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Falcon II Outdoor

Maintenance Manual

Mutoh America Inc.

Summary of content (349 pages)

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Falcon II Outdoor Maintenance Manual Mutoh America Inc.
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Falcon II Outdoor series printers – Maintenance Manual COPYRIGHT NOTICE COPYRIGHT © 2003 Mutoh America Inc. All rights reserved. This document may not be reproduced by any means, in whole or in part, without written permission of the copyright owner. This document is furnished to support the Mutoh’s Falcon II Outdoor series Printer.
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Falcon II Outdoor series printers – Maintenance Manual Important Notice This product has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the product is operated in a commercial environment.
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Falcon II Outdoor series printers – Maintenance Manual TABLE OF CONTENTS 1. Safety Instructions ......................................................................................................................... 11 1.1. Introduction............................................................................................................................. 11 1.2. Warnings, Cautions and Note ................................................................................................. 11 1.3.
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Falcon II Outdoor series printers – Maintenance Manual 4.2.4. Removing the front cover ................................................................................................ 41 4.2.5. Removing the carriage cover ........................................................................................... 43 4.2.6. Removing the panel unit assembly .................................................................................. 44 4.2.7. Removing the Y rail cover....................................
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Falcon II Outdoor series printers – Maintenance Manual 4.7.8. Replacing the cursor roller assembly............................................................................. 118 4.8. Replacing the Maintenance Area .......................................................................................... 122 4.8.1. Replacing the maintenance assembly ............................................................................ 122 4.8.2. Replacing the cleaner.................................................
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Falcon II Outdoor series printers – Maintenance Manual 5.5.7. Band Feed Correction Menu (X Length) ....................................................................... 175 5.5.8. Top & bottom adjustment menu .................................................................................... 177 5.5.9. P_REAR sensor position adjustment menu ................................................................... 179 5.5.10. Test print menu .....................................................................
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Falcon II Outdoor series printers – Maintenance Manual 6.3.3. MAC address write enable menu................................................................................... 222 7. Adjustments ................................................................................................................................. 224 7.1. Introduction........................................................................................................................... 224 7.2. Adjustment.......................
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Falcon II Outdoor series printers – Maintenance Manual 8.5. Jig and Tool List ................................................................................................................... 269 8.5.1. Required Tools............................................................................................................... 269 8.6. Lubrication/Bonding ............................................................................................................. 271 8.7. Transportation of Machine.......
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Falcon II Outdoor series printers – Maintenance Manual 10.4.18. Waste bottle................................................................................................................ 349 10 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 1. SAFETY INSTRUCTIONS 1.1. INTRODUCTION This chapter explains the meaning of safety terms for personnel who operate this equipment, important safety instructions and the positions of the warning labels. Important : • Be sure to follow all instructions and warnings in this manual when using the equipment. 1.2.
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Falcon II Outdoor series printers – Maintenance Manual ¾ Be sure that the following is performed before replacing parts. Turn the printer off. Disconnect the power cable from the electric outlet. Not doing so may cause electric shock or damage to the electric circuit. Unplug the cables connected to the printer. 1.3.2. Caution ¾ Assembling and disassembling the printer are possible only for the parts shown in the operation manual.
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Falcon II Outdoor series printers – Maintenance Manual ¾ Make sure that the power of the printer is OFF before installing the firmware. Installing the firmware with the power ON may damage the main substrate assembly or data may not be properly installed. ¾ Ensure there is sufficient space around the printer when performing maintenance work. ¾ Maintenance must be done by more than one person for : detaching the printer from the stand or attaching it. packing the printer for transportation. 1.4.
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Falcon II Outdoor series printers – Maintenance Manual No. 1 Type CAUTION VORSICHT ATTENTION > Do not open the front cover or touch the media during printing.This will result in poor image quality. > If no printing is to be done for some time, remove the media and put the hold lever in the up position. Otherwise the media may lift up and become wrinkled and you will not be able to obtain good printing results.
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Falcon II Outdoor series printers – Maintenance Manual (2) Back Part No. 3 Type CAUTION THIS UNIT HAS TWO POWER SUPPLY CORDS, WHEN WiNDING UNIT IS PROVIDED. TO REDUCE THE RISK OF ELECTRICAL SHOCK, DISCONNECT ALL POWER SUPPLY CORDS BEFORE SERVICING. 15 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 1.5. OPERATION PROCEDURE LABELS The handling, attachment locations and types of operation procedure labels are explained below. Your printer has labels, which give simple explanations of operations that require particular care. Read and understand the locations and contents of these labels thoroughly before performing your work. No.
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Falcon II Outdoor series printers – Maintenance Manual 2. PRODUCT OVERVIEW 2.1. INTRODUCTION This chapter explains the features, part names, and functions of the printer. 2.2. FEATURES The features of the printer are explained below. (1) High speed output Both models feature new print heads and achieve high speed printing. They also offer printing widths up to 1263 mm in 50-inch, 1643 mm in 64-inch and 2230 mm in 87-inch spec possible.
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Falcon II Outdoor series printers – Maintenance Manual 2.3. PART NAMES AND FUNCTIONS Part names and functions are explained below. 2.3.1. Front No. 1 Name Operation panel 2 3 Ink compartment Front cover 4 Pressure rollers 5 Maintenance cover 6 Stand Function This panel is used to set operational conditions, the status of the printer, and other functions. This is the place for installing ink cartridges. This cover keeps the operator safe from the drive parts of the printer while it is operating.
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Falcon II Outdoor series printers – Maintenance Manual 7 Media cut groove 8 Carriage cover 9 10 Foot switch Paper Guide Only onto the Falcon II Outdoor 4H printer ! Used to cut the media straight when it is cut manually. Only onto the Falcon II Outdoor printer ! This is a cover to protect the user from the internal components of the unit. This is opened during following operation : ¾ When cleaning the cleaning wiper This switch is used to raise and lower the pressure rollers.
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Falcon II Outdoor series printers – Maintenance Manual 2.3.3. Operation panel The operation panel is used to set operation conditions, display the status of the printer and set other functions. The names and functions of the operation keys and status lamps are explained below. (1) Operation Keys. No. 1 2 3 4 5 6 Name [POWER] key [F1] key [F2] key [F3] key [F4] key [MENU ↑] key 7 [MENU ↓] key 8 [ENTER] key Normal Turns the printer on and off. Executes the function assigned to F1.
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Falcon II Outdoor series printers – Maintenance Manual the next menu. (2) LCD monitor and status lamps. No. 10 Name LCD monitor Colour - 11 POWER lamp Green 12 ERROR lamp Red 13 DATA lamp Orange 14 MEDIA SET lamp Orange Status ON OFF Flashing OFF ON Flashing OFF ON OFF 15 ROLL lamp Orange 16 SHEET lamp Orange 17 HEATER lamp Orange ON OFF ON OFF ON Flashing OFF Function The monitor displays the operation status and error messages of the printer. The printer is on.
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Falcon II Outdoor series printers – Maintenance Manual 2.4.2. Setup menu display Indicates that you can make settings using the operation panel. Operations for printing can be conducted with the operation panel. Notes : ¾ Refer to the User’s Guide. 2.4.3. Self-diagnosis Function Display Indicates that you can make settings concerning adjusting the printer using the operation panel. Keys of the operation panel have the same names and functions as the display status of the setup menu.
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Falcon II Outdoor series printers – Maintenance Manual Step 2 : Press the [F1] key or [F2] key on the operation panel to change the parameter. Step 3 : Press the [POWER] key, and then press the [POWER] key again. 23 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 2.5. POSITION AND FUNCTION OF THE HEATING ELEMENTS 2.5.1. Falcon II Outdoor 2 heater printers Heater element Pre-heater (Heater A) Temperature 20 – 50°C Function → Open the pores to make the media more receptive for eco-solvent or eco-solvent plus™ ink. Dryer (Heater D) 20 – 50°C → Applying heating immediately after printing improves ink/media anchorage. → The dryer helps to make the media touch-dry before it reaches the automatic take-up system.
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Falcon II Outdoor series printers – Maintenance Manual Post-Fixer (Heater C) 20 – 70°C → The post-fixer finalizes the fixation process and helps to make the prints touch-dry. Dryer (Heater D) 20 – 50°C → The dryer completes the drying for compatibility with the take-up in combination with higher output speeds. → Stickiness of printed banner materials is improved. 2.5.3. 2 or 4 heater To verify if your printer is equipped with 2 or 4 heaters, please refer to the photo’s mentioned below.
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Falcon II Outdoor series printers – Maintenance Manual 3. SPECIFICATIONS 3.1. INTRODUCTION This section explains the specifications, optional parts and supplies, installation procedures for optional parts, and user support for this printer. 3.2.
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Falcon II Outdoor series printers – Maintenance Manual Interface Graphics Command Language Printers Power Consumption External Dimensions in mm (W x D x H) Weight Noise Level Standard Standard Items 50”- model 1100 VA 80 VA in stand-by mode 2700 x 750 x 1250 64”- model 1300 VA 80 VA in stand-by mode 3100 x 750 x 1250 87”- model 1400 VA 100 VA in stand-by mode 3700 x 750 x 1250 170 kg 195 kg 215 kg Operating: 54 dB or less VCCI (Class A), FCC (Class A), UL, CE, CCIB Hard Disk: 20.
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Falcon II Outdoor series printers – Maintenance Manual 3.3. INTERFACE SPECIFICATIONS This section explains the specifications for the interfaces supported by this product. 3.3.1. Centronics Bidirection Parallel Interface:IEEE1284) (1) Interface Specifications AP-74065, Rev : 1.
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Falcon II Outdoor series printers – Maintenance Manual Shield construction Characteristic impedance Metallic tape + weaving (double shielded cable) 62 Ω 3.3.2. Network Interface (Optional) Specifications Item NetWork Type NetWork I/F Protocol Mode Functions Specifications Ethernet IEEE802.3 10 Base-T,100 Base-TX (RJ-45 connector, twisted pair cable) * Automatic switching TCP/IP • ftp • lpr • socket • Automatic protocol recognition • Transmission speed up to 4 MB/s • Network environment setting by Web.
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Falcon II Outdoor series printers – Maintenance Manual 3.4. INSTALLATION The Installation of the unit is explained below. 3.4.1. Conditions of the installation environment Important : ¾ Do not place the printer in following areas. Doing so may result in the printer falling over and causing injury. Unstable surfaces Slanted place Where vibration of other machines is transmitted. ¾ Do not sit on the printer or put heavy things on the printer. Doing so may cause the printer to fall and injure people.
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Falcon II Outdoor series printers – Maintenance Manual Notes : ¾ Avoid the following places with regard to temperature or humidity. If doing so, it may affect the printing result. Places where the temperature of humidity may rapidly change even though it is within the correct range. Places where there is direct sunlight or strong light. Places where there is direct air from the air conditioner.
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Falcon II Outdoor series printers – Maintenance Manual 4. PARTS REPLACEMENT 4.1. INTRODUCTION This chapter explains the procedures for replacing and removing maintenance parts. Important : ¾ Before replacing parts, be sure to perform following operations. Turn the power OFF. Remove the electrical cable from the socket. Otherwise, you may suffer electric shock or the machine’s electric circuits may be damaged. Disconnect all cables from the machine. Not doing so could cause damage to the printer.
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Falcon II Outdoor series printers – Maintenance Manual 4.2. REMOVING THE COVER When replacing any of the parts inside the printer, it is necessary to remove all covers. The procedures for removing the covers are given below. 1 = I/H cover 2 = Side cover R 3 = side Cover L 4 = Front cover 5 = Panel unit assembly 6 = Y-rail cover 7 = Front paper guide 8 = Rear paper guide 33 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 4.2.1. Removing the I/H cover Step 1 : Remove the ink cartridge. Step 2 : Open the I/H cover lid. Step 3 : Remove the 4 screws fixing the I/H cover. Step 4 : Remove the I/H cover and I/H cover lid. 1 = Screws (M3x12) fixing the I/H cover Step 5 : Remove the 2 screws fixing the ink cover sensor. Step 6 : Remove the ink cover sensor.
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Falcon II Outdoor series printers – Maintenance Manual 4.2.2. Removing side cover R Step 1 : Remove the screw from the upper part of the side cover R. 1 = Screws (M4x12) on the upper part of the side cover R Step 2 : Remove the 2 screws from the bottom of side cover R. 1 = Screws (M4x16) on the side of the bottom of side cover R Step 3 : Remove the 3 screws from the back of the bottom of side cover R. 35 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 1 = Screws (M4x16) on the back of the bottom of side cover R 36 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual Step 4 : Remove the top of the side cover R. Step 5 : Remove the 4 bolts from the front and back of the inner surface on the bottom of side cover R and the front cover nut. 1 = Hexagon socket head cap screws (M4x16) 2 = Cover nut Step 6 : Remove the 6 bolts from the front and back of the bottom surface on the bottom of the side cover R. Step 7 : Remove the bottom of side cover R.
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Falcon II Outdoor series printers – Maintenance Manual 4.2.3. Removing side cover L Step 1 : Remove the screw from the side of the upper part of side cover L. 1 = Screws (M4x12) on the side of the upper part of the side cover L Step 2 : Remove the 2 screws from the front of the bottom of side cover L. 1 = Screws (4x16) on the back of the bottom of side cover L Step 3 : Remove the 3 screws from the back of the bottom of side cover L. 38 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 1 = Screws (M4x16) on the rear of the bottom part of the side cover L 39 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual Step 4 : Remove the 4 bolts and cover nut from the front and back of the inner surface on the bottom of side cover L. 1 = Hexagon socket head cap screws (M4x16) Step 5 : 2 = Cover nut Remove the 6 bolts from the front and back of the bottom surface on the bottom of side cover L. 1 = Hexagon socket head cap screws (M5x18) Step 6 : Remove the bottom of side cover L. Step 7 : Replace the parts inside the printer.
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Falcon II Outdoor series printers – Maintenance Manual 4.2.4. Removing the front cover Step 1 : Open the front cover. Step 2 : Remove the E ring on the left side. Step 3 : Remove the 4 screws on the left and right cover spindles. 1 = E ring Step 4 : 2 = Screws (M3x8) on the left and right cover spindles If the machine is a 50-inch model, remove cover spindle L, and then slide and remove the front cover. 1 = Cover spindle L 41 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual Step 5 : If the machine is 64 or 87-inch model, remove the E ring and the sensor cam, push the cover spindle L to the origin side and then slide and remove the front cover. 1 = Cover spindle L 3 = E ring Step 6 : 2 = Sensor cam Reinstall all parts in the opposite order of the removal procedure. 42 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 4.2.5. Removing the carriage cover Caution : Please note that this cover is only on a Falcon II Outdoor (2 heaters) printer. Step 1 : Remove the I/H cover. Step 2 : Remove side cover R. Step 3 : Remove side cover L. Step 4 : Remove the front cover. Step 5 : Remove the 4 screws fixing the carriage cover. Step 6 : Remove the carriage cover.
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Falcon II Outdoor series printers – Maintenance Manual 4.2.6. Removing the panel unit assembly Step 1 : Remove side cover R. Step 2 : Remove the panel tape power cord. Step 3 : Remove the 4 screws fixing the panel base. 1 = Panel unit assembly 3 = Tape wire 2 = Screws (M3x6) fixing the panel unit assembly Step 4 : Remove the panel unit assembly. Step 5 : Remove the 6 screws fixing the panel board assembly and the panel cover.
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Falcon II Outdoor series printers – Maintenance Manual Step 7 : Remove the 4 screws fixing the panel bracket and the panel board assembly. 1 = Screws (M3x8) fixing the panel board assembly Step 8 : Replace the panel board assembly. Step 9 : Reinstall all parts in the opposite order of the removal procedure. 45 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 4.2.7. Removing the Y rail cover Caution : Removing the Y rail cover, should be performed by at least two persons. Otherwise the Y rail cover may be deformed. Step 1 : Remove side cover R. Step 2 : Remove side cover L. Step 3 : Remove the front cover. Step 4 : Remove the carriage cover. Caution : Please note that this cover is only on a Falcon II Outdoor (2 heaters) printer.
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Falcon II Outdoor series printers – Maintenance Manual Step 6 : Remove the 6 screws from the front of the Y rail cover. 1 = Screws (M4x8) on the front of the Y rail cover Step 7 : Remove the 5 screws from the rear of the Y rail cover. ¾ If the machine is an 87-inch model, there are 8 screws on the rear Y rail cover. 1 = Screws (M4x8) on the rear of the Y rail cover Step 8 : Remove the Y rail cover. Step 9 : Replace the parts inside the printer.
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Falcon II Outdoor series printers – Maintenance Manual 4.2.8. Removing front paper guide Step 1 : Remove side cover L. Step 2 : Remove side cover R. Step 3 : Remove the front cover. Step 4 : Remove the carriage cover. Caution : Please note that this cover is only on a Falcon II Outdoor (2 heaters) printer. Step 5 : Remove the Y rail cover. Step 6 : Remove the screws from the top of front media guide. Notes : ¾ Please note that the amount of screws is size dependent.
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Falcon II Outdoor series printers – Maintenance Manual Step 7 : Remove the screws from the front of front media guide. Notes : ¾ Please note that the amount of screws is size dependent. Falcon II Outdoor 2 heater 1 = Screws on the front of front media guide Falcon II Outdoor 4 heater 1 = Screws on the front of front media guide Step 8 : Standing before the unit move the front paper guide towards you. Step 9 : Loosen the cables from their cable clamps.
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Falcon II Outdoor series printers – Maintenance Manual 4.2.9. Removing rear paper guide Step 1 : Remove side cover L. Step 2 : Remove side cover R. Step 3 : Remove the front cover. Step 4 : Remove the Y rail cover. Step 1 : Remove the screws from the top of the rear media guide. Notes : ¾ Please note that the amount of screws is size dependent. 1 = Screws on the rear paper guide Step 2 : Remove the screws from the rear of rear paper guide.
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Falcon II Outdoor series printers – Maintenance Manual Notes : ¾ Be sure not to damage the cables or connectors. Step 6 : Remove the rear paper guide. Step 7 : Replace the parts inside the printer. Step 8 : Reinstall all parts in the opposite order of the removal procedure. 51 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 4.2.10. Removing the head cover Step 1 : Remove the I/H cover. Step 2 : Remove side cover R. Step 3 : Remove side cover L. Step 4 : Remove the front cover. Step 5 : Remove the carriage cover. Caution : Please note that this cover is only on a Falcon II Outdoor (2 heaters) printer. Step 6 : Remove the Y rail cover. Step 7 : Unlock the head. Notes : ¾ Step 8 : Please refer to the ‘Head lock menu’.
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Falcon II Outdoor series printers – Maintenance Manual 1 = Screws (M3x8) fixing the head cover Step 10 : Remove the head cover. Step 11 : Replace the parts inside the printer. Step 12 : Reinstall all parts in the opposite order of the removal procedure. 53 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 4.2.11. Removing the maintenance cover Step 1 : Remove the I/H cover. Step 2 : Remove side cover R. Step 3 : Remove side cover L. Step 4 : Remove the front cover. Step 5 : Remove the carriage cover. Caution : Please note that this cover is only on a Falcon II Outdoor (2 heaters) printer. Step 6 : Remove the 6 screws fixing the maintenance cover.
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Falcon II Outdoor series printers – Maintenance Manual 4.3. REPLACEMENT OF THE HEATER ELEMENT To replace a heater element of the Falcon II Outdoor series printer, please follow the instructions mentioned in the explanation of the appropriate heater element. 1. Falcon II Outdoor : o 1. Replacing the front heater (Heater D) on a Falcon II Outdoor printer o 2. Replacing the rear heater (Heater A) on a Falcon II Outdoor printer 2. Falcon II Outdoor 4H : o 1.
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Falcon II Outdoor series printers – Maintenance Manual Step 4 : Remove the carriage cover. Step 5 : Remove the Y rail cover. Step 6 : Remove the front paper guide. Step 7 : Remove the front heater strip(s). Step 8 : Degrease the plate. Notes : ¾ Step 9 : Make sure the plate is cleaned properly. Dust, glue and other parts must be removed. Stick the front heater strip(s) onto the plate. Notes : ¾ ¾ Make sure that the strips connect properly.
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Falcon II Outdoor series printers – Maintenance Manual Step 11 : Reinstall all parts in the opposite order of the removal procedure. Notes : ¾ During reinstallation of the plate, make sure there are no cables stuck. 4.3.1.2.
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Falcon II Outdoor series printers – Maintenance Manual Step 9 : Stick (with silicone glue) the two press plates onto the heater strip. ¾ 50” model : X = 380 mm ¾ 64” model : X = 380 mm / Y = 1060 mm ¾ 87” model : X = 660 mm / Y = 1200 mm / Z = 1750 mm Notes : ¾ It will take ± 1 hour to let the glue dry. Step 10 : Reinstall all parts in the opposite order of the removal procedure. Notes : ¾ During reinstallation of the plate, make sure there are no cables stuck. 4.3.2.
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Falcon II Outdoor series printers – Maintenance Manual Step 5 : Remove the front paper guide. Step 6 : Remove the dryer strip(s). Step 7 : Degrease the plate. Notes : ¾ Step 8 : Make sure the plate is cleaned properly. Dust, glue and other parts must be removed. Stick the dryer strip(s) onto the plate. Notes : Make sure that the strips connect properly. Please make sure that the sensor (blue blocks) are positioned on the flat surface of the front paper guide.
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Falcon II Outdoor series printers – Maintenance Manual Notes : ¾ During reinstallation of the plate, make sure there are no cables stuck. 4.3.2.2. Replacing the post fixer (Heater C) on a Falcon II Outdoor 4H printer Before replacing the heater, make sure to have following items: ¾ 50” model : Post Fixer C 50 (EY-80343) ¾ 64” model : Post Fixer C 64 (EY-80333) ¾ 87” model : Post Fixer C 87 (EY-80353) ¾ 1 x sensor insul.
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Falcon II Outdoor series printers – Maintenance Manual Step 9 : Stick onto the sensor a sensor insul. patch. 1 = sensor insul. patch 2 = assembly hole Step 10 : Reinstall all parts in the opposite order of the removal procedure. Notes : ¾ During reinstallation of the plate, make sure there are no cables stuck. 4.3.2.3.
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Falcon II Outdoor series printers – Maintenance Manual Step 6 : Place the plot platform calibre onto the plot platforms. 1 = plot platforms Step 7 : 2 = plot platform calibre onto the plot platforms Fix the plot platform calibre onto the plot platform. 1 = Fix plot platform calibre 2 = reachable screws of plot platform Notes : ¾ Make sure the screws of the plot platform are reachable. 62 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual Step 8 : Remove the screws of the plot platform. 1 = screws plot platform Step 9 : Pull upwards the plot platform calibre and so remove the plot platform with fixer. Step 10 : Remove the fixer. Step 11 : Degrease the plot platform. Notes : ¾ Make sure the plate is cleaned properly. Dust, glue and other parts must be removed. Step 12 : Stick the two fixer strips onto the plot platform.
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Falcon II Outdoor series printers – Maintenance Manual 1 = plot platform 3 = isolation tape 2 = fixer heater strip 64 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual Step 14 : Reinstall all parts in the opposite order of the removal procedure. Notes : ¾ During reinstallation of the plate, make sure there are no cables stuck. 4.3.2.4.
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Falcon II Outdoor series printers – Maintenance Manual Step 13 : Stick (with silicone glue) the two press plates onto the heater strip. ¾ 50” model : X = 380 mm ¾ 64” model : X = 380 mm / Y = 1060 mm ¾ 87” model : X = 660 mm / Y = 1200 mm / Z = 1750 mm Notes : ¾ It will take ± 1 hour to let the glue dry. Step 14 : Reinstall all parts in the opposite order of the removal procedure. Notes : ¾ During reinstallation of the plate, make sure there are no cables stuck. 66 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 4.4. REPLACING BOARD BASES This chapter explains the procedures for replacing the power source board assembly, mainboard assembly, PCI_Linux board assembly and cooling fan assembly. Caution : When handling circuit boards, do not touch the elements on the board with your bare hands. Doing so may cause static electricity and break the elements. 4.4.
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Falcon II Outdoor series printers – Maintenance Manual Step 2 : Remove the Mainboard cover 3. Step 3 : Follow the instructions in “Removing the panel unit assembly” to remove the panel unit assembly. Step 4 : Remove the connector between the cooling fan cable and the cooling fan assembly. Step 5 : Remove the 2 top and 2 bottom screws fixing the cooling fan assembly. Step 6 : Replace the cooling fan assembly. Step 7 : Remove the 15 screws fixing the Mainboard cover.
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Falcon II Outdoor series printers – Maintenance Manual Step 11 : Remove following connectors from the Mainboard assembly.
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Falcon II Outdoor series printers – Maintenance Manual 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 J144 J145 (87) J146 (87) J147 (87) J148 (87) J149 (87) J150 (87) J151 (87) J152 (87) J153 J154 J155 J156 J157 J158 J159 J160 J161 J162 J163 J164 J165 J167 30 30 30 30 30 30 30 30 30 5 5 3 3 2 3 4 4 5 6 7 4 White or black White or black White or black White or black White or black White or black White or black White or black White or black Black White White Black White White White Wh
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Falcon II Outdoor series printers – Maintenance Manual Step 18 : Remove the 6 screws and 4 hexagon spacers fixing the Mainboard assembly. 1 = Mainboard assembly 3 = Hexagon spacer 5 = Cooling fan assembly 7 = I/F guide 2 = HDD_Extension board assembly 4 = Screws (M3x6) 6 = Screws (M3x20) fixing the cooling fan assembly 8 = Screws (M3x8) fixing the I/F guide Step 19 : Replace the HDD_Extension board assembly. Step 20 : Replace the Mainboard assembly.
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Falcon II Outdoor series printers – Maintenance Manual 4.4.2. Replacing the power source board assembly Caution : When removing the power source board assembly, remove the power cable and set it aside for at least 5 minutes in order to completely discharge the electric charge remaining in the electrolytic capacitor before continuing with the procedure. Touching the substrate before discharging the capacitor causes electric shock.
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Falcon II Outdoor series printers – Maintenance Manual Step 6 : Remove the 4 screws fixing the power source. 1 = Power source board assembly 3 = Hexagon nut fixing the power board assembly 5 = Screws (M3x6) fixing the power source 2 = Screws (M4x8) fixing the power board assembly 4 = Power source Step 7 : Replace the power source. Step 8 : Remove the 2 screws and 2 hexagon nuts fixing the power source board assembly. Step 9 : Remove the power source board assembly.
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Falcon II Outdoor series printers – Maintenance Manual 4.4.3. Replacing the inlet assembly, inlet board assembly and lever foot SW cable assembly Step 1 : Follow the instructions in "Replacing the Mainboard assembly, HDD_Extension board assembly, HEAD_DRV board assembly, PCI_Linux board assembly and cooling fan assembly" to remove the Mainboard assembly. Step 2 : Follow step 2 to 4 in "Replacing the power source board assembly" to remove the Mainboard assembly.
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Falcon II Outdoor series printers – Maintenance Manual 4.4.4. Replacing the JUNCTION board assembly Notes : Step 1 : N° 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Step 2 : ¾ To replace board and connect or disconnect the FFC type cable, you should leave the plug disconnected from the power socket for a while. Otherwise, over-current could be generated and damage the board. ¾ Remove the following parts before replacing the JUNCTION board assembly.
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Falcon II Outdoor series printers – Maintenance Manual 4.5. REPLACING THE PF ACTUATOR 4.5.1. Replacing the PF motor assembly Caution : The motor is hot after the product has been operated, so be careful not to burn yourself. Notes : ¾ Remove following covers before replacing the parts in the PF motor assembly.
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Falcon II Outdoor series printers – Maintenance Manual Notes : ¾ When installing the PF motor assembly, move the PF deceleration pulley manually and confirm that the PF deceleration belt is set equally in the center of the PF motor assembly pulley. Step 5 : Reinstall all parts in the opposite order of the removal procedure. Step 6 : Adjust the tension of the PF deceleration belt according to "PF deceleration belt tension adjustment". 77 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 4.5.2. Replacing the PF_ENC assembly and PF scale assembly Notes : ¾ Remove the following covers before replacing the PF_ENC assembly. Side cover L: refer to "Removing side cover L" Step 1 : Remove the PF_ENC assembly connector. Step 2 : Remove the 2 screws fixing the PF encoder installation board.
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Falcon II Outdoor series printers – Maintenance Manual Step 8 : Remove the screws fixing the PF_ENC assembly to the PF encoder installation board. 1 = PF_ENC assembly 2 = Screws (M2x6) fixing the PF_ENC assembly to the PF encoder installation board 3 = PF encoder installation board Step 9 : Replace the PF_ENC assembly. Notes : ¾ When installing the PF_ENC assembly and the PF encoder installation board, make sure they are aligned with the locating bosses.
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Falcon II Outdoor series printers – Maintenance Manual 4.5.3. Replacing the PF deceleration pulley assembly Notes : ¾ Remove following covers before replacing the parts in the PF motor assembly.
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Falcon II Outdoor series printers – Maintenance Manual 4.5.4. Replacing the PF deceleration belt Notes : ¾ Remove following covers before replacing the parts in the PF motor assembly.
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Falcon II Outdoor series printers – Maintenance Manual 4.5.5. Replacing the P_REAR_R sensor assembly and P_REAR_L sensor assembly Notes : ¾ Remove following covers before replacing the P_REAR_R sensor assembly and P_REAR_L sensor assembly.
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Falcon II Outdoor series printers – Maintenance Manual 1 = P_REAR_R sensor assembly 2 = Screws (M2x5) fixing the P_REAR_R sensor assembly Step 5 : Replace the P_REAR_R sensor assembly. Step 6 : Use the same procedure to replace the P_REAR_L sensor assembly. Step 7 : Reinstall all parts in the opposite order of the removal procedure. 4.5.6. Replacing the suction fan assembly Notes : ¾ Remove following covers before replacing the suction fan assembly.
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Falcon II Outdoor series printers – Maintenance Manual 4.5.7. Replacing the lever motor assembly and the arm motor installation board Caution : The motor is hot after the product has been operated, so be careful not to burn yourself. Notes : ¾ Remove following covers before replacing the lever motor.
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Falcon II Outdoor series printers – Maintenance Manual 1 = Lever motor assembly 2 = Hexagon socket head screws with spring washers (M4x10) Step 5 : Replace the CR motor assembly. Step 6 : Remove the hexagon socket head screws with spring washers (2) fixing the arm motor installation board. 1 = Arm motor installation board 2 = Hexagon socket head screws with spring washers (M4x10) Step 7 : Replace the arm motor installation board.
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Falcon II Outdoor series printers – Maintenance Manual 4.5.8. Replacing the transmission photosensor Notes : ¾ Remove following covers before replacing the transmission photosensor.
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Falcon II Outdoor series printers – Maintenance Manual Step 6 : Apply the screw lock to the tab portions of the transmission photosensors to be installed. Step 7 : Reinstall all parts in the opposite order of the removal procedure. Notes : ¾ When installing the U/D cable assembly onto the transmission photosensor, be careful not to confuse the connectors.
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Falcon II Outdoor series printers – Maintenance Manual Step 6 : Apply the screw lock to the tab portions of the transmission photosensors to be installed. Step 7 : Reinstall all parts in the opposite order of the removal procedure. 88 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 4.5.9. Replacing the flushing box assembly Notes : ¾ Step 1 : Remove following covers before replacing the flushing box assembly. Side cover R: refer to "Removing side cover R" Side cover L: refer to "Removing side cover L" Front cover: refer to "Removing the front cover" Carriage cover: refer to "Removing the carriage cover" Y rail cover: refer to "Removing the Y rail cover" Unlock the head.
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Falcon II Outdoor series printers – Maintenance Manual 4.6. REPLACING THE CR ACTUATOR 4.6.1. Replacing the CR motor assembly Caution : The motor is hot after the product has been operated, so be careful not to burn yourself. Notes : ¾ Remove following covers before replacing the CR motor assembly.
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Falcon II Outdoor series printers – Maintenance Manual Notes : ¾ When installing the CR motor cable assembly connector, install the white cable on the right side as shown in the previous figure. 4.6.2. Replacing the steel belt Caution : When replacing the steel belt, be careful not to cut your hands by the belt. Notes : Step 1 : ¾ Do not damage the steel belt. ¾ Remove following covers before replacing the steel belt.
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Falcon II Outdoor series printers – Maintenance Manual 1 = Steel belt adjustment screws Step 4 : 2 = Steel belt Remove the 2 screws fixing the steel belt. 1 = Screws fixing the steel belt Step 5 : 2 = Steel belt Replace the steel belt. Notes : ¾ Be careful when handling the steel belt. The steel belt may be cut off when accreting dust to it or creasing it. Step 6 : Reinstall all parts in the opposite order of the removal procedure.
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Falcon II Outdoor series printers – Maintenance Manual 4.6.3. Replacing the SLIDE motor assembly, HD_SLIDE sensor assembly, and slide motor installation board Caution : The motor is hot after the product has been operated, so be careful not to burn yourself. Notes : ¾ Remove following covers before replacing the SLIDE motor assembly, HD_SLIDE sensor assembly, and slide motor installation board.
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Falcon II Outdoor series printers – Maintenance Manual Step 7 : Replace the slide motor installation board. Step 8 : Reinstall all parts in the opposite order of the removal procedure. Step 9 : Make sure that the Idler moves smoothly. 94 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 4.6.4. Replacing the T fence Notes : ¾ Step 1 : Remove following covers before replacing the T fence. Side cover R: refer to "Removing side cover R" Side cover L: refer to "Removing side cover L" Front cover: refer to "Removing the front cover" Carriage cover: refer to "Removing the carriage cover" Y rail cover: refer to "Removing the Y rail cover" Remove the T fence from the T fence spring hook on the side of the L side frame.
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Falcon II Outdoor series printers – Maintenance Manual Step 4 : Remove the screw fixing the T fence stationary plate. 1 = T fence stationary plate 3 = Screw (M3x6) fixing the T fence stationary plate 2 = T fence Step 5 : Remove the T fence from the hook. Step 6 : Pull out the T fence in the direction of the arrow as shown in the previous figure while being careful not to damage the CR_ENC assembly. Step 7 : Reinstall all parts in the opposite order of the removal procedure.
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Falcon II Outdoor series printers – Maintenance Manual 1 = T fence push plate 3 = CR_ENC assembly 2 = T fence 4 = T fence spring hook 97 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 4.6.5. Replacing the CR slave pulley assembly Notes : ¾ Remove following covers before replacing the CR slave pulley assembly.
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Falcon II Outdoor series printers – Maintenance Manual 4.6.6. Replacing the CR actuator pulley and the CR deceleration belt Notes : ¾ Remove following covers before replacing the CR slave pulley.
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Falcon II Outdoor series printers – Maintenance Manual 4.6.7. Replacing the steel bearer, tube guide, CR tape power cable and ink tube Notes : Step 1 : ¾ To replace the board and connect or disconnect the FFC type cable, you should leave the plug disconnected from the power socket for a while. Otherwise, overcurrent could be generated and damage board. ¾ Remove following covers before replacing the steel bearer, tube guide, CR tape power cable, and ink tube.
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Falcon II Outdoor series printers – Maintenance Manual Step 4 : Remove the 2 screws fixing the tube clamp. 1 = CR tape power cable 3 = Cable push plate 5 = Screws fixing tube clamp (M3x8) Step 5 : 2 = Steel bearer 4 = Screws fixing cable push plate (M3x8) Completely remove tube bundles 1 and 2. 1 = Tube bundle 2 = Tube bundle 2 Step 6 : Remove the 4 screws fixing the tube clamp. Step 7 : Remove the tube clamp. Step 8 : Remove the coupling screws, O-ring and ink tube from the coupling.
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Falcon II Outdoor series printers – Maintenance Manual Step 14 : Replace the CR tape power cable. 1 = Tube push plate 2 = Pipe clamp 4 = Screws fixing tube push plate (M3x8) 2 = Cable clamp 3 = Coupling, O-ring, coupling screws 4 = Screws fixing tube cramp (M3x20) Step 15 : Reinstall all parts in the opposite order of the removal procedure. Notes : ¾ The CR tape power cables must be bundled during installation so that they can not move. ¾ The edge of the tube push plate must be upside when installed.
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Falcon II Outdoor series printers – Maintenance Manual 4.6.8. Replace the cover R sensor assembly and the cover L sensor assembly Notes : ¾ Remove following covers before replacing the cover R sensor assembly and the cover L sensor assembly.
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Falcon II Outdoor series printers – Maintenance Manual Step 3 : Remove the 2 screws fixing the cover L sensor assembly. 1 = Cover L sensor assembly 2 = Screws (M2x8) fixing the cover L sensor assembly Step 4 : Replace the cover L sensor assembly. Step 5 : Reinstall all parts in the opposite order of the removal procedure. Step 6 : Perform cover sensor adjustment according to "Cover sensor adjustment". 104 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 4.7. REPLACING THE CURSOR 4.7.1. Replacing the cutter holder, cutter spring, cutter cap, solenoid assembly and solenoid spring (1) Replacing the cutter spring Step 1 : Open the front cover. Step 2 : Remove the cutter blade from the cutter holder. Step 3 : Remove the cutter spring from the cutter holder. 1 = Cutter spring 2 = Cutter holder Step 4 : Replace the cutter spring.
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Falcon II Outdoor series printers – Maintenance Manual Step 1 : Remove the 2 screws fixing the cutter holder and holder support. 1 = Holder support 3 = Screws (M3x6) fixing the cutter holder and holder support 2 = Cutter holder Step 2 : Remove the cutter holder. Step 3 : Remove the cutter blade and cutter spring from the cutter holder. Step 4 : Remove the cutter cap and Solenoid spring. Step 5 : Remove the screw fixing the solenoid assembly to the cutter cap.
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Falcon II Outdoor series printers – Maintenance Manual Step 10 : Reinstall all parts in the opposite order of the removal procedure. Step 11 : Adjust the cutter according to "Cutter adjustment". 107 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 4.7.2. Replacing the print head assembly and head tape power cable Notes : ¾ To replace the board and connect or disconnect the FFC type cable, you should leave the plug disconnected from the power socket for a while. Otherwise, overcurrent could be generated and damage board. ¾ Remove following covers before replacing the print head assembly and head tape power cable.
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Falcon II Outdoor series printers – Maintenance Manual 1 = Head tape power cable 3 = Head stationary plate / head spacer 5 = Screws (M2.6x5) fixing the head stationary plate 2 = Damper assembly 4 = Step-bore screw 6 = Print head assembly Step 5 : Remove the damper assembly from the print head assembly. Step 6 : Remove the screw and step-bore screw fixing the head stationary plate. Step 7 : Remove the rotation adjustment spring under the head with small flat-head driver or another tool.
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Falcon II Outdoor series printers – Maintenance Manual 4.7.3. Replacing the H ink tube, tube branch and damper assembly Notes : ¾ Remove following covers before replacing the H ink tube, tube branch, and damper assembly.
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Falcon II Outdoor series printers – Maintenance Manual Step 6 : Remove the damper assembly from the print head assembly. 1 = Head tape power cable 3 = Print head assembly 2 = Damper assembly 4 = H ink tube, O-ring Step 7 : Remove the H ink tube, coupling screw and O-ring from the damper assembly. Step 8 : Replace the damper assembly. Step 9 : Replace the H ink tube and O-ring. Notes : ¾ Please soak the O-ring in cleaning liquid before installation.
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Falcon II Outdoor series printers – Maintenance Manual 4.7.4. Replacing the CR board assembly Notes : Step 1 : ¾ To replace the board and connect or disconnect the FFC type cable, you should leave the plug disconnected from the power socket for a while. Otherwise, overcurrent could be generated and damage board ¾ Remove following covers before replacing the CR board assembly.
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Falcon II Outdoor series printers – Maintenance Manual 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 J218 J219 J220 J221 J222 J223 J224 J225 J226 J227 J228 J229 J230 J231 J232 J233 J234 J235 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 5 5 2 White or Black White or Black White or Black White or Black White or Black White or Black White or Black White or Black White or Black White or Black White or Black White or Black White or Black White or Black White or Black White Black White Step 3 : Remov
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Falcon II Outdoor series printers – Maintenance Manual 4.7.5. Replacing the CR_ENC assembly Notes : ¾ Remove following cover before replacing the CR_ENC assembly. Side cover L: refer to "Removing side cover L" Step 1 : Follow step 1 in "Replacing the flushing box assembly" to slide the CR cursor to the left. Step 2 : Remove the CR_ENC assembly connector from the CR board assembly. Step 3 : Remove the T fence from the T fence spring, and then from the CR_ENC assembly.
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Falcon II Outdoor series printers – Maintenance Manual 4.7.6. Replacing the P_EDGE sensor assembly Notes : ¾ Remove following covers before replacing the P_EDGE sensor Assembly.
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Falcon II Outdoor series printers – Maintenance Manual 4.7.7. Replacing the CR cursor assembly Notes : ¾ Remove following covers before replacing the CR cursor assembly.
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Falcon II Outdoor series printers – Maintenance Manual Step 7 : Remove the CR blade spring. 1 = CR cursor assembly 2 = CR blade spring Step 8 : Replace CR cursor assembly. Step 9 : Reinstall all parts in the opposite order of the removal procedure. Step 10 : Perform head height adjustment according to "Head height adjustment". 117 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 4.7.8. Replacing the cursor roller assembly Notes : ¾ Remove following cover before replacing the Cursor roller assembly. Side cover R: refer to "Removing side cover R" Side cover L: refer to "Removing side cover L" Front cover: refer to "Removing the front cover" Carriage cover: refer to "Removing the carriage cover" Y rail cover: refer to "Removing the Y rail cover" Head cover: refer to "Removing the head cover" 4.7.8.1.
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Falcon II Outdoor series printers – Maintenance Manual Step 3 : Remove the E ring fixing the cursor roller assembly (KY-80040) of downside. 1 = CR cursor assembly (KY-80040) 2 = E ring fixing the cursor roller assembly. Step 4 : Replace the cursor roller assembly (KY-80040). Step 5 : Install the spacers and the other parts as shown in the following figure.
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Falcon II Outdoor series printers – Maintenance Manual 1 = Applying position of the screw lock Step 7 : Perform head height adjustment according to "Head height adjustment". 4.7.8.2. B. Replacing the cursor roller assembly (6 high-load bearings) : open bearing type Step 1 : Follow the instructions in "Replacing the CR cursor assembly " to remove the CR cursor assembly. Step 2 : Remove the side cursor roller assemblies and B cursor axises together with flat-head driver or another tool.
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Falcon II Outdoor series printers – Maintenance Manual Step 5 : Install the spacers and the other parts as shown in the following figure.
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Falcon II Outdoor series printers – Maintenance Manual Step 6 : Apply the screw lock to the cursor axis, and install the cursor roller assembly with the axis at the lower position. Notes : ¾ Be sure that the screw lock does not contaminate the cursor roller or the spacer. 1 = Applying position of the screw lock Step 7 : Perform head height adjustment according to "Head height adjustment". 4.8. REPLACING THE MAINTENANCE AREA 4.8.1.
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Falcon II Outdoor series printers – Maintenance Manual 1 = Side plate T 2 = Screws (M3x6) fixing the side plate T Step 3 : Remove the side plate T. Step 4 : Remove the screw fixing the waste fluid receptacle. Step 5 : Remove the waste fluid receptacle. Step 6 : Remove the screw fixing the flushing box installation board. Step 7 : Remove the flushing box installation board. 123 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual Step 8 : Remove the connector and tube from the maintenance assembly. 1 = tube connections Notes : ¾ Step 9 : There is some remaining ink in the tubes. Be careful that the ink is not spilled from the tube onto the printer or items close to the printer. Remove the 6 screws fixing the maintenance assembly.
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Falcon II Outdoor series printers – Maintenance Manual Notes : ¾ Secure the maintenance assembly so that it abuts against the rear right portion. ¾ If the cap tube has not been cut, cut it to the length below, measured from the end of the tube: Numbers in brackets ( ) are the cap numbers from left to right as viewed from the front of the main body.
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Falcon II Outdoor series printers – Maintenance Manual Step 11 : Move the cursor to the opposite side of the origin. Step 12 : Cap once. Step 13 : Use a mirror to check that the cap does not impinge on the nozzle. 1 = Print head (nozzle face) 3 = Cap trace 2 = Nozzle 4 = Mirror Step 14 : Reinstall all parts in the opposite order of the removal procedure. 4.8.2. Replacing the cleaner Step 1 : Follow step 1 to 3 in "Replacing the maintenance assembly" to remove the side plate T.
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Falcon II Outdoor series printers – Maintenance Manual Notes : Step 4 : ¾ Do not touch the cleaner with your bare hands. Oil or grease adhering to the surface of the nozzles can cause the nozzles to fall out. ¾ When removing and installing the cleaner, be sure to remove the hook. Failure to do so could deform the cleaner.
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Falcon II Outdoor series printers – Maintenance Manual 4.8.4. Replacing the transmission photosensor (wiper home position and maintenance home position) Step 1 : Remove the transmission photosensor from the side plate R. 1 = Transmission photosensor (wiper origin side) 2 = Transmission photosensor (maintenance origin side) 4 = Maintenance origin cable assembly 3 = Wiper origin cable assembly 5 = Side plate R Step 2 : Remove each origin cable assembly from the transmission photosensor.
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Falcon II Outdoor series printers – Maintenance Manual 4.9. REPLACING THE PUMP AREA 4.9.1. Replacing the pump assembly Notes : ¾ Step 1 : Remove following covers before replacing the parts in the PF motor assembly.
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Falcon II Outdoor series printers – Maintenance Manual Step 2 : Remove the 4 screws fixing the pump assembly. Falcon II Outdoor 2 heater Falcon II Outdoor 2 heater 1 = Pump assembly 2 = Screws (M3x8) fixing the pump assembly Step 3 : Replace the pump assembly. Step 4 : Reinstall all parts in the opposite order of the removal procedure. Notes : ¾ Follow the instructions in "Pump tubing layout for pump assembly" to connect the tube. 130 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 4.9.2. Replacing the pump assembly Step 1 : Follow the instructions in "Replacing the pump assembly " to remove the pump assembly. Step 2 : Remove the screw fixing the pump assembly. 1 = Pump assembly 2 = Screws (M3x6) fixing the pump assembly Step 3 : Replace the pump assembly. Step 4 : Reinstall all parts in the opposite order of the removal procedure.
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Falcon II Outdoor series printers – Maintenance Manual 4.9.3. Replacing the pump motor assembly Caution : The motor is hot after the product has been operated, so be careful not to burn yourself. Step 1 : Follow the instructions in "Replacing the pump assembly " to remove the pump assembly. Step 2 : Remove the 2 screws fixing the pump motor assembly. 1 = Pump motor assembly 2 = Screws (M3x6) fixing the pump motor assembly Step 3 : Replace the pump motor assembly.
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Falcon II Outdoor series printers – Maintenance Manual 4.10. REPLACING THE CARTRIDGE AREA 4.10.1. Replacing the I/H (ink holder) assembly There are 8 I/H assembly 's installed in this printer. Following procedure is for the removal of 1 I/H assembly. Notes : ¾ Remove following covers before replacing the parts in the I/H assembly.
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Falcon II Outdoor series printers – Maintenance Manual Step 6 : Remove the 3 screws fixing the P/S board installation board. Step 7 : Remove the P/S board installation board. Step 8 : Remove the coupling screws and O-ring from the I/H assembly. Step 9 : Remove the 4 screws fixing I/C slide 2 and the I/H assembly. 1 = I/H assembly 3 = Screws (M3x8) fixing I/C slide 2 and the I/H assembly 2 = I/C slide 2 Step 10 : Remove the I/H assembly.
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Falcon II Outdoor series printers – Maintenance Manual (2) Replacing the ink ID board assembly and the holder pressure spring Step 1 : Remove the I/H assembly. Step 2 : Remove the 2 screws fixing the holder pressure spring. 1 = Holder pressure spring (two-ply use) 3 = Ink ID board assembly 2 = Screws (M3x6) fixing the holder pressure spring 4 = SC cable assembly Step 3 : Replace the holder pressure spring. Step 4 : Remove the SC cable assembly connector from the ink ID board assembly.
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Falcon II Outdoor series printers – Maintenance Manual Step 4 : Slide the cartridge frame assembly in the direction of the arrow to remove it. Step 5 : Replace the cartridge frame assembly. Step 6 : Reinstall all parts in the opposite order of the removal procedure. (4) Replacing the ink sensor assembly (ink NOT sensor, ink END sensor) Step 1 : Remove the I/H assembly. Step 2 : Remove the cables from the I/H assembly clamp. Step 3 : Remove the cartridge frame assembly.
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Falcon II Outdoor series printers – Maintenance Manual Step 9 : Reinstall all parts in the opposite order of the removal procedure. Notes : ¾ When installing the ink NOT sensor, do not tighten the screw tightly. Otherwise, the switch may not come out. Step 10 : Make sure that the Ink NOT sensor switch moves. 4.11. REPLACING SUPPORTS AND SCROLLER 4.11.1.
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Falcon II Outdoor series printers – Maintenance Manual 4.11.2. Replacing the waste fluid bottle assembly (Falcon II Outdoor 4H) Notes : ¾ Step 1 : When replacing the waste fluid bottle assembly, be sure to perform following operation to clear the counter. "High ink initialization" or " Cleaning initialization": refer to "Counter Initialization Menu" Remove the waste fluid bottle assembly. Caution : Waste ink will remain inside the tubes.
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Falcon II Outdoor series printers – Maintenance Manual 4.11.3. Replacing the waste bottle box sensor assembly (F2O 2H) Step 1 : Follow the instructions in "Replacing the waste fluid bottle assembly" to remove the waste fluid bottle assembly. Step 2 : Remove the waste liquid BOX sensor assembly connector from the rear side cap R.
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Falcon II Outdoor series printers – Maintenance Manual Step 6 : Remove the waste liquid sensor installation board. Step 7 : Remove the screws (M2x8) fixing the waste liquid BOX sensor assembly. 1 = Waste liquid sensor installation board 3 = Screws (M2x8) 2 = Waste liquid BOX sensor assembly Step 8 : Remove the waste liquid BOX sensor assembly. Step 9 : Reinstall all parts in the opposite order of the removal procedure.
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Falcon II Outdoor series printers – Maintenance Manual 4.11.4. Replacing the waste bottle box sensor assembly (F2O 4H) Step 1 : Follow the instructions in "Replacing the waste fluid bottle assembly" to remove the waste fluid bottle assembly. Caution : Waste ink will remain inside the tubes. Be careful that the ink is not spilled from the tube onto the printer or items close to the printer. Step 2 : Remove the waste liquid BOX sensor assembly connector from the rear side cap R.
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Falcon II Outdoor series printers – Maintenance Manual Step 4 : Remove the screws fixing the waste liquid sensor assembly. Step 5 : Reinstall all parts in the opposite order of the removal procedure. Notes : ¾ When installing the waste liquid BOX sensor assembly, pay attention to following points : Adjust the waste liquid BOX sensor assembly before installing the waste liquid bottle cover. Position and install it so that "Sensor : Waste liquid tank" is properly switched in "Sensor Menu".
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Falcon II Outdoor series printers – Maintenance Manual 4.11.5. Replacing the scroller R assembly (1) Replacing the scroller R assembly Step 1 : Remove the 4 hexagon socket head springs fixing the scroller R assembly. 1 = Scroller R assembly 2 = Hexagon socket head springs Step 2 : Replace the scroller R assembly. Step 3 : Reinstall all parts in the opposite order of the removal procedure.
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Falcon II Outdoor series printers – Maintenance Manual Step 3 : Remove the E ring fixing the axes of the rollers to be replaced. 1 = Pressure roller 3 = Roller 2 5 = E ring (E-4) 2 = Roller 1 4 = E ring (E-3) Step 4 : Replace the rollers. Step 5 : Reinstall all parts in the opposite order of the removal procedure. 144 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 4.10.6. Replacing the scroller L assembly (1) Replacing the scroller L assembly Step 1 : Remove the 4 hexagon socket head springs fixing the scroller L assembly. 1 = Scroller L assembly 2 = Hexagon socket head springs Step 2 : Replace the scroller L assembly. Step 3 : Reinstall all parts in the opposite order of the removal procedure.
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Falcon II Outdoor series printers – Maintenance Manual Step 3 : Remove the E ring fixing the axes of the rollers to be replaced. 1 = Pressure roller 3 = E ring (E-3) 2 = Roller 1 4 = E ring (E-4) Step 4 : Replace the rollers. Step 5 : Reinstall all parts in the opposite order of the removal procedure. 146 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 5. SELF-DIAGNOSIS FUNCTION 5.1. INTRODUCTION This chapter provides information on the self-diagnosis function. The self-diagnosis function adjusts the printing accuracy. It is used in the manufacturing process, adjustment and maintenance. The self-diagnosis function is implemented in the system firmware. All functions are available from the operation panel. Notes : ¾ Refer to “Part names and functions ". 5.2.
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Falcon II Outdoor series printers – Maintenance Manual (2) Connecting power cable Connect the power cable to the machine's inlet assembly and insert the power plug into an outlet. Notes : ¾ Do not connect three or more power plugs to one outlet. 5.2.2. Starting Up To use the self-diagnosis function, you should first display the self-diagnosis menu on the operation panel. The self-diagnosis menu is completely independent of the normal operation mode and self-diagnosis display mode.
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Falcon II Outdoor series printers – Maintenance Manual 5.3. OPERATIONS IN SELF-DIAGNOSIS MODE This section explains how to operate in the self-diagnosis mode and provides the list of available diagnosis items. 5.3.1. Operating Self-Diagnosis Mode Follow the operation flow shown below to operate the self-diagnosis mode. For more detailed operation steps, refer to the flow chart of the applicable diagnosis item.
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Falcon II Outdoor series printers – Maintenance Manual Step 3 : Press the [F2] key or the [F4] key on the operation panel to modify the set value. Step 4 : To save the modified value, press the [ENTER] key on the operation panel. ¾ The modified set value is stored and a next item is displayed. Notes : ¾ If you press the [CANCEL] key instead of the [ENTER] key, the modification will not be stored. 150 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual Step 5 : To quit the diagnosis menu, press the [CANCEL] key on the operation panel. ¾ The system returns to an upper hierarchy of the diagnosis menu. Step 6 : To exit the self-diagnosis menu, press the [POWER] key. 5.3.2. Diagnosis Items in Self-Diagnosis Menu The Self-Diagnosis menu includes following diagnosis items.
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Falcon II Outdoor series printers – Maintenance Manual 5.4. TEST / INSPECTION MENU In the Inspection menu, you can perform various inspections on the circuit boards, sensors and fans. The Inspection menu includes the following diagnosis items. Initialization item Memory size Description This menu displays the memory size. Refer to → Memory Size Menu Version Displays the versions of the firmware and mainboard assembly.
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Falcon II Outdoor series printers – Maintenance Manual 5.4.1. Memory Size Menu This menu displays the memory size. * RamCapacity * RamCapacity 128 MB Notes : ¾ The Memory Size menu displays the size of the memory installed on the mainboard (128 MB or 256 MB). 153 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 5.4.2. Version Menu This menu displays following contents about the firmware and mainboard assembly. ¾ Firmware version ¾ Backup parameter version ¾ Setting of dip switches of mainboard assembly ¾ Revision of mainboard assembly Notes : ¾ The details of the dipswitch setting of mainboard assembly are as follows. • Switch 1: OFF • Switch 2: OFF * Ver * Firm Parameter rh 2.04, mA 1.00 (1/2) * Ver * DipSW Board Rev 0x03 00 (2/2) 154 AP-74065, Rev.
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Falcon II Outdoor series printers – Maintenance Manual 5.4.3. Operation Panel Menu This menu is used to check the functions of the operation panel keys, LCD, and LEDs. (1) Operation panel key check When you press a key on the operation panel, the name of the key is displayed on the LCD. To exit the operation panel key check, press the [CANCEL] key. (2) LCD check The entire LCD screen is filled in black. You can check for any missing dots. (3) LED check The following LEDs light up in order.
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Falcon II Outdoor series printers – Maintenance Manual 5.4.4. Sensor Menu This menu displays the sensor status in the operation panel. If the displayed sensor status does not match the actual machine status, replace or adjust the relevant sensor referring to "Table Inspection Items in Sensor Menu".
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Falcon II Outdoor series printers – Maintenance Manual * Sensor * Cover InkCover * Sensor * LeverUp LeverDown * Sensor * FootLever PaperEdgeAD * Sensor * PaperRear R PaperRear L * Sensor * Headslide Temp * Sensor * Ink ID 1 Ink ID 2 * Sensor * Ink ID 3 Ink ID 4 * Sensor * Ink ID 5 Ink ID 6 * Sensor * Ink ID 7 Ink ID 8 Open Open (3/12) Cover sensor Ink cover sensor On On (4/12) Lever up sensor Lever down sensor On 04e (5/12) Foot lever SW sensor P_EDGE sensor Off Off (6/12) P_REAR_R sensor P_REAR_L s
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Falcon II Outdoor series printers – Maintenance Manual 5.4.5. Encoder Menu This menu displays the detected values from the following encoders. ¾ CR_ENC (Carriage) ¾ PF_ENC (Media feed) Notes : ¾ For the encoder-detected values, the encoder pulse numbers are displayed in hexadecimal number. * Encoder * CR PF 0000 0000 158 CR_ENC PF_ENC AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 5.4.6. Fan Menu This menu is used to check if the fan operates normally by turning it ON and OFF the fan. As soon as you select this menu, the fan will be activated. When you press the [CANCEL] key, the fan is off and the operation panel displays "Inspection: Fan". * Fan * [Cancel] End 159 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 5.4.7. History Menu This menu is used to check the maintenance history and serious error history. F1 → * Elec. * Maintenance Error ← F2 (1) Maintenance history Maintenance history for the following parts is displayed.
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Falcon II Outdoor series printers – Maintenance Manual * Maintenance * PrintingNumber Cleaning 00000000 00000000 (4/9) Number of printing copies Number of cleanings * Maintenance * Fire 1-A 00000000Mdot Fire 1-B 00000000Mdot (5/9) Discharge amount of head 1-A nozzle ink Discharge amount of head 1-B nozzle ink * Maintenance * Fire 2-A 00000000Mdot Fire 2-B 00000000Mdot (6/9) Discharge amount of head 2-A nozzle ink Discharge amount of head 2-A nozzle ink * Maintenance * Fire 3-A 00000000Mdot Fire 3-B 0
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Falcon II Outdoor series printers – Maintenance Manual (2) Serious error history This menu displays the serious errors that have occurred so far. Notes : ¾ ¾ A serious error history does not include any CPU errors. A serious error history can contain up to 32 error events. * Error * Error0 Error1 Y current X motor (1/16) * Error * Error2 Error3 X motor X motor (2/16) * Error * Error30 Error31 Y current Y current (16/16) 5.4.8. Head Signal Menu This menu is used to check the head-driving signal.
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Falcon II Outdoor series printers – Maintenance Manual 5.5. ADJUSTMENT MENU In this menu, you can align the printing position and correct the media feed operation.
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Falcon II Outdoor series printers – Maintenance Manual 5.5.1. Skew Check Menu In this menu, you can perform media feed and check the degree of skew in the media feed operation by means of the sensors. When you select this item from the Adjustment menu, the machine feeds the length specified by the operation panel and checks for media feed skew by comparing the media edge positions before and after the media feed detected by the sensors.
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Falcon II Outdoor series printers – Maintenance Manual 5.5.2. Head rank input menu Inputs the head rank. The head rank is used to determine the operation voltage of the head and compensate the temperature. Input head rank following the steps below. (1) Selecting input method When inputting head rank, select one of the following methods.
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Falcon II Outdoor series printers – Maintenance Manual (4) Initial ink charge menu When the input head rank has been confirmed, initial ink charge is performed. * Charge * Ink charge → [CANCEL] Initial charge is not executed. Voltage input value is updated. [enter] ↓ ENTER * Charge * [1] No Catridge ↓ Set cartridge * Charge * Ink Charge 166 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 5.5.3 Head Nozzle Check Menu In this menu, you can check if the head nozzles, after refilled, can discharge ink correctly by printing a sample printing. To print out head nozzle check patterns, follow the steps below. The following is the description of the printing method. Step 1 : Set media as necessary. Notes : ¾ Refer to the User’s Guide. ¾ Pressing the [ENTER] key in the Diagnosis menu in self-diagnostic mode moves the lever up and down.
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Falcon II Outdoor series printers – Maintenance Manual Nozzle alignment in horizontal direction (CCW): Prints out patterns in the order of 1A, 1B, 2A, 2B, 3A, 3B, 4A, 4B. Step 4 : If any abnormal conditions are found in the ink discharge status of the head nozzles, perform ink purge on the relevant heads. Step 5 : After the ink purge, the system returns to the purge selection menu.
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Falcon II Outdoor series printers – Maintenance Manual 5.5.4. Head Slant Check Menu This menu prints out a sample printing to check for head slant. Item Slant Front and back All end Description All head slant check. Front and back position and slant of each head relative to the reference head check. Confirmation of the forward and rear positions for all nozzle rows and all heads. Check complete. 5.5.4.1. Slant To perform a Head Slant Adjustment, please follow the steps mentioned below.
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Falcon II Outdoor series printers – Maintenance Manual 1 = This area should be a straight line. Step 6 : Tighten the screw, which secures the Head Fixing Plate. Step 7 : Repeat step 1 to 6 until the adjustment is correct. 170 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 5.5.4.2. Front and back To perform a Head Front/Back Adjustment, please follow the steps mentioned below. Step 1 : Go to [Adjust : Head Slant]. Step 2 : Print out [Front/Back] pattern Step 3 : Loosen the screw, which secures the Head Fixing Plate. 1 = Head fixing plate securing screw 2 = Front/Back Adjustment Screw Step 4 : Adjust the head front/back position by moving the Head Front/Back Adjustment Screw.
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Falcon II Outdoor series printers – Maintenance Manual 1 = Adjust this area so it becomes a straight line. 2 = Check if this area is a straight line. 3 = Check if the lines of “1A and 4B” go in the centre (Also check lines “2A and 3B”, “3A and 2B” and “4A and 1B” Step 5 : Tighten the screw which secures the Head Fixing Plate. Step 6 : Repeat step 1 to 5 until the adjustment is correct. Notes : Please note that when executing “CHECK” in the menu, the plot will not be a straight line.
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Falcon II Outdoor series printers – Maintenance Manual 5.5.5. Repeatability Adjustment Menu This menu is used to align the head positions for two-way printing. To align the head position for two-way printing, you should first print out a Bi-D printing and identify the difference between the CW printing position and the CCW printing position. To perform a Bi-directional Adjustment, please follow the steps mentioned below. Step 1 : Go to [Adjust : Bi-D]. Step 2 : Print out the Bi-Directional pattern.
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Falcon II Outdoor series printers – Maintenance Manual 5.5.6. CW Adjustment Menu In this menu, you can adjust the gap (CR moving direction) between two heads. To adjust the gap between two heads, you should first print out a Uni-D printing and identify the difference between the selected two heads. Then, you enter the difference for the relevant parameter. To perform a Uni-directional Adjustment, please follow the steps mentioned below. Step 1 : Go to [Adjust : Uni-D].
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Falcon II Outdoor series printers – Maintenance Manual 5.5.7. Band Feed Correction Menu (X Length) In this menu, you can correct the media feed distance. To correct the media feed distance, you must first print out check patterns and measure the distance between lines drawn in the media feed direction. Then you enter the measured value through this menu. The system uses this entered value to determine the PF encoder resolution parameter in the firmware.
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Falcon II Outdoor series printers – Maintenance Manual * Feed Adj. * X Length 300 – 1000 + 500 mm ↓ ENTER CANCEL ←← ←← ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ * Feed Adj. * Enter Print Start ↓ ENTER * Feed Adj. * Set paper A media is not set ↓ Media setting * Feed Adj. * Paper Initial →→ ↑ ↑ ↑ ↑ ↑ ↑ →↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ →→→→→ ↓ Finish media initialization * Feed Adj. * Adjustment Print →→ →→→→→ * Feed Adj.
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Falcon II Outdoor series printers – Maintenance Manual 5.5.8. Top & bottom adjustment menu Sets printing margins. Make adjustments following the steps below. Step 1 : Set media as necessary. Step 2 : After the media has been set, pattern printing with band feed compensation and media cutting are performed. The following is the description of the printing method.
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Falcon II Outdoor series printers – Maintenance Manual * Top&Bottom * Set Paper If media is not set ↓ Set media * Top&Bottom * Paper Initial ↓ End Media Initialization * Top&Bottom * Adjustment Print * Top&Bottom * Top Length * Top&Bottom * Top Length * Top&Bottom * Side Display during adjustment printing 0 – 40.0 + 5.0 mm - 0 – 40.0 + 5.0 mm - 0 – 20.0 + 5.0 mm - 178 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 5.5.9. P_REAR sensor position adjustment menu Adjust the P_REAR sensor position in order to accurately detect the length of the cut media. During this adjustment, the P_REAR sensor position can be adjusted inside the firmware by referring to the nozzle, in order to obtain a maximum printable area starting from the ends of the media. Make adjustments following the steps below. Step 1 : Set media as necessary.
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Falcon II Outdoor series printers – Maintenance Manual Step 4 : Input the measurement as the parameter of the P_REAR sensor position. * Rear Sensor * Set Cutting Paper ↓ Set media * Rear Sensor * Paper Initial If media is not set ↓ End media initialization * Rear Sensor * Paper Width 297.0 mm Check media width ↓ ENTER * Rear Sensor * Rear Sensor 7.0 – 27.0 + 17.0 mm - 180 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 5.5.10. Test print menu In this menu, you can print out adjustment patterns for checking various adjustment items. Make adjustments following the steps below. Step 1 : Set media as necessary. Step 2 : After media has been set, the machine prints out the following test Printings. ¾ Nozzle check: Head nozzle check pattern ¾ Adjustment variables: Set values of various adjustment variables Step 3 : Perform selected test print.
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Falcon II Outdoor series printers – Maintenance Manual 5.5.11. Head wash menu In this menu, ink is drained and the head is cleaned at the completion of the manufacturing process and before replacing the print head. Execute a cleaning following the steps below. Step 1 : Initialize the waste ink history. ¾ Refer to ‘Parameter Initialization Menu’ Step 2 : Discharge the waste fluid from the waste fluid bottle. Step 3 : Press the [ENTER] key in the operation panel to confirm the head cleaning menu.
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Falcon II Outdoor series printers – Maintenance Manual * Clean Head * Remove cartridge ↓ Eject all cartridge and press the [ENTER] key to drain ink * Clean Head * Ink Discharge ↓ End Ink draining * Clean Head * Set Cleaning jig ↓ Set the head cleaning jig and press the [ENTER] key to charge the cleaning liquid. * Clean Head * Head Cleaning ↓ Charge cleaning liquid * Clean Head * Remove cleaning jig ↓ Remove the head cleaning jig and press the [ENTER] key to drain the cleaning liquid.
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Falcon II Outdoor series printers – Maintenance Manual 5.5.12. Software Counter Initialization Menu This menu initializes the software counters such as the ink amount counter. Notes : ¾ Before delivery, always initialize the software counters. The software counters that can be initialized through this menu are as follows.
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Falcon II Outdoor series printers – Maintenance Manual 5.5.13. Feed Pitch Check Menu In this menu, you can check the media feed amount for one band by reviewing a sample printing. There is no adjustment item. To check the feed pitch, follow the steps below. Step 1 : Set media as necessary. Step 2 : Select "Adj:SendPitch". Step 3 : Select "Pattern 1" or "Pattern 2" to print feed pitch check patterns. ¾ "Pattern 1": Drawn with 1 inch (2.
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Falcon II Outdoor series printers – Maintenance Manual 5.5.14. Fill printing menu A fill printing pattern is printed by both ends of the head. A: Media feed direction B: 100% print 50-inch specifications and 64-inch specifications are pattern printed in the sequence 1A&4B, 1A&4B, 1A&4B, while 87-inch specifications are printed in the sequence 1A&8B, 1A&4B, 5A&8B. 186 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 5.6. PURGE MENU In this menu, you can purge ink from the printer heads. The Purge menu includes the following diagnosis items. Diagnosis item Normal Powerful Little Initial ink charge Description Performs normal purge. Performs powerful purge. Performs minimum purge. Performs initial ink charge. F1 → F3 → * Cleaning * Normal Little Powerfull Ink charge ← F2 ← F4 ↓ Select item (Normal cleaning) * Normal * Cleaning 187 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 5.7. SAMPLE PRINTING MENU This menu prints out a sample printing. The Sample printing menu includes the following items. Diagnosis item Nozzle Check Adjustment variables Description Prints the head nozzle check pattern. Prints out the set values of various adjustment items. Notes : ¾ F1 → When serial numbers are not input to this product, the serial numbers become blank spaces. * Print * Nozzle Adj.
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Falcon II Outdoor series printers – Maintenance Manual 5.8. PARAMETER MENU In this menu, you can modify the set values of various adjustment items (adjustment parameter). The Parameter menu includes the following items. Initialization item Initialize. Description Initializes the adjustment parameters. Update Updates the adjustment parameters. F1 → * Parameter * Initialize Update Refer to Parameter Initialization Menu Parameter Update Menu ← F2 5.8.1.
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Falcon II Outdoor series printers – Maintenance Manual 5.8.2. Parameter Update Menu This menu updates the adjustment parameters. The parameters that can be updated through this menu are as follows. ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ Head voltage Printing position alignment CW adjustment Media feed distance Mechanical parameter Ink parameter Ink ID mask Serial number Notes : ¾ If you update any parameter in the Parameter Update menu, always turn the power OFF after quitting the menu.
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Falcon II Outdoor series printers – Maintenance Manual (1) Head voltage In this menu, you can enter a head voltage. The head voltage is used to determine the printer head-driving voltage and perform temperature correction. After a head voltage has been entered, the system shifts to the Ink Charge menu.
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Falcon II Outdoor series printers – Maintenance Manual (2) Printing position alignment This updates the printing position alignment parameters. * PrintPos Adj.* # 1 Head 1A * PrintPos Adj. * #1 Head 1B + -28 - + -28 If the parameter is updated * PrintPos Adj. * #1 Head 4B + -48 - ENTER →→→→→ * PrintPos Adj. * Update Parameter ? ↓ ENTER * PrintPos Adj. * Updating parameter (3) CW This updates the CW adjustment parameters. * CW Adj. * Gap 1 - 2 * CW Adj.
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Falcon II Outdoor series printers – Maintenance Manual (4) Media feed distance This updates the media feed distance parameters. * PaperFeedLen. * X Length 290 – 1010 + 500.0 mm ↓ ENTER * PaperFeedLen. * Update Parameter ? ↓ ENTER * Update * Updating Parameter 193 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual (5) Mechanical parameter Update the mechanical position parameters. The setup items are as follows. ¾ ¾ ¾ ¾ Top distance Bottom distance Side margin P_REAR sensor position * Mechparm * Top Length * Mechparm * Bottom * Mechparm * Side * Mechparm * Rear Sensor 0 – 40.0 + 5.0 mm - 0 – 40.0 + 5.0 mm - 0 – 20.0 + 5.0 mm - 0 – 27.0 + 17.
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Falcon II Outdoor series printers – Maintenance Manual * InkParameter * Init. Fill Flag + Set ↓ ENTER * InkParameter * Update Parameter ? If the parameter is changed ↓ ENTER * InkParameter * Updating Parameter (7) Ink ID mask Update the ink ID mask parameters. The setup items are as follows. ¾ ¾ Set: Ink ID is always fixed. When a mask has been set, any cartridge inserted will be handled as dye 4 colours fixed. Reset: Resets the ink ID mask. Cartridge recognition becomes available via smart chip.
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Falcon II Outdoor series printers – Maintenance Manual (8) Serial number entry This is for entering the serial number. * SerialNo. * + DD5*000001 * SerialNo. * + DD5C*00001 * SerialNo. * + DD5C1*0001 * SerialNo. * + DD5C12*001 * SerialNo. * + DD5C123*01 * SerialNo. * + DD5C1234*1 * SerialNo. * + DD5C12345* - Notes : ¾ The third figure of a serial number differs with the machine size. 5: 50 inch 6: 64 inch 8: 87 inch 196 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 5.9. ENDURANCE RUNNING MENU In this menu, you can perform endurance running on the printer heads. The Endurance Running menu includes the following items. Initialization item CR Motor PF motor Razor Blade Head up/down Description Performs carriage stroke. Drives the PF motor. Cuts media. Changes over the head height repeatedly. Head lock Pump Lever motor Tests head lock operation. Performs wiper up/down operation via the selecting menu.
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Falcon II Outdoor series printers – Maintenance Manual 5.9.1. CR Motor Endurance Menu This menu performs endurance running for the CR motor. You can perform carriage stroke according to your desired setting. The available settings are shown below. Setup item Operation speed (CW, CCW) Number of endurance running cycles Description Sets carriage operation speed (CW and CCW).
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Falcon II Outdoor series printers – Maintenance Manual 5.9.2. PF Motor Endurance Menu This menu performs endurance running for the PF motor. You can drive the PF motor according to your desired settings. The available settings are shown below. Setup item Media feed amount Description Sets amount of media feeds per endurance operation.
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Falcon II Outdoor series printers – Maintenance Manual 5.9.3. Cutter Endurance menu This menu performs endurance running for the cutter. You can perform the cutting operation according to the settings. Caution : Pay attention to the following points when performing the cutter endurance operation. ¾ Install usable ink cartridges. ¾ Make sure that media initialization is complete.
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Falcon II Outdoor series printers – Maintenance Manual * Cutter * Time Wait (sec) 40 Check Waiting time 5 Perform endurance ↓ ENTER * Cutter * Count ↓ ENTER * Cutter * End 50 201 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 5.9.4. Head Up/Down Endurance Menu This menu performs endurance running for the head up/down operation. You can perform the capping operation according to your desired settings. The available settings are shown below.
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Falcon II Outdoor series printers – Maintenance Manual 5.9.5. Head Lock Endurance menu Test endurance of head lock. In the Head Lock Endurance menu, you can perform head lock operation according to the set items. Notes : Refer to "Head Up/Down Endurance Menu" The wait time for head lock endurance is set to 10 seconds.
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Falcon II Outdoor series printers – Maintenance Manual 5.9.6. Pump Endurance menu This menu performs endurance running for the pump. In the Pump Endurance menu, you can perform the pump motor assembly endurance operation according to the settings. The available settings are shown below. Setup item Operation speed Description Sets the operation speed of the pump motor assembly.
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Falcon II Outdoor series printers – Maintenance Manual 5.9.7. Lever Motor Endurance Menu This menu performs endurance running for the lever motor. You can drive the lever motor according to your desired settings. The available settings are shown below.
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Falcon II Outdoor series printers – Maintenance Manual 5.9.8. Sequential Printing Endurance Menu This menu performs endurance running for the printer heads. You can operate the printer heads according to your desired settings. The available settings are shown below. Setup item Printing mode Description Set printing mode. Media Cut Sets whether to cut media each time one printing is printed out or not.
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Falcon II Outdoor series printers – Maintenance Manual * Nozzle * Count 5 Perform endurance running ↓ ENTER or CANCEL * Nozzle * End 50 207 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 5.9.9. General Endurance Menu This menu performs the general endurance running. You can operate various driving systems according to your desired settings. The available settings are shown below. Setup item Operation speed (CW, CCW) Media feed amount Description Sets carriage operation speed (CW and CCW).
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Falcon II Outdoor series printers – Maintenance Manual * Total Life * Count 5 Perform endurance running ↓ ENTER or CANCEL * Total Life * End 50 209 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 5.9.10. Endurance Running Check Menu In this menu, you can confirm the number of endurance running cycles that have been already finished. The number of endurance running cycles is stored in NVRAM in the system. Therefore, even if a serious error occurs during endurance running, you can confirm the number of finished cycles just before the occurrence of the serious error.
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Falcon II Outdoor series printers – Maintenance Manual 5.10. HEAD LOCK MENU Lock and unlock the head lock. The following items are in the head lock menu. ¾ ¾ F1 → Lock: Locks the head. Unlock: Releases the head lock. * Head lock * Lock Unlock ← F2 (1/1) ↓ Select (unlock) * Unlock * Wait Little time 211 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 5.11. HEATER SYSTEM MENU This section describes the heater system menu. This menu is used to evaluate the heating elements of the printer. Initialization item Status Temperature Test 30 Test 50 Test Max Version Adjust Description This menu displays the status of the heating system. This menu displays the real temperature of the heating elements. This menu heats the temperature up to 30°C. This menu heats the temperature up to 50°C.
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Falcon II Outdoor series printers – Maintenance Manual 5.11.3. Heater Test 30 Menu This menu heats the temperature up to 30°C. * Test 30 * Sending to heat system The display will mention de current temperature. You can follow the heating of the heater elements on the display up to 30°C. * Temperature * A : R30 B1 : R30 B2 : R30 D1 : R31 D2 : R31 C : R31 5.11.4. Heater Test 50 Menu This menu heats the temperature up to 50°C.
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Falcon II Outdoor series printers – Maintenance Manual 5.11.6. Heater Version Menu This menu displays the version of the control heater board. * Version * Ver = 2.03 5.11.7. Heater Adjust Menu Notes : ¾ With this menu you can calibrate the heaters. Please note that this function is for future use only. 5.12. ECO PREPARE MENU Loading ink for the first time. Please refer to the User’s Guide. 214 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 5.13. MACHINE SIZE SELECT MENU This section describes the select menu of the machine size. Used when the Mainboard is exchanged, etc. Step 1 : If the system is in the operation mode or the self-diagnosis menu mode, press the [POWER] key to power off the unit. Step 2 : Press the [POWER] key while simultaneously pressing and holding the [MENU ↑] key and the [MENU ↓] key. Step 3 : Select the machine size.
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Falcon II Outdoor series printers – Maintenance Manual 6. MAINTENANCE MODE 6.1. INTRODUCTION This chapter provides information on the maintenance mode. The maintenance mode provides the user with functions of displaying and initializing the life counters. It is used in the manufacturing process, adjustment and maintenance. The maintenance mode is implemented in the system firmware. All functions are available from the operation panel. Notes : ¾ Refer to “Operation Panel ". 6.2.
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Falcon II Outdoor series printers – Maintenance Manual 6.2.2. Operating Maintenance Mode For operating the maintenance mode, refer to "Operations in Self-Diagnosis Mode". 217 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 6.3. MAINTENANCE MENU The maintenance menu includes the following diagnosis items. Initialization item Counter Display Menu Counter Initialization Menu MAC address write enable menu F1 → F3 → Description This menu displays the life counters. Initializes the service life counter. Refer to Counter Display Menu Counter Initialization Menu Performs network MAC address writing.
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Falcon II Outdoor series printers – Maintenance Manual Notes : ¾ ¾ All life counters are displayed in decimal number. For 87-inch specifications, the head 5A, 5B, 6A, 6B, 7A, 7B, 8A, 8B are added.
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Falcon II Outdoor series printers – Maintenance Manual * Counter Display * Head 3A Head 3B * Counter Display * Head 4A Head 4B 00000000Mdot 00000000Mdot (10/11) 00000000Mdot 00000000Mdot (11/11) 220 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 6.3.2. Counter Initialization Menu This menu initializes the life counters. The parameters that can be initialized in this menu are as follows.
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Falcon II Outdoor series printers – Maintenance Manual 6.3.3. MAC address write enable menu It could happen that the computer cannot make connection with the Falcon II Outdoor printer. If this is the case, the MAC address of the Falcon II Outdoor printer has probably been set to zero or incorrect. To insert the MAC address into the Falcon II Outdoor printer, please follow the instructions mentioned below. Notes : ¾ For the MAC address, a unique number is assigned for each unit.
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Falcon II Outdoor series printers – Maintenance Manual Step 3 : Press the [F3] key to select the option ‘MAC Address’. Following message will appear on the display. * MAC address * Input Password Step 4 : Press the [F2] key. Step 5 : Press the [F3] key. Step 6 : Press the [F1] key. Step 7 : Press the [F4] key. Step 8 : The password has been inserted. Use the [F1], [F2], [F3] and [F4] key to insert the MAC address. Step 9 : Press the [ENTER] key to confirm.
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Falcon II Outdoor series printers – Maintenance Manual 7. ADJUSTMENTS 7.1. INTRODUCTION Adjustments and adjustment procedures required when replacing parts are explained in this chapter. Notes : ¾ Refer to “Jig and tool list ". 224 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 7.2. ADJUSTMENT The adjustments required when replacing parts are explained below. When adjusting or replacing maintenance parts shown in the table below, a printing adjustment is required using the autodiagnostic function on the printer. Refer to the table below while making adjustments.
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Falcon II Outdoor series printers – Maintenance Manual 11 Band feed correction 12 Top and bottom adjustment 13 Rear sensor position adjustment 14 1 Test Print CR deceleration belt tension adjustment 2 Repeatability adjustment 3 Top and bottom adjustment 4 5 Test Print Initializing CR motor history 1 PF deceleration belt tension adjustment 2 Band feed correction 3 Top and bottom adjustment 4 Rear sensor position adjustment 5 6 Test Print Initializing PF motor history 1 Media sensor s
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Falcon II Outdoor series printers – Maintenance Manual assembly 2 Cutter endurance operation check Carriage assembly 1 Head height adjustment 2 Media sensor sensitivity adjustment 3 Continuous printing endurance operation check 4 Head nozzle check 5 Head angle check 6 Head precision adjustment 7 Repeatability adjustment 8 CW adjustment 9 Top and bottom adjustment 10 Test Print 227 → Cutter Endurance menu → Head height adjustment → Media sensor sensitivity adjustment → Head Nozzle Ch
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Falcon II Outdoor series printers – Maintenance Manual 7.3. PARAMETER BACKUP This chapter explains the different types of parameter backup methods. The different backup parameters related to the operation of the printer are recorded on the NVRAM (Flash-ROM or EEPROM) installed on the Mainboard. There are the following types of backup parameters.
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Falcon II Outdoor series printers – Maintenance Manual 7.3.2. Procedure for creating backup parameters This section explains the procedure for recording backup parameters from the Mainboard assembly onto a memory card. Use the following procedure to create backup parameters. Important : ¾ Before replacing parts, be sure to perform the following operations. Turn the machine power OFF. Remove the product's electrical plug from the socket.
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Falcon II Outdoor series printers – Maintenance Manual 7.3.3. Backup parameter installation procedure The following is the procedure for installing the backup parameter from the memory card into the new Mainboard assembly. Use the following procedure to install backup parameters. (1) When using a flash memory card Step 1 : Install the memory card for the backup into the memory card connector slot for the new Mainboard assembly.
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Falcon II Outdoor series printers – Maintenance Manual Step 4 : Follow the instructions in "Parameter Update Menu" and refer to the printed adjustment variable to enter following setting value. ¾ ¾ ¾ ¾ ¾ ¾ ¾ ¾ Head voltage Printing position alignment (Bi-D) CW adjustment Media feed distance Mechanical parameter (Top margin, Bottom margin, Side margin, P_REAR sensor position) Ink parameter (Initial ink charge flag) Ink ID mask Serial number Notes : ¾ Maintenance history cannot be input. 7.4.
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Falcon II Outdoor series printers – Maintenance Manual 7.4.1. Tools required for work The following tools are required to install firmware. Flash memory card or compatible computer Notes : ¾ Refer to “Jig and Tool list”. 7.4.2. Installation procedure The procedure for installing firmware is explained below. Use the following procedure to install firmware. Important : ¾ Before replacing parts, be sure to perform following operations. Turn the machine power OFF.
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Falcon II Outdoor series printers – Maintenance Manual (1) When using a flash memory card Step 1 : Remove the memory cover. Step 2 : Install the memory card for the installation of firmware into the memory card connector slot (J104) of the Mainboard assembly. Notes : ¾ Install the memory card so that its front points towards the inside of the printer. Step 3 : Turn the power of the printer ON. Step 4 : Firmware installation starts.
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Falcon II Outdoor series printers – Maintenance Manual Step 4 : Send new firmware data by MS-DOS copy command etc. (e.g. "COPY /B rh2.04.jfl LPT1") Firmware installation will take about 60 seconds. The following messages will appear in order on the LED display on the operation panel during installation. ¾ “Loading" ¾ "Erasing" ¾ "Copying" ¾ "Comparing" ¾ "End" Step 5 : Check if the buzzer sounded and whether the firmware was installed correctly. Step 6 : Power the unit OFF.
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Falcon II Outdoor series printers – Maintenance Manual Step 2 : Press simultaneously the [CANCEL] and the [ENTER] key while turning the printer ON. Step 3 : The display will mention the following message. F2 → * User Setting * Rem Update Ver Update (1/1) Step 4 : Press the [F2] key. Step 5 : The heater system board is now being updated. The display will mention the following messages. Erasing sectors Wait flash programming Step 6 : At the end the display will mention the following message.
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Falcon II Outdoor series printers – Maintenance Manual 7.5. STEEL BELT TENSION ADJUSTMENT The procedure for adjusting the steel belt tension is explained below. This section explains the procedure for adjusting steel belt tension. When removing/installing the steel belt, adjust its tension. 7.5.1. Tools required for work The following tools are required when adjusting the tension of the steel belt. ¾ Tension gauge: max. 2.0 N (200 g) ¾ Steel belt tension attachment 2: for gauge diameter 2mm (0.08in.
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Falcon II Outdoor series printers – Maintenance Manual Step 2 : If the tension of the steel belt is not within the range of regulated values, adjust the steel belt tension screws. 1 = Steel belt 3 = CR slave pulley Step 3 : 2 = Steel belt tension screw Move the CR cursor to the left and right once or twice. Adjust the CR driven pulley until the upper and lower margins are identical. Caution : If the tension is not equivalent across the entire belt, it could snap during operation. 237 AP-74065, Rev.
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Falcon II Outdoor series printers – Maintenance Manual 7.6. PF DECELERATION BELT TENSION ADJUSTMENT The procedure for adjusting the tension of the PF deceleration belt is explained below. When removing the PF motor or removing/installing the PF deceleration belt, adjust the tension of the PF deceleration belt. 7.6.1. Tools required for work The following tools are required to adjust the tension of the PF deceleration belt. Tension gauge: max. 50 N (5 kgf) Notes : ¾ Refer to “Jig and tool list” 7.6.2.
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Falcon II Outdoor series printers – Maintenance Manual 7.7. HEAD PRECISION ADJUSTMENT This section explains the procedure for adjusting the head angle. When replacing the head assembly, use the following procedure to adjust the head angle and head forward/rear position. Notes : ¾ When the 6-colour mode has been activated, heads in which a cleaning cartridge has been inserted will not spray. Consequently, these heads cannot be adjusted. Perform adjustments in all modes except for 6-colour mode. 7.7.1.
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Falcon II Outdoor series printers – Maintenance Manual Step 5 : Magnifying by the loupe, move the angle adjustment screw on the head to adjust the head angle until dotted line on printing A becomes straight. Step 6 : If CW is aligned but CCW is not, make adjustments until amount of CW and CCW offset are identical. 1 = Angle adjustment screw Notes : ¾ Step 7 : For 87-inch specifications, the head 5-A, 5-B, 6-A, 6-B, 7-A, 7-B, 8-A, 8-B are added. Tighten the screw fixing the head stationary plate.
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Falcon II Outdoor series printers – Maintenance Manual Step 2 : Select "Adj:HeadSlant". Step 3 : Print "F and B" pattern. Notes : ¾ Before adjusting the head forward/backward, move the head fore/aft adjustment screw until item 3 in following figure reaches 0.5mm. If the adjustment has been made when the screw is too tight, forward/backward adjustment of heads may become misaligned. ¾ The reference head is the following. 50, 64 inch spec: The first head. 87 inch spec: The third head from the left.
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Falcon II Outdoor series printers – Maintenance Manual Step 5 : Using the colour printed by the reference head as a guide, move the head forward/aft adjustment screw, adjusting the head forward/back position until each of the colour is straight. a. Enlarge with magnifying glass. Adjust so that two colours converge on a perpendicular line. (See A in following figure.) b. Confirm that row B adjustments have been made. (See B in following figure.) c. Confirm that solids are properly printed.
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Falcon II Outdoor series printers – Maintenance Manual Notes : Confirmation patterns are printed in the following sequence: ¾ 50, 64 inch model: 1A, 1B, 1A, 2A, 1A, 2B, 1A, 3A, 1A, 3B, 1A, 4A, 1A, 4B, 1B, 2A, 1B, 2B, 1B, 3A, 1B, 3B, 1B, 4A, 1B, 4B, 2A, 2B, 2A, 3A, 2A, 3B, 2A, 4A, 2A, 4B, 2B, 3A, 2B, 3B, 2B, 4A, 2B, 4B, 3A, 3B, 3A, 4A, 3A, 4B, 3B, 4A, 3B, 4B, 4A, 4B ¾ 87 inch model: 1A, 1B, 1A, 2A, 1A, 2B, 1A, 3A, 1A, 3B, 1A, 4A, 1A, 4B, 1A, 5A, 1A, 5B, 1A, 6A, 1A, 6B, 1A, 7A, 1A, 7B, 1A, 8A, 1A, 8B, 1B, 2A
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Falcon II Outdoor series printers – Maintenance Manual 1 = Reference Notes : ¾ Step 7 : For 87-inch specifications, the head 5-A, 5-B, 6-A, 6-B, 7-A, 7-B, 8-A, 8-B are added. Adjust reciprocation per head height. ¾ ¾ ¾ #1: Head height LOW #2: Head height MIDDLE #3: Head height HIGH Notes : ¾ In the event that all parts of unit do not line up due to part or assembly precision error, make adjustments until everything in the area around center lines up in a straight line. 244 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 7.9. CW ADJUSTMENT Step 1 : Start the self-diagnostic function. Notes : ¾ Refer to “Self-Diagnosis Function". Step 2 : Select "Adj:Uni-D". Step 3 : Print CW adjustment pattern. Step 4 : Enlarge using a magnifying glass. Adjust each head until the dotted line on printing A in following figure becomes straight using head 1 as a reference.
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Falcon II Outdoor series printers – Maintenance Manual 7.10. CR DECELERATION BELT TENSION ADJUSTMENT This section explains the procedure for adjusting the tension of the CR deceleration belt. When removing/installing the CR deceleration belt, such as when removing the CR motor, adjust the tension of the CR deceleration belt. 7.10.1. Tools required for work The following tools are required to adjust the tension of the CR deceleration belt. ¾ Tension gauge: max.
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Falcon II Outdoor series printers – Maintenance Manual 7.11. COVER SENSOR ADJUSTMENT This section explains the procedure for adjusting the cover sensor. When replacing the cover sensor assembly or removing/installing the front cover, use this procedure to adjust the cover sensor. Step 1 : Start the self-diagnostic function. Notes : ¾ Refer to “Self-Diagnosis Function ". Step 2 : Select "Check:Test" on the self-diagnostic menu. Step 3 : In the inspection menu, select "Check : Check".
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Falcon II Outdoor series printers – Maintenance Manual 1 = Sensor cam Step 7 : 2 = Set screw Use step 5 to check the display on the operation panel once more. 248 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 7.12. HEAD HEIGHT ADJUSTMENT This section explains the procedure for adjusting the head height. If CR cursor assembly is changed, adjust head height. 7.12.1. Tools required for work The following tools are required when adjusting the head height. CR gap check jig Notes : ¾ Refer to “Jig and Tool List". 7.12.2. Adjustment Procedure Perform the head height adjustment following the procedures below.
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Falcon II Outdoor series printers – Maintenance Manual Step 8 : Adjust head U/D eccentric shaft lever so that CR gap adjustment jig can move freely. Step 9 : Perform CR cursor right/left adjustment. 1 = Platen 3 = Print head 5 = Height 1.2 mm 7 = CR gap adjustment jig 1.2 mm side 2 = CR gap check jig 4 = CR cursor 6 = Height 1.3 mm Step 10 : Fasten the screws (2, one on the right, one on the left) that fasten the head U/D eccentric shaft lever.
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Falcon II Outdoor series printers – Maintenance Manual 7.13. MEDIA SENSOR SENSITIVITY ADJUSTMENT This section explains the procedure for adjusting the sensitivity of the media sensor. When replacing the P_EDGE sensor assembly or Mainboard assembly, adjust the media sensor. Notes : ¾ Pay attention to the following points when adjusting the media sensor. This should be performed in an area where sun light and illumination do not influence the sensor.
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Falcon II Outdoor series printers – Maintenance Manual Notes : ¾ The adjustment values are as follows. HIGH level (with media) A/D value In hexadecimal number : D8 to DF (H) In decimal number : 216 to 223 (H) LOW level (without media) A/D value In hexadecimal number : 30 to 0 (H) In decimal number : 48 to 0 (H) (1) HIGH level (with media) adjustment of the A/D value Step 1 : Set the standard media. Step 2 : Select "Check : Head Lock" in the self-diagnosis menu.
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Falcon II Outdoor series printers – Maintenance Manual Step 9 : Adjust the P_EDGE sensor control shown in the following figure so that the values displayed in the operation panel become the adjustment value. ¾ Control R693: Rough adjustment ¾ Control R694: Fine adjustment 1 = Volume R693 2 = Volume R694 (2) LOW level (without media) A/D value check Step 1 : Adjust the A/D value of the HIGH level following the "(1) HIGH level A/D value adjustment" procedure.
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Falcon II Outdoor series printers – Maintenance Manual 7.14. CUTTER ADJUSTMENT This section explains the procedure for adjusting the cutter. When replacing the sub-platen, replacing the solenoid assembly, or removing/installing media guide F, use this procedure to adjust the cutter. Step 1 : Confirm if the media has been cut correctly. Notes : ¾ Step 2 : Refer to “Cutter Endurance menu". If media guide F has been installed at an angle, adjust it. Notes : ¾ Step 3 : Refer to “Removing media guide F".
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Falcon II Outdoor series printers – Maintenance Manual 1 = Cutter holder 2 = Cutter groove of the sub-platen Step 5 : Tighten the screw fixing the cutter holder. Step 6 : Insert paper into unit. Manually place an indentation into paper. Step 7 : Confirm that the distance between paper indentation and cutter groove is between 0.2 and 0.7mm. 255 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 7.15. PUMP TUBING LAYOUT FOR PUMP ASSEMBLY 7.15.1. Replacing the pump assembly (Rockhopper 4 heater) (1) For 50 or 64 inch spec Notes : ¾ When the pump assembly has been installed to the main body, "pump 1" is the pump on the left and "pump 2" the one on the right, viewed from the front. 1 = Pump 1 2 = Pump 2 Step 1 : Remove the maintenance cover.
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Falcon II Outdoor series printers – Maintenance Manual Step 5 : Remove the pump assemblies. Step 6 : Reinstall the new pump assemblies. Step 7 : Reconnect the tubes. 50” or 64” Falcon II Outdoor 2 heater 50” or 64” Falcon II Outdoor 4 heater (2) For 87 inch spec Notes : ¾ When the pump assembly has been installed to the main body, the pumps are "pump 1", "pump 2", "pump 3" and "pump 4" in sequence from left to right, viewed from the front.
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Falcon II Outdoor series printers – Maintenance Manual Step 2 : Following the instructions in "Self-Diagnosis Functions" to start the equipment up in the self-diagnosis mode and release the head lock. Step 3 : Disconnect the tubes to the heads. Step 4 : Remove the waste tubes from there connector. 1 = connection to the heads Step 5 : Remove the pump assemblies. Step 6 : Reinstall the new pump assemblies. Step 7 : Reconnect the tubes.
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Falcon II Outdoor series printers – Maintenance Manual 7.15.2. Replacing the pump assembly (Rockhopper 2 heater) (1) For 50 or 64 inch spec Notes : ¾ When the pump assembly has been installed to the main body, "pump 1" is the pump on the left and "pump 2" the one on the right, viewed from the front. 1 = Pump 1 2 = Pump 2 Step 1 : Remove the carriage cover according to "Removing the carriage cover". Step 2 : Remove the maintenance cover according to "Removing the maintenance cover".
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Falcon II Outdoor series printers – Maintenance Manual Step 7 : Connect up the tubing in the manner shown in the figure below. 1 = Tube connecting to the waste fluid tube 3 = Tube connecting to cap 1 Step 8 : Use a linking tube to connect the new-part pump tube (DF-43951) to the tube connecting cap 2.
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Falcon II Outdoor series printers – Maintenance Manual Step 10 : Bundle the waste fluid tubes in the large waste fluid tube. 1 = large waste fluid tube Step 11 : Bundle the connectors together in the locking wire saddle. Step 12 : Bundle the remaining tubes, cables and connectors together in the manner shown in the figure below. 261 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual (2) For 87 inch spec Notes : ¾ When the pump assembly has been installed to the main body, the pumps are "pump 1", "pump 2", "pump 3" and "pump 4" in sequence from left to right, viewed from the front. ¾ When the pump assembly has been installed to the main body, the bundling locations are "bundling location A", "bundling location B" and "bundling location C" in sequence from left to right, viewed from the front.
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Falcon II Outdoor series printers – Maintenance Manual Step 2 : Connect up the tubing for pump 1 as shown on the figure below. 1 = Tube connecting to waste fluid tube 3 = Tube connecting to cap 4 Step 3 : Connect up the tubing for pump 2 in the manner shown in the figure below. 1 = Tube connecting to waste fluid tube 3 = Tube connecting to cap 3 Step 4 : 2 = Tube connecting to cap 1 2 = Tube connecting to cap 2 Connect up the tubing for pump 3 as shown in the figure below.
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Falcon II Outdoor series printers – Maintenance Manual Step 5 : Connect up the tubing for pump 4 as shown in the figure below. 1 = Tube connecting to waste fluid tube 3 = Tube connecting to cap 8 Step 6 : 2 = Tube connecting to cap 5 Insert in the waste fluid tubes from the pumps a piece of 15 cm tube (DF-43951). 1 = piece of tube (15 cm) Step 7 : Stick the locking wire saddle onto side plate F. Step 8 : Bundle the tubes and connectors together in the locking wire saddle.
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Falcon II Outdoor series printers – Maintenance Manual 1 = large waste fluid tube Step 10 : Bundle the remaining tubes, cables and connectors together in the manner shown in the figure below. 265 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 8. MAINTENANCE 8.1. INTRODUCTION This chapter provides information about the periodical services, part life, lubrication/bonding and transport. Important : ¾ Before replacing parts, be sure to perform following operations. Turn the machine power OFF. Remove the product's electrical plug from the socket. Otherwise, you may suffer electric shock or the machine’s electric circuits may be damaged. ¾ Disconnect all cables from the machine.
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Falcon II Outdoor series printers – Maintenance Manual 8.2. CLEANING You need to clean the printer periodically to keep it in best working condition. Notes : ¾ ¾ Refer to the User’s Guide. Refer to “Exploded Views/Service Parts List”. Part Platen surface Media guide F Pressure rollers Timing Several times per year Timing fence (CR encoder detection slit plate) Several times per year P_REAR sensor surface Several times per year ¾ ¾ ¾ Cleaner head (Cleaning wiper) Action Clean it.
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Falcon II Outdoor series printers – Maintenance Manual 8.3.1. Service by end-user Perform periodical inspections according to the table below. N° 1 2 Part number DF-43637 + DF-43643 DF-43694 + DF-35399 Quantity 4+1 2+1 3 4 5 / / / / / / N° 1 2 3 4 5 Action Replace the wipers and sponge. Replace the sponge at the back of the capping station. Clean the wipers. Clean caps in the maintenance station. Clean around the bottom of the heads.
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Falcon II Outdoor series printers – Maintenance Manual Month N° 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 7 8 9 10 11 X X X X X X X X X 12 X X X X X X X X X X X X 8.4. PART LIFE INFORMATION This section shows how to check the life of a service part. To know the life of a service part, check the maintenance counter from the counter display menu in the maintenance mode. Notes : ¾ Refer to "Counter Display Menu" for more details of the counter display menu.
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Falcon II Outdoor series printers – Maintenance Manual 6 7 8 9 10 Tweezers Hexagon wrench (1.5 mm to 6.0 mm) Box driver (5.5 mm) Box driver (7.0 mm) E ring holder (E-2.
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Falcon II Outdoor series printers – Maintenance Manual 8.6. LUBRICATION/BONDING This section covers the lubrication/bonding information. After disassembling/assembling this machine, always perform necessary lubrication/bonding according to the table below. Caution : ¾ PF Driving Components Do not oil the printer mechanism with oil other than designated by MUTOH. Doing so may damage the parts or shorten the lifetime.
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Falcon II Outdoor series printers – Maintenance Manual Head base components Head installation board Maintenance components Maintenance assembly Pump Components Combined gear Deceleration gear Idler gear Idler gear axis Winding components PF Driving Components Winding assembly (gear components) Parts Set screw CR Driving Components Adjusting screw of the CR slave pulley Cursor Components Step-bore screw Maintenance components E ring Scroller receptacle R components Others Set screw PF Drivin
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Falcon II Outdoor series printers – Maintenance Manual Pump Components Pump assembly Others Locations where sharp edges are likely to occur Acetate tape is fixed to the pump assembly tube (prevents dislodging of tube). Acetate tape is fixed to tape electrical wires and harnesses, where sharp edges are likely to occur (sharp edge protection). 273 Not specified Not specified AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 8.7. TRANSPORTATION OF MACHINE This section explains transferring and transporting the printer. When you transport the printer, the printer should be repackaged using the original box and packing materials, to protect it from vibration or impact. Transport the printer following the procedures below. (1) Task before transportation Step 1 : Turn on the power to the product. Step 2 : Verify if the product is at a normal status.
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Falcon II Outdoor series printers – Maintenance Manual Notes : ¾ Refer to the User’s Guide. Step 11 : Package the machine (2) Task after transportation Step 1 : Unpack, assemble, and install the machine. Step 2 : Make the machine ready for operation. 275 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 9. TROUBLESHOOTING 9.1. INTRODUCTION This chapter explains the procedures for troubleshooting this product. When the product indicates a failure and an error message is also displayed on the control panel, refer to "Troubleshooting procedures when a message has been displayed" and implement treatment.
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Falcon II Outdoor series printers – Maintenance Manual 9.2.1. Operating condition display This chapter explains the messages displayed, the items to be confirmed and the remedy. No. 1 Message Cover Open Phenomenon The front cover is open. Check point (1) Check if the cover R/L sensor assembly comes on and off properly when the front cover is opened and closed. (2) Make sure that cables for the cover sensor assembly are securely connected. (3) The Mainboard assembly may have a problem.
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Falcon II Outdoor series printers – Maintenance Manual 3 Paper End The paper is not setup (4) Make sure the transmission photosensor cables at the lever motor have been securely installed. • Securely connect the transmission photosensor cables to Mainboard assembly connectors J123 and J124. (5) Check the operation of the foot lever via “Test:Sensor” of the self-diagnostic function. (6) The Mainboard assembly may have a problem.
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Falcon II Outdoor series printers – Maintenance Manual 9.2.2. Message type errors The following explains the messages, items to be confirmed and remedies to take when message type errors occur while the product is operating. Message type errors are displayed when trouble occurs during operation. When message type errors occur, this product displays the following error messages on the operation panel and stops the operation.
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Falcon II Outdoor series printers – Maintenance Manual (6) The CR board assembly may be damaged. (7) The Mainboard assembly may be damaged. 2 Paper Slant The paper is fed askew. (1) Reset the paper and check if the condition recurs. 3 Paper Cut Error Even though cutting operation was performed, the paper was not completely cut and removed. (1) Check the cutter grooves for accumulated paper dust and slip.
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Falcon II Outdoor series printers – Maintenance Manual (5) Check the up and down operation of the solenoid via “Life/Cutter” of the self-diagnostic function. a) The solenoid moves up and down : Check the cutter’s down position relative to the cutter groove. b) It does not move up and down. (6) Open CR cable, faulty solenoid assembly, faulty board assembly, etc., may be the cause. 4 End of Roll Displayed when the end of the roll paper is detected during the use of roll paper.
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Falcon II Outdoor series printers – Maintenance Manual been set to the up position. 5 [ ] Near End The remaining amount of ink is low. Printing is still possible. 6 [ ] Ink End There is no more ink left. Printing in progress is interrupted immediately. (2) Check the P_REAR sensor assembly for the contact condition. •Redo the connections of Mainboard assembly connectors J128 and J129. If the paper is not initialized, the sensor may be damaged. • Replace the P_REAR sensor assembly.
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Falcon II Outdoor series printers – Maintenance Manual (2) Check the ink ID sensor connector for the contact conditions. (3) The Mainboard may be damaged. 8 9 Warning Waste INK Tank Warning Waste INK Tank The waste tank will soon be full. The service life of the ink tube will soon be reached. (1) Check if the message is still displayed after turning the power off and then back on again. (2) The amount of waste ink inside the tank reached the specified level.
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Falcon II Outdoor series printers – Maintenance Manual 10 11 12 13 (Warning Head Life) Hard disk status conect error Network initialize error Waste ink tank sts. No The service life of the print head will soon be reached. There is a problem in the hard disk connections. There is a problem in the network board. The waste tank is not installed. (1) Check if the message is still displayed after turning the power off and then back on again.
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Falcon II Outdoor series printers – Maintenance Manual (2) Check the operation of the waste box sensor assembly via “Sensor/Waste Bin” of the selfdiagnostic function. (3) Check the connections of the connectors. (4) The Mainboard assembly may be damaged. • Replace the waste box sensor assembly. - •Check if the waste box sensor connectors are connected to the rear side cap R. • Redo the connections of the following connectors. • Mainboard : J120 • Replace the Mainboard assembly.
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Falcon II Outdoor series printers – Maintenance Manual 9.2.3. Heating system error The following explains the messages, items to be confirmed and remedies to take when errors handling heating system occur while the product is operating. Heating system errors are displayed when communication trouble occurs between the heater strips and this product. If heating system error occurs, the following error messages are displayed and the printer stops.
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Falcon II Outdoor series printers – Maintenance Manual Notes : ¾ ¾ Check if the connectors are properly connected to the power board. Check if the sensors are connected onto the right connector. 287 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 9.2.4. Data error The following explains the messages, items to be confirmed and remedies to take when data errors occur while the product is operating. Data errors are displayed when data communication trouble occurs between the computer and this product. If data error display occurs, the following error messages are displayed and the printer stops. Solve the problem to delete the error message and restart the printer. No.
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Falcon II Outdoor series printers – Maintenance Manual 9.2.5. Command errors The following explains the messages, items to be confirmed and remedies to take when command errors occur while the product is operating. Command errors are displayed when trouble occurs during analysis of the command data that is sent to this product from the computer. If a command error occurs, the following error messages are displayed and the printer stops. Solve the problem to delete the error message and restart the printer.
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Falcon II Outdoor series printers – Maintenance Manual 9.2.6. Errors requiring restart The following explains the messages, items to be confirmed and remedies to take when errors requiring restart occur while the product is operating. Errors requiring restart are displayed when trouble critical to the operation of this product occurs. ¾ Foreign material disturbing the printer operation has been loaded in the printer. ¾ An electrical circuit (such as board, motor or sensor) failure has occurred.
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Falcon II Outdoor series printers – Maintenance Manual 3 E 016 error CPU Err [00] 4 E 016 error CPU Err [02] 5 E 016 error CPU Err [03] 6 E 016 error CPU Err [04] 7 E 016 error CPU Err [05] 8 E 016 error CPU Err [06] 9 E 016 error CPU Err [07] 10 E 016 error CPU Err [08] 11 E 016 error CPU Err [09] 12 E 016 error CPU Err [10] 13 E 016 error CPU Err [03] Interruption exception error: Trouble occurred in the interrupt process Command boundary exeption errors: Trouble occured in the comma
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Falcon II Outdoor series printers – Maintenance Manual 14 E 016 error CPU Err [12] 15 E 016 error CPU Err [13] 16 E 016 error CPU Err [15] 17 E 016 error CPU Err [22] 18 E 016 error CPU Err [32] 19 E 016 error CPU Err [33] Calculation overflow exception errors: overflows occurred. Trap exception errors : trap occurred Floating point exception error : trouble occurred in the floating points Watch exception error : trouble occurred in the watch.
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Falcon II Outdoor series printers – Maintenance Manual 3 E069 error Paper feed timeout 4 E071 error PF overcurrent 5 E 066 Error CR Motor 6 E 068 Error CR Encoder → Encoder Menu Timeout occurred on paper travel (Xaxis) during operation. Displayed when the pressure roller has not reached the commanded position. An overload occurred in the PF motor (X-axis) during operation. (3) Check “Encoder:PF” under “Test:Encoder” of self-diagnosis function. (4) PF motor assembly may be damaged.
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Falcon II Outdoor series printers – Maintenance Manual 7 E 070 Error CR Timeout Err Time out occurred in the head travel (Yaxis) during operation. Displayed when he carriage has not reached the commanded position. (3) Check if “CR Motor Error” occurs by setting the durability cycles at 50 over larger via “Life: CR Motor” of the selfdiagnostic function. (4) Check the Tfence for contamination, flows and bends. 294 • Check he connections of the following connectors.
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Falcon II Outdoor series printers – Maintenance Manual (5) Check the “Encoder:CR” via “Test/Encoder” of the self-diagnostic functions. 8 E 072 Error CR OverCurrent An overload occurred in the CR motor (Y-axis) during operation. (6) The Mainboard assembly may have a problem. → Error E068 occurs if Mainboard assembly connector J155/COVER-R or J156/COVER-L is not connected. 9 E 073 Error CR Origin CR_HP cannot be detected.
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Falcon II Outdoor series printers – Maintenance Manual 10 11 E 074 Error Cover E 075 Error Head OverCurrent Trouble occurred in the cover sensor. Trouble occurred during printer operation due to an overload of the print head. (1) Check the cover sensor via “Test/Sensor” of the self-diagnostic function. (2) The cover sensor assembly may be damaged. • Make sure that the connection of the cover sensor assembly is good. • Mainboard : J155 – J156 • Replace the cover sensor assembly.
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Falcon II Outdoor series printers – Maintenance Manual 12 E 076 Error PG CR origin The HD_SLIDE home position cannot be detected. (5) The Mainboard assembly may have a problem • Replace the Mainboard assembly • Reset the head error (1) Check the HD_SLIDE sensor via “Sensor/HD_SLID E” of the selfdiagnostic function • Make sure that the connections of the HD_SLIDE sensor assembly connectors are good. • Mainboard : J127 • Replace the HD_SLIDE sensor assembly.
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Falcon II Outdoor series printers – Maintenance Manual 14 E 078 Error Head Cable Trouble occurred in the head cable or head thermister. (2) The Mainboard assembly may have a problem • Replace the Mainboard assembly (1) Make sure that the connections of the head tape power cables are good. •Redo the connections of the following connectors. • CR board : J217 – J232 •Redo the connections of the following connectors. • CR board : J201J216 • Replace the print head assembly.
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Falcon II Outdoor series printers – Maintenance Manual 16 17 E 080 Error Lever Sensor E 081 Error Cap Sensor. Trouble occurred in the lever sensor. Trouble occurred in the cap sensor. (1) Check the operation of the transmission photosensor for the lever up/ down via “Check:sensor “ of the selfdiagnostic function.
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Falcon II Outdoor series printers – Maintenance Manual 18 E 082 Error Wiper Sensor Trouble occurred in the wiper sensor. (3) Is the sensor element of the transmission photosensor at the cap contaminated? (4) Is the transmission photosensor cable at the lever motor securely installed? • Clean the sensor element using cotton swabs. → Replacing the transmission photosensor. • Securely connect the cable for the transmission photosensor cable to Mainboard assembly connectors J123 and J124.
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Falcon II Outdoor series printers – Maintenance Manual (5) Make sure that the connections of the SLIDE motor assembly for the WIPER slide are good. (6) The Mainboard assembly may be damaged. 301 • Replace the SLIDE motor assembly for the wiper SLIDE. → Replacing the SLIDE motor assembly (wiper arm). • Replace the Mainboard assembly. → Replacing the Mainboard assembly, HDD_Extension board assembly, HEAD_DRV board assembly and cooling fan assembly. AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 9.3. TROUBLESHOOTING PROCEDURES WHEN ERRORS ARE NOT DISPLAYED The following explains the messages, items to be confirmed and remedies to take when error messages are not displayed 9.3.1. Problems relating to initial operation This chapter explains the messages displayed, the items to be confirmed and the remedy. No. 1 Phenomenon Power is not supplied. Check point (1) Check the panel unit assembly cables for open or shorted conditions.
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Falcon II Outdoor series printers – Maintenance Manual 2 LCD failure (no display / garbled display) (1) Check if the DIMM (optional memory) is installed. (2) Make sure that the connections of the panel cable connectors at the panel side and the Mainboard assembly side is good. • Check the panel cables for skewed insertion. • Make sure that they are securely locked. (3) The DIMM (optional memory) may be damaged. (4) The panel cables may be damaged. (5) Check the panel unit assembly LCD for damages.
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Falcon II Outdoor series printers – Maintenance Manual 4 Although ink replenishment has started, the ink has not reached the head. (2) Make sure that the connections of the panel cable connectors at the panel unit assembly side and the Mainboard assembly side is good. • Check the panel cables for skewed insertion. • Make sure that they are securely locked. (3) Check if “leverUp” is displayed on the LCD when the pressure arm is at the lower position. (4) The ink ID board assembly may be damaged.
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Falcon II Outdoor series printers – Maintenance Manual 5 Ink is not supplied when ink replenishment is complete. 6 Operation does not take place at all after the power is supplied. 7 When power is supplied, “Initialize” is displayed, then reset. Initialization does not take place even if the paper is set. 8 (1) Make sure that the connections of the head cable connectors at the CR board assembly side and the print head side is good. • Check the head cables for open conditions.
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Falcon II Outdoor series printers – Maintenance Manual 9 Operation does not take place even if the front cover is closed. “TEST:Sensor” of the self-diagnostic function. sensor assembly. 10 Operation does not stop even if the front cover is opened. (2) Panel unit Make sure that the connections of the panel cable connectors at the assembly side and the Mainboard assembly side are good. • Check the panel cables for skewed insertion. • Make sure that they are securely locked.
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Falcon II Outdoor series printers – Maintenance Manual 11 12 Key inputs via operation panel are disabled. Printing does not start even if data is received. (1) Check the operation panel cover for breakage and contamination. (2) Make sure that the connections of the panel cable connectors at the panel unit assembly side and the Mainboard assembly side is good. • Check the panel cables for skewed insertion. • Make sure that they are securely locked. (3) The panel unit assembly may be damaged.
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Falcon II Outdoor series printers – Maintenance Manual 9.3.2. Problems relating to paper feed No. 1 Phenomenon The paper comes off at paper set initialization or during the printing operation. Check point (1) Check if the P_REAR sensor assembly and P_EDGE sensor assembly are operating correctly via “Test:Sensor” of the self-diagnostic function Action • Check if the connections of the following connectors.
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Falcon II Outdoor series printers – Maintenance Manual (7) Check the scrollers for bends. 309 • Replace the scrollers. → User’s Guide AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 9.3.3. Problems relating to the printing operation No. 1 2 3 Phenomenon Continuous printing cannot be performed. Give an extra feed after the printing operation has been completed. Dots are missed in printing Check point (1) The program ROM may have failed. (2) The Mainboard assembly may have a problem. Action • Upgrade the firmware version. Refer to → Firmware installation. • Replace the Mainboard assembly.
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Falcon II Outdoor series printers – Maintenance Manual (2) Repeat head cleaning several times. 4 Cleaning does not fix problems such as clogging or split nozzle. (1) Check the use conditions of the product. (2) Check if the conditions occur after ink replenishment. (3) Check the cleaning wipers for contamination. (4) Check the installation conditions of the cleaning wipers. (5) Check if the QR codes are input correctly. (6) The damper may be damaged. (7) The print head assembly may be damaged.
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Falcon II Outdoor series printers – Maintenance Manual (8) Check if the remaining amount of ink in the cartridge is sufficient. (9) The ink pump assembly may have a problem. (10) The maintenance assembly may have a problem. (11) The Mainboard assembly may have a problem. • If “Near End” or “Ink End” is not displayed when the remaining amount of ink is insufficient, the ink sensor assembly may have a problem. • Replace the ink pump assembly. → Replacing the I/H (inkholder) assembly.
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Falcon II Outdoor series printers – Maintenance Manual 7 Drawn black on a full screen (Or other specified colour) (8) The CR board assembly may have a problem. (9) The HEAD_DRV board may be damaged. • Replace the CR board assembly. → Replacing the CR board assembly • Replace the HEAD_DRV board. (10) The Mainboard assembly may have a problem. • Replace the Mainboard assembly. (1) Check the head and CR cables for skewed insertion. • Redo the connections of the following connectors.
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Falcon II Outdoor series printers – Maintenance Manual 8 9 10 11 Light and slade printing occurs. Irregularities occur in the image picture. The lines in the CR direction split. Black or white streaks occur in printings. (6) The Mainboard assembly may have a problem. • Replace the Mainboard assembly. (1) Check if the use conditions are within the normal operation conditions. (2) Check if printing began immediately after ink replenishment.
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Falcon II Outdoor series printers – Maintenance Manual (6) If the paper in concern is roll paper, check if the scroller is rotating smoothly. (7) Make sure hat the PF belt tension is adjusted correctly. (8) Check if the pump is running during the cleaning operation. (9) Check if he nozzle face is wiped correctly. (10) Check the cleaning wipers for contamination. (11) Check the T fence for contamination (12) Check the rotation of the pressure roller with the pressure arm at the raised position.
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Falcon II Outdoor series printers – Maintenance Manual 12 The printing boundary is smeared. (14) The head assembly may be damaged. • Replace the damaged head assembly. (15) The ink tube may be damaged. • Replace the ink tube. (16) The CR board assembly may have a problem. • Replace the CR board assembly. (17) The Mainboard assembly may have a problem. • Replace the Mainboard assembly (1) Check if the condition is recovered by cleaning.
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Falcon II Outdoor series printers – Maintenance Manual 13 There are many satellite droplets (unnecessary dots) 14 Fiber tracking is shown in prints. 15 Lines look blurred when printed. (6) Check the head assembly for breakage. • Replace the damaged head assembly (7) The CR board assembly may have a problem. (8) The Mainboard assembly may have a problem. • Replace the CR board assembly. (1) Check if the use conditions are within the normal operation conditions.
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Falcon II Outdoor series printers – Maintenance Manual (5) Check the T fence for contamination. (6) Make sure that the CR_ENC assembly and the T fence are not interfering. (7) Check if the pump is running during the cleaning operation. (8) Check if the nozzle face is wiped correctly. (9) Check the cleaning wipers for contamination. (10) Check if the QR code is input correctly. (11) The head assembly may be damaged.
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Falcon II Outdoor series printers – Maintenance Manual 16 Mixed colour lines do not overlap. 17 The positions of black and colours are not aligned. (12) The ink tube may be damaged. • Replace the ink tube. (13) The CR board may have a problem. (14) The Mainboard assembly may have a problem. • Replace the CR board assembly. (1) Check if the tension of the steel belt is properly adjusted. (2) Check the head inclination and height adjustments.
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Falcon II Outdoor series printers – Maintenance Manual (2) Check if the tension of the steel belt is adjusted correctly. (3) Check the T fence for contamination. A: Paper discharging direction 19 Straight lines in the head travel direction are not accurate (straightness) A: Paper discharging direction 20 A limited line in the paper feed direction is not accurate ( in the sub scanning direction) (4) The internal process operation of the Mainboard assembly may be malfunctioning.
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Falcon II Outdoor series printers – Maintenance Manual A : Paper discharging direction 21 Straightness in the paper feed direction is not accurate (paper joint accuracy). A : Paper discharging direction 22 Inaccurate squareness (5) Check the rotation of the pressure roller with the pressure arm at the raised position. (6) Check the grid roller for rugged movement. Also, check the rotary movement for irregularities.
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Falcon II Outdoor series printers – Maintenance Manual (2) Check the rotation of the pressure roller with the pressure arm at the raised position. (3) Check the grid roller for rugged movement. Also, check the rotary movement for irregularities. 23 Abnormal discharge occurs. (1) Check if the two head tape power cables stick together. (2) Make sure that the CR tape power cables are bundled correctly.
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Falcon II Outdoor series printers – Maintenance Manual 9.3.4. Problems relating to noise No. 1 Phenomenon There is noise when the paper is loaded. 2 You hear some noise during printing wait. 3 You hear some noise when the head is moving from side to side. Check point (1) Check the surroundings of the suction fan assembly for obstructions and foreign objects. (2) Check the cables for damage and make sure that the connector connections are good. (3) The suction fan assembly may have failed.
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Falcon II Outdoor series printers – Maintenance Manual (3) Check if rattles are heard when the carriage is moving from side to side. (4) Check the CR cables for noise. (5) Make sure that the CR_ENC assembly and the T fence are not interfering. 4 You hear some noise when the paper is fed. (6) Check the bearings of the CR driven pulley for noise. (7) Check if the tension of the steel belt has been properly adjusted. (8) Check the CR motor assembly for noise.
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Falcon II Outdoor series printers – Maintenance Manual (3) Check the grid roller for rugged movement. Also, check the rotary movement for irregularities. 325 • If foreign materials such as paper dust and waste paper are found on the grid rollers, remove it using a nylon brush. → User’s Guide. AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual 9.3.5. Problems relating to the paper cutting operation No. 1 Phenomenon The cutting operation is not performing correctly. Check point (1) Check the operation panel and make sure that the media cutting setting is not set to off or manual. (2) Check the operation panel and make sure that PaperDet. has not been set to TakeUpRoll. (3) Check the cutter grooves for accumulated paper dust and clips.
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Falcon II Outdoor series printers – Maintenance Manual a) The solenoid moves up and down: check the cutter’s down position relative to the cutter groove. b) It does not move up or down. (8) Open CR cable, faulty solenoid assembly, faulty board assembly, etc. may be the causes. 2 Cutting has been performed during printing. (1) Check if the paper (output) size on the application side is correct. (2) The program ROM may have failed.
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Falcon II Outdoor series printers – Maintenance Manual (3) Check the CR cables for skewed insertion. (4) The CR board may have a problem. (5) The Mainboard may have a problem. 3 4 The cutting operation is in process, but the paper has not been cut. The paper has not been cut as smoothly as expected, resulting in jamming. (1) Check the cutter blade for shipping and deterioration. (2) Check if the cutter cap is securely installed. (3) Check if the cutter moves up and down smoothly.
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Falcon II Outdoor series printers – Maintenance Manual (2) Has the cutter cap been securely installed? (3) Check if the cutter moves up and down smoothly. (4) Check the cutter grooves for accumulated paper dust and slips. (5) Check if the cutter blade is parallel with the groove. 7 Cutting starts after the completion of the print. (6) The cutter may have a problem. (1) Check the operation panel and make sure the InkDryTime has not been set.
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Falcon II Outdoor series printers – Maintenance Manual 9.3.6. Problems relating to online and functions No. 1 Phenomenon Online has not been properly established by Centronics. Check point (1) Check the centronics settings in the operation panel. (2) Replace the interface cables and see if errors still occur. (3) The program ROM may have failed. (4) The Mainboard assembly may have a problem. 2 Online has not been properly established by the network. 3 Scaling is not functioning correctly.
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Falcon II Outdoor series printers – Maintenance Manual 5 Other functions are not performing correctly. a problem. assembly 6 The printing position has been misaligned. (1) Check if CW adjustments are made correctly. (2) Check the top & bottom adjustments (3) The program ROM may have failed. (4) The Mainboard assembly may have a problem. • Make adjustments. (1) The program ROM may have failed. (2) Check the T fence for contamination and bends. • Upgrade the firmware version.
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Falcon II Outdoor series printers – Maintenance Manual 9 After printing has been completed, the paper is fed an extra amount. (3) Check the “Encoder:PF” via “Test:Encoder” of the self-diagnostic function • Make sure that the connections of Mainboard assembly connector J132 are good. • Replace the T fence. • Replace the CR_ENC assembly. • Replace the CR motor. • Replace the CR_BASE board assembly. • Replace the CR tape power cables. (4) The Mainboard assembly may have a problem.
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Falcon II Outdoor series printers – Maintenance Manual 9.3.7. Other problems No. 1 Phenomenon A hang up occurs Check point (1) The internal process operation of the Mainboard assembly may be malfunctioning. (2) The Mainboard assembly may have a problem. 2 The power has been cut off during the printing operation. (1) Make sure that the power cables are not disconnected. (2) Check the power cables for a shorted condition. (3) Check for leakage.
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Falcon II Outdoor series printers – Maintenance Manual 10. APPENDIX 10.1. INTRODUCTION This chapter provides referential information such as service data and exploded views. 10.2. WIRING DIAGRAM FALCON II OUTDOOR 2H 334 AP-74065, Rev. 1.
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Falcon II Outdoor series printers – Maintenance Manual No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Service part Mainboard 50” Mainboard 64” Mainboard 87” Power Supply Mounting MK-51600 --> DF44060 Power Supply Cable Power Inlet Power Inlet To MP-80203 FG Cable L=120 MN RH AC Cable 1 50 AC Cable 1 64 AC Cable 1 87 Ext. Cable AC-Heat Strip R Ext. Cable Sens-Heat R AC Cable 2 50 AC Cable 2 64 AC Cable 2 87 Interf. Cable DB 9M - Jst 50 Interf.
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Falcon II Outdoor series printers – Maintenance Manual 10.3. WIRING DIAGRAM FALCON II OUTDOOR 4H No.
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Falcon II Outdoor series printers – Maintenance Manual 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Fixer B1 RH VU 50" Fixer B2 RH VU 50" Post fixer C RH VU 87" Heater A RH VU 87" Dryer D1 RH VU 87" Dryer D2 RH VU 87" Fixer B1 RH VU 87" Fixer B2 RH VU 87" AC Cable 1 SMDP RJ8/50 VU AC Cable 1 SMDP RJ8/64 VU AC Cable 1 SMDP RJ8/87 VU AC Cable 2 SMDP RJ8/50 VU Ext. Cable AC-Heatstrip R RJ8 UV Ext. Cable AC Heatstrip A RHII 87 Ext. Cable sens-Heat R RJ8 UV Ext.
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Falcon II Outdoor series printers – Maintenance Manual 10.4. FALCON II OUTDOOR : SERVICE PARTS LIST/EXPLODED VIEWS/CONFIGURATION DIAGRAMS This section includes the service parts list, exploded views of respective units and configuration diagrams. Notes : ¾ For the latest ‘exploded views’ and ‘part description’, please refer to the spare part lists of the printer. ¾ For spare parts, please refer to the latest spare part list. ¾ Specifications are liable to changes without prior notice. 10.4.1.
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Falcon II Outdoor series printers – Maintenance Manual 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 DF-42663 (I-69) DF-44060 (I-72) EY-80203 (I-2003) MC-7002 (I-2002) MK-51585 MK-51586 (I-2007) MK-51587 MK-51590 MK-51593 (I-2008) MK-51565 MK-51566 (I-2007) MK-51567 MK-51570 MK-51573 (I-2008) MK-51574 MK-51575 MK-51576 (I-2005) MK-51577 MK-51594 MK-51595 MK-51596 (I-2005) MK-51597 MK-51600 (I-2006) Driver Cooling Fan Cable 1 X X X X X X DC Cable Assy X X X X X X X X
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Falcon II Outdoor series printers – Maintenance Manual 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 DF-42479 (G-22) DF-42480 (G-23) DF-42481 (G-24) DF-42482 (G-25) DF-42483 (G-26) DF-42484 (G-27) DF-42456 (G-31) DF-42457 (G-32) DF-42458 (G-33) DF-42459 (G-34) DF-42460 (G-35) DF-42461 (G-36) DF-42462 (G-37) DF-42463 (G-38) DF-44051 DF-44766 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
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Falcon II Outdoor series printers – Maintenance Manual 8 9 10 11 12 MK-51613 (J-2005) MK-51619 (J-2005) MK-51618 (J-2006) MK-51614 (J-2006) MK-51620 (J-2006) X Fan Extens cable 16 X Fan Extens cable 16 X Fan Extens cable 26 X Fan Extens cable 26 X Fan Extens cable 26 10.4.4. Cursor Components No.
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Falcon II Outdoor series printers – Maintenance Manual 10.4.5. CR Driving components No.
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Falcon II Outdoor series printers – Maintenance Manual 27 28 29 30 31 32 33 34 35 36 37 38 39 40 DF-43935 (B-79/B-80) DF-42564 (B-116) DF-42874 (B-116) DF-42566 (B-116) DF-43437 (B-147) DF-43621 (B-162) DR-401441609 (B-2007) DR-703241990 (B-2008) ME-80303 (B-2005) ME-80304 (B-2003) ME-80305 (B-2002) ME-80306 (B-2006) MY-35600 (B-3000) MY-80427 (B-3002) X X X X X X Ink Tube (50, 64 & 87) X X Steel Belt 50 X X Steel Belt 64 X X Steel Belt 87 X X X X X X X X X X X X X X X X X X
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Falcon II Outdoor series printers – Maintenance Manual 9 10 11 12 MY-80627 MY-80628 MY-80622 MY-80623 Maint. Station Assy RH 4 Heads Maint. Station Assy RH 8 Heads Cap assy 4 heads Cap assy 8 heads X X X X X X X X X X X X F2O – 4 heater 50 64 87 X X X 10.4.7. PF Driving Components No.
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Falcon II Outdoor series printers – Maintenance Manual 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 EY-25582 (A-2010) EY-80201 (A-2009) EY-80202 (A-2003) EY-80204 EY-80205 MY-80203 MY-80213 MY-80223 MY-80203J MY-80213J MY-80223J MY-80210 MY-80220 MY-80230 MY-80210J MY-80220J MY-80230J MY-80251 MY-80261 MY-80271 MY-80321 MY-80322 MY-80323 Power Supply 5V/24V X X X PCB Contr. Board Heat Syst RH2 X X X PCB Powerboard Heat Syst RH2 X X X PCB contr.
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Falcon II Outdoor series printers – Maintenance Manual 18 19 20 21 22 EY-80216 EY-80226 EY-80237 EY-80217 EY-80227 Heat Strip Assy front 1 RH 64 Heat Strip Assy front 1 RH 87 Heat Strip Assy front 2 RH 50 Heat Strip Assy front 2 RH 64 Heat Strip Assy front 2 RH 87 X X X X X 10.4.9. Paper Guide Rear components No.
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Falcon II Outdoor series printers – Maintenance Manual 10.4.12. Pump Components No.
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Falcon II Outdoor series printers – Maintenance Manual 10.4.15. Take-up No.
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No. Service part Service diagram 1 2 3 4 5 6 7 AP-51210 EY-80338 EY-80339 EY-80348 EY-80349 EY-80358 EY-80359 EPDM Insulation Tape 25mm 4mm Fixer B1 RH VU 64" Fixer B2 RH VU 64" Fixer B1 RH VU 50" Fixer B2 RH VU 50" Fixer B1 RH VU 87" Fixer B2 RH VU 87" F2O – 2 heater 50 64 87 F2O – 4 heater 50 64 87 X X X X X X X X X F2O – 2 heater 50 64 87 F2O – 4 heater 50 64 87 X X X X X X X X X 10.4.18. Waste bottle No.