AP74700 Troubleshooting Guide

Troubleshooting
guide
Troubleshooting
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2 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
Table of content
1 TROUBLESHOOTING PROCEDURE WHEN DISPLAYING A MESSAGE ................. 5

1.1 INFORMAL NOTIFICATIONS DURING OPERATION .............................................................. 6
1.2 ERROR NOTIFICATIONS DURING OPERATION .................................................................. 9
1.3 HEATER SYSTEM ERRORS 65” & 90” PRINTERS ONLY ................................................... 16
1.4 HEATER SYSTEM ERRORS 100” PRINTERS ONLY .......................................................... 17
1.5 DATA ERRORS .......................................................................................................... 20
1.6 COMMAND ERRORS .................................................................................................. 21
2 TROUBLESHOOTING WITH ERROR CODES ........................................................... 23

2.1 DRAM ERRORS ....................................................................................................... 23
2.2 CPU ERRORS .......................................................................................................... 24
2.2.1 E 016 error CPU Err(03) .................................................................................. 24
2.3 PF - PAPER FEED ERRORS ....................................................................................... 25
2.4 CARRIAGE RELATED ERRORS ..................................................................................... 27
2.4.1 E066 - CR Motor Err ........................................................................................ 27
2.4.2 E068 - CR Encoder Err .................................................................................... 27
2.4.3 E072 - CR OverCurrent ................................................................................... 27
2.4.4 E070 - CR Timeout Error ................................................................................. 29
2.4.5 E073 - CR Origin Error ..................................................................................... 30
2.4.6 E074 - Cover Sensor Error............................................................................... 30
2.4.7 E076 - PG Origin Err ........................................................................................ 30
2.4.8 E078 - Head Cable Error ................................................................................. 31
2.5 LEVER & PRESSURE ROLLER ERRORS........................................................................ 32
2.5.1 E079 - Lever Over Current ............................................................................... 32
2.5.2 E080 - Lever Sensor Err .................................................................................. 32
2.6 CAPPING STATION ERRORS....................................................................................... 33
2.6.1 E081 - Cap Sensor Err ..................................................................................... 33
2.6.2 Sensor diagnostics........................................................................................... 33
2.6.3 Capping - Motor diagnostics ............................................................................ 33
2.6.4 E082 - Wiper Sensor Err .................................................................................. 34
2.6.5 Wiper - Motor diagnostics ................................................................................ 34
2.6.6 E097 - NVRAM Error ....................................................................................... 35
2.7 HEAD AND FLATCABLE RELATED ERRORS .................................................................... 36
2.8 ETHERNET CARD ERRORS ......................................................................................... 36
2.9 SPITFIRE100 - SPECIFIC ERROR CODES ................................................................ 37
2.9.1 E144 – Head 0 Post timed ............................................................................... 37
2.9.2 E160 – Waste tank full ..................................................................................... 37
2.9.3 E240 – No SlaveBoards ................................................................................... 37
2.9.4 E247 – CHS Start-up Error .............................................................................. 38
2.9.5 E248 – Extpmp Start-up Error .......................................................................... 38
2.9.6 E251 – NMPS Start-up Error............................................................................ 38
2.9.7 E252 – Incompatible HW ................................................................................. 38
2.9.8 E254 – NMPS Incompatible ............................................................................. 38
2.9.9 E255 – CHS Incompatible ................................................................................ 39
2.10 MAINBOARD RELATED ERRORS .................................................................................. 40
2.10.1 E211 – Incompatible hardware ........................................................................ 40
3 AP-74700 – Rev. 1.4 – 07/04/2009
Troubleshooting
2.10.2 E256 – Mode not found .................................................................................... 40

2.10.3 E257 – Mode not available .............................................................................. 40
2.10.4 E258 – Mode Init problem ................................................................................ 40
2.10.5 A259 – Hardware not found ............................................................................. 41
2.10.6 E260 – Incompatible Firmware ........................................................................ 42
2.10.7 E261 – Firmware Init Problem.......................................................................... 42
2.11 WALLET-SIMM-CARD ERROR CODES ......................................................................... 42
3 TROUBLESHOOTING WHEN DISPLAYING NO MESSAGES .................................. 45

3.1 START-UP RELATED PROBLEMS.................................................................................. 46
3.1.1 Initial INK start-up problems on 65” and 90” .................................................... 49
3.1.1.1 Ink and cleaning compatibility-Chart ............................................................. 49
3.1.1.2 Only applicable 65” – 90” machines .............................................................. 53
3.1.1.3 The machine is completely dead – non responding ...................................... 53
3.2 PAPER FEED RELATED PROBLEMS .............................................................................. 55
3.3 PROBLEMS DURING PRINTING OPERATION ................................................................... 56
3.3.1.1 Ink drops falling on media from heads during printing ................................... 63
3.3.1.2 Complete nozzle-row (A or B-channel) is missing......................................... 64
3.3.1.3 Head is firing continuously ............................................................................ 65
3.4 E AUDIBLE NOISE AND INTERFERENCE PROBLEMS ........................................................ 66
3.5 PAPER CUTTING RELATED PROBLEMS ......................................................................... 67
3.6 INTERNAL FIRMWARE AND OPERATION PROBLEMS ........................................................ 69
3.7 MISCELLANOUS PROBLEMS ....................................................................................... 70
3.8 PARAMETER & PRINTING RELATED ISSUES ................................................................. 70
3.8.1 Parameters are not being saved during shutdown ........................................... 70
3.8.2 Network parameter backup does not work properly ......................................... 71
3.8.3 Unstable machine behaviour (CPU errors, machine crashes) ......................... 71
3.8.4 Printer doesn’t start printing, interrupts or intermittently stops during printing .. 72
3.9 PUMP, SUCTION AND CLEANING PROBLEMS ................................................................. 73
3.9.1 Caps are not properly sucking ink out from the nozzles ................................... 73
3.9.2 Blizzard pump related problems....................................................................... 74
3.9.3 Mainboard replacement procedure .................................................................. 75
4 SPITFIRE 100 PCB-BOARD COMMUNICATION AND DIAGNOSTICS .................... 77

4.1 SPITFIRE 100 – BOARDS COMMUNICATION SYSTEM ..................................................... 78
4.2 THE SPITFIRE 100 WORKS WITH 2 DIFFERENT DATA-COMMUNICATION BUS SYSTEMS ...... 79
4.2.1 LVDS-Bus = Low Voltage Differential signalling .............................................. 79
4.2.2 CAN- Bus = Controller Area Network ............................................................... 79
4.3 HOW TO IDENTIFY CAN COMMUNICATION PROBLEMS ON THE PCB-BOARDS? ................ 80
4.3.1 NMPS – Board (New Maintenance Pump System) .......................................... 81
4.3.2 CHS – Board (Contact Heater System board) ................................................. 82
4.3.3 Heater self-test procedure ( in menu 4/7 – utility) ............................................ 83
4.3.3.1 Firmware upgrade procedure for Slave Boards ............................................ 84
4.3.4 CLE – Board (CLIB expander board) ............................................................... 89
4.3.4.1 Diagnosing and solving CAN and LVDS communication problems .............. 89
4.3.5 Heater temperature sensor board .................................................................... 90
4.3.6 Digital temperature sensor ............................................................................... 91
4.3.7 Heater power board ......................................................................................... 92
4 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
Introduction
This chapter explains the procedures for troubleshooting this product.

When the product indicates a failure and the control panel displays an error message, refer to
"Troubleshooting procedures when a message has been displayed" and implement treatment. When the
product indicates failure but an error message has not been displayed, refer to "Troubleshooting procedures
when an error message has not been displayed" and implement treatment.
1 TROUBLESHOOTING PROCEDURE
WHEN DISPLAYING A MESSAGE
This chapter explains the messages displayed when the product is operating normally and when an error
occurs.
There are the following types of messages.
Priority level Message Type Description

Informal notifications Messages displayed during normal operation
1 during operation
Error notifications during Operational error-messages requesting the operator to interact

2 operation
Heater system errors When there is a failure in the heater-system (heater control -
3 heater power board – heater mats & sensors)
Data errors Displayed when data communication trouble occurs between the
4
computer and this product.
Command errors Displayed when trouble occurs during analysis of the command
5
data that is sent to this product from the computer.
5 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
1.1 INFORMAL NOTIFICATIONS DURING OPERATION

This chapter explains how to proceed, when the following messages are displayed on your LCD-display.
N° Message Phenomenon Check point Action

1 Cover Open (1) Verify the L/R cover sensor • Replace the cover sensor
via diagnostics: if the sensor is not
responding
Diagnostics  Test  Sensor
 Cover SW
(2) Open and close the cover, Adjust the sensor-bracket
check if all sensors are or sensor-cam when
“clicking”. necessary
Ensure the sensor is properly The cover-switch is a two-

adjusted: way switch. Or pin 1 and
2 or pin 2 and 3 are
closed.
Malfunction of the switch
might also result in the
following error:
“E068 CR Encoder Error”
Sensor state:
Pin 1 and 2 on the sensor
are closed, Pin 3 is open
(floating)
Pin 2 and 3 on the sensor

are closed, Pin 1 is open
(floating)
!Attention!
Be careful when
adjusting the sensor-
bracket, the sensor-lip is
not fully stressed. This
will decrease life and
possibly damage the
sensor!
Adjust the sensor and
make sure there is a 0,5
to 1mm gap as
illustrated.
6 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
(3) If the cover switches are ok, Verify the cover switch
and the error persists connectors on the
mainboard, (J155 and
J156)
If no spare cover switches
are available, temporary
bypass on own risk is
possible, short circuiting
pins 1 and 2 for both
switches.
In case of a 100” machine,

verify if the magnet-
actuator is properly
adjusted against the
sensor.
(4) The cover switch circuit IC’s Replace the mainboard

on the mainboard assembly assembly if after
may have a problem bypassing the cover
switches, the mainboard is
still not recognizing a
closed cover switch.
2 Set Paper Indicates the lever— (1) Try to put the lever down: If the lever is not
sensor is in the UP - Via the foot pedal responding, try to short
position. - Via the LCD display circuit the 2 pins of the
lever foot pedal.
The lever motor
(2) Check the 2 sensors of the If sensors are responding:
should be the UP
lever UP / DOWN via - Remove A heater platen.
position when
diagnostics: Check if nothing is broken
having this
in de Up/Down mechanism
message.
Diagnostics  Test  Sensor - Replace the photo
 Lever Sensor sensor / sensor bracket if
the sensor is not
responding
(3) Verify if the 2 U-photo • If the photo sensor is
sensors on the lever motor are detached or broken, fix or
properly mounted. replace when necessary.
(4) Check the 2 U-photo • Clean the photo sensor
sensors for dust or blowing compressed air
contamination
(5) Check if the sensors are • Check the connections
properly connected on the Mainboard assy at
connectors J123 and
J124.
(7) If after replacement of the • Replace the Mainboard
sensors, the sensor still doesn’t assembly.
respond in diagnostics, the
Mainboard assembly may have
a problem.
7 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
3 Paper End There is no media (1) Check if both the When you cover the
inside the printer. P_REAR_R and P_REAR_L sensor with paper, the
sensors are properly working: P_REAR sensor should
The roll of media Diagnostics  Test  Sensor switch ON.
has ended  PaperRear R and L. If the sensor is not
responding, check the
sensor alignment.
Replace if necessary.
(2) Check if the sensors are not Clean when necessary

obstructed by dust, dirt or Blow dirt and dust away
media from sensor with
compressed air
(3) Check if both P_REAR Verify connections on

sensors are properly Mainboard assembly,
connected. connectors J128 and
J129.
(4) The P_REAR sensor • Replace the P_REAR

assembly may be broken. sensor assembly.
(5) If after sensor replacement, • Replace the Mainboard

the problem still persists, the assembly.
Mainboard assembly may have
a problem.
8 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
1.2 ERROR NOTIFICATIONS DURING OPERATION

During normal operation of the machine, it can happen that errors may appear on the display, due to normal
operation. These are non-fatal errors that mostly indicate that operator-interaction is required. In most
cases, the machine will just wait until the operator has proceeded. When the specific action has been
executed, the printer will in most cases, automatically reset the error and continue to print.
N° Message Phenomenon Check point Action Refer to

Undefined paper The media-detection (1) Verify if the  Try to move the  Media sensor
has failed, after paper-edge sensor is carriage above a sensitivity
loading the media working properly. piece of white adjustment
Go to Diagnostics  paper. Verify the  Replacing the
Test  Sensor  sensor data in: P_EDGE
P_EDGE. For 65- sensor
90” machines, check Diagnostics  assembly.
also if the sensor is Test  Sensor 
properly calibrated P_EDGE
Adjust the sensor-

potentiometers on
the mainboard
when necessary.
 Verify also if the
sensor is properly
connected. If the
sensor does not
respond when it
should detect
paper and the
sensor-
adjustment
doesn’t work,
replace the
P_EDGE sensor
assembly
(2) Make sure the  Connect the  Replacing the
P_EDGE sensor sensor to the CR CR-board
assembly is properly board connector assembly
connected to the CR- J234.
board, on top of the
carriage.
(3) Make sure the  Securely connect  Replacing the
R_REAR sensor the cables to Mainboard
assembly cables Mainboard assembly,
underneath paper assembly HDD_Extensio
guide R are securely connectors J128 n board
connected. and J129. assembly,
HEAD_DRV
board
assembly and
cooling fan
assembly.
(4) Check the  Redo the  Replacing the
Flatcables for connections of Mainboard
skewed insertion. the following assembly,
connectors : HDD_Extensio
 CR board : J201 n board
– J216 assembly,
 Mainboard : J137 HEAD_DRV
– J152 board
assembly and
cooling fan
assembly.
9 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
(5) The long  Replace the  Replacing the

Flatcables from the Flatcables. steel bearer,
mainboard to the tube guide,
head board may be Flatcable and
damaged. ink tube.
(6) The CR board  The CR-board of  Replacing the
assembly may be the 65-90” CR board
damaged. machine is NOT assembly.
the same as the
100 machine.
The 100” CR
board is adapted
to support the
EPOS-Sensor.
The 65-90” CR
board is adapted
to support an
analog photo
sensor.
 Replace the CR
board assembly.
(7) The Mainboard  Replace the  Replacing the
assembly may be Mainboard Mainboard
damaged. assembly. assembly,
HDD_Extensio
n board
assembly,
HEAD_DRV
board
assembly and
cooling fan
assembly.
2 Paper Slant The media goes Lever up & down to  Verify if media is -
skewed through the re-initialize media- loaded in a
printer. detection straight way.
3 Paper Cut Error Even though cutting (1) Check the cutter  Remove the  Please refer to
operation was grooves for accumulated the User’s
performed, the paper accumulated paper paper dust along Guide.
was not completely cut dust and slip. the direction of
and removed. the grooves.
(2) Has the cutter  Reset the cutter  Please refer to
cap securely been cap securely the User’s
installed? Guide.
(3) Check the  If it does not rise
cutter’s up and down Go to step (4)
sliding operation.  If it rises : Go to
step (5)
(4) Check if the  If it drops: The  Replacing the
cutter drops to the cutter spring may cutter holder, cutter
bottom end under its have a problem. spring, cutter cap,
own weight when the Replace the solenoid assembly
cutter has been cutter spring while and solenoid
installed without the referring to the spring.
cutter spring. unfolded view.
 If it does not drop:
The cutter may
have a problem.
Replace the
cutter. If the
cutter does not
drop after
replaced, replace
the cutter holder.
10 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
(5) Check the up and  OK: The cutter’s  Please refer to

down operation of service life is the User’s Guide
the solenoid via reached or it is  Cutter
“Life/Cutter” of the damaged. adjustment
self-diagnostic Replace the  Replacing the
function. cutter. CR board
a) The solenoid NG: Adjust the assembly.
moves up and down: position of the cutter  Replacing the
Check the cutter’s holder. Mainboard
down position  The connectors assembly,
relative to the cutter may have poor HDD_Extension
groove. contacts. board assembly,
b) It does not move  Check the HEAD_DRV board
up and down. connections of assembly and
the following cooling fan
connectors : assembly.
CR board : J235
CR board : J201 –
J216
Mainboard : J137 –
J152
(6) Open CR cable,  Replace the  Replacing the
faulty solenoid Flatcables. steel bearer,
assembly, faulty  Replace the tube guide, CR
board assembly, solenoid tapes power
etc., may be the assembly cable and ink
cause.  Replace the CR tube.
board assembly  Replacing the
 Replace the cutter holder,
Mainboard cutter spring,
assembly. cutter cap,
solenoid
assembly and
solenoid spring
 Replacing the
CR board
assembly
 Replacing the
Mainboard
assembly,
HDD_Extensio
n board
assembly,
HEAD_DRV
board
assembly and
cooling fan
assembly.
11 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
4 End of Roll Displayed when the (1) Check if the If the message is
end of the roll paper is message is still displayed : go to
detected during the displayed after step (2)
use of roll paper. This turning the power off
is released when the and then back on
lever has been set to again.
the up position. (2) Check the  Redo the  Replacing the
P_REAR sensor connections of Mainboard
assembly for the Mainboard assembly,
contact condition. assembly HDD_Extension
connectors J128 board assembly,
and J129. If the HEAD_DRV board
paper is not assembly and
initialized, the cooling fan
sensor may be assembly.
damaged.  Replacing the
 Replace the P_REAR_R sensor
P_REAR sensor assembly and
assembly. P_REAR_L sensor
assembly.
(3) The Mainboard  Replace the  Replacing the
may be damaged. Mainboard Mainboard
assembly. assembly,
HDD_Extension
board assembly,
HEAD_DRV board
assembly and
cooling fan
assembly.
5 [ ] Near End The remaining amount (1) Check the ink  Operate the lever  Sensor menu
of ink is low. Printing end via “Test: at the end  Replacing the I/H
is still possible. Sensor” of the self- detecting element (ink holder)
diagnostic function. of the ink sensor assembly
There is no more ink assembly to
6 [ ] Ink End left. Printing in check if the ink
progress is interrupted end indication
immediately. changes. (At this
time, the sensor
for detecting the
presence of
cartridges is set
to Yes.) If there is
no response,
replace the ink
sensor assembly.
(2) Check the ink  Redo the  Replacing the
sensor connector for connections of Junction board
the contact the following assembly.
conditions. connectors.
 Junction board :
J401 – J418
 Mainboard : J133
– J134
7 Ink End ALL The printer receives Obviously this is an  Verify if the
an external notification abnormal condition. flatcables
that all ink cartridges between the
are empty. The Check if the ink end mainboard and
notification says that sensors are indeed Ink ID board are
all ink end sensors are activated or not in properly
activated. diagnostics. Try to connected
activate the sensor
manually to see if it  Try to use
responds. another Ink ID
board to see if the
problem persists!
12 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
8 Not Original Ink (1) Check the ink  If the type of the  Sensor menu
end ID via “Test: installed cartridge
Sensor” of the self- does not match
diagnostic function. the displayed
(This is limited to type, the ink ID
when smart chips sensor may be
are set.) damaged.
(2) Check the ink ID  Redo the  Replacing the

sensor connector for connections of JUNCTION board
the contact the following assembly.
conditions. connectors:
Junction board :
J401 – J418
Mainboard : J133
– J134
Install the latest

(3) Check the firmware release!
currently used
firmware Follow
TIB 252 about “not
(4) Verify TIB 252 original ink” and to
check if mainboard
replacement is
necessary
9 Warning Waste The waste tank will (1) Check if the  When a message -
INK Tank soon be full. message is still is displayed : Go
displayed after to step (2)
turning the power off
and then back on
again.
(2) The amount of  Dispose of the -
waste ink inside the waste ink in the
tank reached the waste bottle.
specified level.
(3) If initialization  Install latest
does take effect firmware version.
when the waste ink
is disposed of and
waste ink history is
initialized, the Check
for latest firmware
release.
10 Warning Waste The service life of the (1) Check if the  When a message -
INK Tube ink tube will soon be message is still is displayed : Go
reached. displayed after to step (2)
and then back on
again.
(2) The number of  Replace the ink  Replacing the
times the ink tube tube. steel bearer, tube
was used reached  Initializing CR guide, Flatcable
the maximum motor history. and ink tube.
allowable times.
(3) If initialization  Install the latest
does take effect Firmware release!
when the CR motor
history is initialized
after the ink tube is
replaced, the Check
the firmware
13 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
11 (Warning Head The service life of the (1) Check if the  When a message
Life) print head will soon be message is still is displayed :
reached. displayed after refer to step (2)
and then back on
again.
(2) The number of  Replace the print  Replacing the
times the print head head assembly. print head
was used reached  Initialize the head assembly and head
the maximum unit. tape power cable.
allowable times.  Counter
initialization menu.
(3) If initialization  Install latest
does not take effect firmware version
when the head unit is and re-proceed!
initialized, the Make
sure the latest
firmware version is
installed
12 Hard disk status There is a problem in (1) Check the  Redo the  Replacing the
connect error the hard disk connections of connections of Mainboard
connections. connectors. the following assembly,
connectors. HDD_Extension
 Mainboard : J102 board assembly,
 power source HEAD_DRV board
board (small) assembly and
assembly : CN51 cooling fan
– CN52 assembly.
(2) The  Replace the ink  Replacing the
HDD_MOTHER tube. power source board
board assembly may  Initializing CR assembly.
be damaged. motor history.
(3) Hard disk may be  Replace the hard
damaged. disks.
(4) The Mainboard  Replace the
assembly may be Mainboard
damaged. assembly.
13 Network There is a problem in (1) The network  Replace the  Replacing the
initialize error the network board. interface board may network interface Mainboard
be damaged. board. assembly,
(2) The Mainboard  Replace the HDD_Extension
assembly may be Mainboard board assembly,
damaged. assembly. HEAD_DRV board
assembly and
cooling fan
assembly.
14 Waste ink tank The waste tank is not (1) Check if the  Install the waste -
sts. No installed. waste bottle has bottle correctly.
been installed.
(2) Check the  Replace the -
operation of the waste box sensor
waste box sensor assembly.
assembly via
“Sensor/Waste Bin”
of the self-diagnostic
function.
14 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
(3) Check the  Check if the

connections of the waste box sensor
connectors. connectors are
connected to the
rear side cap R.
 Redo the
connections of
the following
connectors.
 Try to short-circuit
the connector to
check if the
machine then
‘sees’ a waste-
tank!
 Mainboard : J120
(4) If after short-  Replace the
circuiting the waste Mainboard
tank cable, the assembly.
problem is still not ok
and the machine
doesn’t see a waste-
tank, the Mainboard
assembly may be
damaged.
15 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
1.3 HEATER SYSTEM ERRORS 65” & 90” PRINTERS ONLY

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.
Solve the problem to delete the error message and restart the printer.
N° Message Check point Action

1 AC not present AC connector. Check AC connector
2 Error sensors A Sensors A Check if the sensors are connected properly.
3 Error sensor A Sensor A Check if the sensors are connected properly.
4 Conn. err. Left A Sensor A Check if the left sensor is connected properly.
5 Conn. err. Right A Sensor A Check if the right sensor is connected properly.
6 Error sensors D1 Sensors D1 Check if the sensors are connected properly.
7 Error sensor D1 Sensor D1 Check if the sensors are connected properly.
8 Conn. err. Left D1 Sensor D1 Check if the left sensor is connected properly.
9 Conn. err. Right D1 Sensor D1 Check if the right sensor is connected properly.
10 Error sensors D2 Sensors D2 Check if the sensors are connected properly.
11 Error sensor D2 Sensor D2 Check if the sensors are connected properly.
12 Conn. err. Left D2 Sensor D2 Check if the left sensor is connected properly.
13 Conn. err. Right D2 Sensor D2 Check if the right sensor is connected properly.
14 Couldn't reach temp Heater strip After 10 minutes, temperature is not reached. Check
the heater strips.
15 Err: Temp > 85°C! Heater strip Temperature comes higher than the limit. Check the
heater strips.
16 Connection err. A Rear Heater (A) Check the connector of the rear heater.
17 Connection err. D1 Dryer (D1) Check the connector of the front heater (D1).
18 Connection err. D2 Dryer (D2) Check the connector of the front heater (D2).
19 Error sensor B1 Fixer (B1) Check the sensor of the fixer 1 (B1).
20 Error sensor C Post fixer (C) Check the sensor of the fixer (C).
21 Connection err. B1 Fixer (B1) Check the connector of the fixer 1 (B1).
22 Connection err. C Post fixer (C) Check the connector of the post fixer (c).
23 Error sensor B2 Fixer (B2) Check the sensor of the fixer 2 (B2)
24 Connection err. B2 Fixer (B2) Check the connector of the fixer 2 (B2).
25 Error D group Heaters D Temperature difference higher than 15°C between
the sensors of the D heaters.
26 Error A group Heaters A Temperature difference higher then 15°C between
the sensors of the A heaters.
27 Error B group Heaters B Temperature difference higher then 15°C between
the sensors of the B heaters.
Important
 Before checking the connectors, please power off the unit and remove the power cable.
Notes
 Check if the connectors are properly connected to the power board.
 Check if the sensors are connected onto the right connector.
16 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
1.4 HEATER SYSTEM ERRORS 100” PRINTERS ONLY

Heating system errors are displayed when communication trouble occurs between the heater strips and the
CHS (Contact Heater System), sensor- and power-boards inside the spitfire 100.
If heating system error occurs, the following error messages are displayed and the printer stops.
GENERAL HEATER SYSTEM ERRORS

1 Err. No Alive det. Firmware CHS board Reinstall heater firmware or replace heater board
2 Err. Config Read Firmware heater board Restart printer or replace heater board
3 Err. No AC detected AC connector Check AC connector
4 Err. Config Found Firmware heater board Restart printer or replace heater board
5 HeaterSystem Error Contact our Mutoh Service Department
A HEATER SYSTEM

1 Err. A Temp too high (>90°C) Heaterstrip, resistor and Temperature comes higher than the limit.
board Check the heater strips, resistor on heater board
2 Err. A Temp rise Resistor Temperature rises without approval of resistor
3 Err. A1 Strip NC Heaterstrip A1 Check heaterstrip
4 Err. A1 Sens1 NC Sensor 1 heaterstrip A1 Check sensor
5 Err. A1 Sens1 Bad Sensor 1 heaterstrip A1 Check sensor
8 Err. A1 RiseSelfTest Firmware heater board Restart printer or replace heater board
9 Err. A1 WrongSensor Sensor A1, A2 Check sensor
10 Err. A1 No AC detect AC connector Check AC connector
11 Err. A2 Strip NC Heaterstrip A2 Check heaterstrip
16 Err. A2 RiseSelfTest Firmware heater board Restart printer or replace heater board
17 Err. A2 WrongSensor Sensor A1, A2 Check sensor
18 Err. A2 No AC detect AC connector Check AC connector
17 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
B HEATER SYSTEM

1 Err. B Temp too high (>90°C) Heaterstrip, resistor and Temperature comes higher than the limit.
2 Err. B Temp rise Resistor Temperature rises without approval of resistor
3 Err. B1 Strip NC Heaterstrip B1 Check heaterstrip
4 Err. B1 Sens1 NC Sensor 1 heaterstrip B1 Check sensor
5 Err. B1 Sens1 Bad Sensor 1 heaterstrip B1 Check sensor
8 Err. B1 RiseSelfTest Firmware heater board Restart printer or replace heater board
9 Err. B1 WrongSensor Sensor B1, B2, B3, B4 Check sensor
10 Err. B1 No AC detect AC connector Check AC connector
C HEATER SYSTEM

1 Err. C Temp too high (>90°C) Heaterstrip, resistor and Temperature comes higher than the limit.
2 Err. C Temp rise Resistor Temperature rises without approval of resistor
3 Err. C1 Strip NC Heaterstrip C1 Check heaterstrip
4 Err. C1 Sens1 NC Sensor 1 heaterstrip C1 Check sensor
5 Err. C1 Sens1 Bad Sensor 1 heaterstrip C1 Check sensor
8 Err. C1 RiseSelfTest Firmware heater board Restart printer or replace heater board
9 Err. C1 WrongSensor Sensor C1, C2 Check sensor
10 Err. C1 No AC detect AC connector Check AC connector
11 Err. C2 Strip NC Heaterstrip C2 Check heaterstrip
16 Err. C2 RiseSelfTest Firmware heater board Restart printer or replace heater board
17 Err. C2 WrongSensor Sensor C1, C2 Check sensor
18 Err. C2 No AC detect AC connector Check AC connector
18 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
D HEATER SYSTEM

1 Err. D Temp too high (>90°C) Heaterstrip, resistor and Temperature comes higher than the limit.
2 Err. D Temp rise Resistor Temperature rises without approval of resistor
3 Err. D1 Strip NC Heaterstrip D1 Check heaterstrip
4 Err. D1 Sens1 NC Sensor 1 heaterstrip D1 Check sensor
5 Err. D1 Sens1 Bad Sensor 1 heaterstrip D1 Check sensor
8 Err. D1 RiseSelfTest Firmware heater board Restart printer or replace heater board
9 Err. D1 WrongSensor Sensor D1, D2, D3 Check sensor
10 Err. D1 No AC detect AC connector Check AC connector
Important
 Before checking the connectors, please power OFF the unit and remove the power cable.
Notes
 Check if the connectors are properly connected to the power board.
 Check if the sensors are connected onto the right connector.
19 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
1.5 DATA ERRORS

Data errors are displayed when data communication related problems occur between the computer and the
printer.
If a data error is displayed you will get the following error messages and the printer will stop.

1 I 15-1 error Online frame error (1) Check the  Restart printer  Replacing
command [ ] printing data for and rip network card
2 I 15-2 error Overrun error contents that may computer/soft and
command [ ] be judges as an ware. Always Mainboard
3 I 15-3 error Online parity error error. use the correct assembly
command [ ] and latest  HDD_Extensi
4 I 15-4 error Sum check error Data errors may printer drivers. on board
command [ ] occur when  Replace assembly
5 I 15-5 error ESC parameter cancelling a job Mainboard  HEAD_DRV
command [ ] thus the printer is assembly board
6 I 15-6 error Undefined ESC still sending data. assembly
command [ ] Network  cooling fan
7 I 15-7 error Incorrect letters connectivity may assembly
command [ ] ESC also be a possible
8 I 15-8 error Numeral character cause.
command [ ] ESC
9 I 15-9 error Parameter error (2) Mainboard
command [ ] ESC assembly may be
10 I 15-10 error Buffer overflow defective?
command [ ]
Notes
 The command codes for errors may be indicated between brackets [ ].
20 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
1.6 COMMAND ERRORS

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.

1 MH01 error Undefined ESC: A (1) Check the  Restart printer  Replacing the
command [ ] command that has printing data for and rip Mainboard
not been defined in contents that may computer and assembly
command modes be judged as an try again.  HDD_Extensi
was analyzed. error due to Make sure to on board
2 MH02 error Parameter error: possible use latest and assembly
command [ ] Number of communication correct driver-  HEAD_DRV
parameters error between release for the board
following command printer and rip specific assembly
is incorrect. (cancel job, printer!  cooling fan
3 MHO3 error Numeric error: network, etc)  Replace assembly
command [ ] Number of Mainboard
parameters (2) The Mainboard assembly
following command assembly may
is incorrect. have a problem.
4 MH04 error Undefined letter set:
command [ ] Letter sets that
should not exist (do
exist).
5 MH05 error Buffer overflow:
command [ ] Polygon buffer or
downloadable
character buffer
overflows.
Notes
 The command codes for errors may be indicated between brackets [ ].
 For the settings on a computer, refer to the computer's operation manual.
21 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
22 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
2 TROUBLESHOOTING WITH ERROR

CODES
2.1 DRAM ERRORS
E001 - DRAM Error

E002 - Opt. DRAM Error
The RAM memory module is not or badly recognised on the mainboard.
 Be sure RAM memory contacts are clean

 Make sure you us an Original Mutoh Memory Module ONLY.
 3rd party memory-modules will not work properly. Never use these!
23 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
2.2 CPU ERRORS
These errors can appear when internally the machine detected an illegal software command in the central
microprocessor-circuitry inside the mainboard.
This can happen due to:

 Illegal header-commands might be sent from the rip-computer  Make sure the rip is always updated to
the latest version!
Also make sure the latest printer-driver from the Mutoh-website!
If the problem is still occurring:
o Try another rip computer or use a pre-ripped (demo-) file provided by Mutoh.
o Try to rip to a different (analogue) Mutoh-printer, whenever available.
o Try to rip an internal job, e.g. print a palette or distance adjust test
 A power drop or spike on the power supply  Reboot machine

Check if the problem reoccurs. Also always check for a good, stable power connection + properly
grounded.
Generally when a permanent-occurring CPU-error appears on your LCD display, every time after
restarting the machine several times, there are possible clues:
o Install always the latest and correct firmware-version!
SX and SE for new-generation RoHS-compliant mainboards (extreme)
SP and SF for the previous non-RoHS-compliant mainboards (non-extreme)
o The onboard offline-memory may be corrupt. Reset the NVRAM and re-insert all the parameters
manually (not with a backup-flashcard or via Ethernet) via the LCD Display. Manual input avoids
copying corrupted data back.
o With the installed firmware – Always install the correct and the latest firmware version!
o Try with a different Mutoh memory-module with the correct memory-size.
o If this error still reoccurs after these actions, replacing the mainboard and re-inserting the parameters
manually is the last solution. Same reason again, why inserting parameters manually, is to avoid
copying possible NVRAM data to the new mainboard.
Some more specific CPU errors:
2.2.1 E 016 error CPU Err(03)
Data boundary exception errors. Trouble occurred in the data boundary in its internal memory.
 Make sure you us an Original Mutoh Memory Module ONLY.

 3rd party memory-modules will not work reliably!
24 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
2.3 PF - PAPER FEED ERRORS
 E065 - PF Motor Err

 E067 - PF Encoder Err
 E069 - PF Timeout Err
 E071 - PF OverCurrent
 E083 - PF2 OverCurrent
The Paper-Feed motor is failing or the electronics doesn’t receive an encoder-signal from the PF sensor
correctly.
The electronics wants to move the Paper Feed system (PF). The driver IC on the mainboard provides power
to the X-motor (1). Therefore the X-motor starts to turn, resulting in a PF movement (2). PF movement is
detected via the encoder-sensor (3), and gives feedback, back to the electronics.
This closed-loop system is fully controlled in the electronic circuit of the mainboard. It regulates the direction,
electrical current and the speed of the carriage extremely precisely.
PF Encoder Disk
X-Encoder
Forward movement
3
Grid Roller
Backward movement
Grid Roller
2 PF-X-motor
Mainboard
Step 1 : Power supply to motor from electronics

Step 2 : Mechanical movement X encoder
Step 3 : X encoder gives feedback to mainboard
25 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
If anything goes wrong in this process, the following parts inside this loop needs to be verified:
1) Verify the encoder signal of the Paper Feed system

Diagnostic  test  encoder  PF
If the Hex counter changes near PF, when turning the grid-roll shaft, the encoder is ok.
If not ok:
 Be assured that the PF encoder sensor is properly adjusted and positioned
 Check if the encoder disk is clean and not scratched. Clean with Isopropyl alcohol and a fibre-free
tissue only!
Verify the X-motor functionality via the aging procedure

Diagnostics  Life  PF Motor
If the motor is not responding:

 Go to step 3, verify the driver + cable connections
 If still not OK, replace the X-motor
2) Check the X motor driver-IC.
The driver chip is located on the mainboard on U94 for old board revisions. New board
revisions (RoHS) the driver chip is the U109. The following pins should be measured:
 Between pin 1 and 10
The measurement value should be approx. 2 to 3 Meg Ohms. If this is not the case, the driver is
broken, replace the mainboard
26 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
2.4 CARRIAGE RELATED ERRORS
2.4.1 E066 - CR Motor Err

2.4.2 E068 - CR Encoder Err
2.4.3 E072 - CR OverCurrent
The mainboard is not receiving an encoder-signal, from the CR encoder sensor. Even though, the
mainboard sends a signal to the CR-motor to move the carriage.
Basic principles of the CR-Driving and Encoder-system:
Y-Encoder
CW-Movement
3
= Carriage moves left
CCW-Movement
= Carriage moves right
2
Y-motor
Mainboard
Step 1 : Power supply to motor

Step 2 : Mechanical movement moves Y encoder
Step 3 : Y encoder gives feedback to the mainboard
The electronics wants to move the carriage. The driver IC on the mainboard provides power to the Y-motor
(1). Therefore the Y-motor starts to turn, resulting in carriage-movement (2). Carriage movement is
detected via the encoder-sensor (3), back to the electronics.
This closed-loop system is fully controlled in the electronic circuit of the mainboard. It regulates the direction,
electrical current and the speed of the carriage extremely precisely.
27 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
If anything goes wrong in this process, the following parts inside this loop needs to be verified:
1) Check the encoder sensor
Go to diagnostics  test  encoder
If the Hex counter changes near CR_ENC, when moving the carriage, the encoder signal is OK. To be able
to move the carriage freely, the front cover (incl. cover sensors) must be opened.
2) Check the cover switches + connectors
The cover switches make contact with a relay. This relay physically connects/disconnect the Y-motor from
the Y-motor power circuitry. Pin 1 and 2 will measure 0 ohms.
If one of both cover switches is open, the relay will disconnect. Instead the cover switch must close contacts
2 and 3. In this way the /COVER-detection lines integrated inside the electronics, will recognise that the
cover is open and inform the operator.
 Check if the connector J156 is bridged

between pin 1 and 2 on the mainboard
(applicable for SPFR100 only)
For 65”-90” machine verify if the cover-
switch is properly connected!
 Make sure J155 is properly connected to

the cover switch!
Important
 28 Volts is directly connected to the cover switches! Therefore the switches are properly
insulated. Be aware removing the covers, the chassis is not touching the insulation and
breaking so it hits the contacts. This will result in a broken main board!
 Shutting-down the printer while removing the covers is strongly recommended!
The sensor can also be checked via the “test sensor” inside diagnostics.
3) Check the relay RY1 on the mainboard
On the picture, you can see that the relay can switch the Y motor on/off. If the cover is being closed (= both
switches closes too), you should hear the relay clicking.
If the relay RY1 is NOT clicking after closing, verify if the cover switch is really closed. Measure pin 1 and 2
of the connector of J155 and J156. Both pins should be 0 ohms!
If the switches are OK, the relay or the driver of the relay on the mainboard might be is broken. In that case
replace the mainboard
28 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
4) Check the Y motor driver-IC.
The driver chip is located on the mainboard on U97 for old board revisions. New board revisions (RoHS) the
driver chip is the U112. The following pins should be measured:
The measurement value should be approx. 2 to 4 Meg Ohms.

If this is not the case, the driver is broken, replace the mainboard
5) Verify the Y-motor, make sure the carriage is running smoothly and the motor makes no noise.
Make endurance tests via: Diagnostics  Life  CR Motor
If the motor is not responding:

 Go to step 4, verify the driver + cable connections (white cable is +, black cable is -)
 If still not OK, replace the CR-motor
6) Check the steel belt pressure. A wrong steel belt pressure will result in frictioning. Therefore the
“controlled loop feedback”-system will fail.
Blizzard 65” = 1 Newton (100 gr) – Blizzard 90” = 0,9 Newton (90 gr)
If you are sure all previous parts are ok, check the steel belt pressure; check the ‘smoothness’ of the
carriage. Verify the Y-motor and if necessary, replace it.
Verify if the Y-motor belt. Same reason as for the steel belt.
 Verify if the belt is in good shape and properly greased
 Verify the belt’s pressure  35 Newton (3,5 kg)
Verify the carriage movement. The carriage should run smoothly over the whole length.
 The carriage should also run smoothly without steel belt. If not check the carriage-bearings.
 Both steel-belt pulleys should run smoothly
7) Verify if the steel belt is free of grease and dirt! Grease can drip down from the Y-motor CR-belt
if there is too much applied. Please remind that there should be neither grease nor dirt between
the steel-belt and the CR-pulleys! Clean the steel belt if necessary with Isopropyl Alcohol.
2.4.4 E070 - CR Timeout Error
This error occurs when the carriage didn’t move to the expected, correct position within a certain amount of
time.
1) Verify the Carriage movement with aging tests

Diagnostics  Life  CR motor
2) Verify the linear encoder strip. Clean the encoder strip with Isopropyl Alcohol if necessary.
Check if the encoder strip isn’t scratched.
3) Verify the encoder sensor

Diagnostics  Sensor  encoder  CR
Move the carriage and check if the HEX-counter on the LCD-display is going up and down over the
complete length of the Y-rail.
29 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
2.4.5 E073 - CR Origin Error
The origin sensor of the printer Carriage cannot be detected.
Step 1 : Verify the U-pot sensor on top of the Y-rail Check if the U-photo sensor is properly aligned and
the carriage-flag activates it. The U-sensor can be tested by putting some non-transparent
material inside to activate.
Diagnostics  Test  Sensor  CR Home position
Step 2 : Verify cable connections on sensor and mainboard
Step 3 : If sensor is not responding, replace sensor + verify, eventually replace cabling
Step 4 : If still no response after sensor replacement, the mainboard might be defect (replace mainboard)
2.4.6 E074 - Cover Sensor Error
Step 1 : Verify all cover sensors as described in error E068.
Step 2 : Verify cover sensors in Diagnostics  Test  Sensor  Cover switches
Step 3 : Verify if the front cover is closing all the switches properly
Step 4 : Verify sensor cable connections, try to bypass sensors by short-circuiting pins 1 and 2
Step 5 : If still not ok, replace mainboard + cover switches
2.4.7 E076 - PG Origin Err
Step 1 : Verify if the optical sensor is working by putting something a piece of material before it. The
sensor can be tested via:
Diagnostic  sensor  HD_SLIDE sensor
Step 2 : The optical headheight home-sensor (HD_SLIDE) cannot be detected.

Apply some non-reflective and non-transparent black tape on the right carriage headheight
adjustment-bracket. This will improve the performance of the optical sensor (which only detects
black/white transitions) to detect the hole in the adjustment-wheel of the headheight assembly.
Step 3 : Verify the headheight homing sensor and the Up-Down motor via:
Diagnostics  Life  Head U/D
Step 4 : If the motor is not running, replace the motor
Step 5 : If still not ok, verify cable connections.
Step 6 : If all previous steps did not help you any further and a replacement sensor also doesn’t give any
response, only then replace the mainboard.
30 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
2.4.8 E078 - Head Cable Error
The flatcable of head number 1 is not properly connected. This is applicable on as well 4 as 8 heads
machines.
Head 1 MUST always be connected, as the head contains a temperature probe. The machine will always try
to retrieve the temperature during start-up. If you get this error, it indicates, a flatcable is not connected
properly. Verify all flatcable connections. Please refer to flatcable treatment.
In future firmware releases, this error can as well be a fatal error or a non-fatal error (warning message).
Please check the flatcable-treatment chapter for more information how to solve the problem.
31 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
2.5 LEVER & PRESSURE ROLLER ERRORS

2.5.1 E079 - Lever Over Current
Step 1 : The lever motor is drawing too much power. Replace the lever motor.
Step 2 : Verify for any short circuits in the motor wiring between the motor and the mainboard.
Step 3 : Check the Y motor driver-IC.

The driver chip is located on the mainboard on U109 for old board revisions. New board
revisions (RoHS) the driver chip is the U123.
The following pins should be measured:


2.5.2 E080 - Lever Sensor Err
The lever up / down sensor of the lever motor did not respond within a certain time or the Up-Down sensor is
failing.
Step 1 : Verify the Up / Down sensors

Diagnostics  Test  Sensor  Lever Up / Down
 Verify if both sensors are clean
 Verify the cable connections on the sensors and the mainboard
Step 2 : Verify if the gear-wheel / sensor flag of the pinch rollers is properly activating both sensors
Step 3 : Verify if the lever-motor is working and properly geared. Therefore you need to remove the A-
heater platen to be able to verify this.
Step 4 : Check the Y motor driver-IC.

The driver chip is located on the mainboard on U109 for old board revisions. New board revisions
(RoHS) the driver chip is the U123.
The following pins should be measured:


32 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
2.6 CAPPING STATION ERRORS

2.6.1 E081 - Cap Sensor Err
The cap sensor detects if the capping station-assy is in the downward position. It’s a photo sensor that is
fixed inside the capping-station.
2.6.2 Sensor diagnostics
Step 1 : Verify if the sensor is working properly. Insert a non-transparent piece of material inside the
optical U-sensor to activate the sensor. The default value is OFF and should switch ON.
Menu location:
Start up in diagnostics – Test – Sensor – Cap
Step 2 : Push the capping station down and turn the stepper motor to keep it down. Check if the Cap-
sensor goes into the U-sensor properly + verify in sensor diagnostics (see previous step)
Step 3 : Verify if the sensor is properly mounted on the capping-station assembly.
Step 4 : Verify if the optical U-sensor is clean and not covered with ink or contamination
Step 5 : Check the U-sensor cable connection on the sensor and the mainboard
2.6.3 Capping - Motor diagnostics
Step 1 : Verify if the Capping stepper motor is working properly in diagnostics

Motor functionality can be verified multiple times with the Ageing menu.
Menu location:
Start up in diagnostics – Test – Life – Head Lock – Select Wiper U/D off
Step 2 : If the stepper motor is not working properly or loosing torque, verify if the gears and plastic parts
are properly lubricated/greased.
Step 3 : If the stepper motor is not responding at all:

 Verify the stepper motor, replace if necessary
 Replace the mainboard
33 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
2.6.4 E082 - Wiper Sensor Err
The wiper sensor, located below the wiper assembly was not activated when the heads were being wiped.
Sensor diagnostics
Step 1 : Verify if the sensor is working properly. Unlock the carriage from the capping station, using the
Head Unlock in Diagnostics. Move the head on the side. Remove the wiper plate assembly.
Insert a non-transparent piece of material inside the optical U-sensor to activate the sensor. The
default value is OFF and should switch ON.
Menu location:
Start up in diagnostics – Test – Sensor – Wiper
Step 2 : Mount the wiper plate assembly back on the capping station. Move the wiper assy to the outer
position to activate the U-sensor. Check if the Cap-sensor goes into the U-sensor properly and if
the value on the display switches ON and OFF.
Step 3 : Verify if the sensor is properly mounted on the capping-station assembly.

Verify if the sensor-flag properly activates the sensor, check if the flag goes deep enough inside
the sensor.
Step 4 : Verify if the optical U-sensor is clean and not covered with ink or contamination
Step 5 : Check the U-sensor cable connection on the sensor and the mainboard.
2.6.5 Wiper - Motor diagnostics
Step 1 : Verify if the Capping stepper motor is working properly in diagnostics

Motor-functionality can be verified multiple times with the Ageing menu.
Menu location:
Start up in diagnostics – Test – Life – Head Lock – Select Wiper U/D on
Step 2 : If the stepper motor is not working properly or loosing torque, verify if the gears and plastic parts
are properly lubricated/greased.
Step 3 : If the stepper motor is not responding at all:

 Verify the stepper motor, replace if necessary
 Replace the mainboard
34 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
2.6.6 E097 - NVRAM Error

Diagnostics  Test  NVRAM
Free space: bytes free

Max block: largest block free (bytes)
If an error occurs, problems occur or the free space for parameters is very low (<100) try the following:
Diagnostics – MOD Level – Reset to 0, reboot the machine and wait until completed.
Then repeat the diagnostics. If still not ok, clear NVRAM, reboot.
If the test is still failing  Replace mainboard
E100 - 28V P. Supply Err

E101 - 42V P. Supply Err
The machine is not detecting 28 or 48 Volts from the power supply.

Possible reasons:
 Bad contact power connectors
 Short circuit somewhere inside the machine
1) Try to disconnect all possible boards (network card, slave boards, print heads, etc.) to exclude
any short-circuits. It works; reconnect every board step-by-step to find the possible cause.
Pin out to measure the main power supply connected to J101 on the mainboard:
Pin out of the supplemental 12V power supply connected to J102 on the mainboard:
Pin 1 & 2 = 12V
Pin 5 & 6 = GND
Pin 4 = Power On
Pin 5 = 5V
Remark: The machine contains a switching power supply and must always be measured when it is under
load. (This means: connected on the mainboard)
35 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
2.7 HEAD AND FLATCABLE RELATED ERRORS
E102 - Fuse 1 Error

E103 - Fuse 2 Error
E104 - Fuse 3 Error
E105 - Fuse 4 Error
E112 - Fuse 5 Error
E113 - Fuse 6 Error
E114 - Fuse 7 Error
E115 - Fuse 8 Error
E077 - Head OverHeat (Somewhere between head 1 and 8)
 Applicable on old mainboards (< Rev. W) only
E116 - Head Overheat 1
E118 -Head Overheat 3
E120 -Head Overheat 5
The fuses protect the electronic driver components on the mainboard. Every ink-channel has a separate
fuse, so every printhead have 2 fuses, located on the main board below the Head Driver Board.
Old revision mainboards need some soldering, to remove the old fuse and to put a new one.
New revision boards (RoHS) do not need soldering. The fuse can easily be replaced as it is socketed.
Important
 ONLY USE THE FUSE DEFINED IN THE SPARE PARTS FROM MUTOH. DO NOT USE ANY OTHER FUSE AS WE
CANNOT GUARANTEE THE CORRECT TYPE USED.
 PLEASE REFER TO TIB 188 FOR MORE INFORMATION
2.8 ETHERNET CARD ERRORS
E128 – ONLINE Error

E129 – EthROM error
E130 – EthRAM error
E131 – EthBank RAM error
E132 – EthNIC chip error
E133 – EthLback error
1) Check cable connections

2) Check if the Ethernet card is properly connected inside the PCI slot on the mainboard
3) The Ethernet-card might be failing  Replace Ethernet card
36 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
2.9 SPITFIRE100 - SPECIFIC ERROR CODES

2.9.1 E144 – Head 0 Post timed
This error is mainly due to a dirty T-fence (the encoder strip).

Clean the encoder strip with Isopropyl Alcohol and make absolutely sure, the encoder strip is free of
scratches!
2.9.2 E160 – Waste tank full
Check if the waste tank is full
 Empty the waste tank!

If the error persists and cannot be reset because of some reason, use the latest firmware version and try
again!
2.9.3 E240 – No SlaveBoards
The mainboard failed to make contact with the NMPS (“New Maintenance Pump System”) –board.
Possible causes:
 The LVDS-cable is not properly connected to the NMPS-board  Verify LVDS cable and
connections
 Incorrect firmware version in the NMPS-board. Firmware MUST always match with all
boards  Initiate a firmware-update of the slave-boards by starting up the machine + Cancel
+ Enter.
 Verify if there is no error LED indication on the NMPS-board
 Verify if the ALIVE LED on the NMPS-board is flickering  If not, verify power supply and
replace when necessary
 Verify if the CAN-LED’s are not burning continuously  This can indicate a communication
problem or a malfunctioning CAN bus malfunction.
Always check:
 If all RJ45 cable connections on all the slave-boards are properly connected
 If after all those above described actions, the same problem still occurs, replace the
mainboard.
37 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
2.9.4 E247 – CHS Start-up Error
The mainboard failed to make contact with the “Contact Heater System” board during the start-up process.
Possible causes:
o Incorrect firmware version – Firmware MUST always match with all boards, inside the machine
o Firmware update failed on the Contact Heater System board
 If the firmware-update failed on that board, check if during run-time, the ALIVE-LED is
flickering.
 If that LED is not functional the board must be replaced.
o If you are sure the firmware is ok, please check:
 If the CAN communication is working properly (check all the CAN-cables)
The LVDS-LED’s on the board should flicker during communication (start-up, pump-control,
etc)
 There error LED’ on the CHS board have no functionality, please ignore them
 If the alive LED is flickering
 If the CAN LED’s are not burning continuously or bad contact on the CAN interface cable or
chips.
2.9.5 E248 – Extpmp Start-up Error
There is internally something wrong with the NMPS-firmware
- Try to reinstall firmware, make sure all PCB-firmware’s (mainboard, NMPS and CHS) are
synchronised with the correct version
- If the error persists, replace NMPS board. Always verify if the board version is ok after replacement!
2.9.6 E251 – NMPS Start-up Error
The NMPS board failed to start. As a result the internal firmware might not run properly.
This may result in an “E240 No Slave Boards” error notification
- Try to reinstall firmware, make sure all PCB-firmware’s (mainboard, NMPS and CHS) are
synchronised with the correct version
- If the error persists, replace NMPS board. Always verify if the board version is ok after replacement!
2.9.7 E252 – Incompatible HW
The firmware installed is not compatible with the installed main PCB board.
Old firmware only works on older mainboards. Newer firmware versions are downward compatible with the
older mainboards.
Just make sure you install the latest firmware release version on the correct machine, to avoid all kinds of
problems!
2.9.8 E254 – NMPS Incompatible
The firmware version installed on the NMPS board is not compatible with the mainboard.
Make sure you install the latest firmware release on the mainboard.
Also make sure, the NMPS-firmware is updated to the correct version (synchronized with the mainboard’s
firmware)
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Troubleshooting
2.9.9 E255 – CHS Incompatible
The firmware version installed on the Contact Heater System-board is not compatible with the mainboard.
Make sure you install the latest firmware release on the mainboard.
Also make sure, the CHS-firmware is updated to the correct version (synchronized with the mainboard’s
firmware)
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2.10 MAINBOARD RELATED ERRORS

2.10.1 E211 – Incompatible hardware
The firmware installed is not compatible with the installed main PCB board.
Old firmware only works on older generation mainboards.
 Always use the correct firmware version for the correct hardware:
o Non-RohS mainboards have the extension SP (e.g. 3.00sp as for Spitfire 65-90) and SF (e.g. sf4.00
for Spitfire 100)
o RohS-compliant mainboards have the extension SX (e.g. 3.00sx as for Spitfire 65-90) and SF (e.g.
se4.00 for Spitfire 100) and should be solely used in the ‘extreme’ machine versions!
 Always use the latest firmware-version. Older firmware-versions will possibly not be compatible with
newer hardware (especially non-RohS PCB’s.
Using the latest firmwares also offers you to use the latest advantages and I² features to improve the
printer’s performance.
2.10.2 E256 – Mode not found
Problems related to the SIMM card or wallet system.
 Check the specific error-number via diagnostics mode > Chipmgr
 Proceed to the SIMM-Card diagnostics chapter
2.10.3 E257 – Mode not available
Invalid machine settings

Contact the Mutoh service department. When reporting this error notification, always mention the machine-
type, mainboard type (RohS or non-RohS + revision) and serial number!
2.10.4 E258 – Mode Init problem
type, mainboard type (RohS or non-RohS + revision) and serial number!
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2.10.5 A259 – Hardware not found
This is a smart-chip, wallet or CLIB-related problem, including flatcable connection to the mainboard. As this
can be a very complicated problem, the analysis needs to be followed step-by-step.
2 possibilities:
 One smart-chip inside the cartridge-reader, is interfering the cartridge-smartchips or the internal wallet-
SIMM card. All the smart-chips are connected to 1 serial bus. This communication-bus can be
disturbed, preventing some of all smart chips and the wallet, to be ‘read’.
 The sim card or sim card reader is not available or defect. Verify if:
o The Card-reader is properly connected
o The SIMM-card is inserted in its socket properly
o The CLIB board is not properly functioning or badly connected
Verify flatcable connections thoroughly!
Step 1 : Verify if the SIMM card and the SIMM card reader is functional:
 Remove all the cartridges that have a smart-chip.
 Reboot the machine, go to diagnostics mode > ChipMgr
 Verify the chip-status. If the SIMM-chip is ok, go to step 2.
 If the SIMM card is NOT ok:
o And taking into account, all the cartridges have been removed, following parts can be
faulty:
 The SIMM chip is broken; proceed to the service-chip procedure. Check the
specific error-number via diagnostics mode > ChipMgr
 The CLIB board is improperly connected to the Mainboard. Try to swap the 2
flatcables on both sides, to see if the problem ‘shifts’ to other cartridges or
becomes OK.
Step 2 : Go to user-mode, menu “Ink Status”, verify ink status of all cartridge-smartchips separately
 Insert every cartridge one-by-one
 Verify with each inserted cartridge, if the SmartChip is properly recognised. Cartridges with non-
readable SmartChips should be reinserted several times to be sure it’s not bad contact. Check the
smart-chip issues documentation.
If the SmartChip remains unreadable, try another analogue cartridge or swap cartridges located on
another location inside the cartridge-station. Check if the SmartChip can be ‘read’ on this other
location. If still not ok, the chip might be defect.
 Verify the 2 flatcables if they are properly connected, swap the 2 flatcables to verify if the problem
‘shifts’ to another location.
Step 3 : If cartridge SmartChips and wallet can ALL properly be read and the same problem still re-
occurs after rebooting:
 Remove all the cartridges again
 Insert all cartridges one by one, for each inserted cartridge, reboot again. Where the problem
possibly reoccurs, remove the cartridge. Retry with another cartridge. If still not ok:
o The CLIB board might be improperly connected to the Mainboard via the 2 flatcables.
o Try to swap the 2 flatcables on both sides, to see if the problem ‘shifts’ to other cartridges
or another problem appears.
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Troubleshooting
2.10.6 E260 – Incompatible Firmware
Check and make sure that the correct firmware is installed on the correct machine, eg. Spitfire firmware on
Spitfire machine. Blizzard firmware on the blizzard, spitfire 100 on spitfire 100 machine, extreme firmware on
an ‘extreme’ machine, etc.
2.10.7 E261 – Firmware Init Problem

type and serial number!
2.11 WALLET-SIMM-CARD ERROR CODES

Wallet-SIMM errors can be analysed inside the diagnostics-menu:
ChipMgr -> Status
In normal circumstances the chip should indicate, everything is ok and the amount of ml should be visible.
Possible status information when the chip might have a problem:
[E1] Printer chip is broken  Install a service chip
[E2] Printer chip is broken  Install a service chip
[E10] Invalid chip  Install a service chip
[E32] Invalid chip operation occurred  Restart machine
Other errors:
[E….] Chip all chip connections
SIMM-card errors can be due to the Wallet-SIMM card, mounted inside the machine.
However, problems might also occur due to the printer cartridges (e.g. “Not Original Ink”). In fact, in this
case it’s the smart-chips that might be causing this issue. The internal SIMM and the smart-chip
management system (8 smartchip-cartridge-readers) are al interconnected. One chip can interfere with the
others and potentially give an error.
So when you know, cartridges with smart-chips are inside the machine and an [Exx]-error occurs, the error
can be caused by 2 possible reasons:
 The internal SIMM Card
 One of the 8 cartridges with smart-chips
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To make an accurate diagnose of the problem, execute the following steps:
Step 1 : Shutdown the machine and remove all cartridges with SmartChips
Step 2 : Check flatcables between mainboard and cassette led interface board (CLIB)
Step 3 : Check all connections on the CLIB board
Step 4 : Check all connections on SIMM-wallet PCB
Step 5 : Check all connections on the CLIB expander board (SPFR100 only)
Step 6 : Restart the machine without any cartridges, verify if the error still occurs  if not, check TIB252
Step 7 : If the error doesn’t occur, insert every cartridge back one-by-one and verify if every cartridge is
properly recognised in “ink status”
Step 8 : If non of above helps, install a service chip
Step 9 : Follow the service chip activation procedure
In the case, those cassette-smart-chips are responsible for causing an [Exx]-error, you can try the following
topics:
 If the internal wallet is used, the smart-chips on the cartridges can be removed. The credits can be
downloaded inside the printer. Beware that there is no glue or self-adhesive remaining on the smart-chip
or cartridge. This to avoid contamination of the smart-chip reader!
o Ink end will always be detected as this is a physical switch detection
o Ink levels per cartridge will not be readable when using the internal wallet. Only the total ink amount
charged inside the wallet will be readable.
 If smart-chips are used, follow the TIB252, flowchart “not original ink”.
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Troubleshooting
3 TROUBLESHOOTING WHEN
DISPLAYING NO MESSAGES
This chapter explains the messages displayed when the product is not operating normally and no specific
error notification is given.
These error types have been divided into the following sections:
Sections
3.1 Start-up related problems
3.2 Paper feed related problems
3.3 Problems during printing operation
3.4 Audible noise and interference problems
3.5 Paper cutting related problems
3.6 Internal firmware and operation problems
3.7 Miscellaneous problems
3.8 Parameter and print related issues
3.9 Pump, suction, nozzle & cleaning problems
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3.1 START-UP RELATED PROBLEMS

This chapter explains how to proceed, when the following problems are occurring.
N° Phenomenon Check point Action

1 Power is not supplied. (1) Check the panel unit • Replace the panel cables.
assembly cables for open or
shorted conditions.
(2) Make sure that the • Redo the connections of the
connections of the power following connectors.
supply board and Mainboard • Mainboard : J101
assembly are good. • power source board :
CN2/CN4
connections of the inlet board following connectors.
assembly are good. • Inlet board : CN1-CN3
(4) The panel board assembly • Replace the panel board
may be damaged. assembly.
(5) The Mainboard assembly • Replace the Mainboard
may have a problem. assembly.
(6) The power supply board • Replace the power supply
assembly may have a problem. board assembly.1
(7) Check if the flatcables are • Plug or replace the flatcables
well connected
(8) Check if the hard disk is well • Plug the loose cables
connected
(9) Check if the Ethernet board • Remove and plug the board
is well connected
2 LCD failure (no display / garbled (1) Check if the DIMM (optional • The internal programs cannot
display) memory) is installed. Make be started without the DIMM
sure to use only original Mutoh installed in the product. Make
memory modules! 3rd party sure to install the one in the
modules will mostly not work specifications. If not installed,
properly! nothing will be displayed on the
LCD and all LEDs will flash.
connections of the panel cable following connectors.
connectors at the panel side • Mainboard : J109
and the Mainboard assembly • Panel board : J301
side is good.
• Check the panel cables for
skewed insertion.
• Make sure that they are
securely locked.
(3) The DIMM (optional • Replace the DIMM (optional
memory) may be damaged. memory)
(4) The panel cables may be • Replace the panel cables.
damaged.
(5) Check the panel unit • Replace the panel board
assembly LCD for damages. assembly.
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3 Ink load cannot be performed. (1) Check if “Cover Open” is • Adjust the cover sensor.
displayed on the LCD when the Check if both sensors are
front cover is closed. ‘clicking’ when closing the
cover.
(2) Make sure that the •Redo the connections of the
connectors at the panel unit • Mainboard : J105
assembly side and the • Panel board : J301
Mainboard assembly side is
good.
skewed insertion.
securely locked.
(3) Check if “LeverUp” is • Replace the transmission
displayed on the LCD when the photo sensor at the lever.
pressure arm is at the lower
position.
(4) The ink ID board assembly • Replace the ink ID board
(5) The JUNCTION board • Replace the JUNCTION board
assembly may be damaged. assembly.
4 Although ink load has started, (1) The maintenance parts may Check the capping station and
the ink has not reached the be damaged. caps. Verify also if there is no
head. air-ink-leak in the tubings.
(2) The damper may be • Replace the damper.
damaged.
(3) The ink tube may be • Replace the ink tube.
damaged.
(4) The cartridge frame may be • Replace the cartridge frame
damaged. assembly.
5 Ink is not supplied when ink load (1) Make sure that the • Redo the connections of the
is complete. connections of the head cable head cables to the connectors.
connectors at the CR board
assembly side and the print
head side is good.
• Check the head cables for
open conditions.
securely connected.
(2) Check the head cables for • Replace the head cables.
the open conditions.
(3) The print head may be • Replace the print head
damaged. assembly.
(4) Check the CR cables for • Replace the CR tape power
open conditions. cables.
(5) The HEAD_DRV board • Replace the HEAD_DRV
assembly may have a problem. board assembly.
(6) The Mainboard assembly • Replace the Mainboard.
may have a problem
6 Operation does not take place at (1) Check if “Cover Open” is •Adjust the cover sensor.
all after the power is supplied. displayed on the LCD when the • Redo the connections of
front cover is closed. connectors J155 and J156 on
7 When power is supplied, Check the proper operation of the Mainboard assembly.
“Initialize” is displayed, then the cover sensory assembly via • Replace he cover sensor
reset. “TEST: Sensor” of the self- assembly.
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8 Initialization does not take place diagnostic function.

even if the paper is set.
9 Operation does not take place

even if the front cover is closed.
10 Operation does not stop even if (2) Panel unit Make sure that • Redo the connections of the
the front cover is opened. the connections of the panel following connectors.
cable connectors at the • Mainboard : J105
assembly side and the • Panel unit : J301
Mainboard assembly side are
good.
skewed insertion.
securely locked.
(3) Check if “Set Paper” is • Redo the connections of
displayed on the LCD when the Mainboard assembly
pressure arm is at the lower connectors J123 and J124.
position. • Replace the transmission
photo sensor at the lever.
(4) Check if the detection • Redo the connections of
function of the P_REAR sensor Mainboard assembly
assembly is proper via “Test: connectors J128 and J129.
Sensor” of the self-diagnostic • Replace the P_REAR sensor
function. assembly.
11 Key inputs via operation panel (1) Check the operation panel • Replace the operation panel
are disabled. cover for breakage and cover.
contamination.
(2) Make sure that the • Check the connections of the
connectors at the panel unit • Mainboard : J105
assembly side and the • Panel board : J301
Mainboard assembly side is
good.
skewed insertion.
securely locked.
(3) The panel unit assembly • Replace the panel board
12 Printing does not start even if (1) Refer to “Problems during -
data is received. printing operation”.
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3.1.1 Initial INK start-up problems on 65” and 90”
A simplified, automatic procedure for loading the appropriate cleanings and inks has been developed and is
executed via firmware.
This makes it easier for the customer to load the correct liquids inside the printer. The big advantage of the
smart-chip management system is that it can identify, if the correct cartridge inserted. It also assures that
the correct procedure is followed like described in the user’s manual. So there is a double security!
This procedure is of utmost importance as not all solutions and inks are directly compatible. If not-
compatible solutions and inks are mixed, the heads and ink tubings inside the printer might block resulting in
replacement and a lot of work.
3.1.1.1 Ink and cleaning compatibility-Chart
Water-based solution STL-Liquid (Eco Solvent Cleaning) ECO Solvent Ink

Water-based
Compatible Compatible NOT Compatible
solution
STL-Liquid (Eco
Compatible Compatible Compatible
Solvent CLN)
Mild Solvent
NOT Compatible Compatible NOT Compatible
Cleaning
Mild Solvent Ink NOT Compatible NOT Compatible NOT Compatible
As you can see in the chart, ECO-Solvent Inks, are also NOT compatible with either water-based, either,
Mild solvent Cleanings or Ink. So avoid the mixture of these solutions in any case inside the machine’
tubings and heads!
Brand-new machines are shipped are standard delivered with a water-based solution:
 Inside the ink-tubings
 Inside the dampers
 Inside the heads
The chart shows that water-based solution and solvent inks are NOT compatible!
When Solvent inks are mixed with water-based solution, the pigments of the ink will decay and it will block:
 The ink tubings
 The dampers
 The heads
To avoid this, multiple cleaning cycles are required to convert the machine into the correct configuration.
 There is 1 status-flag in the machine depending of firmware version:

o (old firmware versions)  SMS flag – Describes if the machine is working on Eco Ultra
ink (RESET) or Mild Solvent ink (SET).
o (recent firmware versions)  MS ink support – Describes if the machine is working on
Eco Ultra ink (ECO), Mild Solvent ink (MS) or Mild Solvent Plus ink (MS+)
 There are 2 command-flags in the machine:

o SolPrepare flag
o Ink Fill flag
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Troubleshooting
So both flags indicate what the machine has to do, when starting-up the printer. When the flag is SET, the
machine is requested to do the specific action. When the flag is RESET, the printer will assume no action is
required.
Automatic Ink Load Cycle – Spitfire – Automatic Ink Load Cycle – RHIII – Blizzard
Blizzard ECO solvent inks
Mild solvent inks
Status of flags in a brand-new machine: Status of flags a brand-new machine:

 Ink Fill flag = SET  Ink fill flag = SET
 SolPrepare flag = SET  SolPrepare flag = SET
 SMS flag = RESET  SMS flag = RESET
Machine will automatically proceed to: Machine will automatically proceed to:
1st phase: 1st phase:
Water-Based  STL-Liquid Water-Based STL-Liquid
1) The printer will only accept ECO Status flags after loading ECO-cleaning:
cleaning. The printer will try to load  Ink fill flag = SET
ECO cleaning for initial ink load.  SolPrepare flag = RESET
 SMS flag = RESET
2) The printer will only accept ECO- Machine will then automatically proceed to:
Cleaning cartridges 2nd phase
ECO Solvent Cleaning Loading ECO
3) These are factory values for a new Solvent Ink
shipped machine
Machine automatically detects ECO Solvent
Status flags after loading ECO-Cleaning inks.
 Ink Fill flag = SET Status flags after loading Eco-Inks:
 SolPrepare flag = RESET  Ink fill flag = SET
 SMS flag = RESET  SolPrepare flag = RESET
 SMS flag = RESET
Machine will then automatically proceed to: 
2nd phase
ECO Solvent Cleaning  MS cleaning
Machine automatically detects MS inks.

Therefore the flags will change to the following
settings:
 Ink fill flag = SET
 SolPrepare flag = RESET
 SMS flag = SET
Machine will automatically proceed to:

3rd phase
Mild Solvent Cleaning Mild Solvent Ink
Machine will automatically detect MS-INK

Status flags after loading MS-Ink
 Ink fill flag = RESET
 SolPrepare flag = RESET
 SMS flag = SET
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Troubleshooting
Important
 When machines are started-up, the technician must always verify if the according cleaning-
cartridge has emptied after the pumping cycle.
If the cartridge liquid level has not decreased
 DO NOT CONTINUE LOADING THE NEXT LIQUID Charging-PHASE YET!!
Notes
 When putting Solprepare on Set, the ink fill flag will automatically RESET. When the Solprepare is
enabled logically the firmware assumes that there is no ink inside the machine.
In this phase it might be necessary, that the solution of the failed ink-line needs to be loaded into the head
manually, with help of a syringe before proceeding to the next step. Make sure at least 160ml is loaded into
the ink system.
The following chart will clearly explain the ink-loading cycle during an automatic start-up. In case something
goes wrong, actions and parameters are described what can be done do in case of failures like:
- Power interruptions
- Fatal machine errors
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3.1.1.2 Only applicable 65” – 90” machines
How to load ink manually?
Step 1 : Remove the pump maintenance cover.
Step 2 : Carefully remove the pump connection on the corresponding capping station nipple (which goes
to the head)
Step 3 : Connect the syringe and fill it carefully by sucking (pulling-out) the syringe.
Step 4 : Repeat this procedure until sufficient solution has circulated into the ink-system.
3.1.1.3 The machine is completely dead – non responding

There are two possibilities:
 Scenario 1: The machine is not powering at all, the ON/OFF button is not working.
 Scenario 2: The machine is shortly powering ON and immediately shuts down again.
Scenario 1
Symptom:
On-off switching is NOT possible on the LCD control panel, machine remains dead
Procedure:
Step 1 : Try to switch on the machine “manually”.
The machine can be forced switched on when short-circuiting pin connectors 2 and 3 on the main power
connector J101.
Notes
 The contacts must permanently be short-circuited to proceed the complete boot and shutdown
process. Loosening the contact during the boot process, will immediately CUT power with risk
of parameter loss.
The machine will automatically do a complete and repeating boot-shutdown cycle when those 2 pins are
permanently connected. Only disconnect those pins after shutdown of machine software (you will hear the
Y-motor relay clicks ‘OFF’ and fans stop turning) to avoid parameter-loss during this test.
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Troubleshooting
 If this procedure is NOT working, the power supply needs replacement!
If this procedure works we can be sure the power supply is ok.

In this situation there may be a problem:
 With the mainboard – the LCD panel or the flatcable in between
To verify the main board:
 The LCD panel is protected via a round, red-brown fuse located next to the LCD connector on the
mainboard. If the fuse is blown either:
o The Flatcable was misconnected
o The LCD control panel is broken
Scenario 2
You try to startup the machine. The machine starts up and immediately shuts down again = short circuit!
Wait a few minutes and check if the machine can be powered ON again. (= thermal protection)
The machine’s power supply automatically protects itself by shutting down. Short-circuits can only be solved
by disconnecting the respective short-circuiting electronic part.
Step 1 : Disconnect all the cables on the main board. (except the LCD cable + panel + power supplies.)
Step 2 : Check if the machine’s power supply can start up.
Step 3 : Reconnect all cables on by one and try again.
Step 4 : Beware for the head flatcables as these must be connected per pair (A and B channel)
Notes
 BE AWARE THAT WHEN ALL CABLES ARE DISCONNECTED, THE MACHINE MAY GIVE COMPLETELY DIFFERENT
ERRORS.
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3.2 PAPER FEED RELATED PROBLEMS

1 The paper comes off at paper (1) Check if the P_REAR • Check if the connections of the
set initialization or during the sensor assembly and following connectors.
printing operation. P_EDGE sensor assembly • Mainboard assembly : J128/J129,
are operating correctly via J137-J152
“Test: Sensor” of the self- • CR board : J201-J261
diagnostic function • Adjust the sensitivity of the
P_EDGE sensor
• Replace the P_REAR sensor
assembly and P_EDGE sensor
assembly
2 The paper is fed skewed or (2) Check the platen for • If the platen is contaminated by
shifting left and right, during the contamination by paper ink or paper dust, wipe off with a
printing operation. dust and ink. damped soft cloth.
3 The paper is wrinkled at paper (3) Check the rotation of • If the surrounding area of the
set initialization or during the pressure roller with the pressure roller is contaminated by
printing operation. pressure arm at the raised paper dust and waste paper, wipe
position. off with a damped soft cloth.
4 The paper jams up at paper set (4) Check paper guide F for • If foreign materials such as
initialization or during the significant deformation, wastepaper are found on the paper
printing operation. flaws, foreign material, etc. guide F, remove them.
• Replace the paper guide F.
5 After the paper set initialization, (5) Is the flange properly • Securely insert flanges into the
the paper size is detected installed? paper tube for the roll paper.
incorrectly.
(6) Check the rollers of the • Replace the rollers of the scroller.
paper receiver for flaws and
wear that may hinder the
rotation of the scroller.
(7) Check the scrollers for • Replace the scrollers.
bends.
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3.3 PROBLEMS DURING PRINTING OPERATION

1 Continuous printing cannot be (1) The program ROM may • Upgrade the firmware version.
performed. have failed.
(2) The Mainboard • Replace the Mainboard assembly.
assembly may have a
problem.
2 Give an extra feed after the (1) Check if the detection • Make sure that the connections of
printing operation has been function of the P_REAR Mainboard assembly connectors
completed. sensor assembly is correct J128 – J129 are good.
via “Test: Sensor” of the • Replace the P_REAR sensor
self-diagnostic function. assembly.
(2) The program ROM may • Upgrade the firmware version.

have failed.
assembly may have a
problem.
3 Dots are missed in printing (1) Perform the printing • When the nozzle check pattern is
operation via “Print: Nozzle not printed correctly : go to step 2
Check” or “Test: Print” of
the self-diagnostic function.
(2) Repeat head cleaning • If the condition is not restored by
several times. performing the cleaning operation,
leave the product for several hours
then recheck it.
4 Cleaning does not fix problems (1) Check the use • Under low humidity conditions in
such as clogging or split nozzle. conditions of the product. particular, printing is performed
poorly. Check the conditions under
the guaranteed operation
conditions.
(2) Check if the conditions • Printing performance is not stable
occur after ink load. immediately after ink load. Leave
the product for several hours then
recheck it.
(3) Check the cleaning • Using the provided cleaning cloth
wipers for contamination. for cleaning the wipers, slightly
dampen with cleaning liquid it and
wipe the surface of the cleaning
wipers, then recheck their condition
by performing the cleaning
operation.
• If the ink is solid and does not
come off by wiping, replace the
wiper.
(4) Check the installation • Check the installation conditions of
conditions of the cleaning the wipers and fix them securely.
wipers.
(5) Check if the QR codes • Input the correct QR codes.
are input correctly.
(6) The damper may be • Replace the damaged damper.
damaged.
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(7) The print head assembly • Replace the damaged print head
(8) Check if the remaining • If “Near End” or “Ink End” is not
amount of ink in the displayed when the remaining
cartridge is sufficient. amount of ink is insufficient, the ink
sensor assembly may have a
problem.
(9) The ink pump assembly • Replace the ink pump assembly.
may have a problem.
(10) The maintenance • Replace the maintenance
assembly may have a assembly.
problem.
assembly may have a
problem.
5 Nothing has been printed (1) Check the head and CR • Redo the connections of the
cables for skewed insertion. following connectors. Connectors
for the print head.
• CR board : J201 – J232
• Mainboard : J137 – J152
6 Only specific colours are not (2) The head and CR • Replace the CR tape power
printed. cables may be damaged. cables.
(3) Check ink tubes for • Replace the damaged ink tubes.
bends, flaws, air leaks, etc.
(4) The print head assembly • Replace the print head assembly.
may be damaged.
(5) The damper may be • Replace the damaged cable.
damaged.
(6) The ink pump assembly • Replace the ink pump assembly.
may have a problem.
(7) The maintenance • Replace the maintenance
assembly may have a assembly.
problem.
(8) The CR board assembly • Replace the CR board assembly.
may have a problem.
(9) The HEAD_DRV board • Replace the HEAD_DRV board.
may be damaged.
assembly may have a
problem.
7 Drawn black on a full screen (Or (1) Check the head and CR • Redo the connections of the
other specified colour) cables for skewed insertion. following connectors. Connectors
for the print head.
• CR board : J201 – J232
• Mainboard : J137 - J152
(2) The head and CR • Replace the CR tape power
cables may be damaged. cables.
(3) The print head assembly • Replace the print head assembly.
may be damaged.
may have a problem.
(5) The HEAD_DRV • Replace the HEAD_DRV
assembly board may be assembly board
damaged.
assembly may have a
problem.
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Troubleshooting
8 Light and slight printing occurs. (1) Check if the use • Be sure to use the product under
conditions are within the the guaranteed operation
normal operation conditions.
conditions.
(2) Check if printing began • The following phenomena may
immediately after ink load. occur for the first printing that is
processed immediately after ink
load.
• Faint lines are drawn.
• White streaks appear on the
printing.
• If these conditions are observed,
perform cleaning a couple of times
before printing, then check the
result.
• If cleaning does not improve the
result, leave the products for at least
several hours, redo the cleaning
operation, then check the results
again.
9 Irregularities occur in the image (1) Check the band feed • Adjust the band feed.
picture. adjustments.
10 The lines in the CR direction (1) Check the head • Adjust the head.
split. adjustments.
11 Black or white streaks occur in (1) Step could be badly • Adjust the step.
printings. adjusted
(2) Check if the suction fans • Check the connections of the
are operating correctly via following connections.
“Test: Fan” of the self- • Mainboard : J111-J116
diagnostic function.
(3) If the paper in concern is • Make sure the scroller receivers
roll paper, check if the are installed in the correct position.
scroller is rotating smoothly. • Replace the rollers of the scroller.
(4) Make sure that the PF • Adjust the tension of the PF
belt tension is adjusted reduction belt.
correctly.
(5) Check if the pump is • Check that the connections of
running during the cleaning Mainboard connectors J160-J161
operation. are good.
• Replace the pump motor.
• Replace the Mainboard assembly.
(6) Check if he nozzle face • Using the wiper, wipe the nozzle
is wiped correctly. face well.
dampen it with cleaning liquid and
wipe the surface of the cleaning
wipers, then recheck their condition
operation.
wiper.
(8) Check the T fence for • Clean the T fence.
contamination • If contamination cannot be cleaned
up, replace the T fence
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Troubleshooting
(9) Check the rotation of the • If the surrounding area of the

pressure roller with the pressure roller is contaminated by
pressure arm at the raised paper dust and waste paper, wipe it
position. with a soft dampened cloth.
(10) Check if the QR code • Input the correct QR codes.
is input correctly.
(11) The head assembly • Replace the damaged head
damaged.
(13) The CR board • Replace the CR board assembly.
assembly may have a
problem.
(14) The Mainboard • Replace the Mainboard assembly
assembly may have a
problem.
12 The printing boundary is (1) Check if the condition is • If the condition is not recovered by
smeared. recovered by cleaning. performing the cleaning operation a
couple of times, leave the product
for a while then recheck it.
(2) Check if the set paper is • Reset the recommended paper
one of those recommended and recheck the condition. If paper
by MUTOH. not recommended by MUTOH is
used, the paper may not be
recognized correctly by the paper
sensor.
• Check the condition using the
printing mode that is recommended
for the paper.
(3) Check the head • Adjust the head.
adjustments.
(4) Check if the QR code is • Input the correct QR codes.
input correctly.
(5) The CR cables may be • Replace the CR tape power
damaged. cables.
(6) Check the head • Replace the damaged head
assembly for breakage. assembly
may have a problem.
(8) The Mainboard • Replace the Mainboard assembly
assembly may have a
problem.
13 There are many satellite (1) Check if the use • Be sure to use the product under
droplets (unnecessary dots) conditions are within the the guaranteed operation
normal operation conditions.
conditions.
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Troubleshooting
14 Fiber tracking is shown in prints. (2) Check if printing began • The following phenomena may
immediately after ink load. occur for the first printing processed
immediately after ink load.
• Faint lines are drawn.
• White streaks appear on the
printing.
• If these conditions are observed,
perform cleaning a couple of times
before printing, then check the
results.
• If cleaning does not improve the
results, leave the products for at
least several hours, redo the
cleaning operation, then check the
results again.
15 Lines look blurred when printed. (3) Check if the tension of • Adjust the steel belt tension.
the steel belt is properly
adjusted.
(4) Check the head • Adjust the head.
adjustments.
(5) Check the T fence for • Clean the T fence
contamination. • If contaminants cannot be cleaned
up by cleaning, replace the T fence.
(6) Make sure that the • If they interfere with each other,
CR_ENC assembly and the adjust the installation positions of
T fence are not interfering. the CR_ENC assembly and the T
fence.
• If the adjustments do not improve
this, replace the CR_ENC assembly
and the T fence.
(7) Check if the pumps are • Check if all cables are well
running during the cleaning connected to the NMPS board
operation. • Check if all tubes are well
connected
(8) Check if the nozzle face • Using the wiper, wipe the nozzle
is wiped correctly. face well.
dampen it with cleaning liquid and
wipe the surfaces of the cleaning
wipers, then recheck their conditions
operation.
wiper.
(10) Check if the QR code • Input the correct QR codes.
is input correctly.
(11) The head assembly • Replace the damaged head
may be damaged. assembly
damaged.
(13) The CR board may • Replace the CR board assembly.
have a problem.
assembly may have a
problem.
16 Mixed colour lines do not (1) Check if the tension of • Adjust the steel belt tension.
overlap. the steel belt is properly
adjusted.
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Troubleshooting
17 The positions of black and (2) Check the head • Adjust the inclination and height of
colours are not aligned. inclination and height the head.
adjustments.
(3) Check the two-way • Adjust the two-way printing
printing position alignment position alignment.
for problems.
(4) Check if CW • Perform the CW adjustments.
adjustments are made
correctly.
(5) Check if the QR code is • Input the correct QR codes.
input correctly.
(6) Make sure that the • If they are interfering with each
CR_ENC assembly and the other, adjust the installation
T fence are not interfering. positions of the CR_ENC assembly
and the T fence.
• If the adjustments do not improve
this, replace the CR_ENC assembly
and the T fence.
(7) The head assembly may • Replace the damaged head
be damaged. assembly.
18 A limited line in the head travel (1) Check if the use • be sure to use the product under
direction is not accurate (in the conditions are within the the operation conditions.
main scanning direction) normal operation
conditions.
(2) Check if the tension of • Adjust the steel belt tension.
the steel belt is adjusted
correctly.
contamination. • If the contaminants cannot be
cleaned up, replace the T fence.
(4) The internal process • Check the operation again after
operation of the Mainboard initializing parameters and re-
assembly may be inputting and re-adjusting them.
A: Paper discharging direction malfunctioning.
19 Straight lines in the head travel (1) Make sure that the PF • Adjust the tension of the PF
direction are not accurate reduction belt tension is reduction belt.
(straightness) adjusted correctly.
pressure roller with the pressure arm is contaminated by
pressure arm at the raised paper, wipe it with a soft dampened
position. cloth.
(3) Check if rattles are •Clean the dust from the carriage
heard when the carriage is bearings and roller guide. When the
moved from side to side. roller guide is cleaned, apply a light
coat of grease on the roller guide
using a cloth soaked in grease
spray.
A: Paper discharging direction • Replace the CR carriage assembly
(4) Check if the winding • Adjust the swingbars
system is well installed
20 A limited line in the paper feed (1) Check if the use • Be sure to use the product under
direction is not accurate ( in the conditions are within the the operation conditions.
sub scanning direction) normal operation
conditions.
(2) Check if distance is • Compensate the distance.
compensated for the paper
in use.
(3) Check the PF drive • Replace the PF motor assembly.
pulley for looseness.
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Troubleshooting
(4) Make sure that the PF • Adjust the tension of the PF

reduction belt tension is reduction belt.
adjusted correctly.
(6) Check the grid roller for • If foreign material such as paper
rugged movement. Also, dust and wastepaper are found on
check the rotary movement the grid rollers, remove them using
for irregularities. a nylon brush.
A : Paper discharging direction (7) Check if the winding • Adjust the swingbars
system is well installed
21 Straightness in the paper feed (1) Check if the actually • Input the correct head rank.
direction is not accurate (paper installed head rank and the
joint accuracy). registered head rank match.
(2) Adjust the inclination of • Adjust the inclination of the head.
the head.
(3) Check if the tension of • Adjust the steel belt tension.
the steel belt is adjusted
correctly.
(4) Check the two-way • Adjust the two-way printing
printing position alignment position alignment.
for problems.
(5) Check if the CW • Perform the CW adjustments.
adjustments are made
correctly.
contamination. • If contaminants cannot be cleaned
A : Paper discharging direction up, replace the T fence.
(7) Check the CR carriage • Replace the CR carriage
assembly for play. assembly.
22 Inaccurate squareness (1) Check the installation Setup the paper according to the
method of the paper. User’s Guide.
(3) Check the grid roller for • If the surrounding area of the
rugged movement. Also, pressure roller is contaminated by
check the rotary movement paper dust and waste paper, wipe it
for irregularities. with a soft dampened cloth.
23 Illegal printing (1) Check if the flatcables • Plug or replace the flatcables
are well connected
(2) Make sure that the CR • Bundle the CR tape power cables
tape power cables are so that they do not move.
bundled correctly.
(3) Check if the two head • The cores of the head tape power
tape power cables stick cables should be aligned for each
together. head and taped together with
double-sided tape.
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Troubleshooting
3.3.1.1 Ink drops falling on media from heads during printing
Step 1 : Never remove cartridges out of the printer when it’s uncapped!
If cartridges are removed when the machine is not on its capping station, ink will leak out from
heads and air will be sucked through the cartridge-needle.
Step 2 : Once air-bubbles inside the tubing, the risk of smudging and destroying the print is possible!
Step 3 : To solve: proceed with ink load to remove all ink-bubbles from the tubing
InkManager  Ink load
Step 4 : Avoid dust particles below the printer heads by any means. 1 piece of dust on the nozzle-plate
will suck out ink from the heads resulting in ink drops.
Avoid placing the printer in dirty and dusty environments. Clean the machine on a regular basis.
Step 5 : Verify if wipers are in good shape. After wipe action, before printing, verify if the nozzle-plate
around the nozzles, is 100% clean. If not, clean the wipers. If the wipers are not straight
anymore, replace wipers.
Step 6 : The printer is a high-precision instrument that needs care and maintenance, this due to the
nature of the solvent inks.
Be sure to respect the recommended daily maintenance procedures according to the ink used, to
assure optimum performance.
Step 7 : Respect the environmental conditions as described in the installation guide. During winter-time
and cold periods, low environmental humidity will decrease print performance.
Step 8 : Place the machine in an antistatic location. Antistatic flooring is recommended.
Step 9 : All electronic equipment (printer + computer) must be properly earthed.
Step 10 : Very Low environmental humidity also causes plastic materials like banner and vinyl’s to charge
statically. Statically charged materials might cause printing anomalies like:
 Ink drops
 Nozzle inaccuracy and deflection
 Bad printing quality
Step 11 : Printing materials need to be acclimatized in the same environment as the printer for at least 8
hours, before being ready for printing.
Step 12 : Always use the latest released Firmware version.
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Troubleshooting
3.3.1.2 Complete nozzle-row (A or B-channel) is missing
Step 1 : Try if you can recover, performing a cleaning (powerful)
Step 2 : If nozzles still do NOT appear after a cleaning, try to connect a seringe and suck with the seringe
instead, be assured that the seringe is making a proper vacuum.
If a vacuum cannot be created with the seringe, verify:

 If the damper is properly connected to the head’s nipple
 If the damper is intact and the membrane is not punctured
 If the ink-tubing is properly connected from cartridge up to damper. Make sure there is an air-tight
connection between every tube and O-ring.
 If the ink-cartridge is not empty (..and the empty-flag is not being detected properly)
 If the nipple of the printing head is not leaking or broken-off
If a vacuum can be created with the seringe, verify:

 If flatcables are properly connected to the head
 If the fuse on the mainboard is still intact
 If the nozzle-row or the damper is not blocked / dried out
64 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
3.3.1.3 Head is firing continuously
With continuous firing we define the following:
One head or one colour-channel is firing continuously over the whole print-length, over the whole length of
the movement of the carriage, as well over the edge of the media, as on the print platform.
In this situation, firing will occur starting from the flushing-box, over the print platform and over the edge of
the media up till where the carriage stops.
First of all, be assured, the latest firmware-version is installed in the machine!
This can also give an indication, that there might be problems with the fuse of this head- or colour-channel.
Possible indications are (in order of most to less important reason):
 Short flatcables badly connected

 Long flatcables badly connected
 HEAD_DRV board
 Mainboard (mainly checking and/or replacing fuses)
 Print head itself
When that kind of problem is reported it’s always recommended to have at least these spares available for
replacement.
To solve this problem, following the instructions described in TIB188 (Flat Cable Treatment) is strongly
recommended! Flatcables must be in perfect condition and must be connected 100% perfectly!
Notes
 Fuses on the mainboard can be easily measured with an Ohm-meter. A fuse in good condition should
have approx 0 Ohms resistance. Fuses on non-RoHS mainboards must be re-soldered with a new
one, when broken. Fuses on a RoHS mainboard, can easily be replaced with tweezers.
Important
 When replacing fuses, always remove the power-cord and discharge the machine, to avoid
static charge and damage to electronics!
65 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
3.4 E AUDIBLE NOISE AND INTERFERENCE PROBLEMS

1 There is noise when the paper is (1) Check the surroundings of • Remove obstructions and
loaded. the suction fan assembly for foreign material.
obstructions and foreign objects.
(2) Check the cables for damage • If damage is found, replace
and make sure that the the appropriate parts.
connector connections are good.
(3) The suction fan assembly • Replace the suction fan
may have failed. assembly.
2 You hear some noise during (1) Check the area where there • Remove the obstructions and
printing wait. is noise from for obstruction and foreign materials.
foreign materials.
3 You hear some noise when the (1) Check if the high pitch sound • Follow the descriptions in the
head is moving from side to emitted while ink is discharging specifications.
side. during printing, is not confused
with the noise.
(2) Check the screws on the • Re-tighten the screws.
cover for looseness that causes
noise.
(3) Check if rattles are heard • Clean the dust from the
when the carriage is moving from carriage bearings and roller
left to right guide. When the roller guide
has been cleaned, apply a light
coat of grease on the roller
guide using a cloth soaked in
grease spray.
• Replace the CR carriage
assembly.
(5) Make sure that the CR_ENC • If interference is observed,
assembly and the encoder strip adjust the installation positions
are not interfering. of the appropriate
components.
• If the adjustment does not
improve this, replace the
appropriate components.
(6) Check the bearings of the CR • Replace the CR driven pulley
driven pulley for noise. assembly.
(7) Check if the tension of the • Adjust the steel belt tension.
steel belt has been properly
adjusted.
(8) Check the CR motor • Replace the CR motor
assembly for noise. assembly.
(9) Check the carriage roller of • Replace the carriage roller.
the CR carriage assembly for
noise.
4 You hear some noise when the (1) Check the PF reduction belt • Replace the PF reduction
paper is fed. for the skipping of teeth between belt.
the belt and PF reduction pulley.
(2) Check the PF motor • Replace the PF motor
assembly for noise assembly.
(3) Check the grid roller for • If foreign materials such as
rugged movement. Also, check paper dust and waste paper
the rotary movement for are found on the grid rollers,
irregularities. remove it using a nylon brush.
66 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
3.5 PAPER CUTTING RELATED PROBLEMS

1 The cutting operation (1) Check the operation panel and • Change the setting.
is not performing make sure that the media cutting
correctly. setting is not set to off or manual.
(2) Check the operation panel and • Change the setting.
make sure that PaperDet. Has not
been set to TakeUpRoll.
(3) Check the cutter grooves for • Remove the accumulated paper dust
accumulated paper dust and clips. along the direction of the grooves.
(4) Is the cutter cap securely • Reset the cutter cap securely.
installed?
(5) Check the cutter’s up and • If it does not rise : go to step 4
down sliding operation. • if it rises : go to step 5
(6) Check if the cutter drops to the • If it drops :
bottom end under its own weight The cutter spring may have a problem.
when the cutter is installed without Replace the cutter spring while
the cutter spring. referring to the unfolded view.
• If it does not drop :
The cutter may have a problem.
Replace the cutter. If the cutter does
not drop after it is replaced, replace the
cutter holder.
(7) Check the up and down
operation
of the solenoid via “Life/Cutter” of
the
self-diagnostic function.
a) The solenoid moves up and OK :
down: The cutter’s service life has exceeded
check the cutter’s down position or
relative to the cutter groove. the cutter is damaged. Replace the
cutter.
NG :
Adjust the position of the cutter holder.
b) It does not move up or down. • The connectors may have poor
contacts.
Check the connections of the following
connectors.
• CR board : J235
• CR board : J201-J216
• Mainboard : J137-J152
(8) Open CR cable, faulty solenoid • Replace the flatcables.
assembly, faulty board assembly, • Replace the cutter solenoid assembly
etc. may be the causes. • Replace the CR board assembly
• Replace the Mainboard assembly
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Troubleshooting
2 Cutting has been (1) Check if the paper (output) size • Correct the paper (output) size on the
performed during on the application side is correct. application side.
printing. (2) The program ROM may have • Upgrade the firmware version.
failed.
(3) Check the CR cables for • Check the connections of the
skewed insertion. following connectors.
• CR board : J235
• CR board : J201-J216
• Mainboard : J137 – J152
(4) The CR board may have a • Replace the CR board.
problem.
3 The cutting operation (1) Check the cutter blade for • Replace the cutter.
is in process, but the shipping and deterioration.
paper has not been
cut.
4 The paper has not (2) Check if the cutter cap is • Reset the cutter cap securely.
been cut as smoothly securely installed.
as expected,
resulting in jamming.
(3) Check if the cutter moves up • Reinstall the cutter spring.
and down smoothly.
accumulated paper dust and slips. along the direction of the grooves.
(5) Check if the cutter blade is • Make adjustments.
parallel with the groove.
5 The cutting operation (1) The sub-platen (cutter groove) • Clean the surface of the sub-platen
is in process but the requires daily maintenance.
paper does not fall (2) The sub-platen, paper guide or • Provide a proper ground.
off. the paper may be charged with • Check and adjust the ambient
static electricity. humidity so that it meets the normal
operation conditions of the product and
paper.
6 Inaccurate paper (1) Check the cutter blade for • Replace the cutter.
cutting chipping and deterioration.
(2) Has the cutter cap been • Reset the cutter cap securely.
securely installed?
(3) Check if the cutter moves up • Reinstall the cutter spring.
and down smoothly.
accumulated paper dust and slips. along the direction of the grooves.
(5) Check if the cutter blade is • Make adjustments.
parallel with the groove.
(6) The cutter may have a • Replace the cutter.
problem.
7 Cutting starts after (1) Check the operation panel and • Change the settings.
the completion of the make sure the InkDryTime has not
print. been set.
(2) Check the LCD and see if • Printing data remains.
messages for an analysis have
been displayed.
68 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
3.6 INTERNAL FIRMWARE AND OPERATION PROBLEMS

1 No network (1) Verify if the network cables • Use 100BASE-T Cat 5E or higher cross
communication can are ok! cables for direct connections to the host.
be made with the • Use 100BASE-T Cat 5E or higher straight
printer cables for connections using HUBs.
(2) Check the network settings • Reset the settings upon confirmation by a
in the operation panel network administrator.
2 Scaling is not (1) The program ROM may • Upgrade the firmware version to the
functioning correctly. have failed. latest release
3 The printing position (1) Check if CW adjustments • Make adjustments.
has been misaligned. are made correctly.
(2) Check the top & bottom • Make adjustments.
adjustments
(3) The program ROM may • Upgrade to the latest firmware version
have failed.
4 A portion of the data (1) The program ROM may • Upgrade to the latest firmware version
has not been drawn have failed.
(is missing).
5 Garbled characters or (2) Check the T fence for • If contaminated with grease and dusts,
printings are contamination and bends. wipe with a dry cloth.
produced. • If contaminated with ink, wipe with a
lightly dampened cloth and then with a dry
cloth.
•If contamination is severe, replace the T
fence.
(3) Check the “Encoder:PF” via • Make sure that the connections of
“Test: Encoder” of the self- Mainboard assembly connector J132 are
diagnostic function good.
• Replace the T fence.
• Replace the CR_ENC assembly.
• Replace the CR motor.
• Replace the CR_BASE board assembly.
• Replace the CR flatcables.
(4) When after verifying all the • Replace the Mainboard assembly
flatcables, upgrading to the
latest FW and manual
parameter reset and re-
insertion doesn’t help, the
mainboard assembly may have
a problem.
6 After printing has (1) The program ROM may • Upgrade the firmware version.
been completed, the have failed.
paper is fed an extra (2) The rip may give the Check rip settings + source image
amount. command for feeding paper or
the image has white-space
69 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
3.7 MISCELLANOUS PROBLEMS

1 A hang up occurs (1) The internal process • Check the operation again after
operation of the Mainboard or initializing parameters and re-
firmware, may be inputting and re-adjusting them
malfunctioning. manually.
• Make sure to use the latest

firmware release.
2 The power has been cut off (1) Make sure that the power • Securely connect the power
during the printing operation. cables are not disconnected. cables.
(2) Check if there is power on • Check the power using a
the cable. Verify if the cable is multimeter.
not short-circuited.
(3) Check for leakage. • Check the cables for peeled off
insulation and contact with the
case.
3.8 PARAMETER & PRINTING RELATED ISSUES

3.8.1 Parameters are not being saved during shutdown
Step 1 : Be assured to use the latest firmware-version
Step 2 : Check available NVRAM
Diagnostics  Test  NVRAM
Free space: bytes free

Max block: largest block free (bytes)
If an error occurs, problems occur or the free space for parameters is very low (<100), proceed
to the next step
Step 3 : Go to diagnostics – and change MOD-level to 0

(MOD-level defragments internal parameters, clearing memory for additional data, can be re-
verified with Test  NVRAM)
Step 4 : If still not ok:

a. Try to reset the parameters
b. Try to clear the NVRAM
Step 5 : If the problem still persists, the NVRAM might be damaged  replace mainboard
70 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
3.8.2 Network parameter backup does not work properly
Parameter backups via network interface, is only possible if:

 You have the latest FW version
 Your machine has RoHS-compliant hardware
Non-RoHS compliant hardware will not work with this feature!

Parameter-backups are only possible with a parameter-backup card in this case!
It is also recommended to use a directly connected (cross) network cable without any hubs or switches in
between when backing-up or restoring parameters.
3.8.3 Unstable machine behaviour (CPU errors, machine crashes)

If this behaviour still proceeds, after replacing a main-board and restoring the parameter-backup, in some
rare cases, it can happen that something inside the parameters becomes corrupt but we cannot see. This
results mostly in strange machine-behaviour (unknown CPU errors, crashes).
 In that case a parameter backup should not be taken because when you restore it, you might literally
‘restore the problem’ on another board.
In this situation, the clearance of the NVRAM may be proceeded.

Before proceeding to this drastic measure, try to print out the machine setup and parameters. Insert
everything back with the same values afterwards.
Important
 BEFORE PROCEEDING WITH THIS PROCEDURE, ALWAYS USE THE LATEST FIRMWARE VERSION. IF THIS IS NOT
DONE, YOU MIGHT LOSE THE SETTINGS AND WILL MAKE YOUR MACHINE TOTALLY UNUSABLE. IN THIS CASE
MAINBOARD REPLACEMENT IS THE ONLY OPTION.
This procedure takes much more time and is more complicated (the machine doesn’t know if there is ink
inside, eco ink or mid solvent ink, or cleaning, the serial number is gone, head adjustments in parameters
must be re-programmed, distance adjust, etc…). This manual programming, will take much more labour-
time… (up to a few hours)
So, in this situation, manual parameter might anyway still be useful…
71 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
3.8.4 Printer doesn’t start printing, interrupts or intermittently stops

during printing
Step 1 : Try to launch an internal printer test, e.g.

Testprint – Palette
 If this is working, proceed to the next point
Step 2 : Verify network connections

 Verify if the IP-address is ok on Machine, computer and Rip-software
 Check if you can ping the IP-address from the computer command window
 Assure that the IP-address is set-up properly according to ‘normal circumstances’. Make a test
connection by configuring both devices into a mini-class C-network (192.168.x.x subnet 255.255.0.0)
 Disable any computer-firewalls as they might block, interrupt or slow down the printer
 Make sure the network-cabling is ok, always respect the following guidelines:
o Only use stranded UTP-cables, stranded cables have a very high flexibility because it has multiple
copper fibres per cable when for connecting printers to wall sockets, computers, switches and
mounting onto RJ45 connectors.
o Rigid UTP-cables have 1 thick copper core per curve and are designed for fixed wall-mounting and
inside sockets only and are NOT suitable as patch cables! Never use that kind of cables, between
the printer and a computer or wall-socket! Mounting RJ45 connectors on that kind of cables will
guarantee bad contacts with signal-quality loss, network problems resulting in printing problems.
o Make a direct connection between rip-computer and printer with a cross-cable. This ensures
maximum data-transfer without network-interference.
o The newest generation printers require high quality cables. Thus Cat 5E cables are suitable for
Gigabit networking, however CAT6 cables are strongly recommended for optimum signal-quality!
Step 3 : Try to connect to another computer, try to print with a pre-ripped file (e.g. Mutoh adjustment-files)
Step 4 : If still not ok, replace the Network-card and try again
Step 5 : If still identical, replace the mainboard and try again.
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Troubleshooting
3.9 PUMP, SUCTION AND CLEANING PROBLEMS

3.9.1 Caps are not properly sucking ink out from the nozzles
There are several possibilities why the suction doesn’t work properly:
Step 1 : Starting-up and running the machine in a very dirty environment, can potentially contaminate one
or more caps. Therefore there is a risk, the cap air-release valve causing suction problems on
the head.
Possible solutions:
 Multiple tubing flushes with cleaning fluid
 Replace cap
Misalignment of one or more caps. Caps need to be perfectly centred on the nozzle plate and making firm
contact.
Step 2 : Pump malfunction

The pumps are very solid and suitable for solvent inks. Thus they are heavily stressed to
mechanical friction and chemicals (cleanings and ink). So as a precautionary measure, they
need to be replaced during the recommended maintenance.
To test the pump’s performance work as follows:

 Disconnect the pump connection carefully from the capping station nipple
 Connect the pump tube to the pressure meter
 Switch the pump on via:
Ready to work  Tubingflush
 The approximate suction pressure a pump should make is approx. 800 mBar and should
always remain stable during the suction procedure.
Another (however much less reliable) test is to put a 100% flat piece of metal (for example, the head height
jig tool) on top of the cap. When the pump is sucking, the jig tool should be fixed thoroughly on the cap as
the negative pressure is holding it.
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Troubleshooting
3.9.2 Blizzard pump related problems
Only pump 1 & 3 or pump 2 & 4 are working.

On a blizzard-printer, there always should be 2 pumps turning!
1) Verify the MOD-level in the machine-parameters. When MOD level is 8 internal parameters can
confuse the machine-configuration and must be reset. Try to set it on 0.
Diagnostics  Parameter  Update  MOD Level
2) Reboot the machine and wait until completion, it can take a while
3) Verify first if LED’s LD1, LD2, LD3 and LD4 are burning during pump-actions. If not, the pump board
doesn’t get signal from the mainboard. Verify cable-connections, replace mainboard when
necessary.
4) If still not ok and the 4 LED are working, verify the other LED’s on the pump board:
For motor 1 to run : LD1,2 LD7  LD11 must be lit, LD12 remains OFF
If one of these combinations is not matching, the pump PCB board might be broken. The complete
LED-functionality can be found in the MM.
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Troubleshooting
3.9.3 Mainboard replacement procedure
Step 1 : Load the correct, latest firmware

 Via flash-card
 Via parallel cable
Step 2 : Start-up machine, push “Cancel” to select the correct language
Step 3 : Start-up machine, push “up-down” simultaneously to select the correct machine-type
Step 4 : Change the ink-fill flags according to the loaded ink inside the machine
Step 5 : Reinsert following parameters:

 Head ranks
 Serial number
 Calibration
If you have a parameter-backup that is ok, you also restore parameters this way of course. Take into
account, exceptions described elsewhere in this troubleshooting guide.
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Troubleshooting
76 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
4 SPITFIRE 100 PCB-BOARD

COMMUNICATION AND DIAGNOSTICS
This chapter is meant to give a better understanding into the communication between the different intelligent
PCB-boards. This information is necessary so you will be more able to diagnose possible communication
and malfunction problems between the boards and which board to replace.
Before explaining how to diagnose the boards, a brief explanation is required to explain how things work:
Board set-up of machines previous to serial N° MS3K-xxxxxx
More recent machines starting from serial N° MS3K have an extra PCB-board in the CAN-chain, the CLIB
Expander Board (= CLE)
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Troubleshooting
4.1 SPITFIRE 100 – BOARDS COMMUNICATION SYSTEM
78 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
4.2 THE SPITFIRE 100 WORKS WITH 2 DIFFERENT DATA-

COMMUNICATION BUS SYSTEMS
4.2.1 LVDS-Bus = Low Voltage Differential signalling
The LVDS bus (green line) is responsible for the communication between the mainboard and the slave
boards. It is connected to the mainboard, via an on-board RJ-45 Ethernet-like connector and goes to the
NMPS board. This NMPS board translates the LVDS signal to a CAN signal to be able to work with the more
modular CAN network.
4.2.2 CAN- Bus = Controller Area Network
The CAN bus (blue line) is responsible for the communication between all the slave boards inside the printer.
The CAN bus is inherited from the automation and automotive industry and has the big advantage, that it is a
very reliable and modular system where more boards can be interconnected to each other. The
interconnection goes via 9 pin connectors.
A typical characteristic of the CAN bus is that it is a ‘closed’ bus. This means that the CAN-bus needs
always to be terminated on both sides. If not properly terminated, electrical interference in this bus can
disturb the functionality of all the boards in the CAN-chain.
Termination can either be done

- Via an external 9-pins termination plug on a DB9 connector
- Internally soldered inside the PCB board
Every PCB board has a CAN-IN and a CAN-OUT connector plug. If the PCB board only has a CAN-IN and
no CAN-OUT connector, this mostly means that the board is terminated internally.
In our example, the Spitfire 100 the CAN bus starts from the NMPS-board and goes to the CHS-board. You
can clearly see that:
- The CAN bus on the NMPS is terminated on the CAN-IN connector
- The CAN bus on the CHS board is terminated via the CAN-OUT connector
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Troubleshooting
4.3 HOW TO IDENTIFY CAN COMMUNICATION PROBLEMS ON

THE PCB-BOARDS?
Mainly CAN and LVDS communication problems can be diagnosed during start-up of the machine. Before
CAN and LVDS problems can be identified, we need more information about the slave boards. The start-up
sequence of all these boards are chronologically numbered:
Old machine revisions New machine revisions
Warning
 The firmwares between the boards internally, MUST always be compatible!!
 Every PCB-board with CAN-capability has a certain level of ‘intelligence’ driven by a
microprocessor and software.
 If the firmware versions don’t match like mentioned in the firmware update package, the slave-
board might not be able to communicate with other boards.
Every PCB board that contains ‘intelligence’ and CAN connections, has some LED’s which gives the
technician the capability to check if the communication is ok.
Via the activity of the LED’s on every slave board, you can verify the communication between the boards.
The 2 photo’s below gives a clear understanding, where these LED indicators are and how these can be
interpreted.
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Troubleshooting
4.3.1 NMPS – Board (New Maintenance Pump System)
Has 2 main functions in the Spitfire 100:

- Translates the LVDS communication to the CAN bus
- Controls the pumps of the printer
The NMPS board receives 2 power supply signals coming straight from the machine’s power supply.
 24 volt (28 volt) between wires black and yellow.
 5 volt between wires black and red.
Description of the board’s LED’s:

- Alive LED – When this the firmware on the board is running, the Alive LED must always flicker.
When the LED doesn’t flicker, the software doesn’t work and the board will be dead  Replace the
board
- Pump LED – Burns when a pump is turning
- CAN LED – Shows communication activity on CAN bus
- LVDS LED – Shows communication activity on LVDS bus
- Error LED - Combination of 4 LED’s which can indicate when an error happened
In the current firmware versions, these error-LED’s are not used.
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Troubleshooting
4.3.2 CHS – Board (Contact Heater System board)
Main functions in the Spitfire 100:

- Controls the 2 heater power boards (connected via flatcables J661 and J660)
- Reads the sensor information from the heat-strips via the CHS-sensor board (connected with
flatcable to connector J650)
The CHS board receives 2 power sypply signals coming straight from the machine’s power supply (looped
via the NMPS board.)
 24 volt (28 volt) between wires black and yellow.
 5 volt between wires black and red.

board
- Error LED – Combination of 4 LED’s which can indicate when an error happened. In normal
circumstances, the LCD display of the printer will also notify the error-message generated by the
slave-board.
If this is not the case, the table below provides all the possible error-messages:
Notes
 The CHS board is an universal PCB board that is 100% mechanically compatible in different
machines eg Spitfire 100, Viper 100. Please be aware to use the correct partnumber for the
corresponding machine, as the boards are not compatible due to hardware and firmware
differences.
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Troubleshooting
4.3.3 Heater self-test procedure ( in menu 4/7 – utility)
When a heater self-test is performed, the self-test proceeds in the following order:
- Top heater power board (closest to CHS) is activated first.
- LED of relay on this board starts burning and every heater strip is activated during several seconds.
- LED of relay on this board de-activates after test
- Bottom heater power board (furthest to CHS) is activated afterwards
- LED of relay on this board starts burning and every heater strip is again activated during several
seconds
- After successful test both relays on boards switches off and LCD indicates the test finished
During the self-test, every solid-state relay is activated during a few seconds. Every relay controls a heat-
strip separately. When a heatstrip – sensor or relay fails, the error status LED’s will immediately appear on
the CHS control board. This can give a first impression which part is failing.
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Troubleshooting
4.3.3.1 Firmware upgrade procedure for Slave Boards
Boot-up the machine, during booting, press simultaneously “cancel – enter”. The slave boards will update
automatically.
Important
 Do not reboot the machine during updating. If doing so, the boards can be damaged!!
If the self-test or the CHS-board failed, an error-message will appear on the LCD display on the machine.
On the CHS board, the following LED-combinations also indicate the same problem like the LCD:
Error warning Error n° Error name Explanation Action

type (LEDs L4.L1)
Error Led 1 (0 0 0 1) Sensor not Flat line (line is Check the configuration file,
combination connected remaining low) upgrade latest firmware
detected for
specific heat Check if the sensor is
strip-sensor after well connected
having set the
multiplexer. If an ambient temperature sensor
is attached on the chassis, use
this sensor to the respective
‘defective’ sensor to make a test
Check flatcable from sensor

board to connection to J650 of
the CHS-board
Check on the heater sensor

board if following voltages are
present (LED must be burning)
 VEE = 3.3V
 VCC = 5V
 VDD = 28V
If one of these 3 power supplies

is down, check for short circuits
inside the sensor cables: try to
pull-out every cable separately
until the LED goes back on.
When the LED goes on, this last
cable/sensor is broken.
If still not ok, replace the CHS

control board
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Troubleshooting
2 (0 0 1 0) Heater not No AC current Wrong configuration file, upgrade

connected detected by ATD latest firmware
conversion of
hcs12 processor Heater is physically not
after having set connected – check connections
the output for on power boards and next to the
specific heater C-D heater platen
high for a
maximum of Solid state relay of this heater
approximately 2 broken on power board – replace
seconds. power board (swapping the 2
boards can also be a good test
before replacing) – Measuring
the output resistance (without
load) of every solid state relay
should be approx. 2,8 Meg
when disconnected
Heat strip fuse has tripped.

Fuses are auto-resettable. Shut
down the machine, wait 10
minutes and try again.
Measure the heat strips with an

ohm-meter. These are the
approximate values:
- A1, A2 = approx 77 
- B1, B4 = approx 125 
- B2, B3 = approx 154 
- C1, C2 = approx 76 
- D1, D2 = approx 58,4 
3 (0 0 1 1) No temperature No temperature Bad sensor connection, check
rise detected rise detected on connections on C-D heater
during none of all platen and on the heater sensor
heater/sensor sensors after board
self test having heated a
specific heat Wrong configuration file 
strip for a update firmware to latest version
maximum of 15
seconds.
4 (0 1 0 0) Bad sensor For one or more
sensors, all
samples were
out of range
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Troubleshooting
5 (0 1 0 1) ADC out of When no current Measure 5 Volt power supply.

range flows, reference Adjust power supply
for current potentiometer
measurement is on power-supply for getting
taken: error exactly
when out of 5,0 volts.
range. Must be
120< x <134.
This actually
means, the 5 volt
reference
voltage for the
ADC is not
correctly
adjusted.
Warning : use a plastic

screwdriver
to avoid short circuits
(pot meter difficult to reach)
7 (0 1 1 1) Temperature 90°C detected Possible causes:

above 90°C on one or more
sensors (one of Solid state relay short
the possible circuited  replace power board
causes: solid
state relay short Old firmware
circuited).
Wrong flat-cable connection
 try a self-test on CHS board (sensor cables
swapped)  Check cablings
Sensor malfunctioning
 replace sensor
8 (1 0 0 0) No keep active No keep active Can connection gone
received from RJ property set  check CAN and
received from
master LVDS connections
sequencer for
the last 90 Firmware or mainboard may
seconds. Keep be crashed  Use latest
active set firmware versions,
expected at least check if slaveboard firmwares
every 30 are matching with mainboard
seconds (one of firmware
the possible
causes: CAN
connection gone,
RJ crashed,…).
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Troubleshooting
9 (1 0 0 1) Wrong sensor Temperature rise This error can appear if 2 self-

connected to detected on tests are done in a very short
heatstrip sensor which is time span. Wait 5 minutes before
not linked to the 2 self-tests.
heater heated
during self-test In following cases this error can
(long self-test: also appear:
verifies if
sensors are With wrong firmware  update to
properly latest firmware
connected to
right heaters). Wrong connected sensors 
Check if the sensors are correct
and firmly connected
10 (1 0 1 0) Temperature If 90°C detected Possible causes:
rise detected during previous
during waiting use, then, a test A Solid state is unwantedly active
period of self is done during (see output LED) while the input
test. power up to LED is disabled  replace power
verify if no solid board
state relay is
short circuited.
11 (1 0 1 1) No AC No zero detect Wrong configuration file loaded
on 1 or more inside CHS board  upgrade
(possibly all) firmware machine
power boards.
Power board not connected to
CHS board  Check Flatcables
There is no AC Measure fuse on power board

power detected,
on one (or both) With older power board types
of the AC power  check relay if it is functioning
boards. (click)
Measure power-in connector on

Power boards (230 Volts)
Zero detect component may also

be defect on power board (not
possible to verify)
If one of those above is not ok.

Replace power board!
12 (1 1 0 0) Sensor read out Fatal error: the CHS control board is broken 
dead temperature replace
sensors are not Call Mutoh Service if this error
read out occurs
anymore (flat line
detected during
approximately 2
minutes).
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Troubleshooting
13 (1 1 0 1) Error during Configuration file Configuration data in eeprom of

translation of found, but CHS control board is corrupt 
configuration file content gives update firmware to restore
(eeprom data) error during If intermittent of permanent 
into RAM parsing (possible replace CHS control board
cause: eeprom
of hcs12
processor not
working properly
or previous
transfer of config
file was
interrupted
before end was
reached).
15 (1 1 1 1) No valid No configuration Load proper config file in eeprom
configuration file file found in via RS232 or (with respective
in eeprom eeprom (with tool).
respective tool)).
88 AP-74700 – Rev. 1.4 – 07/04/2009

Troubleshooting
4.3.4 CLE – Board (CLIB expander board)
Main functions in the Spitfire 100:

- Controls the changes between ‘printer’-mode and ‘chip’-mode when using a Bulk Ink System

board
- Debug LED – Will blink very shortly or burn (in later versions), when the printer is switched from
“cassette  printer” or inverse
- No error messages are currently generated via this board
Machines with serial number MS3K or higher, have a RoHS compliant mainboard. These machines MUST
have this CLE boards. Machines with a serial N° lower than MS3K do not require this CLE board.
4.3.4.1 Diagnosing and solving CAN and LVDS communication problems
Please beware that the CAN and LVDS-LED’s between the boards mostly ONLY flicker:
- During initialization of the slave boards
- When some action has to be done, by the respective slave board
For example:
- If the machine needs to pump:
o The mainboard will send a message via the LVDS cable to the CAN bus to the NMPS board,
to enable/disable pumps. In this case both LVDS LED’s will flicker.
- If the heaters need to be activated or started up:
o The mainboard sends information via the LVDS cable, LVDS LED’s will flicker
o The NMPS transfers the message via the CAN-bus to the heater-control board, CAN LED’s
on the NMPS will flicker
o The heater-control board receives the message, CAN LED’s on the heater control board will
flicker.
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Troubleshooting
4.3.5 Heater temperature sensor board

The heater temperature sensor board is connected via a blue coloured flat cable to the CHS board. The
sensor board receives 1 power supply.
24V (actually the power supply is 28V)
When powering On the machine, first the primary 5V power supply switches ON. The 24V power supply is
enabled afterwards (between 8 and 30 seconds) and then only the sensor board will be activated.
There are 3 LED’s on the board. These LED’s

indicate the presence of the following powers:
VCC = 5V
VEE = 3.3V
VDD = 24V (28V)
The heater sensor board receives the 28 Volt supply

and converts it via on board DC convertors to:
VCC = 5V
VEE = 3.3V
If there is NO 28V supplied on this board, none of

the power supply outputs will be working!
The VCC power created by this board, is only used

to supply all the sensors + some IC’s.
If there is a short-circuit on one of the sensors (eg

cable is pinched between the chassis) the 5V will not
be working and the 5V LED will not be burning.
Below the sensor connectors, there are 4 LED’s

indicating when sensors are communicating with the
sensor board. The 4 wire communication is a mixed
signal coming from the 16 sensor connections. It is
completely normal if during communication, that all
the LED’s are burning on low intensity.
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Troubleshooting
4.3.6 Digital temperature sensor

Digital sensors measure every heater mat temperature.
The digital sensor receives a 5 volts power supply

signal between the red and black wire, coming from
the sensor board.
If for some reason, the 5 Volt supply is not working,

and 24V is supplied to the sensor board, there might
be a short-circuit in one of the sensor cables.
Disconnect and measure the sensor cables on by

one between R and B.
The resistance may never be 0Ω.
The sensor communication can also easily be

monitored! Make sure the sensor is connected and
the machine is working normally. Put the multimeter
on frequency and measure between B and Y. The
frequency should be approximately 3Khz.
The sensor can be measured with a multi meter.

The power supply is 5V (black and red), put the
meter on Hertz. The measured frequency should be
around 3Khz on the signal line.
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Troubleshooting
4.3.7 Heater power board
The spitfire 100 has 2 heater power boards. The power boards are directly connected to the CHS board,
which controls the power boards via the grey colored flat cables.
Each power board contains 6 solid state relays that switches ON / OFF the 230V power supply to the
connected heater wire. The heater wire and heater boards are connected in the following order.
Each solid state relay can easily be checked if it’s working properly.
There are two methods to check if the relay is workin:
 Monitoring the input and output LED’s (quick –check, but however,
sometime difficult)
 Measuring input and output resistance (most reliable)
Check the LED’s:
If the 5V input LED is burning, the 230V output LED must always burn.
So both must always work on the same time. If one LED is working and
the other one is not, the relay might not be working properly.
Testing relays with a multimeter
The input resistance of the relay is approximately 1KΩ

The output resistance of the relay is approximately 2.9KΩ.
If the resistances are deviating too much and you experience sever
heater problems, replace the heater power board.
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Troubleshooting
Appendix
Media Feed – Distance adjustment basic principles
Between 2 print passes, there is a media-forward movement. Each movement has a maximum tolerance of
20 µm. There are different factors that can influence the media-forward movement!!
Mechanical toleration:
Drive-rolls or Grid-rolls are the rolls that drives the paper into X-direction. This media-movement varies,
depending of the circumference of the drive-roll. The drive-roll tolerance is compensated and in and
adjustable parameter, called the “PaperFeedLen”.
The grid rollers are composed of multiple steel bars, coated with a very hard material. This coating ensures
that the material isn’t frictioning during media feed. Therefore the media feed can be extremely accurate as
the feeding-tolerance is maximum 20 µm.
To make the initial calibration of the grid-roller tolerances, we defined the PaperFeedLen parameter. This
Feed-Adjustment procedure needs to be done inside the diagnostics menu.
Notes
 When proceeding with the adjustment, make sure in the “ready to work” mode, the printer is configured
on the native head-resolution, 360x360 dpi! Other resolutions might cause unreliable results.
 It is recommended to make all the machine calibrations under this setting.
Important
 Any change in this specific parameter, means that all the distance adjustments found for all the
materials used on this printer need to be recalibrated again.
 If the PaperFeedLen parameter has been changed for some reason, all the distance
adjustments you have for your materials will be invalid and have to be recalibrated.
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Troubleshooting
Media toleration
Depending of the media-type used, the radius of the Grid-rollers will change.
This is clearly explained in following illustration:
Media 1
Is a soft material or has a soft backing. Due to the softer backing, the coating on the grid-rollers is slightly
pushed inside the material. When the Grid Roll is turning, the media is feeding forward with radius R1.
Media 2
Is a hard material or has a hard backing. Therefore the grid rolls are pushed less inside the printing material.
When the Grid Roll is turning in exactly the same amount between every pass, the media moves more
forward than the case with Media 1.
The reason is because the circumference of this Grid-roll is bigger because of the bigger radius R2.
This theory proves that the distance-adjustment is strongly depending of the kind of material you like to print.
For this, each material needs at least once, a distance-adjustment calibration for achieving the most optimum
and fine-tuned media-feed movement between each print-pass!
Other factors like:

 Heater temperatures
 Use of the Take-up system
 The backing-type (explained here above), stiffness and friction
 The rollfeed-system
.. Will also have an impact in on the distance-adjustment accuracy!
Therefore a fine-tuning-mechanism exists, calling the “Distance Adjustment” or “Feed Adjust”. This distance-
adjustment adjustable in hundreds of a percentage needs to be executed, for each new material-type, used
on the printer. This procedure can be done via the ‘distance adjustment’ procedure in “Ready to work 
media”
The distance-adjustment can also be adjusted “on the fly” during printing!
94 AP-74700 – Rev. 1.4 – 07/04/2009

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Troubleshooting

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2 AP-74700 – Rev. 1.4 – 07/04/2009

1 TROUBLESHOOTING PROCEDURE WHEN DISPLAYING A MESSAGE ................. 5

2 TROUBLESHOOTING WITH ERROR CODES ........................................................... 23

2.10.2 E256 – Mode not found .................................................................................... 40

3 TROUBLESHOOTING WHEN DISPLAYING NO MESSAGES .................................. 45

4 SPITFIRE 100 PCB-BOARD COMMUNICATION AND DIAGNOSTICS .................... 77

4 AP-74700 – Rev. 1.4 – 07/04/2009

This chapter explains the procedures for troubleshooting this product.

Priority level Message Type Description

Error notifications during Operational error-messages requesting the operator to interact

5 AP-74700 – Rev. 1.4 – 07/04/2009

1.1 INFORMAL NOTIFICATIONS DURING OPERATION

N° Message Phenomenon Check point Action

Ensure the sensor is properly The cover-switch is a two-

Pin 2 and 3 on the sensor

6 AP-74700 – Rev. 1.4 – 07/04/2009

In case of a 100” machine,

(4) The cover switch circuit IC’s Replace the mainboard

7 AP-74700 – Rev. 1.4 – 07/04/2009

(2) Check if the sensors are not Clean when necessary

(3) Check if both P_REAR Verify connections on

(4) The P_REAR sensor • Replace the P_REAR

(5) If after sensor replacement, • Replace the Mainboard

8 AP-74700 – Rev. 1.4 – 07/04/2009

1.2 ERROR NOTIFICATIONS DURING OPERATION

N° Message Phenomenon Check point Action Refer to

Adjust the sensor-

9 AP-74700 – Rev. 1.4 – 07/04/2009

(5) The long  Replace the  Replacing the

10 AP-74700 – Rev. 1.4 – 07/04/2009

(5) Check the up and  OK: The cutter’s  Please refer to

11 AP-74700 – Rev. 1.4 – 07/04/2009

12 AP-74700 – Rev. 1.4 – 07/04/2009

(2) Check the ink ID  Redo the  Replacing the

Install the latest

13 AP-74700 – Rev. 1.4 – 07/04/2009

14 AP-74700 – Rev. 1.4 – 07/04/2009

(3) Check the  Check if the

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1.3 HEATER SYSTEM ERRORS 65” & 90” PRINTERS ONLY

N° Message Check point Action

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1.4 HEATER SYSTEM ERRORS 100” PRINTERS ONLY

GENERAL HEATER SYSTEM ERRORS

N° Message Check point Action

N° Message Check point Action

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N° Message Check point Action

N° Message Check point Action

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N° Message Check point Action

19 AP-74700 – Rev. 1.4 – 07/04/2009

1.5 DATA ERRORS