is up. Cover and Lever This message means that the Front Cover and Pressure Lever are up.
Sequence
1-1

EXA1000
Is the cover sensor arm loose? (Related to opening and closing the front cover) Tighten the cover sensor arm screw. When the front cover is opened and closed, does the cover switch go on and off normally? Adjust the height of the cover switch assembly. Adjust the relative positions of the cover shaft R and front cover fulcrum. Is the cover switch cable connected securely? (Related to opening and closing the front cover) Connect the sensor cable securely to connector J106 (COVER) on the main board assembly. Does the pressure lever move smoothly? (Related to raising and lowering the pressure lever) Adjust the position of the pressure relay plate. Apply grease G-501 to the elongated round hole in the pressure relay plate. (Refer to CAT4000) Is the lever sensor assembly fitted securely? (Related to raising and lowering the pressure lever) Adjust the lever sensor assembly fitting position. Is the sensor unit in the lever sensor assembly dirty? (Related to raising and lowering the pressure lever) Clean the sensor unit with cotton swabs. Is the lever sensor assembly cable fitted securely? (Related to raising and lowering the pressure lever) Connect the lever sensor cable securely to connector J102 (LEVER) on the main board assembly. The panel board assembly may be damaged. (Related to opening and closing the front cover) Replace it. The panel cable may be damaged. (Related to opening and closing the front cover) Replace it. Is the cover limit switch working on "Sensor: Cover" in the printer self-diagnostics? Replace the cover switch assembly Is the lever sensor working on "Sensor: Lever" in the printer self-diagnostics? Replace the lever sensor assembly. The main board assembly may be damaged. (Related to both) Replace it.
1110
1-2
1110
1-3
1110
1-4
1-5
1100
1-6
1100
1-7
1100
1-8
1160
1-9
1170 1040 1110 1040 1100
1-10
1-11
1-12
1140
EXA1000
61

No. 1 Symptom Undefined Media This message means that when media was mounted, it was not able to be recognized.
Sequence

EXA1010
1-1 1-2
Is the edge sensor assembly cable that is attached to the head unit securely connected? Connect it securely to connector J204 (P EDGE) on the head board assembly. Is the XR cable assembly (paper sensor R) cable that is attached below paper guide R securely connected? Connect it securely to connector J107 (XR) on the main board assembly. Use the printer's self-diagnostic Sensor: Edge to confirm the amount of sensor reflection. Using thick coated paper, check whether the paper detection value is within 0090 to 00a4. Replace edge sensor assembly. Adjust with the head board assembly variable resistor (VR1). Check Y cable contacts. Check that they are not inserted obliquely. Reconnect main board assembly connector J111 (HEAD1) and head board assembly connector J201 (MAIN1). The head board assembly may be damaged. Replace it. Check with the self-diagnostic Sensor: X Rear whether the sensor is operating. Replace paper sensor R if Paper End is displayed when media is mounted. The main board assembly may be damaged. Replace it. The Y cable assembly may be damaged Replace it.
1410
1200 1040
1-3
1410
1-4
1-5 1-6 1-7 1-8
1420 1040 1200 1140 1360
EXA1010
62

No. 1 Symptom Media Skew Error
Sequence 1-1 1-2

EXA1020
Reload the media and confirm its current status. If the problem is simply due to poor loading, explain to the user how to load the media properly. Are the fans working normally according to the self-diagnostic Examination: Fans? Check the connectors between fan assembly, fan extension cable assembly and main board assembly. Fan extension cable 1 assembly is J115 (FAN1) on the main board assembly Fan extension cable 2 assembly is J116 (FAN2) on the main board assembly Fan extension cable 3 assembly is J117 (FAN3) on the main board assembly Replace fan assembly. Replace Fan extension cable 1 assembly, Fan extension cable 2 assembly, Fan extension cable 3 assembly. Is the shielding material securely attached in the proper positions? Shield material GA-A, shield GA-B, shield GA-C Re-attach in the proper positions. Is there a problem with the movement of the pressure lever? Apply grease (G501) and adjust the pressure transfer plate. With the pressure lever lowered, do all pressure rollers make contact with the grid roller? (Are any of the pressure rollers idling?) Replace the pressure rollers or the pressure assembly. Is there a uniform gap between head and platen? Use the rail height jig (JD-30395) to adjust the position of the platen. Is there distortion or damage to the grid roller? Replace grid roller. After carrying out the adjustments according to the procedure above, run the self-diagnostic Skew Verification. CAUTION: Since this task will establish the reference position for determining skew, it should be adjusted carefully. 1060 1080
1-3
1-4 1-5
1220 1520 1690 2030
1-6 1-7 2-1
[ Rated Value ]
Condition Cut media Roll media 7m 50m
Rated Value Within 1.5 mm Within 2.5 mm Within 10 mm
EXA1020
63

No. 1 Symptom Media Skew Error
Sequence 1-1 1-2
Model Name: RJ6000-54/62
EXA1020-2
Reload the media and confirm its current status. If the problem is simply due to poor loading, explain to the user how to load the media properly. Are the fans working normally according to the self-diagnostic Examination: Fans? Check the connectors between fan assembly, fan extension cable assembly and main board assembly. Fan extension cable 1 assembly is J115 (FAN1) on the main board assembly Fan extension cable 2 assembly is J116 (FAN2) on the main board assembly Fan extension cable 3 assembly is J117 (FAN3) on the main board assembly Fan extension cable 4 assembly is J118 (FAN4) on the main board assembly Replace fan assembly. Replace Fan extension cable 1 assembly, Fan extension cable 2 assembly, Fan extension cable 3 assembly and Fan extension cable 4 assembly. Is the shielding material securely attached in the proper positions? Shield material GA-A, shield GA-B, shield GA-C Re-attach in the proper positions. Is there a problem with the movement of the pressure lever? Apply grease (G501) and adjust the pressure transfer plate. With the pressure lever lowered, do all pressure rollers make contact with the grid roller? (Are any of the pressure rollers idling?) Replace the pressure rollers or the pressure assembly. Is there a uniform gap between head and platen? Use the rail height jig (JD-30395) to adjust the position of the platen. Is there distortion or damage to the grid roller? Replace grid roller. After carrying out the adjustments according to the procedure above, run the self-diagnostic Skew Verification. CAUTION: Since this task will establish the reference position for determining skew, it should be adjusted carefully.
1060 1080
1-3
1-4 1-5
1220 1520
1-6 1-7 2-1
1690 2030
[ Rated Value ]
Condition Cut media Roll media 7m 50m
Rated Value Within 1.5 mm Within 2.5 mm Within 10 mm
EXA1020-2
64

No. 1 Symptom [User 1] Media End This message is displayed when no media is mounted or printing in cut media mode has been completed.
Sequence

EXA1030
1-1
Is the edge sensor assembly cable that is attached to the head unit securely connected? Connect it securely to connector J204 (P EDGE) on the head board assembly. Is the XR cable assembly (paper sensor R) cable that is attached below the rear paper guide securely connected? Connect it securely to connector J107 (XR) on the main board assembly. Use the printer's self-diagnostic Sensor: Edge to confirm the amount of sensor reflection. Using thick coated paper, check whether the paper detection value is within 0090 to 00a4. Replace edge sensor assembly. The head board assembly may be damaged. Replace it. Check with the printer's self-diagnostic "Sensor: X Rear" whether the sensor is operating. Replace paper sensor R if Paper End is displayed when media is mounted. The main board assembly may be damaged. Replace it. The Y cable assembly may be damaged. Replace it.
1410
1-2
1200
1-3
1040 1410
1-4
1420 1040 1200
1-5
1-6
1140
1-7
1360
EXA1030
65

No. 1 Symptom Remove Media This message is displayed if, after raising the lever during printing and cutting the media, the lever is lowered without the media having been removed.
Sequence

EXA1040
1-1
Switch off the printer temporarily and check that the message is displayed when you switch on again. Use the printer's self-diagnostic "Sensor: Lever" to make sure that the pressure lever is working normally. Check that the liquid crystal display unit does not show that the up and down movement of the pressure lever appears to be chattering when the lever is moved slowly up and down. Check the lever sensor assembly contact. Reconnect main board assembly connector J104 (LEVER). If there seems to be chattering, the sensor may be faulty. Replace the lever sensor assembly. Is the cable of the XR cable assembly (rear paper sensor) that is attached below the rear paper guide connected securely? Connect it securely to connector J107 (XR) on the main board. Use the self-diagnostic Sensor: X Rear to check whether there is media. If media is loaded but No Media is displayed, replace the rear paper sensor. The main board assembly may be damaged. Replace it. 1040
1-2
1-3
1100
1-4
1200
1-5
1200
1-6
1140
EXA1040
66

No. 1 Symptom Roll Media End This message is displayed when roll media is being used and the trailing edge of the media is detected. It will be cancelled by raising the lever.
Sequence

EXA1050
1-1
Switch off the printer temporarily and check that the message is displayed when you switch on again. Use the printer's self-diagnostic "Sensor: X Rear" to make sure that the media end detection is working normally. Cover the paper sensor R (XR cable assembly) with media and confirm that "SENS: Xr Paper On" is displayed. Check the paper sensor R contact. Reconnect main board assembly connector J107 (XR). If "Media Present" does not appear, the sensor may be faulty. Replace the paper sensor R assembly. The main board assembly may be damaged. Replace it. 1040
1-2
1-3
1200
1-4
1140
EXA1050
67

No. 1 Symptom Media Cut Error This message is displayed when the media is not cut and does not fall out despite the cutting operation having been performed.
Sequence 1-1 1-2 1-3

Is there an accumulation of paper dust in the cutter groove? Remove accumulated paper dust along the paper groove. Check how the cutter cap is fitted. Fit the cutter cap securely.
EXA1060
Check the up and down movement of the cutter. With the cutter installed, push it down to the bottom with your finger and check that the power of the spring alone brings it back to the top. If it rises, go to 1-5 If it does not rise, got to 1-4 Remove the cutter and take out the cutter spring. Fit the cutter and check that in this condition, the cutter will fall to the bottom under its own weight. If it falls the cutter spring may be faulty. Refer to the exploded drawings and replace the cutter spring. If it does not fall, the cutter may be faulty. Replace the cutter. Use the printer's self-diagnostic Aging: Cutter to confirm the up-and-down movement of the solenoid.
Refer to the Operation Manual (Basic Manual)
1-4
1-5
Refer to the Operation Manual (Basic Manual)
Check the down position of the cutter blade relative to the cutter groove. [OK] Cutter blade is damaged or worn out. Replace with a new blade. [NG] Refer to REP 1380 position adjustment and adjust the position of the cutter holder. No up/down movement Connection may be faulty. Check the following connectors. Head board assembly connector J206 (SOL) Head board assembly connector J201 (MAIN1) Main board assembly connector J206 (HEAD1) Moves up/down CAUTION: Power must be off when connectors are being disconnected or reconnected, otherwise you may be injured or a board may be damaged. The main board assembly will certainly be damaged if power is applied with main board assembly connectors J111 (HEAD) and J112 (HEAD2) and head board connectors J201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP.
Continued on next page
EXA1060
68

No. 1 Symptom Media Cut Error This message is displayed when the media is not cut and does not fall out despite the cutting operation having been performed.
Sequence 1-6

EXA1061
There may be a broken Y cable lead, faulty solenoid assembly or a faulty board assembly. a. Try fitting a new Y cable. (Check for continuity between connectors) If there is up/down movement, replace Y cable. b. Try fitting a new solenoid assembly. (Check for continuity between connectors) If there is up/down movement, replace solenoid assembly. c. Try replacing the head board assembly. (Reference) after replacement, use the printer's EXAM: Sensor self-diagnostic "Edge" to adjust the amount of sensor reflection. (The adjustment volume is on the head board.) d. Try replacing the main board assembly. (Reference) Back up the parameters before replacing the main board and check the operation after executing Recovery with the new main board assembly.
EXA1061
69

No. 1 Symptom Not enough memory SIMMMB (Intermediate code buffer overflow) When this printer has insufficient memory for the amount of data sent by the personal computer, this message indicates the required memory size.
Sequence

EXA1070
1-1
Check RAM capacity with the printer's self-diagnostic Examination: RAM Capacity. The capacity without optional extended memory is 8 MB. If SIMM has been extended, the value Standard memory 8 MB + Extended memory will be displayed. (If two 36 MB SIMMs have been installed, 80 MB is displayed.) (With Iris 43 WIDE, since a 16 MB SIMM has been added in Slot 1, the display is normally "24 MB") Optional Memory = MB shown in the Setup List is the amount of extended memory only. If there is a difference between the actual memory capacity and the memory capacity shown on the panel or the memory capacity shown in the setup list, the SIMM may be damaged. Replace the SIMM. The main board assembly may be damaged. Replace it.
1010
1-2
1140
1-3
1140
EXA1070
70

No. 1 Symptom Insert Special Cartridge This message is displayed when a cartridge other than a genuine Mutoh cartridge has been installed.
Sequence 1-1

EXA1080
Switch off the printer temporarily and check that the message is displayed when you switch on again. Check whether you are using the specified ink cartridge. Use the printers self-diagnostic Sensor: Cartridge to make sure that the ink cartridge status detection is working correctly. If normal detection fails, the ink ID sensor assembly, junction board assembly, ink ID cable, or main board assembly may be at fault. Check the ink ID sensor assembly connector contacts. Reconnect junction board assembly connectors J406 (Ink ID Sensor 1 BK), J407 (Ink ID Sensor 2 C), J408 (Ink ID Sensor 3 M), J409 (Ink ID Sensor 4 Y), J412 (Ink ID Sensor 5), J413 (Ink ID Sensor 6). If there is no change, move to the next step. Using the printers self-diagnostic Sensor: Cartridge, exchange the position of the connector of the ink ID sensor assembly that is shown as being faulty with the position of any one of J406 to J409, J412 and J413 on the junction board assembly that appears to be normal. If after re-inserting the connectors a different ink cartridge unit now appears to be faulty, it means that the ink ID sensor assembly that was shown as being faulty is damaged. Replace the faulty ink ID sensor assembly. If after re-inserting the connectors there is no change in the part that was shown as being faulty, or all units are shown as being faulty, the damage may be between the junction board assembly and the main board assembly. Check the ink ID cable contacts. Reconnect junction board assembly connector J401 (INK ID Cable) and main board assembly connector J109 (INK ID). Replace the ink ID cable and repeat procedures 1-3 and 1-4. (a) If the fault display is cleared, it means that the ID cable may be faulty. Replace the ink ID cable. (b) If there is no change at all in the symptoms, it means that the junction board assembly or the main board assembly may be faulty. Replace the junction board assembly. Replace the main board assembly.
1-2 1-3
1040
1-4
1340
1-5
1340
1-6
1-7
1470 1470 1140
EXA1080
71

No. 1 Symptom [65YMCK] Ink Low This message is displayed when the amount of ink shown on the operating panel is low. Printing can continue. (Refer to GID2010 for details) [65YMCK] No Ink This message is displayed when the ink shown on the operating panel has been used up. If this message appears while an image is being printed, stop printing immediately. (Refer to GID2010 for details)
Sequence

EXA1090
1-1
Check the no ink cartridge with the printer's self-diagnostic "Sensor: No Ink". Remove all cartridges and gently switch the detector assemblies (BK, C, M and Y) (black plastic levers) on and off to confirm that the displays Sensor: No Ink K (black), Sensor: No Ink C (cyan), Sensor: No Ink M (magenta) and Sensor: No Ink Y (yellow) change. Check the detector assembly connector contacts. Reconnect junction board assembly connector J402 (Detector Assembly BK), J403 (Detector Assembly C), J404 (Detector Assembly M), J410 (Detector1 Assembly [O/5]), J411 (Detector2 Assembly [G/6]). If there is no change, move to the next step. Exchange the position of the connector of the ink detector assembly for the ink for which Ink Low or No Ink is indicated with the position of any one of J402 to J405, J410 and J411 on the junction board assembly that appears to be normal. If after re-inserting the connectors a different ink now appears to be No Ink, it means that the detector assembly is damaged. Replace the detector assembly. If after re-inserting the connectors there is no change in the No Ink display, or No Ink is shown for all inks, the damage may be between the junction board assembly and the main board assembly. Check the ink ID cable contacts. J401 (ink ID cable) on the junction board assembly and J109 (INK ID) on the main board assembly. Disconnect and reconnect them. Replace the ink ID cable and repeat procedure 1-3. (a) If the fault display is cleared, it means that the ID cable may be faulty. Replace the ink ID cable. (b) If there is no change at all in the symptoms, it means that the junction board assembly or the main board assembly may be faulty. Replace the junction board assembly. Replace the main board assembly.
1040
1-2 2
1350
1-3
1350
1-4
1-5
1470
1470 1140
EXA1090
72

No. 1 Symptom [65YMCK] No Cartridge This message indicates that the ink cartridge that is shown on the operating panel is missing.
Sequence

EXA1100
1-1 1-2
Switch off the printer temporarily and check that the message is displayed when you switch on again. Check the no ink cartridge with the printer's self-diagnostic "Sensor: No Ink". Remove all the cartridges and, using an object with a flat tip such as a ball pen, press the switch that detects the presence of the cartridge that is to be checked (these switches are inside the cartridge frame assembly.)
With Sensor: No Cartridge, the following is displayed when all cartridges are removed: Sensor: No Cartridge KCMYOG and the following is displayed when the switch that detects whether the black cartridge is present is pressed: Sensor: No Cartridge CMYOG The same applies to the other cartridges C, M and Y. (Reference) The differences between error messages shown to the user and messages shown by "Test" and "Sensor" diagnostic modes are as follows. Diagnostic mode display O G Cartridge position No. 5 No. 6 5 6
1330
1040
Display to user
CAUTION: Take care. You can be hurt by the ink filling needle when you operate the switch showing whether there is ink in the cartridge frame assembly. For safety, work with the cartridge cover removed.
1-3
Check the cartridge frame assembly connector contacts. Reconnect junction board assembly connector J402 (Detector Assembly BK), J403 (Detector Assembly C), J404 (Detector Assembly M), J410 (Detector1 Assembly [O/5]), J411 (Detector2 Assembly [G/6]). If there is no change, move to the next step. Continued on next page
1350
EXA1100
73

No. 1 Symptom [65YMCK] No Cartridge This message indicates that the ink cartridge that is shown on the operating panel is missing.
Sequence

EXA1101
1-4
Exchange the position of the connector of the cartridge detector assembly for the cartridge for which No Cartridge is indicated with the position of any one of J402 to J405, J410 and J411 on the junction board assembly that appears to be normal. If after re-inserting the connectors a different ink now appears to have No Cartridge, it means that the detector assembly is damaged. Replace the detector assembly. If after re-inserting the connectors No Cartridge appears, or No Cartridge is shown for all cartridges, the damage may be between the junction board assembly and the main board assembly. Reference: Take care when you are replacing the detector assembly that senses whether there is a cartridge present. It can become damaged by overtightening the attaching screw.
1350
1-5
Check the ink ID cable contacts. Reconnect junction board assembly connector J401 (INK ID Cable) and main board assembly connector J109 (INK ID). Replace the ink ID cable and repeat procedure 1-4. If the No Cartridge display is cleared, it means that the Ink ID may be faulty. Replace it. If there is no change in the symptoms, it means that the junction board assembly or the main board assembly may be faulty. Replace the junction board assembly. Replace the main board assembly.
1-6
1-7
1470 1140
EXA1101
74

No. 1 Symptom Capping position not specified The capping position was not displayed at the time of initialization.
Sequence

EXA1110
1-1
Adjust the capping position by running the printer's self-diagnostic "Adjust: Capping position". If the capping position parameter is changed for some reason you will not be able to shift to the next adjustment task so the capping position adjustment should be done first. Check whether the parameters are set to the initial values by running the printer's selfdiagnostic "Adjust: Test print" to output the parameters that have been set. Refer to the functions and operations manual for the initial values of parameters. If the parameters have been restored to their initial values, please contact the "Inquiry desk" and quote your printer serial number to obtain a setup list for the time your printer was shipped from the factory. Enter all parameters in accordance with the setup list. (See PAT4000) The main board assembly may be damaged. Replace it. 1140
2010
1-2
2150
1-3
EXA1110
75

No. 1 Symptom Not Filled This message means "Initial filling has not been done".
Sequence

EXA1120
1-1
With the specified cartridge inserted securely, use the printer's self-diagnostic mode "Sensor: No Ink" or "Sensor: No Cartridge" to check whether the presence of ink and cartridge are being detected normally. For checking, use the [65YMCK] No Ink procedure shown in EXA1090. After adjustment and replacement, carry out initial filling with the printers self-diagnostic Adjust: Enter Rank. With the specified cartridge inserted securely, use the printer's self-diagnostic mode "Sensor: Cartridge" to check whether the status of the special cartridge is operating normally. For checking, use the Insert Special Cartridge procedure shown in EXA1080. After adjustment and replacement, carry out initial filling with the printers self-diagnostic Adjust: Enter Rank.
1040
2040
1-2
1040
2040
CAUTION:
Wait at least 30 minutes after initial filling before printing. Printing quality can not be assured unless ink filling has been stabilized.
EXA1120
76

No. 1 Symptom No Waste Fluid Box This message means that the waste fluid box is not installed.
Sequence

EXA1130
1-1
Switch off the printer temporarily and check that the message is displayed when you switch on again. Use the printer's self-diagnostic "Sensor: Tank Exist/Tank is not" to make sure that the waste fluid box detection is working normally. Slowly remove and replace the waste fluid box to confirm that the present/absent display appears. If the display is not normal, the sensor position may be faulty. Remove the R Cover and adjust the position of the waste fluid box detection switch assembly. Make sure the waste liquid box is making contact. Reconnect main board assembly connector J105 (INK TANK). The waste fluid box detection switch assembly may be faulty. Replace it. 1120 The main board assembly may be damaged. Replace it. 1140 1040
1-2
1120
1-3
1-4
1-5
EXA1130
77

No. 1 2 Symptom Check Waste Fluid Box Waste Fluid Box Full These messages mean that the waste fluid box is filled with waste fluid.
Sequence

EXA1140
1-1
Switch off the printer temporarily and check that the message is displayed when you switch on again. Use the printer's self-diagnostic "Sensor: Tank Exist/Tank is not" to make sure that the waste fluid box detection is working normally. Slowly remove and replace the waste fluid box to confirm that the present/absent display appears. If the display is not normal, the sensor mounting position may be at fault. Remove the R Cover and adjust the mounting position of the waste fluid box detection switch assembly. Make sure the waste liquid box is making contact. Reconnect main board assembly connector J105 (INK TANK). The waste fluid box detection switch assembly may be faulty. Replace it. 1120 The main board assembly may be damaged. Replace it. 1140 1040
1-2
1120
1-3
1-4
1-5
EXA1140
78

No. 1 Symptom Ink Type Error This message is displayed when the wrong type of ink cartridge has been installed.
Sequence

EXA1150
1-1
Use the printer's self-diagnostic "Sensor: Cartridge" to check the ink type. Install all cartridges and check that all six colors have the same type of ink. Sensor: K C M Y O G
1040
Depending on the ink type, the following symbols will be displayed at locations _. D P W N 1-2 : : : : Dye type ink cartridge installed Pigment type ink cartridge installed Wash fluid cartridge installed Other ink cartridge installed
Make sure the detector assembly connector is making contact. Reconnect junction board assembly connectors J406 (INK ID Sensor1 BK), J407 (INK ID Sensor2 C), J408 (INK ID Sensor3 M), J409 (INK ID Sensor4 Y), J412 (INK ID Sensor5), J413 (INK ID Sensor6). If there is no change, move to the next step. Check the ink ID cable contacts. J401 (ink ID cable) on the junction board assembly and J109 (INK ID) on the main board assembly. Disconnect and reconnect them. Replace the ink ID cable and repeat procedure 1-2. (a) If the fault display is cleared, it means that the ID cable may be faulty. Replace the ink ID cable. (b) If there is no change at all in the symptoms, it means that the junction board assembly or the main board assembly may be faulty. Replace the junction board assembly. Replace the main board assembly.
1-3
1-4
1470
1470 1140
EXA1150
79

No. 1 Symptom Network Detection Error The optional network board can not be detected Network Initialization Error An error has occurred during the optional network board initialization operation
Sequence
Data Errors
Items to be Confirmed The main board assembly may be damaged. Replace it. The Ethernet board assembly may be damaged. Replace it.
EXA1230
1-1
1140
1-2 2
Go to MAP1200
Data Errors
EXA1230
80

No. 1 Symptom MH01 Error (Undefined Command) A command that is not defined in any command mode has been analysed MH02 Error (Parameter Error) Wrong number of parameters following the command MH03 Error (Numerical Error) Wrong number of parameters following the command MH04 Error (Undefined Character Set) A nonexistent character set is present MH07 Error (Buffer Overflow) The polygon buffer or the downloadable character buffer has overflowed
Sequence
Command Errors
Items to be Confirmed Try communicating with the available computer and cable. Contact your Mutoh distributor. Is there any record of an error in the printing data? Try changing the type of application driver.
EXA1250
1-1
1-2 2
1-3
If the symptoms persist despite various application driver changes Obtain the printing data (Report to the your distributor after you have obtained it). The main board assembly may be damaged. Replace it. 1140
1-4
Command Errors
EXA1250
81

No. 1 Symptom E001 Error DRAM (Standard DRAM error) This error display means that a fault has occurred in the standard memory of the Main Board that controls the printer.
Sequence
CPU System Faults

Items to be Confirmed The main board assembly may be damaged. Replace it.
EXA1500
1-1
1140
E002 Error Opt. DRAM (Optional DRAM error) This error display means that a fault has occurred in the optional memory of the Main Board that controls the printer.
2-1
This error may occur when there is dust, etc. in extended memory slot 1 or slot 2. Use an air duster to remove the dust and reinstall. Install reliable memory of the same capacity and check with the self-diagnostic Examination: Memory Capacity. Replace optional memory. The main board assembly may be damaged. Replace it. 1140 1010
2-2
2-3
CAUTION:
If only one extended memory is added, it must be installed in Slot 1. (RJ-6000-43 has an extra 16 MB SIMM in Slot 1) (RJ-6000-54/62 has an extra 32 MB SIMM in Slot 1)
CPU System Faults
EXA1500
82

No.
1
CPU System Faults

Sequence
EXA1510
Symptom
E016 CPU Err [00] (Interrupt exception error) Indicates that handling an interrupt has generated an error. E016 CPU Err [02] (Command boundary exception error) Indicates that the boundary of a command has caused an error. E016 CPU Err [03] (Data boundary exception error) Indicates that the boundary of a command has caused an error. E016 CPU Err [04] (Address error exception) (Load or command check) Indicates that an address error has occurred when checking a load or command. E016 CPU Err [05] (Address error exception) (Store) Indicates that an address error has occurred when saving.
Items to be Confirmed Check AC power supply and printer peripheral devices. Contact your Mutoh distributor. Check whether the problem recurs. Even if there is no problem, switch on several times. (Use the same conditions as the customer's) Contact your Mutoh distributor. Check the serial number. Contact your Mutoh distributor. The main board assembly may be damaged. Replace it.
1-1
1-2
1-3
1-4
1140
E016 CPU Err [06] (Bus error exception) (Command check) Indicates that a bus error has occurred when loading or storing a command. E016 CPU Err [07] (Bus error exception) (Data load) Indicates that a bus error has occurred when loading or storing a command. E016 CPU Err [08] (System call exception error) Indicates that a system call has caused an error. E016 CPU Err [09] (Break point exception error) Indicates that a break point has caused an error.
CPU System Faults
EXA1510
83

No.
1
CPU System Faults

Sequence
EXA1520
Symptom
E016 CPU Err [10] (Reserved command exception error) Indicates that a reserved command has caused an error. E016 CPU Err [11] (Unable to use coprocessor exception error) Indicates that the coprocessor has caused an error. E016 CPU Err [12] (Operation overflow exception error) Indicates that an overflow has occurred. E016 CPU Err [13] (Trap exception error) Indicates that a trap has occurred. E016 CPU Err [15] (Floating point exception error) Indicates that a floating point error has occurred. E016 CPU Err [22] (Watchdog timeout exception error) Indicates that the watch has caused an error. E016 CPU Err [32] (Watchdog timeout exception error) Indicates that a watchdog timeout has occurred. E016 CPU Err [33] (Abort error) Indicates that an abort has occurred. E237 Err Transfer Memory (Transfer memory error/Transfer memory access error) Indicates that a fault has occurred in transferring printing data that has been analysed.
Items to be Confirmed Check AC power supply and printer peripheral devices. Contact your Mutoh distributor. Check whether the problem recurs. Even if there is no problem, switch on several times. (Use the same conditions as the customer's) Contact your Mutoh distributor. Check the serial number. Contact your Mutoh distributor. The main board assembly may be damaged. Replace it.
1-1
1-2
1-3
1-4
1140
4 5
8 9
CPU System Faults
EXA1520
84

No. 1 Symptom E129 Error NVRAM This message indicates that a fault has occurred in the NVRAM on the Main board that records printer settings.
Sequence
CPU System Faults

Items to be Confirmed The main board assembly may be damaged. Replace it.
EXA1530
1-1
1140
CPU System Faults
EXA1530
85

No. 1 Symptom E065 Error X Motor This message indicates that a fault has occurred in the media feed motor (X axis) while the printer was working. This occurs when there is a large difference between the motor command value and encoder feedback value. E069 Error X Encoder This message indicates that a fault has occurred in the amount of media movement (X axis) while the printer was working. This occurs when there is no encoder feedback. E071 Error X Timeout This message indicates that a timeout has occurred in the amount of media movement (X axis) while the printer was working. This occurs when the pressure does not reach its designated position. E073 Error X Overcurrent This message indicates that a fault has occurred due to an overload of the media feed (X-axis) motor while the printer was working.
Sequence

EXA1700
1-1 1-2
Use the self-diagnostic Examination: History to check the history of faults. Use the self-diagnostic Aging: Media Feed Motor with a setting of 50 times to check whether the X Motor error occurs. Check connectors J119 (X MOT) and J121 (X ENC) on the main board. Use the self-diagnostic Examination: Encoder to check Encoder X. If it is no good, check the J121 (X ENC) cable connector. Check Power Supply Voltage Check 24 DC The X Motor assembly may be damaged. Replace it. The main board assembly may be damaged. Replace it.
1070 6020
1-3
1050
1-4 1-5
1070
1-6
1140
CAUTION:
If the Power supply board assembly and Main board assembly are replaced without checking 24 V DC on those, there is a risk that the new boards may also be damaged.
EXA1700
86

No. 1 Symptom E066 Error Y Motor This message indicates that a fault has occurred in the head movement motor (Y axis) while the printer was working. This occurs when there is a large difference between the motor command value and encoder feedback value. E070 Error Y Encoder This message indicates that a fault has occurred in the amount of head movement (Y axis) while the printer was working. This occurs when there is no encoder feedback. E072 Error Y Timeout This message indicates that a timeout has occurred in the amount of head movement (Y axis) while the printer was working. This occurs when the carriage has not reached its designated position. 1-6 4 E074 Error Y Overcurrent This message indicates that a fault has occurred due to an overload of the head movement (Y axis) motor while the printer was working.
Sequence

EXA1710
1-1 1-2
Use the self-diagnostic Examination: History to check the history of faults. With power off, move the carriage to left and right. Is the movement restricted? Clean and lubricate the Y rail rollers. Use the self-diagnostic Aging: Carriage Motor with a setting of 50 times to check whether the Y Motor error occurs. Check cable connector J120 (Y MOT) on the main board. Check whether the timing fence (T fence) is dirty or twisted. If there is grease or dirt on the fence, wipe it away with a dry cloth. If there is ink on the fence, wet a cloth with neutral cleaner and wipe lightly. If the T fence is severely soiled and can not be cleaned, it should be replaced Replace the T fence. Use the self-diagnostic Examination: Encoder to check Encoder Y. If it is no good, check cable connections J112 (HEAD2) on the main board assembly and J202 (MAIN2) on the head board assembly. Replace the T fence. Replace the Y motor assembly. Replace the head board assembly. Replace the Y cable (between J112 (HEAD2) on the main board and J202 (MAIN2) on the head board) The main board assembly may be damaged. Replace it. CAUTION: Power must be off when connectors are being disconnected or reconnected, otherwise you may be injured or a board may be damaged. The main board assembly will certainly be damaged if power is applied with main board assembly connectors J111 (HEAD) and J112 (HEAD2) and head board connectors J201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP.
1070 6010
1-3
1-4
1300
1-5
1300 1280 1420 1360
1140
EXA1710
87

No. 1 Symptom E075 Error Sensor Fault This message indicates that condition has occurred in which the origin cannot be detected.
Sequence

EXA1720
1-1 1-2
Use the self-diagnostic Sensor: Origin and carry out the origin sensor test. Check the origin sensor assembly connection. J205 (H ORIGN) on the head board assembly. Reconnect properly. Check Y cable connections. Check that they are not inserted obliquely. J111 (HEAD1) on the main board assembly and J201 (MAIN1) on the head board assembly. Insert them properly. Replace the Y cable between J111 (HEAD1) and J201 (MAIN1). The origin sensor assembly may be faulty. Replace it. The main board assembly may be damaged. Replace it.
1040
1-3
1360
1-4
1450
1-5
1140
CAUTION:
EXA1720
88

No.
1 No power

EXA2000
Symptom
Sequence 1-1
Is there a broken or shorted lead in the switch cable assembly (between the switch and main borad assembly)? Use a tester to check for broken or shorted leads. Replace the switch cable assembly. The inlet assembly may be faulty. Replace it. The power board assembly may be faulty. Replace it. Check the power supply check 120V AC or 240V AC. (Differs according to sales region.) Check the power supply voltage 5 V DC. Check the power supply voltage 24, 42 V DC. Check the connections of the panel cable connectors on the panel board assembly and main board assembly. Check that they are not inserted obliquely and that they are securely locked. Reconnect main board assembly connector J110 (PANEL) and panel board assembly connector J301 (MAIN). The panel cable may be faulty. Replace it. Is there a fault in the panel board assembly liquid crystal display? Replace the panel board assembly. The main board assembly may be damaged. Replace it. CAUTION: Power must be off when connectors are being disconnected or reconnected, otherwise you may be injured or a board may be damaged. The main board assembly will certainly be damaged if power is applied with main board assembly connectors J111 (HEAD) and J112 (HEAD2) and head board connectors J201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP.
1130
1-2 1-3 2 Faulty liquid crystal display (no display/unstable display) 2-1 2-2 2-3 2-4
1150
2-5 2-6 2-7
1170 1160 1140
EXA2000
89

No. 1 Symptom Initial filling of inks failed This symptom means that when new cartridges are first installed, or when a new cartridge is fitted as a result of a "no ink" message, the initial filling operation is not performed. Initial filling begins but the ink does not reach the head or it reaches the head but is not ejected. Go to EXA2020
Sequence 1-1

EXA2010
With the printer cover closed, is the liquid crystal display showing cover open? Adjust cover switch height. Check cover switch assembly connector. J106 (COVER) on the panel board assembly Replace cover switch assembly. Check panel cable connectors. Reconnect main board assembly connector J110 (PANEL) and panel board assembly connector J301 (MAIN). Replace them. With the hold lever down, is the liquid crystal display showing lever up? Adjust the lever sensor. Check J104 (LEVER) cable connection on the main board. Re-insert it. Replace the lever sensor assembly. With the specified cartridge inserted securely, use the printer's self-diagnostic mode "Sensor: No Ink" or "Sensor: No Cartridge" to check whether the presence of ink and cartridge are being detected normally. Check using EXA1100 [65YMCK] No Cartridge procedure. After adjustment or replacement, implement initial filling with the printer's self-diagnostic "Adjust: Head Rank". With the specified cartridge inserted securely, use the printer's self-diagnostic mode "Sensor: Cartridge" to check whether the status of the special cartridge is operating normally. Check using EXA1080 "Insert special cartridge" procedure. After adjustment or replacement, implement initial filling with the printer's self-diagnostic "Adjust: Head Rank". The main board assembly may be damaged. Replace it. After replacement, start self-diagnostic mode and carry out initial filling from Head Rank menu. CAUTION: Wait at least 30 minutes before printing after initial filling. Printing quality can not be assured unless the ink filling is stabilized.
1110
1-2
1170 1100
1-3 1-4
1-5
1040 2040
1-6
1040 2040
1-7
1140
2040
EXA2010
90

Sequence 1-1

EXA2020
Is the cap assembly spring fallen out or broken? If it has fallen out, refit it. If it is broken, replace the cap assembly. Is the capping position correct? Adjust the capping position and check that the ink flows during cleaning. If ink flows, carry out initial filling. Are the pump assembly tubes connected to the cap assembly tubes? Insert the pump assembly tubes into the cap assembly tubes. Is there any looseness in the head unit, the flexible cable keeper unit under the head board, the ink tubes behind the cartridge unit, or the SUS pipe connectors (Bk, Y, M, C, Lm, Lc)? Check that the O-rings are fitted properly. Remove the head cover and check the damper assemblies at the base of the tubes for all four black and color ink tubes. Remove the Y Rail cover and cartridge cover and check the flexible cable keeper unit under the head board assembly and the sides of the cartridge. Is there an air leak in the damper assembly shield unit? Replace the damper assembly and check that ink flows during the cleaning action. If ink flows, carry out initial filling. Are the ink tubes damaged inside the pump assembly? Replace the pump assembly and check that ink flows during the cleaning action. If ink flows, carry out initial filling. Is the pump motor turning during the cleaning action? Check the pump motor cable connector J102 (PUMP MOT) on the main board and try again. Replace the pump motor. If the pump motor does not turn after performing the above tasks, replace the main board assembly. Was there any mismatching of gears during the cleaning operation? Replace the maintenance station assembly. Was the transfer gear shaft damaged during cleaning? Replace the maintenance station assembly. Continued on next page
1240
1-2
1-3 1-4
1-5
1430 2040 1260 2040
1-6
1-7
1230 1140 1270 1270
1-8 1-9
EXA2020
91

Sequence 1-10 1-11

EXA2021
Are there any breaks, cuts or air leaks in the ink tubes? Change each ink tube, cleaning each time and checking that ink flows during cleaning. Check that connectors J207 (HEAD C1) and J208 (HEAD C2) on the head board assembly, and head cables on the print head are not inserted obliquely, and they are locked securely. Insert the connectors again. Is there a broken lead in head cables? Replace head cables. Is the print head assembly damaged? Replace the print head assembly.
1370
1-12 1-13 1-14 1-15
1400
1390 Is the head board assembly damaged? Replace it. Check that the Y cable connector is connected securely and not inserted obliquely. Reconnect head board assembly connectors J201 (MAIN1) and J202 (MAIN2) and main board assembly connectors J111 (HEAD1) and J112 (HEAD 2). Is there a broken lead in Y cables? Replace Y cables. The main board assembly may be damaged. Replace it. 1360 1140 1420
1-16 1-17
CAUTION:
EXA2021
92

No. 1 Symptom After power is switched on, nothing works If nothing is displayed on the panel liquid crystal display unit. Go to EXA2000
1-2 Sequence 1-1

EXA2030
With the printer cover closed, is the liquid crystal display showing cover open? Does the cover switch assembly function work normally with the self-diagnostic Examination/Sensors? Adjust cover switch assembly height. Check cover switch assembly connector and J106 (COVER) on the panel board assembly. Replace cover switch assembly. 1110 Check panel cable connectors. Check that they are not inserted obliquely and they are securely locked. Reconnect the main board assembly connector J110 (PANEL) and the panel board assembly J301 (MAIN). Replace them. With the hold lever down, is the liquid crystal display showing lever up? Check the lever sensor connector J104 (LEVER) on the main board assembly. Replace the lever sensor assembly. Check J104 (LEVER) cable connection on the main board assembly. Re-insert it. Replace the lever sensor assembly. 1100 Does the XR cable assembly (rear paper sensor) detect normally with the self-diagnostic Examination/Sensors? Check the connections of the paper sensor connectors J107 (XR) on the main board assembly. Replace the XR cable assembly (rear paper sensor). Carry out 5 V DC Power Supply Check and 24, 42 V DC Power Supply Check Replace the power board assembly. Is the cable of the switch cable assembly connected properly to J100 (MAIN SW) on the main board assembly? (Refer to EXA2000) Reconnect it. The switch cable board assembly may be faulty. Replace it. Continued on next page 1130 1150
1040
When power is applied, Initializing appears and then a reset is executed. Media is mounted but the initialization operation is not done Printer does not work even with the cover closed Printer does not stop even with the cover opened.
1-3
1170 1110
1-4
1-5
1190 1200
1-6 1-7
1-8
EXA2030
93

No. 1 Symptom After power is switched on, nothing works If nothing is displayed on the panel liquid crystal display unit. Go to EXA2000 2 When power is applied, Initializing appears and then a reset is executed. Media is mounted but the initialization operation is not done Printer does not work even with the cover closed Printer does not stop even with the cover opened.
Sequence

EXA2031
1-9
Is the DC cable assembly connected properly to J001 on the power board assembly and J101 (MAIN POWER) on the main board assembly? (See EXA2000) Reconnect it. Replace it. The main board assembly may be damaged. Replace it.
1130
1-10
1140
EXA2031
94

No. 1 Symptom Ink cartridges are installed but not recognized
Sequence

EXA2040
1-1
With the specified cartridge inserted securely, use the printer's self-diagnostic mode "Sensor: No Ink" or "Sensor: No Cartridge" to check whether the presence of ink and cartridge are being detected normally. Check using EXA1100 [65YMCK] No Ink procedure. After adjustment or replacement, implement initial filling with the printer's self-diagnostic "Adjust: Head Rank". With the specified cartridge inserted securely, use the printer's self-diagnostic mode "Sensor: Cartridge" to check whether the status of the special cartridge is operating normally. Check using EXA1080 "Insert special cartridge" procedure. After adjustment or replacement, implement initial filling with the printer's self-diagnostic "Adjust: Head Rank". CAUTION: Wait at least 30 minutes after initial filling before printing. Printing quality can not be assured unless ink filling has been stabilized.
1350
1040
2040
1-2
1040
2040
EXA2040
95

No. 1 Symptom Can not make entries from the operating panel
Sequence

EXA2050
1-1
Is the panel cover key input unit broken? Replace the panel cover. Check the panel cable connectors. Check that they are inserted obliquely and securely locked. Reconnect main board assembly connector J110 (PANEL) and panel board assembly connector J301 (MAIN). Replace the panel cable. The panel board assembly may be damaged. Replace the panel board assembly. The main board assembly may be damaged. Replace the main board assembly.
1-2
1170 1160
1-3
1-4
1140
EXA2050
96

No. 1 Symptom Data is received but not printed
Sequence

EXA2060
1-1
For checking, use Cannot connect normally with Centronics or Ethernet Board procedures shown in EXA7000.
EXA2060
97

No. 1 Symptom Media is not suction
Sequence

EXA2070
1-1
Are the media suction fans turning? If they are not turning, go to consultation 1-4. Are XR cable assembly (rear paper sensor) and edge sensor detecting normally according to the self-diagnostic sensor test? Check the connections of XR cable assembly and edge sensor. XR cable assembly is the main board assembly J107 (XR). Edge sensor is the head board assembly J204 (P EDGE). Replace XR cable assembly and edge sensor. Are the fans working normally according to the self-diagnostic test? Check the connectors between fan assembly, fan extension cable assembly and main board assembly. Fan extension cable 1 assembly is J115 (FAN1) on the main board Fan extension cable 2 assembly is J116 (FAN2) on the main board Fan extension cable 3 assembly is J117 (FAN3) on the main board Replace fan assembly. Replace fan extension cable 1 ~ 3. Is shielding material fixed securely in the specified places? Shield GA-A, Shield GA-B, Shield GA-C Refit shielding securely. Is +24 V being output between Pin 11 (GND) and Pin 10 (+24V) of connector J001 on the power board assembly? Carry out the "24 V and 42 V power voltage check". The main board assembly may be damaged. Replace it. 1040
1-2
1190 1200
1-3
1060
1080
1-4
1-5
1-6 1-7
1140
EXA2070
98

No. 1 Symptom Media is not suction
Sequence

EXA2070-2
1-1
Are the media suction fans turning? If they are not turning, go to consultation 1-4. Are XR cable assembly (rear paper sensor) and edge sensor detecting normally according to the self-diagnostic sensor test? Check the connections of XR cable assembly and edge sensor. XR cable assembly is the main board assembly J107 (XR). Edge sensor is the head board assembly J204 (P EDGE). Replace XR cable assembly and edge sensor. Are the fans working normally according to the self-diagnostic test? Check the connectors between fan assembly, fan extension cable assembly and main board assembly. Fan extension cable 1 assembly is J115 (FAN1) on the main board Fan extension cable 2 assembly is J116 (FAN2) on the main board Fan extension cable 3 assembly is J117 (FAN3) on the main board Fan extension cable 4 assembly is J118 (FAN4) on the main board Replace fan assembly. Replace fan extension cable 1 ~ 4. Is shielding material fixed securely in the specified places? Shield GA-A, Shield GA-B, Shield GA-C Refit shielding securely. Is +24 V being output between Pin 11 (GND) and Pin 10 (+24V) of connector J001 on the power board assembly? Carry out the "24 V and 42 V power voltage check". The main board assembly may be damaged. Replace it. 1040
1-2
1190 1200
1-3
1060
1080
1-4
1-5
1-6 1-7
1140
EXA2070-2
99

No. 1 Symptom The media comes off when it is initialized or during printing The media is skewed or meanders when it is initialized or during printing The media becomes wrinkled when it is initialized or during printing The media jams when it is initialized or during printing The media tears when it is initialized or during printing
1-3 1-2 Sequence 1-1

EXA3000
Are XR cable assembly (rear paper sensor) and edge sensor detecting normally according to the self-diagnostic sensor test? Check the connections of XR cable assembly and edge sensor. XR cable assembly is the main board assembly J107 (XR). Edge sensor is the head board assembly J204 (P EDGE). Replace XR cable assembly and edge sensor. Are the fans working normally according to the self-diagnostic test? Check the connectors between fan assembly, fan extension cable assembly and main board assembly. Fan extension cable 1 assembly is J115 (FAN1) on the main board Fan extension cable 2 assembly is J116 (FAN2) on the main board Fan extension cable 3 assembly is J117 (FAN3) on the main board Replace fan assembly. Replace fan extension cable 1 ~ 3. Is shielding material fixed securely in the specified places? Shield GA-A, Shield GA-B, Shield GA-C Refit shielding securely. When the pressure lever is raised and lowered, does the pressure unit move up and down smoothly at the same time? Apply grease (G-501) if it does not move smoothly. Is the pressure roller pressing on the media over its entire length? With the pressure lever up, does the pressure rollers seem reluctant to turn? With the pressure lever down, does the pressure rollers idle or contact the platen on one side? With the pressure lever down, is the blade pressing firmly on the media? If there are paper dust or scraps near the pressure roller, wipe with soft damp cloth. If necessary, replace pressure assembly, pressure rollers and blade. If the gap between platen and plate is less than 0.2 mm, adjust platen height.
1040 1200 1410 1060
1080
1-4
1220
1-5
1220 1520 1040
1-6 1-7
Is there major distortion, damage or foreign matter on the front and rear paper guides? Replace front and rear paper guides. Are the adjustment of scroller position and fitting of flanges correct? Adjust scroller position correctly. Fit flanges correctly into the core of the roll media. Is there major distortion or damage to the grid roller? Replace the grid roller.
1-8
1690
EXA3000
100

No. 1 Symptom The media comes off when it is initialized or during printing The media is skewed or meanders when it is initialized or during printing The media becomes wrinkled when it is initialized or during printing The media jams when it is initialized or during printing The media tears when it is initialized or during printing
1-2 Sequence 1-1

EXA3000-2
Are XR cable assembly (rear paper sensor) and edge sensor detecting normally according to the self-diagnostic sensor test? Check the connections of XR cable assembly and edge sensor. XR cable assembly is the main board assembly J107 (XR). Edge sensor is the head board assembly J204 (P EDGE). Replace XR cable assembly and edge sensor. Are the fans working normally according to the self-diagnostic test? Check the connectors between fan assembly, fan extension cable assembly and main board assembly. Fan extension cable 1 assembly is J115 (FAN1) on the main board Fan extension cable 2 assembly is J116 (FAN2) on the main board Fan extension cable 3 assembly is J117 (FAN3) on the main board Fan extension cable 4 assembly is J117 (FAN4) on the main board Replace fan assembly. Replace fan extension cable 1 ~ 4. Is shielding material fixed securely in the specified places? Shield GA-A, Shield GA-B, Shield GA-C Refit shielding securely. When the pressure lever is raised and lowered, does the pressure unit move up and down smoothly at the same time? Apply grease (G-501) if it does not move smoothly. Is the pressure roller pressing on the media over its entire length? With the pressure lever up, does the pressure rollers seem reluctant to turn? With the pressure lever down, does the pressure rollers idle or contact the platen on one side? With the pressure lever down, is the blade pressing firmly on the media? If there are paper dust or scraps near the pressure roller, wipe with soft damp cloth. If necessary, replace pressure assembly, pressure rollers and blade. If the gap between platen and plate is less than 0.2 mm, adjust platen height.
1040 1200 1410 1060
1080
1-3
1-4
1220
1-5
1220 1520 1040
1-6 1-7
Is there major distortion, damage or foreign matter on the front and rear paper guides? Replace front and rear paper guides. Are the adjustment of scroller position and fitting of flanges correct? Adjust scroller position correctly. Fit flanges correctly into the core of the roll media.
EXA3000-2
101

No. 1 Symptom The media size is different after media mounting and initialization Tracing paper and thin media cannot be detected 1-2
Sequence

EXA3010
1-1
Is the media mounted recommended by Mutoh? If it is not media recommended by Mutoh (especially thin tracing paper, etc.), the paper sensors may read incorrectly and be unable to recognize the media. Mount recommended media and try again. Are XR cable assembly (rear paper sensor) and edge sensor detecting normally according to the self-diagnostic sensor test? Check the connections of XR cable assembly and edge sensor. XR cable assembly is the main board assembly J107 (XR). Edge sensor is the head board assembly J204 (P EDGE). Replace XR cable assembly and edge sensor. Use the printer's self-diagnostic Sensor: Edge to confirm the amount of sensor reflection. Using thick coated paper, check whether the paper detection value is within 0090 to 00a4. Check edge sensor connector and head board assembly connector J204 (PEDGE). Adjust the detection value with the head board assembly variable resistor. Replace edge sensor assembly. 1040 1200 1410 1040
1-3
1410
1-4 Check the Y cable connectors. Check that they are not inserted obliquely. Reconnect main board assembly connector J111 (HEAD1) and head board assembly connector J201 (MAIN1). Replace the Y cable. 1-5 The main board assembly may be damaged. Replace it. CAUTION: Power must be off when connectors are being disconnected or reconnected, otherwise you may be injured or a board may be damaged. The main board assembly will certainly be damaged if power is applied with main board assembly connectors J111 (HEAD) and J112 (HEAD2) and head board connectors J201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP.
1360
1140
EXA3010
102

No. 1 Symptom Does not print continuously
Sequence

EXA4000
1-1
Is there a problem with the printer driver software? Upgrade the printer driver version. Is there a problem with the program ROM? Upgrade the version. The main board assembly may be damaged. Replace it.
1-2
1-3
1140
EXA4000
103

No. 1 Symptom There is an extra feed after printing is finished
Sequence

EXA4010
1-1
Is XR cable assembly (rear paper sensor) detecting normally according to the self-diagnostic sensor test? Check the connections of XR cable assembly and main board assembly J107 (XR). Replace XR cable assembly. Is there a problem with the printer driver software? Upgrade the printer driver version. Is there a problem with the program ROM? Upgrade the version. The main board assembly may be damaged. Replace it.
1040 1200 1200
1-2
1-3
1-4
1140
EXA4010
104

No. 1 Symptom Dots are missing from the printing
Bad example

EXA4020
Sequence 1-1 1-2 Clean twice in succession. Are the ink tubes filled with ink? Carry out initial filling. CAUTION: 1-3 1-4
2050 or PAT1000
Wait at least 30 minutes after initial filling before printing. Printing quality can not be assured unless ink filling has been stabilized.
Print the self-diagnostic Printing: Nozzle Check Pattern and the Test Printing. If the nozzle check pattern is printed normally, go to EXA4060. Does the pump motor turn during the cleaning operation? Check the connection of pump motor assembly connector and J102 (PUMP) on the main board assembly. Replace the pump motor assembly. If the pump motor still does not turn, replace the main board assembly. Are the gears and transfer gear shaft broken or badly meshed during the cleaning operation? Replace the maintenance station assembly. Is the cap assembly spring fallen out or broken? If it has fallen out, refit it. If it is broken, replace the cap assembly of the maintenance station assembly. Is the capping position correct? Adjust the capping position, carry out strong cleaning and try again. What is the condition of the wiper section? Dampen the accessory cleaning cloth slightly with clean water and use it to wipe the surface of the cleaning wiper. After the wiper has been cleaned, carry out two successive cleanings. If it is wet with ink, replace it. Are the nozzle surfaces being wiped and rubbed? Check how the wiper is fitted and fasten it correctly. Does the head that is fitted have a rank that is different from the recorded rank? Re-enter the rank of the head correctly. Continued on next page 1250
Good example
1230 1140 1270 1240 1270
1-5 1-6
Cleaning does not cure clogging or deflection

Clogging: There is a discontinuity in line G of the Test Print.
1-7 1-8
Deflection: There is a deflection or offset in the step pattern in line G of the Test Print.
1-9 1-10
1250 2040 1390
EXA4020
105

No. 1 Symptom Dots are missing from the printing
Bad example

EXA4021
Sequence 1-11
Has ink dried on the surface of the print head and inside the nozzles? Use the self-diagnostic Adjustment: Head Cleaning to clean the print head, carry out initial filling with Adjustment: Head Rank and try again. Clean the head nozzle face. CAUTION: Wait at least 30 minutes after initial filling before printing. Printing quality can not be assured unless ink filling has been stabilized.
1620 1660
1-12
Good example
Check that the T-fence and Encoder behind the head board assembly are not touching. If they are touching, adjust them. If adjustment is not effective, replace both the head board assembly and the T-fence. Are the tubes crushed inside the pump assembly? Replace the pump assembly and check the ink flow. If it is good, carry out initial filling. Is the print head assembly damaged? Replace the obstructed print head assembly. The main board assembly may be damaged. Replace it.
1420 1300 1260
1-13 1-14 1-15
1390 1400 1140
Cleaning does not cure clogging or deflection

Clogging: There is a discontinuity in line G of the Test Print.
Deflection: There is a deflection or offset in the step pattern in line G of the Test Print.
EXA4021
106

No. 1 2 Symptom Does not print at all Does not print a specific color
Bad example
1-3 Sequence 1-1 1-2

EXA4030
Check 24, 42 V DC Power Supply Check. Is the cap assembly spring fallen out or broken? If it has fallen out, refit it. If it is broken, replace the cap assembly. Is the capping position correct? Adjust the capping position and use the cleaning operation to check ink flow. If ink flow is confirmed, carry out initial filling. Check the Y cable connections. Check that they are not inserted incorrectly. J201 (MAIN1) and J202 (MAIN2) on the head board J114 (HEAD1) and J115 (HEAD2) on the main board Reconnect main board assembly connector J111 (HEAD1) and head board assembly connectors J201 (MAIN1) and J202 (MAIN2). Replace both Y cables. Is there any looseness in the head unit, the flexible cable keeper unit under the head board assembly, the ink tubes behind the cartridge unit, or the SUS pipe connectors (Bk, Y, M, C, Lm and Lc)? Check that the O-rings are fitted properly. Remove the head cover and check the damper. Remove the Y Rail cover and cartridge cover and check the flexible cable keeper unit under the head board assembly and the sides of the cartridge. 1240
1-4
1360
1-5
Good example
1-6
Is there an air leak in the damper assembly shield unit? Replace the damper assembly and check that ink flows during the cleaning action. If ink flow is confirmed, carry out initial filling. Are the ink tubes damaged inside the pump assembly? Replace the pump assembly and check that ink flows during the cleaning action. If ink flow is confirmed, carry out initial filling. Is there an air leak in the ink tubes? Replace each ink tube, cleaning each time to check for ink flow. If ink flow is confirmed, carry out initial filling. CAUTION: Wait at least 30 minutes after initial filling before printing. Printing quality can not be assured unless ink filling has been stabilized. Continued on next page
1430
1-7
1260
1-8
1370
EXA4030
107

No. 1 2 Symptom Does not print at all Does not print a specific color
Bad example
1-10 Sequence 1-9

EXA4031
With the specified cartridge inserted securely, use the printer's self-diagnostic mode "Sensor: No Ink" or "Sensor: No Cartridge" to check whether the presence of ink and cartridge are being detected normally. Check using EXA1100 [65YMCK] No Cartridge procedure. After adjustment or replacement, implement initial filling with the printer's self-diagnostic "Adjust: Head Rank". Check the connections of head cables 1 and 2. Check that they are not inserted obliquely and they are securely locked. J207 (HEAD BK), J208 (HEAD COL) on the head board assenmbly Reconnect head board assembly connectors J207 (HEAD C1) and J208 (HEAD C2). Replace head cables 1 and 2. Is the head board assembly damaged? Replace it. Is the main board assembly damaged? Replace it. Is the print head assembly damaged? Replace the print head assembly. Is the pump motor turning during the cleaning action? Check the pump motor cable connector J102 on the main board. Replace the pump motor. If the pump motor does not turn after performing the above tasks, replace the main board assembly. Was there any gear damage or mismatching of gears during the cleaning operation? Replace the pump assembly. Was the transfer gear shaft damaged during cleaning? Replace the maintenance station assembly. CAUTION: Power must be off when connectors are being disconnected or reconnected, otherwise you may be injured or a board may be damaged. The main board assembly will certainly be damaged if power is applied with main board assembly connectors J111 (HEAD) and J112 (HEAD2) and head board connectors J201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP.
1040
2040
1390 1420 1140 1390
1-11 1-12 1-13
Good example
1-14
1230 1260 1270
1-15 1-16
EXA4031
108

No. 1 Symptom The entire surface is printed black
Bad example
Sequence

EXA4040
1-1
Check the connections for head cables 1 and 2. Check that they are not inserted obliquely and they are locked securely. Reconnect the head board assembly connectors J207 (HEAD C1) and J208 (HEAD C2). Replace the connectors. Check the Y cable connections Check that they are not inserted obliquely. Reconnect main board assembly connectors J111 (HEAD1) and J112 (HEAD2), and head board assembly connectors J201 (MAIN1) and J202 (MAIN@). Replace both Y cables.
1390
1-2
1360 1-3
Good example
The head board assembly may be damaged. Replace it. 1420 The head head assembly may be damaged. Replace the print head assembly. 1390 The main board assembly may be damaged. Replace it.
1-4
1-5 1140 CAUTION: Power must be off when connectors are being disconnected or reconnected, otherwise you may be injured or a board may be damaged. The main board assembly will certainly be damaged if power is applied with main board assembly connectors J111 (HEAD) and J112 (HEAD2) and head board connectors J201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP.
EXA4040
109

No. 1 2 3 Symptom Printing becomes shaded. The image contains blurs. Transverse lines appear to be split.
Shading and blurring Direction of media feed Split line

EXA4050
Sequence 1-1 1-2
Is the usage site environment in accordance with the operating environment? Use the printer in a proper operating environment. Was the printing done immediately after initial filling? Wait at least 30 minutes after initial filling before printing. Printing quality can not be assured unless ink filling has been stabilized. Is the capping position correct? Adjust the capping position, carry out strong cleaning and try again. Are the fans working normally according to the self-diagnostic Examination: Fan? Check the connectors between fan assembly, fan extension cable assembly and main board assembly. Fan extension cable 1 assembly is J115 (FAN1) on the main board Fan extension cable 2 assembly is J116 (FAN2) on the main board Fan extension cable 3 assembly is J117 (FAN3) on the main board Replace fan assembly. Replace Fan extension cables 1 ~ 3. Is the shielding material securely attached in the proper positions? Shield material GA-A, shield material GA-B, shield material GA-C Re-attach in the proper positions. If the media in question is roll media, does the scroller rotate smoothly? Adjust the position of the scroller support rollers. Replace any roller that is damaged or that moves badly. Is the X speed reduction belt tension adjusted to the prescribed value? 41.2 N (4.2 kg 0.2 Kg). What is the condition of the wiper section? Dampen the accessory cleaning cloth slightly with clean water and use it to wipe the surface of the cleaning wiper. After the wiper has been cleaned, carry out two successive cleanings. If it is wet with ink, replace it. Are the nozzle surfaces being wiped and rubbed? Carry out repairs. Replace the wiper. 1560
1-3 1-4
1060
Black and white lines appear in the printed image (Not including gaps in the step patterns in locations 1G to 7G of the test pattern) If dots are missing, go to EXA4020
Bad example
1080 1080
1-5
1-6
1-7 1-8
Direction of media feed
1250
Good example
1-9
1250
Continued on next page (EXA4051)
EXA4050
110


EXA4050-2
Sequence 1-1 1-2
Is the usage site environment in accordance with the operating environment? Use the printer in a proper operating environment. Was the printing done immediately after initial filling? Wait at least 30 minutes after initial filling before printing. Printing quality can not be assured unless ink filling has been stabilized. Is the capping position correct? Adjust the capping position, carry out strong cleaning and try again. Are the fans working normally according to the self-diagnostic Examination: Fan? Check the connectors between fan assembly, fan extension cable assembly and main board assembly. Fan extension cable 1 assembly is J115 (FAN1) on the main board Fan extension cable 2 assembly is J116 (FAN2) on the main board Fan extension cable 3 assembly is J117 (FAN3) on the main board Fan extension cable 4 assembly is J118 (FAN4) on the main board Replace fan assembly. Replace Fan extension cables 1 ~ 4. Is the shielding material securely attached in the proper positions? Shield material GA-A, shield material GA-B, shield material GA-C Re-attach in the proper positions. If the media in question is roll media, does the scroller rotate smoothly? Adjust the position of the scroller support rollers. Replace any roller that is damaged or that moves badly. Is the X speed reduction belt tension adjusted to the prescribed value? 41.2 N (4.2 kg 0.2 Kg). What is the condition of the wiper section? Dampen the accessory cleaning cloth slightly with clean water and use it to wipe the surface of the cleaning wiper. After the wiper has been cleaned, carry out two successive cleanings. If it is wet with ink, replace it. Are the nozzle surfaces being wiped and rubbed? Carry out repairs. Replace the wiper. Continued on next page 1560
1-3 1-4
1060
Bad example
1080 1080
1-5
1-6
1-7 1-8
1250
Good example
1-9
1250
EXA4050-2
111


EXA4051
Sequence 1-10
Is the T-fence dirty? Clean it. If the T fence is severely soiled and can not be cleaned, replace it. Is the pressure roller pressing on the media over its entire length? With the pressure lever up, does the pressure rollers seem reluctant to turn? With the pressure lever down, does the pressure rollers idle or contact the platen on one side? With the pressure lever down, is the blade pressing firmly on the media? If there are paper dust or scraps near the pressure roller, wipe with soft damp cloth. If necessary, replace pressure assembly, pressure rollers and blade. If the gap between platen and plate is less than 0.2 mm, adjust platen height.
1300
1-11
1220 1520 1230
1-12
Bad example
Is the pump motor turning during the cleaning action? Check the pump motor assembly connector J102 (PUMP) on the main board assembly and try again. Replace the pump motor assembly. If the pump motor does not turn after performing the above tasks, replace the main board assembly. Was there any mismatching of gears during the cleaning operation? Replace the maintenance station assembly.
1-13 1-14
1270 Is the cap assembly spring fallen out or broken? If the part has fallen out, refit it. Replace the cap assembly or the maintenance station assembly. Are the tubes crushed inside the pump assembly? Replace the pump assembly and check the ink flow. If it is good, carry out initial filling. CAUTION: Wait at least 30 minutes after initial filling before printing. Printing quality can not be assured unless ink filling has been stabilized. 2040 1240 1270
1-15
Good example
1-16 1-17
Does the head that is fitted have a rank that is different from the recorded rank? Re-insert print head rank correctly. The print head assembly may be damaged. Replace the obstructed print head assembly. 1390 Continued on next page
EXA4051
112


EXA4052
Sequence 1-18
Has ink dried on the surface of the print head and inside the nozzles? Use the self-diagnostic Adjustment: Head Cleaning to clean the print head, carry out initial filling with Adjustment: Head Rank and try again. Clean the head nozzle face. With the specified cartridge inserted securely, use the printer's self-diagnostic mode "Sensor: No Ink" or "Sensor: No Cartridge" to check whether the presence of ink and cartridge are being detected normally. Check using EXA1100 [65YMCK] No Cartridge procedure. After adjustment or replacement, implement initial filling with the printer's self-diagnostic "Adjust: Head Rank". CAUTION: Wait at least 30 minutes after initial filling before printing. Printing quality can not be assured unless ink filling has been stabilized. 1040
1-19
2040
Bad example
1-20 1-21
The main board assembly may be damaged. Replace it. The head board assembly may be damaged. Replace it.
1140 1420
Good example
EXA4052
113

No. 1 Symptom Edges of printing are blurred
Bad example
Sequence

EXA4060
1-1
Does cleaning restore normal operation? Carry out three successive cleanings. Is media recommended by Mutoh being used? If the media is causing the symptoms, and it is not recommended media, the results cannot be guaranteed. Please use recommended media. Does the head that is fitted have a rank that is different from the recorded rank? Re-enter the rank of the print head correctly. Check that the T-fence and Encoder behind the head board assembly are not touching. If they are touching, adjust them. If adjustment is not effective, replace both the head board assembly and the T-fence. The main board assembly may be damaged. Replace it. 2040 1390
1-2
1-3
1-4
1420 1300
1-5
Good example
1140
EXA4060
114

No. 1 2 3 Symptom Many satellites (unwanted dots) The printing has whiskers Printed lines appear blurred (printing is dirty)
[ Bad example ]
Sequence 1-1 1-2 1-3 1-4 1-5

EXA4070
Is the usage site environment in accordance with the operating environment? Use the printer in a proper operating environment. Is there sufficient ink remaining? Replace with a new cartridge. Do three cleanings in succession. Have the Test Print printed. (Refer to PAT1000) If the nozzle check pattern is printed normally, return to EXA4020. Is the printing less than 30 minutes after initial filling? Wait at least 30 minutes after initial filling before printing. Printing quality can not be assured unless ink filling has been stabilized. Is the steel belt tension adjusted properly? 0.98 N (100 g 20 g) Make sure the encoder and T-fence mounted on the back of the head board assembly are not touching. If they are touching, adjust them. If adjustment does not solve the problem, replace both the head board assembly and the fence. Is there a loose set screw on the Y drive pulley? Re-tighten the set screw. Is the capping position correct? Adjust the capping position and try again after strong cleaning. What is the condition of the wiper section? Dampen the accessory cleaning cloth slightly with clean water and use it to wipe the surface of the cleaning wiper. After the wiper has been cleaned, carry out two successive cleanings. If it is wet with ink, replace it. 1550 2050 or PAT1000
1. Satellites
1-6
2. Whiskers
1-7
1420 1300
1-8
3. Blurring
1-9 1-10
1250
[ Good example ]
EXA4070
115

No. 1 2 3 Symptom Many satellites (unwanted dots) The printing has whiskers Printed lines appear blurred (printing is dirty)
[ Bad example ]
Sequence 1-11 1-12 1-13

EXA4071
Is it able to wipe/rub the nozzle face normally? Check how the wiper is fitted and fasten it correctly. Does the head that is fitted have a rank that is different from the recorded rank? Re-enter the rank of the print head correctly. Are the ink tubes damaged inside the pump assembly? Replace the pump assembly and check that ink flows during the cleaning action. If ink flows, carry out initial filling. Is the pump motor turning during the cleaning action? Check the pump motor assembly connector J102 (PUMP) on the main board assembly and try again. Replace the pump motor assembly. If the pump motor does not turn after performing the above tasks, replace the main board assembly. During the cleaning operation, was there any mismatching or damage to the gears or transfer gear shaft? Replace the maintenance station assembly. Has the cap assembly spring fallen out or been broken? If a part has fallen out, refit it. Replace the cap assembly or maintenance station assembly. Has ink dried on the surface of the print head and inside the nozzles? Use the self-diagnostic Adjustment: Head Cleaning to clean the print head, carry out initial filling with Adjustment: Head Rank and try again. Clean the head nozzle face. CAUTION: Wait at least 30 minutes after initial filling before printing. Printing quality can not be assured unless ink filling has been stabilized.
1250 2040 1390 1260 2040
1. Satellites
1-14
1230
2. Whiskers
1-15
1270 1240 1270 1620 1660 2040
1-16
1-17
3. Blurring
[ Good example ]
1-18 1-19
Is the print head assembly damaged? Replace the obstructed print head assembly. The main board assembly may be damaged. Replace it.
1390 1140
EXA4071
116

No. 1 Symptom Mixed color lines do not overlap
Bad example

EXA4080
Sequence
1-1
Is the steel belt tension adjusted properly? 0.98 N (100 g 20 g) Readjust steel belt tension. Is the Y drive pulley set screw loose? Re-tighten the set screw securely. Is there any mistake in the rank of the head that is actually installed and the rank that is recorded? Re-enter the rank of the print head correctly. Is the problem with the head tilt adjustment? Adjust it. Is there a problem with the reciprocal printing position alignment? Adjust it. Is there a problem with the CW adjustment? Adjust it. Make sure the encoder and fence mounted on the back of the head board assembly are not touching. If they are touching, adjust them. If adjustment does not solve the problem, replace the T fence.
1550
1-2
1310 2040 1390
1-3
Good example
1-4
2060
1-5
2080
Black and color positions are offset

Bad example
1-6
2090
1-7
1300
Good example
EXA4080
117

No. 1 Symptom Inaccurate line length in the direction of head movement (Main scanning direction)
Sequence

EXA4090
1-1
Is the usage site environment in accordance with the operating environment? Use the printer in a proper operating environment. Is the steel belt tension adjusted properly? 0.98 N (100 g 20 g) Re-adjust steel belt tension. Is the timing fence dirty or has foreign matter stuck to it? Clean it. Replace if soiling is not removed by washing or if there is damage. Is the Y drive pulley set screw loose? Re-tighten the set screw securely. The internal processing operation of the main board may be faulty. Initialize, re-enter or re-adjust the parameters and try again.
1-2
1550
1-3
1300
1-4
1280 5010 2000
1-5
EXA4090
118

No. 1 Symptom Inaccurate straight line in the direction of head movement (straightness)
Sequence 1-1

EXA4100
Are the fans working normally according to the self-diagnostic Examination: Fan? Check the connectors between fan assembly, fan extension cable assembly and main board assembly. Fan extension cable 1 assembly is J115 (FAN1) on the main board Fan extension cable 2 assembly is J116 (FAN2) on the main board Fan extension cable 3 assembly is J117 (FAN3) on the main board Replace fan assembly. Replace fan extension cables 1 to 3. Are the front paper guide and platen securely screwed? Tighten it. Is the shielding material securely attached in the proper positions? Shield material GA-A, shield material GA-B, shield material GA-C Re-attach in the proper positions. Is the X drive pulley set screw loose? Replace the X motor assembly. Is the X speed reduction belt tension adjusted to the prescribed value? 41.2 N (4.2 kg 0.2 kg) Readjust the X speed reduction belt tension. If the media in question is roll media, does the scroller rotate smoothly? Adjust the position of the scroller support rollers. Replace any roller that is damaged or that moves badly. Is the pressure roller pressing on the media over its entire length? With the pressure lever up, does the pressure rollers seem reluctant to turn? With the pressure lever down, does the pressure rollers idle or contact the platen on one side? With the pressure lever down, is the blade pressing firmly on the media? If there are paper dust or scraps near the pressure roller, wipe with soft damp cloth. If necessary, replace pressure assembly, pressure rollers and blade. If the gap between platen and blade is less than 0.2 mm, adjust platen height.
1060
1080 1080
1-2
1-3
1-4
1070
1-5

1-6
1560
1-7
1220 1520
EXA4100
119

No. 1 Symptom Inaccurate straight line in the direction of head movement (straightness)
Sequence 1-1

EXA4100-2
Are the fans working normally according to the self-diagnostic Examination: Fan? Check the connectors between fan assembly, fan extension cable assembly and main board assembly. Fan extension cable 1 assembly is J115 (FAN1) on the main board Fan extension cable 2 assembly is J116 (FAN2) on the main board Fan extension cable 3 assembly is J117 (FAN3) on the main board Fan extension cable 4 assembly is J117 (FAN4) on the main board Replace fan assembly. Replace fan extension cables 1 to 3. Are the front paper guide and platen securely screwed? Tighten it. Is the shielding material securely attached in the proper positions? Shield material GA-A, shield material GA-B, shield material GA-C Re-attach in the proper positions. Is the X drive pulley set screw loose? Replace the X motor assembly. Is the X speed reduction belt tension adjusted to the prescribed value? 41.2 N (4.2 kg 0.2 kg) Readjust the X speed reduction belt tension. If the media in question is roll media, does the scroller rotate smoothly? Adjust the position of the scroller support rollers. Replace any roller that is damaged or that moves badly. Is the pressure roller pressing on the media over its entire length? With the pressure lever up, does the pressure rollers seem reluctant to turn? With the pressure lever down, does the pressure rollers idle or contact the platen on one side? With the pressure lever down, is the blade pressing firmly on the media? If there are paper dust or scraps near the pressure roller, wipe with soft damp cloth. If necessary, replace pressure assembly, pressure rollers and blade. If the gap between platen and blade is less than 0.2 mm, adjust platen height.
1060
1080 1080
1-2
1-3
1-4
1070
1-5
1560
1-6
1-7
1220 1520
EXA4100-2
120

No. 1 Symptom Inaccurate line distance in the direction of media feed (Subsidiary scanning distance)
Sequence 1-1

EXA4110
Is the usage site environment in accordance with the operating environment? Use the printer in a proper operating environment. Are you using adjusting the distance with the media that is being used? Carry out distance adjustment. Even if the distance adjustment is being done with the media that is in use, do it for the sake of confirmation. Is the X drive pulley loose? Replace the X motor assembly. Is the X speed reduction belt tension adjusted to the specified value? 41.2 N (4.2 kg 0.2 kg) Readjust X speed reduction belt tension. Is there major distortion in the X speed reduction pulley? Replace the X speed reduction pulley. Is the pressure roller pressing on the media over its entire length? With the pressure lever up, does the pressure rollers seem reluctant to turn? With the pressure lever down, does the pressure rollers idle or contact the platen on one side? With the pressure lever down, is the blade pressing firmly on the media? If there are paper dust or scraps near the pressure roller, wipe with soft damp cloth. If necessary, replace pressure assembly, pressure rollers and blade. If the gap between platen and blade is less than 0.2 mm, adjust platen height. 2120
1-2
1-3
1070
1-4
1560
1-5
1680
1-6
[Standard value] 500 mm 0.1% Since the adjustment here is 300 mm, the measured value, x is such that 299.7 mm x 300.3 mm
1220 1520
1-7
Is the rough surface of the grid roller worn in some places? Is the grid roller heavy to turn? Or does it not turn smoothly? Use a nylon brush to clean away any paper dust or paper scraps from the grid roller. Adjust platen height or refit the rear paper guide. Replace grid roller. Is there major distortion, damage or foreign matter on the front and rear paper guides? Replace front and rear paper guides.
1520, 1040 1690
1-8
1040 1-9 If roll media is being used, does the scroller rotate smoothly? Replace the scroller shaft. Change the media that is being used.
EXA4110
121

No. 1 Symptom Inaccurate straight line in the direction of media feed (joining precision Y)
Sequence

EXA4120
1-1
Is there any mistake in the rank of the head that is actually installed and the rank that is recorded? Enter the rank of the print head correctly. Is the problem with the head tilt adjustment? Adjust it. Is the steel belt tension adjusted to the specified value? 0.98 N (100 g 20 g) Readjust steel belt tension. Is the Y drive pulley set screw loose? Replace it. Is there a problem with the reciprocal printing position alignment? Adjust it. Is there a problem with the CW adjustment? Adjust it. Is the T fence dirty? Clean it. Replace if soiling is not removed by washing or if there is damage. Although the step pattern of the self-diagnostic "Head Nozzle Check" is well adjusted, if the vertical lines of the "Black Head Tilt Check" do not join, carry out the following tasks. Replace the steel flexible belt assembly. Is there play in the cursor? Replace the CR flat spring or the cursor assembly.
1390
2040
1-2
1390
2060
1-3
1550
1-4
1280
1-5
2080
1-6
2090
1-7
1300
1-8
1310
1-9
1310
EXA4120
122

No. 1 Symptom Bad right angle precision
Sequence

EXA4130
1-1
Are the fans working normally according to the self-diagnostic Examination: Fan? Check the connectors between fan assembly, fan extension cable assembly and main board assembly. Fan extension cable 1 assembly is J115 (FAN1) on the main board Fan extension cable 2 assembly is J116 (FAN2) on the main board Fan extension cable 3 assembly is J117 (FAN3) on the main board Replace fan assembly. Replace fan extension cables 1 to 3. Is the shielding material securely attached in the proper positions? Shield material GA-A, shield material GA-B, shield material GA-C Re-attach in the proper positions. Is the pressure roller pressing on the media over its entire length? With the pressure lever up, does the pressure rollers seem reluctant to turn? With the pressure lever down, does the pressure rollers idle or contact the platen on one side? With the pressure lever down, is the blade pressing firmly on the media? If there are paper dust or scraps near the pressure roller, wipe with soft damp cloth. If necessary, replace pressure assembly, pressure rollers and blade. If the gap between platen and blade is less than 0.2 mm, adjust platen height. Is the rough surface of the grid roller worn in some places? Is the grid roller heavy to turn? Or does it not turn smoothly? Use a nylon brush to clean away any paper dust or paper scraps from the grid roller. Adjust platen height or refit the rear paper guide. Replace grid roller.
1060
1080 1080
1-2
1-3
1220 1520
1-4
1520, 1040
1690
EXA4130
123

No. 1 Symptom Bad right angle precision
Sequence

EXA4130-2
1-1
Are the fans working normally according to the self-diagnostic Examination: Fan? Check the connectors between fan assembly, fan extension cable assembly and main board assembly. Fan extension cable 1 assembly is J115 (FAN1) on the main board Fan extension cable 2 assembly is J116 (FAN2) on the main board Fan extension cable 3 assembly is J117 (FAN3) on the main board Fan extension cable 4 assembly is J118 (FAN4) on the main board Replace fan assembly. Replace fan extension cables 1 to 4. Is the shielding material securely attached in the proper positions? Shield material GA-A, shield material GA-B, shield material GA-C Re-attach in the proper positions. Is the pressure roller pressing on the media over its entire length? With the pressure lever up, does the pressure rollers seem reluctant to turn? With the pressure lever down, does the pressure rollers idle or contact the platen on one side? With the pressure lever down, is the blade pressing firmly on the media? If there are paper dust or scraps near the pressure roller, wipe with soft damp cloth. If necessary, replace pressure assembly, pressure rollers and blade. If the gap between platen and blade is less than 0.2 mm, adjust platen height. Is the rough surface of the grid roller worn in some places? Is the grid roller heavy to turn? Or does it not turn smoothly? Use a nylon brush to clean away any paper dust or paper scraps from the grid roller. Adjust platen height or refit the rear paper guide.
1060
1080 1080
1-2
1-3
1220 1520
1-4
1520 1040
EXA4130-2
124

No. 1 Symptom Abnormal noise when media is sucked down
Sequence

EXA5000
1-1
Is the shielding material securely attached in the proper positions? Shield material GA-A, shield material GA-B, shield material GA-C Re-attach in the proper positions. Are the rotating fins of the suctions fans touching the cable or are there paper scraps and foreign matter? Remove obstructions and foreign matter. Check for a broken cable and connections. Replace any parts that are broken. The fan itself may be faulty. Replace it. The main board assembly may be faulty. Replace it. The power board assembly may be faulty. Replace it.
1-2
1-3
1-4
1080
1-5
1140
1-6
1150
EXA5000
125

No. 1 Symptom Abnormal noise when standing by ready to print
Sequence

EXA5010
1-1
Is there something touching or some foreign matter at the place producing the abnormal noise? Remove the obstruction or foreign matter. It a board producing the noise? Replace the board assembly in question. Power board assembly Main board assembly Head board assembly Print head assembly
1-2
1150 1140 1420 1390
EXA5010
126

No. 1 Symptom Abnormal noise when head is moving left and right
Sequence

EXA5020
1-1 1-2 1-3
The abnormal noise could be squirting noise when printing. Explain specifications. Is the abnormal noise caused by a loose screw on the cover? Tighten the screws. Is it a rattle when the cursor moves left and right? Remove dirt from the carriage bearings and roller tracks. Be sure to apply a light Sumi-grease spray to the roller tracks when you clean them. Is the noise coming from the Y flexible plate? Repair it by taking out warping. If the noise is coming from between the steel flexible belt and the tube guide, replace the tube guide assembly. Check whether the cable connected to the head board on the carriage is touching the cover. Also, check whether is it touching the encoder and fence mounted at the back of the head board. If adjusting the position does not solve the problem, replace it. Is the noise coming from the Y pulley box assembly bearing? Replace the Y Motor assembly. Is the noise coming from the Y return pulley bearing? Replace it. Is the steel belt tension adjusted properly? 0.98 N (100 g 20 g) Re-adjust steel belt tension. Is the Y drive pulley screw loose? it securely. Is the noise coming from the Y motor assembly? Replace it. 1280 1320
1-4
1540
1-5
1-6 1-7 1-8
1550 1280 1280
1-9 1-10
EXA5020
127

No. 1 Symptom Abnormal noise when media is fed
Sequence

EXA5030
1-1
Is the abnormal noise due to pressure roller deformation? Replace them. Also, explain the need to raise the lever, as shown in the caution label, when the printer is not printing. Is the X speed reduction belt out of tooth with the X speed reduction pulley? Replace the X speed reduction belt. Is the noise coming from the X motor? Replace it. Is the rough surface of the grid roller worn in some places? Is the grid roller heavy to turn? Or does it not turn smoothly? Use a nylon brush to clean away any paper dust or paper scraps from the grid roller. Adjust platen height or refit the rear paper guide. Replace grid roller.
1220
1-2
1090
1-3
1070
1-4
1520, 1040
1690
EXA5030
128

No. 1 Symptom Abnormal noise when cutting
Sequence

EXA5040
1-1
Has the cutter cap been fixed securely on the top of the cutter as a result of checking in the primary consultation? Refit it. Does the cutter move up and down smoothly? Refit the spring and remove any foreign matter. Is there foreign matter in the cutter groove and front surface of the printing board section? Remove the foreign matter. Is the cutter blade parallel with the printing board cutter groove? Adjust it. The cutter itself may be no good. Replace it. The head board assembly may be damaged. Replace it. The Y cable may be damaged. Replace it. The power assembly board may be faulty. Replace it.
1-2
1-3
1-4
1-5
1-6
1420
1-7
1360
1-8
1150
EXA5040
129

No. 1 Symptom Does not cut normally (Since there is no cutting of cut sheet media, this item applies only to roll media)
Sequence 1-1 1-2 1-3 1-4

EXA6000
Is the tip of the cutter blade chipped or worn? Replace the cutter. Is the cutter cap set securely on the top of the cutter? Refit it. Does the cutter move up and down smoothly? Refit the spring and remove any foreign matter. Is there foreign matter in the cutter groove and front surface of the printing board section? Remove foreign matter. Remove paper dust from the cutter groove. Is the cutter blade parallel with the printing board cutter groove? Adjust it. Use self-diagnostic "Aging:Cutter" to confirm up and down movement. Check the connections on cutter solenoid assembly connector and head board assembly connector J206 (SOL). If there is no up and down movement, the solenoid may be damaged. Replace the cutter solenoid assembly. Check the Y cable connectors Check that they are not inserted obliquely. Re-insert the main board assembly connector J111 (HEAD1) and the head board assembly connector J201 (MAIN1). Replace them. The head board assembly may be damaged. Replace it. The main board assembly may be damaged. Replace it. CAUTION: Power must be off when connectors are being disconnected or reconnected, otherwise you may be injured or a board may be damaged. The main board assembly will certainly be damaged if power is applied with main board assembly connectors J111 (HEAD) and J112 (HEAD2) and head board connectors J201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP. 6030
1-5 1-6
1380
1-7
1360 1420 1140
1-8 1-9
EXA6000
130

No. 1 Symptom Cutting occurs during printing (Since there is no cutting of cut sheet media, this item applies only to roll media)
Sequence

EXA6010
1-1
Is there a problem with the printer driver software? Upgrade the printer driver version. Is there a problem with the program ROM? Upgrade the version. Check the Y cable connectors. Check that they are not inserted obliquely. Insert the main board assembly connector J111 (HEAD1) and the head board assembly J201 (MAIN1). Replace them. The head board assembly may be damaged. Replace it.
1-2
1-3
1-4
1360
1-5
The main board assembly may be damaged. Replace it.
1420
1-6
Cut
CAUTION: Power must be off when connectors are being disconnected or reconnected, otherwise you may be injured or a board may be damaged. The main board assembly will certainly be damaged if power is applied with main board assembly connectors J111 (HEAD) and J112 (HEAD2) and head board connectors J201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP.
1140
EXA6010
131

No. 1 Symptom The cutting operation is normal but the media is not cut The cutting is bad and the media jams (Since there is no cutting of cut sheet media, this item applies only to roll media)
Sequence

EXA6020
1-1
Is the cutter blade chipped or deteriorated as checked in the primary consultation? Replace the cutter. Is the cutter blade chipped or deteriorated as checked in the primary consultation? Replace the cutter. Has the cutter cap been fixed securely on the top of the cutter as a result of checking in the primary consultation? Refit it. Is there foreign matter in the cutter groove and on the surface of front paper guide? Remove the foreign matter. Remove paper dust from the cutter groove. Is the cutter blade parallel with the front of the paper guide? Adjust it.
1-2
1-3
1-4
1-5
EXA6020
132

No. 1 Symptom The cutting operation is normal but the media does not fall out (Since there is no cutting of cut sheet media, this item applies only to roll media)
Sequence

EXA6030
1-1
Are paper guide surfaces being cleaned daily? Clean the surfaces. There may be a static charge on the front paper guide or media. Make a proper earth connection. Check the humidity of the usage environment and bring it within usage environment specifications.
1-2
EXA6030
133

No. 1 Symptom Inaccurate media cutting
Sequence

EXA6040
1-1
Is the cutter blade chipped or deteriorated as checked in the primary consultation? Replace the cutter. Has the cutter cap been fixed securely on the top of the cutter as a result of checking in the primary consultation? Refit it. Does the cutter move up and down smoothly? Refit the spring and remove any foreign matter. Is there foreign matter in the cutter groove and front surface of the printing board section? Remove the foreign matter. Remove paper dust from the cutter groove. Is the cutter blade parallel with the printing board cutter groove? Adjust it. The cutter itself may be no good. Replace it.
1-2
1-3
1-4
1-5
1-6 The media cutting precision of this machine is x 0.3 mm
EXA6040
134

No. 1 Symptom Cutting is delayed for some time after printing has ended White paper is cut
Sequence

EXA6050
1-1
Are internal sample prints output without trouble? Refer to EXA4030 "Does not print at all" Is there a problem with the printer driver software? Upgrade the printer driver version. Is there a problem with the program ROM? Upgrade the version. The main board assembly may be damaged. Replace it.
PAT1000
1-2
1-3
1-4
1140
EXA6050
135

No. 1 Symptom Cannot connect normally with Centronics Cannot connect normally with Network
Sequence 1-1
EXA7000
Try communicating with the available computer and cable. Contact your Mutoh distributor. Does the error occur after the interface cable has been changed? There may be a broken lead in the interface cable or the cable itself may be too long for good communication. Advise the use of a cable that conforms to specifications. Is there a problem with the printer driver software? Upgrade the printer driver version. Is there a problem with the program ROM? Upgrade the version. For network connections, make sure of the type of cable that is to be used for the connection environment. For direct connection of one host and one printer Use a cross cable (100/10Base-T) For connection of several hosts and one printer through a hub Use a straight cable (100/10BaseT) To check connections to the network board, use the board accessory setup utilities or connect directly to the computer (using a crossed cable in the case of 10BASE-T) and use the PING command. Example of use of PING command PING (ping) is run from the MS-DOS prompt under Windows 95/NT. Example: C:\WINDOWS>PING 192.168.41.34 [Enter] PING may be upper or lower case. Connection is indicated by a response such as: Reply from 192.168.41.15: bytes=32 time=4ms TTL32 (This address is the default value.)
1-2
1-3
1-4
1-5
1-6 The main board assembly may be damaged. Replace it. 1140
EXA7000
136

No. 1 Symptom The scale function does not work correctly The mirror function does not work correctly Other functions are not working correctly
Sequence
EXA7020
1-1
Is there a problem with the printer driver software? Upgrade the printer driver version. Is there a problem with the program ROM? Upgrade the version. The main board assembly may be damaged. Replace it.
1-2
1-3
1140
EXA7020
137

No. 1 Symptom Printing position is offset
Sequence
EXA7030
1-1
Is there a problem with the CW adjustment? Adjust it. Is the front-sensor-to-head distance or the cutter-to-head distance causing a problem for top and bottom margin distance adjustments? Adjust them. Is there a problem with the printer driver software? Upgrade the printer driver version. Is there a problem with the program ROM? Upgrade the version. The main board assembly may be damaged. Replace it. 1140
2090
1-2
2130
1-3
1-4
1-5
EXA7030
138

No. 1 Symptom Some data are not printed (omitted)
Sequence
EXA7040
1-1
Is there a problem with the printer driver software? Upgrade the printer driver version. Is there a problem with the program ROM? Upgrade the version. Check whether the timing fence is dirty or twisted. If it is greasy or dusty, wipe it clean. If it is ink stained wipe it lightly with a cloth damped in a neutral detergent. If it is severely soiled and can not be cleaned, replace the T fence. Check Encoder: Y that is in the self-diagnostics examinations. (Examination: Encoder) If it is no good, check the cable connections of J112 (HEAD2) on the main board assembly and J202 (MAIN2) on the head board assembly. Replace the T fence. Replace the Y motor assembly. Replace the head board assembly. Replace the Y cable (between J112 (HEAD2) on the main board assembly and J202 (MAIN2) on the head board assembly). The main board assembly may be damaged. Replace it. CAUTION: Power must be off when connectors are being disconnected or reconnected, otherwise you may be injured or a board may be damaged. The main board assembly will certainly be damaged if power is applied with main board assembly connectors J111 (HEAD) and J112 (HEAD2) and head board connectors J201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP. 1300
1-2
1-3
1-4
1300 1280 1420 1360
1-5
1140
EXA7040
139

No. 1 Symptom Text and printing data are garbled (extra lines appear)
Sequence
EXA7050
1-1
Is there a problem with the printer driver software? Upgrade the printer driver version. Is there a problem with the program ROM? Upgrade the version. Check whether the timing fence is dirty or twisted. If it is greasy or dusty, wipe it clean. If it is ink stained wipe it lightly with a cloth damped in a neutral detergent. If it is severely soiled and can not be cleaned, replace the T fence. Check Encoder: Y that is in the self-diagnostics examinations. (Examination: Encoder) If it is no good, check the cable connections of J112 (HEAD2) on the main board assembly and J202 (MAIN2) on the head board assembly. Replace the T fence. Replace the Y motor assembly. Replace the head board assembly. Replace the Y cable (between J112 (HEAD2) on the main board assembly and J202 (MAIN2) on the head board assembly). The main board assembly may be damaged. Replace it. 1300
1-2
1-3
1-4
1300 1280 1420 1360
1-5
1140
EXA7050
140

No. 1 Symptom There is an extra feed after printing is finished
Sequence
EXA7060
1-1
Are the printing position and location method settings suitable? Set them to suitable values. Is there a problem with the printer driver software? Upgrade the printer driver version. Is there a problem with the program ROM? Upgrade the version. The main board assembly may be damaged. Replace it.
1-2
1-3
1-4
1140
EXA7060
141

No. 1 Symptom The printer hangs up
Sequence
Others
EXA8000
1-1
Bad internal processing in the main board? Initialize parameters after switching the printer off and on temporarily, enter settings manually and the check the operation. Install the program and try again. The main board assembly may be damaged. Replace it.
1600
1-2
1140
Others
EXA8000
142

No. 1 Symptom Power shutdown during printing
Sequence
Others
EXA8010
1-1
Is there a short in the power cable. Check it with a tester. Is there a power leak? Check for contact with the frame due to frayed covering. Check power voltages Power supply voltage check V AC (: 100, 120 or 240) Power supply voltage check 5 V DC Power supply voltage check 24, 42 V DC The main board assembly may be damaged. Replace it.
1-2
1-3
1-4
1150
Others
EXA8010
143

No. 1 Symptom The ink cartridges will not go in
Sequence
Others
EXA8020
1-1
Is the cartridge holder assembly needle deformed or broken? Replace the cartridge frame assembly. Is the ink present/absent sensor (a black plastic lever switch) on the detector assembly damaged? Replace it.
1330
1-2
1350
Others
EXA8020
144

No.
1
Others
EXA8050
Symptom
Ink has overflowed from the waste fluid box
Sequence
1-1 1-2
Check inside the waste fluid box. If it is full of ink, explain to the customer as you replace the waste fluid box. Use the self-diagnostic "Sensor: No Ink" to check the cartridge that has no ink. Remove all cartridges and check that the "No Ink" display changes when you gently press the black plastic switches of all the detector assemblies On and Off. Use the printer's self-diagnostic "Sensor: Tank Exist/Tank is not" to make sure that the waste fluid box detection is working normally. Slowly remove and replace the waste fluid box to confirm that the present/absent display appears. If the display is not normal, the sensor mounting position may be at fault. Remove the R Cover and adjust the mounting position of the waste fluid box detection switch assembly. Check the waste fluid box detection switch contact. J109 (INK TANK) on the main board Insert it correctly. Replace it. Is the waste fluid tube from the flushing box kinked? Fix it and attach it again. Is the flushing box choked with trash? Remove the trash. Replace it. Is the waste fluid tube from the flushing box kinked? Fix it and attach it again. Is the absorbent material for flushing box full of ink? Replace it. The extension tube under the pump assembly may have come away. Remove the maintenance station assembly and check whether the extension tube has come away. Replace the pump assembly. Replace the pump motor assembly. Replace the cap assembly. The ink tube may be cut. Replace the ink tube. Print head, main board assembly and head board assembly may be damaged. Remove ink cartridges and check that each board is normal. 1700
1350
1040
1-3
1040
1-4
1120
1-5
Ink overflows from flushing box
2-1
2-2
2-3
Ink is spilt around the X rail
3-1
1270 1260 1230 1240
3-2
1370
3-3
Others
EXA8050
145

No.
1
Others
EXA8050-2
Symptom
Ink has overflowed from the waste fluid box
Sequence
1-1 1-2
Check inside the waste fluid box. If it is full of ink, explain to the customer as you replace the waste fluid box. Use the self-diagnostic "Sensor: No Ink" to check the cartridge that has no ink. Remove all cartridges and check that the "No Ink" display changes when you gently press the black plastic switches of all the detector assemblies On and Off. Use the printer's self-diagnostic "Sensor: Tank Exist/Tank is not" to make sure that the waste fluid box detection is working normally. Slowly remove and replace the waste fluid box to confirm that the present/absent display appears. If the display is not normal, the sensor mounting position may be at fault. Remove the R Cover and adjust the mounting position of the waste fluid box detection switch assembly. Check the waste fluid box detection switch contact. J109 (INK TANK) on the main board Insert it correctly. Replace it. Is the waste fluid tube from the flushing box kinked? Fix it and attach it again. Is the flushing box choked with trash? Remove the trash. Replace it. Is the waste fluid tube from the flushing box kinked? Fix it and attach it again. Is the absorbent material for flushing box full of ink? Replace it. The extension tube under the pump assembly may have come away. Remove the maintenance station assembly and check whether the extension tube has come away. Replace the pump assembly. Replace the pump motor assembly. Replace the cap assembly. The ink tube may be cut. Replace the ink tube. Print head, main board assembly and head board assembly may be damaged. Remove ink cartridges and check that each board is normal. Is the waste liquid bottle full of ink? Replace it. 1710 1700 1270 1260 1230 1240 1370
1350
1040
1-3
1040
1-4
1120
1-5 2 Ink overflows from flushing box 2-1
2-2 2-3 3 Ink is spilt around the X rail 3-1
3-2 3-3 4 Ink has overflowed from the waste fluid box 4-1
Others
EXA8050-2
146
RJ-6000-43 Replacement and Adjustment Procedures
REP0000
Replacement and Adjustment Procedures
REP0000
147
REP0000-2
REP0000-2
148
REP0000-3
REP0000-3
149
RJ-6000-43 Replacement and Adjustment Procedures Replacement and Adjustment Procedure
REP0010
Right and Left Covers Front Cover Panel Cover and Y Rail Cover Front Paper Guide and Rear Paper Guide Right Side Cap and Left Side Cap Control Box Head Cover X Motor Assembly Fan Assembly and Fan Cable X Speed Reduction Belt Lever Sensor Assembly Cover Switch Assembly Waste Fluid Box Sensor Assembly Switch Cable Assembly and DC Cable Assembly Main Board Assembly Power Supply Board Assembly Panel Board Assembly Panel Cable Extension Board Assembly XR Cable Assembly (Rear Paper Sensor) Pressure Assembly, Pressure Roller and Blade Pump Motor Assembly Cap Assembly Wiper Pump Assembly Maintenance Station Assembly Y Motor Assembly Steel Belt T Fence Assembly
REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP
1010 1020 1030 1040 1041 1050 1060 1070 1080 1090 1100 1110 1120 1130 1140 1150 1160 1170 1180 1200 1220 1230 1240 1250 1260 1270 1280 1290 1300
Cursor Plate Spring and Steel Flexible Guide Assembly Y Return Pulley Assembly Cartridge Frame Assembly Ink ID Sensor Assembly Detector Assembly Y Cable Ink Tubes Cutter Solenoid Assembly Print Head Assembly and Head Cable Y Paper Sensor Assembly Head Board Assembly Dampers Cursor Assembly Origin Sensor and Y Encoder Junction Board Assembly Platen Height Adjustment Tube Guide Assembly How to Adjust Steel Belt Tension How to Adjust X Speed Reduction Belt Tension How to Adjust Print Head How to Capture and Install Backup Parameters How to Install a Program (Software Upgrade) Head Cleaning Procedure How to Clean the Head Nozzle Face X Speed Reduction Pulley Assembly Grid Roller Assembly F Absorbent Material Assembly
REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP
1310 1320 1330 1340 1350 1360 1370 1380 1390 1410 1420 1430 1440 1450 1470 1520 1540 1550 1560 1570
REP 1590 REP 1600 REP REP REP REP REP 1620 1660 1680 1690 1700
REP0010
150
REP0010-2
1010 1020 1030 1040 1041 1050 1060 1070 1080-2 1090 1100 1110 1120 1130 1140 1150 1160 1170 1180 1200 1220 1230 1240 1250 1260 1270 1280 1290 1300
Cursor Plate Spring and Steel Flexible Guide Assembly Y Return Pulley Assembly Cartridge Frame Assembly Ink ID Sensor Assembly Detector Assembly Y Cable Ink Tubes Cutter Solenoid Assembly Print Head and Head Cable Y Paper Sensor Assembly Head Board Assembly Dampers Cursor Assembly Origin Sensor and Y Encoder Junction Board Assembly Platen Height Adjustment Tube Guide Assembly How to Adjust Steel Belt Tension How to Adjust X Speed Reduction Belt Tension How to Adjust Print Head How to Capture and Install Backup Parameters How to Install a Program (Software Upgrade) Head Cleaning Procedure How to Clean the Head Nozzle Face X Speed Reduction Pulley Assembly Grid Roller Assembly F Absorbent Material Assembly Waste Fluid Bottle Assembly
1310-2 1320 1330 1340 1350 1360-2 1370-2 1380 1390 1410 1420 1430 1440 1450 1470 1520 1540-2 1550 1560 1570
REP 1590 REP 1600 REP REP REP REP REP REP 1620 1660 1680 1690 1700 1700
REP0010-2
151
REP0010-3
1010 1020 1030 1040 1041 1050 1060 1070 1080-2 1090 1100 1110 1120 1130 1140 1150 1160 1170 1180 1200 1220 1230 1240 1250 1260 1270 1280 1290 1300
Cursor Plate Spring and Steel Flexible Guide Assembly Y Return Pulley Assembly Cartridge Frame Assembly Ink ID Sensor Assembly Detector Assembly Y Cable Ink Tubes Cutter Solenoid Assembly Print Head and Head Cable Y Paper Sensor Assembly Head Board Assembly Dampers Cursor Assembly Origin Sensor and Y Encoder Junction Board Assembly Platen Height Adjustment Tube Guide Assembly How to Adjust Steel Belt Tension How to Adjust X Speed Reduction Belt Tension How to Adjust Print Head How to Capture and Install Backup Parameters How to Install a Program (Software Upgrade) Head Cleaning Procedure How to Clean the Head Nozzle Face X Speed Reduction Pulley Assembly Grid Roller Assembly F Absorbent Material Assembly Waste Fluid Bottle Assembly
1310-2 1320 1330 1340 1350 1360-2 1370-2 1380 1390 1410 1420 1430 1440 1450 1470 1520 1540-2 1550 1560 1570
REP 1590 REP 1600 REP REP REP REP REP REP 1620 1660 1680 1690 1700 1700
REP0010-3
152
How to remove and replace the Right and Left Covers Item
1. Removal and Replacement Procedure
REP1010

Before carrying out this operation, switch off the power supply and remove the power plug. Before removing the covers, remove roll media with scroller from scroller receiver.
A
Right cover Screw Screw
Right Cover 1. Remove four screws. 2. The cover is caught at the place shown by arrow A. Remove the cover while lifting in the direction of arrow B. 3. Assembling is the reverse of the removal procedure.
Left Cover 1. Remove in the same way as for the Right Cover.
Right cover
Screws
How to remove and replace the Right and Left Covers
REP1010
153
How to remove and replace the Front Cover Item

1. Removal and Replacement Procedure Front Cover 1. Remove the Right Cover. 2. Loosen the two fastening screws on the right side of the Front Cover. (Refer to the diagram on the right) 3. Loosen the Panel Cover Screw and remove the Panel Cover by sliding it about 3 mm to the left. 4. Slide the right side Front Cover Shaft to the right. 5. Remove the Front Cover by sliding it to the right. 6. Replacement is the reverse of the removal procedure but before replacing the Right Cover, open and close the Front Cover to check that the Cover Switch is being pressed correctly.
REP1020
Cover shaft R2 fastening screws
Slide the cover shaft
Front cover
Pull out
How to remove and replace the Front Cover
REP1020
154
How to remove and replace the Panel Cover and Y Rail Cover Item
1. Removal and Replacement Procedure Panel Cover 1. Loosen the two screws on the Front Cover Right Cover Shaft and push the Front Cover to the left. 2. Loosen the Panel Cover Screw (1 screw) by 3 mm or remove it. 3. Slide the Panel Cover to the left (in the direction of arrow A) and remove it towards you (in the direction of arrow B). 4. Assembling is the reverse of the removal procedure.
Screw
REP1030
Replacement and Adjustment Procedure B
Panel cover
Y Rail Cover 1. Remove the Panel Cover. 2. Remove the Front Cover. 3. Remove the Cartridge Cover. (5 screws) 4. Remove the Y Rail Cover Screws (3 front/4 rear). 5. Remove the Y Rail Cover by lifting it upwards. 6. Assembling is the reverse of the removal procedure.
Screw Screws
Screws
How to remove and replace the Panel Cover and Y Rail Cover
REP1030
155
How to remove and replace the Front Paper Guide and Rear Paper Guide Item
1. Removal and Replacement Procedure Front Paper Guide 1. Open the Front Cover. 2. Remove Front Paper Guide Screws, 5 on top and 5 at the bottom. (6 top/6 bottom on 54-inch and 62-inch models) 3. Lift the Front Paper Guide and pull it out towards you. 4. Assembling is the reverse of the removal procedure.
REP1040
Screws Front side Front paper guide
Screws
Rear Paper Guide 1. Remove the Panel Cover. 2. Remove the Front Cover. 3. Remove Ink Cartridge Cover. (3 top/2 bottom screws) 4. Remove the Y Rail Cover. 5. Remove Rear Paper Guide Screws, 6 on top and 5 at the bottom. (6 top/4 bottom on 54-inch model) (6 top/6 bottom on 62-inch model) 6. Lift the Rear Paper Guide from the back of the unit as you pull it out towards you. 7. Assembling is the reverse of the removal procedure.
Rear side
Rear paper guide
How to remove and replace the Front Paper Guide and Rear Paper Guide
REP1040
156
How to remove and replace the Right Side Cap and Left Side Cap
REP1041
Item
1. Removal and Replacement Procedure Right Side Cap 1. Remove the Front Paper Guide. 2. Remove Panel Bottom Cover. (4 screws) 3. Bring the Head to the middle. 4. Hold up the Front Box. 5. Remove two screws from the Front Side Cap. 6. Turn the Right Side Cap clockwise and remove it. 7. Refitting is the reverse of the removal procedure.
Front box
Left Side Cap 1. Remove the Front Paper Guide. 2. Remove X Motor Cover. (4 screws) 3. Hold up the Front Box. 4. Remove two screws from the Left Side Cap. 5. Remove the Left Side Cap upwards. 6. Refitting is the reverse of the removal procedure.
Right side cap
Left side cap
How to remove and replace the Right Side Cap and Left Side Cap
REP1041
157
How to open and close the Control Box Item
REP1050

Before working, be sure to switch off power and remove the power cable from the inlet. Since the Control Box will hit the roll media when it is opened and can not be opened completely, the scroller must be removed.
Opening and closing the Control Box 1. Removal and Replacement Procedure 1. Remove three hexagonal socket head bolts from the front of the Control Box so that the Control Box Cover can be removed.
Screws holding Control box
(Front)
2. Remove the three screws holding the Control Box. Since the Control Box will fall open when the three fastening screws are removed, support it with your hand as you remove the screws. 3. Slide the Control Box Cover to the rear and lift it out. 4. Assembling is the reverse of the removal procedure.
Hexagonal socket head bolts
(Side)
2 1
Control box Control box cover
How to open and close the Control Box
REP1050
158
How to remove and replace the Head Cover Item

1. Removal and Replacement Procedure Head Cover 1. Open the Front Cover. 2. Slide the Head out from the Maintenance Station. Caution: When you pull the Head, dont press the cutter cap, otherwise the cutter blade will be damaged.
REP1060
3. Remove the Head Cover. (2 fastening screws) 4. Assembling is the reverse of the removal procedure.
Screw
Screw
Head
How to remove and replace the Head Cover
REP1060
159
How to replace the X Motor Assembly Item

1. Replacement Procedure 1. 2. 3. 4. 5. How to replace the X Motor Assembly Remove the Front Paper Guide. Remove the Left Cover. Remove the Control Box. Remove the X Motor Cover. Disconnect connectors J120 and J121 from the Main Board Assembly. 6. Remove one cable clamp (black) from the bottom surface of the Rear Frame X Reinforcement and cut the cable tie that holds the cables together. 7. Remove two cable clamps (metal) from the top surface of the Front Frame X Reinforcement and withdraw the cables from the hole in the Front X Reinforcement. 8. Loosen four screws holding the X Motor Assembly so that it does not apply tension to the Speed Reduction Belt. 9. Remove the two screws that hold the X Motor to the X Motor mounting plate and pull out the motor. 10. Assembling is the reverse of the removal procedure.
REP1070
Front X Reinforcement
X Motor Assembly fastening screws X Motor fastening screws Slide
Adjust X Motor tension.
X Motor Assembly fastening screws
Pull out
How to replace the X Motor Assembly
REP1070
160
How to replace the Fan Assembly and Fan Cable Item

1. Replacement Procedure Replace the Fan Assembly 1. Remove the Front Paper Guide. 2. Remove the Fan Duct. (3 fastening screws) 3. Remove the Fan Cable Connector. 4. Remove the Fan. (1 fastening screw) 5. Assembling is the reverse of the removal procedure.
Fan Assembly
REP1080
Fan duct fastening screws
Cable clamp
Replace Fan Extension Cables 1, 2 and 3 1. Remove the Front Paper Guide. 2. Remove the Rear Paper Guide. 3. Remove each Fan Cable Connector. 4. Remove each cable clamp. 5. Open the Control Box. 6. Remove the two cable clamps on the Front Frame X Reinforcement. 7. Remove one cable clamp on the Rear Frame X Reinforcement and cut the cable tie that holds the cables together. 8. Disconnect connectors (J115, J116 and J117) from the Main Board Assembly and remove the cables. 9. Assembling is the reverse of the removal procedure.
Fastening screw
Fan duct
Fan connector
Fan connector J117, J116 and J115
How to replace the Fan Assembly and Fan Cable
REP1080
161
How to replace the Fan Assembly and Fan Cable Item

1. Replacement Procedure Replace the Fan Assembly 1. Remove the Front Paper Guide. 2. Remove the Fan Duct. (3 fastening screws) 3. Remove the Fan Cable Connector. 4. Remove the Fan. (1 fastening screw) 5. Assembling is the reverse of the removal procedure.
Fan Assembly
REP1080-2
Fan duct fastening screws
Cable clamp
Replace Fan Extension Cables 1, 2, 3 and 4

Fastening screw Fan duct
1. Remove the Front Paper Guide. 2. Remove the Rear Paper Guide. 3. Remove each Fan Cable Connector. 4. Remove each cable clamp. 5. Open the Control Box. 6. Remove one cable clamp on the Rear Frame X Reinforcement and cut the cable tie that holds the cables together. 7. Disconnect connectors (J115, J116, J117 and J118) from the Main Board Assembly and remove the cables. 8. Assembling is the reverse of the removal procedure.
Fan connector
Fan connector J118, J117, J116 and J115
How to replace the Fan Assembly and Fan Cable
REP1080-2
162
How to replace the Speed Reduction Belt Item

1. Replacement Procedure Replace the X Speed Reduction Belt 1. Loosen the four screws that fasten the X Motor Assembly to loosen the belt tension. 2. Remove the X Motor (2 fastening screws) from the X Motor Mounting Plate and take off the X Motor. 3. Undo the four screws holding the Speed Reduction Pulley Support and remove the Speed Reduction Pulley Support. 4. Remove the X Speed Reduction Belt from the X Speed Reduction Pulley. 5. Assembling is the reverse of the removal procedure.
REP1090
X Motor Assembly fastening screws X Motor fastening screws
Speed reduction pulley support
X Motor Assembly fastening screws
Adjust X Motor tension.
X speed reduction belt
How to replace the Speed Reduction Belt
REP1090
163
How to replace the Lever Sensor Assembly Item

1. Replacement Procedure 1. 2. 3. 4. 5. 6. Replace the Lever Sensor Assembly Remove the Front Paper Guide. Remove the Panel Cover. Remove the Panel Bottom Cover. Remove the Right Cover. Open the Control Box. Disconnect the Main Board connector J104 (LEVER) and cut the cable tie that holds the cables together. 7. Remove the Panel Cable connector and Tube Holder (one fastening screw) and pull out connector J301 and the Panel Cable (FFC). 8. Remove the Panel Mounting Plate. (3 fastening screws) 9. Remove the two black cable clamps attached to the Front X Reinforcement and pull out the Lever Sensor Assembly cable from the hole. 10. Remove the Lever Sensor Mounting Plate. (1 fastening screw) 11. Remove the Lever Sensor. (2 fastening screws) 12. Assembling is the reverse of the removal procedure.
REP1100
Connector J301
Dowel
Lever sensor Assembly + Push up Tube holder (Panel cable fastening material)
Lever sensor mounting plate
2. Adjustment and Open the Lever and confirm that Lever Up is displayed. Examination Procedure
Sensor fastening screws
Cable clamp Felt
How to replace the Lever Sensor Assembly
REP1100
164
How to replace the Cover Switch Assembly Item

Replace the Cover Switch Assembly 1. Remove the Panel Cover, Front Cover and Rail Cover in that order then undo the two screws holding the Y Rail Cover Support and remove the Y Rail Cover Support. Then remove the Rear Paper Guide. 2. Remove the Right Cover. 3. Undo the two screws holding the Ink Cartridge Unit then lift it up a little and slide it so that you can see the cable that passes beneath it. 4. Open the Control Box and pull out connector J106 from the Main Board. 5. Remove the black cable clamp and cut the cable tie that holds the cables together. 6. Remove the Cover Switch (2 fastening screws). 7. Assembling is the reverse of the removal procedure.
REP1110
Cover sensor arm
Sensor mounting plate Two fastening screws of switch
Open the Front Cover and confirm that Cover Open is displayed.
CAUTION: If the Cover Sensor Arm does not press the Cover Switch when the Front Cover is opened and closed, carry out the "Sensor Mounting Plate Position Adjustment".
+
+ +
Fastening screws
Cover switch
Adjust timing by sliding
Tighten after adjustment
How to replace the Cover Switch Assembly
REP1110
165
How to replace the Waste Fluid Box Sensor Assembly Item

1. Replacement Procedure Replace the Cover Switch Assembly 1. Remove the Right Paper Guide. 2. Open the Control Box. 3. Disconnect connector J105 (INK TANK) from the Main Board Assembly. 4. Remove the Waste Fluid Box Sensor Assembly. (2 fastening screws) 5. Assembling is the reverse of the removal procedure.
REP1120
Screw Waste fluid box sensor assembly
CAUTION: Be careful not to over-tighten when mounting the Waste Fluid Box Sensor Assembly. Tightening torque is 29.4 Ncm (3 kgcm).
Waste fluid box
Reference Since the Waste Fluid Box Sensor Assembly cable passes below the Cartridge Unit, the work will be easier if you remove the two Cartridge Base screws and push it back.
How to replace the Waste Fluid Box Sensor Assembly
REP1120
166
How to replace the Switch Cable Assembly/CD Cable Assembly Item
REP1130

CAUTION: The power cable connector must be disconnected before this operation.
Switch cable assembly
Switch Cable Assembly Replacement 1. Open the Control Box. 2. Disconnect connector J100 (SW) from the Main Board Assembly. 3. Press the Switch Lock and remove it by pushing it out. 4. Remove the cable from the white Cable Clamp. 5. Assembling is the reverse of the removal procedure. After fitting, check that the switch cable is not touching power supply board.
Connector J100 (SW)
DC Cable Replacement 1. Open the Control Box. 2. Disconnect connector J001 from the Power Board Assembly. 3. Disconnect connector J101 (POWER) from the Main Board Assembly and remove the cable. 4. Assembling is the reverse of the removal procedure.
Power board assembly Connector J001 (POWER) Connector J100 (SW) Main board assembly
Connector J001
How to replace the Switch Cable Assembly/CD Cable Assembly
REP1130
167
How to replace the Main Board Assembly Item
REP1140

For main board replacement, in addition to the new main board you must arrange for (1) a memory card for firmware installation and (2) a memory card for backup parameters (Fujitsu 4 MB card is recommended). Some memory cards do not always work. This main board assembly is constructed to accept backup parameters (user parameters and adjustment parameters) in a flash memory card.
Caution:
Be sure to capture these backup parameters before the board is replaced.
1. Capture back- 1. Be sure to take up backup parameters before the Main Board up parameis replaced. ters Caution: If you are unable to do this operation, ask to see the user setup list. For adjustment parameters, you can also contact the Inquiry Desk with the serial number of your plotter and receive adjustment parameters.
Memory card slot
How to replace the Main Board Assembly
REP1140
168
How to replace the Main Board Assembly Item

REP1141

2. Replace the Main Board 1) Disconnect all communications connectors. 2) If the Optional Interface is connected with the two Centronics Interface connector screws, remove it now. 3) Open the Control Box. 4) Disconnect all Main Board Assembly connectors. 5) Remove the Extension Board Assembly (4 screws) and SIMM. 6) Remove the Main Board Assembly. (5 fastening screws) 7) Assembling is the reverse of the removal procedure. REFERENCE SIMM must be inserted from Slot 1. REFERENCE Main board assembly DIP switches are for testing and have no settings. CAUTION: Firmware installation and parameter recovery will be carried out after this but these tasks must be done after the connections have been checked and with the Four extension board assembly fastening screws Control Box closed. Otherwise you may suffer an electric shock or components may be damaged.
Five main board assembly fastening screws
Extension board Main board assembly assembly
3. Install latest program
3. Install the latest program.
4. Install backup 4. Install the backup parameters that were taken up in Step 1 in the new Main Board Assembly. parameters CAUTION: If backup parameters were not taken up in Step 1, enter them manually. For the user setup list, refer to the section on How to set parameters in the Users Guide and Functional Operation Edition. Also, for adjustment parameters, refer to BAC5020 (parameter update). CAUTION: Replace the Waste Fluid Box if backup parameters were not taken up in Step 1. The message Change Tank?: will appear on the panel display. You should confirm by answering Yes.
How to replace the Main Board Assembly
REP1141
169
How to replace the Power Supply Board Assembly Item

CAUTION: CAUTION:
REP1150

The power cable connector must be disconnected before this operation. Since the power supply remains hot after the power is switched off, wait until it has cooled before performing this operation.
Replace the Power Supply Board Assembly 1. Open the Control Box. 2. Disconnect Power Supply Board Assembly connectors J000 and J001. 3. Remove the Power Supply Board Assembly. (5 fastening screws) 4. Assembling is the reverse of the removal procedure.
Connector J001
Connector J000
How to replace the Power Supply Board Assembly
REP1150
170
How to replace the Panel Board Assembly Item

1. Replacement Procedure Replace the Panel Board Assembly 1. Remove the Panel Cover. 2. Disconnect connector J301 from the Panel Board Assembly. 3. Remove the Panel Board Assembly. (4 fastening screws) 4. Assembling is the reverse of the removal procedure. Do not forget to peel the LCD protection film off.
Screws
REP1160
Panel board assembly
Screws
Connector J301
How to replace the Panel Board Assembly
REP1160
171
How to replace the Panel Cable Item

1. Replacement Procedure Replace the Panel Cable 1. Open the Control Box. 2. Remove the Panel Bottom Cover. (4 screws) 3. Remove the Panel Cover. 4. Disconnect connector J301 from the Panel Board Assembly. 5. Remove the Tube Guide. (1 screw) 6. Disconnect connector J110 (PANEL) from the Main Board Assembly and remove the cable. 7. Assembling is the reverse of the removal procedure.
REP1170
J301 Connector Panel cable Tube guide (Panel cable fastening material) Screw
When re-laying a new Panel Cable, refer to the positions of the bends in the previous cable and proceed after first making the bends in the new cable. Use double-sided tape to stick the cable to the underside of the X Rail.
Connector J110
How to replace the Panel Cable
REP1170
172
How to replace the Extension Board Assembly Item

1. Replacement Procedure Replace the Extension Board Assembly 1. Disconnect all communications connectors. 2. Open the Control Box. 3. Remove the Extension Board Assembly. (4 fastening screws) 4. Assembling is the reverse of the removal procedure.
REP1180
Four extension board assembly fastening screws
Extension board assembly
How to replace the Extension Board Assembly
REP1180
173
How to replace the XR Cable Assembly (Rear Paper Sensor) Item

REP1200

Replace the XR Cable Assembly (Rear Paper Sensor) 1. Open the Control Box. 2. Remove connector J107 (XR) from the Main Board Assembly. 3. Remove the Panel Cover. 4. Remove the Front Cover. 5. Remove the Y Rail Cover. 6. Remove the Rear Paper Guide. 7. Remove the two screws holding the Sensor Mounting Plate through the hole in the Flexible Support Cable Guide. CAUTION: Be careful not to damage the Y Cable covering. 8. Remove the sensor from the sensor mounting plate (2 screws) on the Rear Frame X Reinforcement. 9. Assembling is the reverse of the removal procedure.
Five holes for removal of rear paper guide Two holes for removal of sensor
1. Adjust the bundle of Y cable, N belt and ink tubes. (Make sure the pressure arm is lowered then move the head left and right so that there is no twisting.) 2. Carry out "Rear sensor position" with the printer's self-diagnostics under the adjustments menu.
Sensor fastening screws
XR cable assembly (Rear paper sensor)
How to replace the XR Cable Assembly (Rear Paper Sensor)
REP1200
174
How to replace the Pressure Assembly, Pressure Roller and Blade Item
1. Replacement Procedure Replacing the Pressure Assembly 1. Remove right and left covers. 2. Remove panel cover. 3. Remove front cover. 4. Remove Y rail cover. 5. Remove front paper guide 6. Remove rear paper guide 7. Loosen two steel belt tensioning screws.
REP1220
Tension screws
Steel belt
8. Remove one steel belt fastening screw. 9. Remove the steel belt.
Steel belt fastening screw
CAUTION: Be careful not to cut your finger on the edge of the steel belt.
10. Remove the Y motor assembly. (3 fastening screws)
Three Y motor fastening screws
Y motor assembly
How to replace the Pressure Assembly, Pressure Roller and Blade
REP1220
175
REP1221
11. With the pressure roller down, loosen the set screw on the pressure axle fastening spacer.
X rail
Fastening spacer Ball screw driver
12. Operate the pressure lever and with the pressure roller up, remove the E-ring holding the link. 13. The pressure axle that is stuck into the hexagonal hole in the link should be pushed a little way in. At this time, the stepped collar will come off so be careful not to lost it.
E-ring Link
REP1221
176
REP1222

14. Pull out the pressure shaft from the right side of the frame. CAUTION: Be careful. If the pressure axle is taken out completely, the pressure axle fastening spacer and the media keeper will fall into the body of the printer.
Pressure shaft
Pull out
15. Remove the four hexagonal nuts holding tube bracket and lift the entire Y cable tube bracket while you undo the four nuts holding the Y cable guide.
Four screws
16. Remove the screws (5 at the back and 4 below) holding the Y rail reinforcement plate and pull the entire pressure assembly to the back while you slide it towards the X motor and remove it. REFERENCE A special ratchet tool is required for the bottom screw holding the Y rail reinforcement plate (hex. 4 10 mm double SEMS). 17. Remove the pressure assemblies from the Y rail reinforcement plate. (2 screws for each assembly) 18. Refitting is the reverse of the removal precedure.
Pressure assembly Y rail reinforcement plate
Four hexagonal nuts Hex. screw
Ratchet screw driver
REP1222
177
1. Replacement Procedure Blade Replacement 1. Open the front cover. 2. Use a fine straight screwdriver to slightly prize apart the blade attachment and remove the blade. CAUTION: When removing the blade, dont use excessive force to part it as there is a risk of damaging the blade.
Blade
REP1223
Pressure arm
Open
3. To refit, insert the blade on the pressure arm.
Pressure Roller Replacement 1. Follow the blade replacement procedure to remove the blade. 2. Use a fine straight screwdriver to slightly prize apart the pressure roller attachment and remove the pressure roller. CAUTION: When removing the blade, dont use excessive force to part the blade and pressure arm as there is a risk of damaging the pressure arm and the blade. 3. To refit, insert the pressure roller and then the blade on the pressure arm.
Pressure arm
Pressure roller
Open
REP1223
178
How to replace the Pump Motor Assembly Item

1. Replacement Procedure 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Replace the Pump Motor Assembly Remove the Panel Cover. Remove the Front Cover. Remove the Panel Bottom Cover. Remove the Right Cover. Remove the Y Rail Cover. Remove the Panel Cable connector and Tube Fixer (1 fastening screw) and disconnect connector J301. Remove the Panel Mounting Plate. (3 fastening screws) Open the Control Box. Disconnect connector J102 (PUMP) from the Main Board Assembly. Remove the cable clamp fastened to the Front X Reinforcement. Slide the head to the left (in the center section) and remove the entire Maintenance Assembly. (2 top screws/2 front screws) Remove the two screws holding the Pump Motor Plate and lift out the Pump Unit. Remove the four screws holding the Pump Motor Assembly. Assembling is the reverse of the removal procedure.
REP1230
CAUTION: CAUTION:
Apply silicone grease to motor gears. Pass the motor cable through the round hole in the pump motor plate.
2. Adjustment and 1. Carry out the Capping Position Adjustment. Examination Procedure
How to replace the Pump Motor Assembly
REP1230
179
How to replace the Cap Assembly Item

1. Replacement Procedure Replace the Cap Assembly 1. Remove the Panel Cover. 2. Remove the Front Cover. 3. Remove the Y Rail Cover. 4. Remove the Panel Bottom Cover. 5. Remove the Panel Mounting Plate. 6. Remove the Maintenance Assembly. 7. Draw out the tube on the panel side. 8. Remove one screw holding the Cap Assembly. 9. Slide the Cap Assembly towards the gear and lift it out.
Screw
REP1240
Draw out the tube (2 places)
CAUTION: Be careful not to touch the cap surface and the wiper with your hand while you are working. 10. Assembling is the reverse of the removal procedure. CAUTION: When you insert the tubes into the cap assembly refer to the picture on the right so that the tubes do not exert any load. Otherwise the cap assembly will not move smoothly. CAUTION: When screwing the cap assembly to the maintenance frame, push it right back before fastening. 2. Adjustment and Examination Procedure 1. Carry out the Capping Position Adjustment.
How to replace the Cap Assembly
REP1240
180
How to replace the Wiper Item

1. Replacement Procedure Replace the Wiper 1. Remove the Panel Mounting Plate. 2. Move the Wiper back and, with the Wiper rack disconnected, pull the Wiper up and remove it. 3. Assembling is the reverse of the removal procedure. CAUTION: When refitting the Wiper, be careful not to damage the Head contact surface by touching it with your hand or with forceps.
REP1250
Pull up
2 Adjustment and Inspection Procedure
1. Initialize the wiper count.

Wiper Rack section
Felt surface
Rubber surface
[ Printing roller side ]
[ Cap side ]
How to replace the Wiper
REP1250
181
How to replace the Pump Assembly Item
REP1260

REFERENCE When the pump assembly is replaced, the wiper should also be replaced at the same time so be sure to have a spare wiper ready.
1. 2. 3. 4. 5. 6. 7.
Replace the Pump Assembly Remove the Panel Cover. Remove the Front Cover. Remove the Y Rail Cover. Remove the Panel Bottom Cover. Remove the Panel Mounting Plate. Take out the Maintenance Station Assembly. Disconnect and remove the tubes between the Pump Assembly and the Cap Assembly. 8. Remove the waste liquid tube that is clamped to the outside of the Right Frame. 9. Remove the metal plate to which the gear is attached together with two screws. 10. Remove the pump assembly (1 screw), slide it towards the wiper and lift it out. 11. Assembling is the reverse of the removal procedure. REFERENCE Before assembly, check that the wiper is installed on the pump assembly.
2. Adjustment and 1. Carry out the Capping Position Adjustment. 2. Initialize the wiper count. Examination Procedure
CAUTION: Be sure to clamp the waste liquid tube in the proper position on the outside of the right frame. Otherwise the ink will spill and soil the floor and clothing. When you insert the tubes into the cap assembly refer to the picture on the right so that the tubes do not exert any load. Otherwise the cap assembly will not move smoothly.
CAUTION:
How to replace the Pump Assembly
REP1260
182
How to replace the Maintenance Station Assembly Item

1. Replacement Procedure Replace the Maintenance Station Assembly 1. Remove the Panel Cover. 2. Remove the Front Cover. 3. Remove the Y Rail Cover. 4. Remove the Panel Bottom Cover. 5. Remove the Panel Mounting Plate. 6. Open the Control Box. 7. Disconnect the pump motor connector J102. 8. Undo the bundle of cables. 9. Remove the waste liquid tube from the clamp. 10. Remove the Maintenance Station. (2 top screws/2 front screws) 11. Assembling is the reverse of the removal procedure. CAUTION: Be sure to clamp the waste liquid tube in the proper position on the outside of the right frame. Otherwise the ink will spill and soil the floor and clothing. 2. Adjustment and Examination Procedure 1. Carry out the Capping Position Adjustment. 2. Initialize the wiper count.
REP1270
Screw
Screws
How to replace the Maintenance Station
REP1270
183
How to replace the Y Motor Assembly Item

REFERENCE
REP1280

If there is to be no replacement that includes the Y motor assembly, steps 2, 4 and 5 are not necessary.
Screws
Replace the Y Motor Assembly 1. Remove the Left and Right Covers. 2. Remove the Rear Paper Guide. 3. Remove the Steel Belt. 4. Open the Control Box. 5. Disconnect connector J120 (YMOT) from the Main Board Assembly. 6. Remove the Y Motor Assembly. (3 fastening screws) 7. Assembling is the reverse of the removal procedure. REFERENCE Since the Y Motor Assembly Cable passes below the Cartridge Unit, the work will be easier if you remove the two Cartridge Base screws and push it back.
Y motor cable terminal
Y motor assembly
REP1280
184
How to replace the Steel Belt Item

CAUTION: 1. Replacement Procedure 1. 2. 3. 4. 5.
REP1290

Do this work with the pressure roller down.
Replace the Steel Belt Remove left and right covers. Move the head to near the center. Remove the head cover. (2 fastening screws) Loosen the two steel belt tensioning screws. Remove the belt fastening screw and take off half the steel belt towards the Y motor side 6. overlap the end of the steel belt removed in 5. with the end of a new steel belt and attach it with tape. 7. Pass the taped part around the drive pulley, press it into the Y rail and pull it from the return pulley side and fit the new belt into the Y rail. Up to here Press in Tape to old belt using the fitting on the front of the new belt
Steel belt
Tension adjustment screws
New steel belt Old steel belt
CAUTION:
Check that there is no foreign matter or dust on the new steel belt, drive pulley or return pulley as this may cause abnormal printing or belt damage. Be careful not to cut your finger with the end of the steel belt.
Fastening screws
CAUTION:
8. Remove the tape and fasten the new steel tape to the head with the two fastening screws. CAUTION: Be careful that the belt is not twisted in the Y rail.
2. Adjustment and 1. Adjust the steel belt tension. Examination Procedure
How to replace the Steel Belt
REP1290
185
How to replace the T Fence Item

1. Replacement Procedure Replace the T Fence 1. Remove the Panel Cover. 2. Remove the Front Cover. 3. Remove the Y Rail Cover. 4. Loosen the 12 screws holding the T Fence keeper plate (10 screws on 54-inch model and 11 on 62-inch model), slide the plate towards the Y Cable side, then remove the T Fence. CAUTION: Mind the Head Board and take out the T Fence on the X Motor side. 5. Assembling is the reverse of the removal procedure. REFERENCE The T Fence has a front and a back. Assemble it so that the round hole is at the top on the X motor side or on the bottom on the maintenance unit side.
REP1300
Twelve fastening screws
X motor
or or
Correct Wrong
T Fence
2. Cleaning Procedure
How to clean the T Fence 1. Gently wipe the T Fence with a lint-free cloth which has been wet with water or ethanol. (Lint-free cloth is closely woven from extremely fine threads and has no nap and produces no dust.) CAUTION: When wiping the T Fence, be careful not to rub it vigorously.
How to replace the T Fence
REP1300
186
How to Replace the Steel Flexible Guide Assembly and Cursor Plate Spring Item
REP1310
Replace the Steel Flexible Guide Assembly 1. Replacement Procedure Removal 1. Remove the Panel Cover. Hexagonal nut (H for fitting flexible cable support is included.) 2. Remove the Front Cover. 3. Remove the Y Rail Cover. 4. Remove 2 screws holding the Steel Flexible Cable Support to the H Board Fitting Plate. 5. Move the head towards the X Motor side. Tube bracket 6. Remove the Cable Keeper on the Tube Keeper. (2 screws) 7. Undo the four places where the Tube Guide is clamping the Steel Flexible Cable Support and remove the Steel Flexible Cable Support. Assembling 1. 2. 3. 4. Screw the steel bare to the H Board Fitting Plate. Clamp the Steel Flexible Cable Support to the Tube Guide. Fully tighten the screws holding the Steel Flexible Cable Support to the H Board Fitting Plate. Temporarily fasten the CableKeeper to hold the Steel Flexible Cable Support to the Tube Guide. 5. Move the head inside the maintenance assembly then tighten the cable keeper.
Cursor plate spring
Cable keeper Tube keeper
Screw Cartridge pipe
Tube guide assembly
Steel flexible guide
1. Replacement Procedure 1. 2. 3. 4.
Replace the Cursor Plate Spring Remove the Panel Cover. Remove the Front Cover. Remove the Y Rail Cover. (3) Remove to left Bring the head to center of the printer, press down the left and right ends of the cursor plate spring and pull it out to the right. 5. Assembling is the reverse of the removal procedure.
(1) Press and remove
(2) Press Ink tube
Tube guide assembly
Steel flexible guide
How to Replace the Steel Flexible Guide Assembly and Cursor Plate Spring
REP1310
187
How to Replace the Steel Flexible Guide Assembly and Cursor Plate Spring Item
1. Replacement Procedure Removal 1. 2. 3. 4. Replace the Steel Flexible Guide Assembly
REP1310-2
Remove the Panel Cover. Remove the Front Cover. Remove the Y Rail Cover. Undo the two screws holding the steel bare to the H board mounting plate (flexible cable support keeper on 62-inch models). 5. Move the head towards the X Motor side. 6. Remove the Cable Keeper on the Tube Keeper. (2 screws) 7. Undo the part that is clamping the steel bare for the ribbon cable guide and remove the steel bare.
Steel flexible cable Cable keeper Tube keeper
1. Screw the steel bare to the H Board Fitting Plate. Assembling 2. Clamp the Steel Flexible Cable Support to the Tube Guide. 3. Fully tighten the screws holding the Steel Flexible Cable Support to the H Board Fitting Plate. 4. Temporarily fasten the CableKeeper to hold the Steel Flexible Cable Support to the Tube Guide. 5. Move the head inside the maintenance assembly then tighten the cable keeper.
Cursor plate spring
[ 62 inch ]
H board mounting plate Flexible cable support keeper Steel flexible cable (2) Press Ribbon cable guide
Replace the Cursor Plate Spring 1. Replacement Procedure 1. 2. 3. 4. Remove the Panel Cover. Remove the Front Cover. (3) Remove to left Remove the Y Rail Cover. Bring the head to center of the printer, press down the left and right ends of the cursor plate spring and pull it out to the right. 5. Assembling is the reverse of the removal procedure.
(1) Press and remove
Clamping part
Steel flexible cable
How to Replace the Steel Flexible Guide Assembly and Cursor Plate Spring
REP1310-2
188
How to replace the Y Return Pulley Assembly Item

Replace the Y Return Pulley Assembly 1. Replacement Procedure 1. Remove the Panel Cover. 2. Remove the Front Cover. 3. Remove the Y Rail Cover. 4. Remove the Left and Right Covers. 5. Move the Head to the left (X Motor side). 6. Loosen the Steel Belt tension (loosen two tensioning screws). 7. Remove the Steel Belt fastening screws on the left side and slide it out to the Return Pulley. 8. Remove the Y Return Pulley. 9. Assembling is the reverse of the removal procedure.
REP1320
Tension screw
Belt fastening screw
Belt fastening screw
Return pulley
Steel belt
How to replace the Y Return Pulley Assembly
REP1320
189
How to replace the Cartridge Frame Assembly Item

Replace the Cartridge Frame Assembly 1. Carry out Head Cleaning. 2. Remove the Right Paper Guide. 3. Disconnect all connectors J402 to J413 from the junction board assembly leaving only J401 (FFC) connected.
Connector Table J401 J402 J403 J404 J405 J406 J407 J408 J409 J410 J411 J412 J413 MAIN FFC 16-core Detector K Black 4-core Detector C Cyan 4-core Detector M Magenta 4-core Detector Y Yellow 4-core Ink ID K Ink ID C Ink ID M Ink ID Y Black 5-core Cyan 5-core Magenta 5-core Yellow 5-core
REP1330
Ink ID sensor connector
Detector assembly connector
4. Remove the connectors of the cartridge pipes and ink tubes on the cable guide. CAUTION: If there is wash liquid remaining in the ink tubes and head dampers, it may flow out from the head nozzles and spill around the maintenance assembly. Use cotton waste to wipe up any spilt wash liquid. When pipes and tubes are being removed, mark the tubes so that they will not be confused when they are reassembled.
Detector 5 Black 6-core Detector 6 White 6-core Ink ID 5 Ink ID 5 Black 6-core White 6-core
On panel display, 5 = O (Orange) 6 = G (Green) J413 has twisted lines
CAUTION:
Fastening screw
5. Remove the Y Rail Cover Support. (2 fastening screws)
Fastening screw
How to replace the Cartridge Frame Assembly
REP1330
190

REP1331

6. Remove two screws holding the cartridge base. Slide the cartridge base towards (1) then lift as in (2) to separate it from the rear X reinforcement.
Lift
2
Slide Cartridge slide 2
Two screws
Two screws
7. Cut the cable tie holding the cables. 8. Remove the cartridge pipes from the cartridge frame. REFERENCE Be careful not to lose the nuts and Orings on the disconnected cartridge pipes.
9. Undo the two screws holding cartridge slide 2.
REP1331
191

REP1332

10. Remove 2 screws holding the cartridge frame to the cartridge base, slide the cartridge frame in the direction of arrow a and lift to separate it from the cartridge base. 11. To dismantle the cartridge frame, open the upper claw of the frame assembly and needles as in (1) then slide it down (arrow (2)). Next, slide the cartridge in the direction of arrow (3) to remove it.
I/C guide base
Cartridge frame
CAUTION:
Please work carefully as there is a risk of injury from the sharp needles on the frame assembly. Replacements related to the sensors attached to the cartridge frame can be carried out with "cartridge side plates" after this work.
REFERENCE
Cartridge base
12. The I/C guide base attached to the cartridge base can be dismantled when the four claws are disconnected from the back. At the same time, the plates for preventing incorrect insertion and the cushioning spring and felt can be removed. CAUTION: Take care not to mistake the positioning of the plates for preventing incorrect insertion otherwise it will be impossible to insert the cartridges correctly.
Slot 6 None Slot 5 None Slot 4 Slot 3 Slot 2 Slot 1 Slot No. as seen from the top
Y M C K Color
Cartridge slide
REFERENCE
Cartridge side plate 2 Frame assembly and needles
Slots 1 to 4 have plates to prevent each type of incorrect insertion.
REP1332
192

REP1333

13. Assembling is the reverse of the removal procedure. CAUTION: Dont use a tool to tighten the coupling screws but get them as tight as possible with your fingers. If you use a tool, there is a risk of breaking the plastic taps.
1. Carry out the initial filling. CAUTION: Wait at least 30 minutes after the initial filling before printing. Otherwise the printing quality can not be assured.
2. Carry out a test print. 3. Fit a new Waste Fluid Box. CAUTION: About 100 cc of waste fluid will be expelled into the Waste Fluid Box from head cleaning and initial filling. Fit a new Waste Fluid Box. The message Change Tank?: will appear on the panel display. You should confirm by answering Yes.
REP1333
193
How to replace the Ink ID Sensor Assembly Item

1. Replacement Procedure How to replace the Ink ID Sensor Assembly 1. Carry out replacement steps 1 to 10 of the previous item "Cartridge Frame Assembly Replacement" (REP1330-1332). 2. Remove two screws holding the ink ID sensor. 3. Assembly is the reverse of dismantling.
Ink ID sensor connector
REP1340
CAUTION: The ink ID sensor must be installed in the same place as the previous sensor. The printer will not work if the ID is unsuitable.
Ink ID sensor assembly
Two fastening screws
How to replace the Ink ID Sensor Assembly
REP1340
194
How to replace the Detector Assembly Item

1. Replacement Procedure Replace the Detector Assembly 1. Carry out replacement steps 1 to 11 of the previous item "Cartridge Frame Assembly Replacement" (REP1330-1332). 2. The no ink detection sensor and cartridge detection sensor of the detector assembly are each held to the cartridge side plate by one screw. Remove the screws and carry out the replacement. 3. Assembly is the reverse of dismantling.
REP1350
Detector assembly Ink detection switch
Fastening screw
CAUTION: Be careful not to over-tighten when refitting the cartridge sensor. If it is over-tightened the detection section of the sensor will not slide. Tightening torque is 29.4 Ncm (3 kgcm). CAUTION: Detector assemblies have different cable lengths and connectors depending on which slot they are fitted to. Be careful not to confuse them.
Cartridge detection switch Fastening screw
Cartridge frame assembly
How to replace the Detector Assembly
REP1350
195
How to replace the Y Cable Item

1. Replacement Procedure 1. 2. 3. 4. 5. 6. Replace the Y Cable Remove the Panel Cover. Remove the Front Cover. Remove the Y Rail Cover. Open the Control Box. Remove the Rear Paper Guide. Disconnect connectors J111 (HEAD1) and J112 (HEAD2) from the Main Board Assembly. REFERENCE The flat core will come away at the same time. Be careful not to drop it. 7. Remove the cable keeper from the Head Board Assembly. (2 fastening screws) 8. Disconnect connectors J201 (MAIN1) and J202 (MAIN2) from the Main Board Assembly. 9. Remove 4 hex. nuts holding the tube bracket. 10. Withdraw the Y Cable that passes through the Right X Reinforcement into the Control Box, straighten out the bends and pass it through the hole in the left Flexible Cable Guide Support. REFERENCE This work will be easier if you remove the screw holding the ink cartridge base and move the base. 11. Lift the tube bracket up and remove Y Cable together with the N Belt. 12. Assembling is the reverse of the removal procedure. REFERENCE The new Y cable has no fold crease. Make a fold crease in the new cable to match the old cable. CAUTION: Power must be off when connectors are being disconnected or reconnected, otherwise you may be injured or a board may be damaged. The main board assembly will certainly be damaged if power is applied with main board assembly connectors J111 (HEAD) and J112 (HEAD2) and head board connectors J201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP.
REP1360

Cable keeper (2)
Y cable
Hexagonal nut
Cable keeper
Fastening screw Tube keeper Tube bracket Cartridge pipe
X reinforcement R Screw
Junction board assembly Y cable
2. Adjustment
1. When the Y Cable has been laid, first fit the Y Rail Cover only then move the head by hand to confirm does not produce any hindrance, noise or jamming. If there is a fault, adjust by moving the part of the Y Cable on the Head Board Assembly Cable keeper.
How to replace the Y Cable
REP1360
196
How to replace the Y Cable Item

1. Replacement Procedure 1. 2. 3. 4. 5. 6. Replace the Y Cable Remove the Panel Cover. Remove the Front Cover. Remove the Y Rail Cover. Open the Control Box. Remove the Rear Paper Guide. Disconnect connectors J111 (HEAD1) and J112 (HEAD2) from the Main Board Assembly. REFERENCE The flat core will come away at the same time. Be careful not to drop it. Remove the cable keeper from the Head Board Assembly. (2 fastening screws) Disconnect connectors J201 (MAIN1) and J202 (MAIN2) from the Main Board Assembly. Remove the ribbon cable guide clamp parts. Remove 4 hex. nuts holding the tube bracket. Withdraw the Y Cable that passes through the Right X Reinforcement into the Control Box, straighten out the bends and pass it through the hole in the left Flexible Cable Guide Support. REFERENCE This work will be easier if you remove the screw holding the ink cartridge base and move the base. Lift the tube bracket up and remove Y Cable together with the N Belt. Assembling is the reverse of the removal procedure. REFERENCE The new Y cable has no fold crease. Make a fold crease in the new cable to match the old cable. CAUTION: Power must be off when connectors are being disconnected or reconnected, otherwise you may be injured or a board may be damaged. The main board assembly will certainly be damaged if power is applied with main board assembly connectors J111 (HEAD) and J112 (HEAD2) and head board connectors J201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP.
Y cable
REP1360-2
Cable keeper
Clamping part
Ribbon cable guide
7. 8. 9. 10. 11.
Cable keeper Hexagonal nut Tube keeper
X reinforcement R
Junction board assemb
12. 13.
2. Adjustment
1. When the Y Cable has been laid, first fit the Y Rail Cover only then move the head by hand to confirm does not produce any hindrance, noise or jamming. If there is a fault, adjust by moving the part of the Y Cable on the Head Board Assembly Cable keeper.
Tube bracket
Y cable
How to replace the Y Cable
REP1360-2
197
How to replace the Ink Tubes Item

1. Replacement Procedure 1. 2. 3. 4. 5. Replace the Ink Tubes Carry out Head Cleaning and empty the ink inside the tubes. Remove the Panel Cover. Remove the Front Cover. Remove the Y Rail Cover. Remove the Head Board Assembly Cable keeper and disconnect the Y Cable from the connector. 6. Remove the ten tube guide clamps. 7. Undo the two screws holding the tube keeper. 8. Remove the four joining screws and O-rings on the Flexible Cable Guide. 9. Remove the four joining screws and O-rings below the cursor. 10. Assembling is the reverse of the removal procedure. CAUTION: Be careful not to lose the O-rings. Initial filling and printing can not be done if the O-rings are missing.
REP1370
Tube fastening screw (small)
Joining screw (large)
Open the clamp here
Dont use a tool to tighten the coupling screws but get them as tight as possible with your fingers. If you use a tool, there is a risk of breaking the plastic taps. REFERENCE Ink tubes have a tendency to bend. Laying the tubes in the direction of that tendency prevents the tubes from behaving badly and jamming. REFERENCE Couplings have a definite orientation. (See diagram below)
Cartridge side Head side
CAUTION:
Ink tube
Flexible cable guide
Joining screw
Joining screw
Continued on next page (REP1371)
How to replace the Ink Tubes
REP1370
198

1. Replacement Procedure 1. 2. 3. 4. 5. Replace the Ink Tubes Carry out Head Cleaning and empty the ink inside the tubes. Remove the Panel Cover. Remove the Front Cover. Remove the Y Rail Cover. Remove the head board assembly cable keeper and disconnect the Y cable from the connector. 6. Remove the ribbon cable guide and tube guide clamps. 7. Undo the two screws holding the tube keeper. 8. Remove the tube bracket cable keeper. 9. Remove the four joining screws and O-rings on the Flexible Cable Guide. 10. Remove the four joining screws and O-rings below the cursor. 11. Assembling is the reverse of the removal procedure. CAUTION: Be careful not to lose the O-rings. Initial filling and printing can not be done if the O-rings are missing.
REP1370-2

[54 inch] [62 inch]
Ink tube
Ink tube Joining screw (small) Joining screw (small) Joining screw (large) Joining screw (large)
Ribbon cable guide
Tube keeper
Flexible cable guide
Dont use a tool to tighten the coupling screws but get them as tight as possible with your fingers. If you use a tool, there is a risk of breaking the plastic taps. REFERENCE Ink tubes have a tendency to bend. Laying the tubes in the direction of that tendency prevents the tubes from behaving badly and jamming. REFERENCE Couplings have a definite orientation. (See diagram below)
Cartridge side Head side
CAUTION:
Tube guide
Clamping parts
Joining screw
Cable keeper
REP1370-2
199

1. Replacement Procedure Diagram showing construction of joiners
REP1371

(Cartridge side) Cartridge pipe Joint nut (large) DE-49778 O-ring (large) DE-49777 Coupling (black) DE-49992 O-ring (large) DE-49777 Coupling screw (large) DE-49778 Ink tube
Joint nut (large) DE-49778 O-ring (large) DE-49777 Coupling (white) DE-49993 Tube fastening O-ring (small) DE-48949 Ink tube Head pipe
Tube stop screw (small) DE-48950
(Head side)
1. Carry out the initial filling. CAUTION: CAUTION: Wait at least 30 minutes after the initial filling before printing. Otherwise the printing quality can not be assured. If possible, ink cartridges used for initial filling should be cartridges that have not been used previously. Since a large amount of ink is required for filling, filling may fail if there is insufficient ink remaining.
2. Carry out a test print. 3. Fit a new Waste Fluid Box. CAUTION: About 100 cc of waste fluid will be expelled into the Waste Fluid Box from head cleaning and initial filling. Fit a new Waste Fluid Box. The message Change Tank?: will appear on the panel display. You should confirm by answering Yes.
REP1371
200
How to replace the Cutter Solenoid Assembly Item

1. Replacement Procedure 1. 2. 3. 4. 5. 6. 7. Replace the Cutter Solenoid Assembly Remove the Panel Cover. Remove the Front Cover. Remove the Y Rail Cover. Disconnect connector J206 (SOL) from the Head Board Assembly. Remove the Head Cover. Move the Head 20 to 30 cm to the left. Undo the two screws on the left edge of the head and remove the cutter unit. 8. Remove the screw holding the cutter cap. 9. Undo the two screws holding the solenoid to the cutter box and take the solenoid from the box. 10. Assembling is the reverse of the removal procedure. When removing the cutter blade, the head must first be moved to a position over the cutter mat. If the tip of the cutter blade hits against the front paper guide, the tip will be chipped and will no longer be able to cut. REFERENCE There are two types of springs inside the cutter unit, the solenoid spring and the cutter spring. Be careful not to lose them when you are dismantling. 1. When the cutter unit is being assembled its position relative to the cutter mat must be adjusted. Refer to Figure A and fasten it in the correct position.
Cutter blade Platen Cutter mat Fix so that the front corner of the cutter mat groove and the flat part of the cutter blade are aligned. REFERENCE This rib should cover at least half the flat part of the cutter mat. Move the head to make sure that both left and right edges cover at least one-third.
REP1380
Plate nut Two fastening screws
CAUTION:
Solenoid assembly
Cutter cap
Cutter solenoid assembly
Cutter spring
[Diagram A]
How to replace the Cutter Solenoid Assembly
REP1380
201
How to replace the Head and Head Cable Item

1. Replacement Procedure 1. 2. 3. 4. 5. 6. 7. Head, Head Cable Replacement
REP1390
Do head washing. If HEAD1 (left) only is to be replaced, change "6 places" to "3 places". Remove panel cover. Remove front cover. Remove Y rail cover. Remove head cover. Unlock and disconnect FFC entering the head board assembly connectors J207 (HEAD C1) and J208 (HEAD C2) Cut the cable tie holding the head pipes. Undo the tube stop screws holding the head pipes on the damper (6 places) and disconnect the head pipes. REFERENCE When the tube stop screws are removed, there will be O-rings on the head pipes. Be careful not to lose them. 8. Remove the damper positioning materials. (1 screw) 9. Disconnect the dampers from the print head. (6 places) CAUTION: The damper will not function if the film part of the damper is gripped strongly and printing may not work. 10. With a small straight-bladed screwdriver remove the compression spring from where it is attached on the aluminum die-cast side of the head fastening material. (2 places) 11. Remove the screw holding the print head together with H spacer. 12. Slide the left print head, Head 1, towards arrow (1) and after disconnecting the insertion section, lift it out. 13. Remove Head 2 in the same manner. REFERENCE When print heads and head cables are to be replaced: For dismantling, remove Head 1 (left)then Head 2 (right) For assembly, refit Head 2 (right) then Head 1 (left) Cabling makes it impossible to work in the opposite order. 14. Disconnect head cables from the print head connectors.
Insertion section
How to replace the Head and Head Cable
REP1390
202

2. Assembling
REP1391

1. For bending, refer to the head cable that was previously used.
Example of head cable bending for Head 1 (left)
CAUTION: The bend on the print head side of the head cable used with Head 1 (left) should be made such that the protrusion from the connector is minimal. Otherwise the range for adjusting head inclination becomes too small and adjustment is impossible. 2. Print the head rank of the print head that is to be used on the head cable. If the previous head rank is inscribed, this should be cancelled with two lines before the print. 3. Assembly is the reverse of dismantling.
Wrong Correct
CAUTION: The parts inside the print head that are shown in diagram A must not be touched. Otherwise oil and dirt may make it impossible for them to be used properly.
[Diagram A]
Damper connection
Nozzle face
REP1391
203

3. Adjustment and Examination Procedure 1.
REP1392

REFERENCE If a head has been replaced, the nozzle ejection count value should be reset.
Carry out initial filling with ink. REFERENCE Head washing and initial filling consumes a large quantity of waste liquid. The waste liquid box should be replaced when initial filling is finished.
CAUTION: After initial filling, wait for at least 30 minutes before printing. Otherwise the printing quality cannot be assumed. 2. 3. Load roll media in the printer. Do a "Nozzle check" to confirm whether there is incomplete filling or abnormal ejection. If there is a fault, try again after "Cleaning". REFERENCE 4. 5. 6. 7. 8. 9. At rare intervals a dirty wiper may cause faulty ejection and the wiper should be rubbed with a wiper cleaning cloth.
Do Left Tilt adjustment. Do Right Tilt adjustment. Do Repeatability (Normal) adjustment. Do Repeatability (Microdot) adjustment. Do "Unidirectional" adjustment. Do "Unidirectional (Microdot)" adjustment.
10. Do "Test print" to confirm results of adjustments.
REP1392
204
How to replace the Edge Sensor Assembly Item

1. Replacement Procedure Edge Sensor Replacement 1. Remove front cover. 2. Remove panel cover. 3. Remove Y rail cover. 4. Remove head board assembly connector J204 (P EDGE). 5. Remove head cover. 6. Remove edge sensor. (1 fastening screw) Use straight blade screwdriver No. 1. 7. Assembly is the reverse of dismantling. CAUTION: Fastening screws are self-tapping screws. Be careful not to over-tighten. Tightening torque is 29.4 N.cm (3 kg.cm).
Screw (self-tapping)
REP1410
Edge sensor a
How to replace the Edge Sensor Assembly
REP1410
205
How to replace the Head Board Assembly Item

1. Replacement Procedure Replace the Head Board Assembly
REP1420

Screws
1. Remove the Front Cover. 2. Remove the Panel Cover. 3. Remove the Y Rail Cover. 4. Disconnect all connectors from the Head Board. 5. Remove the Head Board. (4 fastening screws) 6. Assembling is the reverse of the removal procedure.
Connector J201 (MAIN1) J202 (MAIN2)
CAUTION: Be sure to switch off the power whenever connectors are disconnected or inserted. Incorrect operation will lead to injury and component damage. The main board assembly will certainly be damaged if power is applied with main board assembly connectors J111 (HEAD) and J112 (HEAD2) and head board connectors J201 (MAIN1) and J202 (MAIN2) inserted with oblique FFP.
Screws
How to replace the Head Board Assembly
REP1420
206
How to replace the Dampers Item

1. Replacement Procedure 1. 2. 3. 4. 5. 6. 7. 8. 9. Dampers Replacement Carry out Head Cleaning. Remove the Panel Cover. Remove the Front Cover. Remove the Y Rail Cover. Remove the Head Cover. Cut the cable tie holding the head pipes. Remove the damper fixer (2 fastening screws). Remove joint screws and move the head pipes up out of the way. Remove the color dampers.
REP1430
Head board assembly
Head cable
CAUTION:
When removing the color dampers, be careful not to grip the transparent film surface of the damper. Rough handling of the transparent film surface may cause an air leak and prevent printing. Damper fixer
10. Assembling is the reverse of the removal procedure. 2. Adjustment and 1. Carry out initial filling. Examination Procedure CAUTION: Wait at least 30 minutes after the initial filling before printing. Otherwise the printing quality can not be assured. 2. Carry out a test print. 3. Fit a new Waste Fluid Box. CAUTION: About 150 cc of waste fluid will be expelled into the Waste Fluid Box from head cleaning and initial filling. Fit a new Waste Fluid Box. The message Change Tank? will appear on the panel display. You should confirm by answering Yes.
Tube fixer
How to replace the Dampers
REP1430
207
How to replace the Cursor Assembly Item

1. Replacement Procedure Cursor Assembly Replacement 1. 2. 3 4. 5. 6. 7. 8. 9. 10. 11.
REP1440
Wash the head to remove the ink. Remove the Panel Cover. Remove the Panel Bottom Cover. Remove the Front Cover. Remove the Y Rail Cover. Remove the Right and Left Covers. Remove the Head Cover. Disconnect connectors J204 (P EDGE), J206 (SOL), J207 (HEAD C1), J208 (HEAD C2) from the head board assembly. Cut the cable tie holding the head pipes. Remove tube stop screws and disconnect head pipes from dampers. Remove two screws from each outer side of the upper part of the cursor and separate the cursor unit from the head board unit. Reverse the disconnected head board unit so as to extend the steel bare and place it on top of the X motor side of the flexible cable guide.
CAUTION: Be careful not to damage the T fence when taking out the head board unit. Scarring may cause abnormal print quality. 12. 13. 14. 15. 16. Loosen the steel belt tension with the Y return pulley. Undo the screws that fasten the belt at both ends of the cursor unit and separate the steel belt. Move the cursor unit between the drive roller on the right and the cap unit. Bend the CR flat spring and remove it. To remove the cursor unit from the Y rail, after undoing one side of the cursor axle E-ring, take out the cursor axle together with both roller bearings. The cursor unit will drop down and can be taken from the Y rail. Be careful not to touch or damage the nozzle face of the head when removing the cursor unit from the Y rail.
How to replace the Cursor Assembly
REP1440
208
How to replace the Cursor Assembly Item

REP1441

17. Remove the head sub-plate that is on the cursor roller side. (2 screws) 18. Remove three fastening screws on the print head side and separate the hear unit and cursor assembly. The belt attachment plate will come away at the same time. 1. Align the cursor assembly with the head unit, bring the head unit in the direction of the arrow (up) and hold it temporarily with three fastening screws. Temporarily attach the head sub-plate. Following the reverse procedure, fit the cursor assembly to the Y rail and continue until just before attaching the head cover. Move the cursor assembly over the right end of platen on the cap side. Place the head height jig under the nozzle face of the print head, press the flat part of the upper edge of the print head and, while the metal part surrounding the nozzles is in close even contact with the head height jig, firmly tighten the screws that had been held temporarily. Withdraw the jig without touching the nozzle face and, using the pressure bracket gap at the back of the printer, firmly fasten the head sub-plate that had been held temporarily. After fitting the Y rail cover, do the initial filling and proceed with item 3. Adjustment and Checking. Fit the remaining covers after adjustment and checking. Execute the "Cap position" adjustment. Execute a "Test print" to see whether any printing adjustments are needed. Depending on the result, carry out any necessary adjustments. Apply the "Margin" adjustment.
All screws shown here are temporarily tightened Cursor assembly
2. Assembling and fitting
M3 16 (cap screw) M4 10 (double SEMS)
Belt attachment plate Head sub-plate M3 5 (double SEMS round) Head unit
2. 3.
4. 5.
Press places shown by arrows Fastening screws (3)
6.
Head height jig Right edge platen CAUTION: As shown below, make sure nozzle face does not touch jig.
7.
1. 3. Adjustment and confirma- 2. tion 3.
Wrong
This will touch nozzle face.
How to replace the Cursor Assembly
REP1441
209
How to replace the Origin Sensor, Y Encoder Item

1. Replacement Procedure 1. 2. 3. 4. 5. Origin Sensor and Y Encoder Replacement Remove panel cover. Remove front cover. Remove Y rail cover. Disconnect all connectors plugged into the head board. Remove head board from the H board mounting plate. (4 screws) 6. Remove Y cable together with the cable keeper. 7. Remove tube guide keeper. (2 screws) 8. Remove steel belt. (2 screws) 9. Remove pipe fittings with head pipes still connected. (2 screws) 10. Remove two screws holding the H board mounting plate. 11. Remove origin sensor or Y encoder from the H board mounting plate. (2 screws each) 12. Assembly is the reverse of dismantling.
REP1450
Origin sensor fitting direction
Cable from origin sensor board in on the cap side
Sensor
Cable
Y encoder and encoder cable fitting direction
CAUTION: Encoder cable connection errors will damage the encoder.
2. Adjustment
1. Execute the "Cap position" adjustment.
Connector mark to left as seen from front of printer
Encoder terminal comes to H board mounting plate attachment section.
How to replace the Origin Sensor, Y Encoder
REP1450
210
How to replace the Junction Board Assembly, Ink ID Cable Item

1. Replacement Procedure Junction Board Assembly Ink ID Cable Replacement 1. Remove the Front Cover. 2. Remove the Panel Cover. 3. Remove the Y Rail Cover. 4. Remove the Rear Paper Guide. 5. Open the Control Box. 6. Disconnect junction cable connector J109 (INK ID). 7. Disconnect all junction board assembly connectors. 8. Remove the junction board assembly. (4 fastening screws) 9. Assembly is the reverse of the removal procedure.
REP1470
Junction cable connection J109 (INK ID) behind here
Detector assembly connector Four fastening screws Junction cable connector J401 Ink ID sensor connector
Junction cable (FFP)
How to replace the Junction Board Assembly, Ink ID Cable
REP1470
211
How to Adjust the Platen Height Item

1. Adjustment and Inspection Procedure Platen Height Adjustment 1. Adjust using rail height jig (JD-30395). Mount the rail height jig on a standard base and set the dial gauge to "0" (2.00 mm).
Rail height jig
REP1520
Standard value : 0 (2.00 mm)
Standard base
Mount the rail height gauge over the ribs at both ends of the platen, loosen the platen retaining screws and adjust the platen up and down until the dial gauge reads 2.10 to 2.20 mm. Standard value 2.10 to 2.20 mm by dial gauge
Measuring position (rib)
Slide
Platen
Adjusting screw
How to Adjust the Platen Height
REP1520
212
How to replace the Tube Guide Assembly Item

1. Replacement Procedure Tube Guide Assembly Replacement 1. Disconnect all connectors from head board. 2. Remove head board. (4 screws) 3. Remove tube guide keeper. (2 screws) 4. Remove two tube guide fastening screws. 5. Undo all parts clamping tube guide ink tubes and steel bares and remove the tube guide. 6. Assembling is the reverse of the removal procedure.
Hexagonal nut
REP1540

Cable keeper Tube keeper
Screw Tube bracket Cartridge pipe
Tube guide assembly Steel bare
Ink tube
Steel bare Tube guide assembly
How to replace the Tube Guide Assembly
REP1540
213
How to replace the Tube Guide Assembly Item

Tube Guide Assembly Replacement 1. Remove panel cover, IC slot cover and Y rail cover 2. Remove H mounting plate cable keeper. 3. Remove all ribbon cable guide clamping parts. 4. Remove the cable keeper on the tube keeper and remove the steel bare. 5. Remove all tube guide clamping parts. 6. Remove tube keeper. 7. Undo tube bracket nut. 8. Lift the tube bracket gently and remove the tube guide assembly. 9. Assembling is the reverse of the removal procedure.
REP1540-2
Cable keeper
Tube keeper Tube bracket
Ribbon cable guide
Clamping parts
Tube guide
How to replace the Tube Guide Assembly
REP1540-2
214
How to Adjust Steel Belt Tension Item

CAUTION:
REP1550

Steel belt are highly susceptible to breakage and end damage and must be handled carefully. Be careful not to cut your hands when handling the steel belt.
CAUTION:
Adjusting screws Steel belt
Steel Belt Tension Adjustment 1. Adjustment and Verification 1. Set the steel belt in the middle of the return pulley and motor pulley. (Center of Y rail) 2. While moving the cursor left and right, turn the return pulley adjusting screw until the steel belt does not tend to come off the pulley or move across the pulley. 3. When the belt adjustment is completed, use a belt tensioning jig to adjust the tension. Move the cursor to the capping position and measure the deflection of the belt at the center of the Y rail. Specification values: 0.98 N (100 g 20 g)
Belt tension attachment JD-42050
4. Finally, move the cursor left and right to check for belt skew.
How to Adjust Steel Belt Tension
REP1550
215
How to Adjust X Speed Reduction Belt Tension Item
REP1560

CAUTION: When the Speed Reduction Belt has been replaced, apply grease to the belt evenly. (Silicone Grease G501)
X Speed Reduction Belt Tension Adjustment 1. Adjustment and Verification 1. Hook a 5 kgf Bar Tension Gauge to the X motor mounting plate, tension the belt and fasten the mounting plate. Specification value: 41.16 N 1.96 N (4.2 kg 0.2 kg)
41.16 N 1.96 N (4.2 kg 0.2 kg)
How to Adjust X Speed Reduction Belt Tension
REP1560
216
How to Adjust the Print Head Item

1. Adjustment and Verification
CAUTION: CAUTION:
REP1570

Avoid touching, knocking or rubbing the nozzle face of the Print Head Assembly. Each Print Head Assembly has a rank that has a major effect on the ejection of ink. Entering a wrong rank will adversely affect the life of the head and the emission of inks. Rank is inscribed on the print head assembly (see diagram on right). The value to be input is a 5-digit number.
1 2 3 4 5
Print Head Adjustment When the Print Head and the Head Cable are removed, make the following adjustments in Diagnostic Mode. Capping Position Adjustment Head Rank Input (Initial filling function is available.) Head Nozzle Verification Left Head Tilt Verification Right Head Tilt Verification Repeatability Printing Positioning, Repeatability Printing Positioning (Microdot) Unidirectional, Unidirectional (Microdot) Margin 1. Run Diagnostic Mode. 2. Lower the Pressure Lever and select Adjustment. 3. After initialization, load media on the printer. If the Print Head is not replaced or removed, go to Step 7.
Head rank (5-digit)
How to Adjust the Print Head
REP1570
217

1. Adjustment and 4. Verification 5.
REP1571

Execute "Capping position adjustment". Apply "Head rank entry". Initial filling can now be done. 6. Enter Head 1 rank. If Head 1 has not been replaced, rank will be recorded as is. 7. Execute "Ink filling". After ink filling, return to the previous level. 8. Mount media. 9. Execute "Head nozzle check". Check whether ejection is normal from all nozzles and proceed to the next item. 10. Execute Left Head Tilt. Adjust with head adjustment material A so that printing with all Head 1 colors forms a straight line. 11. Loosen the screw holding Head 1 and move the head adjustment material A towards (b) if the offset rises to the right, or towards (a) if the offset rises to the left. After gently pressing with a straight-bladed watchmaker's screwdriver or similar in the same direction as the compression spring holding the print head, tighten the screw. (One click changes head adjustment place A by about 0.005 mm) REFERENCE Sometimes simply moving the head adjustment material does not alter the inclination.) Press gently 12. Execute Left Tilt. Repeat steps 10 and 11 until the test pattern is properly aligned. 13. When the inclination adjustment is finished, proceed to the next item.
[Fig. 1]
Here is lined up. 2 1 2 1 3 1 3 1 2
Test pattern 3 2 1 Media eject direction
[Fig. 2]
In this case, adjust towards (a). In this case, adjust towards (b).
[Fig. 3]
Head adjustment plate A
(b)
(a)
REP1571
218
REP1572
1. Adjustment and 14. Execute Right Head Tilt. Verification With Head 1 as a standard, adjust the inclination and depth of Head 2 with head adjustment material A (mainly for inclination) and head adjustment material B (mainly for depth) so that the printed band is a straight line.
[Display when looking at the print head from above] HEAD1 (K) (C) (G) 1 2 3 HEAD2 (M) (Y) (O) 4 5 6
15. Loosen the screw holding Head 2 and, if the parts printed by Head 2 (4 to 6) rise to the right relative to the parts printed by Head 1 (1 to 3), move the head adjustment material towards (b), or towards (a) if the offset rises to the left. Also, if the offset is to the front or back, move the head adjustment material towards (c) or (d). After gently pressing with a straight-bladed watchmaker's screwdriver or similar in the same direction as the compression spring holding the print head, tighten the screw.
Test pattern 5 2 5 3 4 6 1 3 6 4 1 Media eject direction
d 16. Execute Right Head Tilt. Repeat steps 14 and 15 until the test pattern is properly aligned. c c 17. When the right head tilt is properly adjusted, proceed to the next item. Press gently b a Fastening screw
REP1572
219

REP1573

18. Execute "Repeatability" This makes three 1-pass bi-directional scans and compensates for the offset of the second scan (CCW printing) relative to the first and third scans (CW printing).
Media eject direction Third line
19. Check the printing, first for black then for color, and record a positive increment if the second scan (CCW printing) is offset towards the cap side, or a negative decrement for the opposite direction. (Repeat the printing after the registration.) Repeat until both directions are aligned.
Second line First line
20. When repeatability printing position alignment has been achieved, proceed with the Repeatability (Microdot) adjustment in the same manner.
Plus
Minus
21. Execute "Unidirectional". This corrects the initial printing position (5 mm from media edge) and compensates for the position of Head 2 relative to Head 1 (head pitch).
22. With a steel ruler, measure from the edge of the media to the position of the black printing and enter the measured value.
Distance to edge of media (5 mm)
REP1573
220

REP1574

23. Next, check the printing and record a positive increment if Head 2 is to be moved towards the cap side relative to Head 1, or a negative decrement for the opposite direction. Repeat items 20 to 23 until the starting position and the printing positions of Head 1 and Head 2 are aligned.
Pitch between heads
24. When "Unidirectional" is finished, execute the "Unidirectional (Microdot)" adjustment in the same manner.
25. Execute "Margin". This corrects the printer's media detection position and the actual printing position.
26. Use a steel ruler and a loupe to measure from the edge of the media to the printing position and make the correction by entering the actual measured value.
Bottom distance (20 mm) Left side margin (5 mm) Top distance (25 mm) Right side margin (5 mm)
27. Complete the adjustments by switching off the power.
REP1574
221
How to Capture and Install Backup Parameters Item
REP1590

CAUTION: Failure to switch off the power before mounting and unmounting flash memory card may cause damage to the Main Board and make it impossible to install data properly.
1. Capture Backup Parameters
1. Switch off power to the printer. 2. Mount a backup-only flash memory card in the slot at the back of the printer. 3. Turn on the power. All LEDs light up instantly and PLOTTER CARD appears in the printers LCD display unit. 4. When ENTER is pressed, P C Started appears in the printers LCD display unit and parameters start to be absorbed. 5. When parameters have been completely absorbed, P C Completed appears in the printers LCD display unit to indicate that the comparison of absorbed parameters has ended normally. 6. Switch off and remove the flash memory.
2. Install
1. Switch off power to the printer. 2. Mount a backup-only flash memory card in the same slot at the back of the printer. 3. Turn on the power. All LEDs light up instantly and PLOTTER CARD appears in the printers LCD display unit. Menu Up or Menu Down will change this to CARD PLOTTER. 4. When ENTER is pressed, C P Started appears in the printers LCD display unit and parameters start to be installed. 5. When parameters have been completely installed, C P Completed appears in the printers LCD display unit to indicate that the comparison of installed parameters has ended normally. 6. Switch off and remove the flash memory card.
3. Verify
1. Switch on power to the printer and verify that it is working normally. Model Name: RJ6000-43/54/62
How to Capture and Install Backup Parameters
REP1590
222
How to Install a Program (Software Upgrade) Item

CAUTION:
REP1600

Failure to switch off the power before mounting and unmounting flash memory may cause damage to the Main Board and make it impossible to install data properly.
1. Install
1. Switch off power to the printer. 2. Mount the latest program flash memory card in the slot at the back of the printer. 3. Switch on the power. 4. The following message will appear in the liquid crystal display: Erase Copy Compare End The buzzer will sound. (It will end after about 60 seconds) 5. Switch off power to the printer. 6. Remove the flash memory card.
2. Verify
1. Switch on power to the printer and verify from the initialization and panel display that the version has been upgraded.
REFERENCE:
N The following flash memory card is used for program installation:

RJ-6000 Vx.xx 4 MB
How to Install a Program (Software Upgrade)
REP1600
223
Head Cleaning Procedure 1

CAUTION 1: When to Clean the Head

Panel diagnostic functions (when implemented from panel only)
REP1620
Head Wash must be carried out whenever this printer is moved by truck or when the parts shown below are replaced. When this operation is performed, there is a risk that the inks remaining in the head and ink tubes may be spilt and soil the printer. < Replacement Parts > Head, Damper, Cursor Assembly, Cartridge Frame Assembly, Ink Tubes CAUTION 2: Head Cleaning Jig
1. To start panel diagnosis, switch on while pressing [Cleaning], [Menu Display] and [Shift] at the same time. 2. Select "Adjustment" menu "Head Wash" self-diagnosis. 3. Rm All Cartridge When this display appears, take out the specified cartridge. (Alternatively, the ink cartridges may be removed beforehand.) 4. Set Wash Jig When this display appears, mount the cleaning jig. 5. Ink Absorb When this display appears, cleaning fluid is being sucked from within the head and tubes. 6. Rm Wash Jig When this display appears, remove the cleaning jig. 7. Washing When this display appears, cleaning fluid remaining inside the head and tubes is being ejected. 8. AJST: Home When this display appears, it is the end.
When you are using the Head Cleaning Jig, the 100 cc jig bottle should contain at least 50 cc of cleaning fluid and its cap should be loosened. If the cap of the jig bottle is tightly closed, the ink will flow back into the bottle. Also, when you have finished using the Head Cleaning Jig, return the cleaning fluid from the 100 cc bottle to the 500 cc cleaning fluid bottle (JD-42054). CAUTION 3: What to do After the Initial Filling
Wait for at least 30 minutes after the initial filling before you use the printer for printing. Otherwise picture quality can not be assured. # Head Cleaning is a self-diagnostic function not available to the user.
REFERENCE
Head washing includes all six colors at the same time. Therefore, you should prepare six sets of head washing jigs. Single color or separate head washing is not possible.
Head Cleaning Procedure 1
REP1620
224
How to Clean the Head Nozzle Face

If the nozzles are clogged by paper dust or foreign matter clinging to the Head Nozzle Face, use the following procedure to remove it. CAUTION: Be careful not to touch the nozzle face directly with your fingers otherwise normal ejection may not be possible. 1. Turn off the Power Switch and return the Head to the home position. (The Power Cable may remain connected) 2. Open the front cover and remove "Panel bottom cover" and "Panel bottom cover support" 3. Move the head to the place where the "Panel bottom cover" was removed. 4. Soak a lint-free cloth in water or distiled water and gently wipe the Head Nozzle Face. (Lint-free cloth is closely woven from extremely fine threads and has no nap and produces no dust.) CAUTION: Dont wipe with fluffy cloth or tissue paper as these tend to make the clogging worse. CAUTION: Be careful not to rub the nozzle face too hard. 5. Move the head to the maintenance assembly. 6. Refit the "Panel bottom cover" and "Panel bottom cover support" 7. Turn on the Power Switch and print out a diagnostic pattern. If there are no dots missing from the G-line step pattern, the task is completed. If some dots are missing, repeat Steps 1 to 7.
REP1660
How to Clean the Head Nozzle Face
REP1660
225
How to replace Speed Reduction Pulley Assembly Item

1. Replacement Procedure 1. 2. 3. Speed Reduction Pulley Replacement Remove the left cover. Remove the X motor cover. Loosen the four screws on the X motor mounting plate and relieve the belt tension. 4. Loosen the bearing stopper screw and remove it. 5. Remove the speed reduction pulley support and bearing. 6. Loosen the two coupling screws. 7. Loosen the stopper screw. 8. Remove the X speed reduction belt from the speed reduction pulley. 9. Withdraw the speed reduction pulley assembly towards the right side. 10. Assembly is the reverse of dismantling.
REP1670

Bearing stopper Bearing
Speed reduction pulley assembly
Speed reduction pulley support
X motor mounting plate
Stopper Coupling
2. Adjustment and Inspection Procedure
1.
Adjust the X speed reduction belt tension.
Speed reduction pulley assembly
How to replace Speed Reduction Pulley Assembly
REP1670
226
How to replace Grid Roller Assembly Item

1. Replacement Procedure Grid Roller Assembly Replacement 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Remove left cover. Remove front paper guide. Remove rear paper guide. Remove X motor cover. Remove right and left side caps. Remove speed reduction pulley assembly. Remove platen mounting plate (with platen attached). Raise pressure lever. Remove all bearing box screws. Move all bearing boxes to a position where the grid roller can be taken out upwards. CAUTION: In order to install bearing boxes and adjustment spacers in the positions prior to replacement, check their distribution. Take care not to lose any adjustment spacers. Platen mounting plate
REP1690
Grid roller assembly Bearing keeper
Coupling Bearing Box
11. Remove the bearing keepers from both sides of the grid roller to be replaced. 12. Loosen the coupling screws, slide the bearing boxes to the side and take out the grid roller assembly. 13. Assembly is the reverse of dismantling. CAUTION: Install bearing boxes and spacers in the same positions as before the replacement. Install bearing boxes by pushing them far back and moving them to the left. Apply lock-tight to the screw threads when installing bearing boxes. Be careful not to damage the grid roller.
[43 inch]
[54/62 inch]
1. Adjustment and 1. Adjust the platen height. Inspection 2. Adjust X speed reduction belt tension. Procedure
Adjusting spacer
How to replace Grid Roller Assembly
REP1690
227
How to replace F Absorbent Assembly Item

1. Replacement Procedure F Absorbent Assembly Replacement 1. Remove the absorbent material from the F box. 2. Insert the absorbent material assembly in the F box.
REP1700
F box
Absorbent material
How to replace F Absorbent Assembly
REP1700
228
How to replace Waste Liquid Tank Assembly Item

1. Replacement Procedure Waste Liquid Tank Assembly Replacement 1. Remote X motor cover. 2. Take out the waste liquid tube from the left waste liquid bottle. CAUTION: Be careful not to scatter the ink. 3. Remove the left waste liquid bottle mounting plate. 4. Undo the waste liquid bottle cap and remove the left waste liquid bottle. 5. Assembly is the reverse of dismantling.
REP1710
Waste fluid bottle mounting plate
Waste fluid tube
Waste fluid bottle L
How to replace Waste Liquid Tank Assembly
REP1710
229
RJ-6000-43 Fundamental Knowledge
GID0000
Fundamental Knowledge
Basic Specifications System Block Diagram Operating Sequence Power On Sequence Power Off Sequence Media Detection Sequence Normal Standby Sequence Encoder Disconnected Check Sequence Origin Detection Sequence Media Cutting Sequence Printing Sequence (Including Flushing) GID1000 GID3000
GID4010 GID4020 GID4030 GID4040 GID4050 GID4060 GID4070 GID4080
GID0000
230
GID0000-2
Basic Specifications System Block Diagram Operating Sequence Power On Sequence Power Off Sequence Media Detection Sequence Normal Standby Sequence Encoder Disconnected Check Sequence Origin Detection Sequence Media Cutting Sequence Printing Sequence (Including Flushing) GID1000-2 GID3000
GID0000-2
231
GID0000-3
Basic Specifications System Block Diagram Operating Sequence Power On Sequence Power Off Sequence Media Detection Sequence Normal Standby Sequence Encoder Disconnected Check Sequence Origin Detection Sequence Media Cutting Sequence Printing Sequence (Including Flushing) GID1000-3 GID3000
GID0000-3
232
RJ-6000-43 Basic Specifications

System Printing System 43 inch On-demand piezo driving system (Large capacity, 6-color, independently removable ink cartridges: 220 cc 5 cc) (Dying ink and pigment ink are changeable) Shortest distance printing (bidirectional or unidirectional) 360 dpi x 360 dpi 720 dpi x 720 dpi 1440 dpi x 720 dpi System Area Available for Printing (Margins) Standard: Cut media Roll media Compatible: Cut media Roll media

43 inch Front 25mm 25mm 25mm 25mm Back 20mm 20mm 20mm 20mm Right 10mm 10mm 5mm 5mm
GID1000
Printing Direction Resolution Media Transport Media Supply and Eject CPU Input Buffer
Multi-point pressure grid roller system Cut Media: Front supply/front eject 64 bit RISC CPU Standard: 8 MB (main) + 4 MB (plain) Extended: 16 MB, 32 MB Expansion slots: 2 slots (16 MB installed in one slot as standard) Maximum: 72 MB (main) + 1 MB (plain) Printer commands: MH-GL, MH-GL/2, (MH-RTL), RTL-PASS The larger of 0.1% of movement distance or 0.5 mm Media: Thick coated paper (roll media) Working temperature: 20C, Humidity: 60%, Printing mode: High quality/720 dpi Within 0.5 mm/500.0 mm Media: Thick coated paper (roll media) Working temperature: 20C, Humidity: 60%, Printing mode: High quality/720 dpi High quality paper, coated paper, thick coated paper, art paper, glossy paper, glossy photographic paper, glossy film, Yupo film, Yupo tac film, cloth, fire-resistant cloth, glossy PVC tac film (Media other than the above and new media are based on OEM assessment.) Standard 2-inch 1089.6 mm (42.9 inch) 1069.6 mm (42.1 inch) 50 m (maximum size roll that can be mounted) 1300 mm Media longer than this can be loaded but media size cannot be detected and it is handled as roll media. Weight External Dimensions Option: 3-inch Roll Media: Rear supply/front eject Media Holding System Media Cutting System Ink Cartridges Kanji Interfaces Head Life Environmental Conditions
Operating environment
Left 10mm Printing quality is assured within standard margins 10mm 5mm If media wider than 1361.6 mm is used, the left and right 5mm margins will be different from those shown on the left.
Pressure roller lowered by manually operated lever Transverse auto-cut system Black, cyan, magenta, light cyan, light magenta: each 220 cc 5 cc Black, cyan, magenta and (light cyan, light magenta) or (orange, green): each 220 cc 5 cc Conforms to JIS1, JIS2 (1990 edition stroke font built-in) (Font has some independent codes unspecified by JIS) Standard Option Bidirectional Centronics: IEEE 1284 (compatible, nibble, ECP modes) Ethernet: WindowsNT, Windows95, TCP/IP, NetWare, EtherTalk support
Dye ink Pigment ink
Commands Linear Precision
Angular Precision
Temperature: 10C to 35C, humidity 20% to 80% (no condensation) Temperature: 2C/h, Humidity: 5%/h Temperature: -10C to 60C, humidity 20% to 90% (no condensation) AC100 ~ 120 V 10%, AC200 ~ 240 V 10% Auto Change 50 Hz 1 Hz / 60 Hz 1 Hz Auto Change 60 W or less 75 W or less 75 W or less 1264 mm 1656 mm 580 mm 49.0 kg (480.2 N) 15.5 kg (151.9 N)
Rate of change Storage environment
Media Types
Power Supply Power Supply Power Consumption
(Voltage) (Frequency) Standby Printing Cleaning Height Width Depth Body Legs
Roll Media Tube Diameter Maximum Media Width Media Sizes Maximum Roll Media Length Maximum Cutting Media Length
GID1000
233

System Printing System 54 inch On-demand piezo driving system (Large capacity, 6-color, independently removable ink cartridges: 220 cc 5 cc) (Dying ink and pigment ink are changeable) (For domestic is dying ink only) Shortest distance printing (bidirectional or unidirectional) 360 dpi x 360 dpi 720 dpi x 720 dpi 1440 dpi x 720 dpi System Area Available for Printing (Margins) Standard: Cut media Roll media Compatible: Cut media Roll media

GID1000-2
Multi-point pressure grid roller system Cut Media: Front supply/front eject 64 bit RISC CPU Standard: 8 MB (main) + 4 MB (plain) Extended: 16 MB, 32 MB Expansion slots: 2 slots (32 MB installed in one slot as standard) Maximum: 72 MB (main) + 1 MB (plain) Printer commands: MH-GL, MH-GL/2, (MH-RTL), RTL-PASS The larger of 0.1% of movement distance or 0.5 mm Media: Thick coated paper (roll media) Working temperature: 20C, Humidity: 60%, Printing mode: High quality/720 dpi Within 0.5 mm/500.0 mm Media: Thick coated paper (roll media) Working temperature: 20C, Humidity: 60%, Printing mode: High quality/720 dpi High quality paper, coated paper, thick coated paper, art paper, glossy paper, glossy photographic paper, glossy film, Yupo film, Yupo tac film, cloth, fire-resistant cloth, glossy PVC tac film (Media other than the above and new media are based on OEM assessment.) Standard 2-inch Option: 3-inch 1371.6 mm (54 inch) 1351.6 mm (53.2 inch) 50 m (maximum size roll that can be mounted) 1300 mm Media longer than this can be loaded but media size cannot be detected and it is handled as roll media. Weight External Dimensions (For domestic: Standard 3-inch Option: 2-inch) Roll Media: Rear supply/front eject Media Holding System Media Cutting System Ink Cartridges Kanji Interfaces Head Life Environmental Conditions
Dye ink Pigment ink
Angular Precision
Temperature: 10C to 35C, humidity 20% to 80% (no condensation) Temperature: 2C/h, Humidity: 5%/h Temperature: -10C to 60C, humidity 20% to 90% (no condensation) AC100 ~ 120 V 10%, AC200 ~ 240 V 10% 50 Hz 1 Hz / 60 Hz 1 Hz 60 W or less 90 W or less 75 W or less 1149 mm 2215 mm 650 mm (680 mm) 78 kg (764.4 N) 17 kg (166.6 N) Auto Change Auto Change
Media Types
GID1000-2
234

System Printing System 62 inch On-demand piezo driving system (Large capacity, 6-color, independently removable ink cartridges: 220 cc 5 cc) (Dying ink and pigment ink are changeable) (For domestic is dying ink only) Shortest distance printing (bidirectional or unidirectional) 360 dpi x 360 dpi 720 dpi x 720 dpi 1440 dpi x 720 dpi System Area Available for Printing (Margins) Standard: Cut media Roll media Compatible: Cut media Roll media

GID1000-3
Multi-point pressure grid roller system Cut Media: Front supply/front eject 64 bit RISC CPU Standard: 8 MB (main) + 4 MB (plain) Extended: 16 MB, 32 MB Expansion slots: 2 slots (32 MB installed in one slot as standard) Maximum: 72 MB (main) + 8 MB (plain) Printer commands: MH-GL, MH-GL/2, (MH-RTL), RTL-PASS The larger of 0.1% of movement distance or 0.5 mm Media: Thick coated paper (roll media) Working temperature: 20C, Humidity: 60%, Printing mode: High quality/720 dpi Within 0.5 mm/500.0 mm Media: Thick coated paper (roll media) Working temperature: 20C, Humidity: 60%, Printing mode: High quality/720 dpi High quality paper, coated paper, thick coated paper, art paper, glossy paper, glossy photographic paper, glossy film, Yupo film, Yupo tac film, cloth, fire-resistant cloth, glossy PVC tac film (Media other than the above and new media are based on OEM assessment.) Standard 2-inch Option: 3-inch 1574.8 mm (62 inch) 1554.8 mm (61.2 inch) 50 m (maximum size roll that can be mounted) 1300 mm Media longer than this can be loaded but media size cannot be detected and it is handled as roll media. Weight External Dimensions (For domestic: Standard 3-inch Option: 2-inch) Roll Media: Rear supply/front eject Media Holding System Media Cutting System Ink Cartridges Kanji Interfaces Head Life Environmental Conditions
Dye ink Pigment ink
Angular Precision
Temperature: 10C to 35C, humidity 20% to 80% (no condensation) Temperature: 2C/h, Humidity: 5%/h Temperature: -10C to 60C, humidity 20% to 90% (no condensation) AC100 ~ 120 V 10%, AC200 ~ 240 V 10% 50 Hz 1 Hz / 60 Hz 1 Hz 60 W or less 110 W or less 75 W or less 1163.5 mm 2350 mm 650 mm (680 mm) 85 kg (833 N) 17.5 kg (171.5 N) Auto Change Auto Change
Media Types
GID1000-3
235
Names of Parts
1. Exterior parts of the Main Unit
GID1100
Rear Paper Guide Left Cover Front Cover Y Rail Cover Operating Panel Cartridge Cover
Right Cover
Scroller Pressure Lever
Pressure Lever Knob Front Paper Guide Control Box Scroller Adjusting Screw Waste Fluid Box Ink Cartridge Slots (6 slots)
Front View
Rear View
Names of Parts
GID1100
236
Names of Parts
2. Parts of the Main Unit media transport system and left and right frames
GID1110
Y Rail Platen Flushing Box
Y Rail Pressure Bracket
Suction Fan Assembly Pressure Roller X Motor Shielding
Speed Reduction Pulley Support Pressure Arm Blade Grid Roller
Speed Reduction Pulley X Speed Reduction Belt
Names of Parts
GID1110
237
Names of Parts
3. Main Unit Y Drive Section
GID1120
Y Return Pulley Shaft Y Driven Pulley
T Fence
Y Cable
Belt fastening screws (2) Cover Switch
Drive Pulley Left Frame Y Motor Assembly Right Frame Waste Fluid Tube Steel Belt Cutter Guide Waste Fluid Box Detector Switch Lever Lock Pressure Lever Cutter Groove Pressure Relay Plate Lever Sensor Assembly Waste Fluid Box (Supply)
Front Paper Guide
Main Unit Y Drive Section
Names of Parts
GID1120
238
Names of Parts
4. Head Section
GID1130
Head pipes (6) Head cables (2) Printer Head Assembly (Color)
Origin Sensor Head Board Assembly
Cable Tie Cutter Cap Cutter Blade (s) Linear Encoder
Cutter Holder
Cursor
Damper Fixer Paper Sensor Assembly H Adjustor B (1)
Head Mount H Adjustor A (2) Tube Stop Screws (6) Dampers (6)
Head Section
Names of Parts
GID1130
239
Names of Parts
5. Maintenance Station Parts
GID1140
Pump Motor Assembly Pump Motor Gear
P Motor Flange Pump Motor Plate Damper CR
Cap Assembly
Flat Washer CR Damper Axle
Wiper Pump Speed Reduction Gear 1 Pump Speed Reduction Gear 2
Pump Idler Gear Pump Gear Ink Tube Extension Tube
Pump Assembly
Maintenance Base Speed Reduction Gear Bearer
Maintenance Unit
Names of Parts
GID1140
240
Names of Parts
6. Cartridge Holder Section
GID1150
Ink Tubes Cartridge Sensor (Detector assembly 6 types)
Coupling Screws Coupling BK
Cartridge Pipe (6 types)
Coupling Screws
Cartridge Side Plates (6)
Ink Cartridge Needle
Insertion Error Prevention Plates (4) Cartridge Base
Ink ID Sensor (6 types) Remaining Ink Sensor (Detector Assembly 6 types)
IC Guide Bases (6)
Cartridge Holder Section
Names of Parts
GID1150
241
System Block Diagram
GID3000
System Block Diagram
GID3000
242
Power On Sequence
GID4010
Power Switch ON
[Checks Standard DRAM]
error occurs error occurs [Write initial values to NVRAM]
Serious Error (StdDRAM) Serious Error (OptDRAM)
[Checks Optional DRAM] error occurs [Checks NVRAM] error occurs [Read NVRAM] [Initialize Tasks] < Enter Self-diagnostic Key >
Serious Error (NVRAM)
Self-diagnostic Standby
[Cover & Lever monitoring begins] error occurs [Encoder diagnostic check] [Motor excitation on] error occurs [Origin detection] < Is capping position registered? > Origin position not set No
Serious Error (Encoder)
Serious Error (Sensor) Error Display Strong Cleaning Normal Standby
< Carriage not at capping position on startup >
Power On Sequence
GID4010
243
Power Off Sequence
GID4020
Power Switch Off
< Origin detection in progress > < Media initialization in progress > < Media cutting in progress > < Open Cover >
[Servo slows and stops] [Servo slows and stops] [Servo slows and stops]
< Lever up and location other than capping position > < Cleaning in progress > < Printing in progress > [Servo slows and stops] [Move to capping position]
< Lever down and location other than capping position > [Write settings to NVRAM] < Is Power Switch on ? > [Power off]
[Reset software]
Power Off Sequence
GID4020
244
Media Detection Sequence

GID4030
< Panel setting: cut sheet > YES [Media trailing edge detection]
No
[Media width detection at trailing edge detection position] Media feed Media rewind [Media width detection]
[Media leading edge detection] [End]
GID4030
245

(1) Media Edge Base Value Detection [Moves the carriage to a position where the reflection sensor has no media] [Sets media edge gain to half, waits 2 ms] [ad1 = reads reflection sensor] [Sets media edge gain to normal, waits 2 ms] [ad2 = reads reflection sensor] [Sets media edge gain to half] [Moves the carriage to a position where the reflection sensor is over media] < Reflection sensor reading <= 0 x 56 ? >
Yes
GID4031
[Sets media edge gain to normal] [Waits 2 ms] [Base value = ad2]
No
[Base value = ad1]
GID4031
246

(2) Media Leading Edge Detection A direction Head B direction
GID4032
Rear Sensor (XR)
[Moves carriage to a position where the reflection sensor comes over the media, a = reflection sensor reading] [Moves 10 mm towards B, b = reflection sensor reading] [Moves 5 mm towards A, c = reflection sensor reading] [Media edge Z = { (a + b + c) + c x 3} 6 = { c + (a + b + c)3}2] [Moves media slowly back to a position where reflective sensor value becomes Z] < Cut media moved 200 mm > No < Roll media moved 3010 mm > < Reflective sensor value became Z > Yes [Moves forward 7 mm] [Moves media slowly back to a position where reflective sensor value becomes Z] < Media moved 10 mm > < Reflective sensor value became Z > Yes No [Media detection error] Yes No [Media detection error]
No Yes [End]
GID4032
247

(3) Media width detection A direction B direction Carriage Maintenance unit Media width detection < Is the carriage over the maintenance unit? >
Yes No
GID4033
[Move carriage to maintenance unit] Switch gain and read again, then select the more suitable of the two values to determine gain.
[Media edge base value detection]
[Moves the carriage to a position where the reflection sensor is over media, a = reflection sensor reading] [Moves 5 mm towards A, b = reflection sensor reading] [Moves 10 mm towards B, c = reflection sensor reading] [Media edge (Z) = ( + (a+b+c) 3) 2] [Moves the carriage slowly towards B to a position where the reflection sensor becomes equal to the Z value]
No Yes
< Moved 144.875 mm > < Reflection sensor reached Z > [e1 = encoder count]
Yes No
[Media detection error]
[Quick detection] 144.875mm [Slow detection] 50.0mm
Right edge detection
[Move the carriage to a position where the reflection sensor is over media] [Move the carriage slowly towards A to a position where the reflection sensor becomes equal to the Z value] Left edge [Quick detection] 43 inch: 1098.125mm detection 54 inch: 1403.125mm 62 inch: 1555.425mm [Slow detection]
50.0mm
No
< 43 inch: Moved 1098.125 mm > < 54 inch: Moved 1403.125 mm > < 62 inch: Moved 1555.425 mm > < Reflection sensor reached Z > [e2 = encoder count]
Yes
No
Yes
[Media width = e2-e1 : move carriage to the position of e1]
GID4033
248

Head
GID4034
Rear sensor (XR) [Move media forward until XR sensor goes "off" status] < Media moved 1300 mm > Yes < XR sensor becomes "off" status > No [Recognizes that roll media is loaded]
No Yes
[Move forward 7 mm] [Move media slowly back until XR sensor goes "off" status] < Media moved 30 mm > < XR sensor becomes "off" status > Yes [Media detection error]
No Yes
No
[End]
GID4034
249
Normal Standby Sequence
GID4040
Normal Standby Condition
< Receive online data > < Analyse received data > < Mount media > < Enter the Cancel key > [Initializes media] < Printing in progress > < Reception/Analysis in progress > < Standby > < End data analysis > [Begins printing] [Media is mounted when either XF or XR sensor is on] [Printing is forcibly ended] [Data already received/analysed is ignored] [If roll media is mounted, it is cut]
Normal Standby Sequence
GID4040
250
Encoder Disconnected Check Sequence
GID4050
Compete check for disconnected encoder
[Initializes PWM gate array] [Checks X-axis + direction] < Origin sensor ? > ON [Check Y-axis + direction] [Check X-axis - direction] [Check Y-axis - direction] [END] OFF [Checks Y-axis - direction] [Checks X-axis - direction] [Checks Y-axis + direction]
Check each axis in each direction for disconnection
[PWM output on] [PWM torque output] < Move 5 pulses ? > Yes < 20 msec elapsed ? > No No
Yes [Increases PWM torque]
< Moves 5 pulses ? > Yes
No < 20 msec elapsed ? > No Yes
[End]
[Encoder error]
Encoder Disconnected Check Sequence
GID4050
251
Origin Detection Sequence

Origin Detection A direction B direction Origin Machine Origin Flag
GID4060
Origin Detection
< Inside origin flag ? > No
Yes
[Move (200 mm) towards A while monitoring Origin sensor off] < Moved 200 mm ? > < Origin sensor off ? > Yes [Moves 1 mm towards A and set origin sensor off] Yes No [Faulty sensor error]
[Moves (43 inch: 1410 mm, 54 inch: 1755 mm, 62 inch 1890 mm) towards B while monitoring Origin sensor off] < Origin sensor off ? > Yes [Moves 2 mm towards A and set origin sensor off] No
[Moves carriage 10 mm towards A] < Origin sensor on ? > No Yes [Moves 20 mm towards B and set origin sensor on]
[Moves carriage 25 mm towards B] < Origin sensor on ? > Yes
(Go to next page)
GID4060
252

[Moves 10 mm towards B]
GID4061
[Moves (50 mm) towards A until origin sensor goes off] < Moved 50 mm without sensor going off ? > [Let current position be "a"] [Moves 5 mm towards A] [Moves (35 mm) towards B until origin sensor goes off] Yes < Moved 35 mm without sensor going off ? > No [Let current position be "b"] [Set the origin between points "a" and "b"] [Moves to origin] [End] Yes [Faulty sensor error]
No
GID4061
253
Media Cutting Sequence

Detects trailing edge of media
(2) (3) (1) Maintenance Unit Media Cutting No No Yes < Printing in progress ? > < Manual cutting requested ? > < XR sensor is "off" status ? > Yes If media has just been initialized, feed 10 mm [Wait ink drying period]
GID4070
No
< Is ink drying period finished ? > < Manual cutting requested ? >
Yes Yes
[Moves forward 186 mm] < Manual cut finished key entry occurred > [Waiting for key entry]
[Moves to a point 1/3 of media from right edge] [Cut towards (1)] [Moves to a point 1/3 of media from left edge] [Cut towards (2)] [Moves to a point 1/3 of media from left edge] [Cut towards (3)]
[ End ]
[Try to shake out the media] [Moves 20 mm forward] (45 mm in the case of a retry) [Moves 20 mm back] (45 mm in the case of a retry)
Yes < Tried 3 times ? > No
[Moves 5 mm forward] [Moves 5 mm back]

Yes No
< Tried 3 times ? >
Retry once if media can not be shaken out

Yes
< There is media at the position detected by the edge sensor >
No
[Media cutting error]
[ End ]
Media Cutting Sequence
GID4070
254
Printing Sequence (Including Flushing)

Color Printing Sequence < Are you printing with media already mounted when power was switched on ?>
No Yes

[Pull media 300 mm forward] [Pull media 250 mm forward] [Pull media 150 mm forward]
GID4080
< Did you wait for 20 minutes after initialization ? >

No
Yes
[Move to position for starting to plot] < Printing Mode ?>
360dpi High Speed

360 360: 2-pass bidirectional [Moves carriage and prints] [Moves media 4.3 mm forward]
Yes
360dpi Standard
360 360: 4-pass bidirectional [Moves carriage and prints] [Moves media 2.18 mm forward]
Yes
360dpi High Quality 360 360: 4-pass unidirectional [Moves carriage and prints] [Moves media 2.18 mm forward]
Yes
< Printing finished ? >
No
No
No
[End] < Printing Mode ?> 720dpi High Speed 720 720: 4-pass bidirectional [Moves carriage and prints] [Moves media 2.15 mm forward]
Yes
[End]
[End]
720dpi Standard 720 720: 4-pass unidirectional [Moves carriage and prints] [Moves media 2.15 mm forward]
Yes
Yes
No
No
No
[End] < Printing Mode ?> 1440dpi High Speed 1440 720: 4-pass bidirectional [Moves carriage and prints] [Moves media 1.13 mm forward]
Yes
[End]
[End]
1440dpi Standard 1440 720: 8-pass unidirectional [Moves carriage and prints] [Moves media1.13 mm forward]
Yes
Yes
No
No
No
[End] Note: Flushing occurs each time.
[End]
[End]
43-inch: Flushes on right side 54-inch: Flushes on right side (for bidirectional printing with pigment inks, flush left & right) 62-inch: Flushes on right side (for bidirectional printing with pigment inks, flush left & right)
Printing Sequence (Including Flushing)
GID4080
255
RJ-6000-43 Stored Test Patterns
PAT 0 0 0 0
Stored Test Patterns

< Stored Test Patterns > These are patterns that are stored in the printer and can be output by the user or the serviceman when required without using a host computer. The printer contains the following three stored test patterns, any of which can be output directly by keys.
No. 1.
Name of Stored Test Pattern Test Pattern
Name of Direct Keys [Shift]+[PRINT LAYOUT]
Purpose and Details

When trouble related to printing (such as picture quality or printing precision) has occurred, having this pattern output in the field can become the basis for identifying the cause of the problem from the maintenance manual. In A3 size, it is a 7-color pattern showing picture quality and printing precision. When printing with A0 media mounted, in addition to the A3 size pattern, the J line pattern will be printed over the entire width in the Y direction. Printing will be in accordance with the printing mode set on the panel.
Reference Page PAT1000
2.
3.
Print Quality Adjustment Pattern
[Shift]+[CLEANING]
Print quality adjustment pattern for obtaining the best printing quality. Mount A3 or bigger cut media or roll media. Pattern A is for adjusting the Repeatability printing position of the left head. Pattern B is for adjusting the Repeatability printing position of the right head. Pattern C is for aligning the printing positions of the left and right heads. The printing mode set on the panel will be ignored. Outputs the user information currently set in the printer A4 size, settings are output as test. The printing mode set on the panel will be ignored.
PAT3000
4.
Setup List
[Shift]+[MEDIA]
PAT4000
PAT 0 0 0 0
256
PAT 0 0 0 0 - 2

No. 1.
Purpose and Details

2.
3.
[Shift]+[CLEANING]
PAT3000
4.
Setup List
[Shift]+[MEDIA]
PAT4000
PAT 0 0 0 0 - 2
257
PAT 0 0 0 0 - 3

No. 1.
Purpose and Details

2.
3.
[Shift]+[CLEANING]
PAT3000
4.
Setup List
[Shift]+[MEDIA]
PAT4000
PAT 0 0 0 0 - 3
258
Stored Test Patterns/Test Pattern

Test Pattern When trouble related to printing (such as picture quality or printing precision) has occurred, having this pattern output in the field can become the basis for identifying the cause of the problem from the maintenance manual. In A3 size, it is a 7-color pattern showing picture quality and printing precision. When plotting with A0 media mounted, in addition to the A3 size pattern, the J line pattern will be printed over the entire width in the Y direction.
PAT 1 0 0 0
1. Make sure no data are being received then mount an A3 or larger sheet of cut media or roll media in the printer. 2. Start printing by pressing [Shift]+[PLOT LAYOUT] at the same time. During printing, [Printing ] will appear in the liquid crystal display unit. When the image quality faults shown below have occurred, you can investigate the type of problem by consultation based on reports using the location numbers on the consultation pattern.
Image Quality Fault Printed result differs from other machines No printing at all Entire surface printed black Printing density varies Black and white stripes appear in the printing Edges of printing are blurred Dots missing from printing Row Many satellites (unwanted dots) Whiskers on the printing Lines are blurred Frame and Mixed color lines do not overlap Black and color positions are offset Printed length is abnormal Location for Confirmation Whole Whole Whole Rows C, D, E, H Rows C, D, E, H, J Rows C, D, E, G Row G Whole Rows A, B, I Frame, Row I Rows A, B, I Row I Frame
Plotted over the entire width of the media that is loaded
Stored Test Patterns/Test Pattern
PAT 1 0 0 0
259
Stored Test Patterns/Print quality adjustment pattern

Print quality adjustment pattern This prints patterns shown in the diagram on the right for making fine adjustments of printing quality. Pattern A is for adjusting the Repeatability printing position of the left head. Pattern B is for adjusting the Repeatability printing position of the right head. Pattern C is for aligning the printing positions of the left and right heads. 1. Make sure no data are being received then mount an A3 or larger sheet of cut media or roll media in the printer. 2. Start printing by pressing [Shift]+[CLEANING] at the same time. During printing, [Accur. Adj Plot] will appear in the liquid crystal display unit. 3. Choose the best precision from lines 1) to 7) in patterns A, B and C and make adjustments using the following procedures. 4. [Pattern A: 4] is displayed. Use the setting Value + and - keys to enter the number of the best image and press [ENTER]. 5. [Pattern B: 4] is displayed. Use the setting Value + and - keys to enter the number of the best image and press [ENTER]. 6. [Pattern C: 4] is displayed. Use the setting Value + and - keys to enter the number of the best image and press [ENTER]. 7. [[User 1] Plot OK] is displayed. The specified values are now stored in the printer.
PAT 3 0 0 0
Alignment Print
Good and bad examples of Patterns A and B
Bad
Good
Bad
Good and bad examples of Patterns C
Bad
Good
Bad
Stored Test Patterns/Print quality adjustment pattern
PAT 3 0 0 0
260
Stored Test Patterns/Setup List

Setup List This prints out a list of user data currently set in the printer. 1. Make sure no data are being received then mount an A4 or larger sheet of cut media or roll media in the printer. 2. Start printing by pressing [Shift]+[Print Settings] at the same time. During printing, [Printing ] will appear in the liquid crystal display unit.
PAT 4 0 0 0
Setup List
Panel Settings Plot Mode Density Roll/Cut Media Command Command Plot area Position Terminate Resolution OnlineTimer Overwrite = = = = Normal 360 dpi Cut Normal Information Type PROM NVRAM Opt. Memory = = = = RJ-6 Color V 1.04 V 1.00 32MB Function InkDryTime Halftone CMY BLACK Scale Mirror Direct. CutPos. MediaCut Copy InkDensity Serial No. = CD100029 ! Error ! 0 : None [ ] 3 : None [ 1 : None [ ] 4 : None [ 2 : None [ ] 5 : None [ ] ] ]
= = = = = = =
RTL-PASS Normal P1 Normal 360 dpi 90 sec Last
PositionOffset X = 0 mm Y = 0 mm
Centro Mode Timing
= =
Bi Centro A-B
= = = = = = = = = =
30 sec Speed Yes 100.0% Off Command Data Auto 1 Normal
Dist. Adj DataX = 1000.00 RealX = 1000.00
Network IP Address
192,034,043,015
Utilities ErrorDisplay
Off
Stored Test Patterns/Setup List
PAT 4 0 0 0
261
RJ-6000-43 Self-Diagnostic Functions
BAC0000
Self-Diagnostic Functions
This chapter explains about self-diagnostic functions that are not available to the user. These functions are intended for use during manufacture, adjustment and maintenance and include Panel Diagnosis operated from the panel. For the RJ-6000-43, since post-adjustment parameters (settings and mechanical constants) are saved in non-volatile memory, due care is needed in using them.
Self-Diagnosis Tree -------------------------------------------------------------------------BAC0010 How to Start Self-Diagnosis ---------------------------------------------------------------BAC0020 1. Examination ----------------------------------------------------------------------------------BAC1000 Memory Capacity-----------------------------------------------------------------------BAC1010 Version ------------------------------------------------------------------------------------BAC1020 Panel --------------------------------------------------------------------------------------BAC1030 Sensors -----------------------------------------------------------------------------------BAC1040 Encoders ---------------------------------------------------------------------------------BAC1050 Fans ---------------------------------------------------------------------------------------BAC1060 Ethernet Board --------------------------------------------------------------------------BAC1065 History: Last error message ---------------------------------------------------------BAC1070 History: Head nozzle ejection count check --------------------------------------BAC1070 Head Drive Waveform ----------------------------------------------------------------BAC1080 2. Adjustment -----------------------------------------------------------------------------------BAC2000 Capping Position Adjustment -------------------------------------------------------BAC2010 Skew Verification -----------------------------------------------------------------------BAC2030 Head Rank Input (Initial Filling)-----------------------------------------------------BAC2040 Head Nozzle Verification -------------------------------------------------------------BAC2050 Left Head Tilt Verification ------------------------------------------------------------BAC2060 Right Head Tilt Verification ----------------------------------------------------------BAC2070 Repeatability Printing Positioning (Normal dot, Micro dot) ------------------BAC2080 CW Adjustment (Normal dot, Micro dot) -----------------------------------------BAC2090
Flush Pointer Adjustment ------------------------------------------------------------BAC2110 Media Feed Distance Compensation ---------------------------------------------BAC2120 Margin Adjustment ---------------------------------------------------------------------BAC2130 Rear Sensor Position Adjustment--------------------------------------------------BAC2140 Test Print ---------------------------------------------------------------------------------BAC2150 Head Wash ------------------------------------------------------------------------------BAC2160 3. Cleaning ---------------------------------------------------------------------------------------BAC3000 Normal, Powerful 4. Test Printing ---------------------------------------------------------------------------------BAC4000 Head Printing Verification Check Black In-filling Adjustment Parameters 5. Parameters -----------------------------------------------------------------------------------BAC5000 Initialize -----------------------------------------------------------------------------------BAC5010 Update ------------------------------------------------------------------------------------BAC5020 6. Aging -------------------------------------------------------------------------------------------BAC6000 Carriage Motor --------------------------------------------------------------------------BAC6010 Media Feed Motor----------------------------------------------------------------------BAC6020 Cutter --------------------------------------------------------------------------------------BAC6030 Maintenance Unit-----------------------------------------------------------------------BAC6040 Head ---------------------------------------------------------------------------------------BAC6050
BAC0000
262
BAC0000-2
BAC0000-2
263
BAC0000-3
BAC0000-3
264
Self-Diagnosis Tree 1
1. Examination 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 Memory Capacity Versions Panel Sensors Encoder Fan Ethernet Board History Memory Capacity Firmware Parameters DIP Switches Keys LCD LEDs and Buzzer X Front, X Rear, Cover, Lever Origin, No Ink, No Cartridge, Ink ID, Media Edge Temperature, Waste Fluid Tank Encoder X Encoder Y Fan Check On Fan Check Off Maintenance (Head Nozzle Ejection Count) L Head Ejections: mdot L Wiping Count: L Rubbing Count: R Head Ejections: mdot R Wiping Count: R Rubbing Count: W Wiping Count: W Rubbing Count: Quantity of Ink in Waste Fluid Tank Black Ink Remaining Cyan Ink Remaining Magenta Ink Remaining Yellow Ink Remaining G Ink Remaining O Ink Remaining Failure Error 1 ~ 7 VK KC1 CHG ND2 ND1 TR1 FLUSH
BAC0010
BAC1000 BAC1010 BAC1020 BAC1030 BAC1040 BAC1050 BAC1060 BAC1065 BAC1070
1.9
Head Drive Waveform
CPU System and Mechanical System Errors (Last error message display) Head Waveform
BAC1070 BAC1080
BAC0010
265
2. Adjustments
BAC0011
2.1 2.2 2.3
Capping Position Adjustment Skew Verification Head Rank Input (including Initial Filling)
Left Rank: Right Rank: Filling Printing Normal Cleaning Powerful Cleaning Printing Printing Left Differential Right Differential Left Differential Right Differential
Gap adjustment Gap adjustment
BAC2010 BAC2030 BAC2040
2.4
Head Nozzle Verification
BAC2050
2.5 2.6 2.7 2.8 2.9
Left Head Tilt Verification Right Head Tilt Verification Repeatability Printing Positioning (Normal dot) Repeatability Printing Positioning (Micro dot) CW Adjustment (Normal dot)
BAC2060 BAC2070 BAC2080 BAC2080 BAC2090 BAC2090 BAC2110
2.10 CW Adjustment (Micro dot) 2.11 Flush Pointer Adjustment
Left Pointer Right Pointer Left Pointer (left flushing) Right Pointer (right flushing)
2.12 Media Feed Distance Compensation 2.13 Front-to-Head, Cutter-to-Head Distance Adjustment Top Distance Bottom Distance Distance Distance Head Printing Verification Black in-filling Adjustment Parameters
BAC2120 BAC2130
2.14 Rear Sensor Position Adjustment 2.15 Test Print
BAC2140 BAC2150
2.16 Head Wash
BAC2160
BAC0011
266
3. Cleaning 3.1 Normal 3.2 Powerful Test Printing 4.1 Head Printing Verification 4.2 Black infill printing 4.3 Adjustment Parameters Parameters 5.1 Initialization Capping Position X Encoder Resolution Maintenance History Error History Serial Number Complete Capping Position Head Rank Print Positioning Print Positioning (Micro dot) Media Transport Distance Mechanical Parameters

BAC3000
BAC0012
4.
BAC4000
5.
BAC5000 BAC5010 Left Head Right Head Wiper BAC5020 Left Right L Delay R Delay Gap L Delay R Delay Gap Head-to-Edge Sensor X Front-to-Head Head-to-Cutter X Front-to-X Rear Media Edge (Black) Left Flash Pointer (Color) RIght Flash Pointer Left Flashing Left Flash Pointer RIght Flashing RIght Flash Pointer PaperWidAdj BAC6000 BAC6010 BAC6020 BAC6030 BAC6040 BAC6050
5.2
Updating
6.
Aging 6.1 Carriage Motor 6.2 Media Feed Motor 6.3 Cutter 6.4 Maintenance Unit 6.5 Head
Left Right
BAC0012
267
How to Start Self-Diagnosis

These pages deal with the hidden diagnostic functions of the RJ-6000-43/54/62 Inkjet Printer. These hidden diagnostics are mainly intended for examining boards and determining mechanical and firmware adjustment parameters. These functions are incorporated into the printer firmware but they are not disclosed to end users. They are enabled by applying power to the printer while holding down several special panel keys. It is not possible to access the hidden diagnostic functions from the normal printer mode. Updated firmware adjustment parameters can be registered by exiting diagnostic mode or by switching off the power. Firmware adjustment parameters are also registered when there is a serious MOE failure error on adjustment. The printer will be reset on exiting diagnostic mode. Diagnostic functions are as follows. Table 1: Hidden diagnostic functions
Item Examination Adjustment Cleaning Test printing Parameters Aging Details Verification of RAM capacity, version, panel, sensors, encoders, fans, network board, history and waveform Manufacturing processes, adjustments on head replacement and adjustments to media feed system Mode specified head cleaning Head nozzle verification printing, black in-filling and adjustment parameters Initialization, updating Carriage motor, media feed, cutter, maintenance unit, head DIAG: Exam
BAC0020
Operations for selecting Diagnostics items are shown below.

To terminate self-diagnostics, switch off the power. Menu Up ENTER DIAG: Exam Menu Down DIAG: Adjustment Back Menu Down DIAG: Cleaning Back Menu Up ENTER Cleaning Menu Menu Up ENTER DIAG: Test Print Back Menu Down DIAG: Parameter Menu Up ENTER Parameter Menu Menu Up Back ENTER DIAG: Aging Back Menu Down Aging Menu Menu Down Test Print Menu Menu Down Menu Up Back ENTER Adjustment Menu Examination Menu
1. Power supply to the printer is off. 2. Switch on the power with the [Head Cleaning] + [Menu Display] + [Shift] keys held down. 3. The panel LCD will display DIAG: EXAM. X and Y excitation remains off.
Note 1: Note 2: Note 3: Note 4: Note 5: The system will not revert to normal mode even if there is no key entry for three minutes. Roll media mode is set automatically. Panel keys that can be operated are [CANCEL] and the keys for menu display (Menu Up and Down, Back, Value + and , ENTER) To terminate self-diagnostics, switch off the power. To feed media, press [MENU] while holding down the [Shift] key when the Diagnostics Menu is displayed.
How to Start Self-Diagnosis
BAC0020
268
Examination
This is intended for board checking. X and Y excitation is not turned on by selecting Examination from the Diagnostics Menu. The X and Y excitation condition will be preserved as it is at the time you select an item to be examined. Items to be examined are as follows. EXAM:
BAC1000
To return to the Diagnostics Menu from the Examination Menu, press [Back].
Menu Up ENTER EXAM: Ram Capacity Memory Capacity Display Back ENTER EXAM: Version Back Menu Down EXAM: Panel Back Menu Down EXAM: Sensor Back Menu Down EXAM: Encoder Back Menu Down EXAM: Fan Menu Down EXAM: Option Board Menu Down EXAM: Record Menu Down EXAM: Head Drive Back Menu Down Menu Up Back ENTER Waveform Check Menu Up Back ENTER History Display Menu Up Back ENTER Initialize Data Display Menu Up ENTER Fan Check Menu Up ENTER Encoder Check Menu Up ENTER Sensor Check Menu Up ENTER Panel Check Version Display Menu Down Menu Up
Table 1-1: Board examination items Item Details Memory Capacity Check memory capacity Versions Programs, Backup parameters, DIP Switches Panel Keys, LCD, LEDs, Buzzer Sensors XF, XR, Covers, Levers, Origin, Ink out, No cartridge, Ink ID, Media edge, Thermistor, Waste fluid tank Encoders X-axis (media feed), Y-axis (carriage) Fans Check on/off Network Initializing, None, Error, Initialization Error, Initialization OK History Maintenance, Major failure Head Waveform Check head drive waveform
Examination
BAC1000
269
Examination: Memory Capacity

This procedure is used to check the capacity of the memory on a board. When this item is selected, the memory capacity is displayed on the panel or terminal. EXAM: Memory Capacity Ram Capacity: 40 MB
BAC1010
Press [ENTER] to shift to EXAM: Version or [Back] to shift to EXAM: Memory Capacity.
Examination: Memory Capacity
BAC1010
270
Examination: Version
This confirms firmware version (program, backup parameters) and DIP switches (On:0, Off:1, switch No. 1 is the least significant byte, 8 is the most significant byte). Each is displayed on the panel when this item is selected. EXAM: Version
Menu Up VER: Firm Menu Down VER: Param Menu Down VER: Dip SW Menu Down 1.00 Menu Up 1.00 Menu Up 0xFF Verify DIP switches Backup parameter version display Program version display
BAC1020
Reference DIP switch 1 Off 1 On 1 Off 1 On
2 Off 2 Off 2 On 2 On
: : : :
0 X 03 0 X 02 0 X 01 0 X 00
Press [ENTER] to shift to EXAM: Panel or [Back] to shift to EXAM: Version.
Examination: Version
BAC1020
271
Examination: Panel
This procedure is used to check panel keys, LCD, LEDs and buzzer. EXAM: Panel
BAC1030
PANEL: Key Menu Up PANEL: L c d Menu Up ENTER IIIIII Menu Down
Panel key check
Under key check, when each key is pressed that key is shown on the LCD. Press the [ENTER] key to shift to LCD check after 2 seconds. Under LCD check, the screen is repeatedly filled with black from the right edge. Under LED and buzzer check, LEDs are lit in sequence from Data, Error, Standard, Thin, High Quality, Normal, High Speed, Low, High Roll Media, Cut Sheet and finally the sounding of the buzzer is checked.
Panel LCD check
PANEL: L e d B u z z e r Menu Down
Panel LED and buzzer check
Press [ENTER] to shift to EXAM: Sensor or [Back] to shift to EXAM: Panel.
Examination: Panel
BAC1030
272
Examination: Sensors
BAC1040
This procedure is used for checking, from displays on panel or terminal, the status of sensors for XF (the X Front Sensor), XR (the X Rear Sensor), cover, lever, origin, no ink (K, C, G, M, Y, O), cartridge (K, C, G, M, Y, O), ink ID, media edge sensor level, head thermistor value and whether or not the waste fluid tank is present.
Menu Up SENS: K D C D G D M P Y W O N Menu Down Menu Up 004e Menu Up 25, 25C Menu Up Exist Waste fluid tank sensor check Temperature sensor check Media edge sensor check Ink type check
EXAM: Sensor
Menu Up SENS: Xf Paper Menu Down SENS: Xr Paper Menu Down SENS: Cover Menu Down SENS: Lever Menu Down SENS: Origin Menu Down SENS: No Ink Menu Down SENS: No Car Menu Down Menu Up KCGMYO Menu Up KCGMYO Cartridge sensor check No Ink sensor check Menu Up Open Menu Up Down Menu Up On Origin sensor check Lever sensor check Cover sensor check Menu Up Off X Rear sensor check Off X Front sensor check
SENS: Edge Menu Down SENS: TEMP Menu Down SENS: Tank Menu Down
No Cart. means No Cartridge. Color is expressed by an alphabetical letter. Cartridge indicates the Special Cartridge sensor. KCGMYO ink ID display D = dye, P = pigment, W = cleaning liquid, N = other brand,
= no cartridge
Press [ENTER] to shift to [EXAM: Encoder] or [Back] to shift to [EXAM: Sensor].
Examination: Sensors
BAC1040
273
Examination: Encoders
This procedure is used to verify the values of X-axis (media feed) and Y-axis (carriage) from displays on the panel or the terminal. EXAM: Encoder
Menu Up ENCODER : X Menu Down ENCODER : Y Menu Down 0000 Menu Up FFFF Y encoder check X encoder check
BAC1050
Press [ENTER] to shift to EXAM: Fan or [Back] to shift to EXAM: Encoder.
Examination: Encoders
BAC1050
274
Examination: Fans
This procedure is used to verify that the fans are working by turning them on and off. EXAM: Fan Fan: On Fan: Off Fan goes off 10 seconds after starting Displayed for 5 seconds after fan has gone off
BAC1060
Panel keys are ignored during fan on/off display. 5 seconds after displaying Fan Off, the display will shift to EXAM: Fan.
Examination: Fans
BAC1060
275
Examination: Ethernet Board

This procedure is used to verify the initialization of Ethernet board data. EXAM: Option Board
OptBoard: Initialize Ethernet board initialization is in progress. Wait until the next message is displayed.
BAC1065
OptBoard: No
There is no Ethernet board.
OptBoard: Wrong
The Ethernet board is wrong.
OptBoard: Error
An error has occured during initialization of the Ethernet board.
OptBoard: OK
Ethernet board has been initialized.
After confirming the status of initialization of the Ethernet Board from the messages shown above, press [ENTER] to move to EXAM: Record.
Examination: Ethernet Board
BAC1065
276
Examination: History
This procedure is used to verify the history of maintenance (head ejection count and numbers of wipings and rubbings, the numbers of wipings and rubbings with the wiper, volume of waste fluid, and the amount of ink remaining) and serious failures (MOE type). Operations for the selection of history items are shown below. EXAM: Record
Menu Up RECORD: Menu Down RECORD: Menu Down Mainte Menu Up Error Verify error history Verify maintenance history
BAC1070
If [Back] is pressed while the History menu is displayed, the display will shift to EXAM: Record.
BAC1070
277
Maintenance History Panel and Terminal displays are shown below. EXAM: Mainte
Menu Up L Head Count: Menu Down L Wiping: Menu Down L Rubbing: Menu Down R Head Count: Menu Down R Wiping: Menu Down R Rubbing: Menu Down W Wiping: Menu Down W Rubbing: Menu Down Menu Up 4 Number of times Wiper rubbings Menu Up 4 Number of times Wiper wipings Menu Up 2 Number of times Color head rubbings Menu Up 2 Number of times Color head wipings Menu Up 0M Number of Color head ejections (Unit 1 Mdot) Menu Up 2 Number of times Black head rubbings Menu Up 2 Number of times Black head wipings 0M Number of Black head ejections (Unit 1 Mdot) Waste-Ink: Menu Down KRemainder: Menu Down CRemainder: Menu Down MRemainder: Menu Down YRemainder: Menu Down GRemainder: Menu Down ORemainder: Menu Down Menu Up
BAC1071
120 cc Menu Up Full Menu Up Full Menu Up Full Menu Up Full Menu Up Full Menu Up Full
Volume of ink waste fluid
Number of ejections remaining to end of black ink
Number of ejections remaining to end of cyan ink
Number of ejections remaining to end of magenta ink
Number of ejections remaining to end of yellow ink
Number of ejections remaining to end of G ink
Number of ejections remaining to end of O ink
Quit from Maintenance History by entering the [ENTER] or [Back] key. Press the [ENTER] key to shift to "RECORD: Error" or the [Back] key to shift to RECORD: Mainte.
BAC1071
278
Serious Failure History This procedure is used to verify the history of serious failures. CPU errors are not included in the serious failure history. Error 0 is the latest error, up to 7 previous errors are displayed. Panel displays are shown below.
BAC1072
RECORD: Error
Menu Up Err0 Menu Down Err1 Menu Down Err2 Menu Down : X : X : Y CURRENT Menu Up MOTOR Menu Up ENCODER X encoder error X motor error Y over-current error
Quit from Maintenance History by entering the [ENTER] or [Back] key. Press the [ENTER] key to shift to RECORD: Mainte or the [Back] key to shift to RECORD: Error.
BAC1072
279
Examination: Head Waveform

This confirms the ejection action waveform for both heads. CAUTION: When this item is selected, it will try to force the head nozzles to eject. Therefore the cables connected to the head board should be disconnected. EXAM: Head Drive
Menu Up Head Driver: VK Menu Down Head Driver: KC1 Menu Down Head Driver: CHG Menu Down Head Driver: ND2 Menu Down Head Driver: ND1 Menu Down Head Driver: TRI Menu Down Head Driver: FLUSH Menu Down Menu Up Menu Up Menu Up Menu Up Menu Up Menu Up ENTER PullOut Head Cable ENTER ENTER KEY to END
BAC1080
Left Head Left Head Right Head Right Head
VK voltage COM VK voltage COM
[Terminal] TP17 Q5E TP15 Q3E
Press [ENTER] for "Test: Memory", [PREV] for "Test: Head Driver"
Examination: Head Waveform
BAC1080
280
Adjustment
This procedure is used for correcting media feed and printing position. This is done by mechanical adjustments (head tilt) and firmware parameter adjustments. If this item is selected when X and Y excitations are off, the X and Y excitations will be turned on and the initialization sequence will be carried out. Items for adjustment are listed in Table 2-1. All these procedures are implemented during production. When the head is replaced, head cleaning (followed by switching off and replacing the head), head rank input, ink filling and print positioning are implemented. CW adjustment, reciprocal printing positioning and zone delay compensation are carried out when the printing position is to be corrected after a change of media type. If media feed is off, the media feed distance is compensated. Table 2-1 Adjustment items
Item Capping Position Adjustment Skew Verification Head Rank Input Head Nozzle Verification Black Head Tilt Verification Color Head Tilt Verification Repeatability Printing Positioning CW Adjustment Flush Pointer Adjustment Media Feed Distance Compensation XF-XR Sensor Distance XF, Cutter-to-Head Distance Test Print Head Wash Details To adjust capping position parameters in the firmware To use sensor results to check for media skew To enter a specific value for a specific head and fill inks After filling inks, to check head nozzle ejection by print results To check left head tilt by printing (mechanical adjustment) To check right head tilt by printing (mechanical adjustment) To align reciprocal printing position by printing To align the shafts of the two heads by printing and adjust left margin To adjust the position for flushing into the flushing box To print a line in the X direction and enter its distance (X resolution adjustment) To measure the distance XF and XR sensors with cut media To adjust top, bottom, left and right margins To check head nozzles and adjust parameters (enter serial numbers) Done after manufacturing and before head replacement
BAC2000
Adjustment
BAC2000
281
Adjustment
Press [Back] to return to the self-diagnostics Menu from the Adjustment Menu. DIAG: Adjustment
Menu Up ENTER AJST: Home Menu Down Menu Up Back Capping Position Adjustment AJST: UniDir Print Menu Down AJST: Flash Point Menu Down AJST: X Length Menu Up Menu Down AJST: Margin Menu Up Menu Down AJST: Rear Sns Posi Menu Up Menu Down AJST: Test Print Menu Up Menu Down AJST: Head Wash Menu Up
BAC2001
Menu Up
Menu Up
AJST: Chk Paper Mov Menu Down AJST: Head Rank Menu Down AJST: ChkNozzles Menu Down AJST: Left Tilt Menu Down AJST: Right Tilt Menu Down AJST: BiDir Print Menu Down AJST: UniDir (MD) Menu Down AJST: UniDir Print Menu Up Menu Up
Menu Up
Menu Up
Menu Up
Menu Up
Menu Up
Note: MD = Microdot
Adjustment
BAC2001
282
Adjustment: Capping Position

This procedure is used for aligning the capping position correctly by adjusting the capping position parameters in the firmware. When this item is selected, the printer carries out the home position detection sequence and then automatically pushes the carriage against the maintenance unit to detect the carriage position at that time. The position displayed is the distance from the home position flag. AJST: Home
Origin Detect After the origin has been detected, the capping position will be detected Home Detect After the carriage has moved to the capping position, that position is displayed Home: -74.000
BAC2010
Press [ENTER] to update the capping positions and move to AJST: Measure High, press [Back] to move to AJST: Home without updating the capping position.
Adjustment: Capping Position
BAC2010
283
Adjustment: Media Skew

This procedure will feed a specific amount of paper (a single pass band feed) and the sensors will read the position of the edge of the media before and after feeding and check for any discrepancy. If no media is loaded when this item is selected, you will be asked to load the media. After media initialization, when the amount of media feed is entered, the edge sensors will detect the left and right edges of the media and media feed will begin. After feeding the specified amount, the edge sensors will again detect the left and right edges of the media and any difference from the readings before media was fed will be checked and displayed. A media recognition error before and after feeding, or detection by the rear sensor of no paper during feeding, will cause a media error to be displayed and this procedure may be terminated by pressing any key. To terminate the procedure when processing is not in progress, press [Back] on the panel. To escape from this item, press [Back] while no processing is in progress. CAUTION: Make sure media is properly loaded.

Press [ENTER] to move to Adjustment: Rank Input or [Back] to move to AJST: ChkPaperMov. Other panel keys are ignored during processing. Standard values Condition Cut Sheet 7m Roll Media 50 m A0 1.5 mm or less 2.5 mm or less 10 mm or less Media
BAC2030
Thick coated paper
The first time this adjustment is made, the reference position for media skew will be determined by detecting the right edge (origin side). If the adjustment is made with a bad media loading position, that position will become the reference position and Media skew error will occur frequently.
AJST: Chk Paper Mov

Set Paper If no media is loaded After media has been loaded Paper Initial After media initialization has been completed Setting can be specified in units of 1.0 m 0.1 m using the VALUE + and - keys ENTER
Paper Feed
Paper Edge Detect
Paper Feed Media feed ends normally Paper Edge Detect Media edge detection ends normally >0.100 mm> Non-origin side +0.100 mm + for cap side, - for opposite side
Capping position side
Adjustment: Media Skew
BAC2030
284
Adjustment: Head Rank

This is to enter the rank for the left or right head. This is used to determine the head operating voltage and for temperature correction. The panel holds rank setting ranges. A rank outside the range that is entered from the terminal is invalid. When the right rank is set, pressing the [ENTER] key will switch to the ink filling menu. AJST: Head Rank
Settings are changed by + and -, from the left normal rank, frequency ID, micro-rank are all displayed when Menu Down Menu Up everything is confirmed. Right Rank: 26III Parameters are updated by setting the entire right rank. Press [ENTER] to move to the following item Left Rank: 21117 FILL START Press [ENTER] to move to the following item Set Cartridge
BAC2040
CAUTION:
The following operations must not be performed during ink filling. Printing will not work properly if ink filling is stopped or interrupted. Switching off the power Opening the front cover Raising the pressure lever Removing an ink cartridge
CAUTION:
The ink filling operation will not proceed unless all six ink cartridges are of the same kind.
Ink fill * min
Update head rank with [ENTER]. Shift to ink filling menu by entering right rank and pressing [ENTER]. Under the ink filling menu, [ENTER] starts ink filling and [Back] shifts to "Adjust: Nozzle check".
Adjustment: Head Rank
BAC2040
285
Adjustment: Head Nozzles

After filling the inks, this procedure uses printing results to check whether the head nozzles are ejecting the ink properly. If the nozzles are ejecting ink badly, implement the cleaning treatment in this procedure. If there is no media, the printer will request media. If it is out of ink, it will ask for an ink cartridge. If there is media and ink, the Head Nozzle Check Pattern will be printed. This and subsequent items that require printing for adjustment or checking include requests for media and inks. If the [CANCEL] key is pressed during printing, the printer will stop printing.
AJST: ChkNozzles
Set Paper Paper Initial Media initialization in progress [C] no ink Adjustment Print END: ChkNozzles Menu Down CLEAN: Normal Menu Down If there is no cyan ink for instance After installing a cyan ink cartridge Adjustment print is displayed Printing is finished Menu Up is output Menu Up Menu Up
o g
BAC2050
If [ENTER] is pressed while Nozzle check completed is displayed, the AJST: BlackTilt menu will be appear. If [Back] is pressed while no processing is in progress, AJST: ChkNozzles will be restored. Head Nozzle Check Pattern (6 colors) Check Items Nozzle ink eject check (missing, discontinuous, meandering) Satellite Timing fence Single-pass, bidirectional X 180 dpi Y 360 dpi
Printing method
If media is not loaded After media has been loaded
y c
m k
5
G C K O Y M G C K O Y M G C K O Y M G C K O Y M G C K
Cleaning After cleaning is finished, the menu will return to the start
Head Nozzle Check Pattern Lettering is not printed in the Head Nozzle Check Pattern.
Adjustment: Head Nozzles
25 Model Name: RJ6000-43/54/62
CLEAN: Powerful Menu Down Menu Up [Menu Down] completed START: ChkNozzles Select cleaning [Enter] to move to the following
BAC2050
286
Adjustment: Left Head Tilt

This procedure uses printing results to check whether the left head is tilted. If it is tilted, it needs to be adjusted mechanically. AJST: Left Tilt
Adjustment Print Printing finished END: Check Tilt Menu Down START: Check Tilt Menu Up Press [ENTER] to print again, next menu is end [Menu Down] is output Displayed during printing
Model Name: RJ6000-43/54/62 Left Head Tilt Check Pattern Check Items Print Method Left head tilt Single-pass, uni-direction X 180 dpi, Y 720 dpi
BAC2060
Width 4.5 Press [ENTER] while END: Check Tilt is displayed to move to AJST: Right Tilt.
5 c k c k g k g k c k c k g k g k c k c k g k g k
Paint Vertical width 6
30 m or less
k g k
30 m or less
Right side (g side) is too far forward.
Right side (g side) is too far back.
Adjustment: Left Head Tilt
25
BAC2060
287
Adjustment: Right Head Tilt

This procedure uses printing results to check whether the right head is tilted. If it is tilted, it needs to be adjusted mechanically.
AJST: Right Tilt Adjustment Print Printing finished END: Check Tilt Menu Down START: Check Tilt Menu Up Press [ENTER] to print again, next menu is end k [Menu Down] is output Displayed during printing
Model Name: RJ6000-43/54/62 Right Head Tilt Check Pattern Check Items Print Method Right head tilt (based on Left head) Single-pass, uni-directional X 180 dpi, Y 360 dpi
BAC2070
The center of the right head Width 9 5 y c y g m o k g o m k
Press [ENTER] while END: Check Tilt is displayed to move to AJST: BiDirPrint.
Paint Vertical width 6 25 y c y 30 m or less The center of the left head
Standard values y c y
30 m or less
Adjustment: Right Head Tilt
BAC2070
288
Adjustment: Repeatability Printing Position
BAC2080
This procedure is used to align left and right Normal-Dot and Micro-Dot repeatability printing positions. This involves making a bidirectional test print and from the results adjusting the CCW printing delay (position and timing) by entering into the firware the differences between the CW printing position and the CCW printing position. There are separate differences for both black and color normal dots and micro dots.
Bidirectional position adjustment for Normal-Dot DIAG: Adjustment
Bidirectional position adjustment for Micro -Dot DIAG: Adjustment
AJST: BiDirPrint ENTER Adjustment Print ENTER KCG Err: -250 m Menu Down Menu Up Setting can be specified in units of 10 m using the VALUE + and - keys Press [ENTER] to update reciprocal difference Displayed during printing
AJST: BiDir (MD) ENTER Adjustment Print ENTER KCG Err: -250 m Menu Down MYO Err: -250 m Press [ENTER] after correction Print Start? ENTER If [ENTER] is pressed at MYO Err: and the parameter has been changed, the left and right CCW printing delays (position and timing) will each be updated in the firmware and another adjustment print will be made. If the parameter was not changed, Print Start? will be displayed. If [ENTER] is pressed, another print will be made. If [Back] is pressed, the display will move to AJST: UniDirPrint. (BAC2090) Continued next page Menu Up Setting can be specified in units of 10 m using the VALUE + and - keys Press [ENTER] to update reciprocal difference Displayed during printing
Setting can be specified in units of MYO Err: -250 m 10 m using the VALUE + and - keys Press [ENTER] Press [ENTER] Press [ENTER] to update the reciprocal difference after correction without correction Print Start? ENTER If [ENTER] is pressed at MYO Err: and the parameter has been changed, the left and right CCW printing delays (position and timing) will each be updated in the firmware and another adjustment print will be made. If the parameter was not changed, Print Start? will be displayed. If [ENTER] is pressed, another adjustment print will be made. If [Back] is pressed, the display will move to AJST: BiDir (MD).
Setting can be specified in units of 10 m using the VALUE + and - keys Press [ENTER] Press [ENTER] to update the reciprocal without correction difference
BAC2080
289

Repeatability printing position alignment pattern (6 colors) Adjustment items Left and right repeatability printing position alignment Printing method Single-pass, bidirectional X 180 dpi, Y 720 dpi
BAC2081
CW printing CCW printing CW printing
Standard values
50 m or less
70 m or less
BAC2081
290
Adjustment: CW
BAC2090
Left and right head axial adjustment for normal dots and microdots. Have the printer print unidirectionally and from the results enter the position error for CW printing (separately for Normal-Dot and Micro-Dot) to adjust the right head CW printing delay (position and time) and the left head CCW printing delay (position and time) in the firmware. CW Adjustment for Normal-Dot Panel DIAG: Adjustment
AJST: UniDirPrint ENTER Adjustment Print ENTER Head Gap: -34765m Press [ENTER] after correction Displayed during printing Setting can be specified in units of 5 m Press [ENTER] to update gap Adjustment Print ENTER Head Gap: -34765 m Press [ENTER] after correction Setting can be specified in units of 5 m Press [ENTER] to update gap
CW Adjustment for Micro-Dot Panel DIAG: AJST

AJST: UniDir (MD) ENTER Displayed during printing
Set values are updated by [ENTER]. In the case where [ENTER] was pressed under "Head Gap:", if the parameter change is changed another adjustment print will be made. If [ENTER] is pressed without the parameter being changed, control shifts to "Adjust: CW (MD)".
Set values are updated by [ENTER]. In the case where [ENTER] was pressed under "Head Gap:", if the parameter change is changed another adjustment print will be made. If [ENTER] is pressed without the parameter being changed, control shifts to "Flush Pointer adjustment".
Adjustment: CW
BAC2090
291
Adjustment: CW
CW Adjustment Pattern (6 colors) Adjustment Items Left and right head axial alignment Printing method Single-pass, uni-directional X 180 dpi, Y 360 dpi
BAC2091
0.7 g o y m o y c m o y k 9 m k
Standard value
50 m or less
+
Enter this distance
Adjustment: CW
25
BAC2091
292
Adjustment: Flush Pointer

This procedure is for adjusting the position for flushing over the flushing boxes on both sides of the left and right heads. The adjustment causes flushing into the flushing box and from the results the flushing positions for both left and right heads are entered in 720 dpi units. Enter a positive value to shift the flushing position towards the cap unit side, or a negative value for the opposite direction. AJST: FlushPoint
Flushing Cap unit side flushing box ejection finished Setting can be specified in 1 pulse units 2424 using the VALUE + and - keys (- for cap unit side, + for opposite side) ENTER 3699 [ENTER] causes flushing to the flushing box on the opposite side Flushing Opposite side flushing box ejection finished Left Point: ENTER Right Point: 40000 38700
BAC2110
Left Point:
Right Point:
Press [ENTER] to update the settings. If a change has been made, flushing will be repeated. If [ENTER] was pressed with no change having been made, the display will move to the AJST: XLength menu.
Adjustment: Flush Pointer
BAC2110
293
Adjustment: Media Feed Distance

This procedure is used to adjust the distance for media transport. The adjustment determines the resolution in the firmware for the X encoder by causing lines to be printed in the direction of media feed and entering their distance.
AJST: X Length Adjustment Print Printing finished XLine Len: Setting can be specified in 0.1 mm units using the VALUE + and - keys When parameter is changed and [ENTER] is pressed 300.0 mm Press [ENTER] for another adjustment print, [Back] to move to next menu Press [ENTER] to update the settings. If settings have been changed, another adjustment print will be made. If there was no change, the display will move to the AJST: Margin menu. Displayed during adjustment printing

Media feed distance adjustment pattern Adjustment items Printing method Adjust the distance for media transport Four-pass, bidirectional 360 dpi
BAC2120
k m c
Print Start?
100 % 70
150
300
k r g y bmc
Output direction
Standard values Up to 500 mm 0.1% Here, the adjustment is 300 mm so the actual value, x, will be 299.7 x 300.3 mm
Adjustment: Media Feed Distance
BAC2120
294
Adjustment: Top and Bottom, Left and Right Margins

This procedure involves cutting the media, printing and cutting the media again, then entering the distances between front sensor and head, cutter and head, and the media edge sensors and head. Moreover, in order to know the media width exactly, it determines the correction value of the media edge detecting position. AJST: Margin
An adjustment print is made after the leading edge of the media is cut. Adjustment Print Displayed during adjustment printing After print finished and the media was cut T Margin: Menu Down B Margin: Menu Down > Margin: Menu Down < Margin: 25.0 mm Menu Up 20.0 mm Menu Up 5.0 mm Menu Up 5.0 mm Setting can be specified in 0.1 mm units using the VALUE + and - keys Setting can be specified in 0.1 mm units using the VALUE + and - keys
BAC2130
Front/Cutter to Head Distance Adjustment Pattern Adjustment Items Printing Method Top and bottom margins, left and right margins Black, single-pass, uni-directional 360 dpi
Bottom distance 20
5
Black paint, vertical width 9 Top distance 25
Press [ENTER] to update settings. Press [ENTER] at Bottom Distance to move to AJST: Rear Sns Posi. Output direction
Adjustment: Top and Bottom, Left and Right Margins
BAC2130
295
Adjustment: Rear Sensor Position

This procedure is used to ensure the proper detection of the length of cut sheet media. It adjusts the position of the rear sensor in the firmware by entering the media length after cut media has been loaded and detected. This item is essential in the production process but it is no longer necessary once media feed distance compensation has been carried out. When this item is selected, whether media is loaded or not, it will ask for cut sheet media. If panel diagnosis decides that media is loaded, this will be assumed to be cut sheet media and media initialization will begin. Therefore roll media should not be loaded. After the media has been initialized, it will be ejected. To terminate this program without updating the setting, press the [Back] while no processing is in progress.
BAC2140
AJST: Rear Sns Posi

Set CuttingPaper After loading media Paper Initial After initializing media Paper X: 594.0 mm Enter Paper Y: 840.0 mm Setting can be specified in 0.1 mm units using the VALUE + and - keys
Press [ENTER] to update the setting, and move to AJST: Test Print.
Adjustment: Rear Sensor Position
BAC2140
296
Adjustment: Test Print

This procedure is used to check adjustments by printing a test pattern. it also prints adjustment parameters and if no serial number has been entered at that time, serial number input will be requested. Online data signal reception is always enabled but any data should not be transmitted during the processing of a self-diagnostic sequence.
AJST: TestPrint PRINT: ChkNozzles Menu Up PRINT: Black Fill Menu Up Menu Down Menu Down ENTER Print Printing finished ENTER Print Printing finished ENTER
BAC2150
PRINT: Parameters
Print Printing finished On [ENTER], if no serial number is registered Back Parameter is printed but serial number is not printed.
Register Serial Number ENTER 1 BZ400001
Adjustment parameter printing begins
Digits to be entered will blink from the left. Use the VALUE + and - keys to change the settings Use [ENTER], [Menu Up] and [Menu Down] to move between digits
Press [Back] after adjustment parameter printing has finished to move to AJST: HeadWash. At other times, press [Back] to move to AJST: TestPrint. 1 Display varies according to type of printer. This is for RJ-6000-43A.
Adjustment: Test Print
BAC2150
297
Adjustment: Head Wash

This procedure is used at the end of the production process or before prior to head replacement. Note: If you suspect the cartridge sensor to be faulty, you can carry out the following procedure by pressing the [ENTER] key.
BAC2160
AJST: Head Wash Rm All Cartridge After all cartridges are removed Set Wash Jig After withdrawing a specified amount of ink Ink Absorb After all cleaning jigs are installed Washing After cleaning fluid has been extracted Rm Wash Jig After cleaning jig has been removed Washing After head cleaning has been completed, the display will move to AJST: Home.
Adjustment: Head Wash
BAC2160
298
Cleaning: Normal, Powerful

This procedure is used for head nozzle cleaning. The items are as follows. Item Normal Powerful Details Normal cleaning (wiping) Powerful cleaning (wiping and rubbing)
BAC3000
Normal Normal cleaning (wiping). It moves to next menu, CLEAN: Powerful when Normal cleaning is finished.
Cleaning selection operation is shown below. Press [Back] to return to the Diagnostics Menu ENTER CLEAN: Normal Menu Down CLEAN: Powerful Menu Down Menu Up
Printing finished To next menu
Powerful This procedure carries out powerful cleaning (wiping and rubbing). The operation is the same as for normal cleaning.
when Normal cleaning is finished
Cleaning: Normal, Powerful
BAC3000
299
Test Printing: Head Printing, Black in-filling, Parameters

This procedure is used for test printing. The items are as shown below. For adjustment parameter prints, if no serial number has been entered, a serial number will be requested. Online data signal reception is always enabled but no signals are transmitted during the processing of a diagnostic sequence. Item Details Head Printing Verification Adjustment pattern printing Check in-filling Black in-filling Adjustment Parameters Display firmware adjustment parameters
Model Name: RJ6000-43/54/62 1. Head Printing Verification To check that the head prints and print an adjustment pattern. Panel Adjustment Print
BAC4000
After the adjustment pattern printing has been finished, PRINT: ChkNozzles will appear.
Procedures for the selection of items from panel are shown below. Press [Back] to return to the Diagnostics Menu.
DIAG: Test Print Menu Up PRINT: ChkNozzles Menu Down PRINT: Black Fill Menu Down PRINT: Parameters Menu Down Menu Up Menu Up
2. Check black in-filling To print by filling an area with black color. Panel Adjustment Print
ENTER End ENTER End Black infill printing Print
After the adjustment pattern printing has finished, "Print: black in-fill" appears. 3. Adjustment Parameters This procedure is used to print firmware adjustment parameters. Panel Adjustment Print
Press [ENTER] to print firmware adjustment parameters but if no serial number has been registered, registration will be requested.
Test Printing: Head Printing, Black in-filling, Parameters
BAC4000
300
Parameters
This procedure concerns changing adjustment parameters. Details are as shown below. A special purpose memory card is used to back up backup parameters to the memory card and to update the backup parameters from the memory card. Item Initialize Update Details Initalize adjustment parameters Input adjustment parameter values
BAC5000
DIAG: Parameter
Menu Up PARAM: Initial Menu Down PARAM: Update Menu Down Menu Up Back ENTER
Parameter initialization
Press [Back] to return to the Diagnostics Menu.
Parameters
BAC5000
301
Parameters: Initialize
Initialization This procedure is used to initialize adjustment parameters. Items are: Capping Position, X Resolution, Zone Delay, Head Height, Maintenance History (Left Head, Right Head, Wiper), Serial Number and Complete Initialization. INIT: Parameter
BAC5010
INIT: Home Menu Down INIT: X Length Menu Down INIT: Maintenance Menu Down INIT: ErrorRecord Menu Down INIT: Serial No. Menu Down INIT: All Menu Down Menu Up Menu Up Menu Up INIT: Wiper Menu Up INIT: Right Head Menu Up ENTER INIT: Left Head Menu Up
Press [ENTER] to display Param Initial?. Press [ENTER] again to initialize. After initialization, INIT: Parameter is restored. Press the [BACK] key to restore PARM: Initial without initializing.
Parameters: Initialize
BAC5010
302
Parameters: Update
Update This procedure will update adjustment parameters. Note: The actual writing to flash memory is done when diagnostics are completed or power is switched off. PARAM: Update
UPDATE: Home Menu Down Menu Down UPDATE: Print Posi Menu Down UPDATE: Microdot Menu Down UPDATE: X Length Menu Down Menu Up Next menu is "UPDATE: Home" UPDATE: Mech Param Menu Up Menu Up Menu Up Menu Up UPDATE: Head Rank Previou menu is "UPDATE: Mech Param"
BAC5020
Press [ENTER] to input the adjustment parameter. Press [BACK] to return to PARM: Update.
Parameters: Update
BAC5020
303
Update: Capping Position Parameter

This procedure will update the capping position parameter. UPDATE: Home
Home: Use the VALUE + and - keys to change -2162 the setting If there is a change, a confirmation message will appear when you press [ENTER]
BAC5021
Param Update?
Update Parameter
After this display, [Menu Down] will appear The update message will appear when you press [ENTER]
If [Back] is pressed instead of the second [ENTER], a message that the parameter is not updated will appear and the display will move to UPDATE: Home
Update: Capping Position Parameter
BAC5021
304
Update: Head Rank Parameter

This procedure will update the head rank parameter. UPDATE: Head Rank
Left Rank: Menu Down Right Rank: 21117 Menu Up 21117
Use the VALUE + and - keys to change the setting and press [ENTER] to confirm the change. Use the VALUE + and - keys to change the setting and press [ENTER] to confirm the change.
BAC5022
If there is a change, a confirmation message will appear when you press [ENTER]. Param Update? The update message will appear when you press [ENTER] Update Parameter
After this display, [Menu Down] will appear
If [Back] was pressed, a message that the parameter is not updated will appear and the display will move to UPDATE: Head Rank.
Update: Head Rank Parameter
BAC5022
305
Update: Print Positioning Parameter

This procedure will update the print positioning parameter. UPDATE: PrintPosi (and Micro-Dot)
DelayL: -0.250 mm Menu Down Menu Up
Use the Setting + and - keys to change the setting and press [ENTER] to confirm the change. Use the VALUE + and - keys to change the setting and press [ENTER] to confirm the change.
BAC5023
DelayR: -0.250 mm Menu Down Menu Up
L-RGap: -34.290 mm
Use the Setting + and - keys to change the setting and press [ENTER] to confirm the change.
If there is a change, a confirmation message will appear when you press [ENTER] Param Update? The update message will appear when you press [ENTER] Update Parameter
If [Back] was pressed, a message that the parameter is not updated will appear and the display will move to UPDATE: PrintPosi.
Update: Print Positioning Parameter
BAC5023
306
Update: Media Transport Distance Parameter

This procedure will update the media transport distance parameter. UPDATE: X Length
Xlength: 300.0 mm Use the VALUE + and - keys to change the setting If there is a change, a confirmation message will appear when you press [ENTER]
BAC5024
Param Update? The update message will appear when you press [ENTER] Update Param After this display, [Menu Down] will appear
If [Back] was pressed, a message that the parameter is not updated will appear and the display will move to UPDATE: X Length.
Update: Media Transport Distance Parameter
BAC5024
307
Update: Mechanical Parameters

This procedure will update the mechanical parameters.
UPDATE: Mech Param
HtoEdge: 25.180 mm Menu Down XFtoH: Menu Down HtoCut: Menu Down Menu Up 30.890 mm Menu Up 15.390 mm Menu Up
Use the VALUE + and - keys to change the setting and press [ENTER] to confirm the change. Use the VALUE + and - keys to change the setting and press [ENTER] to confirm the change. Use the VALUE + and - keys to change the setting and press [ENTER] to confirm the change. Use the VALUE + and - keys to change the setting and press [ENTER] to confirm the change.
BAC5025
XFtoXR: 123.700 mm Menu Down Paper Edge: Menu Down LeftFlushP: Menu Down RightFlushP: Menu Down AnotherLFP: Menu Down AnotherRFP: Menu Down PaperWidAdj: Menu Up 2809 Menu Up 2424 Menu Up 3699 Menu Up 38700 Menu Up 40000 Menu Up
Use the VALUE + and - keys to change the setting and press [ENTER] to confirm the change.
Use the VALUE + and - keys to change the setting and press [ENTER] to confirm the change. If there is a change, a confirmation message will appear when you press [ENTER]
-5
Param Update?
The update message will appear when you press [ENTER]
Update Param
If [Back] was pressed, a message that the parameter is not updated will appear and the display will move to UPDATE: Mech Param.
Update: Mechanical Parameters
BAC5025
308
Aging
This procedure concerns the aging of the mechanism and head. Details of the items are as follows. Item Carriage Motor Media Feed Motor Cutter Maintenance Head Details Reciprocal carriage scanning Media feed roller drive Media cutting Capping In-fill printing
BAC6000
Selection of items from the panel is shown below. DIAG: Aging

Menu Up ENTER AGING: Y Motor Menu Down AGING: X Motor Menu Down AGING: Cutter Menu Down AGING: Mainte Unit Menu Down AGING: Head Menu Down Menu Up Menu Up Menu Up Menu Up Back End Carriage motor aging
Press [Back] to return to the Diagnostics Menu.
Aging
BAC6000
309
Aging: Carriage Motor

This procedure is used for aging the carriage motor. Select uni-directional print scanning mode or bidirectional print scanning mode and specify a number of times for repeatability scanning of the carriage. If the specified number is -1, aging will continue until a key is entered.
AGING: Y Motor AGING Y: UniDir Prn
BAC6010
Menu Up
AGING Y: BiDirPrn
Menu Down
Press [ENTER] to move to number of agings
[ENTER]
AGING COUNT: 50 Use the VALUE + and - keys to change the setting Terminate endurance with [ENTER], [Back] or [CANCEL]
Press [ENTER] to begin aging AGING: End AGING END: 50 Escape with [ENTER] or [Back] 10
Aging: Carriage Motor
BAC6010
310
Aging: Media Feed

This procedure is used for aging the media feed motor. Repeatability operation is carried out for a specified number of times. AGING: X Motor
AGING COUNT: 50 Use the VALUE + and - keys to change the setting Press [ENTER], [Back] or [CANCEL] to end aging.
BAC6020
Press [ENTER] to begin aging AGING: End AGING END: 50 10
Aging: Media Feed
BAC6020
311
Aging: Cutter
This procedure is used for aging the cutter. Media is cut a specified number of times.
BAC6030
AGING: Cutter
AGING COUNT: 50 Use the VALUE + and - keys to change the setting Press [ENTER], [Back] or [CANCEL] to end aging
Aging: Cutter
BAC6030
312
Aging: Maintenance Unit

This procedure is used for aging the capping. Capping is carried out a specified number of times. AGING: Mainte Unit
AGING COUNT: 50 Use the VALUE + and - keys to change the setting Press [ENTER], [Back] or [CANCEL] to end aging.
BAC6040
Aging: Maintenance Unit
BAC6040
313
Aging: Head
This procedure is used for aging the print head. Select left or right and carry out infill printing a specified number of times. AGING: Head
AGING HEAD: Menu Down AGING HEAD: Left Menu Up Right ENTER AGING COUNT: 50 Press [ENTER] to begin aging AGING: End AGING END: 50 10
BAC6050
Press [ENTER] to specify a number of times to carry out aging in the same way as the carriage motor and return to AGING: Head when finished.
Aging: Head
BAC6050
314
RJ-6000-43 Maintenance Parts
C AT 0 0 0 0
Maintenance Parts
Maintenance Parts List Maintenance Tool List Lubrication Points Exploded Drawings
CAT1000 CAT2000 CAT4000 CAT5000
C AT 0 0 0 0
315
C AT 0 0 0 0 - 2
Maintenance Parts
CAT1000-2 CAT2000 CAT4000 CAT5000
C AT 0 0 0 0 - 2
316
C AT 0 0 0 0 - 3
Maintenance Parts
CAT1000-3 CAT2000 CAT4000 CAT5000
C AT 0 0 0 0 - 3
317
RJ-6000-43 Maintenance Parts List

Name of Part Main Board Assembly Power Supply Board Assembly Head Board Assembly Panel Board Assembly Extension Board Assembly Lever Sensor Assembly Cover Switch Assembly Waste Fluid Box Sensor Assembly XR Cable Assembly Detector 1 Assembly Detector 2 Assembly Detector Assembly (Black) Detector Assembly (Y) Detector Assembly (M) Detector Assembly (C) Edge Sensor Y Assembly Origin Sensor Assembly X Motor Assembly CR Motor Assembly Pump Motor Assembly Cutter Solenoid Assembly Vacuum Fan Assembly Panel Cable Switch Cable Assembly DC Cable Assembly Y Cable Head Cable Print Head Assembly (Color) Cap Assembly Pump Assembly Wiper Maintenance Station Assembly Cartridge Frame Assembly Damper (Color) Ink Tube Pressure Assembly X Speed Reduction Belt Steel Belt Part Number DF-41586 DF-41587 DF-41588 DF-40097 DF-40098 DF-41589 DF-41590 DF-41591 DF-41592 DF-41593 DF-41594 DF-40106 DF-40107 DF-40146 DF-40147 DF-41595 DF-40109 DF-41597 DF-41598 DF-41599 DF-40113 DF-40173 DF-41617 DF-41619 DF-41618 DF-41600 DF-41601 DF-40690 DF-41602 DF-41603 DF-40125 DF-41604 DF-40127 DF-40129 DF-41605 DF-41529 DF-40137 DF-41606 Exploded View Page CAT5008-3C CAT5008-5D CAT5007-7A CAT5008-7E CAT5008-3B CAT5003-8C CAT5003-8D CAT5003-8A CAT5003-4D CAT5006-7E CAT5006-8F CAT5006-4A CAT5006-6D CAT5006-6C CAT5006-4C CAT5007-2D CAT5007-5B CAT5002-2E CAT5005-8F CAT5004-7B CAT5007-1C CAT5002-3F, 5F, 6F CAT5008-6E CAT5008-4F CAT5008-4D CAT5005-6C CAT5007-3B, 5C CAT5007-3C, 4C CAT5004-6B CAT5004-5C CAT5004-5B CAT5004-5B
CAT5006-4B, 4C, 5C, 6D, 6E, 7F

Name of Part T Fence Cursor Assembly Y Return Pulley Assembly Pressure Roller Blade Scroller Roller Scroller Receive Roller FAN Extension Cable 1 Assembly FAN Extension Cable 2 Assembly FAN Extension Cable 3 Assembly X Motor Extension Cable Assembly X ENC Extension Cable Assembly Y Motor Cable Assembly ENC Cable Flange (2-inch) Flange (3-inch) O-ring (Small) O-ring (Large) Tube Guide Assembly Steel Flexible Bare Assembly Junction Board Assembly Ink ID Sensor 1 Assembly Ink ID Sensor 2 Assembly Ink ID Sensor 3 Assembly Ink ID Sensor 4 Assembly Ink ID Sensor 5 Assembly Ink ID Sensor 6 Assembly Ink ID Cable Speed Reduction Pulley Assembly Grid Roller Assembly F Absorbent Assembly Part Number DF-41607 DF-41608 DF-40144 DF-41530 DF-40696 DF-41633 DF-41634 DF-41620 DF-41621 DF-41622 DF-41623 DF-41624 DF-41625 DF-41626 DF-40446 DF-40447 DF-40487 DF-40488 DF-41677 DF-41616 DF-41536 DF-41609 DF-41610 DF-41611 DF-41612 DF-41613 DF-41614 DF-41615 DF-41841 DF-41840 DF-42007
C AT 1 0 0 0
Exploded View Page CAT5005-2B CAT5007-8D CAT5005-2C CAT5005-3E, 4F CAT5005-3E, 4F CAT5002-3D, 4C CAT5003-5B CAT5002-3D, 4B CAT5003-6B CAT5002-5F CAT5002-4F CAT5002-3F CAT5002-1F CAT5002-2F CAT5005-7F CAT5007-5A CAT5005-6B CAT5005-8B CAT5006, CAT5007 CAT5006, CAT5007 CAT5006-1B CAT5006-2B CAT5003-3D CAT5006-3B CAT5006-4B CAT5006-5C CAT5006-5D CAT5006-6E CAT5006-7F CAT5003-3D CAT5002-2C CAT5004-3C, 5D, 7E CAT5004-8E
CAT5007-2B, 4B CAT5006-2C CAT5005-3E, 4F CAT5002-2E CAT5005-2F
C AT 1 0 0 0
318

Name of Part Main Board Assembly Power Supply Board Assembly Head Board Assembly Panel Board Assembly Extension Board Assembly Lever Sensor Assembly Cover Switch Assembly Waste Fluid Box Sensor Assembly XR Cable Assembly Detector 1 Assembly Detector 2 Assembly Detector Assembly (Black) Detector Assembly (Y) Detector Assembly (M) Detector Assembly (C) Edge Sensor Assembly Origin Sensor Assembly X Motor Assembly CR Motor Assembly Pump Motor Assembly Cutter Solenoid Assembly Vacuum Fan Assembly Panel Cable Switch Cable Assembly DC Cable Assembly Y Cable Head Cable Print Head Assembly (Color) Cap Assembly Pump Assembly Wiper Maintenance Station Assembly Cartridge Frame Assembly Damper (Color) Ink Tube Pressure Assembly X Speed Reduction Belt Steel Belt Part Number DF-41586 DF-41587 DF-41588 DF-40097 DF-40098 DF-41589 DF-41590 DF-41591 DF-41592 DF-41593 DF-41594 DF-40106 DF-40107 DF-40146 DF-40147 DF-41595 DF-40109 DF-41597 DF-41598 DF-41599 DF-40113 DF-40173 DF-41617 DF-41619 DF-41618 DF-41986 DF-41601 DF-40690 DF-41602 DF-41603 DF-40125 DF-41604 DF-40127 DF-40129 DF-41987 DF-41529 DF-40137 DF-41991 Exploded View Page CAT5008-3D CAT5008-5D CAT5007-7A CAT5008-7E CAT5008-3B CAT5003-7D CAT5003-7D CAT5003-7A CAT5003-4D CAT5006-7E CAT5006-8F CAT5006-4B CAT5006-6D CAT5006-6C CAT5006-5C CAT5007-2D CAT5007-5B CAT5002-2E CAT5005-8F CAT5004-7B CAT5007-1C CAT5002-4F, 6F, 7C, 7F CAT5008-6F CAT5008-4F CAT5008-4D CAT5005-6C CAT5007-3B, 5C CAT5007-3C, 4C CAT5004-6B CAT5004-5C CAT5004-5B CAT5004-5B
CAT5006-3B, 4C, 5C, 6D, 6E, 7D

Name of Part T Fence Cursor Assembly Y Return Pulley Assembly Pressure Roller Blade Scroller Roller Scroller Receive Roller FAN Extension Cable 1 Assembly FAN Extension Cable 2 Assembly FAN Extension Cable 3 Assembly FAN Extension Cable 4 Assembly X Motor Extension Cable Assembly X ENC Extension Cable Assembly Y Motor Cable Assembly ENC Cable Flange (2-inch) Flange (3-inch) O-ring (Small) O-ring (Large) Tube Guide Assembly Steel Flexible Bare Assembly Junction Board Assembly Ink ID Sensor 1 Assembly Ink ID Sensor 2 Assembly Ink ID Sensor 3 Assembly Ink ID Sensor 4 Assembly Ink ID Sensor 5 Assembly Ink ID Sensor 6 Assembly Ink ID Cable Speed Reduction Pulley Assembly Grid Roller Assembly Grid Roller Assembly (2) F Absorbent Assembly Waste Fluid Bottle Assembly Part Number DF-41992 DF-41608 DF-40144 DF-41530 DF-40696 DF-41633 DF-41634 DF-41620 DF-41621 DF-41622 DF-41993 DF-41994 DF-41995 DF-41625 DF-41626 DF-40446 DF-40447 DF-40487 DF-40488 DF-41997 DF-41996 DF-41536 DF-41609 DF-41610 DF-41611 DF-41612 DF-41613 DF-41614 DF-41615 DF-41988 DF-41840 DF-41989 DF-42007 DF-42008
C AT 1 0 0 0 - 2
Exploded View Page CAT5005-2B CAT5007-8D CAT5005-2C CAT5005-3E, 4F CAT5005-3E, 4F CAT5002-3D, 4C CAT5003-5B CAT5002-3D, 4B CAT5003-6B CAT5002-6F CAT5002-5F CAT5002-3F CAT5002-5B CAT5002-1F CAT5002-2F CAT5005-7F CAT5007-5A CAT5005-6B CAT5005-8B CAT5006, CAT5007 CAT5006, CAT5007 CAT5006-1B CAT5006-2B CAT5003-3D CAT5006-3B CAT5006-4C CAT5006-5C CAT5006-5D CAT5006-6E CAT5006-7F CAT5003-3D CAT5002-2C CAT5004-4C, 5D, 7E CAT5004-2B CAT5004-8E CAT5002-4E
CAT5007-2B, 4B CAT5006-2C CAT5005-3E, 4F CAT5002-2E CAT5005-2F
C AT 1 0 0 0 - 2
319

Name of Part Main Board Assembly Power Supply Board Assembly Head Board Assembly Panel Board Assembly Extension Board Assembly Lever Sensor Assembly Cover Switch Assembly Waste Fluid Box Sensor Assembly XR Cable Assembly Detector 1 Assembly Detector 2 Assembly Detector Assembly (Black) Detector Assembly (Y) Detector Assembly (M) Detector Assembly (C) Edge Sensor Assembly Origin Sensor Assembly X Motor Assembly CR Motor Assembly Pump Motor Assembly Cutter Solenoid Assembly Vacuum Fan Assembly Panel Cable Switch Cable Assembly DC Cable Assembly Y Cable Head Cable Print Head Assembly (Color) Cap Assembly Pump Assembly Wiper Maintenance Station Assembly Cartridge Frame Assembly Damper (Color) Ink Tube Pressure Assembly X Speed Reduction Belt Steel Belt Part Number DF-42010 DF-41587 DF-41588 DF-40097 DF-40098 DF-41589 DF-41590 DF-41591 DF-41592 DF-41593 DF-41594 DF-40106 DF-40107 DF-40146 DF-40147 DF-41595 DF-40109 DF-41597 DF-41598 DF-41599 DF-40113 DF-40173 DF-41617 DF-41619 DF-41618 DF-41998 DF-41601 DF-40690 DF-41602 DF-41603 DF-40125 DF-41604 DF-40127 DF-40129 DF-41999 DF-41529 DF-40137 DF-42001 Exploded View Page CAT5008-3C CAT5008-5D CAT5007-8B CAT5008-7E CAT5008-3B CAT5003-7D CAT5003-7D CAT5003-7B CAT5003-4D CAT5006-7E CAT5006-7F CAT5006-4A CAT5006-6D CAT5006-5B CAT5006-4B CAT5007-2D CAT5007-5B CAT5002-2E CAT5005-8F CAT5004-7B CAT5007-1C CAT5002-4F, 5E, 6B, 7F CAT5008-6E CAT5008-4F CAT5008-4D CAT5005-6C CAT5007-3B, 5C CAT5007-2C, 4C CAT5004-6B CAT5004-5B CAT5004-5B CAT5004-5A
CAT5006-3B, 4C, 5C, 6D, 6E, 7F

Name of Part T Fence Cursor Assembly Y Return Pulley Assembly Pressure Roller Blade Scroller Roller Scroller Receive Roller FAN Extension Cable 1 Assembly FAN Extension Cable 2 Assembly FAN Extension Cable 3 Assembly FAN Extension Cable 4 Assembly X Motor Extension Cable Assembly X ENC Extension Cable Assembly Y Motor Cable Assembly ENC Cable Flange (2-inch) Flange (3-inch) O-ring (Small) O-ring (Large) Tube Guide Assembly Steel Flexible Bare Assembly Junction Board Assembly Ink ID Sensor 1 Assembly Ink ID Sensor 2 Assembly Ink ID Sensor 3 Assembly Ink ID Sensor 4 Assembly Ink ID Sensor 5 Assembly Ink ID Sensor 6 Assembly Ink ID Cable Speed Reduction Pulley Assembly Grid Roller Assembly F Absorbent Assembly Waste Fluid Bottle Assembly Part Number DF-42002 DF-41608 DF-40144 DF-41530 DF-40696 DF-41633 DF-41634 DF-41620 DF-41621 DF-41622 DF-41993 DF-41994 DF-41995 DF-41625 DF-41626 DF-40446 DF-40447 DF-40487 DF-40488 DF-42003 DF-42004 DF-41536 DF-41609 DF-41610 DF-41611 DF-41612 DF-41613 DF-41614 DF-41615 DF-41988 DF-41840 DF-42007 DF-42008
C AT 1 0 0 0 - 3
Exploded View Page CAT5005-2B CAT5007-8D CAT5005-2C CAT5005-3E, 4F CAT5005-3E, 4F CAT5002-4C, CAT5003-5B CAT5002-4B, CAT5003-5B CAT5002-6F CAT5002-5F CAT5002-3F CAT5002-5B CAT5002-1F CAT5002-2F CAT5005-7F CAT5007-5A CAT5005-6B CAT5005-8B CAT5006, CAT5007 CAT5006, CAT5007 CAT5006-1B CAT5006-2B CAT5003-3D CAT5006-3A CAT5006-3B CAT5006-5C CAT5006-5D CAT5006-6E CAT5006-7E CAT5003-3D CAT5002-2C CAT5004-2B, 4C, 6D, 7E CAT5004-8E, 4C CAT5002-4D
CAT5007-2A, 4B CAT5006-1C CAT5005-3E, 4F CAT5002-2E CAT5005-2F
C AT 1 0 0 0 - 3
320
Maintenance Tool List

No. 1 Drawing No. Name Personal Computer Appearance Remarks Commercial item No. 5 Drawing No.

Name Bar tension gauge 49 N (5 kgf) (made by Ooba S/S) Appearance
C AT 2 0 0 0
Remarks Commercial item
JD-30410
Head cleaning jig assembly (6 sets required)
Special item, includes rubber bush and mini-fitting
JD-30395
Rail height jig assembly
Special item
2.1
JD-42052
Rubber bushing Replace after using 20 times Mini-fitting (made by Inaiseieido)
Special item (consumable)
JD-30432
Rail height reference base assembly
Special item
2.2
JD-42053
Special item (commercial item) Special item 8 Phillips screwdriver No. 1 Commercial item
JD-42050
Belt tension attachment
9 4 Bar tension gauge 4.9 N (500 gf) (made by Ooba S/S) Commercial item 10
Phillips screwdriver No. 2
Commercial item
Hex nut driver 5.5 mm
Commercial item
C AT 2 0 0 0
321

No. 11 Drawing No. Name Standard screwdriver Appearance Remarks Commercial item No. 20 Drawing No.

Name Multimeter Appearance
C AT 2 0 0 1
Remarks Commercial item
12
Allen key 1.5 mm
Commercial item 21 JD-41844 Cleaning fluid A-29 (18-liter) Special item
13
Allen key 2 mm
Commercial item
14
Allen key 2.5 mm
Commercial item 22 JD-42054 Cleaning fluid bottle, 500 ml Special item (Commercial item)
15
Allen key 3 mm
Commercial item
16
Spanner 5.5 mm
Commercial item 23 Ball driver 1.5 mm Commercial item
17
Spanner 17 mm
Commercial item
18
Tweezers
Commercial item
24
Ball driver 2.5 mm
Commercial item
19
Jeweller's screwdriver
Commercial item
25
Hexagon ratchet spanner
Commercial item
C AT 2 0 0 1
322

No. 26 Drawing No. Name M-block (Height: 20) Appearance Remarks Commercial item No. Drawing No.

Name Appearance
C AT 2 0 0 2
Remarks
27
JD-42145
Head height jig
Special item
28
Pocket microscope (Magnification: 25x to 50x)
Commercial item
C AT 2 0 0 2
323
Lubrication Points
C AT 4 0 0 0
No. 1
Name of Unit Pressurization Unit Maintenance Unit
Lubrication Point Pressure cam
Brand, Product Number Shin-Etsu Chemical Co., Ltd., Silicone Grease G501 Shin-Etsu Chemical Co., Ltd., Silicone Grease G501 Shin-Etsu Chemical Co., Ltd., Silicone Grease G501 Shin-Etsu Chemical Co., Ltd., Silicone Grease G501 Shin-Etsu Chemical Co., Ltd., Silicone Grease G501 Sumiko Lubricants Co., Ltd Sumi Grease Spray Shin-Etsu Chemical Co., Ltd., Silicone Grease G501
Application To improve sliding
Remarks or similar
Exploded View Page CAT5005-3D, 5E
Transfer gear bearings
To improve durability
or similar
CAT5004-7B
R Frame
Sliding parts around pressurizing relay plate X speed reduction belt parts
To improve sliding
or similar
CAT5003-7F
X Drive
To improve durability
CAT5002-2E
Y Rail
Back of roller track
For inserting roller, reducing cursor noise To prevent burning
or similar
CAT5005-5E
Y Rail
Cursor track
Soak a cloth and apply lightly or similar
CAT5005-5E
Covers
Cover pins and frame holes
For cover opening/closing action and noise
CAT5001-6D CAT5003-6D
Lubrication Points
C AT 4 0 0 0
1 Exploded Drawing
7
8
CAT5001-2
RJ-6000-43 COVER UNIT
[Packaging Items] Carton Cushioning material (bottom right) Cushioning material (bottom left) Cushioning material (top right) Cushioning material (top left) Cushioning material (top center) Joint Pallet Top plate Vinyl bag A Accessories carton Package supporting material
43E DE-21480 DE-21481 DE-21482 DE-21483 DE-21484 DE-21485 DF-41441 DE-34526 DF-41585 DF-40976 DE-33903 DF-41780
43A DE-21567 DE-21562 DE-21563 DE-21564 DE-21565 DE-21566 DF-41441 DE-34526 DF-41585 DF-40976 DE-33903 -
[Shipping Items] Supporting materials (scroller roller handle fittings) Wing bolt (large) Head fasteners Wing bolt (small) Lever retainer Bare support Cable keeper Flexible belt keeper
DF-40463 DF-49510 DE-41440 DF-48262 DF-40337 DE-34742 DF-40338 DE-34668
[Accessories] Power cable (for E) Power cable (for A) Cable clump Face screw Paper towels (5)
Towels Poly bag
DE-34436 DE-34435 DE-49162 DF-48958 DF-41300 DF-41298
CAT5001-2
8
324
1 Exploded Drawing
7
8
CAT5002-2
RJ-6000-43 FRAME UNIT: LEFT
B
Scroller Receiver Roller DF-41634
C
Scroller Roller Assy DF-41633
Speed Reduction Pulley Assy DF-41841
Scroller Receiver Roller DF-41634 Scroller Roller Assy DF-41633
X Speed Reduction Belt DF-40137
E
FAN Extension Cable 3 Assy DF-41622 X Motor Assy DF-41597 Suction Fan Assy DF-40173
Suction Fan Assy DF-40173 X Motor Extension Cable Assy DF-41623 X_ENC Extension Cable Assy DF-41624
FAN Extension Cable 2 Assy DF-41621
Suction Fan Assy DF-40173
CAT5002-2
8
325
1 Exploded Drawing
7
8
CAT5003-2
RJ-6000-43 FRAME UNIT: RIGHT

Waste Fluid Box Sensor Assy DF-41591
Waste Fluid Tank RJ8-HEB
C
Lever Sensor Assy DF-41589
Junction Board Assy DF-41536 Cover Switch Assy DF-41590
D
INK_ID Cable DF-41615
XR Cable Assy DF-41592
CAT5003-2
8
326
1 Exploded Drawing
7
8
CAT5004-2
RJ-6000-43 X DRIVE UNIT, MAINTENANCE UNIT

Maintenance Station Assy DF-41604
B
Wiper DF-40125 Pump Motor Assy DF-41599 Cap Assy DF-41602
Pump Assy DF-41603
Grid Roller Assy DF-41840
Coupling Assy DF-40693
F Absorbent Assy DF-42007 F Absorbent 1 DF-41326 F Absorbent 2 DF-41327
Adjusting Spacer (t = 0.1) DF-41578A Adjusting Spacer (t = 0.2) DF-41578B Adjusting Spacer (t = 0.3) DF-41578C
CAT5004-2
8
327
1 Exploded Drawing
7
8
CAT5005-2
RJ-6000-43 Y DRIVE UNIT

Flange (2 inch) DF-40446 Flange (3 inch) DF-40447
B
T Fence DF-41607
Y Cable DF-41600
Y Return Pulley Assy DF-40144
Pressure Assy DF-41529
E
Pressure Roller DF-41530 Blade addition DF-40696
Steel Belt DF-41606
Y Motor Cable Assy DF-41625
CR Motor Assy DF-41598
CAT5005-2
8
328
1 Exploded Drawing
7
8
CAT5006-2
RJ-6000-43 CARTRIDGE UNIT, PIPING UNIT

INK_ID Sensor 1 Assy DF-41609 Detector Assy (K) DF-40106
Tube Guide Assy DF-41677
O-ring (large) 100 units Cartridge Frame Assy DF-40488 DF-40127
Steel Bare Assy DF-41616
INK_ID Sensor 2 Assy DF-41610
Detector Assy (C) DF-40147
O-ring (large) 100 units DF-40488
Cartridge Frame Assy DF-40127
Ink Tube DF-41605

C
Detector Assy (M) DF-40146
D
# O-ring (large) 100 units DF-40488 # O-ring (large) 100 units DF-40488
O-ring (large) 100 units DF-40458 Cartridge Frame Assy DF-40127
Detector Assy (Y) DF-40107
Detector 1 Assy DF-41593
# O-ring (small) 100 units DF-40487

F
# O-ring (large) 100 units #Cartridge Frame Assy DF-40488 DF-40127
CAT5006-2
8
329
1 Exploded Drawing
7
8
CAT5007-2
Damper (color) DF-40129
RJ-6000-43 HEAD UNIT, CURSOR UNIT

Damper (color) DF-40129 Head Board Assy DF-41588 Damper (color) DF-40129 Damper (color) DF-40129 ENC Cable Assy DF-41626
O-ring (small) 100 units DF-40487
Head Cable DF-41601

Origin Sensor Assy DF-40109
Head Cable DF-41601

Cutter Solenoid Assy DF-40113
Print Head Assy (color) DF-40690
C
Print Head Assy (color) DF-40690 Edge Sensor Assy DF-41595
Cursor Assy DF-41608
CAT5007-2
8
330
1 Exploded Drawing
7
8
CAT5008-2
RJ-6000-43 P.C.B. UNIT, PANEL UNIT
Extension Board Assy DF-40098
MAIN Board Assy DF-41586
DC Cable Assy DF-41618
D
Power Board Assy DF-41587
Panel Board Assy DF-40097
Panel Cable DF-41617
Switch Cable Assy DF-41619
CAT5008-2
8
331
1 Exploded Drawing
7
8
CAT5009-2
RJ-6000-43 STAND UNIT
C
(Jig tools) Hexagon Ratchet Spanner (5) Hexagon Ratchet Spanner (6) DF-41419 DF-41402
CAT5009-2
8
332
1 Exploded Drawing
7
8
CAT5001-3
[Packaging Items] Vinyl bag A Accessories carton Carton Cushioning material (bottom right) Cushioning material (bottom left) Cushioning material (top right) Cushioning material (top left) Pallet DF-40976 DE-33903 DE-21568 DE-21570 DE-21571 DE-21564 DE-21565 DE-34758
[Packaging Items] Supporting materials (scroller roller handle fittings) Wing bolt (large) Head fasteners Wing bolt (small) Lever retainer Bare support Cable keeper Bare keeper
DF-40463 DE-49510 DE-41440 DE-48262 DF-40337 DE-34742 DF-40338 DE-34668
[Accessories] Power cable (for J) Power cable (for A) Power cable (for E, K) Replacement plug (for J) Cable clamps Face screws Paper towels (5) Towels Poly bag F absorbent material 1 F absorbent material 2
DE-33809 DE-34435 DE-34436 DF-40090 DE-49162 DE-48958 DF-40337 DF-41298 DE-41326 DE-41327
CAT5001-3
8
333
1 Exploded Drawing
7
8
CAT5002-3
RJ-6000-54 FRAME UNIT: LEFT
Waste Fluid Bottle Assy DF-42008
D
D
Scroller Roller Assy DF-41633 X Speed Reduction Belt DF-40137
X Motor Assy DE-41597

X Motor Extension Cable Assy DF-41994 X_ENC Extension Cable Assy DF-41995
FAN Extension Cable 2 Assy DF-41621 Suction Fan Assy DF-40173
CAT5002-3
8
334
1 Exploded Drawing
7
8
CAT5003-3

Waste Fluid Box Sensor Assy DF-41591 Waste Fluid Tank RJ8-HEB Scroller Receiver Roller DF-41634
C
JUNCTION Board Assy DF-41536 Cover Switch Assy DF-41590
D
CAT5003-3
8
335
1 Exploded Drawing
7
8
CAT5004-3

F Absorbent Assy DF-42007 Grid Roller Assy (2) DF-41989 Maintenance Station Assy DF-41604
Pump Assy DF-41603
D
F Absorbent Material Assy DF-42007
Adjustment Spacer (t = 0.2) DF-41578B Adjustment Spacer (t = 0.3) DF-41578C
CAT5004-3
8
336
1 Exploded Drawing
7
8
CAT5005-3

B
T Fence DF-41992
Y Cable DF-41986
E
Steel Belt DF-41991
CR Motor Assy DF-41598
CAT5005-3
8
337
1 Exploded Drawing
7
8
CAT5006-3

INK_ID Sensor 1 Assy DF-41609 Tube Guide Assy DF-41997 Detector Assy (K) DF-40106
Ink Tube DF-41987 INK_ID Sensor 3 Assy DF-41611 Detector Assy (M) DF-40146
D
#O-ring (large) 100 units DF-40488 #O-ring (large) 100 units DF-40488
#O-ring (small) 100 units DF-40487

E
CAT5006-3
8
338
1 Exploded Drawing
7
8
CAT5007-3

Damper (color) DF-40129 Head Board Assy DF-41588 Damper (color) DF-40129 Damper (color) DF-40129 ENC Cable Assy DF-41626
Head Cable DF-41601 O-ring (small) 100 units DF-40690
B
Origin Sensor Assy DF-40109 Head Cable DF-41601
C
CAT5007-3
8
339
1 Exploded Drawing
7
8
CAT5008-3
RJ-6000-54 P.C.B UNIT, PANEL UNIT
Extension Board Assy DF-40098
MAIN Board Assy DF-41586 DC Cable Assy DF-41618
D
E
Switch Cable Assy DE-41619
CAT5008-3
8
340
1 Exploded Drawing
7
8
CAT5009-3
C
(Jig tools) Hexagon Ratchet Spanner (5) Hexagon Ratchet Spanner (6) DF-41419 DF-41402
CAT5009-3
8
341
1 Exploded Drawing
7
8
CAT5001-4
[Packaging Items] Vinyl bag A Accessories carton Carton Cushioning material (bottom right) Cushioning material (bottom left) Cushioning material (top right) Cushioning material (top left) Pallet DF-40976 DE-33903 DE-21552 DE-21570 DE-21571 DE-21572 DE-21573 DE-34714 [Accessories] Power cable (for J) Power cable (for A) Power cable (for E, K) Replacement plug (for J) Cable clamps Face screws Paper towels (5) Towels Poly bag F absorbent material 1 F absorbent material 2
[Packaging Items] Supporting materials (scroller roller handle fittings) Wing bolt (large) Head fasteners Wing bolt (small) Lever retainer Bare support Cable keeper Bare keeper
DF-40463 DE-49510 DE-41440 DE-48262 DF-40337 DE-34742 DF-40338 DE-34668
DE-33809 DE-34435 DE-34436 DF-40090 DE-49162 DE-48958 DF-40337 DF-41298 DE-41326 DE-41327
CAT5001-4
8
342
1 Exploded Drawing
7
8
CAT5002-4
RJ-6000-62 FRAME UNIT
C
Waste Fluid Bottle Assy DF-42008
D
Scroller Receiver Roller DF-41634 Scroller Roller Assy DF-41633 X Speed Reduction Belt DF-40137
X Motor Assy DF-41597
FAN Extension Cable 3 Assy DF-41622 Suction Fan Assy DF-40173
X Motor Extension Cable Assy DF-41994 X_ENC Extension Cable Assy DF-41995 Suction Fan Assy DF-40173
CAT5002-4
8
343
1 Exploded Drawing
7
8
CAT5003-4

Waste Fluid Box Sensor Assy DF-41591 Scroller Receiver Roller DF-41634 Waste Fluid Tank RJ8-HEB
C
Junction Board Assy DF-41536
Cover Switch Assy DF-41590
D
CAT5003-4
8
344
1 Exploded Drawing
7
8
CAT5004-4

F Absorbent Material Assy DF-42007 Maintenance Station Assy DF-41804
Pump Assy DF-41603
D
F Absorbent Material Assy DF-42007
Adjustment Spacer (t = 0.2) DF-41578B Adjustment Spacer (t = 0.3) DF-41578C
CAT5004-4
8
345
1 Exploded Drawing
7
8
CAT5005-4

B
T Fence DF-42002
Y Cable DF-41998
Steel Belt DF-42001 CR Motor Assy DF-41598
CAT5005-4
8
346
1 Exploded Drawing
7
8
CAT5006-4

INK_ID Sensor 1 Assy DF-41609 Tube Guide Assy DF-42003
Ink Tube DF-41999
C
Detector Assy (M) DF-40146
D

O-ring (large) 100 units DF-40488 Cartridge Frame Assy DF-40127
CAT5006-4
8
347
1 Exploded Drawing
7
8
CAT5007-4

Damper (color) DF-40129 Damper (color) DF-40129 Damper (color) DF-40129 ENC Cable Assy DF-41626 Head Board Assy DF-41588
Head Cable DF-41601 O-ring (small) 100 units DF-40690
B
Origin Sensor Assy DF-40109 Head Cable DF-41601
C
CAT5007-4
8
348
1 Exploded Drawing
7
8
CAT5008-4
RJ-6000-62 P.C.B UNIT, PANEL UNIT
Mother Board Assy DF-40098
MAIN Board Assy DF-41586 DC Cable Assy DF-41618
D
Switch Cable Assy DE-41619
CAT5008-4
8
349
1 Exploded Drawing
7
8
CAT5009-4
(Jig tools) Hexagon Ratchet Spanner (5) Hexagon Ratchet Spanner (6)
DF-41419 DF-41402
CAT5009-4
8
350

Mutoh 6000

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MAINTENANCE MANUAL

Full-Color Inkjet Printer

Model Name: RJ6000-43/54/62

Model Name: RJ6000-43/54/62

Some Thoughts on Maintenance Work

Model Name: RJ6000-43/54/62

Some Thoughts on Maintenance Work

Model Name: RJ6000-43/54/62

Precautions For Maintaining This Printer

Model Name: RJ6000-43/54/62 Maintenance Unit Tubes

Head Cleaning Jig

Take Care When Inserting Head Cable and Y Cable

Printing After Initial Filling

Thorough Waste Fluid Box Replacement

Precautions For Maintaining This Printer

Model Name: RJ6000-43/54/62

Model Name: RJ6000-43/54/62

PAT 0000 BAC 0000 CAT 0000

PAT 0000-2 BAC 0000-2 CAT 0000-2

PAT 0000-3 BAC 0000-3 CAT 0000-3

Model Name: RJ6000-43/54/62

Model Name: RJ6000-43

TRB0000 TRB1000 TRB1001

EXA0000 EXA1000~ EXA1200~ EXA1250~ EXA1500~ EXA1700~

MAP0000 MAP1000 MAP1200 MAP1250 MAP1500 MAP1700

EXA2000~ EXA3000~ EXA4000~ EXA5000~ EXA6000~ EXA7000~ EXA8000~

MAP2000 MAP3000 MAP4000 MAP5000 MAP6000 MAP7000 MAP8000

Model Name: RJ6000-43

Model Name: RJ6000-43

Model Name: RJ6000-43

Model Name: RJ6000-43

PAT0000 PAT1000 PAT3000 PAT4000

CAT0000 CAT1000 CAT2000 CAT4000 CAT5000

Model Name: RJ6000-43

Model Name: RJ6000-54

TRB0000-2 TRB1000 TRB1001

EXA0000-2 EXA1000~ (1020-2) EXA1200~ EXA1250~ EXA1500~ EXA1700~

MAP0000-2 MAP1000 MAP1200 MAP1250 MAP1500 MAP1700-2

MAP2000-2 MAP3000-2 MAP4000-2 MAP5000 MAP6000 MAP7000 MAP8000

Model Name: RJ6000-54

Model Name: RJ6000-54

Model Name: RJ6000-54

Model Name: RJ6000-54

PAT0000-2 PAT1000 PAT3000 PAT4000

CAT0000-2 CAT1000-2 CAT2000 CAT4000 CAT5000

Model Name: RJ6000-54

Model Name: RJ6000-62

TRB0000-3 TRB1000 TRB1001

EXA0000-3 EXA1000~ (1020-2) EXA1200~ EXA1250~ EXA1500~ EXA1700~

MAP0000-3 MAP1000 MAP1200 MAP1250 MAP1500 MAP1700-2

MAP2000-2 MAP3000-2 MAP4000-2 MAP5000 MAP6000 MAP7000 MAP8000

Model Name: RJ6000-62

Model Name: RJ6000-62

Model Name: RJ6000-62

Model Name: RJ6000-62

PAT0000-3 PAT1000 PAT3000 PAT4000

CAT0000-3 CAT1000-3 CAT2000 CAT4000 CAT5000

Model Name: RJ6000-62

How to use the Maintenance Manual

Model Name: RJ6000-43/54/62

How to use the Maintenance Manual

CON4040 CON4050 CON4060

How to use the Maintenance Manual

Model Name: RJ6000-43/54/62