MM Albatros Rev3

Maintenance Manual
PJ-1304NX Albatros Printer
MUTOH EUROPE N.V. AP-74020, Rev. 3.0 – 26/06/01

Maintenance Manual – PJ-1304NX Albatros Printer
2 AP-74020, Rev. 3.0 – 26/06/01

COPYRIGHT NOTICE
COPYRIGHT © 2001 Mutoh Europe N.V. all rights reserved.
This document may not be reproduced by means, in whole or in part, without written permission of the
copyright owner.
This document is furnished to support the Mutoh PJ-1304NX Albatros printer. In consideration of the
furnishing of the information contained in this document, the party to whom it is given assumes its custody
and control and agrees to the following :
1) The information herein contained is given in confidence, and any part thereof shall not be copied or
reproduced without written consent of Mutoh Europe N.V.
2) This document or the contents herein under no circumstances, shall be used in the manufacture or
reproduction of the article shown and delivery of this document shall not constitute any right or license to
do so.
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IMPORTANT CONSIDERATIONS
This machine is an information technology device of Class A designed to the Voluntary Regulation on RF
Noises from IT Devices (VCCI). It may cause RF noises to other electric appliances.
In this case, the user may need to take appropriate actions.
1. Radio disturbance
This machine generates a weak radio wave. It may cause a radio disturbance to radios and television
sets if installed or used inappropriately. If the machine is considered a cause of radio disturbance, take
the following actions to eliminate the radio disturbance.
· Change the antenna orientation or reroute the antenna cable.
· Change the orientation of this machine.
· Change the distance between this machine and the affected radio/TV receivers.
· If this machine uses the same power line as the affected radio/TV receivers, use a different power line
for the machine.
2. Trademarks used in this manual.

· MUTOH, PJ-1403NX, MH-GL, MH-GL2, HM-RTL and RTL-PASS are trademarks or product names of
MUTOH INDUSTRIES LTD.
· HP, HP759X, HP758, C2848, HP-GL, HP-GL/2 and HP-RTL are trademarks or product names of U.S.
Hewlett Packard Company.
· EPSON ESC/P is a trademark or product name of Seiko Epson Corporation.
· CENTRONICS and BITRONICS are trademarks or product names of U.S. Centronics Data Computer
Co. Ltd.
· Windows3.1, Windows95, Windows98, Windows NT3.51, Windows NT4.0 and MS-DOS are
trademarks or product names of U.S. Microsoft Corporation.
· DOS/V and PC-DOS are trademarks or product names of U.S. IBM Corporation.
· NetWare is a trademark or product name of U.S. Apple Computer Inc.
· All company and product names referred to in this manual are proprietary names of individual
companies.
Warning :
· All rights reserved. This manual is only intended for the personal use by the
user himself. The contents of this manual, even a portion, shall not be
copied, reproduced or reprinted without a prior permission by MUTOH
INDUSTRIES LTD.
· The information in the manual and the specifications of this machine are
subject to change without notice.
· We have every possible effort to provide accurate information in this
manual. However, if you have any questions and suggestions or find any
errors, please contact us or your dealer.
· MUTOH INDUSTRIES LTD. is not liable for any damages or troubles
resulting from the use of this machine or this manual.
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6 AP-74020, Rev. 3.0 – 26/06/01

WARRANTY CONDITIONS
1. MUTOH INDUSTRIES LTD. will repair or replace malfunctioning parts only when we approve that the
malfunction is caused by a structural defect in the system or components of the machine manufactured by
us. This is the only warranty that we provide.
However, if the cause of malfunction is not identified, we will determine what to do by discussing with the
customer.
2. MUTOH INDUSTRIES LTD. is not liable for any direct or indirect damages or lost benefits that are caused
by unexpected misuses of this machine or modifications without permission
3. The term of warranty is shown in the guarantee.
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8 AP-74020, Rev. 3.0 – 26/06/01

MANUAL OBJECTIVES AND STRUCTURE
1. Purpose of this manual
This manual describes the maintenance, inspection and installation of the full colour ink jet printer
PJ-1304NX made by MUTOH INDUSTRIES LTD.
This manual is written for service engineer in charge of maintenance / inspection of this machine.
Make sure to read and understand the contents and instructions in this manual before working on the
machine.
2. Structure of this manual
Chapter Contents
1. SAFETY This section describes the meaning of warning terms that those who own,
install, operate or service this machine must understand as well as safety
rules to be observed and warning labels attached to the machine.
2. OUTLINE This section describes the features, structures and operations of this
machine.
3. SPECIFICATIONS This section describes the specifications of this machine.
4. PART REPLACEMENT This section describes how to remove and replace the component parts.
5. CHECK AND This section describes the attention points when replacing parts. Also,
ATTENTION POINTS. there will be descriptions how to check the operation of some parts.
6. SELF DIAGNOSIS This section describes the self diagnosis feature.
7. MAINTENANCE This section describes how to adjust, inspect and clean components.
8. TROUBLESHOOTING This section describes the possible causes of malfunctions and abnormal
operations as well as the appropriate actions.
9. APPENDIX This section provides the machine maintenance information and
disassembly drawings for reference.
Note :
This machine incorporates a self-diagnosis program. It will be of use for you to locate
failures and adjust or inspect the machine.
9 AP-74020, Rev. 3.0 – 26/06/01

3. Reference documents
Use the following documents for better understanding this manual.
· User’s Manual (Basic)

· User’s Manual (Function)
· User’s Manual (Driver)
· Albatros PJ-1304NX Operation Instruction
4. Symbols used in this manual
Warning Term Meaning

Warning :
Indicates a danger that can cause death or

serious injuries if not avoided.
Caution :
Indicates a danger that can cause slight or medium

injuries or damages to the entire machine or some
parts of it, if not avoided.
Note :
Indicates information needing a special attention.
10 AP-74020, Rev. 3.0 – 26/06/01

Table of Contents
Maintenance Manual 1
Table of Contents. 11
1. SAFETY 17
1.1. Introduction 17
1.2. Types of Meanings of Warning Messages 18
1.3. General Safety Rules 19
1.4. Special Safety Rules 20
1.5. Warning Label. 21
1.5.1. Warning Label Maintenance. 21
1.5.2. Warning Label Positions. 22
1.6. Air Purification system 24
2. OUTLINE 25
2.1. Introduction 25
2.2. Feature 26
2.3. Component List 28
2.4. Component Name and Function 29
2.4.1. Components at Front Section 29
2.4.2. Rear section 31
2.4.3. Operation Panel 32
2.4.4. Operation Principles 35
3. Specifications. 43
3.1. Introduction.
43
3.2. Specifications.
44
3.3. Media specifications.
45
3.4. Printing specifications.
46
3.5. Working conditions.
47
3.5.1. How to move this machine.
48
3.5.2. How to hold stands
49
3.6. Interface specifications
50
3.6.1. Centronics specifications.
50
3.6.2. Parallel Interface Pin Numbers and Signal Correspondence Table.
50
3.6.3. Recommended specifications for Centronics Cable.
51
3.6.4. Network Interface (Optional) Specifications.
51
4. Part replacement 53
4.1. Introduction.
53
4.2. Covers.
54
4.2.1. Removing covers.
54
4.2.2. Replacing Panel Board Assembly.
57
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4.3. X-axis driving mechanism, left and right side base plate. 58
4.3.1. Replacing X motor assembly, X speed reduction belt, speed reduction pulley. 59
4.3.2. Replacing cord heater assembly, thermistor assembly. 62
4.3.3. Replacing grid roller assembly, coupling, split coupling assembly, grid roller
shaft bearing. 64
4.3.4. Replacing Bearing Box. 66
4.3.5. Replacing paper X sensor (F,R), paper sensor cable assembly. 67
4.3.6. Replacing lever sensor assembly. 68
4.3.7. Replacing cover switch (F) assembly. 69
4.3.8. Replacing cover switch (R) assembly. 70
4.3.9. Replacing rotary damper. 71
4.3.10. Replacing the Pressure Lever damper. 72
4.4. Y-axis driving mechanism. 73
4.4.1. Replacing Y return pulley assembly, steel belt. 74
4.4.2. Replacing Y-axis motor assembly. 75
4.4.3. Replacing synchronous belt, dual pulley S. 76
4.4.4. Replacing T fence (192LPI). 77
4.4.5. Replacing bearer, bearer cable assembly, Y cable assembly, 5-line tube 78
assembly 80
4.4.6. Replacing pressure roller. 81
4.4.7. Replacing pressurizes assemblies. 84
4.4.8. Replacing pressure spring. 85
4.5. Head unit. 86
4.5.1. Replacing head cooling fan assembly and head cooling fan cable assembly.
4.5.2. Replacing on-chip head cable assembly, print head assembly, head pressing 87
spring, paper edge sensor.
4.5.3. Replacing HEAD-CONT board assembly, head/base cable assembly, timing 90
encoder assembly, C-BASE assembly and ORG sensor assembly. 92
4.5.4. Replacing cursor shaft assembly, bearing, pinch roller spacer. 94
4.5.5. Replacing subtank assembly. 95
4.6. Cap unit.
4.6.1. Replacing maintenance unit cover assembly, Cap Motor, 2-way Valve 96
Assembly, Wiping Unit Assembly, Cap Unit Sensor Assembly, TBL-RT Assembly. 101
4.7. Ink supply unit. 102
4.7.1. Replacing TBL-RE board assembly. 103
4.7.2. Replacing air pump assembly. 104
4.7.3. Replacing 2-way valve, 3-way valve (solenoid valves for ink supply). 105
4.8. Control box. 106
4.8.1. Replacing suction fan.
4.8.2. Replacing POWER switch assembly, POWER CONT board assembly, DC 107
power supply assembly, HV-CONT board assembly.
4.8.3. Replacing extension board assembly, mainboard assembly, subboard 108
assembly, C box fan and SIMM32M. 110
4.9. Stand, sheet winder, supply unit base.
4.9.1. Replacing waste ink sensor assembly, tank sensor cable assembly, spin motor 111
and TBL-BOT board assembly. 113
4.9.2. Replacing transfer belt for agitations. 114
4.9.3. Replacing rewinder motor assembly, torque limiter assembly, rewinder switch. 116
4.9.4. Replacing rewinder sensor cable assembly, reflect panel.
12 AP-74020, Rev 3.0 – 26/06/01

5. Check and attention points. 117

5.1. Introduction. 117
5.2. How to correctly install firmware? 118
5.3. Valve check procedure. 119
5.4. Tubes. 121
5.4.1. Tubes on the subtank. 121
5.4.2. Tube connection on the head. 121
5.5. What should I check before starting up or shutting down the Albatros? 122
6. Self diagnosis. 123

6.1. Introduction.
123
6.2. Outline.
124
6.3. Preparation.
126
6.3.1. Preparatory operations.
126
6.3.2. Starting diagnosis function.
127
6.4. Operation.
129
6.5. Adjustment Menu.
130
6.5.1. Cap Position Adjustment.
131
6.5.2. Wiping Position adjustment.
132
6.5.3. Head Accuracy Adjustment.
133
6.5.4. Repeatability Printing position (CCW) Adjustment.
135
6.5.5. Line Feed Correction.
136
6.5.6. Sensor Position Adjustment.
138
6.6. Setup Menu.
139
6.6.1. Head Ink Ejection Wave Form Setting.
140
6.6.2. Head temperature setting.
141
6.7. Inspection Menu.
142
6.7.1. Panel inspection.
143
6.7.2. Sensor Status Check.
144
6.7.3. Ink Ejection Count Check.
145
6.7.4. Test Print Menu.
146
6.8. Endurance Operation Menu.
147
6.8.1. Carriage Motor (Y motor) Endurance Operation.
148
6.8.2. Paper Feed Motor (X motor) Endurance Operation.
149
6.8.3. Cap Endurance Operation.
150
6.8.4. Wipe Endurance Operation.
151
6.8.5. Spin Motor (Ink Stirring System) Endurance Operation
152
7. Maintenance. 155
7.1. Introduction.
7.2. Adjustment. 155
7.2.1. Head Height Adjustment. 156
7.2.2. Power Supply Unit Voltage Adjustment 157
7.3. Periodic Inspection. 159
160
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8. Troubleshooting. 161
8.2. Error Display in Operation Panel and Corrective Actions. 162
8.2.1. Error Message. 162
8.2.2. Command Error. 164
8.2.3. Error Needing Reboot. 165
8.3. Machine’s Abnormal Condition and Malfunction. 167
9. Appendix 179
9.2. Tube Routing Drawing. 180
9.3. Wiring diagram. 184
9.3.1. Electric Cable Connection Compatibility Chart. 188
9.4. Explanation of the valves. 190
9.5. Service Parts List. 192
9.6. Jig List. 194
9.7. Head Cleaning kit. 195
9.7.1. Assembly Procedure. 195
9.7.2. Head Cleaning Procedure. 197
9.8. Exploded View. 200
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1. SAFETY
1.1. Introduction
This section describes the meaning of warning terms that those who own, install; operate or service this
machine must understand as well as safety rules to be observed and warning labels attached to the
machine.
Warning :
Always observe the instructions and warnings in this manual when installing,
operating and servicing this manual.
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1.2. Types of Meanings of Warning Messages

The warning messages in this manual and the contents of warning labels attached to this machine are
classified into the following three levels according to the degree of danger (or seriousness of possible
accidents).
Make sure to understand the meanings of warning terms shown below and observe all instructions in this
manual.
Warning Term Meaning

Warning :
Indicates a danger that can cause death or

serious injuries if not avoided.
Caution :
Indicates a danger that can cause slight or medium

injuries or damages to the entire machine or some
parts of it, if not avoided.
Note :
Indicates information needing a special attention.
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1.3. General Safety Rules

This section describes general safety rules that must be observed to use this machine safely.
Þ Do not touch the switches or buttons with wet hands. Doing so may cause electric shock if the
grounding is poor or electric leakage occurs.
Þ Do not operate the machine with any covers open.

Before operating this machine, always check that all covers are mounted correctly.
Do not put your hands or any part of your body near the movable parts while the machine is running.
Otherwise you may be injured.
Þ The operators must wear a protective cap, clothes and shoes suitable for machine operation. Long
hairs must always be tied up. Loose clothes or long hairs not tied up may be entangled in the
machine’s movable parts, resulting in serious injuries.
Þ Before starting a maintenance / inspection work, first turn off the main power switch and wait three
minutes or more. The machine keeps electric power for a while after the power supply is shut off.
Therefore, if you start to work on the machine immediately after the machine is turned off, you may
suffer electric shock.
Þ Do not use a tool with a sharp point such as a pen to operate the remote control panel. Doing so can
damage the control panel. Only use your fingers to press the buttons on the control panel.
Þ Do not use the machine in a place with extremely low or high temperatures and / or high humidity.
Þ Do not use this machine near radios and TV sets. Doing so may cause a radio disturbance.
Þ Do not use solvent such as benzine thinner to clean this machine.
Þ Do not use the same power line for this machine as that for other electric noise-generating devices.
Þ Do not put objects on this machine. Exercise extreme caution not to apply vibrations or impacts to this
machine.
Þ When moving this machine, do not tilt or shake it. Doing so may cause ink leakage, resulting in
malfunctions.
Þ Before operating this machine, always check that no objects such as tools are placed on the machine.
An object on the machine may fall into the inner mechanism during an operation, causing a damage to
the machine.
Þ The ink and jetwash are hazardous If these liquids attaches to any part of your body, wash them off
using soap and water.
Þ When you disconnect any tubes, anywhere in this machine, you must shorten it by 1cm. This to ensure
a good circulation of the air or liquid.
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1.4. Special Safety Rules

This section describes the machine-unique safety rules that must be observed to use this machine safely.
Observe the following rules in addition to the general safety rules.
Þ Before cleaning this machine, always pull out the power supply cable or turn off the main power switch.
Otherwise, another person may operate the machine while you are cleaning, causing injuries.
Þ The ink used for this machine contains an organic solvent (cyclohexanone).
Always observe the local rules to avoid organic solvent addiction.
Depending on the local rules for prevention of organic solvent addiction, you may need to use some
kinds of ventilation systems (local ventilation, push-pull type or general ventilation) that have specified
functions.
If someone swallows ink or jetwash, immediately call for a doctor and contact an appropriate authority
related to poisonous substances. Do not try to make the person throw up. Ink or jetwash in eyes or
their evaporative gages may cause an addiction. If such situation occur, immediately take appropriate
actions following the introductions shown on the ink or cleaner bottles.
Þ The ink used for this machine contains an organic solvent of Type 2 (cyclohexanone), an inflammable
substance. Do not put the ink near fire. Under a dry environment, static electricity may cause a
combustion. Before handling the ink, jetwash or waist fluid, always remove static electricity collected on
your body by touching a grounded metal. In addition, take appropriate anti-static measures so that no
electrically charged materials come near the ink, jetwash or waist fluid.
Þ The waist fluid from this machine is classified as industrial waste oil. You must dispose of the waist fluid
appropriately according to the governmental or local regulations.
Þ Do not use the same power line as that for other machines which may generate noises. Doing so may
cause abnormal operations or malfunctions.
Þ Store the ink in a temperature from 5°C and 30°C. An cold environment may cause the ink to freeze.
Þ Supply ink or jetwash up to 80% (about 1Litre) of the ink capacity. Do not overfill. If you overfill the ink
tank, the ink may leak during some operations such as automatic ink restoration / supply, causing a
malfunction.
Þ This machine works with 90 – 132V AC or 180 – 250V AC depending on the model type. Do not use a
voltage other than specified. Also, make sure to connect the ground wire to an appropriate ground.
20 AP-74020, Rev 3.0 – 26/06/01

1.5. Warning Label.

Several warning labels are attached to the machine at the areas needing special cautions. Before starting to
use this machine, fully understand the positions of these warning labels and the contents of dangers they
indicate.
1.5.1. Warning Label Maintenance.
Check that the information on the warning labels is fully readable. If any letters or figures are hard to
recognize, clean or replace the label.
Use a cloth, water and neutral detergent to clean the warning labels.
Do not use organic solvent or gasoline.
Any warning labels that are damaged, missing or difficult to read, must be replaced.
Caution 1 :
Caution 2 :
Caution 3 :
Warning 4 :
Caution 5 :
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Caution 6 :
Warning 7 :
Caution 8 :
1.5.2. Warning Label Positions.
The warning label positions are shown below.
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1.6. Air Purification system.

The vapours of the solvents used in the Mutoh Albatros may cause a number of physical discomforts such
as : headache, irritation of the airways, skin and eyes. In some European countries, solvent ink vapour
concentration levels should be kept below 12ppm and there should be no exhaust to the outside air.
Mutoh’s Air Purification System (APS) is specifically designed to filter the solvents used in Mutoh solvent inks
for the PJ-1304NX printer. This Air Purification System will take ware of unpleasant and annoying smells,
and bring solvent levels in the working area far below the accepted safely levels.
The purification system is based on active carbon and there is no need for an exhaust to the outside.
Visit our website for more information (http://www.mutoh.be).
Warning !
The air purification system should only be used in combination with the Mutoh
Albatros PJ-1304NX printer and the original Mutoh inks. Use in combination with
other inks may cause fire because of polymerisation effect in the activated carbon
filters. If you want to use the air purification system for other purposes, please
first contact Mutoh Europe for technical advice.
24 AP-74020, Rev 3.0 – 26/06/01

2. OUTLINE
2.1. Introduction.
This section describes the features, structures and operations of this machine.
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2.2. Feature
The main features of this machine are as follow :
< Outstanding weatherproof performance>
The solvent ink used for this machine permeates well into a printing media, exhibiting a long-time
weatherproof performance (3 years) even without any post processes. No need for laminating that is
indispensable for conventional water-pigment ink, you can save the processing cast and do not have to
worry about laminating films coming off from the printing media. In addition, a special clear coating is
available for tarpaulins and flexible faces, which gives gloss to their printing faces and facilitates cleaning of
these printed media.
< Media quality kept to the maximum >
This machine prints colours directly on a media, keeping the quality of the media. It also allows you to attach
a printed tuck film using squeegee and water and then perform air purging or apply RF bonding to tarpaulin
and FF sheets.
< Printing speed>
The choice between 192 dpi or 384 dpi is mainly determined by the application.
For long-distance viewing, 192 dpi is more than sufficient. When the image also is meant to be seen from a
short distance (< 2m), a higher resolution such as 384 dpi is in order.
As such, the 192 dpi output quality can only be judged from a distance and not from close by. Blurred edges
will appear crisp when looked at from a distance. The image also will appear brighter and better.
192 384 DM DP BD Speed

dpi dpi
Long Distance viewing (> 2m) – Draft – Speed – X X 13m²/h
Normal Density (*)
Long Distance viewing (> 2m) – Draft – Speed – X X X 6.5m²/h
Double Density
Long Distance viewing (> 2m) – Draft – Normal – X 6.5m²/h
Normal Density
Long Distance viewing (> 2m) – Quality – Speed – X X X 6.5m²/h
Normal Density
Long Distance viewing (> 2m) – Quality – Speed – X X X X 3.5m²/h
Double Density
Short Distance viewing (< 2m) – Draft – Speed – X X 3.5m²/h
Normal Density
Short Distance viewing (< 2m) – Quality – Speed – X X X 1.6m²/h
Normal Density
(DM = Dot Mask / DP = Double Print / BD = Bi-directional / X = enabled)
(*) The 13m²/h mode is a top speed draft mode, not intended for final output. Most media
require more ink than can be put down in this mode.
26 AP-74020, Rev 3.0 – 26/06/01

< Various printing modes >
Please notice that the output quality should be judged only with Dot Masking enabled.
The overall output quality in a specific mode is mainly influenced by 3 factors :

a. Nozzles clogging.
b. Ability to cover all space with ink.
c. Drying characteristics.
a) To mask clogged nozzles, use the DOT MASK function. For final plots always set DOT MASK ON. For
draft tests, use DOT MASK OFF.
b) Sufficiently covering all white space with ink ( = obtaining good density, avoid banding) is a very media
dependent aspect. As the Mutoh Albatros works on a wide range of media, it is logic that the maximum
output quality is very media-type dependent.
Insufficient density and banding effects on the Albatros output can be caused by following reasons:
· In the selected print mode, the Albatros cannot fire the amount of ink that is needed (drop
volume too small).
· The media in use has a small dot gain and ink drops do not sufficiently “grow” on the surface
of the media (some PVCs show this problem).
· The media absorbs so much ink that you can never reach the desired density (typically
woven materials can show this artefact).
The Mutoh Albatros has different possibilities to increase the amount of ink on the media:
· Double Print Mode:
Þ Every dot is fired twice; the amount of ink fired is doubled. In this case, the print
speed is reduced by 50%.
· Increase the output resolution (192 dpi à 384 dpi / 384 dpi à 768 dpi)
Þ By increasing the output resolution, the printer can fire 2 times as much ink droplets
in length and in width. In total, four times more ink can be put down.
Please note however:

· There is a limit as to how much ink you can put on a certain media (saturation point).
· Using the maximum amount of ink for a specific colour does not guarantee that all image
artefacts will have disappeared. In this case, if there is no abnormal head clogging, the
media compatibility should be questioned.
c) The drying characteristics can be influenced and improved by 2 settings:

· Bi-directional printing: When printing bi-directionally you obtain faster printing
time.
Note, however that because of the reduced drying time and the reversed ink order
( LèR: K, C, M, Y / RèL: Y, M, C, K ) effects might occur which change the visual
appearance.
· Platen heater: Changing the platen heater temperature vastly influences the
printing quality, so that you should set the appropriate temperature for each media. (refer to
Daily Use – To which temperature should I set the platen heater?).
< Tank capacity >
The total capacity is 1.2 litres.
Notes :
You will notice however, that the bottles are marked with a circle, indicating the ONE
LITER LEVEL. DO NOT FILL THE BOTTLES OVER THIS MARK!
The Albatros’s ink and jetwash supply system is pressurized. He printer needs the extra
space for building up pressure.
27 AP-74020, Rev 3.0 – 26/06/01

2.3. Component List.

The components of this machine are listed in the following table.
Component Quality
Printer body 1 set
Scroller 2 sets
Main ink tank (include stirrers) 4
Jetwash tank 1
Waste ink tank 1
Fiber free paper towel 1 package
Sheet rewinder 1 set
Power supply cable 1
Conversion plug 1
Printer driver for Windows 1
Printer driver for Macintosh 1
[PS3RIP] 1 set
Glove 1 pair
Funnel 1
Level gauge 1
Spanner 1
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2.4. Component Name and Function.

The names and functions of respective components are outlined below.
2.4.1. Components at Front Section.
No. Name Function

1 Operation Panel Includes printer operation keys, a LCD display and status indicator (LED).
2 Jetwash Tank Put the maintenance fluid into this tank.
3 Ink Tank Put the ink into this tank.
4 Air Tube Regulates air pressure inside each bottle.
5 Ink Tank Tube Routed from under the right cover. Connects between the ink tank and the
solenoid valve (marked with K, C, M and Y).
6 Jetwash Tube Located under the right cover. Connects between the jetwash tank and the
maintenance unit solenoid valve (marked with J).
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7 Tank Tray Set the jetwash tank, ink tanks and waste ink tank on this tray. Arrange
the ink tanks in the order of BLACK, CYAN, MAGENTA and YELLOW from
the front to the rear.
8 Waste Ink Tank Waste ink, which are consumed from ink and jetwash when the power is
turned on or the nozzles are cleaned, will be collected in this tank.
9 Waste Ink Tank Tube Connects between the waste ink tank and the maintenance unit pump (with
a W mark).
10 Hold Lever Move this lever up or down to set or remove paper.
11 Cutter Used to cut roll after printing.
12 Power Switch A sequence switch to supply power to the machine.
13 Sheet Winder Wind paper media.
14 Winder Scroller Shaft Set the winder paper core to this shaft.
15 Winder Paper Wind printed media on this paper core.
16 Memory Card Cover for optional memory.
17 Circuit Board Box Contains the main CPU board and other circuit boards.
30 AP-74020, Rev 3.0 – 26/06/01

2.4.2. Rear section
No. Name Function

1 Scroller Stay Supports the scroller shaft.
2 Scroller Shaft Set roll media to this shaft.
3 Ink Subtank Ink from the ink tube is stored temporarily in the ink subtank located at the
carriage.
4 Carriage Moves along the guide with the print head mounted on it.
5 Five-line Tube Supply each colour ink from the ink tank and jetwash tank to the head unit.
6 Bear Cable A black catarpillar that guides cables and the five-line tube to the head unit.
7 Head Unit Contains the head unit and the printer head.
8 Guide A rail along which the head nit slides.
9 Rear Cover A protective cover for the carriage.
10 Pressure Roller Holds media.
31 AP-74020, Rev 3.0 – 26/06/01

2.4.3. Operation Panel.
The operation panel is used to set the operation conditions, display the machine status and feed media back
and forward.
OPERATION KEYS.
Name On-line status mode Seting menu mode Pause mode

[CANCEL] key · While printing : Ends Nothing occurs. · While printing : Ends
printing and deletes (Dump print status : printing and deletes
the remaining data of released) the remaining data of
the applicable the applicable
printing file. printing file.
· While analysing · While analysing

data: Deletes all data data: Deletes all data
already received and already received and
analysed and ignores analysed and ignores
the entire data file. the entire data file.
Before data Before data
reception : Nothing reception : Nothing
occurs. occurs.
· While waiting for dry · While waiting for dry

ink : feeds out media. ink : feeds out media.
[BACKWARD] key Feeds media backwards. Changes the menu items Nothing occurs.
[LAST/-] key *1 or parameter values in
the reverse order.
[FORWARD] key Feeds media forwards. Changes the menu items Nothing occurs.
[NEXT/+] key *1 or parameter values in
the regular order.
[TOP MARGIN] key Initialises media position. Moves to previous level Nothing occurs.
[PREVIOUS] key *1 menu.
Parameter values not
confirmed are invalid (not
changed).
[MENU] key Displays setting menu. Confirms menu and Nothing occurs.
[ENTER] key parameter value.
32 AP-74020, Rev 3.0 – 26/06/01

[PAUSE] key Temporarily stops Moves to on-line status Moves to on-line status
[ONLINE] key operation. While display mode. display mode.
printing: Temporarily During pause : restarts
stops printing (data printing.
reception / analysis is
under way).
[RESOLUTION] key Changes printing Nothing occurs. Nothing occurs.
resolution to 192 dpi, 384
dpi, 768 dpi in order. *1
[PRINT MODE] key Changes printing mode Nothing occurs. Nothing occurs.
to unidirectional, bi-
directional, double print
in order.
[TEST PRINT] key Moves to test print menu. Nothing occurs. Nothing occurs.
*1
[PARAMETER] key Moves to print setting Nothing occurs. Nothing occurs.
menu. *1
[POSITION ADJ] key Moves to print position Nothing occurs. Nothing occurs.
adjustment menu. *1
Moves to menu. *1
[INK FILL] key Moves to ink refill / Nothing occurs. Moves to ink refill /
withdrawal menu. *1 withdrawal menu.
[HEAD CLEAN] key Moves to head cleaning Nothing occurs. Moves to head cleaning
menu. *1 menu.
[AUTO] key Auto wind mode : Auto wind mode : Auto wind mode :
Changes to manual Changes to manual Changes to manual
mode. mode. mode.
Manual wind mode : Manual wind mode : Manual wind mode :
Changes to auto mode. Changes to auto mode. Changes to auto mode.
[ROLL-OFF] key Auto wind mode : Auto wind mode : Auto wind mode :
Nothing occurs. Nothing occurs. Nothing occurs.
feeds out paper.. feeds out paper. feeds out paper.
[ROLL-UP] key Auto wind mode : Auto wind mode : Auto wind mode :
Nothing occurs. Nothing occurs. Nothing occurs.
Winds paper. Winds paper. Winds paper.
*1 Except when DATA lamp is off and machine is printing : Valid while DATA lamp is on / blinking or
machine is printing : Invalid.
33 AP-74020, Rev 3.0 – 26/06/01

STATUS DISPLAY LAMPS.
Lamp name Colour Turns on Blinking Turns off

ERROR lamp Red An error is detected. No errors detected or
* The error contents are error display mode
shown in the LCD. disabled.
DATA lamp Green Data are being received. Data are being Except data reception
analysed. and analysis.
AUTO lamp Green Auto wind mode. Manual wind mode.
HIGH lamp Green Resolution : 768 dpi *1 Other resolution
selected.
MEDIUM lamp Green Resolution : 384 dpi *2 Other resolution
selected.
LOW lamp Green Resolution : 192 dpi *3 Other resolution
selected.
UNI-DRCTN lamp Green Printing mode : Unidirectional Bidirectional mode.
BI-DRCTN lamp Green Printing mode : Bidirectional Unidirectional mode.
DOUBLE lamp Green Printing mode : double print Single print mode.
*1 Single printing with recommended paper for 768 dpi mode is desirable.
(Print quality and dry-up time are affected.)
34 AP-74020, Rev 3.0 – 26/06/01

2.4.4. Operation Principles.
The machine’s operation sequences are shown below (V2.04).
Power On sequence :
All Valves ON / OFF repeating (warming-up).

¯
Starts the stirrer motor (stops one minute later).
¯
The main tank releases the air.
¯
Collect ink from the subtank to the main tank (only when the subtank ink level is higher than LOW level).
¯
Cleaning sequence.
¯
Fill ink from the main tank to the subtank.
¯
Suck ink from the subtank to the head.
¯
Cleaning Normal.
ü If the power is switched ON without not fitting the waste ink tank or waste ink to full, it will execute
the procedure from 1 to 4 and do not proceed item 5 onward.
ü If the power is switched ON without ink at any KCMY, execute the procedure from 1 to 5 and do not
proceed item 5 onward. (It will indicate an error message.)
Stirrer mode auto-mode sequence :
During the power ON, repeat the stirring movement for one minute in every 10 minutes.
Ink collection sequence (from the subtank to the main tank).
Close the subtank air opening.

¯
Decrease the main tank pressure.
¯
Ink collection (up to the subtank LOW level) *timeout is 60 seconds.
¯
Ink collection (60 seconds).
¯
The pomp stops.
¯
The main tank releases air.
35 AP-74020, Rev 3.0 – 26/06/01

Ink filling sequence (from the main tank to the subtank)
Increase the main tank pressure.

¯
Ink is sent by pressure (up to subtank LOW level) – timeout is 180 seconds.
¯
Ink is sent by pressure (up to subtank HIGH level) – timeout is 60 seconds.
¯
Ink suction sequence (from the subtank to the heads).
If there is not ink at the HIGH level, fill the ink.

* If one of four inks cannot fill ink, the following procedure will stop. (error message)
¯
Jetwash is filled in the head tube.
¯
Spit 42000 shots on the capping unit (3KHz oscillation).
¯
The cap closes.
¯
Decrease the pressure at the waste ink tank.
¯
Ink suction (continuance 10 seconds, interval 30 seconds).
* During continuance 10 seconds, ink will be sucked 3 times.
When the ink level goes lower than LOW level, it would stop.
¯
The waste ink tank releases air.
¯
The cap opens.
36 AP-74020, Rev 3.0 – 26/06/01

Cleaning sequence
¯
The air is sent by pressure for 40 seconds.
¯
Jetwash is sent to all colours simultaneously and sent air by pressure.
¯
3P valves for all colours repeat ON/OFF for 40 times.
¯
¯
Wiping performance at the nozzles surface (2 trips) ----Vacuum. (*1)
¯
The subtank air valve is ON and purging 50000 shots ----No vacuum. (*1)
¯
After purging, it stops for 0.5 second, the subtank air valve is OFF. (*1)
(*1) ® It executes KCMY head individually for 4 times.
¯
After jetwash is sent by pressure for 5 seconds, the air is sent for 10 seconds (1KHz oscillation). (*2)
¯
Shifts to the capping position, after the air is sent for 10 seconds, it goes back to the purge position (*2).
(*2) ® It executes KCMY head individually for 4 times.
¯
After jetwash is sent by pressure for 5 seconds, the air is sent for 10 seconds (1KHz oscillation).
* It executes KCMY head individually for 4 times.
¯
¯
The waste ink is collected.
¯
After the air is sent by pressure for 40 seconds, shifts to the capping position. Immediately, it shifts back to
the purging position (executing 4 times KCMY head individual).
¯
¯
The wiping at the nozzle surface (one way) ----Vacuum.
¯
¯
After purging, it stops for 0.5 second, the subtank air valve is OFF. (*3)
(*3) It executes KCMY head individually for 4 times.
¯
The wiping at the stainless surface (2 trips) ----No vacuum.
¯
¯
The waste ink is collected (this will be done with item 20).
¯
Suck the waste ink from the maintenance box.
¯
Suck the ink and jetwash from the capping nit.
¯
The waste ink tank release the air.
ü In this sequence, the subtank air valve would be OFF except after the wiping procedure during the
purging.
37 AP-74020, Rev 3.0 – 26/06/01
Cleaning : wash
Ink is collected from the subtank to the main tank.
¯
Cleaning sequence.
Cleaning : Powerful
¯
Cleaning sequence.
¯
Fill ink to subtank.
¯
Suck ink from the subtank to the head.
¯
Cleaning : Normal.
* The restriction when [INK UNLOADED] message indicates : Cleaning : Powerful will not be executed.
Cleaning : Normal.
If there is no ink at HIGH level, fill ink.

* If one of four inks cannot fill ink, the following procedure will stop (error message).
¯
Spit 42000 shots on the capping unit. (3KHz oscillation)
¯
The cap closes.
¯
¯
Ink suction (interval 40 seconds).
* When the ink level goes lower than LOW level, it would stop.
¯
¯
The cap opens.
¯
The wiping procedure on the stainless surface (2 trips).
¯
Spit 1000 shots at the pure position (3KHz oscillation).
* The restriction when [INK UNLOADED] message indicates : Cleaning : Normal will not be executed.
38 AP-74020, Rev 3.0 – 26/06/01

Cleaning : Economy
If there is not ink at the HIGH level, fill the ink.
* If one of four inks cannot fill ink, the following procedure will stop (error message).
¯
Spit 42000 shots on the capping unit (3 KHz oscillation).
¯
The cap closes.
¯
¯
Ink suction (interval 17 seconds).
* When the ink level goes lower than LOW level, it would stop.
¯
¯
The cap opens.
¯
The wiping procedure on the stainless surface (2 trips)
¯
Spit 1000 shots at the purge position (3KHz oscillation).
* The restriction when [INK UNLOADED] message indicates : Cleaning : Normal will not be executed.
Auto cleaning
ü The auto-cleaning function can be set by [MODIFICATION] menu on the panel ---- The settings for
auto-cleaning are : Off, Start, Start & 1 to 5 and 1 to 5 hours (every hour). When the setting is OFF,
auto cleaning will not be executed.
Except OFF setting, this executes Cleaning : Normal and Cleaning : Economy one after the other
automatically during printing or when you start printing according to the auto-cleaning setting time.
Regular purging
Regardless of during or idle, spits 530 shots in every 6 seconds at the purge position (3KHz oscillation).
* During the stand-by mode, it will ,not execute the purging.
39 AP-74020, Rev 3.0 – 26/06/01

Power OFF sequence

¯
¯
¯
Jetwash is sent to all colours simultaneously and sent air by pressure.
¯
¯
¯
Wiping performance at the nozzles surface (2 trips) ----Vacuum
¯
¯
After purging it stops for 0.5 second, the subtank air valve is OFF. (*1)
¯
After jetwash is sent by pressure for 5 seconds, the air is sent for 10 seconds (1 KHz oscillation). (*2)
¯
Shifts to the capping position, after the air is sent for 10 seconds, it goes back to the purge position. (*2)
¯
¯
¯
¯
¯
The waste ink is collected.
¯
¯
¯
The wiping at the nozzles surface (one way) ----Vacuum (*4)
¯
The subtank air valve is ON and purging 50000 shots ----No vacuum (*4)
¯
After purging, it stops for 0.5 seconds, the subtank air valve is OFF. (*4)
¯
The wiping at the stainless surface (2 trips) ----No vacuum
¯
¯
The waste ink is collected (this will be done with previous item).
¯
40 AP-74020, Rev 3.0 – 26/06/01

Suck the ink and jetwash from the capping unit.

¯
¯
Collect ink from the subtank to the main tank.
¯
Shuts down the power (OR shift to the stand-by mode).
ü During this sequence operation, the subtank air valve would be OFF except after the wiping
procedure during the purging.
ü When you switch the power OFF-ON-OFF, it will not execute the power off sequence and shut down
the power immediately.
Going to the stand-by sequence

ü The stand-by time (H) can be selected with Cleaning > Stand-by of the maintenance function on the
operation panel ---- This stand-by time (H) can be set from 1,2 or 3 to 15 hours (every hour).
ü When the stand-by time is set to 1 or 2 hours, it does not execute Cleaning : Normal and it shifts to
the stand-by mode.
ü Waiting print data at one hour interval (regular purging), it executes the wiping on the stainless
surface (2 trips) ---- If the operation is the same as Cleaning : Normal, it only executes Cleaning :
Normal.
Waiting print data after H/3 hours, it executes Cleaning : Normal. (*1)
¯
Waiting print data after 2H/3 hours, it executes Cleaning : Normal. (*1)
(*1) If any ink of KCMY is not loaded, previous cycle will not be executed.
¯
After waiting data H hours, it executes the power off sequence.
¯
Stand-by mode (operating with the panel is available).
¯
Receive print data.
¯
Cleaning sequence. (*2)
¯
Fill ink from the main tank to the subtank. (*2)
¯
Suck the ink from the subtank to the head. (*2)
¯
Cleaning : Normal. (*2)
(*2) When it receives data at no ink at KCMY, it will not execute these items. (indicate error message).
41 AP-74020, Rev 3.0 – 26/06/01

42 AP-74020, Rev 3.0 – 26/06/01

3. Specifications.
3.1. Introduction.
This section describes the specifications of this machine.
43 AP-74020, Rev 3.0 – 26/06/01

3.2. Specifications.
The main specifications and standard dimensions are shown respectively in the table below.
Thoroughly understand the contents of this section to use the machine correctly.
Main specifications
Item Spec.
Model PJ-1304NX
Printing method On-demand ink jet
Recording method Shuttle method (interlace)
Printing speed Please refer to 2.Outline, 2.2. Feature, < Printing speed >
Resolution 192/384/(768) dpi
Colours Full colours (16.7 million colours)
Ink Solvent based pigment ink, four colours (C, M, Y, K)
Ink tank capacity 1.2 litre/colour (Ink should be all 1.0 litre/colour)
Main memory 40 MB as standard (72 MB at maximum)
Input interface 8 bits parallel (Centronics compliant)
Media feed Roll media or cut sheet feeding by hand
Maximum roll media length 50 m (up to maximum weight of 30 kg)
Cutting method Manual cutting
Maximum acceptable media width 1.372 mm
Minimum media size A4 (Landscape)
Maximum printing width 1.362 mm
Maximum printing length 50 m (limited to the ability of application software in use)
Command MH-GL2 (MH-RTL), RTL-PASS
Power supply AC90 – 132V or AC180 – 250V depending or the model type,
50/60 HZ ± 1 Hz
Power consumption 550 W or less at maximum, 60 W or less
Working environment 15–35°C, 20–80% (RH) (Recommended temperature 20–30°C)
Applicable standards VCC I Class A IT device
Outer dimensions Approx. 2.300(W) x 670(D) x 1.130 (H) mm
Weight Approx. 125 kg
Main standards
Item Standard value
Distance accuracy X Within 0 to + 0.5%/15m
Distance accuracy Y Within ± 1.0mm/1.372mm
Right angle accuracy Within ± 0.5mm/500mm
Printing start position accuracy Set position within ± 1.0mm
Maximum acceptable roll media length 50 m (to be adjusted by weight)
Maximum media width 1.372mm
Maximum printing width 1.362mm
Maximum media weight allowable 30 kg/f (298N)
Maximum media thickness allowable 0.6mm
44 AP-74020, Rev 3.0 – 26/06/01

3.3. Media specifications.

Type MF Tarpaulin FF
Name A B A B A B
Code 70681 70682 70683 70684 70685
Product PJ-MF PJ-MF PJ-TP PJ-TP PJ-FF Sheet
Film Film Sheet Sheet
Model PJ-MF3G125 PJ-MF3GA120 PJ-TP-52K13 PJ-TP-135K13 PJ-FF-75K13x30
x30 x30 x30 X20
Spec Chroloethene Chroloethene Tarpaulin Tarpaulin Flexible face
Film 1.250 mm Film 1.200 mm 1.300 mm 1.370 mm 1.370mm x 30M
X30M X30M x30M x20M
Feature 3-5 years PCV 3-5 years PCV Low strength Medium Mat-like Glossy
(80 µm) (80 µm) Strength
Driver or table PJ-MF-3G PJ-MF-3GA PJ-TP-52K PJ-TP-135K PJ-FF-75K
192 dpi x2 192 dpi x2 384dpi x2 is for
back light
45 AP-74020, Rev 3.0 – 26/06/01

3.4. Printing specifications.

Item Specification
Image density 1.1 or more when measured with spectrometer.
Non-uniformity in density Non-uniformity in band/across bands: 0.2 or less when measured with
spectrometer. (Single colour full surface printing in both directions: less
than 3 as target.)
Synchronization unevenness Gap between 1-dot lines printed at intervals of 3 dots
192 dpi : 489 – 569 µm
384 dpi : 244 – 284 µm
Printing resolution Resolution per head : 38.4 dpi
Various interlace printing modes for printing quality improvement
192 dpi x 192 dpi (5 passes) single way / dual way
(according to speed evaluation)
Vertical width accuracy *Assuming platen heater is ON (by tests on actual machines)
192 dpi single way : 175 – 255 µm
(192 dpi PVC marking film used, 25°C, 60%)
(384 dpi PVC marking film used, 25°C, 60%)
(Media recommended for 768 dpi used, 25°C, 60%)
46 AP-74020, Rev 3.0 – 26/06/01

3.5. Working conditions.

Environment Item Conditions
Working environment Installation area 7 m² or more
Floor strength needed 2.490 Pa (300 kg/m²) or more (no vibration)
Voltage AC90 – 132V or 180 – 250V depending on the model
type
Frequency 50/60 Hz ± 1 Hz
Current capacity An outlet with 10A or more capacity should be used
Temperature 20°C – 30°C Fluctuation rate : less than 2°C per hour
(recommended temperature)
Humidity 20% - 80% (no dew condensation)
Fluctuation rate : less than 5% per hour
Machine temperature Less than 55°C at positions one can touch
while platen heater is ON (according to test on actual machines)
Storing environment Temperature 0 – 40°C
Humidity 10 – 90% RH
Installation environment Inclination angle Machine shall not be tipped over when the inclination
is 10°.
< Installation space >
The space required to install this machine is shown in the picture bellow.
47 AP-74020, Rev 3.0 – 26/06/01

3.5.1. How to move this machine.
Note :
This machine, if relocated by an unqualified person, may malfunction or be damaged.
Step 1 : If you have to move this machine a little distance in the same floor for an inevitable reason;
Clean the head and withdraw ink; turn the machine off, extract all ink and jetwash, then drain all
waste fluid from the ink fluid tank.
Step 2 : Turn and raise the level feet so that they are well apart from the floor. Move the machine slowly
and carefully.
48 AP-74020, Rev 3.0 – 26/06/01

3.5.2. How to hold stands
Extend the four level feet under the bottom of the machine stand to make the machine level and hold the
stand securely.
1. Place the accessory level gauge along the left cover as shown.
2. Turn the front and rear level feet at the left side of the stand to adjust their heights so that the air inside
the level gauge comes at the center.
3. Place the level gauge along the right cover and adjust the level feet heights as described above.
49 AP-74020, Rev 3.0 – 26/06/01

3.6. Interface specifications.
3.6.1. Centronics specifications.

(bi-directional parallel interface : IEEE1284 compatible)
Modes Compatible, Nibble, ECP

Port Port 1
Data length 8 bits
Transmission direction Unidirectional (receive only), bi-directional
Connector pin numbering
3.6.2. Parallel Interface Pin Numbers and Signal Correspondence Table.
Pin Direct Signal Name Signal Direction Pin Direct Signal Name Signal Direction
No. No.
1 STROBE PJ Printer ¬ 19 SG
2 DATA1 PJ Printer ¬ ® 20 SG
10 ACK PJ Printer ® 28 SG
11 BUSY PJ Printer ® 29 SG
12 P ERROR PJ Printer ® 30 SG
13 SELECTED PJ Printer ® 31 INIT PJ Printer ¬
14 AUTOFD PJ Printer ¬ 32 FAULT PJ Printer ®
15 Not used 33 Not used
16 SG 34 Not used
17 FG 35 Not used
18 + 5V 36 SELECTIN PJ Printer ¬
50 AP-74020, Rev 3.0 – 26/06/01

3.6.3. Recommended specifications for Centronics Cable.
Interface IEEE 1248 (bi-directional parallel) compatible

Cable type AWG28 x 18 pair (twisted pair)
Shield type Metal tapes and braiding (double – shielded cable)
Characteristic impedance 62
3.6.4. Network Interface (Optional) Specifications.
Port Port 2 (only when optional interface board is fitted).

Network type Ethernet IEEE802.3
Network I/F 10 Base-T, 100 Base-TX (automatic switching)
(RJ-45 connector, twisted pair cable, category 5)
Protocol TCP/IP NetWare (V3.1J) EtherTalk
Mode · ftp · remote printer · printer name
· lpr mode zone name
· socket · print server · zone name
Functions · Automatic protocol recognition
· Transmission speed up to 330 KB/s
(differs according to networking environment)
· IP address and other settings are enabled by the accessory utility
software (Printset) and general browser software.
51 AP-74020, Rev 3.0 – 26/06/01

52 AP-74020, Rev 3.0 – 26/06/01

4. Part replacement
4.1. Introduction.
This section describes how to remove and replace the component parts.
Warning :
Before working on the machine, always turn the machine off and pull out the
power supply plug. Otherwise you may suffer electric shock.
53 AP-74020, Rev 3.0 – 26/06/01

4.2. Covers.
This section describes how to replace the covers.
4.2.1. Removing covers.
You must remove appropriate covers before replacing the inner parts.
The following is the cover removal procedures.
Note :
· Before removing the covers, remove the roll media together with the scroller.
· The covers (right cover, supply cover, left cover, rear cover, Y-axis cover, front
cover) need not to be serviced.
(1) Right cover
Step 1 : Remove seven screws retaining the right cover to the base plate and one screw (M4) retaining
the cover to the right side plate.
Step 2 : Remove the right cover.
(2) Supply cover
Step 1 : Remove six screws retaining the supply cover to the base plate.
Step 2 : Remove the supply cover.
(3) Left cover
Step 1 : Remove seven screws retaining the left cover to the base plate.
Step 2 : Remove the left cover.
54 AP-74020, Rev 3.0 – 26/06/01

(4) Rear cover
Step 1 : Remove four screws retaining the rear cover to the hinge pin.
Step 2 : Open the rear cover and slightly slide it leftward to remove.
(5) Y-axis rail cover
Step 1 : Remove the screws retaining the Y-axis rail cover to the left and right side plates (two for each).
Step 2 : Slightly open the front cover and remove the two screws retaining the cover to the cover shaft
say.
Step 3 : Slightly lift the Y-axis rail cover and move it rearward to remove.
(6) Front cover
Step 1 : Remove the two screws of the front cover located near to the origin.
Note :
Do not remove the screws (2) at the opposite side (X motor side).
Step 2 : Slightly open the front cover and slide it toward the origin to remove.
55 AP-74020, Rev 3.0 – 26/06/01

(7) Tank tube cover.
Step 1 : Unlock the three T-fasteners and remove the tank tube cover.
56 AP-74020, Rev 3.0 – 26/06/01

4.2.2. Replacing Panel Board Assembly.
Step 1 : Remove the two screws retaining the panel cover to the base plate.
Step 2 : Detach the panel cover by lifting it diagonally.
Note :
The panel cable and ground cable are connected to the panel cover
assembly. Exercise cautions not to damage these cables.
Step 3 : Remove the ground cable retaining screw from the panel cable.
Step 4 : Disconnect the panel cable connector.
Step 5 : Remove the four retaining screws from the panel cover and remove the panel board assembly.
57 AP-74020, Rev 3.0 – 26/06/01

4.3. X-axis driving mechanism, left and right side base plate.
The following is the replacement procedures for the X-axis driving mechanism and the parts at the left and
right side plates.
Note :
Before replacing the parts, remove the covers from the machine.
58 AP-74020, Rev 3.0 – 26/06/01

4.3.1. Replacing X motor assembly, X speed reduction belt, speed reduction pulley.
(1) X motor assembly
Step 1 : Remove the four screws retaining the control box to the base plate and open the box.
Step 2 : Disconnect X-axis motor connector (J18) and the X-axis encoder connector (J20) from the
mainboard assembly.
Step 3 : Remove the five screws retaining the paper guide R3 to the rear of the base plate.
Step 4 : Remove the paper guide R3.
Step 5 : Remove the four screws retaining the X-axis rail cover to the base plate.
Step 6 : Remove the X-axis rail cover.
Step 7 : Remove the X-axis motor assembly cable and loosen the four screws retaining the X-axis motor
bracket.
Step 8 : Remove the two screws retaining the X-axis motor to the X-axis motor bracket.
Step 9 : Remove the X-axis motor.
59 AP-74020, Rev 3.0 – 26/06/01

(2) replacing X speed reduction belt
Step 1 : Remove the speed reduction pulley common support and remove the X-axis reduction belt.
Note :
Adjustment X-axis reduction belt tension : 4.0 kg/f
60 AP-74020, Rev 3.0 – 26/06/01

(3) Replacing speed reduction pulley assembly
Step 1 : Remove the bearing, axial collar and spring from the reduction pulley assembly.
Step 2 : Loosen the two screws of the coupling and remove the X-axis pulley shaft by sliding it leftward.
Note :
To install the axial collar to the speed reduction pulley common support, face its raised
side to the grid roller assembly shaft bearing. If the collar is installed reversely, the
speed reduction pulley will not work.
61 AP-74020, Rev 3.0 – 26/06/01

4.3.2. Replacing cord heater assembly, thermistor assembly.
Step 1 : Open the control box and disconnect the PCB POWER CONT board assembly connectors
(J107, J108, J109).
Step 2 : Remove the paper guide F from the machine

· Retaining screws : 6 at the top, M3x6 binding head, 5 at the front M3x8 W
Step 3 : Pull out the plug 1 and partition 1.
Step 4 : Remove the ferrite core.
Step 5 : Disconnect the platen heater intermediate cable connector and pull it out from below.
Step 6 : Disconnect the thermistor connector.
Step 7 : Remove the platen from the machine.

· Retaining screws : 16 M3x6 (binding head)
· Plastic washer : 16
Note :
Do not lose the plastic washer for platen.
62 AP-74020, Rev 3.0 – 26/06/01

Step 8 : Turn over the platen and remove the heater holder.
· 1 block : 8x3 blocks.
· Retaining screws : 16 M3x6 small black round head
Caution :
When installing the heater holder, exercise enough caution not to cut or
short the cord heater.
Step 9 : Remove the cord heater assembly.
Step 10 : Remove the one thermistor retaining screw from the back of the platen.
Step 11 : Remove the thermistor assembly.
63 AP-74020, Rev 3.0 – 26/06/01

4.3.3. Replacing grid roller assembly, coupling, split coupling assembly, grid roller shaft bearing.
Step 1 : Remove the cable pocket cover from the cable pocket.
Step 2 : Remove the four screws retaining the paper guide R2 to the machine.
Step 3 : Remove the paper guide R2.
Caution :
The paper guide R2 has a FG mesh at the both ends. Exercise caution not
to damage these meshes.
Step 4 : While looking from above as shown in the figure, remove the screws from between the Y-axis
rail and the cable pocket.
64 AP-74020, Rev 3.0 – 26/06/01

Step 5 : Slide out the paper guide R1 from behind the machine.
· Retaining screws : 5 M3x6 binding head
Step 6 : Remove the pressure roller. Remove the grid roller shaft bearing holder by lifting and sliding
rearward.
Step 7 : Loosen the screws of the coupling and slide the speed reduction pulley assembly to the left.
Note :
When replacing grid rollers except the one at the speed reduction pulley
side, you need not to slide the speed reduction pulley to the left.
Step 8 : Remove the split coupling assembly.
Step 9 : Push up the pressure arm. Lift the grid roller assembly and rotate it toward you to remove.
Then remove the grid roller shaft bearing.
65 AP-74020, Rev 3.0 – 26/06/01

4.3.4. Replacing Bearing Box.
Step 1 : Remove the four screws retaining the bearing box to the machine.
Step 2 : Remove the bearing box.
Note :
Use a ratchet wrench or an equivalent tool to remove the rear two screws
of the bearing box.
66 AP-74020, Rev 3.0 – 26/06/01

4.3.5. Replacing paper X sensor (F,R), paper sensor cable assembly.
Step 1 : Remove the paper guides F, R2, R3 and solenoid valve cover from the machine. Disconnect
the TBL-RE board assembly connector J3 (PAPER).
Step 2 : Using a short screw driver, remove the paper X sensor (R) and the paper sensor cable together
with the rear sensor bracket.
Step 3 : Remove the paper X sensor (F) and the paper sensor cable from the front sensor bracket.
67 AP-74020, Rev 3.0 – 26/06/01

4.3.6. Replacing lever sensor assembly.
Step 1 : Remove the solenoid valve cover from the machine. Disconnect the TBL-RE board assembly
connector J2 (LEVER).
Step 2 : Remove the one screw retaining the lever sensor bracket to the right side plate.
Step 3 : Remove the lever sensor and bracket.
Bracket
Sensor
Step 4 : Remove the lever sensor.
68 AP-74020, Rev 3.0 – 26/06/01

4.3.7. Replacing cover switch (F) assembly.
Step 1 : Remove the solenoid valve cover from the machine. Disconnect the Power board assembly
connector E21
Step 2 : Remove the one screw retaining the sensor bracket (F) to the right side plate.
Step 3 : Remove the cover switch (F) and bracket.
Step 4 : Remove the cover switch.
69 AP-74020, Rev 3.0 – 26/06/01

4.3.8. Replacing cover switch (R) assembly.
Step 1 : Remove the solenoid valve cover from the machine. Disconnect the Power board assembly
connector E22.
Step 2 : Remove the one screw retaining the sensor bracket (R) to the right side plate.
Step 3 : Remove the cover switch (R).
Notes :
Please note that there is also a front and rear cover switch at the left side of the printer.
· Front and rear : on Power board EA-47791 (Cover Cable)
70 AP-74020, Rev 3.0 – 26/06/01

4.3.9. Replacing rotary damper.
Step 1 : Remove the right and left covers from the machine.
Step 2 : Remove the two damper retaining screws and the damper.
Note :
· The dampers installed in the front of the origin and behind the X motor
are identical (marked with “R”)
· The damper installed behind the origin is marked with “L”.
71 AP-74020, Rev 3.0 – 26/06/01

4.3.10. Replacing the Pressure Lever damper.
Step 1 : Remove the screw holding the damper hold on the bracket.
Step 2 : Remove the pressure lever damper.
To reinstall the pressure lever damper, please proceed as follows:
Step 1 : Put the lever down.
Step 2 : Connect the damper key to the damper hold (please refer to picture below).
Step 3 : Connect the damper key on the cam shaft.
Step 4 : Connect the damper hold on to the bracket (1 screw).
72 AP-74020, Rev 3.0 – 26/06/01

4.4. Y-axis driving mechanism.

The following is the replacement procedures for respective parts in the Y-axis driving mechanism.
Note :
Before starting any replacement procedure in this section, always remove the covers
from the machine.
73 AP-74020, Rev 3.0 – 26/06/01

4.4.1. Replacing Y return pulley assembly, steel belt.
Step 1 : Fully loosen the steel belt adjusting screws (upper and lower).
Step 2 : Remove the screws (one at both sides) that retain the carriage to the steel belt.
Step 3 : Remove the steel belt.
Step 4 : Remove the Y return pulley assembly.
Note :
Adjust the steel belt tension to 125 – 150 g/f.
74 AP-74020, Rev 3.0 – 26/06/01

4.4.2. Replacing Y-axis motor assembly.
Step 1 : Open the control box and disconnect the mainboard assembly’s Y-axis motor connector (J19)
and the Y-axis encoder connector (J21) (with connecting cable).
Step 2 : Remove the paper guide R3 from the machine.
Step 3 : Remove the three screws retaining the Y-axis motor to the C motor bracket and remove the
synchronous belt.
Step 4 : Remove the Y-axis motor.
Note :
Adjust the synchronous belt tension to 4 kg/f.
75 AP-74020, Rev 3.0 – 26/06/01

4.4.3. Replacing synchronous belt, dual pulley S.
Step 1 : Remove the steel belt from the Y-axis rail.
Step 2 : Remove the dual pulley S and the synchronous belt.
76 AP-74020, Rev 3.0 – 26/06/01

4.4.4. Replacing T fence (192LPI).
Step 1 : Remove the T fence holder retaining screws (13) from the Y-axis rail and remove the T fence.
Note :
Follow the instructions below when installing the T fence :
· Face the T fence hole up.

· Align the T fence edge with the T fence holder edge.
· If you touch the T fence with bear hands, clean the T fence using ethanol.
· Make sure the indication is on the side of the eye of the sensor.
77 AP-74020, Rev 3.0 – 26/06/01

4.4.5. Replacing bearer, bearer cable assembly, Y cable assembly, 5-line tube assembly.
Step 1 : Remove the solenoid valve cover from the machine and remove the solenoid valve side ink
tubes (5) from the L-shaped mini fitting.
Caution :
· When you reuse an once removed ink tube, cut its end by about 10
mm length using the specified cutter before connecting it.
· If any ink enter your eyes, immediately clean your eyes in water.
Step 2 : Remove the two cable guide plate retaining screws from the HEAD-CONT board assembly.
Step 3 : Remove the two cable holder screws from the cable support.
Step 4 : Remove the two bearer bracket 1 retaining screws (M3x6 flat head) from the cable support.
Step 5 : Remove the bearer bracket 1.
78 AP-74020, Rev 3.0 – 26/06/01

(1) Bearer, bearer cable assembly
Step 1 : Remove the two bearer retaining screws (M3x6, flat head) from the bearer bracket 2.
Step 2 : Pull out the ink tubes from the bearer.
Step 3 : Remove the bearer.
Step 4 : Remove the bearer bracket 2 from the cable pocket.
Step 5 : Disconnect the Y cable from the bearer cable and remove the bearer cable.
(2) Y cable assembly
Step 1 : Open the control box and disconnect the sub board assembly connectors J210 (C-BASE), J211
(HEAD-L) and J212 (HEAD-U).
Caution :
Always cover the connector terminal faces with insulating tape.
Step 2 : Remove the paper guide R3 from the machine and remove the Y cable assembly.
79 AP-74020, Rev 3.0 – 26/06/01

4.4.6. Replacing pressure roller.
Step 1 : Using a flathead precision screwdriver or an equivalent tool, slightly open the pressure roller
arm and remove the pressure roller.
Caution :
Do not apply excessive force to the pressure roller arm. Doing so may damage the
pressure roller or the arm.
80 AP-74020, Rev 3.0 – 26/06/01

4.4.7. Replacing pressurizes assemblies.
Step 1 : Remove the cursor axis assembly and remove the head unit from the Y-axis rail.
Retract the head temporally.
Caution :
Do not apply impact to the print head when removing the head unit. Any impact may
damage the print head.
Step 2 : With the hold lever raised, remove the pressure link retaining E ring.
Step 3 : With the pressure link installed, lower the hold lever.
Step 4 : Slide the cam shaft slightly to the left and remove it from the right side plate.
Step 5 : To remove the Y-axis rail from the machine, remove the following retaining screws.
· 4 Hexagon socket bolt
· 4 Flathead M4x8
Step 6 : Slightly move forward and lift the Y-axis rail.

81 AP-74020, Rev 3.0 – 26/06/01
Step 7 : Remove the Y-axis rail from the machine and place it on appropriate stands.
Step 8 : To protect the T fence, remove the T fence by removing the fence holder (13 screws).
82 AP-74020, Rev 3.0 – 26/06/01

Step 9 : Turn over the Y-axis rail and remove the cam shaft by pulling it out toward the origin.
Step 10 : Remove the pressurizes assemblies from the Y-axis rail.

· Two retaining screws (M4xW) x 20 units.
83 AP-74020, Rev 3.0 – 26/06/01

4.4.8. Replacing pressure spring.
Step 1 : Remove he Y-axis rail cover from the machine and remove the pressure spring using a spring
hook.
84 AP-74020, Rev 3.0 – 26/06/01

4.5. Head unit.

This section describes how to replace the parts in the head unit.
Note :
85 AP-74020, Rev 3.0 – 26/06/01

4.5.1. Replacing head cooling fan assembly and head cooling fan cable assembly.
Step 1 : Remove the two screws (black) retaining the head cover to the carriage.
Step 2 : Remove the head cover.
Step 3 : Disconnect the cooling fan connector (FAN) from the C-BASE board assembly.
Step 4 : Remove the two hexagon nuts retaining the head cooling fan assembly and remove the head
cooling fan from the head cover.
Step 5 : Remove the head cooling fan cable assembly from the head cover.
86 AP-74020, Rev 3.0 – 26/06/01

4.5.2. Replacing on-chip head cable assembly, print head assembly, head pressing spring, paper
edge sensor.
(1) On-chip head cable assembly
Step 1 : Remove the head cover.
Step 2 : Remove the ink tubes from the mini fitting.
Step 3 : Disconnect the print head assembly connector and the HEAD-CONT board assembly connector
(J5, J6) and remove the on-chip head cable assembly.
(2) Print head assembly
Step 1 : Loosen the carriage adjusting screw.
Step 2 : Using a pair of tweezers, remove the flat spring from the carriage hook pin.
Step 3 : Remove the print head assembly by pushing rearward and lifting it.
87 AP-74020, Rev 3.0 – 26/06/01

Caution :
· Before replacing the print head, always cover the platen with a sheet of paper to
prevent it from dirt.
· The head is susceptible to electronic, impact and dust. Always perform an antistatic
measure using a ground band, etc. and carefully handle the head.
· Do not press the ink tube port strongly when replacing the print head. The port is
prone to impact and may be damaged. Hold the head only at the head bracket 2.
(3) Head pressing spring
Step 1 : Remove the four retaining screws from the carriage and remove the head pressing spring.
88 AP-74020, Rev 3.0 – 26/06/01

(4) Paper sensor
Step 1 : Remove the one paper edge sensor retaining screw from the carriage.
Step 2 : Disconnect the connector J14 (EDGE) from the C-BASE board assembly and the remove paper
sensor.
89 AP-74020, Rev 3.0 – 26/06/01

4.5.3. Replacing HEAD-CONT board assembly, head/base cable assembly, timing encoder assembly,
C-BASE assembly and ORG sensor assembly.
(1) HEAD-CONT board assembly; head/base cable assembly
Step 1 : Remove the head cover from the machine.
Step 2 : Remove the four bearer cable assembly retaining screws and two spacers.
Step 3 : Disconnect the all connectors from the HEAD-CONT board assembly and remove the HEAD-
CONT board assembly.
Step 4 : Remove the head/base cable assembly.
(2) Timing encoder assembly
Step 1 : Disconnect the connector J12 (ENC) from the C-BASE board assembly.
Step 2 : Remove the screw retaining the timing encoder to the H board bracket and detach the encoder
by sliding it leftward.
Step 3 : Disconnect the connector and remove the timing encoder assembly.
Note :
When installing the timing encoder assembly, adjust its position forward or rearward so
that the T fence comes to the center.
90 AP-74020, Rev 3.0 – 26/06/01

(3) C-BASE board assembly
Step 1 : Disconnect the all connectors from the C-BASE board assembly.
Step 2 : Remove the six spacer from the C-BASE board assembly.
Step 3 : Remove the C-BASE board assembly.
(4) ORG sensor
Step 1 : Remove the screw retaining the ORG sensor to the H board bracket and remove the sensor.
91 AP-74020, Rev 3.0 – 26/06/01

4.5.4. Replacing cursor shaft assembly, bearing, pinch roller spacer.
(1) Cursor shaft assembly, bearing (3-9), pinch roller spacer
Step 1 : Remove the head cover from the machine.
Step 2 : Remove the one pressure plate retaining screw and remove the pressure plate.
Step 3 : Remove the ultra spring and the cursor shaft assembly.
Step 4 : Remove the E ring and remove the bearing (3-9) and the pinch roller spacer.
(2) Bearing (4-12), bearing (3-9)
Step 1 : Remove the mini fittings from the filters for the all four colour inks.
Step 2 : Remove the on-chip head cable assembly from the print head assembly.
Step 3 : Remove the HEAD-CONT board assembly and the C-BASE board assembly.
Step 4 : Remove the carriage retaining screws (hexagon socket screws x 2).
Step 5 : Remove the H board bracket retaining screws (3) from the Y-axis cursor.
Step 6 : Remove the steel belt from the Y-axis cursor.
92 AP-74020, Rev 3.0 – 26/06/01

Step 7 : Remove the cursor shaft assembly and remove the Y-axis rail.
Step 8 : Pull out the bearing (3-9) and (4-12) and the Teflon spacer from the Y-axis cursor.
Note :
Exercise enough caution not to damage the bearing (3-9) and (4-12) and the Teflon
spacer when pulling them out.
93 AP-74020, Rev 3.0 – 26/06/01

4.5.5. Replacing subtank assembly.
Step 1 : Disconnect the subtank connector.
Caution :
When you reconnect the connectors to the subtank, please verify :
White connector Þ Furthest position versus the bracket.

Grey connector Þ Middle position.
Colour connector Þ Closest to the bracket.
The colour of the connector should be placed
at the right subtank (connector and subtank
same colour).
Colour (Y, M, C, K)
Grey
White
Step 2 : Remove the tubes from the mini fittings and solenoid valves.
Caution :
· Do not allow residual ink inside the tubes to clean or

splashes.
· If you get ink into your eyes, immediately clean the eyes in
water.
· Do not apply excessive rearward force when removing the
tubes between the solenoid valves and the subtank.
· When you reuse an once removed ink tube, cut its end by
the length of 10 mm with the specified cutter before connecting the
tube.
Step 3 : Remove the four subtank retaining screws from the subtank bracket.
Caution :
There is an electrode plate for the ink sensor under he subtank cover. Do
not bend or touch the plate. Even a finger print on the electrode plate may
result in a machine failure.
Step 4 : Remove the subtank assembly.
94 AP-74020, Rev 3.0 – 26/06/01

4.6. Cap unit.

This section describes how to replace the parts of the cap unit.
Note :
95 AP-74020, Rev 3.0 – 26/06/01

4.6.1. Replacing maintenance unit cover assembly, Cap Motor, 2-way Valve Assembly, Wiping Unit
Assembly, Cap Unit Sensor Assembly, TBL-RT Assembly.
(1) Replacing maintenance box cover.
Step 1 : Remove the supply cover.
Step 2 : Remove the three screws retaining the solenoid valve cover to the machine.
Step 3 : Remove the solenoid valve cover.
Step 4 : Remove the two screws retaining the cap unit to the X-axis rail.
Step 5 : Remove the cap unit.
Step 6 : Remove the front retaining screw for the maintenance box and loosen the four hexagon nut
screws at the rear of the cap unit. Open the maintenance unit cover assembly.
96 AP-74020, Rev 3.0 – 26/06/01

Step 7 : Slightly raise the maintenance box, pull out the five waste fluid tubes and remove the
maintenance box assembly.
Step 8 : Remove the five ink tubes from the manifold.
Caution :
· Exercise enough caution not to allow residual ink inside the

tube to leak or splash.
length of 10 mm with the specified cutter before connecting the tube.
Note :
To remove the ink tubes, lever the tube end away from the manifold by using a pair of
tweezers or an equivalent tool.
97 AP-74020, Rev 3.0 – 26/06/01

(2) 2-way valve (solenoid valve for waste ink)
Step 1 : Remove the TBL-RE board assembly.
Step 2 : Remove the two screws retaining the RE board bracket.
Step 3 : Remove the RE board assembly.
Step 4 : Remove the four screws retaining the waste ink valve bracket.
Step 5 : Remove the waste ink valve bracket.
Step 6 : Pull out the waste ink tube from the maintenance box.
Note :
For five of the waste ink tubes, make access from the hole of the
maintenance box. For the remaining one, make access from under the
maintenance box.
Step 7 : Remove the two screws retaining the 2-way valve (solenoid valve for waste ink) to the waste ink
valve bracket.
98 AP-74020, Rev 3.0 – 26/06/01

Step 8 : Remove the 2-way valve (solenoid valve for waste ink).
Note :
The 2-way valve (solenoid valve for waste ink) should be replaced together with the
waste ink tube.
(3) Cap motor
Step 1 : Pull out the TBL-RT board assembly cap, motor connector J3 (C MOT), wiping unit and
connector J4 (W MOT).
Step 2 : Loosen the motor pinion holding screw.
Step 3 : Remove the motor pinion.
Step 4 : Remove the two screws retaining the cap motor to the purge base plate.
Step 5 : Remove the cap motor.
(4) Wiping unit, cap unit sensor assembly
Step 1 : Remove the three screws retaining the wiping unit to the X-axis rail.
Step 2 : Remove the wiping unit.
Step 3 : Remove the screws retaining the cap sensor bracket to the X-rail.
99 AP-74020, Rev 3.0 – 26/06/01

Step 4 : Remove the cap sensor bracket from the X-rail.
Step 5 : Hold the cap sensor (photo interrupter) lugs and remove the sensor from the bracket.
(5) TBL-RT board assembly
Step 1 : Disconnect the all TBL-RT board assembly connectors and remove the six retaining screws.
Step 2 : Remove the TBL-RT board assembly.
Note :
When installing the TBL-RT board assembly, make sure to screw the ground wire
together at the right lower corner of the board.
100 AP-74020, Rev 3.0 – 26/06/01

4.7. Ink supply unit.

This section describes how to replace the parts of the ink supply unit.
Note :
101 AP-74020, Rev 3.0 – 26/06/01

4.7.1. Replacing TBL-RE board assembly.
Step 1 : Remove the solenoid valve cover from the machine.
Step 2 : Disconnect the all connectors from the TBL-RE board assembly and remove the six retaining
screws.
Note :
The screws at the upper right corner of the TBL-RE board assembly is also used to
retain the ground wire of the TBL-2 cable.
102 AP-74020, Rev 3.0 – 26/06/01

4.7.2. Replacing air pump assembly.
Step 1 : Remove the supply unit cover from the machine.
Step 2 : Disconnect the TBL-RT board assembly connector J11 (PUMP).
Step 3 : Remove the pump motor tubes from the mini fitting.
Step 4 : Remove the two screws (M3x35W) retaining the pump motor to the supply unit base.
Step 5 : Remove the air pump motor.
Note :
There is a vibration-proof rubber between the supply unit base and the pump motor.
103 AP-74020, Rev 3.0 – 26/06/01

4.7.3. Replacing 2-way valve, 3-way valve (solenoid valves for ink supply).
Step 1 : Remove the ink supply tube (five-line tube) from the solenoid valve.
Caution :
· Exercise enough caution not to allow residual ink inside

the tube to leak or splash.
· If you get ink into your eyes, immediately clean the eyes in
water.
the length of 10 mm with the specified cutter before connecting the
tube.
Note :
To remove the ink tubes, lever the tube end away from the mini fitting by
using a pair of tweezers or an equivalent tool.
Step 2 : Remove the supply base from the base unit.
Step 3 : Remove the ink tubes from the mini fitting.
Step 4 : Remove the two screws retaining the solenoid valve to the supply unit base.
Step 5 : Remove the solenoid valve.
104 AP-74020, Rev 3.0 – 26/06/01

4.8. Control box.

This section describes how to replace the parts of the control box.
Note :
Before removing the parts, always remove the covers from the machine.
105 AP-74020, Rev 3.0 – 26/06/01

4.8.1. Replacing suction fan.
Step 1 : Open the control box and disconnect the fan motor intermediate cable connector J202 (VFAN)
from the subboard assembly.
Step 2 : Remove the paper guide F from the machine.

· Retaining screws : 6 upper M3x6 binding head, 5 front M3x8 W sems
Step 3 : Disconnect the all connectors from the vacuum fan and pull out the fan motor intermediate
cable from below.
Step 4 : Remove the two screws (M3x12) retaining the vacuum fan to the machine.
Step 5 : Remove the suction fan.
106 AP-74020, Rev 3.0 – 26/06/01

4.8.2. Replacing POWER switch assembly, POWER CONT board assembly, DC power supply
assembly, HV-CONT board assembly.
(1)POWER switch assembly
Step 1 : Open the control box and disconnect the POWER CONT board assembly connector (J101).
Step 2 : Remove the two POWER switch assembly retaining screws from the control box.
Step 3 : Remove the POWER switch assembly.
(2) POWER CONT board assembly, DC power supply assembly, HV-CONT board assembly
Step 1 : Open the control box and disconnect the connectors.
Step 2 : Remove the POWER CONT board assembly retaining screws and take out the assembly from
the control box.
Step 3 : Remove the DC power supply assemblies and HV-CONT board assembly from the POWER
CONT board assembly.
107 AP-74020, Rev 3.0 – 26/06/01

4.8.3. Replacing extension board assembly, mainboard assembly, subboard assembly, C box fan and
SIMM32M.
(1) Subboard assembly
Step 1 : Open the control box and disconnect the all connectors from the subboard assembly.
Step 2 : Remove the subboard assembly retaining screws and take out the assembly from the control
box.
(2) Extension board assembly
Step 1 : Open the control box and disconnect the mainboard assembly connector J15 (extension board).
Step 2 : Remove the four screws retaining the extension board assembly to the rail bracket and take out
the assembly from the control box.
(3) Mainboard assembly
Step 1 : Open the control box.
Step 2 : Remove the two screws (M3x6 binding head, small) at the left of the control box and remove the
rail bracket (two screws in each at right and left).
Step 3 : Remove the 10 retaining screws. Slightly move the mainboard assembly to the right and
remove the assembly.
Note :
To remove an optional board, first remove the mainboard assembly.
108 AP-74020, Rev 3.0 – 26/06/01

(4) C box fan
Step 1 : Open the control box and disconnect the power CONT board assembly connector (J126).
Step 2 : Remove the C box fan retaining screws (2 hexagon nut (M3), 2 round head (M3x35 W sems)).
Step 3 : Remove the C box fan.
(5) SIMM32M
Step 1 : Remove the memory cover at the front of the control box.
Step 2 : Remove the SIMM32M.
109 AP-74020, Rev 3.0 – 26/06/01

4.9. Stand, sheet winder, supply unit base.

This section describes how to replace the parts of the stand, sheet winder and supply unit base.
110 AP-74020, Rev 3.0 – 26/06/01

4.9.1. Replacing waste ink sensor assembly, tank sensor cable assembly, spin motor and TBL-BOT
board assembly.
(1) Tank sensor cable assembly, waste ink sensor assembly
Step 1 : Remove the cover 2 and 3 from the machine.
Step 2 : Disconnect the connector.
Step 3 : Remove the two ink sensor bracket retaining screws.
Step 4 : Remove the ink sensor bracket.
Note :
After installing the ink sensor bracket, you must make adjustment.
Step 5 : Remove the ink sensor (photo interrupter) from the ink sensor bracket.
Note :
Use the same procedure for the waste ink sensor replacement.
(2) Replacing spin motor, TBL-BOT board assembly
Step 1 : Disconnect the TBL-BOT board assembly connector J3 (SPIN MOTOR).
Step 2 : Remove the spin motor.
Step 3 : Disconnect the all TBL-BOT board assembly connectors and remove the six retaining screws.
Step 4 : Remove the TBL-BOT board assembly.
Note :
The screw at the upper right corner of the TBL-BOT board assembly is also used to
retain the ground wire of the TBL-2 cable.
111 AP-74020, Rev 3.0 – 26/06/01

112 AP-74020, Rev 3.0 – 26/06/01

4.9.2. Replacing transfer belt for agitations.
Step 1 : Remove the tank covers 2 and 3.
Step 2 : Remove the transfer belt for agitation in order accessing from under the tank holder.
113 AP-74020, Rev 3.0 – 26/06/01

4.9.3. Replacing rewinder motor assembly, torque limiter assembly, rewinder switch.
(1) Rewinder switch assembly
Step 1 : Remove the tank cover 2 and disconnect the TBL-BPOT board assembly connector J4 (R-
MOT).
Step 2 : Remove the screw (hexagon socket bolt M4x40 W sems) retaining the sheet rewinder to the
machine.
Step 3 : Remove the sheet rewinder.
Step 4 : Remove the rewinder cover and chassis from the sheet rewinder.
Step 5 : Remove the two screws (M3x16 W) retaining the rewinder switch assembly to the rewinder side
plate (left side).
Step 6 : Remove the rewinder switch assembly.
Note :
After installing the rewinder switch assembly, always make adjustment.
114 AP-74020, Rev 3.0 – 26/06/01

(2) Rewinder motor assembly
Step 1 : Remove the driving shaft holding snaps (left and right, two in total).
Step 2 : Pull out the bearing.
Step 3 : Remove the three rewinder motor retaining screws from the rewinder side plate (right side).
Step 4 : Remove the rewinder motor assembly.
Note :
Before removing the rewinder motor assembly, always remove the rewinder switch
assembly.
(3) Torque limiter assembly
Step 1 : Remove the snap retaining the mini keeper to the limiter shaft and remove the mini keeper.
Caution :
When installing the motor gear and limiter switch, adjust their positions so that slight
looseness is secured. If the motor operates with no looseness, the mini keeper may be
damaged.
115 AP-74020, Rev 3.0 – 26/06/01

4.9.4. Replacing rewinder sensor cable assembly, reflect panel.
(1) Rewinder sensor cable assembly
Step 1 : Remove the tank cover 2 and disconnect the TBL-BOT board assembly connector J5 (RS1).
Step 2 : Remove the two screws retaining the rewinder sensor bracket to the rewinder sensor base
Step 3 : Remove the rewinder sensor bracket.
Step 4 : Remove the two screws (M3x6 binding head) retaining the rewinder sensor to the rewinder
sensor bracket.
Step 5 : Remove the rewinder sensor.
(2) Replacing reflector
Step 1 : Remove the two screws retaining the reflector to the sensor bracket.
Step 2 : Remove the reflector.
Note :
When installing the rewinder sensor and reflector, adjust their orientations to each so
that the sensor LED lights up with no blocking objects between the reflector and the
sensor.
116 AP-74020, Rev 3.0 – 26/06/01

5. Check and attention points.
5.1. Introduction.
This section describes the attention points when replacing parts. Also, there will be descriptions how to
check the operation of some parts.
117 AP-74020, Rev 3.0 – 26/06/01

5.2. How to correctly install firmware?

Step 1 : Make a backup of the basic values.
1. Switch the machine “OFF”.

2. Insert the Backup Card in the slot at the left side of the control box.
3. Switch the power “ON”.
4. Using the [NEXT/+] or [LAST/-] key, select “PLOTTER à CARD” on the display
and press the [ENTER] key to confirm.
5. When the procedure finished, the display gives the message :
PàC COMPLETED
A beep will confirm completion. Now you can switch the power “OFF”.
6. Take out the Backup Card.
Step 2 : The PJ-1304NX has to be switched “OFF”.
Step 3 : Insert the Flash Card into the slot at the left side of the Control Box.
Step 4 : Switch the power “ON”.
Step 5 : The end of the loading sequence is shown on the display with the word “END”. Three beeps
will also confirm completion.
Step 6 : Switch the power “OFF”.
Step 7 : Remove the Flash Card.
Step 8 : Start the machine and verify on the display, if the new Firmware is installed, if this is not the
case repeat step 3 to step 8.
Step 9 : Reload the Basic Values into the machine.
1. Switch the machine “OFF”.

2. Insert the Backup Card in the slot at the left side of the Control Box.
3. Switch the power “ON”.
4. Using the [NEXT/+] or [LAST/-] key, select “CARD à PLOTTER” on the
display and press the [ENTER] key to confirm.
5. When the procedure finished, the display gives the message :
CàP COMPLETED
A beep will confirm completion. Now you can switch the power “OFF”.
6. Remove the Backup Card.
Caution :
Do not switch the power “OFF” during the procedure.
118 AP-74020, Rev 3.0 – 26/06/01

5.3. Valve check procedure.

When servicing an Albatros Printer (PJ-1304NX) with firmware V1.05 or higher, it is possible to check the
valves in the ‘INSPECTION MODE’.
Warning :
If the printer is already switched ‘ON’, please perform a ‘HEAD WASH’ cycle first.
As the ‘INSPECTION MODE’ stops the periodic purging of the print heads, not
performing a wash cycle might cause nozzle blockage.
If the printer is switched ‘OFF’, move to step 3.
Step 1.: Cleaning the heads.
If the printer is already switched ‘ON’, please perform a ‘HEAD WASH’ cycle first.
1. From the online status display, press the [HEAD CLEAN] key to shift to the cleaning menu.
* Online *
Ready to Print
2. Press the [NEXT/+] or [LAST/-] keys to select the operation : “Wash”.
* Head Clean *
Wash>
3. Press the [ENTER] key to confirm the selected operation.
4. Press the [NEXT/+] or [LAST/-] keys to select all heads.
* Head Wash *
KCMY
5. Press the [ENTER] key to confirm the heads to be cleaned.
6. After confirmation, press [ENTER] to start the cleaning cycle. If a wrong selection was made,
press [CANCEL] and start again.
PREV. Key : Cancel

ENTER Key : Wash KCMY
7. During cleaning the display shows following message :
PREV. Key : Cancel

Cleaning
8. When Cleaning is completed, the online status is automatically restored.
KCMY Unloaded
Press ink key
119 AP-74020, Rev 3.0 – 26/06/01

Step 2 : With the power switch, perform following toggle combination : OFF – ON – OFF.
Caution :
Only to be done with the printer switched “ON”.
Step 3 : While pressing and holding the [AUTO], [ROLL OFF] and [ROLL UP] keys simultaneously, switch
the Albatros Printer ‘ON’. Hold the keys pressed until you hear a beep. The Albatros Printer will
boot up in Inspection Mode.
Inspection Mode
Step 4 : Press the [NEXT/+] or [LAST/-] keys to select the valve inspection.
Inspection Menu
Valve>
Step 5 : Press the [ENTER] key to confirm.
* Waste Valve K *
OFF
Step 6 : Pressing the [ENTER] switch, you can inspect the selected valve.
· When pressing [ENTER], the display will confirm your manipulation by changing the ‘OFF’ in the
LCD to ‘ON’.
· A click in the printer (when pressing [ENTER]) means that the valve is OK.
If there is no click, the selected valve is broken.
Now press [ENTER] so that the display again shows ‘OFF’.
Step 7 : Press the [NEXT/+] or [LAST/-] keys to select the Valve you want to inspect. Then repeat step 6.
Step 8 : When you have finished inspecting the Valves, you can switch ‘OFF’ the Albatros.
Step 9 : Switch the Albatros Printer ‘ON’. The printer will fill the heads with ink automatically.
* ONLINE *
Filling INK
When the Filling of the heads is finished, the display shows following message :
* ONLINE *
Ready to Print
120 AP-74020, Rev 3.0 – 26/06/01

5.4. Tubes.
Caution :
When you disconnect any of the tubes, anywhere in this machine, you must shorten it by
1 cm.
This, to ensure a good circulation of the air or liquid.
5.4.1. Tubes on the subtank.
L = 320 mm, connected with the soft tube on the head.

L = 65 mm
WN-4L804
Tubes should be fixed rather forward

L = 20 mm (toward the heads). Otherwise the tubes
may touch the Y-rail cover.
L = 40 mm
Connect the tube (L = 65 mm) and the long tube (L = 320 mm) with the L-shaped –mini-fitting (E-VPL306).
5.4.2. Tube connection on the head.
Caution :
On the head, between the hard tube (L = 320 mm) and the soft tube (WN-4L825), there
is a special mini fitting.
This mini fitting (E-VPI-236) has a special construction. Do not use another one,
because it should influence your print results in a negative way.
121 AP-74020, Rev 3.0 – 26/06/01

5.5. What should I check before starting up or shutting down the

Albatros?
1.Please check the waste liquid level.
If the waste tank is half full when starting up or shutting down, the initialisation sequence cannot be
completed. A full waste bottle during powering off can also cause internal damage.
2.Is there enough jetwash in the jetwash tank?

If the level is below 600cc, the cleaning cycle will not be completely executed.
3.Is there enough ink in each ink tank?

If the level is below 400cc, during starting up, the printer will give an [INK UNLOAD] error, preventing the
normal ink filling procedure.
4.Is each tank cap closed tightly?

First check if the white packing is fitted inside the cap. If the cap is loose or if there is no white packing,
the pressure inside the tank will not increase, causing an ink filling or ink collection failure.
5.Check the covers and the pressure lever?

Before starting up, or shutting down, please make sure to close the cover and to gently lower the media
hold lever.
6.Is the capacity of the bottles 1.2 litres?

The TOTAL capacity of the bottles is indeed 1.2 litres. You will notice however, that the bottles are
marked with a circle, indicating the ONE LITER LEVEL. DO NOT FILL THE BOTLLES OVER THIS
MARK !!!
The Albatros’s ink and jetwash supply system is pressurized. The printer space for building up pressure.
122 AP-74020, Rev 3.0 – 26/06/01

6. Self diagnosis.
6.1. Introduction.
This section describes the self diagnosis feature.
Note :
For the detailed operation procedures refer to “Basic Operation” and “Functional
Operation” in the separate users manual.
123 AP-74020, Rev 3.0 – 26/06/01

6.2. Outline.
The self diagnosis function adjusts the printing accuracy, which is used when manufacturing, adjusting or
servicing the machine.
The self diagnosis function is incorporated in the main menu as a hidden item. All operations can be
performed only through the operation panel.
Note :
For each name of each part on the operation panel, refer to “Component name and
function”.
Self diagnosis function list :
Diagnosis Function Contents Page

item
Adjustment Cap position · Adjust cap position between maintenance unit-head
(locate origin position)
· Adjust contact of head to maintenance rubber cap.
· Visually check that the both contact with each other at
their centers.
Wiping position · Adjust wiping position between wipe head-unit.
· Visually check that the both contact with each other at
their centers.
Head accuracy · Print a pattern for checking head accuracy.
· While checking linearity of each colour pattern edge,
adjust head inclination.
· Use head adjusting screw on the carriage to adjust head
inclination and back and forth position.
· Adjust head inclination so that the pattern become
straight and verify that there is no clogging.
· Adjust gaps so that all colour patterns become straight
relative to black pattern.
· Adjust head back and forth position so that all colours
patterns lined up relative to black pattern.
CCW printing position · Print a pattern for checking repeatability printing position
(Repeatability printing · Adjust respectively for 192, 384 and 768 dpi modes.
position) · Due to a delay from ink ejection and ink landing on
media, ink ejection position should be adjusted so that a
shot of ink lands to the same position in both forward and
return printing.
Line Feed Correction · Print a Headaccuracy pattern for checking the longest
(LFRectify & column.
XLength) · Set XLength to 100%
· Make a print in XLength menu.
· Adjust in LFRectify.
Sensor · Print a pattern for checking margins.
Top margin (TM), Left margin (LM)
124 AP-74020, Rev 3.0 – 26/06/01

Setting Ink ejection wave · Print a pattern for nozzle check after selecting head,
form resolution and density.
· Modifying wave form for “Basis” density changes wave
form parameters for each density.
Head temperature · Set head temperature.
Test Panel · Check panel (LCD, LED, keys).
· Check that panel components (LED, LCD, keys)
normally operate.
Sensor · Check sensor status.
Dot discharge count · Check ink ejection count.
Print Nozzle check · Check nozzle status by printing.
(normal)
Nozzle check · Check nozzle status by printing in dot mask mode.
(dot mask)
SetupList · Print out current parameter values.
Adjust · Print out all current adjustment patterns.
Endurance Carriage motor · Perform endurance operation of carriage motor.
Paper feed motor · Perform endurance operation of paper feed motor.
· Repeat stroking operation until main roller makes two
rotations.
Cap motor · Repeat cap operation.
Wipe motor · Repeat wiping operation for all heads.
Spin motor · Perform endurance operation of spin motor.
Total · Perform endurance operation of carriage motor, paper
feed motor, cap, wiping and spin motor in order.
125 AP-74020, Rev 3.0 – 26/06/01

6.3. Preparation.
Before starting up the self diagnosis function, some preparations must be made on the machine.
6.3.1. Preparatory operations.
Perform the following operations before using self diagnosis function.
(1) Connecting adjustment tanks
Connect ink tanks (four colours), jetwash and waste fluid tank (all tanks should be separately prepared for
adjustment).
Note :
· Always use tanks separately for adjustment because the tanks attached to a
machine just delivered are all new.
· Fill the ink tanks and nozzle cleaner tank only to 80% at maximum.
(2) setting printing medium
Set roll media for adjustment.
Note :
Use the marking film PJ-MF-3G for adjustment.
(3) Connecting power supply cable
Connect the power supply cable between the machine’s AC inlet and a power outlet.
Note :
Do not use one power outlet for more than two machines.
126 AP-74020, Rev 3.0 – 26/06/01

6.3.2. Starting diagnosis function.
To use the self diagnosis function, the diagnosis menu must be called out in the LCD of the operation panel.
The operation to combine out the diagnosis menu is different depending on whether the machine is on or off.
In case of a self diagnosis that has been started while the machine is off, the ink filling procedure ends by
tricking the machine into believing that the ink tanks have been refilled. Therefore, even though the ink tanks
are not actually refilled, the machine does not display the message “Not Refilled”.
If the ink has been already refilled to the head, you can start printing. If not, you must perform a powerful
cleaning.
If you need no printing, you do not have to perform a powerful cleaning.
In addition, at the end of a self diagnosis, a cap suction operation is performed as the last step of the power
off sequence.
Note that the time needed for a powerful cleaning is about 25 minutes.
When machine is OFF.
When the machine is OFF, follow the procedure below to display the diagnosis menu.
1. While pressing and holding the [Cancel], [ONLINE] and [PRINT MODE] keys simultaneously, turn
the machine on.
2. Continue pressing the keys until the message shown * MUTOH PJ-1304NX *
is displayed (about 10 seconds). PRM Initializing
· The diagnosis menu will start. DIAGNOSIS MENU

Included
* Main Menu *
Diagnosis>
127 AP-74020, Rev 3.0 – 26/06/01

When machine is ON.
When the machine is on, follow the procedure below to display the diagnosis menu
1. From the Main menu, select “Utility” by using the * Main Menu *
[NEXT/+] or [LAST/-] key and press the [ENTER] Utility>
key.
2. In the Utility menu, select “Version” by using the * Utility *
[NEXT/+] or [LAST/-] key and press the [ENTER] Version>
key.
3. In the Utility menu, press the [LAST/-] key three * Version * 40MB
times, press the [NEXT/+] key three times and press Program : V2.04
the [ENTER] key.
· The diagnosis menu will start. * Main Menu *
Diagnosis>
128 AP-74020, Rev 3.0 – 26/06/01

6.4. Operation.
The diagnosis functions consists of the following five functions :
Þ Adjustment
Þ Setting
Þ Test
Þ Print
Þ Endurance
The operation procedures for the respective functions are provided in the following sections.
Caution :
The parameters (setting, mechanical constants) that have been adjusted are stored in
non-volatile memory. Exercise enough caution while using the diagnosis functions.
129 AP-74020, Rev 3.0 – 26/06/01

6.5. Adjustment Menu.

The following adjustments are available in this menu :
Þ Cap position
Þ Wiping position
Þ Head inclination, back and forth position, inter-head distance
Þ Repeatability printing position
Þ Line feed correction
Þ Paper feed distance
Þ Paper front edge sensor and paper width sensor positions.
Follow the procedure below to display the Adjustment menu.
1. From the diagnosis menu, select “Adjust” by using * Diagnosis *

the [NEXT/+] or [LAST/-] key and press the [ENTER] Adjust>
key.
2. In this menu, you can select from the adjustment

items shown in the figure , using the [NEXT/+] or
[LAST/-] key.
* Diagnosis * Þ * Adjust *
Adjust> HeadAccuracy>
Þ * Adjust *
CCWPrint>
Þ * Adjust *
XLength>
Þ * Adjust *
LFRectify>
Þ * Adjust *
Sensor>
Þ * Adjust *
CapPosi>
Þ * Adjust *
WipePosi>
130 AP-74020, Rev 3.0 – 26/06/01

6.5.1. Cap Position Adjustment.
In this menu, you adjust the cap position so that the capping rubber of the maintenance unit closely contacts
to the head.
This adjustment allows you to determine the origin position.
Follow the procedure below for the adjustment.
1. From the Adjustment menu, select “Capposi” by * Adjust *

using the [NEXT/+] or [LAST/-] key and press the CapPosi>
[ENTER] key.
2. In the cap Position menu, select “Confirm” by using * Adj>CapPosi *

the [NEXT/+] or [LAST/-] key and press the [ENTER] Confirm>
key.
· The machine will perform cap operation.
3. Visually check (in different directions) that each

capping rubber and the head contact with each other
at their centers (cap position).
4. If the cap position is inappropriate, select “Modify” in * Adj>CapPosi *

the Cap Position menu by using the [NEXT/+] or Modify>
[LAST/-] key and press the [ENTER] key.
5. Pressing the [NEXT/+] key causes the cap position * Adj>CapPosi *

to move away from the origin (+ 0.1 mm). -332.60mm²
Pressing the [LAST/-] key causes the cap position to
move toward the origin (- 0.1 mm).
6. Repeat step 2 to step 5 until an appropriate cap

position is obtained.
131 AP-74020, Rev 3.0 – 26/06/01

6.5.2. Wiping Position adjustment.
In this menu, you adjust the gap between the wipe unit and the head to ensure correct wiping operations.
Follow the procedure below for adjustment.
1. From the Adjustment menu, select “WipePosi” by * Adjust *

using the [NEXT/+] or [LAST/-] key and press the WipePosi>
[ENTER] key.
2. In the wiping position menu, select “Confirm” by * Adj>WipePosi *

using the [NEXT/+] or [LAST/-] key and press the Confirm>
[ENTER] key.
· The machine will perform a wiping operation.
3. Visually check that the wipe unit and the head

contact with each other at their centers (wiping
position).
4. If the wiping position is inappropriate, select “Modify” * Adj>WipePosi *

in the Wiping position menu by using the [NEXT/+] or Modify>
5. Pressing the [NEXT/+] key causes the wiping * Adj>WipePosi *

position to move away from the origin (+ 0.1 mm). -273.00mm
Pressing the [LAST/-] key causes the wiping position
to move toward the origin (- 0.1 mm).
6. Repeat step 2 to step 5 until an appropriate wiping

position is obtained.
132 AP-74020, Rev 3.0 – 26/06/01

6.5.3. Head Accuracy Adjustment.
In this menu, you print a pattern for checking the head accuracy and adjust the head inclination, back and
forth position and inter-head distance.
· For the head inclination, adjust the adjusting screw at the head so that each colour pattern edge of the
printed pattern forms a straight line.
· For the head back and forth position, adjust the adjusting screw so that each colour line forms a
straight line relative to the black line.
· For the inter-head distance, adjust the unidirectional and bi-directional printing operations so that each
colour lines up relative to the black line.
For standard values refer to the table below :
Head accuracy item Spec.

Head inclination ± 33µm (no clogging)
Inter-head distance · Unidirectional printing : ± 53µm or less
· Bidirectional printing : ± 50µm or less
Head back and forth position ± 33µm or less
1. From the Adjustment menu, select “HeadAccuracy” * Adjust *

by using the [NEXT/+] or [LAST/-] key and press the HeadAccuracy>
[ENTER] key.
2. In the Head accuracy menu, select “Confirm(Print)” * Adj>HeadAccuracy *

by using the [NEXT/+] or [LAST/-] key and press the Confirm(Print)>
[ENTER] key.
·A pattern for checking the head accuracy will be
printed.
3. Use the relevant adjusting screws to adjust the head

inclination and back and forth position.
4. To adjust the inter-head distance, select “Gap” in the * Adj>HeadAccuracy *

Head Accuracy menu by using he [NEXT/+] or Gap>
5. In the Head Gap menu, select a colour to be * Adj>HeadAccuracy *

adjusted (cyan, magenta or yellow) by using the BK-C: 32.00mm>
[NEXT/+] or [LAST/-] key and press the [ENTER]
key. * Adj>HeadAccuracy *
·BK-C (cyan) BK-M: 64.00mm>
·BK-M (magenta)
·BK-Y (yellow) * Adj>HeadAccuracy *
BK-Y: 96.00mm>
133 AP-74020, Rev 3.0 – 26/06/01

6. Pressing the [NEXT/+] key causes the printing

position to move away from the origin (+ 0.1 mm).
Pressing the [LAST/-] key causes the printing
position to move toward the origin (- 0.1 mm).
7. Repeat step 2 to step 6 until all adjustments are

completed.
134 AP-74020, Rev 3.0 – 26/06/01

6.5.4. Repeatability Printing position (CCW) Adjustment.
To adjust the repeatability printing position, first print a pattern for checking the repeatability printing position.
Make this adjustment respectively for the 192 dpi, 384 dpi and 768 dpi modes.
Ensure that each colour pattern forms a straight line.
Note :
The pattern shall be straight with the maximum deviation of ± 50µm.
Due to a delay from ink discharge and ink attachment on paper, the ink discharge position should be
adjusted so that a shot of ink attaches to the same position in both he forward and return printing.
1. From the adjustment menu, select “CCWPrint” by * Adjust *

using the [NEXT/+] or [LAST/-] key and press the CCWPrint>
[ENTER] key.
2. In the CCW Printing position menu, select a * Adj>CCWPrint *

resolution mode to be adjusted by using the 192dpi>
key.
· Three resolutions, 192 dpi/384 dpi/768 dpi, are
available.
3. In the CCW Printing (192) menu, select * Adj>CCWPrint(192) *

“Confirm(Print)” by using the [NEXT/+] or [LAST/-] Confirm(Print)>
key and press the [ENTER] key.
·A pattern for checking the repeatability printing
position will be printed.
4. To adjust the repeatability printing position, select * Adj>CCWPrint(192) *

“Modify” in the CCW Print (192) menu by using the Modify>
key.
5. Pressing the [NEXT/+] key causes the return printing * Adj>CCWPrint(192) *

position to move away from the origin (+ 0.1 mm). 0.00mm>
Pressing the [LAST/-] key causes the return printing
position to move toward the origin (- 0.1 mm).
6. Repeat step 3 to step 5 until an appropriate printing

condition is obtained.
· Make the above adjustment respectively for 192
dpi / 384 dpi / 768 dpi modes.
135 AP-74020, Rev 3.0 – 26/06/01

6.5.5. Line Feed Correction.
The Line Feed Adjustment is one of the key adjustments to obtain a good print quality. We recommend this
action to avoid banding and white lines in the print.
The Line Feed Correction (LFRectify) and Paper Feed Distance (XLength) are no longer separated. They
are now bundled into one adjustment. We have found that separated adjustment of both corrections may
lead to mistakes in the print.
Warning :
Do NOT change other settings in these menus as the ones described in this
document.
Step 1 : Make a print in ‘HeadAccuracy’ menu.
From the HeadAccuracy menu, select Confirm(Print) by using the [NEXT/+] or [LAST/-] key and press the
[ENTER] key.
Step 2 : Visually check which colour has the longest column in the ‘Head Front and back Position’ check
pattern.
Choose the best column judging from the middle part of the print.
Step 3 : Check if the Paper Feed Distance is set to 100%.
Select “Modify” in the XLength menu by using the [NEXT/+] or [LAST/-] key and press the [ENTER] key.
Set the value to 100% by using the [NEXT/+] or [LAST/-] key.
Step 4 : Make a print in the “XLength” menu.
In the “XLength” menu, select “Confirm(Print)” by using the [NEXT/+] or [LAST/-] key and press the [ENTER]
key.
A vertical line will be printed. Measure the printed length.
The length of the line should be between 300.00 mm and 301.50 mm.
300.0 mm is the minimum tolerance of the printed line.
301.5 mm is the maximum tolerance of the printed line.
If this is the case, go to step 5.

If this is not the case, adjust this value in LFRectify and not in XLength(refer to step 6 & 7).
(The value in XLength should always be 100.00%.)
136 AP-74020, Rev 3.0 – 26/06/01

Step 5 : Calculate the difference in percent between the measured length compared to the minimum and
maximum tolerance of the line length.
Notice that 1 mm stands for 0.33%.
For example : XLength is 301.00 mm

· The difference between 301.00 mm and 300.00 mm is 1 mm.
Þ - 1 mm stands for –0.33 % (minimum tolerance)
· The difference between 301.00 mm and 301.50 mm is 0.5 mm.
Þ + 0.5 mm stands for + 0.16% (maximum tolerance)
Step 6 : Make a print in the “LFRectify” menu.
In the LFRectify menu, select “Confirm(Print)” by using the [NEXT/+] or [LAST/-] key and press the [ENTER]
key.
Step 7 : Visually check, only the colour of step 2, which pattern has the best quality.
Not OK
OK
Not OK
If the current pattern is not the best pattern, adjust the value by using the [NEXT/+] or [LAST/-]
key in “Modify” menu of LFRectify.
Warning :
The modification limits are the values calculated in step 5.
Do NOT use modification values higher than the corrections

calculated in step 5.
For example :
Step 1 : Make a print in the ‘Head Accuracy’ menu.

Step 2 : Cyan is the longest column.
Step 3 : Set the “XLength” menu to 100.00%.
Step 4 : Make a print in the “XLength” menu. The measured length is 299.00mm.
Add 0.50 % in the “Modify” menu of LFRectify.
(Must be between 300.00 mm and 301.5 mm. Add minimum 1 mm. 1 mm stands for 0.33%.)
Step 5 : · The difference between 300.5 mm and 300.00 mm is 0.5 mm.

Þ - 0.5 mm stands for – 0.16% (minimum tolerance).
· The difference between 300.5 mm and 301.5 mm is 1 mm.
Þ + 1 mm stands for + 0.33% (maximum tolerance).
Step 6 : Make a print in the “LFRectify” menu.

Step 7 : Look at the cyan pattern and the best pattern is – 50%. The maximum allowed adjustment in
the modification menu of LFRectify is – 16%.
137 AP-74020, Rev 3.0 – 26/06/01

6.5.6. Sensor Position Adjustment.
In this menu, you adjust the positions of the paper front edge sensor and the paper width sensor.
Print a pattern for checking margins and check the top margin (TM) and left margin (LM).
1. From the Adjustment menu, select “Sensor” by using * Adjust *

the [NEXT/+] or [LAST/-] key and press the [ENTER] Sensor>
key.
2. In the Sensor menu, select “Confirm(Print)” by using * Adj>Sensor *

the [NEXT/+] or [LAST/-] key and press the [ENTER] Confirm(Print)>
key.
· A margin check pattern will be printed.
3. Measure the top margin of the printed media and

input the value.
4. Next measure the origin side margin and input the

value.
Note :
Once the parameters are changed, you must initialise the media position to check the
margins. To do so, exit the diagnosis menu and press the [TOP MARGIN] key.
The standard margins are as follows :

· Top margin (TM) ® 40.0 ± 5 mm
· Left margin (LM) ® 5.0 ± 2 mm
5. If the measured top margin is not as specified, select * Adj>Sensor *

“PFSensor” in the Sensor menu by using the PFSensor>
key.
6. Pressing the [NEXT/+] key moves the paper front * Adj>PFSensor *

edge sensor by + 0.1 mm, resulting in a narrower 98.70mm
margin.
Pressing the [LAST/-] key moves the paper front
edge sensor by - 0.1 mm, resulting in a wider
margin.
7. If the measured origin-side margin is not as * Adj>Sensor *

specified, select “PWSensor” in the Sensor menu by PWSensor>
using the [NEXT/+] or [LAST/-] key and press the
[ENTER] key.
8. Pressing the [NEXT/+] key moves the paper width * Adj>PWSensor *

sensor by + 0.1 mm, resulting in a wider origin-side 146.10mm
margin.
Pressing the [LAST/-] key moves the paper width
sensor by - 0.1 mm, resulting in a narrower origin-
side margin.
9. Repeat step 2 to step 8 until each measurement falls

in the specified range.
138 AP-74020, Rev 3.0 – 26/06/01

6.6. Setup Menu.

In this menu, you set the following parameters.
· Ink ejection wave form
· Head temperature
To enter the setup menu, follow the procedure below.
1. From the diagnosis menu, select “Setup” by using * Diagnosis *

the [NEXT/+] or [LAST/-] key and press the [ENTER] Setup>
key.
2. Select the parameters to be set by using the

[NEXT/+] or [LAST/-] key as follows.
* Diagnosis * * Setup *
Setup> Wavefrom>
* Setup *
HeadTemp>
139 AP-74020, Rev 3.0 – 26/06/01

6.6.1. Head Ink Ejection Wave Form Setting.
This is to change the ejection wave form setting.

Follow the procedure below to set the discharge wave form.
1. From the Setting menu, select “Waveform” by using * Setup *

the [NEXT/+] or [LAST/-] key and press the [ENTER] Waveform>
key.
2. Select a head, resolution and density.

· Head : black, cyan, magenta, yellow
· Resolution : 192 dpi, 384 dpi
· Density : Basis, density 1 - 5
3. In the wave form menu, select “Black” by using the * Set>Wave *
[NEXT/+] or [LAST/-] key and press the [ENTER] Black>
key.
4. In the Wave form (K) menu, select “192 dpi” by using * Set>Wave(K) *
the [NEXT/+] or [LAST/-] key and press the [ENTER] 192dpi>
key.
5. In the Wave form (K192) menu, select “Basis” by * Set>Wave(K192) *

using the [NEXT/+] or [LAST/-] key and press the Basis>
[ENTER] key.
Note :
Selecting the “Basis” density wave form will update the wave form parameters for
respective densities.
6. In the Wave form (K192D0) menu, select * Set>Wave(K192D0) *

“Confirm(Print)” by using the [NEXT/+] or [LAST/-] Cofirm(Print)>
key and press the [ENTER] key.
· A nozzle check pattern will be printed.
< Modifying wave form parameters >
The wave form parameters can be modified only when the density is set to “Basis”.
1. From the Wave form (K192D0) menu, select “Modify” * Set>Wave(K192D0) *

by using the [NEXT/+] or [LAST/-] key and press the Modify>
[ENTER] key.
2. Change the parameter value to be modified by using * Set>Wave(K192D0) *

the [NEXT/+] or [LAST/-] key. T1 : 36.0us
· Each parameter value is necessary to determine * Set>Wave(K192D0) *

the wave form parameters for respective densities T2 : 14.0us
based on the “Basis” density.
* Set>Wave(K192D0) *
T3 : 12.0us
* Set>Wave(K192D0) *
DD : 1.0us
140 AP-74020, Rev 3.0 – 26/06/01

6.6.2. Head temperature setting.
In this menu, you set or modify the head temperature.

To do so, follow the procedure below.
1. From the setup menu, select “HeadTemp” by using * Setup *

the [NEXT/+] or [LAST/-] key and press the [ENTER] Headtemp>
key.
2. In the Temperature menu, select “Confirm(Print)” by * Set>Temp *

using the [NEXT/+] or [LAST/-] key and press the Confirm(Print)>
[ENTER] key.
Note :
This printing function is not available with this machine.
3. In the Temperature menu, select “Modify” by using * Set>Temp *

the [NEXT/+] or [LAST/-] key and press the [ENTER] Modify>
key.
4. Select the item to be set by using the [NEXT/+] or * Set>Temp *

[LAST/-] key. K : 0.0°C>
· Set the temperature respectively for all heads.
5. * Set>Temp *
C : 0.0°C>
6. * Set>Temp *
M : 0.0°C>
7. * Set>Temp *
Y : 0.0°C>
Note :
In general, set the temperature to 40°C for all heads.
141 AP-74020, Rev 3.0 – 26/06/01

6.7. Inspection Menu.

In this menu, the following components can be inspected.
· Panel
· Sensor status
· Ink ejection count
To enter the inspection menu, follow the procedure below.
1. From the diagnosis menu, select “Test” by using the * Diagnosis *

[NEXT/+] or [LAST/-] key and press the [ENTER] Test>
key.
2. Select the items to be inspected by using the

* Diagnosis * * Test *
Test> Panel>
* Test *
Sensor>
* Test *
DotCount>
142 AP-74020, Rev 3.0 – 26/06/01

6.7.1. Panel inspection.
In this menu, you inspect the operation panel.

Check that the LED/LCD/keys function normally.
Follow the procedure below for inspection.
1. From the Test menu, select “Panel” by using the * Test *

[NEXT/+] or [LAST/-] key and press the [ENTER] Panel>
key.
2. To inspect the panel LCD (liquid crystal display), * Test>Panel *

select “LCD” in the Panel menu by using the LCD>
key.
a. Black dots should be displayed on the entire
LCD face.
b. Press the [CANCEL] key to return to the
Test menu.
3. To inspect the panel LEDs, select “LED” in the Panel * Test>Panel *

menu by using the [NEXT/+] or [LAST/-] key and LED>
press the [ENTER] key.
a. The LEDs on the operation panel should
light up in the following order and a buzzer
will sound.
[DATA] ® [ERROR] ® [AUTO] ® [HIGH] ®
[MIDIUM] ® [LOW] ® [UNI-DRCTN] ® [BI-DRCTN]
® [DOUBLE]
4. To inspect the panel keys, select “Key” in the Panel * Test>Panel *

menu by using the [NEXT/+] or [LAST/-] key and Key>
press the [ENTER] key.
a. Press a key on the operation panel. The
name of the pressed key should be
displayed on the LCD.
b. Press the [CANCEL] key to return to the
Inspection menu.
143 AP-74020, Rev 3.0 – 26/06/01

6.7.2. Sensor Status Check.
This is to check the sensor status.

Check that each sensor activates or deactivates correctly.
Follow the procedure below for check.
1. From the Inspection menu, select “Sensor” by using * Test *

the [NEXT/+] or [LAST/-] key and press the [ENTER] Sensor>
key.
2. Check the status of each sensor by using the

* Test>Sensor *
PFront : OFF
* Test>Sensor *
PRear : OFF
* Test>Sensor *
PFloor : OFF
* Test>Sensor *
Cover : CLOSE
* Test>Sensor *
Lever : DOWN
* Test>Sensor *
WasteTank : READY
* Test>Sensor *
JetWash : READY
* Test>Sensor *
Ink(Tank) : KCMY
* Test>Sensor *
Ink(Lo) : KCMY
* Test>Sensor *
Ink(Hi) : KCMY
144 AP-74020, Rev 3.0 – 26/06/01

6.7.3. Ink Ejection Count Check.
This is to check the ink ejection count of each head.

If the ejection count is more than 4 billion (average per nozzle), replace the head.
Follow the procedure below for checking.
1. From the Test menu, select “DotCount” by using the * Test *

[NEXT/+] or [LAST/-] key and press the [ENTER] DotCount>
key.
2. Check the ejection of each head by using the

* Test>DotCount *
Bk : 0
* Test>DotCount *
C: 0
* Test>DotCount *
M: 0
* Test>DotCount *
Y: 0
Note :
The head ejection count cannot be reset to 0. When replacing a head, always record
the head’s ejection count.
145 AP-74020, Rev 3.0 – 26/06/01

6.7.4. Test Print Menu.
In this menu, you can perform the following test printing.

· Nozzle check (normal) print
· Nozzle check (dot mask) print
· Parameter print
Follow the procedure below to [ENTER] key the printing menu.
1. From the Diagnosis menu, select “Print” by using the * Diagnosis *

[NEXT/+] or [LAST/-] key and press the [ENTER] Print>
key.
2. To print a normal nozzle check, select * Print *

“Nozzle(Normal)” in the Print menu by using the Nozzle(Normal)>
key.
3. To print a dot mask nozzle check, select * Print *

“Nozzle(DotMask)” in the print menu by using the Nozzle(DotMask)>
key.
4. To print the parameters, select “SetupList” in the * Print *

Print menu by using the [NEXT/+] or [LAST/-] key SetupList>
and press the [ENTER] key.
·For the parameter values, refer to the following list
as sample.
146 AP-74020, Rev 3.0 – 26/06/01

6.8. Endurance Operation Menu.

In this menu, you can perform an endurance operation on the following components.
· Carriage motor
· Paper feed motor
· Cap
· Wipe
· Spin motor
· Total operation
Follow the procedure below to [ENTER] key the endurance operation menu.
1. From the diagnosis menu, select “Trial” by using the * Diagnosis *

[NEXT/+] or [LAST/-] key and press the [ENTER] Trial>
key.
2. Select the item to be endurance-tested by using the

* Diagnosis * * Trial *
Trial> Carriage>
* Trial *
Feed>
* Trial *
Cap>
* Trial *
Wipe>
* Trial *
Stir>
* Trial *
Total>
147 AP-74020, Rev 3.0 – 26/06/01

6.8.1. Carriage Motor (Y motor) Endurance Operation.
This is to perform an endurance operation on the carriage motor.

The carriage will repeat its stroking to the media width (if media is set) or to the maximum width (if no media
is set).
Follow the procedure below to start the operation.
1. From the Trial menu, select “Carriage” by using the * Trial *

[NEXT/+] or [LAST/-] key and press the [ENTER] Carriage>
key.
2. The carriage motor will start its endurance operation. * Trial>Carriage *

Prev. 0
·The number of operations is displayed at the * Trial>Carriage *

bottom of the LCD. 0
3. To end the operation and return to the Trial menu,

press the [CANCEL] key.
148 AP-74020, Rev 3.0 – 26/06/01

6.8.2. Paper Feed Motor (X motor) Endurance Operation.
This is to perform an endurance operation on the media feed motor.

The media feed motor repeats a stroking operation amounting to two rotations of the main roller.
1. From the Trial menu, select “Feed” by using the * Trial *

[NEXT/+] or [LAST/-] key and press the [ENTER] Feed>
key.
2. The paper feed motor will starts its endurance * Trial>Feed *

operation. Prev. 0
·The number of operations is displayed at the * Trial>Feed *


149 AP-74020, Rev 3.0 – 26/06/01

6.8.3. Cap Endurance Operation.
This is to perform a cap endurance operation.

The cap operation is repeated.
1. From the Trial menu, select “Cap” by using the * Trial *

[NEXT/+] or [LAST/-] key and press the [ENTER] Cap>
key.
2. The cap endurance will be started. * Trial>Cap *

Prev. 0
·The number of operations is displayed at the * Trial>Cap *


150 AP-74020, Rev 3.0 – 26/06/01

6.8.4. Wipe Endurance Operation.
This is to perform a wiping endurance operation.

The Wipe operations for all heads are repeated.
1. From the Trial menu, select “Wipe” by using the * Trial *

[NEXT/+] or [LAST/-] key and press the [ENTER] Wipe>
key.
2. The Wipe endurance operation will be started. * Trial>Wipe *

Prev. 0
·The number of operations is displayed at the * Trial>Wipe *


151 AP-74020, Rev 3.0 – 26/06/01

6.8.5. Spin Motor (Ink Stirring System) Endurance Operation
This is to perform an endurance operation on the spin motor.

1. From the Trial menu, select “Stir” by using the * Trial *

[NEXT/+] or [LAST/-] key and press the [ENTER] Stir>
key.
2. The Spin motor will starts its endurance operation. * Trial>Stir *

Prev. 0:00:00
·The number of operations is displayed at the * Trial>Stir *

bottom of the LCD. 0:00:00

152 AP-74020, Rev 3.0 – 26/06/01

6.8.6. General Endurance Operation
Endurance operations for the carriage motor, paper feed motor, cap, wipe and spin motor are performed in
order repeatedly.
1. From the Trial menu, select “General” by using the * Trial *

[NEXT/+] or [LAST/-] key and press the [ENTER] Total>
key.
2. Each endurance operation will be performed in the

order shown below.
Carriage motor ® Paper feed motor ® Cap ® Wipe
® spin motor

153 AP-74020, Rev 3.0 – 26/06/01

154 AP-74020, Rev 3.0 – 26/06/01

7. Maintenance.
7.1. Introduction.
This section describes how to adjust, inspect and clean the components.
155 AP-74020, Rev 3.0 – 26/06/01

7.2. Adjustment.
After adjusting or replacing the components list in the table below, you must always adjust the print image
quality by using the self diagnosis function (refer to the previous chapter).
Order Replaced or adjusted part Adjustment item Reference

1 Print head assembly Cap position X Cap Position Adjustment
Wipe position X Wiping Position Adjustment
Ink ejection wave form X Head Ink Ejection Wave Form
Setting
Head temperature X Head Temperature Setting
Head accuracy X Head accuracy Adjustment
(Head inclination, back and forth
position, inter-head distance)
CCW printing position X Repeatability Printing position
(Repeatability printing position) (CCW) Adjustment
PF sensor (Top margin) X Sensor Position Adjustment
PW sensor (Left margin) X Sensor Position adjustment
2 Wiping unit assembly Wipe position X Wiping Position Adjustment
3 Maintenance unit cover Cap position X Cap Position Adjustment
assembly
Capping motor assembly
4 X motor assembly Head Accuracy X Head Accuracy Adjustment
Grid roller assembly (Head’s back and forth position)
Grid roller shaft bearing LF/X distance correction X Line Feed Correction
Reduction pulley assembly X Paper Feed Distance (X-axis
Split coupling 1, 2 Distance) Correction
X speed reduction belt PF sensor (Top Margin) X Sensor Position adjustment
5 Y motor assembly Cap position X Cap Position Adjustment
Steel belt assembly Wipe position X Wiping Position Adjustment
Timing fence Head Accuracy X Head Accuracy Adjustment
Driven pulley assembly (Inter-head distance)
Dual pulley assembly CCW printing position X Repeatability Printing Position
Synchronous belt (repeatability printing position) (CCW) Adjustment
PW sensor X Sensor position Adjustment
(Left margin)
6 Paper edge sensor PF sensor X Sensor Position Adjustment
assembly (Top margin)
7 ORG sensor assembly PW sensor X Sensor Position Adjustment
(Left margin)
8 Mainboard assembly All items X Self Diagnosis
(Unless adjusting parameters
are re-entered)
156 AP-74020, Rev 3.0 – 26/06/01

7.2.1. Head Height Adjustment.
This section describes how to adjust the head height.
(1) Adjusting jig
Before adjusting the head height, prepare the following jig.
· 2 Adjusting jigs (J-43677).
Adj. Side 9.5mm Adj. Check 9.3mm

9.7mm
J-43677
(2) Adjusting procedure
Step 1 : Remove the head cover from the head.
Step 2 : Loosen the head bracket screws (Hexagon screw x 2).
Step 3 : Place the carriage at the left hand side of the media sensor.
Step 4 : First, adjust it at the ‘adjustment side’ of the jig. Then, use ‘adjustment check’ to confirm the
tolerance of the height. The ‘adjustment check’ side should not fit in at 9.7 mm and should fit in
at 9.3 mm without touching.
Caution :
The carriage must be set on the left side of the media sensor. Always
tighten the left carriage fixation screw first. Then, tighten the right carriage
fixation screw so that you can control the carriage inclination.
157 AP-74020, Rev 3.0 – 26/06/01

Caution :
There are lifted portions as shown on the back of the head bracket.
Always apply the adjusting jigs to these portions. Applying th jigs to the
other areas may damage the bracket or head.
(3) Print image quality adjustment
After adjusting the head height, always perform the following self diagnosis to adjust the print image quality.
Note :
For the details of the self diagnosis function, refer to the previous chapter.
1) Cap position
2) Wipe position
3) Head accuracy
4) Repeatability printing position
5) LF correction
158 AP-74020, Rev 3.0 – 26/06/01

7.2.2. Power Supply Unit Voltage Adjustment
To adjust the voltage of power supply units, follow the procedure below.
1) Fully turn counter-clockwise the two voltage adjusting volumes for the HV power supply (36, 50W) on the
Power CONT board assembly board.
2) Turn the main power ON.
3) Using the voltage adjusting volumes, adjust the output voltage of the respective HV power supplies to
38.9 – 39.0 V.
Caution :
Do not turn the voltage adjusting volumes quickly. Doing so will cause a machine
failure. Always turn the volumes slowly and gradually.
Note :
These power supplies incorporate an over-voltage protection circuit that is activated

when the voltage excessively rises. If the over-voltage protection circuit is activated,
turn the main power off and turn the volume to its original position.
Then, wait for a while and repeat the voltage adjustment.
4) As for the other power supply units (5, 12, 24, 36V – 75W), check that the output voltage of each unit
falls in the following specified range.
If the measurements are not as specified, adjust the voltages by using the applicable voltage adjusting
volumes.
Measurement Voltage range

voltage
5V 4.8V – 5.2V
12V 11.7V – 12.3V
24V 23.4V – 24.6V
36V 35.1V – 36.9V
HV (78V) 38.9V – 39.0V (77.8V – 78.0V)
Note :
The voltages shown in round brackets indicate the measured at the head voltage
check terminals of the Head-CONT board assembly.
159 AP-74020, Rev 3.0 – 26/06/01

7.3. Periodic Inspection.

To maintain a stable level of printing quality, some components should be replaced at certain intervals.
Note :
For the replacement procedures of respective parts, refer to “Part Replacement”.
Refer to the table below, perform regular inspection.

Note :
For the names of the parts to be replaced, refer to the “Exploded Views”.
Replacement part Part No. Qty Timing

1 Filter Assembly WN-4L902 7 Every 6 moths
2 New Maintenance Box Cover Assembly WN-4M001 1 Every 6 moths
3 Wipe Rubber WN-4L706 1 Every 6 moths
4 Absorbent Plate WN-4L795 1 Every 6 moths
5 Wipe Cleaner WN-4L681 1 Every 2 moths
6 Mesh WN-4L980 1 Every 6 moths
7 Pump Assembly WN-4L579 1 Every 12 moths
8 Cursor Axis WN-4L903 2 Every 12 moths
160 AP-74020, Rev 3.0 – 26/06/01

8. Troubleshooting.
8.1. Introduction.
This section describes the possible causes of malfunctions and abnormal operations as well as the
appropriate actions.
161 AP-74020, Rev 3.0 – 26/06/01

8.2. Error Display in Operation Panel and Corrective Actions.

There are three types of error displays.
· Error message
· Command error
· Error needing reboot
8.2.1. Error Message.
An error message indicates a failure in the machine operation.

When this type of error occurs, the machine corresponds in two ways : displays the error and continues
printing, or displays the error and stop printing. If the machine stops printing, eliminate the cause of the
error. Then the machine will restart printing.
If this type of error occurs, a short beep sounds twice. Some errors are accompanied with a continuous
buzzer sound.
Error / Symptom Error message Cause Action

Capping error No Capping Position Cap position is not registered The error will not be cancelled
Set the Position until the cap position is
adjusted. Adjust the cap
position.
Interlock error Media Hold Lever Up Lever is raised. Lower lever to cancel error.
Hold Down the Lever
Cover Open Cover is open. Close cover to cancel error.
Close the Cover
Lever Up & Cover Open Lever is raised and cover is · Lower lever and close cover
Hold Down & Close open. to cancel error.
· If an interlock error occurs,

the buzzer operates
continuously. In this state, the
machine cannot perform its
regular head purge operation,
resulting in higher possibility of
nozzle clogging. So, cancel
the error as soon as possible
(within 5 minutes).
Paper error No media There is no media. · Set media and close lever.
Set media Machine tries to detect media
width and if it is successful,
returns to normal on-line mode.
· Media setting with the head

refilled with ink should be
finished as quickly as possible
(Within 5 minutes).
Media Width Misread Machine failed to detect media Raise lever, reset media and
Reset Media width. lower lever. Machine will retry
media detection.
Media Skew Media is set slantwise and out Raise lever, reset media and
Reset Media of its normal position. lower lever. Machine will retry
media detection.
162 AP-74020, Rev 3.0 – 26/06/01

Ink error No waste Bottle Waste fluid tank is not set. Set waste fluid tank to cancel
Set Vacant Bottle error.
Waste Bottle Full Waste tank is full. · Set empty waste fluid tank to
Set vacant Bottle cancel error.
· Waste fluid must be

transferred to separate
container (used ink bottle or
Jetwash bottle, etc.) and
disposed of as industrial waste.
[K/C/M/Y] Unloaded Ink of displayed colour is fully · After refilling, press [INK
Press Ink Key consumed. FILL] key and select “ink refill”
in Ink refill / recovery menu
·[K/C/M/Y]: this portion of

message shows only the colour
(black, cyan, magenta or
yellow) that has not been
refilled.
[K/C/M/Y] Ink Empty Ink of displayed colour is not · After refilling, press [INK
Fill & Press Ink Key refilled. FILL] key and select “ink refill”
in Ink refill / recovery menu
·[K/C/M/Y]: this portion of

message shows only the colour
(black, cyan, magenta or
yellow) that has not been
refilled.
Referential message * Online * Ink of displayed colour is Refill ink tank to cancel error. If
(Only buzzer sounds. Error [K/C/M/Y] Ink Low reduced. print data is analysed before
LED does not light up) ink refilling, machine returns to
normal printing state.
Insufficient Jetwash Jetwash Low Machine runs short of Jetwash. Refill Jetwash tank to cancel
Fill Jetwash error.
Option error Unfit Network Board Network interface board is Turn machine off and replace
Replace the Board compatible. network interface board with
Network Board Fail Network interface board cannot correct and normally operating
Replace the Board be initialised. one. However, machine
cannot operate with standard
centronics interface even
without network interface
board.
HDD Access Fail HDD (hard drive disk) cannot Turn machine off and replace
Replace the HDD be accessed. HDD with correct and normally
operating one. However,
machine can operate with
standard SIMM even without
HDD.
163 AP-74020, Rev 3.0 – 26/06/01

8.2.2. Command Error.
A command error is issued when a failure occurs during analysis of command data received from the host
computer. The main causes include :
· The type of the command data set by the host computer is different from the command setting in the
machine.
· The command data set by the host computer contain syntax errors.
When a command error occurs, the error LED lamp lights up and a long sound of buzzer sounds three times.
This type of error is automatically cancelled when the printing operation is finished. It is cancelled also when
you manually end the printing by pressing the [CANCEL] key.
Note :
The [ ] portion of each command error may contain the name of the command that has
caused the error.
Error Name / Symptom Error message Cause Action

Undefined command error Command error A command not defined in · First check that command
MH01[ ] MH-GL command mode has settings of your host computer
been analysed. are compatible with those of
Number of parameters outside Command error Number of parameters this machine. For host
specified range MH02[ ] following command is computer settings, refer to
improper. instruction manuals of host
Number of parameters outside Command error Number of parameters computer or CAD or RIP.
specified range MH03[ ] following command is
improper. Number of · [ ] contains name of
parameters outside specified command causing error.
range. However, in MH-RTL and RTL-
Undefined character set Command error Unavailable character set is PASS modes, it always show
MH04[ ] selected. [RTL].
Buffer overflow Command error Polygon buffer or download
MH05[ ] character buffer is overflowed.
164 AP-74020, Rev 3.0 – 26/06/01

8.2.3. Error Needing Reboot.
An error needing reboot is issued when a fatal problem for the machine operation occurs. This kind of error
is mainly caused by an obstacle preventing the machine’s X/Y-axis movements and electric board failures.
If an error needing reboot occurs, the machine shut off the power to its driving systems and all LEDs on the
operation panel start flashing and a long sound of buzzer is repeated intermittently. The buzzer sound can
be stopped by pressing any key on the operation panel.
If this kind of error occurs, first turn the machine off, take appropriate actions for the error and turn the
machine on after waiting 10 seconds or more.
The machine corresponds as follows to an error needing reboot.
1) Shuts off the power to the driving systems.
2) Makes all operation panel LEDs flash and makes a intermittent long sound of buzzer repeatedly. The
buzzer sounds will not stop until a key input is provided.
3) Displays the error code and error name on the LCD.
Error Name / Symptom Error message Cause Action

Paper feed motor error E065 error X-axis motor has an error. Remove objects or paper that
X-axis Motor are preventing driving system
Carriage motor error E066 error Y-axis motor has an error. movements and reboot the
Y-axis Motor machine
Paper feed encoder error E069 error X-axis encoder has an error.
X-axis Encoder
Carriage encoder error E070 error Y-axis encoder has an error.
Y-axis Encoder
Paper feed in-position timeout E071 error In-position timeout error for X-
X-axis Timeout axis occurs.
Carriage in-position timeout E072 error In-position timeout error for Y-
Y-axis Timeout axis occurs.
Overcurrent to carriage motor E073 error X-axis overcurrent error occurs.
X-axis Over Current
E074 error Y-axis overcurrent error occurs.
Y-axis Over Current
Sensor detection error E075 error Sensor cannot be detected due · Check appropriate
Sensor Failure to error. components and reboot
Ink refill error E076 error Ink cannot be refilled due to machine. When this error
Ink Fill Failure error. occurs, some components or
Ink recovery error E077 error Ink cannot be recovered due to board may need to be
Ink Restore Failure error. replaced.
Platen operation error E078 error Platen heater operation error
Platen Heater Fail occurs. · If ink refill error or ink
Head heater operation error E079 error Head heater operation error recovery error occurs, check if
Head Heater Failure occurs. cover of ink tanks (4 colours),
Wiping error E080 error Wiping error occurs. nozzle cleaner tank or waste
Wiping Failure fluid tank are loose.
Capping error E081 error Capping error occurs.
Capping Failure
Subtank (K) Failure E082 error An operating error has
Subtank (K) Failure occurred in the Subtank (K).
Subtank (C) Failure E083 error An operating error has
Subtank (C) Failure occurred in the Subtank (C).
Subtank (M) Failure E084 error An operating error has
Subtank (M) Failure occurred in the Subtank (M).
Subtank (Y) Failure E085 error An operating error has
Subtank (Y) Failure occurred in the Subtank (Y).
HeadHeater (K) Failure E086 error An operating error has
HeadHeater (K) Failure occurred in Head Heater (K).
HeadHeater (C) Failure E087 error An operating error has
HeadHeater (C) Failure occurred in Head Heater (C).
HeadHeater (M) Failure E088 error An operating error has
HeadHeater (M) Failure occurred in Head Heater (M).
HeadHeater (Y) Failure E089 error An operating error has
HeadHeater (Y) Failure occurred in Head Heater (Y).
165 AP-74020, Rev 3.0 – 26/06/01

Flash ROM writing error E129 error Flash ROM writing error
NVRAM Failure occurs.
Mainboard DRAM error E193 error Error occurs to DRAM on
DRAM Failure mainboard.
Slot 1 SIMM error E194 error Error occurs to SIMM on slot 1.
SIMM (1) Failure
Slot 2 SIMM error E194 error Error occurs to SIMM on slot 2.
SIMM (2) Failure
No standard SIMM error E240 error Standard SIMM is not installed.
No SIMMs
CPU transfer memory access E237 error CPU transfer memory access
error TransMemory Failure error occurs.
Interrupt exception error E016 error Interruption exception error If a CPU error occurs, turn
CPU error [00] occurs to CPU. machine off, wait 10 seconds
Command environment E016 error Command environment or more and turn machine on.
exception error CPU error [02] exception error occurs to CPU. If this type of error occurs,
Data environment exception E016 error Data environment exception some components or boards
error CPU error [03] error occurs to CPU. may need to be replaced.
Address error exception 1 E016 error Address error exception 1
CPU error [04] occurs to CPU.
Address error exception 2 E016 error Address error exception 2
Bus error exception 1 E016 error Bus error exception 1 occurs to
CPU error [06] CPU.
Bus error exception 2 E016 error Bus error exception 2 occurs to
CPU error [07] CPU.
System call exception error E016 error System call exception error
Break point exception error E016 error Break point exception error
Reserved command exception E016 error Reserved command exception
error CPU error [10] error occurs to CPU.
Co-processor disable exception E016 error Co-processor disable exception
error CPU error [11] error occurs to CPU.
Computation overflow E016 error Computation overflow
exception error CPU error [12] exception error occurs to CPU.
Trap exception error E016 error Trap exception error occurs to
CPU error [13] CPU.
Floating point exception error E016 error Floating point exception error
Watch exception error E016 error Watch exception error occurs
CPU error [22] to CPU.
Watch dog timeout error E016 error Watch dog timeout error occurs
CPU error [32] to CPU.
Abort error E016 error Abort error occurs to CPU.
CPU error [33]
166 AP-74020, Rev 3.0 – 26/06/01

8.3. Machine’s Abnormal Condition and Malfunction.

This section describes the machine’s abnormal conditions and malfunctions that are not accompanied with
an error message.
Category Symptom Cause Action

Electrical The machine will not turns on. · Power supply plug is disconnected. · Check connectors in C-BOX.
· Power supply board failure. ·Check voltage (5V).
· Low voltage due to multiple device

connection to the same power outlet.
Electrical Defective LCD (no display). · Connectors are disconnected. Check connectors (panel, Subboard
assembly)
· Board failure.
Mechanical Ink tank cannot be refilled. · “Not refilled” is not displayed. ·Check for air leak due to loose ink
Electrical tank cap or coupling for nipple.
parts ·Ink bottle cap is open.
· Check for white packing on back of
·Ink amount not detected correctly. cap.
·Ink supply tubes are blocked. ·Check for cracks due to improper
shaping of ink tank.
·Solenoid valve connectors are
disconnected (MK, MC, MM, MY). ·Check for 0.4mm spacers inserted at
3-way valve.
·Pump is stopping.
·Check for ink leak from solenoid
valve.
·Check cap unit position (up/down,

right/left)
· Check for cracks or shrinkage in

cap rubber
· Check head nozzles for clogging.
· If solenoid valves make no clicking

sounds or 12V DC is not supplied to
connectors, check subboard and RT
board. Replace them as necessary.
Electrical Ink is not ejected even after ink · Poor cleaning. · if head makes no oscillating noise,
Adjustment tank is refilled. (“Ready to Print” is check driving voltage. Output
displayed) ·Inappropriate cap position. voltages of 36V power supplies in
control box should be adjusted to
·Inappropriate cap height. 38.9 – 39.0 V in each. Check that
voltages at TP1, TP2, TP4 and TP5
·Head inlet is dislocated from its on headboard are 77.8 – 78.0 V.
correct position (tube almost
disconnected). · Replace headboard and subboard
and recheck operation.
·Solenoid valve (3-way) failure.
·Head connector disconnected or

broken.
·Damaged head.
167 AP-74020, Rev 3.0 – 26/06/01

Electrical Machine will not detect media · Lever sensor assembly/paper · Check if machine detects lever UP.
Media width after media is set. sensor assembly failure or
disconnected connectors. · Replace lever sensor assembly/
paper X sensor assembly and check
·Paper sensor (front/rear) failure or operation.
disconnected connectors.
· For lever sensor, replace Subboard
· Release lever not fully lowered. assembly and check operation.
· Either of paper sensors is not · For paper X sensor, replace

blocked with media. Mainboard assembly or subboard
assembly and check operation.
· Transparent media is used.
· Replace media and check
· Media setting position operation.
inappropriate.
· Replace timing fence and check
· Timing fence contaminated on operation.
scratched.
· Board failure.
· Paper width detecting portion has

become black.
Electrical Machine does not stop paper · Motor failure. Replace X motor assembly / paper X
feeding at initialisation (media sensor and check operation.
setting) after power is turned on. · Paper X sensor failure.
Electrical Ink overflows when refilled. · Subtank ink sense cable is not · Check ink sensor cable connector
F/W connected to terminal or connector is of subtank.
disconnected.
· Check solenoid valve connection (if
· Board is broken (mainly, C-BASE crossed or not).
board assembly).
· Replace 3-way valve (3-way valve
·Jetwash has entered subtank. must have one 0.4mm spacer).
· Ink sensor failure. · Use F/W of version 1.03 or later.

Elecrical Ink cannot be withdrawn. · Ink bottle cap is open. · Same as above
F/W ( If ink is not detected, machine will
· No ink bottle. not start ink recovering sequence).
· Blocked or bent tubes. · Additionally tighten coupling at ink

bottle cap. If white packing at back of
· Defective solenoid valve (failure, cap is missing, air leak occurs.
disconnected connector).
· Pump is stopping. · Replace ink bottle and check
operation.
· Ink bottle sensor failure.
· Adjust position of ink bottle sensor
photo-interrupter.
· Replace photo-interrupter and

check position.
· Replace Subboard assembly and

check operation.
Electrical Machine will not perform ink · Ink bottle cap is open / air leaks. · additionally tighten coupling at ink
Mechanical refilling (ink tank is filled). bottle cap. If white packing at back of
· Poor operation of ink bottle sensor. cap is missing, air leak occurs.
· Initial refilling has not been done · Replace ink bottle and check
correctly. operation.
· Board is broken (mainly, C-BASE · Replace C-BASE board assembly

board). and check operation.
· Blocked / bent tubes. · Replace 3-way valve on subtank

and check operation.
· Ink bottle sensor failure.
· Adjust position of ink bottle sensor
photo-interrupter.
168 AP-74020, Rev 3.0 – 26/06/01

Mechanical Media goes slantwise or · Inappropriate setting of print media. · Reset media referring to “Loading
Media meanders. roll media” in User’s Manual (Basic).
Printing · Improper installation of pressure
accuracy roller. · Check pressure assembly status.
Additionally tighten retaining screws /
· Loose coupling / split coupling. hexagon socket button bolts.
· Paper attaches to paper guide due · MUTOH-recommended media have

to friction. antistatic coating on their back faces.
If media other than recommended are
used, check that they have antistatic
coating on their back faces.
Mechanical Media wrinkles / rubs head. · Insufficient head height. · Adjust head platen distance to 2.0 –
Media 2.3 mm.
Adjustment · Platen temperature partially high or
Setting low. · Some types of media, developing
wrinkles on it, can rub head unless
· Media has been left set for a long heater is off.
time.
· Cold media can develop wrinkles
· No vacuum operation. when quickly heated by platen heater,
rubbing head. If this occurs, perform
· Inappropriate media. more than –hour seasoning on media
under appropriate working conditions.
· Pressure roller inclined.
· Other possible causes include
· Platen heater is too hot (thermistor pressurezer assembly, suction fan; or
failure). platen heater thermistor failures.
· Poor smoothness of media. · Media that has been left set to the
machine can develop wrinkles on it
· Too high printing density. due to pressure from pressure lever.
Always remove media from machine
· Defective grid roller. if it is not necessary.
· Media slippage. · Remove dirt / foreign objects from

grid roller.
· Replace grid roller and check

operation.
Electrical Machine does not detect media · media partially contaminated and · Replace media with MUTOH
Mechanical size (width) correctly. blackened. recommended one and check
Media operation.
· Paper X sensor contamination /
failure. · Replace paper edge sensor.
· Media edges curled.

Electrical Electrical leak when heater is · Heater and platen makes Remove heater cable in control box
turned on (breaker trips). shortcircuit. and check insulation between heater
connector terminals and FG. If any
· Connectors connected incorrectly. abnormal condition is found,
reassemble platen heater.
· Cable is cut or damaged.
169 AP-74020, Rev 3.0 – 26/06/01

Electrical Platen heater temperature does · Heater connector is disconnected · Remove heater cable from control
Assembly not rise or lower. or heater circuit is open. box and check resistance between
terminals 1 and 2, and 3 and 4 at
· Thermister connector is heater connector (it should read
disconnected or thermister circuit is about 140 W).
open. Replace heater and check operation.
· Thermister / heater connectors (in · Check voltage at heater connector

control box) are incorrectly at power cont board assembly.
connected. If 100V AC is not supplied, relay on
relay board or SSR is damaged.
· Board failure. Replace power cont board assembly.
· Replace mainboard assembly and

check operation.
· Replace thermister and check

operation.
· Caution : Improper installation of

thermister may prevent thermister
from detecting temperature, resulting
in blown temperature fuse inside
heater.
Adjustment Wiping operation cause nozzle · Wipe position is incorrect. · Using self-diagnosis function, check
Cleaning clogging. and adjust wipe position.
· Wipe is dirty.
· Clean or replace wipe and check
· Wipe cleaner is dirty. operation.
· Ink or dirt attaches around head · Replace wipe cleaner and check
nozzle. operation.
· remove head and clean nozzle face

with non-woven cloth dampened in
Jetwash. Do not touch nozzle face.
Or replace head and check operation.
Adjustment Nozzles are clogged or ink ejects · Improper capping. · Adjust cap height/position and
Mechanical incorrectly even after cleaning. check operation.
Electrical · Cap rubber deformed or shrunk.
Environment · Replace cap rubber and check
Cleaning · 3-way valve on subtank is operation.
Ink damaged.
· Replace 3-way/2-way valves and
· 3-way valve for waste fluid is check operation.
damaged.
· Check for air leak at ink bottle.
· Air leaks at ink bottle.
· Replace ink bottle and check
· Defective filter (especially near operation.
head).
· Replace filter and check operation.
· Head completely clogged.
· Adjust working temperature /
· Board failure. humidity correctly.
· Too high head height (incorrect ink · Replace head or clean head with
discharge). specified cleaning kit and check
operation.
· Ink is aged.
· Replace Head Board assembly,
mainboard assembly and check
operation.
· Adjust head height to 2.0 – 2.3 mm

· Replace ink with new one and

check operation.
170 AP-74020, Rev 3.0 – 26/06/01

Electrical No printing or partial printing. · Head failure. · Check if oscillation noise is heard.
Adjustment (Ink refilling is performed
normally) · Poor connection of connectors. · Check if working temperature and
humidity respectively fall in following
· Clogged filter. ranges.
15 – 35°C
· Board failure. 20 – 80%RH
· Poor cleaning. · Check each head for 78V voltage.

If proper voltage is not supplied,
· Defective 3-way valve. defective or inappropriately adjusted
36V power supply / head board
assembly may be the cause. Check
if output of 36V power supplies (two)
is adjusted to 38.9 – 39.0V.
If 36V power supply output is
incorrect, adjust it as follows : First
voltage adjusting knob fully counter
clockwise and turn power on. Then
slowly turn voltage adjusting knob
clockwise to obtain appropriate
voltage.
If voltage not rise, exchange left and
right 36V power supplies and check
voltage. Or, replace 36V power
supply unit, power cont board
assembly and check operation.
· Print nozzle check patterns. If

machine prints only either odd
number column or even number
column pattern, head is damaged.
Replace head and check operation.
·Check ink supply route.

Print quality To much ink scattering. · Density setting is too dense. · Lower density and check operation.
Setting
Mechanical · Head is dirty with dust. · Perform powerful cleaning.
· Inappropriate head ink ejection · Enter key ink ejection wave form
wave form setting (T1, T2, T3 values parameter corresponding to head No.
to be changed). inscribed on head or decrease T3
value and check operation.
· Poor contact at head connectors.
· Adjust wipe position and check
· Defective wiping. operation.
· Head failure. · Clean or replace wipe rubber and

check operation.
· Clean head with specified cleaning

equipment.
Print quality All nozzles eject ink, resulting in · Head failure. · Upgrade C-base board assembly to
Electrical full face printing. revision B and check operation.
· Connectors not connected.
· Board failure. check operation.
· Replace 3-way valve above subtank

Print quality Printing density dispersed. · Platen heater temperature not · Lower platen heater temperature or
Mechanical suited for media turn off platen heater end check
Environment operation.
· Media is slipping or adhering.
· Adjust working temperature or
· Dirt on media (oil, etc) humidity to specification.
· Inappropriate head height. · Adjust height to 2.0- 2.3 mm using

head height adjusting jig and check
· Head failure. operation.

equipment.

equipment.
171 AP-74020, Rev 3.0 – 26/06/01
Print quality Y-axis (main scan) lines look · Improper setting of head ink · Enter key ink ejection wave form
Adjustment cracked. ejection wave form (T1, T2, T3 parameter corresponding to head No.
Electrical values to be changed). inscribed on head and check
Media operation.
· Dirt on head.
· Adjust wipe position and check
· Defective wiping. operation.
· Defective ink. · Clean or replace wipe rubber and

check operation.
· Dirt on timing fence.
equipment.
· Clean or replace timing fence and

check operation.
· Replace ink and check operation.

Print quality White lines are created along Y- · Nozzle clogged. · Perform cleaning / powerful
Adjustment axis (main scan). cleaning and check operation.
Electrical · Unstable media feeding.
Media · Check if media rolling condition is
· Media feeding not synchronized. eccentric. Or, replace media and
check operation.
· Gap between media and roller.
· Adjust head position, LF, X distance
· Poor ink permeation in media. accuracy and check operation.
· Poor adjustment of X-axis · Adjust gap position and check

accuracy. operation.
· Replace Y-axis motor assembly and

check operation.
Print quality Share in printing along Y-axis · Dirt on timing fence. · Clean or replace timing fence and
Adjustment (main scan). (Unidirectional / check operation.
Electrical Bidirectional) · Poor adjustment of Y-axis distance
Media accuracy. · Adjust head inclination, CCW print
Colours to be mixed are not position, repeatability print position
correctly laid over each other. · Loose steel belt. and check operation.
Distance accuracy along Y-axis is · Defective pulley (sealer peeling off). · Adjust steel belt tension or replace
poor. steel belt and check operation.
· Y-axis motor failure.
· Replace motor assembly or
· Share in printing due to wrinkles on synchronizing belt and check
media. operation.
· Lower platen heater temperature or

turn platen heater off and check
operation.
· Replace media with recommended

one and check operation.
Print quality Distance accuracy along X-axis · Poor adjustment of X-axis distance · Readjust head position, LF, X-axis
Adjustment (sub scan) is poor. accuracy. distance accuracy and check
Electrical operation.
Mechanical · Loose screws at coupling.
Media · Additionally tighten coupling / split
· Defective grid roller. coupling screws and check operation.
· X-axis motor failure. · If grid roller is damaged or dirt with

foreign objects, clean or replace it
· Defective pulley (sealer peeling off). and check operation.
· Defective pressure roller. · Replace X-axis motor assembly and

check operation.
· This can occur with media other
than recommended. · Replace pressure roller assembly
· his can occur because media
attached to paper guide F due to · Replace media with recommended
static electricity. one and check operation.

humidity to specification and check
operation.
172 AP-74020, Rev 3.0 – 26/06/01
Print quality Lines along X-axis (sub scan) not · Media other than recommended is · Replace media with recommended
Media smooth. used. one and check operation.
Environment
Adjustment · Poor adjustment of X-axis · Check if working temperature and
Mechanical accuracy. humidity respectively fall in following
Electrical ranges.
· Improper setting of head discharge 15 – 35°C
wave form (T1, T2, T3 values to be 20 – 80%RH
changed).
· Readjust head position, LF, X-axis
· Loose screws at coupling. distance accuracy and check
operation.
· Defective grid roller.
· Additionally tighten coupling / split
· X-axis motor failure. coupling screws and check operation.
· Defective pulley (sealer peeling off). · If grid roller is damaged or dirt with
foreign objects, clean or replace it
· Defective pressure roller. and check operation.
· This can occur with media other · Replace X-axis motor assembly and
than recommended. check operation.
· This can occur because media · Replace pressure roller assembly

attached to paper guide F due to and check operation.
static electricity.
humidity to specification and check
operation.
Operation Right angle accuracy is poor. Poor setting of media. · Reset media and check operation.
Mechanical
Loose screws at coupling. · Additionally tighten coupling / split
coupling screws and check operation.
Operation Long media printing not available · Due to HOST TIME OUT. · Set larger value at printer side
Electrical (Machine stops in the interim). HOST TIME OUT time or disable it
Spec. · Defective board. and check operation.
· Defective cable. · Replace mainboard assembly and

check operation.
· Printer driver not compatible.
· Replace printer cable with IEEE-
1248 compliant one and check
operation.
· Adjust printing length within

specified range of RIP or printer
driver.
Environment Nozzles are clogged when · Due to working environment. · Check if working temperature and
Adjustment performing 100% full face single humidity respectively fall in following
colour printing on long media. · Improper setting of head ink ranges.
ejection wave form (T1, T2, T3 15 –35°C
values to be changed). 20 – 80%RH
· Enter ink ejection wave form

parameter corresponding to head No.
inscribed on head and check
operation.
Media Ink drips or is blurred when · Media other than recommended is · Replace media with recommended
Adjustment performing mixed colour full face used. one and check operation..
Ink printing.
· Poor wiping. · Shorten wipe time and check
operation.
· Platen heater is off.
· Clean or replace wipe rubber and
· Defective ink. check operation.
· Ink ejection amount too much. · Adjust platen heater temperature to

suitable value for media and check
operation.
· Reduce print density and check

operation.
· Replace ink add and check

operation.
173 AP-74020, Rev 3.0 – 26/06/01

Mechanical Dots not demanded are printed at Dirt on timing fence. · Clean or replace timing face and
Electrical certain positions or some dots are check operation.
missing. Board failure.
· Replace mainboard assembly or
SIMM and check operation.
Environment Media becomes dirty during · Gap between media and roller. · Check if working temperature and
Adjustment sequential printing. humidity respectively fall in following
Electrical · Poor wiping. ranges.
Mechanical 15 – 35°C
· Board failure. 20 – 80%RH
· Solenoid valve failure. · Replace media with recommended

· Shorten wipe time and check

operation.

check operation.
· Replace C-BASE board assembly

· Replace solenoid valve on subtank

Environment Nozzles are clogged during · Due to working environment. · Check if working temperature and
Adjustment printing on long size media. humidity respectively fall in following
Electrical · Poor wiping. ranges.
Mechanical 15 – 35°C
· Defective filter. 20 – 80%RH
· Board failure. · Shorten wipe time and check

operation.
· Solenoid valve failure.
· Head failure. check operation.
· Replace filter and check operation.
· Replace C-BASE board assembly

· Replace solenoid valve on subtank

· Replace head and check operation.

Operation Density or printing positions are · Media edges not held by pressure · Set media correctly.
Media different between left and right rollers.
Mechanical sides of media. · Check if suction fan is operating.
· Gap between media and roller.
· Lower platen heater temperature or
· Dirt or scratch on timing fence. turn platen heater off and check
operation.
· Replace media with recommended

· Clean or replace timing fence and

check operation.
Mechanical Ink is not stirred within specified · Mixing belt transfer belt removed. · Disassemble supply base and
Transport time. reassemble.
procedure · Stirrer not put in ink bottle.
Electrical · Put in ink bottles (not in waste fluid
· Mixing magnet attached to spin and Jetwash bottles.)
motor is removed.
· Replace spin motor.
· Mixing motor spin motor failure.
· Replace subboard assembly or
· Board failure. TBL-BOT board assembly and check
operation.
174 AP-74020, Rev 3.0 – 26/06/01

Mechanical Ink overflows from maintenance · Solenoid valve failure. · Replace 3-way valve for waste fluid
Electrical box. and check operation.
· Blocked waste fluid hole.
· Check if maintenance box /
· Blocked manifold. manifold is blocked with dust.
· Bent waste fluid tube. · Check waste fluid tubes for bent.
· Improper installation of · Check if TT spacers in maintenance

maintenance box. bow are properly installed and
tightened.
Cleaning Abnormal noise is heard when · Dirt on cursor bearing and bearing · Clean bearing / bearing rail and
Mechanical head moves. rail. check operation.
· Damaged cursor bearing. · Replace cursor shaft assembly and

check operation.
· Loose cursor retaining screws.
· Additionally tighten cursor shaft
retaining screws and check operation.
Media is not automatically · [AUTO] key not pressed. · Set to auto wind. Or, manually
rewound. operate wind motor.
· Scroller not set properly.
· Set scroller and check that limit
· Wind switch failure. switch activates (adjust wind switch
so that it turns off when scroller is
· Loose screws for gears in unit. raised by about 1 mm).
· Wind sensor failure. · Additionally tighten screws retaining

drive shaft in wind unit and check
· Motor failure. operation.
· Winder paper core is excessively · Replace switch / sensor / motor and

eccentric. check operation.
· Media heavier than specified is · Replace winder paper core and

used. check operation (wind paper core
must have eccentricity of 5 mm or
· Board failure. less).
· Check if media weight is 20kg or

less.
· Replace TBL-BOT board assembly

or subboard assembly and check
operation.
Media not sucked. · Vacuum fan connector · Check vacuum connectors.
disconnected.
· Replace vacuum fan and check
· Vacuum fan failure. operation.
· Board failure. · replace subboard assembly and

check operation.
Abnormal noise from vacuum fan. · Improper cable routing causes fan · Reroute fan cable.
vanes to hit cables.
· Replace vacuum fan and check
· Defective vacuum fan. operation.
Machine will not enter on-line Mismatched centronics spec. · Use the same transfer protocol and
mode (centronics, network) Defective printer cable. check operation.
Board failure.
· Replace printer cable with IEEE-
1248 compliant one and check
operation.

check operation.
HDD not recognized. · HDD is not properly installed. · Turn power off and insert HDD until
seated (If Subboard assembly
· HDD failure. revision is “A”, its relay switch
interfere with HDD. Assembly
· Board failure. version up is needed).
· Replace HDD, Extension board

assembly / subboard assembly /
operation.
175 AP-74020, Rev 3.0 – 26/06/01

Assembly Head Voltage is too low or too · Connectors not connected properly. · Check on-chip head cable
Adjustment high. connection.
· Improper voltage adjusting volume
position. · Check if output of 36V power
supplies (two) is adjusted to 38.9 –
· Head Failure. 39.0V.
If 36V power supply output is
· Power supply failure. incorrect, adjust it as follows : First
voltage adjusting volume fully counter
· Board failure. clockwise and turn power on. Then
slowly turn voltage adjusting volume
clockwise to obtain appropriate
voltage. If voltage does not rise,
exchange left and right 36V power
supplies and recheck voltage. Or,
replace 36V power supply unit /
Power cont board assembly and
check operation.
·Replace head and check operation.

Pars Newly installed SIMM not · SIMM is not installed correctly. · Remove SIMM, clean socket and
Cleaning recognized. reinstall SIMM. Then check
· Defective SIMM. operation.
· Replace SIMM and check

operation.
Cleaning Machine operates abnormally · Origin detector failure. · Clean or replace timing encoder
Assembly when detecting origin. and check operation.
Mechanical · Origin flag does not reach origin
detector. · Adjust origin flag and timing
encoder positions and check
· Board failure. operation.
· Replace headboard assembly,

operation.
Driver data Machine does not exit from data Printer driver version is old. · Use Windows95 printer driver of
reception mode even after it Improper data transferred. version 1.01 or later and check
finished printing. operation (this symptom will not occur
with NT/Mac).
· Ending code not sent from host.

Check host (driver) setting.
Data Machine hangs up when receiving Data format mismatch. · Make machine print with either of
Cable data. Defective printer cable. MH-GL2, RTL or RTL-PASS data
Electrical Board failure. formats and check operation.
· Use IEEE-1248 compatible printer

cable and check operation.

check operation.
Data Machine stops for a long time Data transfer is too slow (Host · Data transfer demand is excessive
during print operation. failure). for current Host CPU. Replace Host
Resolution is excessively high. and check operation.
· Reduce resolution and check

operation.
Adjustment Power OFF sequence not · waste fluid / Jetwash / ink bottle · F/W of version 1.02 or earlier ends
Electrical performed correctly. sensor failure. power off sequence when any of
cover / lever / waste fluid / nozzle
· Board failure. cleaner / ink bottle sensors activates.
Update F/W to version 1.03 or later
· Replace sensors one by one and

check operation.
· replace subboard assembly and

check operation.
176 AP-74020, Rev 3.0 – 26/06/01

Environment Power ON sequence not · Unstable input power. · Check capacity of input power.
Adjustment performed correctly.
Electrical · Waste fluid / Jetwash / Ink bottle · Replace sensors one by one and
sensor failure. check operation.
· Board failure. · Replace power supplies /

operation.
· Replace subboard assembly and

check operation.
Operation No display on panel. Power is not on. · Turn power ON.
Environment Unstable input power.
Electrical Board failure. · Check capacity of input power.
· Replace 5V power supply /

mainboard assembly ands check
operation.
177 AP-74020, Rev 3.0 – 26/06/01

178 AP-74020, Rev 3.0 – 26/06/01

9. Appendix
9.1. Introduction.
This section provides the machine maintenance information and disassembly drawings for reference.
179 AP-74020, Rev 3.0 – 26/06/01

9.2. Tube Routing Drawing.
180 AP-74020, Rev 3.0 – 26/06/01

181 AP-74020, Rev 3.0 – 26/06/01

182 AP-74020, Rev 3.0 – 26/06/01

183 AP-74020, Rev 3.0 – 26/06/01

9.3. Wiring diagram.
184 AP-74020, Rev 3.0 – 26/06/01

185 AP-74020, Rev 3.0 – 26/06/01

186 AP-74020, Rev 3.0 – 26/06/01

187 AP-74020, Rev 3.0 – 26/06/01

9.3.1. Electric Cable Connection Compatibility Chart.
For destinations of wiring harnesses, refer to the table mentioned below.
No. DWG No. Cable name

E1 EA-47732 Ink sense cable assembly
E5 - -
E6 - -
E7 - -
E8 - -
E9 - -
E10 EA-47737 Head cooling fan cable assembly
E11 EA-47731 Timing encoder assembly
E12 EA-47730 Paper edge sensor assembly
E13 EA-47729 Head/base cable assembly
E14 - -
E15 - -
E16 - -
E17 - -
E18 - -
E19 EA-47703 Table cable 2 assembly
E20 EA-47725 Lever sensor assembly
E21 EA-47723 Cover switch assembly
E22 EA-47723 Cover switch assembly
E23 EA-47717 Paper sensor cable assembly
E24 EA-47717 Paper sensor cable assembly
E25 EA-47729 Head / base cable assembly
E27 EA-47736 On-chip head cable assembly
E31 EA-47727 Bare cable assembly
E34 EA-47728 Y cable assembly
E38 - -
E39 - -
E40 EA-47699 Y motor extension cable assembly
(E40) EA-47700 Y encoder extension cable assembly
E41 EA-47701 Panel cable assembly
E42 EA-47715 Tape wire
E45 EA-47682 Sub DC cable assembly
E46 EA-47683 HV DC cable assembly
E47 EA-47771 HC MAIN cable assembly
E48 EA-47679 AC control cable assembly
E50 EA-47709 VFAN cable assembly
E51 EA-47710 Platen thermister cable assembly
E52 EA-47710 Heater control cable 1 assembly
188 AP-74020, Rev 3.0 – 26/06/01

E55 EA-47680 POWER switch assembly
E56 EA-47714 C BOX fan
E57 EA-47689 AC inlet assembly
E58 EA-47691 Power AC cable assembly
E59 EA-47770 HC AC cable assembly
E60 EA-47770 HC AC cable assembly
E65 EA-47696 5V Power DC cable assembly
E69 EA-47692 HC Power DC cable assembly
E70 EA-47772 HC HV cable assembly
E71 EA-47772 HC HV cable assembly
E72 - -
E73 - -
E74 - -
E75 - -
E76 - -
E77 - -
E78 - -
E79 - -
E80 - -
E81 - -
E82 - -
E83 - -
E84 - -
E85 - -
E86 - -
E87 EA-47740 Maintenance unit position sensor cable
E91 - -
E92 EA-47718 Rewind unit cable assembly
E93 EA-47721 Rewind sensor cable assembly
E94 EA-47739 Tank sensor cable assembly
189 AP-74020, Rev 3.0 – 26/06/01

9.4. Explanation of the valves.

Name Liquid / Air 3P / 2P Function
Waste Valve K INK 2P Sucks out black-ink from the head through the capping
station.
Waste Valve C INK 2P Sucks out cyan-ink from the head through the capping
station.
Waste Valve M INK 2P Sucks out magenta-ink from the head through the
capping station.
Waste Valve Y INK 2P Sucks out yellow-ink from the head through the capping
station.
Waste Valve P INK 3P Drains the capping station.
Valve MK INK 2P Arranges the black-ink flow from the bottle to the
subtank.
Valve MC INK 2P Arranges the cyan-ink flow from the bottle to the
subtank.
Valve MM INK 2P Arranges the magenta-ink flow from the bottle to the
subtank.
Valve MY INK 2P Arranges the yellow-ink flow from the bottle to the
subtank.
Valve W JETWASH 2P Arranges the jetwash flow from the bottle to the Valve
P7.
Valve P1 AIR 3P Controls the outgoing air.
Valve P2 AIR 3P Controls the incoming air.
Valve P3 AIR 3P Connection between valve 1, valve 2 valve 5 and valve

6.
Valve P4 AIR 3P Controls the pressure in the J-, K-, C-, M- and Y- bottle.
Valve P5 AIR 3P Connection between valve 7, valve 4 and valve 3.
Valve P6 AIR 3P Control vacuum in waste bottle.
Valve P7 INK / AIR 3P Mixes jetwash with air.
Head Valve K INK 3P Controls the black-ink / jetwash flow from the subtank to
the head.
Head Valve C INK 3P Controls the cyan-ink / jetwash flow from the subtank to
the head.
Head Valve M INK 3P Controls the magenta-ink / jetwash flow from the
subtank to the head.
Head Valve Y INK 3P Controls the yellow-ink / jetwash flow from the subtank
to the head.
Head Valve A AIR 2P Controls the pressure in the subtanks.
190 AP-74020, Rev 3.0 – 26/06/01

Head Valve K
Head Valve C
Head Valve M
Head Valve Y
Head Valve A
Waste Valve K
Waste Valve C
Waste Valve M
Waste Valve Y
Waste Valve P
Valve P5
Valve P3
Valve P4
Valve P2
Valve P1
Valve MK
Valve MC
Valve MM
Valve MY
Valve W
Valve P6
Valve P7
191 AP-74020, Rev 3.0 – 26/06/01

9.5. Service Parts List.

For service parts, please refer to the table mentioned below.
Note :
Also please refer to the “exploded views”.
Nr Description Part No. Exploded View

1 X Motor Assy DE-33658B CAT0003B
2 Y Motor Assy DE-46883A CAT0004B
3 X Speed Reduction Belt DF-49802 CAT0003B
4 Speed Reduction Pulley Assy DF-40517C CAT0003B
5 Stirring Rod 35mm (order together with WN-4L799) E-11-4206-06 CAT0009B
6 Reflection Plate E-39-R1 CAT0010B
7 Transfer Belt for Agitation E-3X305K CAT0009B
8 Teflon Spacer E-CT-401 CAT0005B
9 Photo Micro Sensor E-EE-SPZ-301-A CAT0010B
10 Rotary Damper, L E-FRN-F1-L203 CAT0003B
11 Rotary Damper, R E-FRN-F1-R203 CAT0003B
12 Mini Fitting ( 2,5 - 3 mm ) E-VPI236 CAT0005B
13 Mini Fitting I Shape E-VPI336 CAT0005B, 7B
14 Mini Fitting L Shape E-VPL306 CAT0005B, 6B, 7B
15 Mini Fitting T Shape E-VPT306 CAT0005B
16 Main Tank Sensor ( for 110v unit) E-SG-2481
17 TT Spacer TT-0305 E-TT-0305 CAT0006B
18 Clean Stick E-TX712A
19 Power Supply Assy 5V/50W (for 110/220V) E-ZWS50PF-5/J CAT0008B
24 HV CONT Board Assy (for 110V) EA-3B528 CAT0008B
25 Power CONT Board assy (for 220V) EA-3B535 CAT0008B
26 Cord Heater Assy (for 220V) EA-3B536 CAT0002B
27 HV controller Board 110V/220V EA-3B542 CAT0008B
28 Power CONT Board Assy (for 110V) EA-3B464 CAT0008B
29 Main Board Assy EA-3B465 CAT0008B
30 Sub Board Assy EA-3B466 CAT0008B
31 Extention Board Assembly EA-3B467 CAT0008B
32 C-Base Board Assy EA-3B468 CAT0005B
33 Cord Heater Assy (for 110V) EA-3B499 CAT0002B
34 TBL-RE Board Assy EA-3B506 CAT0007B
35 TBL-RT Board Assy EA-3B507 CAT0007B
36 TBL-BOT Board Assy EA-3B508 CAT0009B
37 Head-CONT Board Assy EA-3B515 CAT0005B
38 Paper X Sensor F, R EA-46051 CAT0002B
39 Power Switch Assy EA-47680 CAT0008B
40 Thermister Assy EA-47711 CAT0002B
41 C Box Fan EA-47714 CAT0008B
42 Paper Sensor Cable Assy EA-47717 CAT0002B
43 Rewind Switch Assy EA-47720 CAT0009B
44 Winder Sensor Cable Assy EA-47721 CAT00010B
45 Cover Switch Assy EA-47723 CAT0003B
46 Lever Sensor Assy EA-47725 CAT0003B
47 Y Cable Assy EA-47728 CAT0004B
48 Head / Base Cable Assy EA-47729 CAT0005B
49 Paper Edge Sensor Assy EA-47730 CAT0005B
192 AP-74020, Rev 3.0 – 26/06/01

50 Timing Encoder Assy EA-47731 CAT0005B

51 ORG Sensor Assy EA-47733 CAT0005B
52 On-Chip Head Cable Assy EA-47736 CAT0005B
53 Head Cooling Fan Cable Assy EA-47737 CAT0005B
54 Head Cooling Fan Assy EA-47738 CAT0005B
55 Tank Sensor Cable Assy EA-47739 CAT0009B
56 Maint Unit Post Sensor Cable EA-47740
57 Solvent Resistant Sensor EA-47781 CAT0006B, 9B
58 Bare Cable Assy EA-47809 CAT0004B
59 Carriage WN-12112 CAT0005B
60 Main Bottle WN-24547 CAT0009B
61 Ink Bottle Assy WN-24576 CAT0009B
62 Wiping Unit Assy WN-24577 CAT0006B
63 Grid Roller Assy WN-38746 CAT0002B
64 2P Valve Assy WN-38794 CAT0005B, 7B
65 3P Valve Assy WN-38795 CAT0005B, 7B
66 Synchronous Belt WN-4L475 CAT0004B
67 Steel Belt WN-4L477 (Same as WN-4L896) CAT0004B
68 Head Pressure Spring WN-4L549 CAT0005B
69 Pump Assy WN-4L579 CAT0007B
70 Wiper Cleaning Roller WN-4L681 CAT0006B
71 Wiper Rubber WN-4L706 CAT0006B
72 Bearer WN-4L718 CAT0004B
73 Absorbing Plate WN-4L795 CAT0006B
74 Magnet Holder (order together with E-11-4206-06) WN-4L799 CAT0009B
75 Soft Tube 3 mm l = 25 mm WN-4L815
76 Soft Tube 2 mm l = 18 mm (Printhead) WN-4L825
77 Nozzle WN-4L828
78 Agitation Motor WN-4L834 CAT0009B
79 Cap Motor WN-4L835 CAT0006B
80 Bearing (3-9) WN-4L841 CAT0005B
81 Bearing(4-12) WN-4L842 CAT0005B
82 Coupling Assy WN-4L892 CAT0002B
83 Split Coupling WN-4L893 CAT0002B
84 Pressure Assy WN-4L894 CAT0004B
85 Y Return Pulley Assy WN-4L895 CAT0004B
86 Steel Belt Assy WN-4L896 (Same as WN-4L477) CAT0004B
87 Timing Fence WN-4L897 CAT0004B
88 Dual Pulley Assy WN-4L898 CAT0004B
89 Winder Motor Assy ( 1 st) WN-4L899 CAT0009B
90 Print Head Single Colour Assy WN-4L901 CAT0005B
91 Filter Assy WN-4L902 CAT0005B
92 Cursor Axis Assy WN-4L903 CAT0005B
93 Sub Tank Assy WN-4L904 CAT0005B
94 Panel Assy WN-4L905 CAT0001B
95 2M Tube For Albatros WN-4L913 CAT0005B, 6B, 7B
96 Mesh WN-4L980 CAT0006B
97 Winder Motor Assy ( Rev2) WN-4L995 CAT0009B
98 Torque Limitter Assy WN-4L999 CAT0009B
99 New Maintenance Box Cover WN-4M001 CAT0006B
193 AP-74020, Rev 3.0 – 26/06/01

9.6. Jig List.

No. Jig drawing Jig name Spec./description
No.
1 - - -
2 Being Carriage height setting jig Used to ensure a 8.5mm gap when installing carriage to
prepared Y-axis rail.
3 Available on Push-pull gauge 5kg push-pull gauge should be used to adjust X belt
the market tension to 4kg ± 200g.
4 Available on Push-pull gauge 200g push-pull gauge should be used to adjust Y steel
the market belt tension to 125g ± 20g.
5 JD-42050 Y tension attachment To be attached to the tip of Y steel belt tension push-pull
gauge.
Note :
A screw is needed to attach the Y tension attachment to the tip of the Y steel belt tension
push-pull gauge.
194 AP-74020, Rev 3.0 – 26/06/01

9.7. Head Cleaning kit.

This section illustrates the structure of the cleaning kit at the head along with the procedures to assemble
and clean its components.
9.7.1. Assembly Procedure.
To assemble the cleaning unit, follow the procedure below.
(1) Assembling Waste Fluid Container.
1) Open glass cover by pulling up the lever as shown in Figure A and press the ring inward to remove the
cover as shown in Figure B.
2) Remove the glass cover and silicon packing by pulling the ring outward. Replace the glass cover with
the plastic cover and reassemble the components. Then, install the assembled cover to the container
keeper as shown in Figure B.
195 AP-74020, Rev 3.0 – 26/06/01

(2) Cutting Tube.
From the thick tube (I.D.6, O.D.15, length 2m) which is an accessory of the compact air pump, make the
following short tubes : 100mm x 1.300mm x 1.250mm x 2.
(3) Assembling Cleaning Kit.
Assemble the cleaning kit referring to the figure below.
196 AP-74020, Rev 3.0 – 26/06/01

9.7.2. Head Cleaning Procedure.
(1) Preparation.
1) First, filter the necessary amount of Jetwash with 1µm filter (to be used in Step 3, 4).
2) Fill the ultrasonic cleaner with water up to the line on the inner wall of the vessel. Fill the thermos with
about 200ml water.
3) Fill the main tank with Jetwash filtered in Step 1 (about 500ml).
4) Wipe out all dirt from inside the beaker using KIM WIPE. Flash the beaker in the Jetwash filtered with a
1µm filter to remove all microscopic particles (repeat this two or three times). Then, fill the beaker with
the Jetwash filtered in Step 1 to about 300ml.
5) Adjust the ultrasonic cleaner and thermos temperatures to 45°C.
(2) Cleaning Procedure.
1) Install the head to the tube A (tube C remains open to air) and set all components as shown in figure.
Then activate the pump to make the 40 to 45°C Jetwash flow to the head and check for nozzle plugging
and inappropriate direction of ink the ejection.
2) Pull out tube B from the main tank and install it to the head. Activate the pump to make compressed air
(0.7kg/cm²) flow to the head. While doing so, wipe out the nozzle face with KIMWIPE EX-L. Also,
remove dirt from the head.
197 AP-74020, Rev 3.0 – 26/06/01

Caution :
Do not use a dirty KIMWIPE EX-L to wipe print head nozzles.
3) Restore the condition in step 1 (connect tube A to the head and tube B to the top of the main tank), make
the 40 to 5°C Jetwash flow to the head and check for nozzle clogging and inappropriate direction of ink
the ejection.
Lines off ejected Jetwash should be straight to the length of 12mm.
If OK, proceed to Step 8.
4) Connect the head to the tube C and activate the pump to suck the Jewash inside the head from the inlet.
Then, submerge the nozzle front ends in the Jetwash in the beaker on the ultrasonic cleaner. Activate
the ultrasonic cleaner and suck from the inlet for 10 seconds. After that, deactivate the pump and wait
10 seconds.
Note :
During the waiting time, the Jetwash in the main tank may leak from the tube A. To
prevent this, you may have to remove tube B from the pin at the top of main tank
and attach tube A instead.
5) Take out the head from the beaker and activate the pump to suck the Jetwash inside the head from the
inlet for about 10 seconds.
6) Restore the condition in step 2 and wipe out the head nozzle face with KIMWIPE EX-L while making
compressed air flow to the head. Then, restore the condition in step 1 and check for nozzle clogging and
inappropriate direction of the ejection while making 40 – 45°C Jetwash flow to the head. If the lines of
ejected Jetwash are all straight (not crossed) to the length of 12mm, proceed to Step 8.
7) Repeat Step 3 to Step 6 for about 20 minutes. If the head does not restore its normal operation after
that, perform Step 4 and clean the head in the ultrasonic cleaner for about 10 minutes. If the head is still
defective even after that, discard it.
8) Connect the head to tube C and suck the Jetwash inside the head from the inlet. Then, submerge the
nozzle front and in the Jetwash in the beaker on the ultrasonic cleaner. Activate the ultrasonic cleaner
and suck from the inlet for 10 seconds. After that, deactivate the pump and wait 10 seconds.
9) Take out the head from the beaker and activate the pump to suck the Jetwash inside the head from the
inlet for about 10 seconds.
10) Connect the head to tube B and wipe out the head nozzle face with KIMWIPE EX-L while operating the
pump to make compressed air (0.3 – 0.4 kg/cm²) flow to the head. Then, restore the condition in Step 1
and check for nozzle clogging and inappropriate direction of the ejection while making the 40 – 45°C
Jetwash flow to the head. The lines of discharged Jetwash should be all straight (not crossed) to the
length of 12mm (if not, return to Step 4).
11) Suck the Jetwash inside the head from the inlet for 10 seconds.
12) Connect the head to tube B. Activate the pump to make clean dry air flow to the head for one minute or
more, thereby dry up inside the head. Continue this operation until no Jetwash oozes out from the
nozzles.
198 AP-74020, Rev 3.0 – 26/06/01

13) Attach a low tack on the nozzle face and cut it along the outline of the head.
Note :
Dirty Jetwash used in the beaker may be one of the causes for a head cleaning
failure. If the Jetwash in the beaker is darkly coloured, discard it and use new
Jetwash filtered with a 1µm filter. (Slightly coloured Jetwash may be reused if it is
filtered with a 1 µm filter.
Condition :
· Vacuum (for sucking from inlet) : -20 - -40 cmHg
· Positive pressure (for supplying air or Jetwash) : 0.75kg/cm² (For Step 10 only : 0.3 – 0.4kg/cm²)
· Only Jetwash filtered with a 1µm filter must be used.
DWG No. Item

PJ-SOJW*8 Jetwash
E-EX-L KIMWIPE
E-JAWP04700 Omni-pore membrane
E-89-023-02 Filter mask (10 in one package)
E-T6-6937-01L Sanitary SQ glove
E-SLFA05010 Filter
WN-4L719 Filter
E-8403 Low tack tape
199 AP-74020, Rev 3.0 – 26/06/01

9.8. Exploded View.

The following pages show the explored view of the machine.
q PJ-1304NX Cover (CAT0001B)

q PJ-1304NX X-axis driving (CAT0002B)
q PJ-1304NX Left / right side panel (CAT0003B)
q PJ-1304NX Y-axis driving (CAT0004B)
q PJ-1304NX Head (CAT0005B)
q PJ-1304NX Cap Unit (CAT0006B)
q PJ-1304NX Ink supply unit (CAT0007B)
q PJ-1304NX Control box (CAT0008B)
q PJ-1304NX Rewinder supply base (CAT0009B)
q PJ-1304NX Stand (CAT0010B)
q PJ-1304NX Layout of the ink tube (CAT0011B)
200 AP-74020, Rev 3.0 – 26/06/01

Explored view Nov. 01. 2000
4L456
4L580
L
Bearer Ground Plate
4L982
Y Motor Assembly (A0)
4L898
38768
42051
WN-4L839
WN-3L840
WN-4L553
(spring)
M3
N-40190D
310
8(W)
8(W)
6(W) Black
1
WN-4L586
Magnet base
WN-4L518
Setting Form
NS-05030081
4L745
N-40196X
Main
Compression Coil Spring

E-C179
E-4ER-25
5
5
Filter Assembly
212 AP-74020, Rev. 3.0 – 26/06/01

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Maintenance Manual

PJ-1304NX Albatros Printer

MUTOH EUROPE N.V. AP-74020, Rev. 3.0 – 26/06/01

2 AP-74020, Rev. 3.0 – 26/06/01

COPYRIGHT © 2001 Mutoh Europe N.V. all rights reserved.

3 AP-74020, Rev. 3.0 – 26/06/01

4 AP-74020, Rev. 3.0 – 26/06/01

2. Trademarks used in this manual.

5 AP-74020, Rev. 3.0 – 26/06/01

6 AP-74020, Rev. 3.0 – 26/06/01

3. The term of warranty is shown in the guarantee.

7 AP-74020, Rev. 3.0 – 26/06/01

8 AP-74020, Rev. 3.0 – 26/06/01

MANUAL OBJECTIVES AND STRUCTURE

1. Purpose of this manual

2. Structure of this manual

9 AP-74020, Rev. 3.0 – 26/06/01

Use the following documents for better understanding this manual.

· User’s Manual (Basic)

4. Symbols used in this manual

Warning Term Meaning

Indicates a danger that can cause death or

Indicates a danger that can cause slight or medium

Indicates information needing a special attention.

10 AP-74020, Rev. 3.0 – 26/06/01

11 AP-74020, Rev 3.0 – 26/06/01

12 AP-74020, Rev 3.0 – 26/06/01

5. Check and attention points. 117

6. Self diagnosis. 123

13 AP-74020, Rev 3.0 – 26/06/01

14 AP-74020, Rev 3.0 – 26/06/01

15 AP-74020, Rev. 3.0 – 26/06/01

16 AP-74020, Rev. 3.0 – 26/06/01

17 AP-74020, Rev 3.0 – 26/06/01

1.2. Types of Meanings of Warning Messages

Warning Term Meaning

Indicates a danger that can cause death or

Indicates a danger that can cause slight or medium

Indicates information needing a special attention.

18 AP-74020, Rev 3.0 – 26/06/01

1.3. General Safety Rules

Þ Do not operate the machine with any covers open.

Þ Do not use solvent such as benzine thinner to clean this machine.

19 AP-74020, Rev 3.0 – 26/06/01

1.4. Special Safety Rules

20 AP-74020, Rev 3.0 – 26/06/01

1.5. Warning Label.

1.5.1. Warning Label Maintenance.

21 AP-74020, Rev 3.0 – 26/06/01

1.5.2. Warning Label Positions.

The warning label positions are shown below.

22 AP-74020, Rev 3.0 – 26/06/01

23 AP-74020, Rev 3.0 – 26/06/01

1.6. Air Purification system.

24 AP-74020, Rev 3.0 – 26/06/01

25 AP-74020, Rev 3.0 – 26/06/01

< Outstanding weatherproof performance>

< Media quality kept to the maximum >

< Printing speed>

192 384 DM DP BD Speed

26 AP-74020, Rev 3.0 – 26/06/01

< Various printing modes >

The overall output quality in a specific mode is mainly influenced by 3 factors :

Please note however: