Valuejet 1604 ServiceManual

MAINTENANCE
MANUAL
Full-Colour Inkjet Printer
VJ-1604
Use this manual for the maintenance

Rev. VJ1604E-M-00 and inspection of machine.
Important Notice VJ-1604 Maintenance Manual
Important Notice
1. For Users in Europe
Important:
This is a Class A product approved for industrial environ-
ments. In a domestic environment this product may cause
radio interference in which case you may be required to take
adequate measures.
2. For Users in the United States

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant
to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial environment.
This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful interference to radio communications.
Operation of this equipment in a residential area is likely to cause harmful interference in which case the
user will be required to correct the interference at his own expense.
3. Trademark Mentioned in this Manual

• MUTOH, ValueJet, VJ-1604 are registered trademarks or product names of MUTOH INDUSTRIES
LTD.
• Centronics and BiCentronics are registered trademarks or product names of Centronics Data Computer
Corporation.
• Windows95, Windows98, Windows98SE, Windows NT4.0, Windows2000, Windows XP, and MS-
DOS are registered trademarks or product names of Microsoft Corporation.
• Intel and Pentium are trademarks or registered trademarks of Intel Corporation.
• Other company and product names may be registered trademarks or product names.
• No part of this product or publication may be reproduced, copied, or

transmitted in any form or by any means, except for personal use,
without the permission of MUTOH INDUSTRIES LTD.
• The product and the contents of this publication may be changed
without prior notification.
• MUTOH INDUSTRIES LTD. has made the best efforts to keep this
publication free from error, but if you find any uncertainties or
misprints, please call us or the shop where you bought this equipment.
• MUTOH INDUSTRIES LTD. shall not be liable for any damages or
troubles resulting from the use of this equipment or this manual.
(1)
VJ-1604 Maintenance Manual Warranty Limitations
Warranty Limitations
1. MUTOH INDUSTRIES LTD. warrants part repair or replacement as a sole measure only if a failure is
found in the system or in the materials and workmanship of the product the seller produced.
However, if the cause of failure is uncertain, decide the action after due mutual consultation.
2. The warranty shall not apply to any direct or indirect loss, or compensation for the loss due to the product
that has been subject to misuse, neglect, or improper alternation.
(2)
About this Manual VJ-1604 Maintenance Manual
About this Manual
1. Purpose and Target Readers

This manual explains preparations needed before maintaining and checking operations for MUTOH Full
Color Ink Jet Printer (VJ-1604).
This manual is prepared for the maintenance personnel of this printer.
Before using this printer, fully understand the contents and directions in this manual.
2. Manual Configuration
Section Contents
1 Safety Instructions Explains types of warnings, cautions and warnings labeled on the printer
for the both operators of the printer and maintenance personnel.
2 Product Overview Explains the features, part names, and functions of the printer.
3 Specifications Explains the specifications of the printer.
4 Parts Replacement Explains the procedures of replacement and removal of the service parts
of the printer.
5 Self-Diagnostic Mode Explains the self-diagnostic functions of the printer.
6 Maintenance Mode Explains the maintenance mode of the printer.
7 Adjustment Explains the adjusting procedures of the printer parts.
8 Maintenance Explains daily maintenance of the printer.
9 Troubleshooting Explains troubles that may occur when using the printer and how to
solve them.
10 Appendix Explains the maintenance information and the exploded views for this
printer.
Use the built-in self-diagnostic program to locate a defective part and adjust/
check during maintenance.
(3)
VJ-1604 Maintenance Manual About this Manual
3. Manual Notation
The following symbols are used in this manual for easier understanding of the information.
Symbol Meaning
Must be followed carefully to avoid death or serious bodily injury
WARNING
Must be observed to avoid slight or moderate bodily injury or damage to

CAUTION your equipment
Contains important information and useful tips on the operation of the

NOTE product
Indicates useful tips for operating or understanding the equipment

TIP
Indicates reference pages in this manual
(4)
VJ-1604 　 Maintenance Manual
General Table of Contents
1 Safety Instructions
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.4.1 Handling the Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.4.2 Locations and Types of Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.5 Operation Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1.5.1 Handling the Operation Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.5.2 Locations and Types of Operation Labels . . . . . . . . . . . . . . . . . . . . . . 1-10
2 Product Overview
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Part Names and Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.3.1 Front Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3.2 Rear Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.3 Operation Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4 Printer Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.4.1 Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.4.2 Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.4.3 Self-Diagnosis Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.4.4 Maintenance Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
3 Specifications
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Product Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Interface Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3.1 USB Interface Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3.2 Network Interface Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
5
3.4 Options/Supplies List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.4.1 Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4.2 Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.5 Choosing a Place for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
4 Parts Replacement
4.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.2 Removal of Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.2.1 Removing R Side Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.2.2 Removing Operation Panel Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.2.3 Removing L Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.2.4 Removing Ink Holder (I/H) Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.2.5 Removing Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.2.6 Removing Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.2.7 Removing Media Guide F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.2.8 Removing Media Guide R2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.2.9 Removing Scroller Receiver (L, R). . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.3 Replacement of Board Base Section Components. . . . . . . . . . . . . . . . . 4-17
4.3.1 Removing Connector Panel and Cooling Fan . . . . . . . . . . . . . . . . . . . 4-17
4.3.2 Removing Main Board Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.3.3 Replacing Main Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.3.4 Replacing HEATER CONT board assembly . . . . . . . . . . . . . . . . . . . . 4-22
4.3.5 Replacing HEATER RELAY board assembly . . . . . . . . . . . . . . . . . . . 4-25
4.3.6 Replacing Power Board Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
4.3.7 Replacing Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
4.3.8 Replacing Inlet Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
4.4 Replacement of PF Driving Section Components. . . . . . . . . . . . . . . . . . 4-31

4.4.1 Replacing PF Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
4.4.2 Replacing PF_ENC Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
4.4.3 Replacing PF_ENC Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
4.4.4 Replacing Heater and Thermistor Assembly . . . . . . . . . . . . . . . . . . . . 4-34
4.5 Replacement of CR Driving Section Components . . . . . . . . . . . . . . . . . 4-38

4.5.1 CR Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
4.5.2 Replacing CR_HP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
4.5.3 Replacing Lever Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
4.5.4 Replacing T Fence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
4.5.5 Replacing CR Driven Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
4.5.6 Replacing Pressure Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
6
4.6 Replacement of Head Section Components . . . . . . . . . . . . . . . . . . . . . . 4-48

4.6.1 Replacing Print Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
4.6.2 Replacing Cutter Holder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
4.7 Replacement of Maintenance Section Components . . . . . . . . . . . . . . . . 4-57

4.7.1 Removing Maintenance Base Assembly . . . . . . . . . . . . . . . . . . . . . . . 4-57
4.7.2 Replacing Pump Cap Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61
4.7.3 Replacing Cleaner Head (Cleaning Wiper) . . . . . . . . . . . . . . . . . . . . . 4-63
4.7.4 Replacing Flushing Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
4.8 Replacement of Ink Supply Section Components . . . . . . . . . . . . . . . . . . 4-66

4.8.1 Replacing Ink Holder (I/H) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
4.8.2 Replacing Ink Sensor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
4.8.3 Replacing Cover Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
4.8.4 Replacing Heater Junction Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
4.9 Replacement of Frame Section Components . . . . . . . . . . . . . . . . . . . . . 4-73

4.9.1 Replacing Suction Fan Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
4.9.2 Replacing P_REAR Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
4.10 Replacement of Cable Guide Section Components . . . . . . . . . . . . . . . . 4-75

4.10.1 Replacing CR Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
4.10.2 Replacing Ink Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76
4.10.3 Replacing CR Tape Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
5 Self-Diagnosis Mode
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.2.1 Preparations on Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.2.2 Starting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3 Operations in Self-Diagnosis Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.3.1 Operating Self-Diagnosis Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.2 Diagnosis Items in Self-Diagnosis Menu . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.4 Platen Adjustment Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.5 Inspection Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.5.1 Memory Size Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.5.2 Version Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.5.3 Operation Panel Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.5.4 Sensor Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.5.5 Encoder Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.5.6 Fan Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
7
5.5.7 History Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5.5.8 Head Waveform Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5.6 Ink Charging Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.7 Adjustment Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

5.7.1 Head Nozzle Check Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5.7.2 Skew Check Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5.7.3 Head Slant Check Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
5.7.4 Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
5.7.5 Uni-D / Bi-D Low Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
5.7.6 Uni-D / Bi-D High Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
5.7.7 Side Margin Adjustment Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
5.7.8 Test Printing Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
5.7.9 HeadWash Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
5.7.10 Software Counter Initialization Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
5.7.11 Feed Pitch Check Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
5.7.12 Solid Print Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
5.8 Cleaning Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
5.9 Sample Printing Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
5.10 Time Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
5.11 Parameter Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

5.11.1 Parameter Initialization Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
5.11.2 Parameter Update Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
5.12 Servo Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

5.13 Endurance Running Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
5.13.1 CR Motor Endurance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
5.13.2 PF Motor Endurance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
5.13.3 Wiper Motor Endurance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
5.13.4 Pump Endurance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
5.13.5 Print Head Endurance (Nozzle Print) Menu . . . . . . . . . . . . . . . . . . . . . 5-63
5.13.6 General Endurance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
5.13.7 Endurance Running Check Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
5.14 Media Feed Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
5.15 ExControl Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66

5.15.1 Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
5.15.2 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
5.15.3 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5.15.4 History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
8
5.16 PaperInitial Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
6 Maintenance Mode
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Operations in Maintenance Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2.1 Starting Up the Maintenance Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.2 Operating Maintenance Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.3 Maintenance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.3.1 Counter Display Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3.2 Counter Initialization Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3.3 Counter Print Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3.4 Media Feed Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
7 Adjustment
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2 Adjustment Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.3 Working with Dedicated Network Software . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7.3.1 Parameter Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.3.2 Jigs and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.3.3 Required Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.3.4 Receiving Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.3.5 Firmware Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.3.6 Sending Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7.3.7 Sub Controller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.3.8 RTC Date & Time Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7.4 PF Speed Reduction Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . 7-20

7.4.1 Jigs and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7.4.2 Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7.5 PF Encoder Assembly Position Adjustment . . . . . . . . . . . . . . . . . . . . . . 7-22

7.6 CR Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
7.7 Head Alignment (Horizontal Height) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
7.8 Head Alignment (Vertical Slant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
7.9 Cutter Holder Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

7.9.1 Jigs and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
9
7.10 PG Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

7.10.1 Jigs and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
7.11 Media Sensor Sensitivity Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

7.11.1 P_EDGE Sensor Sensitivity Adjustment . . . . . . . . . . . . . . . . . . . . . . . 7-32
7.11.2 P_REAR Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
8 Maintenance
8.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2 Periodical Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3 Part Life Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4 Lubrication/Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.5 Transportation of Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
9 Troubleshooting
9.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2 Troubleshooting with Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9.2.1 Operation Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2.2 Errors with Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.2.3 Data Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.2.4 Command Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
9.2.5 Errors Requiring Reboot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
9.2.6 Error Messages During File Transmission . . . . . . . . . . . . . . . . . . . . . . 9-29
9.3 Troubleshooting Without Error Messages. . . . . . . . . . . . . . . . . . . . . . . . 9-33

9.3.1 Initial Operation Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
9.3.2 Media Feed Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
9.3.3 Printing Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
9.3.4 Noise Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-62
9.3.5 Online Function Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-65
9.3.6 Other Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-68
9.3.7 Problems in Using Dedicated Network Software . . . . . . . . . . . . . . . . . 9-71
10 Appendix
10.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.2 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10
10.3 Maintenance Part List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.4 Jigs and Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

10.4.1 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10.5 Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
11
12
VJ-1604 　 Maintenance Manual 1 Safety Instructions
1 Safety Instructions
1.1 Introduction ............................................................................................. 1- 2
1.2 Warnings, Cautions and Notes.............................................................. 1- 2
1.3 Important Safety Instructions ................................................................ 1- 3
1.4 Warning Labels ....................................................................................... 1- 6
1.4.1 Handling the Warning Labels......................................................... 1-6
1.4.2 Locations and Types of Warning Labels........................................ 1-7
1-1 Rev.-00
1 Safety Instructions VJ-1604 　 Maintenance Manual
1.1 Introduction
This chapter explains the meaning of safety terms for personnel who installs, operates, or maintains this
equipment, important safety instructions, and the warning labels attached to the equipment.
WARNING
Make sure to follow all instructions and warnings on this manual when installing, operating,
or maintaining the equipment.
1.2 Warnings, Cautions and Notes

Safety terms in this manual and the contents of warning labels attached to the printer are categorized into the
following three types depending on the degree of risk (or the scale of accident).
Read the following explanations carefully, and follow the instructions in this manual.
Table 1-1 Safety Terms Descriptions

Safety terms Details
Must be followed carefully to avoid death or serious bodily injury
WARNING
Must be observed to avoid slight or moderate bodily injury or damage to

DANGER
whole or part of the product
Contains important information and useful tips on the operation of the
NOTE product
Indicates useful tips for operating or understanding the printer
TIP
Indicates “prohibited” operations
Indicates required operations
Indicates reference page in this manual
Rev.-00 1-2
1.3 Important Safety Instructions

General safety instructions that must be observed to use the equipment safely are explained below.
WARNING
Do not place the printer in the following areas. Doing so may result in the printer
tipping or falling over and causing injury.
• Unstable surfaces
• Angled place
• Areas subject to vibration by other equipment
Do not stand on or place heavy objects on your printer. Doing so may result in the
printer tipping or falling over and causing injury.
Doing so could obstruct ventilation and cause fire.
Do not cover the ventilation hole of your printer with cloth, such as a blanket or table
cloth.Doing so may result in fire.
Do not place the printer in humid and dusty areas. Doing so may result in electrical
shock or fire.
Make sure to use the power cable packed with the printer you purchased. Not doing
so may result in electrical shock or fire.
Make sure that the following is performed before parts replacement.

• Turn off the power of the printer.
• Remove the power cable from the power outlet.
Not doing so may cause electric shock or damage to the electric circuit.
• Unplug the cables connected to the printer.
Failure to do so could result in damage to the printer.
1-3 Rev.-00
CAUTION
Assembling and disassembling of the printer are possible only for the parts that
disassembling procedures are shown in this manual. Do not disassemble any frame
parts or parts that disassembling procedures are not shown in this manual.
Doing so may cause trouble that cannot be restored, as the printer is originally
assembled in the factory with a high accuracy of 1/100 mm.
Do not touch the elements on the circuit board with bare hands.
Doing so may cause static electricity and break the elements.
Do not press the transparent film on the damper assembly with your hands. Doing so
may discharge the ink filled inside the damper assembly.
Be careful not to damage the transparent film on the damper assembly.

Do not touch the nozzles of the print head. Make sure that the nozzles do not get any
dust.
Never lube the printer mechanism with lube other than that designated by MUTOH.
Doing so may damage the parts or shorten the lifetime.
There are some remaining ink in the tubes. Be careful that the ink is not spilled from the
tube outlet onto the printer or items close to the printer.
If you need to operate the printer with the cover removed for maintenance, be careful
not to get hurt by the driving parts.
If the power board assembly needs to be removed, remove the power cable and wait
for 5 minutes or more before taking it out; this will discharge the residual electrical
charge of the electrolytic capacitor.
Touching the board before the capacitor discharges may cause electric shock.
When connecting or removing an FFC type cable on a MAIN board assembly
connector, make sure to connect or remove the cable perpendicular to the connector.
Connecting or removing at a slant angle may damage, break or short circuit the inner
terminal of the connector. That may damage the elements on the board.
When connecting or removing an FFC type cable on the CR board assembly connector,
make sure to connect or remove the cable perpendicular to the connector.
Connecting or removing at a slant angle may damage, break or short circuit the inner
terminal of the connector. That may damage the elements on the board.
Make sure there is sufficient space around the printer when performing maintenance
work.
Maintenance must be done by more than two person for the following work.
• When disassembling or reassembling the product and the optional stand
• When packing the printer for transportation
Rev.-00 1-4
1.4 Warning Labels

The handling, attachment locations, and types of warning labels are explained below.
Warning labels are attached to areas where care should be taken. Read and understand the positions and
contents thoroughly before maintenance operation.
1.4.1 Handling the Warning Labels

Make sure to note the following when handling the warning labels.
NOTE
• Make sure that all warning labels can be recognized. If text or illustrations cannot be seen clearly,
clean or replace the label.
• When cleaning warning labels, use a cloth with water or neutral detergent. Do not use a solvent or
gasoline.
• If a warning label is damaged, lost, or cannot be recognized, replace the label.
1-5 Rev.-00
1.4.2 Locations and Types of Warning Labels
(1) Main Body

The locations of warning labels on the main body are shown below.
5 4 3 2 1
6
Rev.-00 1-6
Table 1-2 List of Warning Labels

No. Warning label type
1 (Front cover open/close caution)
2 (Head nozzle drying caution)
3 (Burn caution)
4 (Cleaning caution)
1-7 Rev.-00
Table 1-2 List of Warning Labels

5 (Steel belt caution)
6 (High temperature caution)
7 (Electric shock caution)
8 (Ink handling caution)
9 (Waste fluid tube handling caution)
Rev.-00 1-8
(2) Scroller (Optional)

The locations of warning labels on the scroller are shown below.

1 (Catching caution)
1-9 Rev.-00
Rev.-00 1-10
VJ-1604 Maintenance Manual 2 Product Overview
2 Product Overview
2.1 Introduction ............................................................................................. 2- 2
2.2 Features ................................................................................................... 2- 2
2.3 Part Names and Functions..................................................................... 2- 3
2.3.1 Front Section ................................................................................. 2-4
2.3.2 Rear Section .................................................................................. 2-5
2.3.3 Scroller Section (Optional) ............................................................. 2-6
2.3.4 Operation Panel ............................................................................. 2-7
2.4 Plotter Status......................................................................................... 2- 10
2.4.1 Normal ......................................................................................... 2-10
2.4.2 Setup Menu ................................................................................. 2-10
2.4.3 Self-Diagnosis Function ............................................................... 2-10
2.4.4 Maintenance Mode ...................................................................... 2-10
2-1 Rev.-00
2 Product Overview VJ-1604 Maintenance Manual
2.1 Introduction
This chapter explains the features, part names, and functions of the plotter.
2.2 Features
The features of the plotter are explained below.
(1) Fast Print

This model uses the new head prints images faster.
Realizing printing width of 1615 mm in uni-direction printing mode.
(2) Variety of Print Media

The height of the print head position can be set high/low, so that this model can print on the media of which
thickness is between 0.08 and 0.3 mm.
(3) Vivid Color Reproduction

For Vivid color reproduction, this model has high-capacity (220 ml) 4 color ink cartridges with exclusive
smart IC chip on it. With the IC chip, you can manage the ink level of the cartridges and can get better
productivity.
Also, With variable dot mechanism, this model enhances the level of color expression.
(4) Multi-Heater System

The media-heating system which have been equipped to PJ series is changed to match the solvent ink. There
are 3 heaters on Pre / Platen / After positions and improved the ink fixability and drying property.
(5) Effective Utilization of Media

The JOG function for setting print start position on purpose is equipped. You can print on the margin(s) of a
media which is already printed.
(6) RIP
Special software RIP is sold for options.
Rev.-00 2-2
2.3 Part Names and Functions

Part names and functions are explained below.
NOTE
For the directions described in this document, refer to the following figure.
Upper
Left Rear
Front Right
Lower
2-3 Rev.-00
2.3.1 Front Section

8 3 13 2
13
10
10
9
6
4
11
5 12 12 5
Table 2-1 Part Names and Functions of Front Section

No. Name Function
1 Media set lever Used for fixing or releasing the media
• Lower the lever to fix the media
• Lower the lever further to fix the media firmly
Used to improve the accuracy of media feeding
* The accuracy of media feeding may decline depending on media.
• Raise the lever to release the media
2 Operation panel Used to set operational conditions, the status of the plotter, and other
functions
3 Front cover Keeps the operator safe from the drive parts of the plotter while it is
operating. Opened and closed when media is set or jammed. It is normally
closed.
4 Waste fluid tank Used to store waste ink discharged from print head
5 Stand Used to set the plotter on the level surface of the floor
6 Media Guide Used to feed media smoothly when setting media and printing
The heater (after-heater) for drying ink is installed inside.
7 Platen Installed inside the front cover
The heater (platen heater) for drying ink is installed.
8 Pressure roller Installed inside the front cover
Used to press the media from above and hold it when printing
Rev.-00 2-4
Table 2-1 Part Names and Functions of Front Section (Continued)

No. Name Function
9 Media cut groove Installed inside of the front cover
Used to cut printed media straight
10 Maintenance cover Used to protect users from the mechanical parts inside the plotter in the
following cases:
- Cleaning the cleaning wiper
- Cleaning around the print head
This cover must usually be closed.
11 Waste fluid cock Opened/closed when discharging waste fluid from waste fluid tank. This
cover must usually be closed.
12 Adjuster Used to keep the plotter level
13 Media holding plate Installed inside the front cover
By attaching media holder plates to both sides of the media, it is possible
to prevent media warp.
2.3.2 Rear Section
3 4 2
5 67 1
Table 2-2 Part Names and Functions of Rear Section

No. Name Function
1 Roll media holders Used to load the roll media
Include flanges where roll media is attached, and the levers that fix the roll
media holders.
2 Media feed slot Insert media from here when feeding media
3 Ink cartridge slot Holds the ink cartridge
2-5 Rev.-00
Table 2-2 Part Names and Functions of Rear Section (Continued)

No. Name Function
4 Media guide Used for feeding media smoothly when the media is set or printed.
The heater (pre-heater) to warm media is installed.
5 AC inlet Used for connecting the power cable
6 USB connector Not used for this printer
7 Network interface Connector to connect a network interface cable
connector
2.3.3 Scroller Section (Optional)
2 8
5
3
1 4 7
Table 2-3 Part Names and Functions of Scroller Section

No. Name Function
1 Take-up device Used to take up printed media
2 Absorbing roller Used to guide printed media to the scroller
3 Scroller receiver Set the scroller for the take-up device here
4 Scroller release lever Used to poise the scroller when rotating the scroller manually
5 Scroller Used to take up printed media
6 Scroller height Adjusts the height of scroller receiver
adjustment screw
Rev.-00 2-6
Table 2-3 Part Names and Functions of Scroller Section (Continued)

No. Name Function
7 Scroller horizontal Adjusts the horizontal position of the scroller
position adjustment
screw
8 Power switch Turns the plotter on/off
2.3.4 Operation Panel

The operation panel is used to set operational conditions, display the status of the plotter, and set other
functions.
The names and functions of the operation keys and status lamps are explained below.
TIP
Operation manual
8, 9 10
17
13
14 15
16
11
6
12
1
5
3 4 7 2
2-7 Rev.-00
(1) Operation Keys
NOTE
Some keys have multiple functions and names depending on the plotter status (normal or setup menu
display). See "2.4 Plotter Status" p.2-10 for more details.
No. Name Normal Setup menu display

1 [Menu] key Changes the LCD monitor display to Changes the setup menu display
setup menu status. status to normal status.
2 [Enter] key - - Selects the menu to be set and shifts
to the next hierarchy.
- Determines and saves the parameter
value.
[Cleaning] key If held down for 2 seconds or more, -
starts cleaning the plotter head.
3 [Cancel] key - During plotting: Terminates printing - Returns to the previous menu
forcibly and deletes 1 file of hierarchy. Changed parameter values
remaining data. are disabled.
- During reception/analysis: Deletes - Changes the setup menu display
the data that has been already status to normal status.
received/analyzed and ignores 1 file
of data received after that.
-
4 [<] key -Changes the setting value in the
following menu:
• Origin setting menu
[Nozzle Check] key If held down for 2 seconds or more, -
starts checking the plotter nozzle.
5 [>] key Sets the cleaning mode. Displays lower rank menu items.
- The lamp for the cleaning mode
lights on (green).
6 [Backward ↑] key Feeds the media in the reverse -
direction.
[+] key - -Changes the menu in forward order.
-Changes the setting value in forward
order.
-Increases the value when inputting
setting value.
7 [Forward ↓] key Feeds the media in the forward -
direction.
[-] key - - Changes the menu in the reverse
direction.
- Decreases the value when inputting
values.
Rev.-00 2-8
No. Name Normal Setup menu display

8 [Power] key Turns the plotter on and off. Turns the plotter on and off.
(2) LCD Monitor and Status Lamps
No. Name Color Status Function

9 Power lamp Green On The plotter is switched on.
Blinking An error has occurred. The contents will be displayed on the
LCD monitor.
Off The plotter is switched off.
10 Data lamp Orange On - The plotter is analyzing received data.
- The plotter is printing data.
Blinking The plotter is receiving data.
Off The plotter is not receiving, analyzing or printing data.
11 High lamp Green On The print head height is set to High position.
Off The print head height is set to Low position.
12 Low lamp Green On The print head height is set to Low position.
Off The print head height is set to High position.
13 Wave lamp Green On The effect menu is set to Wave.
Off The effect menu is set to None.
14 Fine & S.Fine Green On The effect menu is set to either Fine or SuperFine.
lamp
Off The effect menu is set to Wave.
15 Strong lamp Green On - The cleaning mode is set to Strong.
- When the Normal lamp is also on, the cleaning mode is set
to Economy.
Off - The effect menu is set to Wave.
- When the Wave lamp is also off, the effect menu is set to
None.
16 Normal lamp Green On - The cleaning mode is set to Normal.
- When the Strong lamp is also on, the cleaning mode is set
to Economy quality.
Off The cleaning mode is set to Strong.
17 LCD monitor - - This monitor displays the operation status and error
messages of the plotter.
TIP
When an error that requires plotter to restart (i.e. crucial failure for opration), all the lamps blinks with
alarm sound.
2-9 Rev.-00
2.4 Plotter Status

The status of the plotter is explained below.
2.4.1 Normal
Indicates that the plotter can print when media is loaded.
Each setup concerning printing can be operated by using operation panel.
TIP
Operation manual
2.4.2 Setup Menu

Each setup concerning printing can be operated by using operation panel.
The settings required for normal printing are usually made on the plotter driver or application, but can also
be made using the operation panel.
TIP
Operation manual
2.4.3 Self-Diagnosis Function

Indicates that each settings concerning printing using the operation panel. Names and functions of the
operation panel keys are the same as those of setup menu display.
TIP
"5 Self-Diagnosis Mode" p.5-1
2.4.4 Maintenance Mode

Indicates that each setup concerning to the life counter on this plotter can be operated by using the operation
panel. Names and functions of the operation panel keys are the same as those of setup menu display.
TIP
"6 Maintenance Mode 2" p.6-1
Rev.-00 2-10
VJ-1604 　 Maintenance Manual 3 Specifications
3 Specifications
3.1 Introduction ............................................................................................. 3- 2
3.2 Product Specifications ........................................................................... 3- 2
3.3 Interface Specifications.......................................................................... 3- 4
3.3.1 Network Interface Specifications.................................................... 3-4
3.4 Options/Supplies List ............................................................................. 3- 4
3.4.1 Options .......................................................................................... 3-4
3.4.2 Supplies ......................................................................................... 3-4
3.5 Choosing a Place for the Printer .......................................................... 3- 6
3-1 Rev.-00
3 Specifications VJ-1604 　 Maintenance Manual
3.1 Introduction
This chapter explains the specifications of the product, optional parts, and supplies. Installation environment
requirements are also explained.
3.2 Product Specifications

(1) Main Unit Specifications
Item Specifications
Model name VJ-1604
Plotting method On-demand piezo drive
Motor driving method Firmware servo / DC motor drive
Media feeding method Multi-point pressure grid roller method
Media fixing method Pressurizing roller manual-down method
Media supply and Roll media

Rear feeding / front ejection
ejection
Roll media outer diameter 150 mm (5.9 in.) or less
Roll media weight 30 kg (66 lb.) or less
Maximum media length 50 m (164 ft.)
Maximum media width 1625 mm (63.9 in.)
Maximum media thickness 0.3 mm (0.01 in.)
Maximum plot length 18 m (59.1 ft.)
Maximum plot width 1615 mm (63.6 in.)
Plotting margins Top: 15 mm, Bottom: 5 mm, Left: 5-25 mm, Right: 5-25 mm
Media cutting method Horizontal manual cut
Head height adjustment 2 levels: Normal / High
Distance accuracy The larger value either ± 0.25 mm or ± 0.1% of moving distance
• Used media: Roll MF-3G
• Plot length: 1219 mm (4 ft.)
• Operating temperature: 22 to 30ºC (71.6 to 86F)
• Operating humidity: 40 to 60%
• PG: Low
• Plot mode: Graphics1
Right angle accuracy ±0.1mm or less against the moving distance (500.0mm)
• Used media: Roll MF-3G
• Operating temperature: 22 to 30ºC (71.6 to 86F)
• Operating humidity: 40 to 60%
• Plot mode: Graphics1
CPU 64Bit RISC CPU
Memory 256MB
Rev.-00 3-2
Item Specifications
Command MH-RTL (RTL-PASS)
Interface Network Interface (Ethernet IEEE802.3)
Ink Supply method Tube supply from four separate cartridges
Cartridge Black, cyan, magenta, yellow: 220ml ± 5ml for each color
Environmental conditions Temperature Humidity

Operation environment 20ºC (68F) to 30ºC (86F) 40% to 60%, with no condensation
Plotting accuracy warranty range 22ºC (71.6F) to 30ºC (86F) 40% to 60%, with no condensation
Rate of change 2ºC/hour or less 5%/hour or less
Storage Without ink -20ºC (-4F) to 60ºC (140F) 20% to 80%, with no condensation
environment
With ink -10ºC (14F) to 40ºC (104F) 20% to 80%, with no condensation
Power source Voltage AC 90 - 132V
Frequency 50Hz / 60Hz ± 1Hz
Power During Plotting 1200W (when heater is ON)

consumption
During standby 40W or less (when standby heater is OFF)
Outer dimensions Height 1262mm (49.7 in.) * including dedicated stand
Width 2698 mm (106in.)
Depth 845 mm (33.3 in.)
Weight 173 kg (380.6 lb.)
3-3 Rev.-00
3.3 Interface Specifications

This section explains the specification of the interfaces Supported for this printer.
3.3.1 Network Interface Specifications
Item Specifications
Network type Ethernet IEEE802.3
Network I/F 10BASE-T / 100BASE-TX Auto-switching
(RJ-45 connector twist pair cable)
MDI / MDI-X Auto-switching
Corresponding TCP/IP
protocol
3.4 Options/Supplies List

3.4.1 Options
TIP
For more information about the take-up device (optional), contact the following.
• MUTOH distributor
• MUTOH sales office
3.4.2 Supplies
(1) Ink Cartridge
Name Model Sales units

Ink cartridge K (Black: 220 ml ± 5 ml) VJ-MSINK3-BK220 1 box (1 piece per box)
Ink cartridge C (Cyan: 220 ml ± 5 ml) VJ-MSINK3-CY220 1 box (1 piece per box)
Ink cartridge M (Magenta: 220 ml ± 5 ml) VJ-MSINK3-MA220 1 box (1 piece per box)
Ink cartridge Y (Yellow: 220 ml ± 5 ml) VJ-MSINK3-YE220 1 box (1 piece per box)
Cleaning cartridge (220 ml ± 5 ml) VJ-MSINK3-CL220 1 box (1 piece per box)
Rev.-00 3-4
(2) Other Supplies
Name Model Sales units

Waste ink bottle RJ8000-HET 1 box (1 piece per box)
3-5 Rev.-00
3.5 Choosing a Place for the Printer

WARNING
• Do not place the printer in a location under the following conditions. Doing so may cause
the product to fall, become damaged, or cause injury.
• Unstable surfaces
• Slanted areas
• Locations that are subject to vibration from other product
• Do not stand on the printer or place any heavy objects on it.
Doing so may cause it to fall over, become damaged, or cause injury.
• Do not cover the ventilation hole of the printer with cloth, such as a blanket or table cloth.
Doing so could prevent the printer from ventilating and cause fire.
• Keep the printer away from humid and dusty areas. Failure to do so may result in
electrical shock or fire.
(1) Installation Environment Requirements

Choose a place for printer installation following the requirements of the table below.
Table 3-1 Installation Environment Requirements List

Floor loading capability 2940Pa (300kgf/m2) or over
Electrical Voltage AC 90-132 V
specification
Frequency 50/60Hz ± 1Hz
s
Capacity Main side: 8.5 A, Heater side: 8.5A
Environmental conditions Temperature Humidity
Operation 20º C (68F) - 32ºC (86F) 40% - 60%, with no condensation
environment
Plotting accuracy 22ºC (71.6F) - 30ºC (86F) 40% - 60%, with no condensation
warranty range
Rate of change 2ºC/hour or less 5%/hour or less
Storage -20ºC - 60ºC 20% - 80%
environment No condensation (when ink is not
charged)
Rev.-00 3-6
NOTE
• Avoid the following temperature and humidity conditions. Otherwise, Plotted images may appear
differently from what you expect.
• Places where sudden changes in temperature and humidity are expected, even though the
condition is within the range specified
• Places where direct sunlight or excessive lighting are expected
• Places where air conditioners blow directly
• MUTOH recommends that the printer should be installed where air conditioning can be adjusted
easily.
(2) Required Space

Install the printer on a flat surface that fulfills the following conditions.
• The place to install printer with the optional stand should have enough loading capacity.
NOTE
For the printer and the optional stand, refer to"3.2 Product Specifications" p.3-2.
a= 600 mm
b=1000 mm
c=1000 mm
d=1000 mm
e=1550 mm
e
a
d
b c
* Do not use VJ-1604 without stand.
3-7 Rev.-00
Rev.-00 3-8
VJ-1604 　 Maintenance Manual 4 Parts Replacement
4 Parts Replacement
4.1 Introduction ............................................................................................. 4- 6
4.2 Removing Covers ................................................................................... 4- 7
4.2.1 Removing Panel Cover .................................................................. 4-9
4.2.2 Removing Maintenance Cover....................................................... 4-9
4.2.3 Removing Maintenance Cover U ................................................. 4-10
4.2.4 Removing Side Maintenance Cover R......................................... 4-11
4.2.5 Removing Side Maintenance Cover L ......................................... 4-12
4.2.6 Removing Side Top Cover R ....................................................... 4-12
4.2.7 Removing Side Top Cover L........................................................ 4-14
4.2.8 Removing Rear Side Cover ......................................................... 4-15
4.2.9 Removing Cartridge Cover (Upper) ............................................. 4-17
4.2.10 Removing Cartridge Cover (middle) ............................................ 4-18
4.2.11 Removing Cartridge Cover (lower) .............................................. 4-19
4.2.12 Removing Switch Cover R ........................................................... 4-19
4.2.13 Removing Switch Cover L............................................................ 4-20
4.2.14 Removing Front Cover................................................................. 4-21
4.2.15 Removing Rear Top Cover .......................................................... 4-21
4.2.16 Removing Top Cover ................................................................... 4-23
4.2.17 Removing Media Guide F (Upper) ............................................... 4-24
4.2.18 Removing Media Guide R (Upper)............................................... 4-27
4.2.19 Removing Media Guide R (Lower)............................................... 4-29
4.3 Replacing Covers.................................................................................. 4- 30
4.3.1 Replacing Panel Unit ................................................................... 4-30
4-1 Rev.-00
4 Parts Replacement VJ-1604 　 Maintenance Manual
4.3.2 Replacing Maintenance Cover Sensor ......................................... 4-31
4.3.3 Replacing Front Cover Sensor ..................................................... 4-32
4.3.4 Replacing Front Cover Gear, Damper Gear (Sintered) ................ 4-35
4.4 Replacing Board Base (X Rail Section) ...............................................4- 39
4.4.1 Opening Board Box 64 ................................................................. 4-40
4.4.2 Replacing Power Board Assembly ............................................... 4-41
4.4.3 Replacing HEATER CONT Board ................................................ 4-42
4.4.4 Replacing HEATER RELAY Board............................................... 4-44
4.4.5 Replacing Cooling Fan (24V) Assembly (for Main Board)............ 4-46
4.4.6 Replacing Cooling Fan (24V) Assembly (in Media Guide F) ........ 4-48
4.4.7 Replacing MAIN Board ................................................................. 4-49
4.4.8 Replacing Fuse............................................................................. 4-53
4.4.9 Replacing Inlet Assembly ............................................................. 4-55
4.5 Replacing Board Base Section (Y Rail Section) .................................4- 58
4.5.1 Replacing Heater Junction Board Assembly ................................ 4-58
4.6 Replacing X Rail Section ......................................................................4- 60
4.6.1 Replacing PF Speed Reduction Belt ............................................ 4-60
4.6.2 Replacing PF Motor Assembly ..................................................... 4-61
4.6.3 Replacing PF Encoder Assembly ................................................. 4-63
4.6.4 Replacing PF_ENC Scale, PF Speed Reduction Pulley .............. 4-64
4.6.5 Replacing P_REAR Sensor Assembly ......................................... 4-65
4.6.6 Replacing Lever Up Sensor.......................................................... 4-67
4.6.7 Replacing Heater, Thermistor....................................................... 4-68
4.6.8 Replacing Suction Fan ................................................................. 4-76
Rev.-00 4-2
4.6.9 Replacing Platen Non-Reflective Tape ........................................ 4-77
4.6.10 Replacing Media Holder............................................................... 4-78
4.6.11 Replacing Flushing Tray .............................................................. 4-80
4.6.12 Replacing Flushing Absorber....................................................... 4-82
4.7 Replacing Y Rail Section...................................................................... 4- 84
4.7.1 Replacing Steel Belt..................................................................... 4-84
4.7.2 Replacing CR Motor Assembly .................................................... 4-87
4.7.3 Replacing CR Drive Pulley Assembly .......................................... 4-89
4.7.4 Replacing T Fence....................................................................... 4-91
4.7.5 Replacing CR Origin Sensor........................................................ 4-94
4.7.6 Replacing CR Driven Pulley......................................................... 4-96
4.7.7 Replacing Steel Bearer ................................................................ 4-97
4.7.8 Replacing CR Tape Wire ............................................................. 4-99
4.7.9 Replacing Pressure Roller ......................................................... 4-101
4.7.10 Replacing Ink Tube .................................................................... 4-102
4.8 Replacing Cursor Section .................................................................. 4- 105
4.8.1 Releasing Head Lock................................................................. 4-105
4.8.2 Removing CR Board Cover ....................................................... 4-106
4.8.3 Replacing CR Board Assembly.................................................. 4-106
4.8.4 Replacing CR Encoder Assembly.............................................. 4-108
4.8.5 Replacing PG Origin Sensor Assembly ..................................... 4-109
4.8.6 Replacing Cursor Roller Arm Assembly..................................... 4-110
4.8.7 Removing Print Head Cover ...................................................... 4-110
4.8.8 Replacing Damper Assembly L_Assy........................................ 4-112
4-3 Rev.-00
4.8.9 Replacing Print Head.................................................................. 4-114
4.8.10 Replacing Head FFC .................................................................. 4-116
4.8.11 Replacing P_EDGE Sensor Assembly ....................................... 4-118
4.9 Replacing Maintenance Section.........................................................4- 120
4.9.1 Removing Maintenance Inner Cover .......................................... 4-120
4.9.2 Replacing Cleaner Head ............................................................ 4-121
4.9.3 Replacing Maintenance Assembly ............................................. 4-122
4.10 Replacing IH Section ...........................................................................4- 125
4.10.1 Replacing Ink ID Board Assembly .............................................. 4-125
4.10.2 Replacing Frame Assembly, Needle .......................................... 4-128
4.10.3 Replacing Ink Cartridge Control Cable ....................................... 4-132
4.10.4 Replacing Cartridge Holder Assembly........................................ 4-132
4.10.5 Replacing two-way Valve ........................................................... 4-133
4.10.6 Replacing Sub-Tank Lower Absorber Assembly ........................ 4-135
4.11 Replacing Leg Section ........................................................................4- 136
4.11.1 Replacing Waste Fluid Bottle ..................................................... 4-136
4.12 Replacing Roll Media Holder Assembly ............................................4- 138
4.12.1 Replacing Roll Media Holder Assembly on the VJ16_L side...... 4-138
4.12.2 Replacing Roll Media Holder Assembly on the VJ16_R side ..... 4-139
4.13 Replacing Take-up Section.................................................................4- 140
4.13.1 Removing Take-up Cover........................................................... 4-140
4.13.2 Replacing Scroller ...................................................................... 4-141
4.13.3 Replacing VJ Take-up CNT Board Assembly............................. 4-143
4.13.4 Replacing CR_HP Sensor, Lever Sensor................................... 4-150
Rev.-00 4-4
4.13.5 Replacing Peripheral Devices of VJ Take-up Motor Assembly.. 4-153
4-5 Rev.-00
4.1 Introduction
This chapter provides information on removal and replacement of service parts.
WARNING
• Before starting part replacement, always perform the following operations.

• Turn OFF the machine power.
• Remove the power plug from the outlet.
Otherwise, you may suffer electric shock or the system circuit may be damaged.
• Remove any cables connected to the plotter.
Otherwise, the plotter may be damaged.
CAUTION
The components in the plotter can be disassembled only if so instructed in this manual. Do
not disassemble the frame components and other components that are not instructed to
disassemble in the manual.
The plotter has been assembled in the MUTOH factory with extremely high precision up to
1/100mm. If disassembled inappropriately, it may not restore its normal functionality.
NOTE
After replacing any service parts, perform necessary lubrication and bonding following the
instructions in section "8.5 Lubrication/Bonding" p.8-7.
Rev.-00 4-6
4.2 Removing Covers

This section describes the procedures to replace covers.
11
8 10
5
7 4
2
3
12
13
5
19
17 18
16 8
15
13
9
14
20
21
Table 4-1 Cover Component List

No. Part name
1 Panel cover
2 Maintenance cover R
3 Maintenance cover U_R
4 Side maintenance cover R
4-7 Rev.-00
Table 4-1 Cover Component List (Continued)

No. Part name
5 Side top cover R
6 Maintenance cover L
7 Maintenance cover U_L
8 Side top cover L
9 Side maintenance cover L
10 Front cover
11 Acrylic plate
12 Media guide F (upper)
13 Board box 64
14 Rear side cover
15 Cartridge cover (lower)
16 Cartridge cover (middle)
17 Cartridge cover (upper)
18 Rear top cover
19 Top cover
20 Media guide R (upper)
21 Media guide R (lower)
Rev.-00 4-8
4.2.1 Removing Panel Cover

1. Open the maintenance cover R.
2. Remove the screws (2 pieces) that retain the panel cover.
2 2
No. Part name

1 Panel cover
2 Screws that retain the panel cover
(pan-head screw with spring washer and flat washer M4 × 8)
3. Remove the panel cover.

4. To reassemble the unit, reverse the removal procedure.
4.2.2 Removing Maintenance Cover
NOTE
The procedure to remove the maintenance cover R is the same as the one for the maintenance cover L.
1. Open the maintenance cover.

2. Lift up the maintenance cover.
3. Remove the maintenance cover.
4-9 Rev.-00
No. Part name

1 Maintenance cover
4.2.3 Removing Maintenance Cover U
NOTE
The procedure to remove the maintenance cover U_R is the same as the one for the maintenance
cover U_L.

"4.2.2 Removing Maintenance Cover" p.4-9
Rev.-00 4-10
2. Remove the screws (2 pieces) that retain the maintenance cover U.
No. Part name

1 Maintenance cover U
2 Screws that retain the maintenance cover U
3. Remove the Maintenance cover U.

4.2.4 Removing Side Maintenance Cover R

1. Remove the screws (2 pieces) that retain the side maintenance cover R.
No. Part name

1 Side maintenance cover R
2 screws that retain the side maintenance cover R
4-11 Rev.-00
2. Lift up and remove the side maintenance cover R.

4.2.5 Removing Side Maintenance Cover L

1. Remove the screws (2 pieces) that retain the side maintenance cover L.
1
No. Part name

1 Side maintenance cover L
2 Screws that retain the side maintenance cover L
2. Lift up and remove the side maintenance cover L.

4.2.6 Removing Side Top Cover R
NOTE
Before removing the side top cover R, close the front cover.
1. Remove the side maintenance cover R.

"4.2.4 Removing Side Maintenance Cover R" p.4-11
Rev.-00 4-12
2. Remove the screws (2 pieces) that retain the side top cover R.
2 1
No. Part name

1 Side top cover R
2 Screws that retain the side top cover R
3. Remove the side top cover R to the direction shown in the picture below.
4-13 Rev.-00
4.2.7 Removing Side Top Cover L
NOTE
Before removing the side top cover L, close the front cover.
1. Remove the side maintenance cover L.

"4.2.5 Removing Side Maintenance Cover L" p.4-12
2. Remove the screws (2 pieces) that retain the side top cover L.
2 1
No. Part name

1 Side top cover L
2 Screws that retain the side top cover L
3. Remove the side top cover L to the direction shown in the picture below.
Rev.-00 4-14
4.2.8 Removing Rear Side Cover

2. Remove the side top cover L.
"4.2.7 Removing Side Top Cover L" p.4-14
3. Remove the screws (2 pieces) that retain the rear side cover 3.
1 2
No. Part name

1 Rear side cover 3
2 Screws that retain the rear side cover 3
(tapping screw M3 × 8)
3 Rear side cover
4. Remove the rear side cover 3.
4-15 Rev.-00
5. Remove the screws (2 pieces) on the lower part of the rear side cover.
No. Part name

1 Rear side cover
2 Screws that retain the rear side cover
6. Remove the screws (3 pieces) on the left and right side of the rear side cover.
Rear left view 1 Rear right view
2 1 2
No. Part name

1 Rear side cover
2 Screws that retain the rear side cover
Rev.-00 4-16
7. Remove the rear side cover.
No. Part name

1 Rear side cover
4.2.9 Removing Cartridge Cover (Upper)

1. Remove the ink cartridge (6 pieces).
2. Remove the screws (4 pieces) that retain the left and right part of the cartridge cover (upper).
2 Rear left view 1 1 Rear right view 2
No. Part name

1 Cartridge cover (Upper)
2 Screws that retain the cartridge cover (Upper)
4-17 Rev.-00
3. Remove the screws (2 pieces) on the upper part of the Cartridge cover (Upper).
No. Part name

1 Cartridge cover (upper)
2 Screws that retain the cartridge cover (upper)
4. Remove the cartridge cover (upper).

4.2.10 Removing Cartridge Cover (middle)

"4.2.9 Removing Cartridge Cover (Upper)" p.4-17
2. Remove the screws (2 pieces) that retain the cartridge cover (middle).
No. Part name

1 Cartridge cover (middle)
2 Screws that retain the cartridge cover (middle)
Rev.-00 4-18
3. Remove the cartridge cover (middle).
4.2.11 Removing Cartridge Cover (lower)

1. Remove the screws (4 pieces) that retain the cartridge cover (lower).
2 Left view 1 1 Right view 2
No. Part name

1 Cartridge cover (lower)
2 Screws that retain the cartridge cover (lower)
2. Remove the cartridge cover (lower).

4.2.12 Removing Switch Cover R

1. Remove the side top cover R.
"4.2.6 Removing Side Top Cover R" p.4-12
4-19 Rev.-00
2. Remove the screws (3 pieces) that retain the switch cover R.
Rear view Right view 1
1 2 2
No. Part name

1 Switch cover R
2 Screws that retain the switch cover R
3. Remove the switch cover R.

4.2.13 Removing Switch Cover L

2. Remove the screws (3 pieces) that retain the switch cover L.
Rear view Left view 1
2 1 2
No. Part name

1 Switch cover L
2 Screws that retain the switch cover L
Rev.-00 4-20
3. Remove the switch cover L.

4.2.14 Removing Front Cover
CAUTION
Front cover removal must be done by two or more persons.
1. Remove the screws that retain the left and right side of the front cover (4 pieces respectively).
Left view 2 2 Right view
No. Part name

1 Front cover
2 Screws that retain the front cover
(Trusco screw M4 × 6)
2. Remove the front cover.

4.2.15 Removing Rear Top Cover
CAUTION
Rear top cover removal must be done by 2 or more persons.
1. Remove the Side Top Cover R.

2. Remove the Rear side cover.
"4.2.8 Removing Rear Side Cover" p.4-15
4-21 Rev.-00
3. Remove the Side Top Cover L.

4. Remove the Cartridge cover (upper).
5. Remove the screws (5 pieces) on the back of the rear top cover.
6. Remove the screws (5 pieces) on the upper side of the rear top cover.
No. Part name

1 Rear top cover
2 Screws that retain the rear top cover
3 Screws that retain the rear top cover
(cup screw M3 × 8)
7. Remove the rear top cover.

Rev.-00 4-22
4.2.16 Removing Top Cover
CAUTION
Top cover removal must be done by 2 or more persons.
1. Remove the front cover.

"4.2.14 Removing Front Cover" p.4-21
"4.2.15 Removing Rear Top Cover" p.4-21
3. Remove the screws (6 pieces) that retain the back of the top cover.
Rear view 1
No. Part name

1 Top cover
2 Screws that retain the top cover
4-23 Rev.-00
4. Remove the screws (5 pieces) that retain the front of the top cover.
Front view 1
No. Part name

1 Top cover
2 Screws that retain the top cover
5. Remove the top cover.

4.2.17 Removing Media Guide F (Upper)
CAUTION
Media guide F (upper) removal must be done by 2 or more persons.

"4.2.2 Removing Maintenance Cover" p.4-9
Rev.-00 4-24
2. Remove the screws (2 pieces) that retain the media guide FR.
1 Right upper view Lower view 2
No. Part name

1 Media guide FR
2 Screws that retain the media guide FR
3. Remove the media guide FR.

4. Remove the screws (2 pieces) that retain the media guide FL.
1 Left upper view Lower view 2
No. Part name

1 Media guide FL
2 Screws that retain the media guide FL
5. Remove the media guide FL.
4-25 Rev.-00
6. Remove the screws (5 pieces) that retain the bottom of the media guide F (upper).
No. Part name

2 Screws that retain the media guide F (upper)
7. Remove the screws (5 pieces) that retain the media guide F (upper).
No. Part name

2 Screws that retain the media guide F (upper)
(binding small screw M3 × 6)
8. Lift up the media guide F (upper).
Rev.-00 4-26
9. Remove the two connectors to the after-heater and the two connectors to the after-thermistor that are in
side the media guide F (upper).
3 2
1 4
No. Part name

2 Media guide F (lower)
3 Connector to the after-thermistor
4 Connector to the after-heater
10. Remove the media guide F (upper).

4.2.18 Removing Media Guide R (Upper)
CAUTION
Media guide R (upper) removal must be done by 2 or more persons.
1. Remove media.
4-27 Rev.-00
2. Remove the screws (4 pieces) that retain the media guide R (upper).
No. Part name

2 Screws that retain the media guide R (upper)
3. Push backward the media guide R (upper).

4. Remove the two connectors to the pre-heater and the two connectors to the pre-thermistor that are in side
the media guide R (upper).
3 4
No. Part name

1 Rear top cover
3 Connector to the pre-thermistor
4 Connector to the pre-heater
5. Remove the media guide R (upper).

Rev.-00 4-28
4.2.19 Removing Media Guide R (Lower)
CAUTION
Media guide R (lower) removal must be done by 2 or more persons.
1. Remove the media guide R (upper).

"4.2.18 Removing Media Guide R (Upper)" p.4-27
NOTE
If the roll media holder overlaps the screw holes, displace the roll media holder.
2. Remove the screws (8 pieces) that retain the media guide R (lower).
2 1
No. Part name

1 Media guide R (lower)
2 Screws that retain the media guide R (lower)
3. Remove the media guide R (lower).

4-29 Rev.-00
4.3 Replacing Covers

This section describes the procedures to replace the covers.
4.3.1 Replacing Panel Unit
CAUTION
• When replacing the panel unit, first pull out the AC cable.
Power may be turned on depending on how the cable is connected, and that may damage
the board.
• When connecting and removing the FFC type cables (panel tape wires), always pull or
push the cables perpendicularly.
Pulling or pushing them slantwise may damage/short/break the terminals in the
connectors, causing a breakdown of the on-board devices.
• The cables can be connected or removed up to 5 times.
1. Remove the panel cover.

"4.2.1 Removing Panel Cover" p.4-9
2. Remove the panel to conversion board tape wire.
3. Release the four panel unit back tabs (4 pieces) from the panel stay.
2 Front view 2 1 Rear view
1 3
2 4 2 3 2
No. Part name
1 Panel unit
2 Panel unit tab
3 Panel stay
4 Panel FFC
4. Remove the panel unit.

5. Replace the panel unit.
Rev.-00 4-30
4.3.2 Replacing Maintenance Cover Sensor
(1) Replacing Maintenance Cover Sensor R

1. Remove the maintenance cover U.
"4.2.3 Removing Maintenance Cover U" p.4-10
2. Detach the connector for the maintenance cover sensor assembly.
3. Remove the screws (2 pieces) that retain the maintenance cover sensor assembly.
1 3
No. Part name

1 Maintenance cover sensor assembly
2 Screws that retain the maintenance cover sensor assembly
3 Connector for the maintenance cover sensor assembly
4. Remove the maintenance cover sensor assembly.

5. Replace the maintenance cover sensor assembly.
TIP
The maintenance cover sensor looks like the following.
Opened Closed
4-31 Rev.-00
(2) Replacing Maintenance Cover Sensor L

The procedure to replace the maintenance cover sensor L is the same as the one for the maintenance cover
sensor R.
4.3.3 Replacing Front Cover Sensor
(1) R Side
1. Remove the Side top cover R.
"4.2.12 Removing Switch Cover R" p.4-19
3. Detach the connector for the cover sensor (C) assembly_R.
Rev.-00 4-32
4. Remove the screws (2 pieces) that retain the cover sensor (C) assembly_R.
3 1
No. Part name

1 Cover sensor (C) assembly_R
2 Screws that retain the cover sensor (C) assembly_R
(pan-head screw with spring washer and flat washer M2 ×
12)
3 Damper cover R
5. Remove the cover sensor (C) assembly_R.

TIP
The cover sensor looks like the following.
Opened Closed
(2) L Side
1. Remove the Side top cover L.
"4.2.13 Removing Switch Cover L" p.4-20
3. Detach the connector for the cover sensor (C) assembly_L.
4-33 Rev.-00
4. Remove the screws (2 pieces) that retain the cover sensor (C) assembly_L.
1 3
No. Part name

1 Cover sensor (C) assembly_L
2 Screws that retain the cover sensor (C) assembly_L
12)
3 Damper cover L
5. Remove the cover sensor (C) assembly_L.

TIP
The cover sensor looks like the following.
Opened Closed
Rev.-00 4-34
4.3.4 Replacing Front Cover Gear, Damper Gear (Sintered)

(1) R Side
"4.2.12 Removing Switch Cover R" p.4-19
2. Remove the screw (1 piece) that retain the switch plate R.
2 3
No. Part name

1 Switch plate R
2 Screws that retain the switch plate R.
3 Front cover axis
3. Remove the switch plate.

4. Remove the screws (3 pieces) that retain the damper cover R.
2 1
No. Part name

1 Damper cover R
4-35 Rev.-00
No. Part name

2 Screws that retain the damper cover R
5. Remove the damper cover R.

6. Remove the flange bushing.
1 4
No. Part name

1 Flange bushing
2 Front cover gear
3 Front cover axis
4 Damper gear (sintered)
7. Replace the front cover gear.

8. Replace the damper gear (sintered).
Rev.-00 4-36
(2) L Side
"4.2.13 Removing Switch Cover L" p.4-20
2. Remove the screw (1 piece) that retain the switch plate L.
3 2
No. Part name

1 Switch plate L
2 Screws that retain the switch plate L
3 Front cover axis
3. Remove the switch plate.

4. Remove the screws (3 pieces) that retain the damper cover L.
1 2
No. Part name

1 Damper cover L
2 Screws that retain the damper cover L
4-37 Rev.-00
5. Remove the damper cover L.

6. Remove the flange bushing.
1 2
No. Part name

1 Flange bushing
2 Front cover gear
3 Front cover axis
4 Damper gear (sintered)
7. Replace the front cover gear.

8. Replace the damper gear (sintered).
Rev.-00 4-38
4.4 Replacing Board Base (X Rail Section)

This section describes the procedure to replace the power supply or the board in the X rail section.
The boards are arranged as follows.
Inside view of paper guide F Inside view of board box 64
1 2 3 4
No. Part name

1 HEATER RELAY board assembly
2 HEATER-CONT board assembly
3 Power board assembly
4 Main board assembly
4-39 Rev.-00
4.4.1 Opening Board Box 64

1. Remove the AC inlet cables (2 pieces), and the other cables (LAN, USB).
2. Remove the screws (5 pieces) that retain the board box 64.
CAUTION
If you remove the screws that retain the board box 64, the box opens downwards because
of it's weight. Remove the last screw while holding the box by hand, or you may be injured.
2 Left view Right view 2
1 1
Rear view
2
No. Part name

1 Board box 64
2 Screws that retain the board box 64
3. Open the board box 64 downwardly.

4. To close the unit, reverse the opening procedure.
Rev.-00 4-40
4.4.2 Replacing Power Board Assembly
CAUTION
If the power board assembly needs to be removed, remove the power cable and wait for 5
minutes or more before dismount the assembly; this will discharge the residual electrical
charge of the electrolytic capacitor.
Touching the board before the capacitor discharges may cause electric shock.

"4.2.17 Removing Media Guide F (Upper)" p.4-24
2. Remove the connectors.
3. Remove the screws (9 pieces) that retain power board assembly.
No. Part name

1 Power board assembly
2 Screws that retain the power board assembly
(cup screw M3 × 6)
4. Remove the power board assembly.

5. Replace the power board assembly.
4-41 Rev.-00
4.4.3 Replacing HEATER CONT Board
CAUTION
• Before you replace a board assembly, remove the AC inlet cable.

You may suffer electric shock due to standby current.
• When you handle a circuit board, do not touch any devices on it with bare hands.
Doing so may cause electrostatic discharge and damage the devices.
• When connecting and removing the FFC type cables to/from the MAIN board assembly
connectors, always pull or push the cables perpendicularly.

Rev.-00 4-42
2. Detach the connectors listed below from the HEATER CONT board.
Table 4-2 Connectors to HEATER CONT board
No. Connector # of Color Connect to Remark

No. Pins
1 J1 8 Black Config CN
2 J2 2 White Feeder Motor
3 J3 6 White Feeding Unit Sensor
4 J4 4 White Roll Motor
5 J5 7 White Roll Unit Sensor
6 J6 40 Black HEATER RELAY A (J3) FFC
7 J7 40 Black Not in use
8 J8 4 White DC IN [HEATER JUNCTION (J2)]
9 J9 8 Gray Communication [HEATER JUNCTION LAN
(J3)]
10 J10 8 Gray LVS [MAIN (143)] LAN
11 J11 5 White Debug
12 J12 5 Yellow SMARTCARD Not in use
13 J13 RSV IN 1 Not in use
14 J14 RSV OUT 1 Not in use
15 J15 RSV OUT 2 Not in use
16 J16 RSV IN 2 Not in use
17 J17 THRM 1 Not in use
18 J18 THRM 2 Not in use
19 J19 8 White DC IN -> [MAIN J46]
20 J20 2 White AC OUT -> DC5V/24V (CN1)
21 J21 3 Red POW-ON -> POW [MAIN (J45)]
22 J22 2 White AC-IN -> Terminal Stand
23 J23 2 White EXT-AC-OUT -> HEATER RELAY A
(J1)
4-43 Rev.-00
3. Remove the screws (4 pieces) that retain the HEATER CONT board.
2 2
No. Part name

1 HEATER CONT board
2 Screws that retain the HEATER CONT board.
(cup screw M3 × 6)
4. Replace the HEATER CONT board.

4.4.4 Replacing HEATER RELAY Board
CAUTION

1. Remove the Media guide F (upper).

Rev.-00 4-44
2. Detach the connectors listed below from the heater relay board.
Table 4-3 Connectors to Heater Relay Board

No. Pins
1 J1 2 White EX-AC-OUT [HEATER CONT (J23)]
2 J2 4 White Plt_Heat 1
3 J3 40 Black HEATER CONT (J6) FFC
4 J4 2 White Not in use
5 J5 4 White Plt_Heat 2
6 J6 2 White Inlet (Large)
7 J7 2 White Pre_Heat
8 J8 2 White Pre_Heat
9 J9 4 White Aft_Heat
10 J10 2 Blue Cooling FAN
11 J11 4 White Vacum FAN (#1, #2)
12 J12 2 White Platen_Thrm 1
13 J13 2 Black Platen_Thrm 2
14 J14 4 Black Vacum FAN (#3, #4)
15 J15 2 Red Pre_Thrm 1
16 J16 2 Yellow Pre_Thrm 2
17 J17 3 White Aft_Thrm 1
18 J18 3 Black Aft_Thrm 2
19 J19 3 Red Reserve 1 Thrm
20 J20 3 Yellow Reserve 2 Thrm
4-45 Rev.-00
3. Remove the screws (6 pieces) that retain the heater relay board.
No. Part name

1 Heater relay board
2 Screws that retain the heater relay board
(cup screw M3 × 6)
4. Remove the heater relay board.

5. Replace the heater relay board.
4.4.5 Replacing Cooling Fan (24V) Assembly (for Main Board)

1. Open the board box 64.
"4.4.1 Opening Board Box 64" p.4-40
2. Detach the connector to the cooling fan (24V) assembly.
Rev.-00 4-46
3. Remove the screws (2 pieces) that retain the cooling fan (24V) assembly.
1 Back of the leg holder base
3 2
No. Part name

1 Cooling fan (24V) assembly
2 Screws that retain the cooling fan (24V) assembly
30)
3 Connector to the cooling fan (24V) assembly
4. Replace the cooling fan (24V) assembly.

4-47 Rev.-00
4.4.6 Replacing Cooling Fan (24V) Assembly (in Media Guide F)

1. Remove the Media guide F (upper).
2. Remove the connector to the cooling fan (24V) assembly.
2 Inside view of paper guide F 1
3 4
No. Part name

2 Cooling fan mounting plate
3 Screws that retain the cooling fan mounting plate
4 Connector to the cooling fan (24V) assembly
4. Remove the cooling fan mounting plate.

1 Inside view of paper guide F
3 2
No. Part name

Rev.-00 4-48
No. Part name

2 Screws that retain the cooling fan (24V) assembly
30)
6. Remove the cooling fan (24V) assembly.

4.4.7 Replacing MAIN Board
CAUTION

NOTE
Be sure to back up the parameters before replacing the MAIN board assembly.
"7.3.1 Parameter Backup" p.7-7
4-49 Rev.-00
(1) Replacing SODIMM

No. Part name

1 SODIMM
2. Open the lock to both sides.

3. Remove the SODIMM.
4. Replace the SODIMM.
NOTE
Push in the SODIMM following the notches until click sound occurs.
(2) Replacing Main Board Assembly

1. Remove the board box 64.
2. Remove the SODIMM.
"(1) Replacing SODIMM" p.4-50
Rev.-00 4-50
3. Detach the connectors listed below from the MAIN board assembly.
CAUTION
When connecting and removing the FFC type cables to/from the MAIN board assembly
Pulling or pushing them slantwise may damage/short/break the terminals in the connectors,
causing a breakdown of the on-board devices.
Table 4-4 Connectors to Main Board Assembly
No. Connector # of Colors Connect to Remark

No. Pins
1 J1 14 White P/S (CON301) FFC
2 J2 6 Black Config_CN
3 J3 144 Black SODIMM
4 J4 6 Black CLKDV_JTAG
5 J5 28 Black PANEL_UNIT
6 J6 8 Silver LAN
7 J7 Option_IF Not in use
8 J8 Option_IF Not in use
9 J9 30 Black CR Board (J206) FFC
12 J12 4 White PF_ENC
13 J13 USB
14 J14 8 Black Maint.Cover_Sensor
15 J15 8 Blue Ink_Sensor_C
16 J16 8 Red Ink_Sensor_M
17 J17 8 Yellow Ink_Sensor_Y
18 J18
19 J19
20 J20 2 White PF_MT
21 J21 3 White CR_MT
22 J22 4 White PUMP_MT
23 J23
4-51 Rev.-00
Table 4-4 Connectors to Main Board Assembly (Continued)
No. Connector # of Colors Connect to Remark

No. Pins
24 J24 3 White CR_ORG
25 J25 2 White Vacum_FAN_1
26 J26 2 White Vacum_FAN_1
27 J27 3 Black W_ORG
28 J28 2 Red Vacum_FAN_3
29 J29 2 Yellow Vacum_FAN_4
30 J130 3 Blue Lever_up
31 J31
32 J32 2 White COOLING_FAN_1
33 J33 3 Red Waste_Fluid_Full_Sensor
34 J34 COOLING_FAN_2
35 J35 4 Yellow Waste_Box_Sensor_L
36 J36 2 Red COOLING_FAN_3
37 J37
38 J38 3 Yellow F_Cover_R_Sensor
39 J39
40 J40 4 Blue F_Cover_L_Sensor
41 J41 5 Black Debug CN
42 J42 4 Black P_REAR_R
43 J43 8 Silver LDVS -> [HEATER CONT (J10)] LAN
44 J44 8 Black CPLD
45 J45 Not in use
46 J46 4 White HEATER CONT (J19)
Rev.-00 4-52
4. Remove the screws (6 pieces) that retain the MAIN board assembly.
No. Part name

2 Screws that retain the MAIN board assembly
(cup screw M3 × 6)
5. Remove the MAIN board assembly.

6. Replace the MAIN board assembly.
8. Install the firmware.
"7.3.5 Firmware Installation" p.7-12
9. Install the parameters backup.
"7.3.1 Parameter Backup" p.7-7
4.4.8 Replacing Fuse
CAUTION
• Remove the AC inlet cable to replace the fuse before performing work.
• When replacing fuses, install the fuse which conforms to the specifications (250V-15A,
φ10.31mm x 38.1mm).
• The double pole/neutral line has a fuse.

2. Replace the blown fuses.
4-53 Rev.-00
• There are two fuses for one power supply (four fuses in total).
CAUTION
Don’t touch the cap of a fuse with bare hands.
3 4
1 2
No. Part name

1 Fuse (main side)
2 Fuse (heater side)
3 Fuse holder (main side)
4 Fuse holder (heater side)
Rev.-00 4-54
TIP
The fuses are called F1, F2, F3, F4 from the left. Each functions as follows.
No. Function
F1 MAIN LIVE
F2 MAIN NEUTRAL
F3 HEATER LIVE
F4 HEATER NEUTRAL
4.4.9 Replacing Inlet Assembly
CAUTION
• Remove the AC inlet cable to replace the fuse before replacing the AC inlet.
(1) Replacing AC Inlet Small (Main Side)

2. Remove the connectors (3 pieces).
No. Part name

1 AC inlet small
2 Connector
4-55 Rev.-00
3. Remove the screws (2 pieces) that retain the AC inlet small.
No. Part name

1 AC inlet small
2 Screws that retain the AC inlet small
(countersunk head screw M3 × 6)
4. Remove the AC inlet small from outside.

5. Replace the AC inlet small.
Rev.-00 4-56
(2) Replacing AC Inlet Large (Heater Side)

2. Remove the connectors (3 pieces).
No. Part name

1 AC inlet large
2 Connector
3. Remove the screws (2 pieces) that retain the AC inlet large.
No. Part name

1 AC inlet large
2 Screws that retain the AC inlet large
4. Remove the AC inlet large from inside.

5. Replace the AC inlet large.
4-57 Rev.-00
4.5 Replacing Board Base Section (Y Rail Section)

This section describes the procedure to replace the boards in the Y rail section.
4.5.1 Replacing Heater Junction Board Assembly
CAUTION

1. Move the carriage to the opposite side of the origin.

"4.8.1 Releasing Head Lock" p.4-105
4. Detach the connector to the heater junction board assembly.
Table 4-5 Connectors to Heater Junction Board Assembly

No. Pins
1 J1 Config CN
2 J2 4 White DC IN -> HEATER CONT (J8)
3 J3 Communication -> HEATER CONT (J9) LAN
4 J4 10 White HEATER CONT (J10) Option
5 J5 10 White INK SLOT1
11 J11 8 White SubTank1
Rev.-00 4-58
Table 4-5 Connectors to Heater Junction Board Assembly (Continued)

No. Pins
17 J17 EX ACT1 Not in use
18 J18 EX SLOT1 Not in use
25 J25 EX DC OUT Not in use
5. Remove the screws (4 pieces) that retain the heater junction board assembly.
Rear view 2 Enlarged view 3
No. Part name

1 Heater junction board assembly
2 Screws that retain the heater junction board assembly
(cup screw M3 × 6)
3 Y rail assembly
NOTE
Use a ratchet to remove the screws that retain the heater junction board assembly.
4-59 Rev.-00
6. Replace the heater junction board assembly

4.6 Replacing X Rail Section

This section describes the procedure to replace the X rail section.
4.6.1 Replacing PF Speed Reduction Belt
CAUTION
Do not touch the motor right after starting-up the plotter. Otherwise, you may be burned.
1. Open the maintenance cover L.

4. Loosen the screws (2 pieces) that retain the PF motor.
1 4
No. Part name

1 PF motor
2 Screws that retain the PF motor
3 PF speed reduction belt
4 PF drive mounting plate
5. Confirm that the PF speed reduction belt has been loosened.
Rev.-00 4-60
6. Detach the PF speed reduction belt.
NOTE
When installing the PF motor assembly, ensure that the PF speed reduction belt is evenly guided
along the center part of the PF motor assembly pulley by moving the speed reduction pulley by hand.
7. Replace the PF speed reduction belt.

8. Retain the PF motor by pushing the motor backward.
9. Confirm that the PF speed reduction belt is not loosened.
4.6.2 Replacing PF Motor Assembly
CAUTION
1. Initialize the PF motor counter.

"5.11.1 Parameter Initialization Menu" p.5-47
5. Detach the PF speed reduction belt.
"4.6.1 Replacing PF Speed Reduction Belt" p.4-60
4-61 Rev.-00
6. Detach the PF motor cable from the motor connector.
3 2
No. Part name

1 PF motor
2 PF motor connector
3 PF motor cable assembly
7. Remove the screws (2 pieces) that retain the PF motor.
1 4
No. Part name

1 PF motor
2 Screws that retain the PF motor
3 PF speed reduction belt
4 PF drive mounting plate
8. Remove the PF motor.

9. Replace the PF motor.
10. Lightly tighten the screws that retain the PF motor.
Rev.-00 4-62
11. Install the PF speed reduction belt.
NOTE
When installing the PF motor assembly, ensure that the PF speed reduction belt is evenly guided
along the center part of the PF motor assembly pulley by moving the speed reduction pulley by hand.
12. Retain the PF motor by pushing the PF motor backward.

13. Confirm that the PF speed reduction belt is not loosened.
4.6.3 Replacing PF Encoder Assembly

2. Remove the screws (2 pieces) that retain the PF encoder assembly.
1 4
No. Part name

1 PF encoder
2 Screws that retain the PF encoder
3 ENC scale holder
4 PF-ENC scale
3. Remove the PF encoder assembly.

4. Replace the PF encoder assembly.
NOTE
When reassemble the PF_ENC assembly and the PF encoder bracket, make sure the embossed notch
is in the correct position.
4-63 Rev.-00
5. Adjust the PF_ENC scale.

"7.5 PF Encoder Assembly Position Adjustment" p.7-25
4.6.4 Replacing PF_ENC Scale, PF Speed Reduction Pulley
NOTE
While replacing the PF scale assembly, make sure to avoid deforming the PF scale. If it is deformed,
image quality may be affected.

2. Loosen the PF speed reduction belt.
"4.6.1 Replacing PF Speed Reduction Belt" p.4-60
3. Remove the screws (2 pieces) that retain the PF speed reduction pulley to the PF connection axis.
4. Remove the screws (4 pieces) that retain the PF speed reduction pulley to the PF_ENC scale.
5 4
2 3 5
No. Part name

1 PF_ENC scale
2 ENC scale holder
3 PF speed reduction pulley
4 Screws that retain the PF speed reduction pulley to the PF
connection axis
5 Screws that retain the PF speed reduction pulley to the PF_ENC
scale
(P tight cup screw M3 × 8)
5. Remove the ENC scale holder.
Rev.-00 4-64
6. Remove the ENC scale

7. Remove the PF speed reduction belt.
8. Remove the PF speed reduction pulley.
9. Replace the PF speed reduction pulley.
10. Replace the PF_ENC scale.
11. Adjust the PF_ENC scale.
"7.5 PF Encoder Assembly Position Adjustment" p.7-25
4.6.5 Replacing P_REAR Sensor Assembly
TIP
The P_REAR sensor assembly is located near the center of the X rail (joint part of the grid roller).

"4.2.19 Removing Media Guide R (Lower)" p.4-29
3. Detach the connector (MAIN J42) to the P_REAR_R sensor assembly.
TIP
The P_REAR_R sensor assembly cable is a stranded wire of red, black, blue, and orange.
4-65 Rev.-00
4. Remove the screws (2 pieces) that retain the P_REAR_R sensor assembly.
Rear view 1 Enlarged view
3 2
No. Part name

1 P_REAR_R sensor assembly
2 Screws that retain the P_REAR_R sensor assembly
(cup screw M2 × 5)
3 R sensor bracket
5. Remove the P_REAR_R sensor assembly.

6. Replace the P_REAR_R sensor assembly.
Rev.-00 4-66
4.6.6 Replacing Lever Up Sensor

1. Open the maintenance cover.
3. Remove the lever up sensor cable assembly.
4. Remove the lever up sensor assembly.
Rear view Enlarged view

3 1
No. Part name

1 Lever up sensor cable assembly
2 Lever up sensor assembly
3 Cover stay RR
5. Replace the lever up sensor assembly.
4-67 Rev.-00
6. Apply adhesive material.
No. Part name

1 Lever up sensor assembly
2 Adhesive material application surface
4.6.7 Replacing Heater, Thermistor
NOTE
Set the heater to the original position without bending. The surface temperature of the platen changes
and printing quality becomes poor if the heater assembly position is set insufficiently.
(1) Replacing the Pre-heater, Pre-thermistor
NOTE
Set the heater to the original position without bending. The surface temperature of the platen changes
and printing quality becomes poor if the heater assembly position is set insufficiently.
Rev.-00 4-68
The pre-heater is arranged as follows.
No. Part name

1 Pre-heater 1
2 Pre-heater 2
1. Lift up the media guide R (upper).

"4.2.18 Removing Media Guide R (Upper)" p.4-27
2. Detach the connectors (2 pieces) to the pre-heater and the connectors (2 pieces) to the pre-thermistor.
1 2
No. Part name

1 Connectors to the pre-heater thermistor
2 Connectors to the pre-heater
4-69 Rev.-00
3. Remove the pre-heater heat insulator from the part where the heater or the thermistor is broken.
TIP
The pre-heater heat insulator and the pre-heater are affixed using double-faced tape.
4. Mark the location of the broken pre-heater.
NOTE
Affix the pre-heater at the correct position. If not, the temperature of the media guide R cannot be
appropriate and image quality may be affected.
5. Remove the broken pre-heater.
3 Rear view of media guide R
1 2
No. Part name

2 Pre-heater
3 Pre-heater heat insulator
6. Replace the pre-heater.

7. Remove the thermistor film.
8. Remove the pre-thermistor.
Rev.-00 4-70
TIP
The pre-thermistor is affixed using thermistor film.
4 Back of paper guide R (Upper) 3
1 2
No. Part name

2 Pre-thermistor
3 Pre-heater heat insulator
4 Thermistor film
9. Remove the pre-thermistor.

10. Replace the pre-thermistor.
4-71 Rev.-00
(2) Replacing Platen Heater, Platen Thermistor

The platen heater is arranged as follows.
No. Part name

1 Platen heater 1
2 Platen heater 2
1. Open the front cover.

2. Remove the screws (16 pieces) that retain the platen.
1 2
No. Part name

1 Platen
2 Screws that retain the platen
3. Lift up the platen.
Rev.-00 4-72
4. Remove the connectors (2 pieces) to the platen heater and the connectors (2 pieces) to the platen
thermistor.
1 Rear view of platen 4
No. Part name

1 Heat insulator platen
2 Connectors to the platen heater
3 Connectors to the platen thermistor
4 Heat insulator thermistor
5. Remove the heat insulator heater or the heat insulator thermistor from the part where the heater or the
thermistor is broken.
TIP
The heat insulator platen, the heat insulator thermistor and the platen heater are affixed using
double-faced tape.
6. Mark the location of the broken platen heater.
NOTE
Affix the platen heater at the correct position. If not, the temperature of the platen cannot be
appropriate and image quality may be affected.
7. Remove the broken platen heater.

8. Replace the platen heater.
9. Remove the screw (1 piece) that retains the platen thermistor holder.
10. Detach the platen thermistor holder.
11. Replace the platen thermistor.
4-73 Rev.-00
(3) Replacing After-Heater, After-Thermistor

The after-heater is arranged as follows.
No. Part name

1 After-heater 1
2 After-heater 2
1. Lift up the media guide F (upper).

2. Detach the connectors (2 pieces) to the after-heater and the connectors (2 pieces) to the after-thermistor
inside the media guide F (upper).
3 Rear view of media guide F 1
No. Part name

1 After-heater heat insulator
2 Connectors to the after-thermistor
3 Connectors to the after-heater
Rev.-00 4-74
4. Remove the after-heater heat insulator from the part where the heater or the thermistor is broken.
TIP
The after-heater heat insulator and the after-heater are affixed using double-faced tape.
5. Mark the part where the after-heater is broken.
NOTE
Affix the after-heater at the correct position. If not, the temperature of the media guide F (upper)
cannot be appropriate and image quality may be affected.
6. Remove the broken after-heater.
1 Rear view of media guide F
2 3
No. Part name

2 After-heater
7. Replace the after-heater.
4-75 Rev.-00
8. Remove the after-thermistor.
Rear view of media guide F 3
1 2
No. Part name
2 After-heater thermistor
9. Remove the after-thermistor.

10. Replace the after-thermistor.
4.6.8 Replacing Suction Fan

The suction fan is arranged as follows.
No. Part name

1 Suction fan 1
2 Suction fan 2
3 Suction fan 3
4 Suction fan 4
Rev.-00 4-76
1. Remove the platen.

"(2) Replacing Platen Heater, Platen Thermistor" p.4-72
2. Remove the connector to the suction fan.
3. Remove the screws (2 pieces) that retain the suction fan.
2 3
No. Part name

1 Suction fan
2 Screws that retain the suction fan
3 Connector to the suction fan
4. Remove the suction fan.

5. Replace the suction fan.
4.6.9 Replacing Platen Non-Reflective Tape

2. Strip the platen non-reflective tape.
4-77 Rev.-00
No. Part name

1 Platen
2 Platen non reflective tape
NOTE
Once the platen non-reflective tape is stripped, it must not be reused.
3. Replace the platen non-reflective tape.
4.6.10 Replacing Media Holder

Rev.-00 4-78
3. Remove the screws (2 pieces) that retain the media holder stopper.
No. Part name

1 Media holder stopper
2 Screws that retain the media holder stopper
4. Remove the media holder stopper.

5. Pull out the media holder from the left side (the opposite side of the origin).
No. Part name

1 Media holder
2 Platen
6. Replace the media holder.

4-79 Rev.-00
4.6.11 Replacing Flushing Tray

The flushing tray is arranged as follows.
2 1
No. Part name

1 Flushing tray R
2 Flushing tray L
CAUTION
When replacing the flushing tray, wear rubber gloves
(1) Replacing Flushing Tray R

Rev.-00 4-80
3. Lift up the flushing frame hook.
2 3
No. Part name

1 Flushing tray
2 Flushing frame
3 Flushing frame hook
4. Remove the flushing frame.

5. Detach the flushing tray by pushing the flushing tray from behind the flushing frame.
No. Part name

1 Flushing tray
2 Flushing frame
6. Replace the flushing tray.

4-81 Rev.-00
(2) Replacing Flushing Tray L

2. Lift up the flushing frame hook.
2 3
No. Part name

1 Flushing tray
2 Flushing frame
3 Flushing frame hook

4. Detach the flushing tray by pushing the flushing tray from behind the flushing frame.
5. Replace the flushing tray.
4.6.12 Replacing Flushing Absorber
CAUTION
When replacing the flushing absorber, wear rubber gloves.

"4.6.11 Replacing Flushing Tray" p.4-80
Rev.-00 4-82
2. Replace the flushing absorber (3 pieces).
No. Part name

1 Flushing absorber
TIP
The flushing absorbers are three thicknesses.
4-83 Rev.-00
4.7 Replacing Y Rail Section

This section describes the procedure to replace the Y rail section.
4.7.1 Replacing Steel Belt
CAUTION
• When replacing the steel belt, be careful not to cut your hand with the steel belt.
• Steel belt replacement must be done by 2 or more persons.
NOTE
Pay close attention in handling the steel belt. Bending or dust on the steel belt may cause steel belt
breakage.

6. Move the carriage to the left side (opposite side of the origin).
7. Loosen the steel belt adjustment screws (2 pieces).
1 5
3 2
4 5
Rev.-00 4-84
No. Part name

1 CR driven pulley
2 Steel belt adjustment screws
40)
3 Steel belt
4 Return pulley mounting plate
5 Screw cap
8. Remove the screws (2 pieces) that retain the belt.
3 Left view 1 1 Right view 3
2 2
No. Part name

1 Head cover
2 Steel belt
3 Screws that retain the belt
9. Pull off the steel belt.

10. Remove the CR driven pulley.
11. Insert the measure through the hole of the Y drive base to the inside of Y rail.
4-85 Rev.-00
12. Pull out the measure from the hole of the return pulley mounting plate.
View of origin side 2 3 View of opposite side to origin
1 1
No. Part name

1 Measure
2 Y drive base
13. Affix the steel belt to the tip of the measure using tape.
2 1
No. Part name

1 Measure
2 Steel belt
3 Tape
14. Wind up the measure with the steel belt affixed to it.
15. Detach the steel belt from the measure after the tip of the measure comes out from the hole of the Y drive
base.
16. Affix one side of the steel belt to the right side of the carriage.
17. Install the CR driven pulley.
Rev.-00 4-86
18. Affix the other side of the steel belt to the left side of the carriage.
19. Adjust the steel belt tension.
"7.4 Steel Belt Tension Adjustment" p.7-22
4.7.2 Replacing CR Motor Assembly
CAUTION
Do not touch the motor after continuous operation. You may get burned by the motor heated
up.

3. Remove the CR motor cable assembly.
TIP
Connect the white cable of the CR motor cable assembly to the side of the CR motor assembly where
the red seal is affixed.
The polarity of the CR motor assembly and CR motor cable assembly is as follows.
• Red seal: +
• White cable: +
• Black cable: -
4-87 Rev.-00
4. Loosen the hexagon socket screws (4 pieces) that retain the CR motor assembly.
1 3
2 2
No. Part name

1 CR motor assembly
2 CR motor spacer
3 Hexagon socket screws (M4 × 6)
4 CR motor cable assembly
5. Confirm that the CR speed reduction belt is loosened.
2 4
No. Part name

1 CR motor assembly
2 CR speed reduction belt
3 Y drive base
4 CR drive pulley
6. Remove the CR speed reduction belt.

7. Remove the hexagon socket screws (4 pieces) that retain the CR motor assembly.
8. Remove the CR motor assembly.
Rev.-00 4-88
9. Replace the CR motor assembly.
NOTE
When installing the CR motor assembly, ensure that the steel belt is evenly guided along the center
part of the CR motor assembly pulley by moving the carriage by hand.
10. Adjust the CR speed reduction belt tension.

"7.6 CR Speed Reduction Belt Tension Adjustment" p.7-27
4.7.3 Replacing CR Drive Pulley Assembly

3. Loosen the hexagon socket screws (4 pieces) that retain the CR motor assembly to loosen the CR speed
reduction belt.
1 3
2 2
No. Part name

1 CR motor assembly
2 Hexagon socket screws (M4 × 6)
3 CR motor cable assembly
4-89 Rev.-00
4. Confirm that the CR speed reduction belt is loosened.
2 4
No. Part name

1 CR motor assembly
2 CR speed reduction belt
3 Y drive base
4 CR drive pulley
5. Loosen the steel belt adjustment screws (2 pieces).
1 5
3 2
4 5
No. Part name

1 CR driven pulley
2 Steel belt adjustment screws
40)
3 Steel belt
6. Remove the CR drive pulley.
Rev.-00 4-90
7. Remove the CR speed reduction belt.

8. Replace the CR drive pulley assembly.
NOTE
• The parts accompanied when removing the CR drive pulley are collectively called CR drive pulley
assembly.
• When replacing the CR speed reduction belt, reuse the CR drive pulley assembly that is currently
used.

10. Adjust the CR speed reduction belt tension.
"7.6 CR Speed Reduction Belt Tension Adjustment" p.7-27
4.7.4 Replacing T Fence

6. Move the carriage to the left side (opposite side of the origin)
7. Detach the T fence spring from the T fence spring hook in the left side of the Y rail (opposite side of the
origin).
4-91 Rev.-00
8. Detach the T fence from the T fence spring.
2 3
No. Part name

1 T fence spring
2 T fence spring hook
3 T fence
9. Detach the T fence from the T fence guide plate (3 pieces).
No. Part name

1 T fence guide plate
2 T fence
Rev.-00 4-92
10. Detach the T fence from the hook of the T fence clamping plate.
No. Part name

1 T fence clamping plate
2 T fence
11. Replace the T fence.
NOTE
When assembling the T fence, make sure to follow the instructions below.
• If the T fence is coated with protective film, remove the film and attach the T fence correctly.
• Correctly attach the T fence to the hook on the T fence bracket referring to the figure for step 8.
• Allow a margin between the T fence and the hook of the clamping plate.
• When retaining the clamping plate with screws, allow a margin so that the T fence can slightly
move.
• Referring to the following figures, insert the T fence in the T fence guide plate and CR_ENC
assembly.
4-93 Rev.-00
2 1 4 3
No. Part name

1 T fence guide plate
2 T fence
3 CR_ENC assembly
4 Carriage
4.7.5 Replacing CR Origin Sensor

3. Move the carriage to the left side (opposite side of the origin)
4. Remove the CR_ORG cable assembly.
Rev.-00 4-94
5. Remove the CR origin sensor.
1 2
No. Part name

1 CR origin sensor
2 CR_ORG cable assembly
3 Y rail
6. Replace the CR origin sensor.

No. Part name

1 Adhesive material application surface
4-95 Rev.-00
4.7.6 Replacing CR Driven Pulley
NOTE
After installing the CR driven pulley, always ensure that the steel belt is evenly guided along the
center part of the CR motor assembly pulley by moving the carriage left and right by hand.

2. Remove the Side top cover L.
3. Remove the steel belt adjustment screws (2 pieces).
1 5
3 2
4 5
No. Part name

1 CR driven pulley
2 Adjustment screws
40)
3 Steel belt
5 Screw cap
4. Confirm that the steel belt is loosened.

5. Remove the CR driven pulley.
6. Remove the screw caps (2 pieces).
7. Replace the CR driven pulley assembly.
Rev.-00 4-96
NOTE
Seven parts are accompanied when removing the CR drive pulley. They are collectively called CR
driven pulley assembly except for the screw caps.

4.7.7 Replacing Steel Bearer

1. Remove the Side top cover R.
3. Remove the screws (4 pieces) that retain the steel bearer.
2 1
No. Part name

1 Steel bearer
2 Screws that retain the steel bearer
4-97 Rev.-00
4. Remove the film FFC retainers (6 pieces).
2 1
No. Part name

1 Steel bearer
2 Film FFC retainer
5. Remove the screws (3 pieces each) that retain the cable guides (2 pieces).
2 2
1 2
No. Part name

1 Cable guide
2 Screws that retain the cable guide
18)
6. Remove the cable guide.

7. Remove the steel bearer.
8. Replace the steel bearer.
Rev.-00 4-98
4.7.8 Replacing CR Tape Wire
CAUTION
• When replacing the board or connecting and removing FFC, first remove the power plug
and leave it for a while. Overcurrent may occur and damage the board.
• When connecting and removing the FFC type cables to/from the CR board assembly
connectors, always pull or push the cables perpendicularly to the connector.
connectors, resulting in a breakdown of the on-board devices.
1. Remove the CR cover.

"4.8.2 Removing CR Board Cover" p.4-106
2. Remove the steel bearer.
"4.7.7 Replacing Steel Bearer" p.4-97
3. Remove the board box cover 64.
4. Detach CR-FFC (3 pieces) from the CR board assembly (J201 - J203).]
5. Detach CR-FFC (3 pieces) from the MAIN board assembly (J9 - J11).
6. Remove the screws (2 pieces) that retain the FFC guide (1 piece).
7. Remove the FFC guide.
8. Remove the FT guide material.
1 3
No. Part name

1 FFC guide
2 Screws that retain the FFC guide
3 FT guide
4-99 Rev.-00
9. Pull out the CR_FFC from the hole on the origin side of the cable guide.
10. Pull out the CR_FFC from the hole on the leg holder base (64).
2 Cable guide 1 3 Back of leg holder base 64 1
the
No. Part name

1 CR_FFC
2 Cable guide
3 Leg holder base (64)
11. Replace the CR_FFC.
TIP
Fold the CR_FFC as follows.
A: valley fold
335 mm Face the printed
side front side
60 mm A CR board side
MAIN board 330 mm Fix the ferritic core with cable holder
side
12. Connect the CR_FFC (3 pieces) to the CR board assembly (J201 - J203).
13. Draw the CR_FFC through the same path as above.
14. Connect the CR_FFC to the MAIN board assembly (J9 - J11).
Rev.-00 4-100
4.7.9 Replacing Pressure Roller

2. Lift up one end of the pressure arm slightly with a finger and hold it.
3. Pull down the other end of the pressure roller.
2 1
No. Part name

1 Pressure roller
2 Pressure arm
4. Confirm that one end of the pressure roller is detached.

5. Pull down the other end of the pressure roller.
6. Remove the pressure roller.
7. Replace the pressure roller.
4-101 Rev.-00
4.7.10 Replacing Ink Tube

1. Perform ink discharge operation to discharge ink entirely from the ink paths.
"5.7.8 HeadWash Menu" p.5-40
3. Remove the cartridge cable cover plate.
"4.10.1 Replacing Ink ID Board Assembly" p.4-125
4. Remove the screws (4 pieces each) that retain the tube guide plate.
2 2
1 1
2 2
No. Part name

1 Cable guide plate
2 Screws that retain the cable guide plate
(P tight cup screws M3 × 8)
5. Remove the tube guide plates (2 pieces).

6. Remove the FFC guides (6 pieces).
Rev.-00 4-102
7. Remove the tube clamp (6 pieces).
No. Part name

1 Ink tube
2 Film FFC guide
3 Tube clamp
8. Remove the screws (2 pieces) that retain the tube guide plate.
Upper view 1 Lower view 3
No. Part name

1 Tube guide plate
2 Screws that retain the tube guide plate
3 Ink tube
9. Remove the tube guide plate.

10. Detach the ink tube from the three-way joint.
4-103 Rev.-00
11. Pull out the ink tube from inside the carriage.
No. Part name

1 Three-way joint
2 Ink tube
12. Loosen the joint screw on the tip of the sub tank.
13. Detach the ink tube from the joint tube.
3 1
No. Part name

1 Ink tube
2 Joint tube
3 Joint screw
14. Remove the ink tube.

15. Replace the ink tube.
17. Charge ink.
"5.6 Ink Charging Menu" p.5-22
Rev.-00 4-104
4.8 Replacing Cursor Section

This section describes the procedure to replace the cursor section.
4.8.1 Releasing Head Lock

When head lock is released on the software, the carriage moves to the origin position after the power is turned
off. This section describes the procedure to release head lock with the power turned off.

2. Push down the cap on the left side of carriage.
No. Part name

1 Cap
3. Move the carriage to the opposite side to the origin while holding down the cap.
NOTE
For enabling head lock again, the cap does not need to be pushed down. Move back the carriage to
the position where the carriage is fixed with a sound.
4-105 Rev.-00
4.8.2 Removing CR Board Cover

2. Remove the screws (2 pieces) that retain the CR board cover.
No. Part name

1 CR board cover
2 Screws that retain the CR board cover
3. Remove the CR board cover.
4.8.3 Replacing CR Board Assembly
CAUTION
• When replacing the board or connecting and removing FFC, first remove the power plug
and leave it for a while. Overcurrent may occur and damage the board.
• When connecting and removing the FFC type cables to/from the CR board assembly
connectors, always pull or push the cables perpendicularly to the connector.
connectors, resulting in a breakdown of the on-board devices.

2. Remove the head FFC (2 pieces).
Rev.-00 4-106
3. Remove the CR_FFC (3 pieces).
6 4 3 5
2 1
5 6
No. Part name

1 CR board assembly
2 Head FFC
3 CR_FFC
4 Connector
5 Screws that retain the CR board assembly 1
(cup screw M3 × 6)
6 Hexagon spacer
4. Detach the connectors to the CR board assembly listed below.
Table 4-6 Connectors to CR board assembly

No. Pins
1 J201 30 Black MAIN (J11) FFC
6 J206 2 White CUTTER_SOL
7 J207 4 White CR_ENC
8 J208 4 Black P_EDGE
9 J209 3 White PG_ORIGIN
10 J210 2 Black HEAD_FAN_1
11 J211 2 Red HEAD_FAN_2
4-107 Rev.-00
5. Remove the screws (2 pieces) that retain the CR board assembly and the hexagon spacer (2 pieces).
6. Remove the CR board assembly.
7. Replace the CR board assembly.
4.8.4 Replacing CR Encoder Assembly
NOTE
When removing the CR_ENC assembly, pay attention to avoid nicking the T fence.

3. Open the rear side cover.
4. Detach the connector to the CR encoder assembly.
5. Remove the screws (2 pieces) that retain the CR encoder assembly.
1 Rear view of carriage 4 Section view 1
2 3 5
No. Part name

1 CR encoder assembly
2 Screws that retain the CR encoder assembly
3 Y rail assembly
4 CR board mounting base
5 T fence
6. Remove the CR encoder assembly.

7. Replace the CR encoder assembly.
Rev.-00 4-108
4.8.5 Replacing PG Origin Sensor Assembly

2. Open the side top cover R.
3. Remove the PG origin sensor relay assembly.
4. Remove the PG origin sensor assembly.
2 1
No. Part name

1 PG origin sensor relay assembly
2 PG origin sensor assembly
5. Replace the PG origin sensor assembly.

4-109 Rev.-00
4.8.6 Replacing Cursor Roller Arm Assembly

1. Remove the head cover.
"4.8.6 Replacing Cursor Roller Arm Assembly" p.4-110
2. Lift up the cursor roller arm assembly to the direction shown below, and lift up the cursor arm spring.
CAUTION
Note that the tension of the cursor arm spring is high.
3. Confirm that the bearing is detached from the cursor guide.

4. Pull off the cursor roller arm to the direction shown below with the cursor arm spring being lifted up.
Ԙ Ԙ
ԙ ԙ
1 1
No. Part name

1 Cursor roller arm
2 Cursor arm spring
5. Replace the cursor roller arm assembly.
NOTE
Five parts are accompanied when removing the cursor roller arm. They are collectively called cursor
roller arm assembly except for the cursor arm spring.
4.8.7 Removing Print Head Cover

Rev.-00 4-110
3. Detach the connectors (2 pieces) to the head fan assembly from the head fan relay assembly.
2 3
No. Part name

1 Connector to the head fan assembly
2 Head fan relay assembly
3 CR board cover
4. Remove the screws (2 pieces) that retain the print head cover.
2 2
No. Part name

1 Print head cover
2 Screws that retain the print head cover
5. Remove the print head cover.
4-111 Rev.-00
4.8.8 Replacing Damper Assembly L_Assy
CAUTION
The cables can be connected or removed up to 5 times.
2. Remove the print head cover.
"4.8.7 Removing Print Head Cover" p.4-110
3. Remove the screws (3 pieces) that retain the damper guide plate.
1 2
No. Part name

1 Damper guide plate
2 Screws that retain the damper guide plate
3 Ink tube
4. Remove the damper guide plate.

5. Remove the joint screws (2 pieces) of the related color.
6. Remove the head tubes (2 pieces) of the related color.
7. Remove the damper assembly L (2 pieces) of the related colors.
8. Replace the damper assembly L_Assy.
Rev.-00 4-112
CAUTION
• Don’t touch the transparent film on the side of the damper assembly L. Ink charged in the
damper assembly L will discharge.
• Take care not to damage the transparent film on the side of the damper assembly L.
• Place cotton waste under the detached damper to prevent residual ink discharging.
2 3
No. Part name

1 Damper assembly L
2 Joint screw M7
3 VJ tube 3-4
9. Replace the damper assembly L.
NOTE
The damper assembly L and the O ring are combined so that it is collectively called damper assembly
L_assembly.

11. Charge ink.
"5.6 Ink Charging Menu" p.5-22
4-113 Rev.-00
4.8.9 Replacing Print Head
CAUTION
• While operation, pay special attention not to touch the head nozzles or contaminate them
with foreign objects.
• The print head assembly has been adjusted. Do not disassemble it.

3. Remove the damper L assembly.
"4.8.8 Replacing Damper Assembly L_Assy" p.4-112
4. Remove the screws (2 pieces) that retain the print head guide.
No. Part name

1 Print head guide
2 Screws that retain the print head guide
5. Remove the print head guide.
Rev.-00 4-114
6. Remove the print head.
No. Part name

1 Print head
7. Remove the head FFC (2 pieces) from the print head.
2 Front 1 Back
1 2
No. Part name

1 Head FFC
2 Print head
8. Replace the print head.

4-115 Rev.-00
4.8.10 Replacing Head FFC
CAUTION
• While operation, pay special attention not to touch the head nozzles or contaminate them
with foreign objects.
• The print head assembly has been adjusted. Do not disassemble it.
2. Initialize the head counter.
"5.7.10 Software Counter Initialization Menu" p.5-41
4. Remove the damper assembly L.
"4.8.8 Replacing Damper Assembly L_Assy" p.4-112
5. Remove the damper fixing material.
6. Remove the print head.
"4.8.9 Replacing Print Head" p.4-114
2 1
No. Part name

1 CR board assembly
2 Head FFC
7. Remove the screws (2 pieces) that retain the flat core holder.
Rev.-00 4-116
8. Remove the flat core holder (2 pieces).

9. Remove the flat core (2 pieces).
3 4 1
.
No. Part name

1 Flat core holder
2 Screws that retain the flat core holder
3 Flat core
4 Head FFC
10. Replace the head FFCs (2 pieces).
NOTE
Fold the head FFC as follows.
A: mountain fold 10 mm 90 mm
B: valley fold
CR board side A B A Print head side

Face the printed 10 mm
side front side
• Turn the second one inside out to fold the same way.
• Contact the non-engraved surfaces of the head FFC with each other so that the engraved surfaces
face outwardly.
4-117 Rev.-00
4.8.11 Replacing P_EDGE Sensor Assembly

2. Detach the connector to the P_EDGE sensor assembly from the CR board assembly (J208).
"4.8.3 Replacing CR Board Assembly" p.4-106
3. Remove the screw (1 piece) that retain the P_EDGE sensor assembly.
No. Part name

1 P_EDGE sensor assembly
2 Screws that retain the P_EDGE sensor assembly
4. Detach the cable of the P_EDGE sensor assembly from the clamp (4 pieces).
Left lower view 2 Upper view 1
2 1
No. Part name

1 Cable of the P_EDGE sensor assembly
2 Clamp
5. Replace the P_EDGE sensor assembly.
Rev.-00 4-118
TIP
The cable of the P_EDGE sensor assembly is a stranded wire of red, black, blue and orange.
4-119 Rev.-00
4.9 Replacing Maintenance Section

This section describes the procedure to replace the maintenance section.
4.9.1 Removing Maintenance Inner Cover

1. Remove the maintenance cover U.
"4.2.3 Removing Maintenance Cover U" p.4-10
3. Remove the screws (4 pieces) that retain the maintenance inside cover.
1 Front view Upper view 2
2 1
No. Part name

1 Maintenance inside cover
2 Screws that retain the maintenance inside cover
4. Remove the maintenance inside cover.
Rev.-00 4-120
4.9.2 Replacing Cleaner Head

"4.9.1 Removing Maintenance Inner Cover" p.4-120
2. Using tweezers, detach the cleaner head from the hook at the cleaner head retaining section, and remove
it upwardly.
No. Part name

1 Cleaner head
3. Replace the cleaner head.
NOTE
When reassemble the cleaner head, pay attention to the following.
• Do not touch the cleaner head with bare hands.
• Make sure that the cleaner head get no dust or oil.
• Install the cleaner head so that the point of the cleaner head is located to the observer's right side.
No. Part name

1 Cleaner head
2 Head point
• Insert the cleaner head into the holder to the full depth securely and hook it.
4-121 Rev.-00
4.9.3 Replacing Maintenance Assembly
NOTE
There are some remaining ink in the tubes. Be careful that the ink is not spilled from the tube outlet
onto the plotter or the covers.
2. Remove the cleaner head.
"4.9.2 Replacing Cleaner Head" p.4-121
3. Remove the maintenance inner cover.
"4.9.1 Removing Maintenance Inner Cover" p.4-120
4. Detach the connector to the wiper origin sensor relay assembly from the MAIN board assembly (J27).
"4.4.7 Replacing MAIN Board" p.4-49
5. Detach the connector to the pump motor relay assembly.
No. Part name

1 Connector to the wiper origin relay cable
6. Remove the screws (1 piece) that retain flushing box holder.

7. Remove the flushing box holder.
8. Remove the screws (1 piece) that retain the head lock holder.
Rev.-00 4-122
9. Remove the head lock holder.
4 3
No. Part name

1 Flushing box holder
2 Screws that retain the flushing box holder
3 Head lock holder
4 Screws that retain the head lock holder
10. Remove the screws (1 piece) that retain the waste fluid guide cover.
11. Remove the waste fluid guide cover.
12. Pull off the waste fluid tube.
13. Remove the screws (4 pieces) that retain the waste fluid guide.
14. Replace the waste fluid guide.
1 2
4 5
No. Part name

1 Waste fluid guide cover
4-123 Rev.-00
No. Part name

2 Screws that retain the waste fluid guide cover
(tapping screw M3 × 6)
3 Waste fluid guide
4 Screws that retain the waste fluid guide
5 Waste fluid tube
15. Remove the screws (2 pieces) that retain the maintenance holder.
16. Remove the screws (6 pieces) that retain the maintenance base.
2 3 2
No. Part name

1 Maintenance base
2 Pan-head screw with spring washer and flat washer M3 × 6
3 Tapping screw M3 x 6
4 Pan-head screw with spring washer and flat washer M4 × 8
17. Remove the maintenance base.

18. Replace the maintenance assembly.
Rev.-00 4-124
4.10 Replacing IH Section

This section describes the procedure to replace the IH section.
4.10.1 Replacing Ink ID Board Assembly

"4.2.10 Removing Cartridge Cover (middle)" p.4-18
3. Remove the screws (2 pieces) that retain the cartridge cable cover plate.
2 2
No. Part name

1 Cartridge cable cover plate
2 Screws that retain the cartridge cable cover plate
4. Remove the cartridge cable cover plate.

5. Remove the screws (2 pieces) that retain the I/C slide (2).
6. Remove the I/C slide (2).
7. Remove the screws (2 pieces) that retain the cartridge side plate.
4-125 Rev.-00
8. Remove the cartridge side plate.
1 3
2 4
No. Part name

1 I/C slide (2)
2 Screws that retain the I/C slide (2)
3 Cartridge side plate
4 Screws that retain the cartridge side plate
9. Remove the screws (2 pieces) that retain the holder pressure spring (4 pieces).
1 3
No. Part name

2 Holder pressure spring
3 Screws that retain the holder pressure spring
Rev.-00 4-126
10. Remove the holder pressure spring.
TIP
There are two holder pressure springs respectively in the upper and lower portion.
11. Detach the cable of the ink ID board assembly from the clamp.
12. Detach the ink cartridge control cable from the ink ID board assembly.
13. Remove the ink ID board assembly.
1 4
2 3
No. Part name

1 Ink ID board assembly
2 Ink cartridge control cable
3 Clamp
14. Replace the ink ID board assembly.
NOTE
The card board holder is accompanied when removing the ink ID board assembly. They are
collectively called ink ID board assembly.
4-127 Rev.-00
4.10.2 Replacing Frame Assembly, Needle

3. Remove the screws (2 pieces) that retain the I/C slide (2).
5. Remove the screws (2 pieces) that retain the cartridge side plate.
1 3
2 4
No. Part name

1 I/C slide (2)
2 Screws that retain the I/C slide (2)
4 Screws that retain the cartridge side plate
Rev.-00 4-128
7. Remove the joint screw M6.
1 4
2 3
No. Part name

1 Frame assembly, needle
2 Joint screw M6
4 Ink tube
NOTE
• An O ring is inside the joint screw. Be careful not to lose the O ring.
• Soak the O ring in the specified cleaning fluid before installing.
4-129 Rev.-00
8. Detach the hook of the cartridge slide.
1 2
No. Part name

1 Cartridge slide
3 Hook
9. Move the hook of the cartridge slide to the direction shown below.
10. Remove the cartridge slide.
1 2
No. Part name

1 Cartridge slide
2 Hook of the cartridge slide
11. Detach the ink cartridge control cable from the clamp.
12. Move the frame assembly and the needle to the direction shown below.
Rev.-00 4-130
13. Remove the frame assembly and the needle.
No. Part name

1 Hook of the frame assembly and the needle
2 Clamp
14. Remove the screw (1 piece) that retains the ink cartridge control cable to the frame assembly and the
needle.
1 2
No. Part name

2 Screws that retain the ink cartridge control cable
(B tight band screw M2 x 8)
15. Remove the ink cartridge control cable.

4-131 Rev.-00
4.10.3 Replacing Ink Cartridge Control Cable
TIP
There are three connectors to the ink cartridge control cable.
1. Detach the ink cartridge control cable from the ink ID board assembly.
"4.10.1 Replacing Ink ID Board Assembly" p.4-125
2. Detach the ink cartridge control cable from the frame assembly and the needle.
"4.10.2 Replacing Frame Assembly, Needle" p.4-128
3. Remove the screw (1 piece) that retains the ink cartridge control cable to the cartridge side plate.
4 3
1 2
No. Part name

2 Screws that retain the ink cartridge control cable
4. Remove the connector to the ink cartridge control cable from the HEATER JUNCTION board assembly
(J5 - J10).
5. Replace the ink cartridge control cable.
4.10.4 Replacing Cartridge Holder Assembly

2. Remove the cartridge cover (middle)
Rev.-00 4-132

5. Remove the joint screw M6.
"4.10.2 Replacing Frame Assembly, Needle" p.4-128
6. Detach the ink cartridge control cable from the clamp.
"4.10.3 Replacing Ink Cartridge Control Cable" p.4-132
7. Replace the cartridge holder assembly.
NOTE
The cartridge holder assembly is composed of many parts. Refer to exploded view for details.
4.10.5 Replacing two-way Valve

"4.2.11 Removing Cartridge Cover (lower)" p.4-19
3. Remove the screws (8 pieces) that retain the two-way valve.
2 1
No. Part name

1 Two-way valve mounting plate
2 Screws that retain the two-way valve
4-133 Rev.-00
4. Remove the screws (4 pieces) that retain the two-way valve mounting plate.
1 1
No. Part name

1 Two-way valve mounting plate
2 Screws that retain the two-way valve
5. Remove the Two-way valve mounting plate.

6. Detach the ink tube (2 pieces) from the two-way valve.
7. Remove the two-way valve.
2 Rear view (when replacing cyan)
Y
M
C
K
No. Part name

1 Two-way valve
2 Ink tube
8. Replace the two-way valve.

Rev.-00 4-134
4.10.6 Replacing Sub-Tank Lower Absorber Assembly

"4.2.11 Removing Cartridge Cover (lower)" p.4-19
2. Remove the screws (4 pieces) that retain the absorber mounting plate.
2 2
3 3
No. Part name

1 Absorber mounting plate
2 Screws that retain the absorber mounting plate
3 Screws that retain the absorber mounting plate
3. Pull out the absorber mounting plate.

4. Replace the sub-tank lower absorber assembly.
NOTE
The sub-tank lower absorber is accompanied when removing the absorber mounting plate. They are
collectively called sub-tank lower absorber assembly.
4-135 Rev.-00
4.11 Replacing Leg Section

This section describes the procedure to replace the leg section.
4.11.1 Replacing Waste Fluid Bottle
NOTE
• Discharge waste fluid fully to replace the waste fluid bottle.
• Confirm that there remains no waste fluid in the waste fluid tube.
1. Initialize the waste fluid counter.

"5.11.1 Parameter Initialization Menu" p.5-47
3. Remove the connector to the level switch (waste fluid).
No. Part name

1 Connector to the level switch (waste fluid)
2 Cover stay RR
4. Remove the waste fluid tube.

5. Loosen the cap of the waste fluid bottle.
Rev.-00 4-136
6. Loosen the nut of the level switch (waste fluid).
2 4
No. Part name

1 Waste fluid bottle
2 Waste fluid tube
3 Cap of the waste fluid bottle
4 Nut of the level switch (waste fluid)
7. Pull out the nut of the level switch (waste fluid) and the cap of the waste fluid bottle from the connector
side of the level switch (waste fluid).
No. Part name

1 Cap of the waste fluid bottle
2 Nut of the level switch (waste fluid)
8. Replace the waste fluid bottle.

9. Replace the level switch (waste fluid).
4-137 Rev.-00
4.12 Replacing Roll Media Holder Assembly

This section describes the procedure to replace the roll media holder assembly.
4.12.1 Replacing Roll Media Holder Assembly on the VJ16_L side

"4.2.19 Removing Media Guide R (Lower)" p.4-29
2. Release the roll media fixing lever.
No. Part name

1 Roll media fixing lever
3. Pull out the roll media holder assembly on the VJ16_L side from the left side.
1 2
No. Part name

1 Roll media Holder assembly on the VJ16_L side
2 Roll media Holder assembly on the VJ16_R side
4. Replace the roll media holder assembly on the VJ16_L side.
Rev.-00 4-138
NOTE
The roll media holder assembly on the VJ16_L side is an integral part.
4.12.2 Replacing Roll Media Holder Assembly on the VJ16_R side

• Follow the same procedures as for the replacement of the roll media holder assembly on the VJ16_L side.
"4.12.2 Replacing Roll Media Holder Assembly on the VJ16_R side" p.4-139
• Pull out the roll media holder assembly on the VJ16_R side from the right side.
4-139 Rev.-00
4.13 Replacing Take-up Section

This section describes the procedure to replace the take-up section.
4.13.1 Removing Take-up Cover
NOTE
Lower the release lever to the FREE side before removing the take-up cover.
1. Remove the screws (pan-head machine screw M3 × 8: 2 pieces) that retain the rubber foot.
1 No. Part name

1 Rubber foot
2 Screws that retain the rubber
foot
2 1
2. Detach the lever from the release cam.
No. Part name

1
1 Release cam
2 Lever
Rev.-00 4-140
3. Remove the screws (binding small screw M3 × 5: 7 pieces) that retain the take-up cover.
2
No. Part name
1 Take-up cover
1 2 Screws that retain the take-up
cover
4. Remove the take-up cover.

4.13.2 Replacing Scroller
(1) Replacing Holding Roller

1. Remove the E ring (E-6) that retains the holding roller using a driver.
No. Part name

1 holding roller
2 E ring that retains the holding
roller
1 2
2. Remove the holding roller and the bearing.

3. Fit the E ring (E-6) to the holding axis using a long-nose pliers.
4-141 Rev.-00
(2) Replacing Holding Roller L

1. Remove the screw that retains the holding roller L on the scroller receiver (left).
No. Part name

2
1 Holding roller L
3 2 Screws that retain the holding
roller L
3 Scroller receiver (left)
1
2
2. Remove the scroller receiver (left).

(3) Replacing Drive Collar

1. Remove the screws (pan-head screw with spring washer and flat washer M3 × 8: 2 pieces) that retain the
drive collar on the take-up scroller (left).
No. Part name

2 1 Drive collar
3 2 Screws that retain the drive

collar
3 Take-up scroller (left)
2. Remove the drive collar.

Rev.-00 4-142
4.13.3 Replacing VJ Take-up CNT Board Assembly
(1) Removing Board Chassis

1. Remove the screws (pan-head screw with spring washer and flat washer M3 × 6: 4 pieces) that retain the
board chassis on the chassis (out).
No. Part name

1 Board chassis
2
2 Screws that retain the board
chassis
3 3 Chassis (out)
1
2
2. Detach the motor cable, W_ON sensor relay assembly and the W_OFF sensor relay assembly from the
connector to the VJ take-up CNT board assembly that appears.
No. Part name

1 VJ take-up CNT board assembly
2
2 Motor cable
1
3 W_ON sensor relay assembly,
the W_OFF sensor relay
assembly
4-143 Rev.-00
(2) Replacing VJ Take-up CNT Board Assembly
NOTE
Remove the screw that retains the board chassis.
"(1) Removing Board Chassis" p.4-143
1. Remove the cable of the DC cable assembly and the VJ take-up SW board assembly from the connector
to the VJ take-up CNT board assembly.
No. Part name

2
3
1 2 DC cable assembly
3 VJ take-up SW board assembly
2. Remove the screws (pan-head screw with spring washer and flat washer polished M3 × 6: 4 pieces) that
retain the VJ take-up CNT board assembly on the board chassis.
2
No. Part name
2 Screws that retain the VJ take-up
CNT board assembly
1
3 Board chassis
3
2
3. Remove the VJ take-up CNT board assembly.

Rev.-00 4-144
(3) Replacing Power Board Assembly (of take-up section for foreign use)
NOTE
Remove the screws that retains the board chassis before replacing the power board assembly.
1. Detach the AC cable assembly and the DC cable assembly from the connector to the power board
assembly (of take-up section for foreign use).
No. Part name

1 Power board assembly (of take-
up section for foreign use)
2 AC cable assembly
1 2
3 DC cable assembly
3
2. Remove the screws (pan-head screw with spring washer and flat washer polished M 4 × 8: 4 pieces) that
retain the power supply cover on the hexagon spacer.
1 No. Part name

1 Power supply cover
2 Screws that retain the power
supply cover
2 2 3 Hexagon spacer
3. Detach the hexagon spacers (4 pieces) from the power board assembly.
4. Detach the power board assembly (of take-up section for foreign use) from the board chassis.
4-145 Rev.-00
(4) Replacing VJ Take-up SW Board Assembly
NOTE
Remove the screws that retains the board chassis before replacing the VJ take-up SW board assembly.
1. Detach the cable of the VJ Take-up SW Board Assembly from the connector to the VJ take-up CNT board
assembly.
1
No. Part name
2 Cable of the VJ take-up SW
board assembly
2
2. Remove the screws (undersunk head screw M3 × 6: 2 pieces) that retain the SW mounting plate on the
board chassis.
1 2
No. Part name
1 SW mounting plate
2 Screws that retain the SW
mounting plate
3
3 Board chassis
Rev.-00 4-146
3. Remove the screws (pan head screw M3 × 8: 4 pieces) that retain the VJ take-up SW board assembly on
the SW mounting plate.
2 1
No. Part name
1 VJ take-up SW board assembly
2 Screw that retains the VJ take-up
3
SW board assembly
3 SW mounting plate
4. Remove the VJ take-up SW board assembly.

(5) Replacing AC Cable Assembly
NOTE
Remove the screws that retains the board chassis before replacing the AC cable assembly.
1. Remove the cable of the VJ take-up SW board assembly from the connector to the VJ take-up CNT board
assembly.
No. Part name

1
2 Cable of the VJ take-up SW
board assembly
4-147 Rev.-00
2. Detach the AC cable assembly from the connector to the power board assembly (of take-up section for
foreign use).
No. Part name

1 up section for foreign use)
2 AC cable assembly
3. Replace the AC cable assembly.

(6) Replacing DC Cable Assembly
NOTE
Remove the screws that retains the board chassis before replacing the DC cable assembly.
1. Remove the screws that retain the DC cable assembly on the board chassis (pan-head screw with spring
washer and flat washer polished M4 × 8: 2 pieces).
No. Part name

3 1 DC cable assembly
2 Screws that retain the DC cable
assembly
3 Board chassis
2
Rev.-00 4-148
2. Detach the DC cable assembly from the connector to the power board assembly (of take-up section for
foreign use).
1
No. Part name
2 up section for foreign use)
2 DC cable assembly
3. Cut the KI tie that retain the DC cable assembly to replace the DC cable assembly.
4. To reassemble the unit, reverse the removal procedure. Retain the DC cable assembly using the KI tie.
4-149 Rev.-00
4.13.4 Replacing CR_HP Sensor, Lever Sensor
(1) Replacing W_ON Sensor Relay Assembly, W_OFF Sensor Relay Assembly
NOTE
Remove the screws that retains the board chassis before replacing W_ON sensor relay assembly or
W_OFF sensor relay assembly.
1. Remove the cable of the W_ON sensor relay assembly and W_OFF sensor relay assembly from the
connector to the VJ take-up CNT board assembly.
1
No. Part name
2 2 Cable of W_ON sensor relay
assembly and W_OFF sensor
relay assembly
2. Detach the W_ON sensor relay assembly and the W_OFF sensor relay assembly from the CR_HP sensor
and the lever sensor.
1
No. Part name
1 CR_HP sensor, lever sensor
2 W_OFF sensor relay assembly
3. Replace the W_ON sensor relay assembly and W_OFF sensor relay assembly
Rev.-00 4-150
(2) Replacing CR_HP Sensor, Lever Sensor
NOTE
Remove the screws that retains the board chassis before replacing the CR_HP sensor or the lever
sensor.
1. Remove the cable of the W_ON sensor relay assembly and W_OFF sensor relay assembly from the
connector to the VJ take-up CNT board assembly.
1
No. Part name
retains the sensor mounting plate (87NX) on the right of the inside chassis.
3
No. Part name
1 Sensor mounting plate (87NX)
2 Screws that retains the sensor
mounting plate (87NX)
1
3 Right of the inside chassis
4-151 Rev.-00
3. Detach the W_ON sensor relay assembly and the W_OFF sensor relay assembly from the CR_HP sensor
and lever sensor.
1
No. Part name
1 CR_HP sensor, the lever sensor
4. Detach the CR_HP sensor and the lever sensor from the sensor mounting plate (87NX).
2
No. Part name
1 Sensor mounting plate (87NX)
2 CR_HP sensor, the lever sensor
1
Rev.-00 4-152
4.13.5 Replacing Peripheral Devices of VJ Take-up Motor Assembly
(1) Replacing Drive Roller

1. Remove the flat head screws (set screw with thin tip M4 × 6: 2 pieces) that retain the drive roller on the
drive axis C.
No. Part name

1 Drive roller
1 2 Screws that retain the drive
roller
3 Drive axis C
2 3
2. Remove the drive roller.

4-153 Rev.-00
(2) Replacing VJ Take-up Motor Assembly
CAUTION
NOTE
Remove the following parts before replacing the VJ take-up motor assembly.
• Take-up cover: "4.13.1 Removing Take-up Cover" p.4-140
• Screw for the board chassis: "(1) Removing Board Chassis" p.4-143
retain the motor mounting plate on the right of the inside chassis.
2
No. Part name
1 Motor mounting plate
2 Screws that retain the motor
1 mounting plate
3 3 Right of the inside chassis
2. Detach the chain from the sprocket large.
1
No. Part name
1 Chain
2 Sprocket large
Rev.-00 4-154
3. Remove the screws (pan-head screw with spring washer and flat washer polished M4 × 6:2 pieces) that
retain the axis holder on the motor mounting plate.
No. Part name

1 Axis holder
3
2 Axis holder
3 Motor mounting plate
1
4. Remove the bearings.

5. Replace the VJ take-up motor assembly.
4-155 Rev.-00
Rev.-00 4-156
VJ-1604 　 Maintenance Manual 5 Self-Diagnosis Mode
5 Self-Diagnosis Mode
5.1 Introduction ............................................................................................. 5- 4
5.2 Preparation .............................................................................................. 5- 4
5.2.1 Preparations on Machine ............................................................... 5-4
5.2.2 Starting Up ..................................................................................... 5-4
5.3 Operations in Self-Diagnosis Mode ...................................................... 5- 6
5.3.1 Operating Self-Diagnosis Mode ..................................................... 5-6
5.3.2 Diagnosis Items in Self-Diagnosis Menu ....................................... 5-8
5.4 Platen Adjustment Menu ...................................................................... 5- 10
5.5 Inspection Menu.................................................................................... 5- 11
5.5.1 Memory Size Menu ...................................................................... 5-12
5.5.2 Version Menu............................................................................... 5-13
5.5.3 Operation Panel Menu ................................................................. 5-14
5.5.4 Sensor Menu ............................................................................... 5-15
5.5.5 Encoder Menu ............................................................................. 5-17
5.5.6 Fan Menu..................................................................................... 5-17
5.5.7 History Menu................................................................................ 5-18
5.5.8 Head Waveform Menu ................................................................. 5-21
5.6 Ink Charging Menu................................................................................ 5- 22
5.7 Adjustment Menu.................................................................................. 5- 23
5.7.1 Head Nozzle Check Menu ........................................................... 5-25
5.7.2 Skew Check Menu ....................................................................... 5-27
5.7.3 Head Slant Check Menu .............................................................. 5-28
5.7.4 Voltage Adjustment...................................................................... 5-31
5-1 Rev.-00
5 Self-Diagnosis Mode VJ-1604 　 Maintenance Manual
5.7.5 Uni-D/Bi-D Low/High Adjustment ................................................. 5-33
5.7.6 Side Margin Adjustment Menu ..................................................... 5-38
5.7.7 Test Printing Menu ....................................................................... 5-39
5.7.8 HeadWash Menu.......................................................................... 5-40
5.7.9 HeadWash Menu 2....................................................................... 5-40
5.7.10 Software Counter Initialization Menu............................................ 5-41
5.7.11 Feed Pitch Check Menu ............................................................... 5-42
5.7.12 Solid Print Menu ........................................................................... 5-43
5.8 Cleaning Menu .......................................................................................5- 44
5.9 Sample Printing Menu ...........................................................................5- 45
5.10 Time Setting ...........................................................................................5- 46
5.11 Parameter Menu.....................................................................................5- 47
5.11.1 Parameter Initialization Menu ....................................................... 5-47
5.11.2 Parameter Update Menu .............................................................. 5-49
5.12 Servo Setting .........................................................................................5- 54
5.13 Endurance Running Menu ....................................................................5- 56
5.13.1 CR Motor Endurance Menu.......................................................... 5-57
5.13.2 PF Motor Endurance Menu .......................................................... 5-58
5.13.3 Pump Endurance Menu................................................................ 5-59
5.13.4 Print Head Endurance (Nozzle Print) Menu ................................. 5-60
5.13.5 General Endurance Menu ............................................................ 5-61
5.13.6 Endurance Running Check Menu................................................. 5-62
5.14 Media Feed Menu...................................................................................5- 62
Rev.-00 5-2
5.15 ExControl Menu .................................................................................... 5- 63
5.15.1 Version......................................................................................... 5-63
5.15.2 Sensor ......................................................................................... 5-64
5.15.3 Mist Fan ....................................................................................... 5-66
5.15.4 Heater .......................................................................................... 5-66
5.15.5 History.......................................................................................... 5-66
5.16 PaperInitial Menu .................................................................................. 5- 67
5-3 Rev.-00
5.1 Introduction
This chapter provides information on the self-diagnosis function.
The self-diagnosis function adjusts the printing accuracy. It is used in the manufacturing process, adjustment,
and maintenance.
The self-diagnosis function is implemented in the system firmware. All functions are available from the
operation panel.
TIP
"2.3 Part Names and Functions" p.2-3
5.2 Preparation
Before you can use the self-diagnosis function, you must make the machine ready to call up the self-diagnosis
menu.
5.2.1 Preparations on Machine

Before starting up the self-diagnosis function, perform the following preparations.
(1) Setting Printing Media

Set a roll media for adjustment.
NOTE
• In the self-diagnosis menu display status, the media type is automatically set to MF-3G.
• During adjustment, use coated paper for the media.
(2) Connecting Power Cable

Connect the power cable to the machine’s inlet assembly and insert the power plug into an outlet.
NOTE
Do not connect three or more power plugs to one outlet.
5.2.2 Starting Up
To use the self-diagnosis function, you must first call up the self-diagnosis menu on the operation panel.
The self-diagnosis menu is completely independent of the normal operation mode and self-diagnosis display
mode. To call up the self-diagnosis menu, follow the steps below.
Rev.-00 5-4
1. If the system is in the operation mode or the self-

diagnosis menu mode, press [Power] key to turn
the plotter off.
2. While holding down [Setting/value -] key,
[Setting/value +] key and [>] key in the operation
panel simultaneously, press [Power] key.
The system will enter the self-diagnosis mode
and display the self-diagnosis menu.
5-5 Rev.-00
5.3 Operations in Self-Diagnosis Mode

This section explains how to operate in the self-diagnosis mode as well as providing the list of available
diagnosis items.
5.3.1 Operating Self-Diagnosis Mode

Follow the operation flow shown below to operate the self-diagnosis mode.
TIP
For more detailed operation steps, refer to the flow chart of the applicable diagnosis item.
1. Press [<] key or [>] key in the operation panel to

select the item to be diagnosed, and press [Enter]
key.
• The selected item is accepted.
• If the item has a sub menu, the sub menu is
displayed.
2. When the LCD monitor in the operation panel

indicates a setting value, the value can be
modified.
Press [Setting/value +] key or [Setting/value -]
key in the operation panel to modify the value.
3. To save the modified value, press [Enter] key in

the operation panel.
The modified set value is stored and the next item
is displayed
NOTE
If you press [Cancel] key, or, [Setting/value
+] key or [Setting/value -] key, instead of
[Enter] key, the modification is not stored.
Rev.-00 5-6
4. To quit the diagnosis, press [Cancel] key in the

operation panel.
The system returns to an upper hierarchy of the
diagnosis menu.
5. To exit the self-diagnosis menu, press [Power]

key.
5-7 Rev.-00
5.3.2 Diagnosis Items in Self-Diagnosis Menu

The self-diagnosis menu includes the following diagnosis items.
Table 5-1 Diagnosis Items in Self-Diagnosis Menu

Diagnosis item Contents Reference
Platen Adjustment Performs temperature setting for the platen heater to 42 °C. "5.4 Platen
Menu Adjustment Menu"
p.5-10
Inspection Menu Performs various inspections on the circuit boards, sensors, "5.5 Inspection
and fans. Menu" p.5-11
Ink Charging Menu Performs ink charging. "5.6 Ink
Charging Menu"
p.5-22
Adjustment Menu Performs various adjustments for the plotter mechanism. "5.7
Adjustment Menu"
p.5-23
Cleaning Menu Performs cleaning of the print head. "5.8 Cleaning
Menu" p.5-44
Print Menu Performs sample printing necessary for adjustment. "5.9 Sample
Printing Menu" p.5-
45
Time Setting Menu Performs setting the time of the plotter. "5.10 Time
Setting" p.5-46
Parameter Menu Configures various adjustment parameters. "5.11
Parameter Menu"
p.5-47
Servo Menu Performs adjustment for the servo motor. "5.12 Servo
Setting" p.5-54
Endurance Running Performs endurance running of the plotter mechanism. "5.13
Menu Endurance Running
Menu" p.5-56
Media feed Menu Feeds media into the plotter forward or backward. "5.14 Media
Feed Menu" p.5-62
ExControl Menu Diagnoses the controller board. "5.15 ExControl
Menu" p.5-63
PaperInitial Menu Performs initialization and media detection setting. "5.16
PaperInitial Menu"
p.5-67
Rev.-00 5-8
Previous menu
[Enter] key
Adj.Platen Menu
[Cancel] key
Next menu Previous menu [Enter] key
Test Menu
[Cancel] key
InkCharge Menu
[Cancel] key
Next menu Previous menu
[Enter] key
Adjustment Menu
[Cancel] key
[Enter] key
Cleaning Menu
[Cancel] key
[Enter] key
Print Menu
[Cancel] key
[Enter] key
SetTime Menu
[Cancel] key
[Enter] key
Parameter Menu
[Cancel] key
ࠪࡦ࠲ࠐࡦ㧦࡛࠙ࠪࡈࠖ࡯࠻ࠐ Servo Menu

[Cancel] key
Endurance Menu
[Cancel] key
PaperFeed Menu
[Cancel] key
ExControl Menu
[Cancel] key
PaperInitial Menu
[Cancel] key
Next menu
5-9 Rev.-00
5.4 Platen Adjustment Menu

In the platen adjustment menu, you can set the temperature of the pre-heater and platen heater to 42°C.
Parts assembly and adjustment should be done in the condition.
* This item displays platen temperature only.
[>] key [<] key

[Enter] key
PlatenHeater 1
[Cancel] key
[>] key [<] key
[Enter] key
PlatenHeater 2
[Cancel] key
[>] key
Fig. 5-1 If the heater temp. does not reach 42°C
[>] key [<] key

[Enter] key
Platen Heater 1
[Cancel] key
[>] key [<] key
[Enter] key
Platen Heater 2
[Cancel] key
[>] key
Fig. 5-2 If Pla1 reaches 42°C
* Pla2 is a reference value. Though Pla2 does not reach 42°C, Pla1 reaches 42°C and it will be complete.
Rev.-00 5-10
5.5 Inspection Menu

In the inspection menu, you can perform various inspections on the circuit boards, sensors, and fans.
The inspection menu includes the following diagnosis items.
Table 5-2 Diagnosis Items for Inspection Menu

Diagnosis Contents Reference
item
Memory size Displays the size of memories installed on the MAIN board assembly "5.5.1 Memory
Size Menu" p.5-12
Version Displays the versions of the firmware and MAIN board assembly "5.5.2 Version
• Firmware version Menu" p.5-13
• Backup parameter version
• Setting of dip switches
• Revision of MAIN board assembly
Operation Used to check the functions of the operation panel keys, LCD, and "5.5.3
panel LED. Operation Panel
Menu" p.5-14
Sensor Displays the status of the following sensors. "5.5.4 Sensor
• CR_ORG sensor Menu" p.5-15
• Wiper sensor
• Cover sensor
• Lever sensor
• Head slide sensor
• Waste fluid box sensor
• P_EDGE sensor
• P_REAR sensor
• Head transistor thermistor sensor
• Head thermistor sensor
Encoder Displays the detected values from the following encoders. "5.5.5 Encoder
• CR (Carriage) Menu" p.5-17
• PF (Media feed)
Fan Used to check if the following fans operate normally by turning them "5.5.6 Fan
ON and OFF. Menu" p.5-17
• Suction fan
• Cooling fan
• Head fan
History Used to check the following records. Used to initialize the serious "5.5.7 History
error history. Menu" p.5-18
• Maintenance history
• Serious error history
Head Used to check the head-driving waveform. "5.5.8 Head
waveform Waveform Menu"
p.5-21
5-11 Rev.-00
Previous menu
[Enter] key Ram Capacity Menu
[Cancel] key
[Enter] key Version Menu
[Cancel] key
[Enter] key Panel Menu
[Cancel] key
[Enter] key Sensor Menu
[Cancel] key
[Enter] key
Encoder Menu
[Cancel] key
[Enter] key
Fan Menu
[Cancel] key
[Enter] key
History Menu
[Cancel] key
Next menu Previous menu [Enter] key Head Signal Menu
[Cancel] key
5.5.1 Memory Size Menu

This menu displays the size of memories installed on the MAIN board assembly.
[Cancel] key
Test Menu
Rev.-00 5-12
5.5.2 Version Menu

This menu displays the following contents about the firmware and MAIN board assembly.
• Firmware version
• Backup parameter version
• Setting of dip switches of MAIN board assembly
• Revision of MAIN board assembly
TIP
Settings for the DIP switch on the MAIN board assembly are displayed as follows:
• ON: 0, OFF: 1
• Switch No.1: LSB
• Switch No.2: MSB
[<] key
Firmware version
[>] key [<] key
Backup parameter version
[>] key [<] key
Setting of DIP switches
of main board assembly
[>] key [<] key
Revision of main board assemb
[>] key
5-13 Rev.-00
5.5.3 Operation Panel Menu

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

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

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

The following LEDs light up in the following order. The LCD displays the name of the LED that is currently
illuminated.
• Power lamp
• Data lamp
• High lamp
• Low lamp
• Wave lamp
• Fine & S.Fine lamp
• Strong lamp
• Normal lamp
[<] key Operation Panel Key Check

[Enter] key
[Cancel] key (twice)

[>] key [<] key LCD Check
[Enter] key
[Cancel] key
[>] key [<] key LED Check
[Enter] key
[Cancel] key
[>] key
Rev.-00 5-14
5.5.4 Sensor Menu

This menu displays the sensor status on the operation panel.
If the displayed sensor status does not match the actual machine status, replace or adjust the relevant sensor
referring to the table below.
Table 5-3 Inspection Items in Sensor Menu

No. Sensor name Status in display Reference
1 CR_HP sensor ON / OFF "4.13.4 Replacing CR_HP
Sensor, Lever Sensor" p.4-150
2 Waste fluid tank sensor ON / OFF -
3 Wiper sensor ON / OFF -
4 Maintenance cover sensor (L/R) Open / Close -

5 Lever sensor Up / Down "4.6.6 Replacing Lever Up
Sensor" p.4-67
6 P_EDGE sensor 0 to 255 "4.8.11 Replacing P_EDGE
Sensor Assembly" p.4-118
7 P_REAR sensor 0 to 255 "4.6.5 Replacing P_REAR
Sensor Assembly" p.4-65
8 Headslide Low / High
9 Head thermistor ** ºC "4.8.9 Replacing Print Head"
p.4-114
10 H transistor 1, 2 ** ºC -
NOTE
For the following sensors, the sensor sensitivity is displayed in decimal number.
• P_EDGE sensor
5-15 Rev.-00
[<] key
CR_HP Sensor
[>] key [<] key
Waste Tank Sensor
[>] key [<] key
Wiper Sensor
[>] key [<] key
Cover Sensor
[>] key [<] key
Maintenance Cover L Sensor
[>] key [<] key
Maintenance Cover R Sensor
[>] key [<] key
Lever Sensor
[>] key [<] key
P_EDGE Sensor
[>] key [<] key
P_REAR Sensor
[>] key [<] key

Head Gap Sensor
[>] key [<] key
Head Sensor
[>] key [<] key

H Transistor 1
[>] key [<] key

H Transistor 2
[>] key
Rev.-00 5-16
5.5.5 Encoder Menu

This menu displays the detected values from the following encoders.
• CR_ENC (Carriage)
• PF_ENC (Media feed)
NOTE
For the encoder-detected values, the encoder pulse numbers are displayed in hexadecimal number.
Previous menu
CR_ENC
PF_ENC
Next menu
5.5.6 Fan Menu

This menu is used to check if the fans operate normally by turning them ON and OFF.
If this operation is selected, the fans operate as follows:
• Suction fan: Turns to ON

• Cooling fan: Turns to OFF
• Head fan: Turns to ON
If you press [Cancel] key, the suction fan is deactivated and the cooling fan is resumed, and the display shifts
to "Inspection: Fan".
[<] key
[>] key [<] key
[>] key [<] key
[>] key
5-17 Rev.-00
5.5.7 History Menu

This menu is used to check maintenance history and serious error history.
This menu is used to check maintenance history and serious error history and to initialize serious error history.
Previous menu
Maintenance history
Serious error history
Next menu
Initialization of the serious
Next menu communication
(1) Maintenance History

This displays the past maintenance records on the following components.
• Number of wiping of wiper

• Number of CR motor activation cycles
• Number of PF motor activation cycles
• Number of printed copies
• Number of cleaning cycles
• Discharged amount of head ink (K, C, M, Y)
• Pump count (number of pump wheel cycles)
• Number of lock solenoid downs
NOTE
All values of maintenance history are indicated in hexadecimal form.
Rev.-00 5-18
[<] key
Frequenc[ of the wiper blade used
[>] key [<] key
CR Motor driving (Unit : Operation count)
(Ink tube reciprocating count and the function)
[>] key [<] key
PF Motor driving (Unit : 220 pulse)
[>] key [<] key

Frequenc[ of printing
[>] key [<] key
Frequenc[ of cleaning
[>] key [<] key
Head 1-A Fire (Unit: Mdots)
[>] key [<] key
Head 1-B Fire (Unit: Mdots)
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key

[>] key [<] key

Frequenc[of the pump operation
(Pump wheel rotation count)
[>] key [<] key
Frequency of the lock solenoid moving down
[>] key
5-19 Rev.-00
(2) Serious Error History

Indicates serious error history.
NOTE
• The serious error history does not include CPU error.
• The serious error history menu indicates the history up to 32.
Previous menu
Next menu
(3) Error Initialization

This menu is used to initialize the serious error history.
[Enter] key
Rev.-00 5-20
5.5.8 Head Waveform Menu

This menu is used to check the head-driving waveform.
NOTE
Magnification can be selected from the range of x1-1000000. Nozzle can be selected among A to H
and ALL.
Previous menu
[Enter] key
Next menu
5-21 Rev.-00
5.6 Ink Charging Menu

In the ink charging menu, you can charge ink.
The ink charging menu includes the following items.
Table 5-4 Ink Charging menu
Charging item Contents

InkCharge Performs initial ink charging.
LittleCharge Performs a small amount of ink charging.
[<] key
[Enter] key
[>] key [<] key
[>] key
* In “LittleCharge“ process, the plotter charges a small amount of ink, which is one-fourth of
“InkCharge“ main suction steps.
Rev.-00 5-22
5.7 Adjustment Menu

In this menu, you can align the printing position and correct the media feed operation.
The adjustment menu includes the following diagnosis menus.
Table 5-5 Diagnosis Items in Adjustment Menu

Head nozzle check Prints out a printing to check the ink discharge "5.7.1 Head Nozzle
performance of the head nozzles. Check Menu" p.5-25
Skew check Performs media feed and detects the degree of skew in "5.7.2 Skew Check
media feed by the sensor. Menu" p.5-27
Head slant check Prints out a printing to check for print head slant "5.7.3 Head Slant
(horizontal and vertical direction). Mechanical Check Menu" p.5-28
adjustment must be performed as necessary.
Volt. adjustment Adjusts the print position of VSD3 - small dot. "5.7.4 Voltage
Adjustment" p.5-31
Uni-D / Bi-D Prints out a printing to align the nozzle line distance "5.7.5 Uni-D/Bi-D
adjustment Low (Uni-D) of PG Low and the position of the repeated Low/High Adjustment"
printing. p.5-33
Uni-D 240: 240 cps
Uni-D 320: 320 cps
Uni-D 240B: 240 cps (Banner)
Bi-D 240: 240 cps
Bi-D 320: 320 cps
Bi-D 240B: 240 cps (Banner)
Uni-D / Bi-D Prints out a printing to align the nozzle line distance "5.7.5 Uni-D/Bi-D
adjustment High (Uni-D) of PG High and the position of the repeated Low/High Adjustment"
printing. p.5-33
Uni-D 240: 240 cps
Uni-D 320: 320 cps
Bi-D 240: 240 cps
Bi-D 320: 320 cps
Side margin Sets the side margin. "5.7.6 Side Margin
adjustment Adjustment Menu" p.5-
38
Test printing Prints out a head nozzle check pattern, an adjustment "5.7.7 Test Printing
pattern, adjustment parameters, serious error history or a Menu" p.5-39
dot pattern.
HeadWash Cleans the tubes and heads using cleaning liquid. "5.7.8 HeadWash
Menu" p.5-40
5-23 Rev.-00
Table 5-5 Diagnosis Items in Adjustment Menu (Continued)

HeadWash 2 Cleans the tube heads using shipping fluid to maintain "5.7.9 HeadWash
the condition at the time of shipping. Menu 2" p.5-40
Software counter Clears various software counters. "5.7.10 Software
initialization Counter Initialization
Menu" p.5-41
Feed amount check Used to check the media feed amount per band. "5.7.11 Feed Pitch
Check Menu" p.5-42
Solid print check Performs solid nozzle print check (color selection, nozzle "5.7.12 Solid Print
selection and print direction selection are available). Menu" p.5-43
[<] key
[Enter] key
Nozzle Check Menu
[Cancel] key
[>] key [<] key
[Enter] key
Check Skew Menu
[Cancel] key
[>] key [<] key
[Enter] key
Head Slant Menu
[Cancel] key
[>] key [<] key
[Enter] key
Voltage Adjustment Menu
[Cancel] key
[>] key [<] key
[Enter] key
Uni-D/Bi-D Low Adjustment Menu
[Cancel] key
[>] key [<] key
[Enter] key
Uni-D/Bi-D High Adjustment Menu
[Cancel] key
[>] key [<] key
[Enter] key
Side Margin Adjustment Menu
[Cancel] key
[>] key [<] key
[Enter] key
Test Print Menu
[Cancel] key
[>] key [<] key
[Enter] key
Head Wash Menu
[Cancel] key
[>] key [<] key [Enter] key
Software Counter Initialization Menu
[Cancel] key
[>] key [<] key
[Enter] key
Feed Pitch Check Menu
[Cancel] key
Solid Print Menu
[Cancel] key
[>] key
Rev.-00 5-24
5.7.1 Head Nozzle Check Menu

In this menu, you can check if the head nozzles that has been charged can discharge ink correctly by printing
a sample printing. To check the head nozzle, follow the steps below.
1. Set media as necessary.

2. After media is set, the machine prints out head nozzle check patterns in the following modes.
• 1 pass, Uni-D
• PF: 360 dpi
• CR: 360 dpi
3. Check the printed head nozzle check patterns for the following points.
• Ink nozzle discharge amount (omission, discontinuity, meandering)
• Satellite
• T fence
• Nozzle alignment in vertical direction
• Nozzle alignment in horizontal direction
Nozzle check: Prints out the pattern in the order of A to H
Nozzle alignment in vertical direction: Prints out the pattern in the order of A to H
Nozzle alignment in horizontal direction (CW direction): Prints out the pattern in the order of A to H
Nozzle alignment in horizontal direction (CCW direction): Prints out the pattern in the order of A to H
5-25 Rev.-00
4. If any abnormal conditions are found in the ink discharge status of the head nozzles, perform cleaning.
TIP
"5.7.11 Feed Pitch Check Menu" p.5-42
5. After cleaning, make the machine print out head nozzle check patterns again.
Media set
If media is not set

Finish
printing
Display during adjustment printing
Previous menu
Next menu
Rev.-00 5-26
5.7.2 Skew Check Menu

Feed the paper to check the skew size using sensor.
When you select this item from the Adjustment Menu, the plotter feeds the loaded media by one pass and
checks difference of the media edge positions before and after the media feed detected by the sensor.
NOTE
Before performing skew check, ensure that the media is set correctly.
The plotter determines the media setting reference position during first detection of media left edge.
Therefore, the media that is not set correctly may cause errors as below.
• Media error occurs during skew check and plotter operation stops.
• During media initial operation after power is turned on or media is cut, "Undefined Paper"
frequently occurs.
0.1 m increments
[Enter] key
If media is not set
Media set
Finish media initialization
Media edge detection finishes normaly
Table 5-6 Skew Amount Specification

Condition Specification
Roll media 7m 2.5 mm or less
50 m 10 mm or less
5-27 Rev.-00
5.7.3 Head Slant Check Menu

The plotter has 8 nozzle lines per head. This menu adjusts the slant of each nozzle line evenly.
Check the head slant from a sample printing, and perform mechanical adjustment if necessary.
Table 5-7 Head slant checking items
Items Contents
Head slant in horizontal direction Head slant check in horizontal direction
Head slant in vertical direction Head slant check in vertical direction
[<] key
[>] key [<] key
[>] key
[Enter]
If setting is not in PG-Low

[Enter]
(1) Horizontal Direction Checking

This menu prints out a sample printing to check for head slant in the horizontal direction.
To perform head slant check, follow the steps below.

2. After media is set, the plotter prints out head slant check patterns in the following modes.
• 1 pass, Uni-D
• PF: 360 dpi, CR: 360 dpi
Rev.-00 5-28
3. Check the printed head slant check patterns. Checking items are as follows:
• Head slant
A: Check the point to check the slant.

B: Media feed direction
C: OK
D: Move the head adjustment cam upward
E: Move the head adjustment cam downward
5mm B
A
20mm
5mm
C D E
4. If any head slant is found, perform mechanical adjustment.
TIP
"7.7.1 Head Alignment (Horizontal Height)" p.7-30
5. After mechanical adjustment, make the machine print out head nozzle check patterns again.
Finish printing
Previous menu
Finish printing

Output pattern
Next menu
5-29 Rev.-00
(2) Vertical Direction Checking

This menu prints out a sample printing to check for head slant in the vertical direction.
To perform head slant check, follow the steps below.

2. After media is set, the machine prints out head slant check patterns in the following modes.
• 1 pass, Uni-D
• PF: 360 dpi, CR: 360 dpi
3. Check the printed head slant check patterns. Checking items are as follows:
A: Check the point to check the vertical slant.
C: OK
D: Move the vertical-slant adjusting cam to the right.
E: Move the vertical-slant adjusting cam to the left.
4-B 4-A 3-B 3-A 2-B 2-A 1-B 1-A
CCW
4-B 4-A 3-B 3-A 2-B 2-A 1-B 1-A
B CW
C D E
Rev.-00 5-30
4. If any head slant is found, perform mechanical adjustment.
TIP
"7.7.2 Head Alignment (Vertical Slant)" p.7-32
5. After mechanical adjustment, make the machine print out head nozzle check patterns again.
Finish printing
Previous menu
Finish printing

Output pattern
Next menu
5.7.4 Voltage Adjustment

This menu is used to adjust the voltage of VSD 3 small dot so that the print position will be corrected.
Check the small dot is on the center of the middle dots in the CR direction.
When adjusting, change the voltage up to 5V (0.1V increment) considering the current voltage as a basis.
Items Contents
240 CW Adjusts the VSD 3-S at 240 cps / CW printing.
240 CCW Adjusts the VSD 3-S at 240 cps / CCW printing.
Previous menu
Next menu
Next menu
5-31 Rev.-00
The following figure shows a case for 240 CW.
[Enter] key
If media is not set
Media set
If head gap is PG-Low
Change head gap (to PG-Low)

If the temperature of the pre-heater and
platen heater is below 42 C
Finish warm-up * Pressing [Cancel] key stops control and start printing
Finish printing
Press [Setting/Value+] or [Setting/Value-] key
to change unit to pulse
Volt range: -5V to 5V (0.1V)
VH3L-1 to VH3L-4
VH3S-1 to VH3S-4
Print pattern: 240 CW
2B 2A 1B 1A 2B 2A 1B 1A
CW
240CPS A
A: Print direction
B: Adjust the voltage so that the small dot printed positions (shown as dot-line) are the same with the
middle dot printed positions (in the CR direction).
C: Executed adjustment item is printed like this.
Rev.-00 5-32
Items Speed
240 CW CW 240 CPS
320 CW CW 320 CPS
240 CCW CCW 240 CPS
320 CCW CCW 320 CPS
* Print pattern: Uni-D, 2 pass, 1A to 2B print

1st pass: prints middle dot
2nd pass: prints small dot
5.7.5 Uni-D/Bi-D Low/High Adjustment

Adjusts the gap of the print heads (in the CR moving direction) when the head is in the PG Low/High and the
print position of the head in repeatability printing.
To adjust, perform printing in repeatability printing and correct CW and CCW printing positions by inputting
parameters.
* Check the plotout at the origin, center and the opposite side to origin, and perform adjustment so that the
gap is even.
Adjustment items are shown below.
Table 5-8 Uni-D / Bi-D menu items
Item Contents
Uni-D 240 Adjusts CW at 240 CPS. PG Low or High
Uni-D 320 Adjusts CW at 320 CPS. PG Low or High
Uni-D 240B Adjusts CW at 240 CPS-Banner. PG Low or High
Uni-D 320B Adjusts CW at 320 CPS-Banner. PG Low or High
Bi-D 240 Adjusts Bi-D at 240 CPS. PG Low or High
Bi-D 240B Adjusts Bi-D at 240 CPS-Banner. PG Low or High
Table 5-9 Uni-D / Bi-D adjustment items
Item Contents
Set up Sets the selected parameter.
Print (when Bi-D is Prints pattern according to the selected item with the
selected, Print 1 is current parameter.
displayed)
5-33 Rev.-00
Table 5-9 Uni-D / Bi-D adjustment items (Continued)
Item Contents
Print 2 (Print 2 is Prints pattern according to the selected item with the
displayed only when current parameter, plus with the values of ±2 / ±4 / ±6 / ±8
Bi-D is selected) to the current parameter.
Check the gap of those printed patterns.
The actual procedure is as follows.

2. After that, plotter starts printing automatically.
3. Check the printed pattern of CW adjustment.
(The following shows a case for Uni-D 240 Low Print)
Prints the pattern in the order of 1A to 4B.
Uni-Lo
240CPS
A
Banner
- + - + - + - + - + - + - + - +
4B 4A 3B 3A 2B 2A 1B 1A
B C
A: Media feed direction

B: Adjust the setting value so that these point matches.
Uni-D 240: Uni-Lo/Hi 240 CPS
Uni-D 320: Uni-Lo/Hi 320 CPS
Uni-D 240B: Bi-Lo/Hi 240 CPS-Banner
Uni-D 320B: Bi-Lo/Hi 320 CPS-Banner
* Either “Lo“ or “Hi“ is displayed where explained as “Lo/Hi“ above.
Rev.-00 5-34
(The following shows a case for Bi-D 240 Low Print 1)

Prints the pattern by using 2A nozzle line.
* Both Uni-D / Bi-D High should be adjusted in the same procedure.
Bi-Lo
240CPS
A
Banner
- + - + - + - + - + - + - + - +
2A 2A 2A 2A 2A 2A 2A 2A
B C

Bi-D 240: Bi-Lo/Hi 240 CPS
Bi-D 240B: Bi-Lo/Hi 240 CPS-Banner
Bi-D 320B: Bi-Lo/Hi 320 CPS-Banner
(The following shows a case for Bi-D 240B Low Print 2)

Prints the pattern by using 2A nozzle line.
Bi-Lo
240cps A
Banner
-+ -+ -+ -+ -+ -+ -+ -+
4B 4A 3B 3A 2B 2A 1B 1A
B C
5-35 Rev.-00

Check the plotout at the origin, center and the opposite side to origin, and perform adjustment so that the gap
is even.
If any abnormal conditions are found, identify the gap of the print positions and enter it as the CW adjustment
parameter.
After that, print test pattern again as necessary.
(The following shows a case for Uni-D 240.)
[<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key

[Enter] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key
[<] key
[>] key [<] key
[>] key
Rev.-00 5-36
Enter parameters when Bi-D is selected as follows.

(The following shows a case for Bi-D 240.)
[>] key
[<] key [>] key
[<] key [>] key
[<] key
• The following shows a case for “Print” (or Print 1 / Print 2) is selected.
* Common for Bi-D, Uni-D
If media is not set

Media set
If head gap is PG-High
Change head gap (to Low)
If the temperature of the preheater and
platen heater is below 42 C
* Pressing [Cancel] key stops control and start printing
Displayed during adjustment printing

Finish printing
Back to Uni-D/Bi-D top menu
• The following shows a case for “Set up” is selected (Uni-D 240).
Enter parameters when Uni-D is selected as follows.
[<] key
* Press [Setting/Value+] or [Setting/Value-] key
to change the setting value.
[>] key [<] key 1 pulse = 1/720 inch
Pulse range: -100 VQ 100
[>] key [<] key * “#2 A” is not displayed because the position is
referred as the basis when adjusting.
[>] key [<] key

* “#2” is displayed if High menu is selected.
Also, “240B” or “320B” is displayed
[>] key [<] key according to the mode selection.
[>] key [<] key
[>] key [<] key
[Enter] key
[>] key [<] key
Returns to “Uni-D 240” setup menu
[>] key
5-37 Rev.-00
(The following shows a case for “Bi-D 240 - Setup” is selected.)

[<] key Press [Setting/Value+] or [Setting/Value-] key
to change unit to pulse‫ޓ‬
1 pulse = 1/2880 inch
[>] key [<] key Pulse range: -400 VQ400
Back to Uni㨺D/Bi-D Top menu
[>] key
5.7.6 Side Margin Adjustment Menu

This menu is used to adjust the printing margins.
To adjust the margins, follow the steps below.

2. After media is set, the plotter prints out band feed correction adjustment patterns and cuts the media in
the following modes.
• Black, 1 pass, Uni-D, 360 dpi
* If "check" is selected, black replaces magenta.
3. Check the printed side margin adjustment patterns for the measurement.
TOP
1: Side margin
2: Media feed direction
4. Enter each measured value as the parameter.
(Input range: 0.0 to 20.0 mm (0.1 mm increments))
Press [Cancel] key to go back to
̌Adj. 7 SideMargin̍ Menu
Press [Setting/value+] or [Setting/value-] key

to select initialize or check
After pressing [Enter]key
After printing
Side Margin: 0.1㨙㨙 increments
Range: 0.0 - 20.0 mm
Rev.-00 5-38
5.7.7 Test Printing Menu

In this menu, you can print out adjustment patterns for checking various adjustment items.

2. After media is set, the machine prints out the following test printings.
• Print1: Adjust ALL: Prints adjustment patterns.
• Print2: Parameter ALL: Prints adjustment parameters.
• Print3: Log Info: Prints the serious error history.
3. Press the [Enter] key in the operation panel to start the selected test printing.
[<] key Printing adjustment pattern

[Enter] key
[>] key [<] key
[>] key
5-39 Rev.-00
5.7.8 HeadWash Menu

This menu is used to purge ink and clean the heads before print head replacement.
1. Press [Enter] key in the operation panel to determine the Head Cleaning Menu.
2. Remove all ink cartridges.
3. Press [Enter] key in the operation panel to discharge ink.
4. After ink is discharged, install the head cleaning jig.
5. Press [Enter] key in the operation panel to charge cleaning liquid.
6. After cleaning liquid is charged, remove the head cleaning jig.
Remove all cartridges and press [Enter] key to discharge ink
Finish Ink Discharge
Set cleaning jig and press [Enter] key to charge shipping liquid
After shipping liquid is charged
Remove cleaning jig and press [Enter] key to discharge

shipping liquid
5.7.9 HeadWash Menu 2

Maintain the conditions of the heads at the time of shipping by cleaning tubes and heads with shipping fluid.
* This function is not usually used in maintenance work.
Go to “Adj 10: HeadWash2“ after charging shipping fluid.
Insert cleaning cartridge,

then press [Enter] key to fill shipping fluid
After shipping fluid is filled
Remove the cleaning cartridge,

then press [Enter] key to discharge the shipping fluid
Rev.-00 5-40
5.7.10 Software Counter Initialization Menu

This menu is used to initialize the software counters such as the ink consumption counter.
NOTE
The counters are initialized before delivery. Do not initialize them during maintenance.
The software counters that can be initialized through this menu are as follows.
Table 5-10 Software Counters to be Initialized

Counter Initial
value
Ink consumption counter K 0
Ink consumption counter C 0
Ink consumption counter M 0
Ink consumption counter Y 0
Cumulative print timer 0
User not-filled flag 0
Not-filled flag 1
1. Pressing the [Enter] key in the operation panel performs the software counter initialization. Pressing
[Cancel] key cancels the initialization.
Adjustment Menu
[Enter] key
Finish initialization
5-41 Rev.-00
5.7.11 Feed Pitch Check Menu

In this menu, you can check the media feed amount for one band by reviewing a sample printing. There is no
adjustment items.
To check the feed pitch, follow the steps below.

2. Select "Adj 12: SendPitch".
3. Select the feed pitch.
• Pattern 1: Prints at intervals of 360 (720) dpi. This resolution causes no gaps.
• Pattern 2: Prints at intervals of 1440 dpi. This causes a gap in one line out of four lines.
4. Pattern 1 is printed as shown below.
Feed amount
for one band
[<] key [Enter] key
[>] key [<] key Finish Printing or [Cancel] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key
Rev.-00 5-42
5.7.12 Solid Print Menu

This menu is used to print solid print patterns with head on both ends.
• A printed patter is as follows.
5mm B
Specified color nozzles of both series A and B

Nozzles for series B only A
Nozzles for series A only
5mm 20mm

B: 100% printing
Print the pattern in the order of 1A&1B, 1B&1B, 1A&1A.
Previous menu
Press [Setting/value +] or [Setting/value -] key
to select color to check
Next menu
[Enter] key
Previous menu
to select nozzle to eject ink
ALL: All nozzles
ODD: Odd numbered nozzles
Next menu Previous menu EVEN: Even numbered nozzles
Next menu
[Enter] key
Previous menu
to select color to check
CW: Eject ink when CW scanning
CCW: Eject ink when CCW scanning
Next menu
5-43 Rev.-00
5.8 Cleaning Menu

In this menu, you can clean ink from the print heads.
The cleaning menu includes the following diagnosis items.
Table 5-11 Diagnosis Items in Cleaning Menu
Diagnosis item Contents
Economy Performs economy cleaning
Normal Performs normal cleaning
Powerful Performs powerful cleaning
Previous menu [Enter] key

Economy Cleaning
[Cancel] key
Normal Cleaning
[Cancel] key
[Enter] key
Strong Cleaning
[Cancel] key
Next menu
Rev.-00 5-44
5.9 Sample Printing Menu

This menu prints out a sample printing.
The sample printing menu includes the following items.
Table 5-12 Diagnosis Items in Sample Printing Menu
Adjust ALL Prints adjustment patterns.
Parameter ALL Prints out the set values of various adjustment items.
Error history Prints serious error history.
NOTE
If you have not registered the serial number of the machine, you must enter the number before you
can start the adjustment variable printing.
[<] key Adjust Pattern printing

[Enter] key
[>] key [<] key Adjust Parameter printing

[Enter] key
[>] key [<] key Error record printing

[Enter] key
[>] key [<] key Dot diameter printing

[Enter] key
[>] key
5-45 Rev.-00
5.10 Time Setting

Sets the calender controlled by RTC (Real Time Clock) on the MAIN board.
Previous menu
Change the Year setting value input (1digit input)
by pressing [setting/value+] or [setting/value-]
Change the Month setting value input (1digit input)
Change the Date setting value input (1digit input)
Change the Hour setting value input (1digit input)
Change the Minute setting value input (1digit input)
Rev.-00 5-46
5.11 Parameter Menu

In this menu, you can modify the set values of various adjustment items (adjustment parameters).
The parameter menu includes the following items.
Table 5-13 Diagnosis Items in Parameter Menu
Initialization Initializes the adjustment parameters. "5.11.1 Parameter
Initialization Menu"
p.5-47
Update Updates the adjustment parameters. "5.11.2 Parameter
Update Menu" p.5-49
[<] key [Enter] key

Parameter Initialization Menu
[Cancel] key
[>] key [<] key
[Enter] key
Parameter Update Menu
[Cancel] key
[>] key
5.11.1 Parameter Initialization Menu

This menu initializes the adjustment parameters. The parameters that can be initialized through this menu are
as follows.
• Uni-D / Bi-D parameter, wiper, CR motor, PF motor, pump, waste ink)

• Initialization of all items
[<] key [Enter]

key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key
5-47 Rev.-00
(1) Voltage Adjustment

This menu updates the voltage adjustment parameter (VSD3 small dot).
Table 5-14 Voltage adjustment item
Items Contents
Previous menu
Next menu
(2) Uni-D/Bi-D Low/High

This menu updates the Uni-D/Bi-D adjustment parameter.
[<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key
Rev.-00 5-48
5.11.2 Parameter Update Menu

This menu updates the adjustment parameters. The parameters that can be updated through this menu are as
follows.
NOTE
The updated parameters will not be stored in the flash memory unless the system power is turned
OFF.
• Head rank
• Voltage adjustment
• Uni-D/Bi-D Low
• Uni-D/Bi-D High
• Side margin
• Not-filled flag
• Serial number
• Smart chip name update
• DebugBit
[<] key [Enter] key

Head Parameter Update Menu
[Cancel] key
Head Voltage Offset Menu

[Cancel] key
[Cancel] key
Uni-D/Bi-D Low Update Menu
[Cancel] key Uni-D/Bi-D High Update Menu

[Cancel] key Side Margin Update Menu

[Cancel] key Ink Parameter Update Menu

Serial No.Update Menu
[Cancel] key
[>] key [<] key
[Enter] key
Chip name
[Cancel] key
[>] key [<] key
[Enter] key
Debug Bit
[>] key [Cancel] key
5-49 Rev.-00
(1) Head Rank

This menu updates the head rank parameters. The head rank is used to determine the print head driving
voltage and correct the head temperature.
After head rank is entered, the system shifts to the Ink Charge Menu.
[Enter] key
[Enter] key
[Enter] key Error will occur if input value is wrong.

Press [Enter] key to retry
[Cancel]
[Enter] key Initial Ink charge will not executed.
key
Head ID will be updated.
[Enter] key
[Enter] key
[Enter] key
(2) Voltage Adjustment

This menu updates the voltage adjustment parameter (VSD3 small dot).
Table 5-15 Voltage adjustment item
Items Contents
240 CW Adjusts the VSD 3-L (S) at 240 cps. CW printing.
240 CCW Adjusts the VSD 3-L (S) at 240 cps. CCW printing.
320 CW Adjusts the VSD 3-L (S) at 320 cps. CW printing.
320 CCW Adjusts the VSD 3-L (S) at 320 cps. CCW printing.
[<] key
[>] keys [<] key
[>] key [<] key
[>] key [<] key
[>] key
If 240 CW is selected
Offset range: -5V to 5V (0.1V increment)
VH3L-1 to VH3L-4
VH3S-1 to VH3S-4
Rev.-00 5-50
(3) Uni-D / Bi-D Low

This menu updates the Uni-D/ Bi-D adjustment parameter.
Table 5-16 Uni-D / Bi-D update Item

Item Contents
Uni-D 240 Adjusts Uni-D at 240 CPS. PG Low or High
Uni-D 320 Adjusts Uni-D at 320 CPS. PG Low or High
Uni-D 240B Adjusts Uni-D at 240 CPS-Banner. PG Low or High
Uni-D 320B Adjusts Uni-D at 320 CPS-Banner. PG Low or High
Uni-D / Bi-D adjustment parameters are updated.
[<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key
5-51 Rev.-00
(The following shows a case for “Uni-D 240” is selected.)
If any value has been changed

[<] key
[>] key [<] key [Enter]
[>] key [<] key

* Press [Setting/Value +] or [Setting/Value -] key
to change the set value
[>] key [<] key
Range: -100 to 100
* “2A” is not displayed because the value is the basis
[>] key [<] key
* If “High” is selected, the values of #2 will be displayed
[>] key [<] key
[>] key [<] key
[>] key
(4) Side Margin

This updates the side margin parameters.
When any parameter has been changed
[Enter]
㧡㧚㧜
key
[Enter] key
(5) Ink Not-filled Flag

This updates the ink parameter. The setting items are as follows.
• Not Charge: Cleaning is not completed, and ink is not charged

• UserCharge: Cleaning is completed, and ink is not charged
• User/Init Charge: Cleaning is completed, and ink is charged
[Enter] key
When any parameter
has been changed
[Enter] key
NOTE
When selecting "Reset", be sure to install the cartridge.
Rev.-00 5-52
(6) Serial Number Entry

This is for entering the serial number.
㧲㧮㧢㧖㧜㧜㧜㧜㧜㧜 Enter Serial Number (digit by digit)

[>] key [<] key
㧲㧮㧢㧭㧖㧜㧜㧜㧜㧜
[>] key [<] key
㧲㧮㧢㧭㧝㧖㧜㧜㧜㧜
[>] key [<] key
㧲㧮㧢㧭㧝㧞㧖㧜㧜㧜
[>] key [<] key
㧲㧮㧢㧭㧝㧞㧟㧖㧜㧜
[>] key [<] key
㧲㧮㧢㧭㧝㧞㧟㧠㧖㧜
[>] key [<] key
㧲㧮㧢㧭㧝㧞㧟㧠㧡㧖
(7) ChipName Update

This menu is for updating company name on the smart chip.
㧯㨔㨕㨜㧺㨍㨙㨑㧦‫ޓޓޓޓޓޓޓޓޓޓ‬㧝 Press [Setting/value+] / [Setting/value-]

to change the value.
1: Mutoh
2: AgfaGS
3: Iris
4: AgfaPP
(8) Debug bit

* This menu is for experiment and not used for ordinary maintenance work.
* Debug Bit (Set digit by digit)

Press [Settting/Value] or [Setting/Value] key
= ?MG[ =?MG[ to change the value
* The default value for all items is “0”
= ?MG[ =?MG[
= ?MG[ =?MG[
= ?MG[ =?MG[
= ?MG[
5-53 Rev.-00
5.12 Servo Setting

* Do not change the parameters. This menu is basically for check.
Table 5-17 Servo setting item
Items Contents
240 cps CW Servo setting at CR CW direction, 240 cps
240 cps CCW Servo setting at CR CCW direction, 240 cps
320 cps CW Servo setting at CR CW direction, 320 cps
320cps CCW Servo setting at CR CCW direction, 320 cps
Table 5-18 Servo adjustment item
Items Contents
Proportional gain Sets proportional gain/
Integral gain Sets integral gain
Low-pass filter Sets low-pass filter
PWM scale Sets PWM scale
ωC Sets ω C
Rev.-00 5-54
[<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key
[Enter] key㧔When selecting 240cps CW 㧕
[<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key
[Enter] key
Change the value (unit to count) by pressing

[setting/value+] or [setting/value-] key
* The maximum / minimum / count value for each item is shown blow.
Items Max. Min. Count

GP (Proportional gain) 0 × 2000 0 × 7800 0 × 200
GI (Integral gain) 2 0 × 800 1
GLPF (Low-pass filter) 0 255 1
PWM (PWM scale) 10 15 1
ω C (Position gain) 30 60 5
5-55 Rev.-00
5.13 Endurance Running Menu

Performs endurance running of mechanicals and the head.
The endurance running menu includes the following items.
Table 5-19 Diagnosis Items in Endurance Running Menu

CR motor Performs carriage stroke. "5.13.1 CR Motor
Endurance Menu" p.5-
57
PF motor Drives the PF motor. "5.13.2 PF Motor
58
Pump Drives the pump motor assembly. "5.13.3 Pump
59
Nozzle print Performs sequential print operation of the print head. "5.13.4 Print Head
Endurance (Nozzle
Print) Menu" p.5-60
General endurance Performs endurance running on the CR and PF "5.13.5 General
concurrently. Endurance Menu" p.5-
61
Confirmation Confirms the number of endurance running cycles. "5.13.6 Endurance
Running Check Menu"
p.5-62
Previous menu [Enter] key

CR Motor Endurance Menu
[Cancel] key
PF Motor Endurance Menu
[Cancel] key
Pump Motor Endurance Menu
[Cancel] key
Sequential Printing Endurance Menu
[Cancel] key
General Endurance Menu
[Cancel] key
Endurance Running Check Menu
[Cancel] key
Rev.-00 5-56
5.13.1 CR Motor Endurance Menu

This menu performs endurance running for the CR motor.
You can operate the carriage stroke according to your desired settings. The available settings are shown
below.
Table 5-20 Set Items in CR Motor Endurance Menu

Set item Contents Set value Remark
Running speed (CW, Set the carriage running speed 240, 320, (400) Unit: cps
CCW) (CW direction, CCW direction) * 400 CPS cannot be
selected depending
on versions.
Number of endurance Set the number of endurance -1 to 10000
running cycles running cycles
CAUTION
When the CR motor endurance running is performed, note the following;

• Install available ink cartridges.
If the CR motor endurance running is performed without ink cartridges, ink inside the tube
may leak through the ink holder during the carriage movement.
TIP
• If the number of endurance running cycles is set to -1, the carriage continuously repeats endurance
running until cancel input is given from the operation panel.
• The maximum counter value for endurance running cycles is 99999999 (up to 8-digit number). If the
number of cycles exceeds the maximum value, the counter is reset to 0.
• The carriage moving distance is fixed to the maximum value of print area.
CW-speed
[Enter] key
CCW-speed
[Enter] key
Endurance Count
[Enter] key
Performing endurance
[Enter] or [Cancel] key
5-57 Rev.-00
5.13.2 PF Motor Endurance Menu

This menu performs endurance running for the PF motor.
You can drive the PF motor according to your desired settings. The available settings are shown below.
Table 5-21 Set Items in PF Motor Endurance Menu

Media feed amount Set the media feed amount 0.1 to 100 Unit: mm
per endurance running
cycle
Number of endurance Set the number of -1 to 10000
running cycles endurance running cycles
TIP
• The following table shows the motor moving parameters to media feed amount.
Speed 35CPS
Acceleration 0.1G
Deceleration 0.1G
• The maximum counter value for endurance running cycles is 99999999 (up to 8-digit number). If the
number of cycles exceeds the maximum value, the counter is reset to 0.
Enter a media feed amount by using ±.

Range : 0.1 to 100.0 mm
[Enter]
Endurance Count
[Enter]
Performing endurance
[Enter] or [Cancel]
Rev.-00 5-58
5.13.3 Pump Endurance Menu

This menu performs endurance running for the pump motor assembly.
You can drive the pump motor assembly according to your desired settings. The available settings are shown
below.
Table 5-22 Set Items in Pump Motor Assembly Endurance Menu

Running speed Set the running speed of Super high / High /
pump motor assembly. Normal / Low
Number of endurance Set the number of endurance -1 to 10000
running cycles running cycles
TIP
• The maximum counter value for endurance running cycles is 99999999 (up to 8-digit number). If
the number of cycles exceeds the maximum value, the counter is reset to 0.
Previous menu
[Enter]
Next menu Previous menu key
[Enter]
[Enter]
[Enter]
Next menu key
Endurance Count
Performing Endurance [Enter] key
[Enter] or [Cancel ] key
5-59 Rev.-00
The pump endurance running sequence is as follows.
1. Pump endurance running starts.

2. Pump phase detection is performed.
3. Rotates with the specified suction speed. This rotation is counted as one cycle.
Step 2 above is repeated the number of times specified as follows.
Super high: 4000
High: 3000
Normal: 2000
Low: 1000
4. Pump release is performed.
5. Pump endurance running ends.
5.13.4 Print Head Endurance (Nozzle Print) Menu

This menu performs endurance running for the plot head.
In the sequential plotting endurance menu you can operate sequential plotting endurance operation on the plot
head according to your desired settings.

Number of endurance Sets the number of -1 to 10000
-
TIP
Endurance Count
[Enter] key
Performing endurance running
Rev.-00 5-60
5.13.5 General Endurance Menu

This menu performs the general endurance running.
You can operate various driving systems according to your desired settings.
The available settings are shown below.
Table 5-23 Set Items in General Endurance Menu

Running speed (CW, Set the carriage running 240, 320, (400) Unit: cps
CCW) speed (CW direction, * 400 CPS cannot be
CCW direction) selected depending on
versions.
Media feed amount Set the media feed 0.1 to 100 Unit: mm
amount per cycle
Number of endurance Set the number of -1 to 10000
TIP
• In the general endurance menu, the following operations are performed as one cycle of endurance
running
• Carriage stroking: 1 stroke
• Media feed: 1 cycle
• If the number of endurance running cycles is set to -1, the carriage continuously repeats stroking
until cancel input is given from the operation panel.
CW-speed
[Enter] key
CCW-speed
[Enter] key
Media feed amount
[Enter] key
Endurance count
[Enter] key
Performing endurance running
5-61 Rev.-00
5.13.6 Endurance Running Check Menu

In this menu, you can confirm the number of endurance running cycles that have been already finished.
The number of endurance running cycles is stored in NVRAM in the system. Therefore, even if a serious error
occurs during endurance running, you can confirm the number of finished cycles just before the occurrence
of the serious error.
[<] key
Number of endurance running cycles
for the CR Motor
[>] key [<] key
for the PF Motor
[>] key [<] key
for the Head Lock
[>] key [<] key
for the Pump motor
[>] key [<] key
for Sequential Printing
[>] key [<] key
Number of general endurance running cycles
[>] key
5.14 Media Feed Menu

In this menu, you can feed media into the plotter frontward or backward.
The mechanical initialization should be done if it is not performed yet.
Rev.-00 5-62
5.15 ExControl Menu

In this menu, you can diagnose the equipment on the controller board.
Table 5-24 Controller Board Check Item
Items Contents
Version Firmware, board revision -
Sensors Tank status, Electromagnetic valve, Pre-heater

thermistor, platen thermistor 1/2, after-heater
-
thermistor, Ink ID for 4 cartridges, Ink NOT sensor for
4 cartridges, ink END sensor for 4 cartridges
Mist fan Checks mist fan operation -
Heater Pre-heater, platen heater, after-heater -
History Maintenance history confirmation -
[<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key
5.15.1 Version
In this menu, you can check the ROM version of the controller board firmware, and the version of the
controller board. The firmware version (AP version) is displayed as “XX.XX“. The controller board version
is displayed in hex format (2 digits).
[<] key
[>] key [<] key
[>] key
5-63 Rev.-00
5.15.2 Sensor
The status of the following sensors on the controller board is displayed.
[<] key
[>] key [<] key
[>] key [<] key
[>] key
(1) Tank Status

Displays the status of sub tank and electromagnetic valve.
[<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key
(2) Electromagnetic Valve Check

Checks if the electromagnetic valve on the sub tank operates correctly.
[<] key
[>] key [<] key
[>] key [<] key
[>] key [<] key
[>] key
Rev.-00 5-64
Pressing [Enter] key or [Cancel] key turns on/off the electromagnetic valve.
[Enter] key
[Cancel] key
(3) Miscellaneous
Displays the status of the following sensors on the panel.
• Pre-heater thermistor
• Platen heater thermistor
• After-heater thermistor
• Ink ID for 4 cartridges
• Ink NOT sensor for 4 cartridges
• Ink END sensor for 4 cartridges
[<] key
Pre-heater1 condition display
[>] key [<] key
Pre-heater2 condition display
[>] key [<] key
Platen Heater1 condition display
[>] key [<] key
Platen Heater2 condition display
[>] key [<] key
After Dryer heater1 condition display

[>] key [<] key
After Dryer heater2 condition display

[>] key [<] key
K Ink ID condition display

[>] key [<] key
C Ink ID condition display

[>] key [<] key
M Ink ID condition display

[>] key [<] key
Y Ink ID condition display

[>] key [<] key
Ink NOT sensor condition display
[>] key [<] key
Ink END sensor condition display
[>] key
5-65 Rev.-00
5.15.3 Mist Fan

Checks if the mist fan operates correctly.
When this menu is selected, the mist fan is turned on (activated).
5.15.4 Heater
In this menu, you can check whether pre-heater, platen heater, and after-heater works properly or not. The
plotter sets the temperature at 50°C and controls the selected heater process. Press [Cancel] key to stop the
operation.
If the temperature reaches to the set value, the plotter keeps the temperature control.
[<] key
[>] key [<] key
[>] key [<] key
[>] key
[Enter] key㧔When selecting Pre㧕
5.15.5 History
You can check the maintenance history of the controller board control device.
The history is displayed in H (hour) / M (min.) / S (sec.).
Total operating time of each heater shows the period from when the plotter is used in self-diagnosis mode.
Daily operating time is not counted.
[<] key
Time of using Pre-heater
[>] key [<] key
Time of using Platen Heater

[>] key [<] key
Time of using After Dryer Heater
[>] key
Rev.-00 5-66
5.16 PaperInitial Menu

In this menu, you can set the media detection method in the self-diagnosis mode. The default value is the same
as the one in the normal operation mode.
Select either Top & Width / Width / Off. When Off is selected, you can set the media width in the media width
setting menu.
Table 5-25 Media Detection Item
Items Contents
Top & Width Normal media detection mode
Width Detects media width.
Off Does not detect media.
[-] key
[+] key [-] key
[+] key [-] key
[+] key
When Off is selected

Input media width
to change the value
Range: 1000 to 1625 mm
5-67 Rev.-00
Rev.-00 5-68
VJ-1604 　 Maintenance Manual 6 Maintenance Mode 2
6 Maintenance Mode 2
6.1 Introduction ............................................................................................. 6- 2
6.2 Operations in Maintenance Mode.......................................................... 6- 2
6.2.1 Starting Up the Maintenance Mode ............................................... 6-2
6.2.2 Operating Maintenance Mode........................................................ 6-2
6.3 Maintenance Menu.................................................................................. 6- 3
6.3.1 Counter Display Menu ................................................................... 6-3
6.3.2 Counter Initialization Menu ............................................................ 6-6
6.3.3 Counter Print Menu........................................................................ 6-7
6.3.4 Media Feed Menu .......................................................................... 6-8
6-1 Rev.-00
6 Maintenance Mode 2 VJ-1604 　 Maintenance Manual
6.1 Introduction
This chapter provides information on the maintenance mode.
The maintenance mode provides the user with functions of displaying and initializing the life counters. It is
used in the manufacturing process, adjustment, and maintenance.
The maintenance mode is implemented in the system firmware. All functions are available from the operation
panel.
TIP
"2.3 Part Names and Functions" p.2-3
6.2 Operations in Maintenance Mode 2

This section explains how to start up and operate the maintenance mode as well as provides the list of
available diagnosis items.
6.2.1 Starting Up the Maintenance Mode 2

To use the maintenance mode 2, you must first call up the maintenance menu on the operation panel.
The maintenance menu is completely independent of the normal operation mode and setup menu display
mode. To run the maintenance menu, follow the steps below.
1. If the system is in the operation mode or the setup

menu mode, press the [Power] key to turn the
power off.
2. While holding down [Setting/value] key, [>] key
and [<] key in the operation panel
simultaneously, press [Power] key.
The maintenance mode will start running and
display the maintenance menu.
Rev.-00 6-2
6.2.2 Operating Maintenance Mode 2

"5.3 Operations in Self-Diagnosis Mode" p.5-6
6.3 Maintenance Menu

The maintenance menu includes the following diagnosis items.
Table 6-1 Diagnosis Items in Maintenance Menu

Counter: Indication Displays the life counter "6.3.1 Counter Display
Menu" p.6-3
Counter: Init Counter Initializes the life counter "6.3.2 Counter
Initialization Menu" p.6-6
Counter: Print Prints the life counter values "6.3.3 Counter Print
Menu" p.6-7
PaperFeed Feeds media into the printer frontward or backward "6.3.4 Media Feed
Menu" p.6-8
Previous menu
[Enter] key
Counter display
[Cancal] key
[Enter] key
Counter initialization
[Cancal] key
[Enter] key
Counter print
[Cancal] key
Media feed
[Cancal] key
Previous menu
6.3.1 Counter Display Menu

This menu displays the life counters. It consists of the following diagnosis items.
NOTE
All life counters are displayed in decimal number.
Table 6-2 Diagnosis Items in Counter Display Menu

Used Ink K Displays the ink consumption (K) counter.
Used Ink C Displays the ink consumption (C) counter.
6-3 Rev.-00
Table 6-2 Diagnosis Items in Counter Display Menu(Continued)

Used Ink M Displays the ink consumption (M) counter.
Used Ink Y Displays the ink consumption (Y) counter.
Print Number Displays the total number of printed copies.
Waste Ink Displays the waste ink amount counter.
CR Motor Displays the life counter of the CR motor.
PF Motor Displays the life counter of the PF motor.
PUMP Displays the life counter of the pump unit.
HEAD K1, K2 Displays the life counter of the head nozzle (K).
HEAD C1, C2 Displays the life counter of the head nozzle (C).
HEAD M1, M2 Displays the life counter of the head nozzle (M).
HEAD Y1, Y2 Displays the life counter of the head nozzle (Y).
Cleaner Displays the life counter of the cleaning unit.
Rev.-00 6-4

Ink consumption (K) counter

Ink consumption (C) counter
Ink consumption (M) counter
Ink consumption (Y) counter

Total number of printed copies
Waste ink amount counter
Life counter of the CR motor
Life counter of the PF motor
Life counter of the pump unit
Life counter of the head nozzle (K1)

Life counter of the head nozzle (K2)
Life counter of the head nozzle (C1)

Life counter of the head nozzle (C2)

Life counter of the head nozzle (Y1)
Life counter of the head nozzle (Y2)
Life counter of the head nozzle (M1)

Life counter of the head nozzle (M2)
Life counter of the cleaner head
Next menu
6-5 Rev.-00
6.3.2 Counter Initialization Menu

This menu initializes the life counters. The parameters that can be initialized in this menu are as follows.
Table 6-3 Diagnosis Items in Counter Initialization Menu

Print Num. Initializes the total print counter.
Ink Initializes the ink amount counter.
All Initializes the life counter.
NVRAM Initializes the NVRAM.
Timer Initializes the timer.
CR Motor Initializes the CR motor life counter.
PF Motor Initializes the PF motor life counter.
Head Unit Initializes the head nozzle life counter.
Cleaning Initializes the life counter of the cleaning unit.
PUMP Initializes the life counter of the pump unit.
Shipping Batch initializing before shipping
(Print Num., CR Motor, PF Motor, Cleaning)
Rev.-00 6-6
Previous menu [Enter]

key
6.3.3 Counter Print Menu

This menu prints the life counter values.
[Enter] key
After media is set
6-7 Rev.-00
6.3.4 Media Feed Menu

This menu feeds media into the printer frontward or backward.
The mechanical initialization should be performed, if it is not performed yet.
Rev.-00 6-8
VJ-1604 Maintenance Manual 7 Adjustment
7 Adjustment
7.1 Introduction ............................................................................................. 7- 2
7.2 Adjustment Item...................................................................................... 7- 2
7.3 Working with Dedicated Network Software.......................................... 7- 6
7.3.1 Parameter Backup ......................................................................... 7-6
7.3.2 Jigs and Tools................................................................................ 7-6
7.3.3 Required Environment ................................................................... 7-7
7.3.4 Receiving Parameters.................................................................. 7-10
7.3.5 Firmware Installation.................................................................... 7-11
7.3.6 Sending Parameters .................................................................... 7-15
7.3.7 Sub Controller Installation............................................................ 7-16
7.3.8 RTC Date & Time Setting ............................................................ 7-19
7.4 Steel Belt Tension Adjustment ............................................................ 7- 21
7.4.1 Jigs and Tools.............................................................................. 7-21
7.4.2 Adjustment Procedure ................................................................. 7-21
7.5 PF Encoder Assembly Position Adjustment ...................................... 7- 24
7.5.1 Adjustment Procedure ................................................................. 7-24
7.6 CR Speed Reduction Belt Tension Adjustment ................................. 7- 26
7.6.1 Jigs and Tools.............................................................................. 7-26
7.6.2 Adjustment Procedures................................................................ 7-26
7.7 Head Accuracy Adjustment ................................................................. 7- 29
7.7.1 Head Alignment (Horizontal Height) ............................................ 7-29
7.7.2 Head Alignment (Vertical Slant)................................................... 7-31
7-1 Rev.-00
7 Adjustment VJ-1604 　 Maintenance Manual
7.8 PG Height Adjustment ..........................................................................7- 33
7.8.1 Jigs and Tools .............................................................................. 7-33
7.8.2 Adjustment Procedure .................................................................. 7-33
7.9 P_EDGE Sensor Sensitivity Adjustment .............................................7- 35
7.9.1 Jigs and Tools .............................................................................. 7-36
7.9.2 Adjustment Procedure .................................................................. 7-36
Rev.-00 7-2
VJ-1604 　 Maintenance Manual 7 Adjustment
7.1 Introduction
This chapter provides information on necessary adjustment items and procedures.
TIP
"8.4 Jigs and Tools" p.8-6
7.2 Adjustment Item

This section describes the adjustment items required in part replacement procedures.
When you adjust or replace any of the maintenance parts listed in "Table 7-1 Adjustment Item List", you must
always adjust the plotout quality using the self-diagnosis function referring to Table 7-1"Adjustment Item
List"(p.7-3).
Table 7-1 Adjustment Item List

Part replaced or Adjustment Adjustment item Reference
adjusted order
Printer head 1 Head rank input (including initial ink "(1) Head Rank"
charge) p.5-50
"5.6 Ink Charging
Menu" p.5-22
2 Head nozzle check "5.7.1 Head Nozzle
Check Menu" p.5-25
3 Head slant check "5.7.3 Head Slant
Check Menu" p.5-28
"7.7 Head
Accuracy
Adjustment" p.7-30
4 Uni-D / Bi-D Low Adjustment "5.7.5 Uni-D/Bi-D
Uni-D / Bi-D High Adjustment Low/High
Adjustment" p.5-33
5 Test printing "5.7.7 Test
Printing Menu" p.5-39
6 Reset of head unit life counter "5.11.1 Parameter
Initialization Menu"
p.5-47
7-3 Rev.-00
Table 7-1 Adjustment Item List(Continued)

adjusted order
Main board 1 Parameter backup "7.3.1 Parameter
assembly Backup" p.7-7
2 Firmware installation "7.3.5 Firmware
Installation" p.7-12
3 Head rank input (no need for initial ink "(1) Head Rank"
charge) p.5-50
Check Menu" p.5-25
Adjustment" p.5-33
6 Side margin adjustment "5.7.6 Side Margin
Adjustment Menu"
p.5-38
7 P_EDGE sensor sensitivity adjustment "7.9 P_EDGE
Sensor Sensitivity
Adjustment" p.7-36
CR motor assembly 1 CR belt tension adjustment "7.6 CR Speed
Reduction Belt
Tension Adjustment"
p.7-27
Adjustment" p.5-33
Adjustment Menu"
p.5-38
PF motor assembly 1 Side margin adjustment "5.7.6 Side Margin
Adjustment Menu"
p.5-38
2 P_ENC position adjustment "7.5 PF Encoder
Assembly Position
Adjustment" p.7-25
Rev.-00 7-4

adjusted order
P_EDGE sensor 1 P_EDGE sensor sensitivity adjustment "7.9 P_EDGE
assembly Sensor Sensitivity
Adjustment" p.7-36
Adjustment Menu"
p.5-38
PF_ENC assembly 1 PF_ENC assembly mounting position "7.5 PF Encoder
adjustment Assembly Position
Adjustment" p.7-25
2 PF_ENC inspection "5.5.5 Encoder
Menu" p.5-17
Adjustment Menu"
p.5-38
T fence 1 CR encoder inspection "5.5.5 Encoder
Menu" p.5-17
Adjustment" p.5-33
Adjustment Menu"
p.5-38
CR driven pulley 1 CR belt tension adjustment "7.6 CR Speed
Reduction Belt
Tension Adjustment"
p.7-27
Adjustment Menu"
p.5-38
7-5 Rev.-00

adjusted order
Carriage assembly 1 PG height adjustment "7.8 PG Height
Adjustment" p.7-34
2 CR belt tension adjustment "7.6 CR Speed
Reduction Belt
Tension Adjustment"
p.7-27
3 CR encoder inspection "5.5.5 Encoder
Menu" p.5-17
4 P_EDGE sensor adjustment "7.9 P_EDGE
Sensor Sensitivity
Adjustment" p.7-36
5 Sequential printing endurance operation "5.13.4 Print Head
check Endurance (Nozzle
Print) Menu" p.5-60
6 Head rank input "(1) Head Rank"
p.5-50
"5.13.4 Print Head
Endurance (Nozzle
Print) Menu" p.5-60
Adjustment Menu"
p.5-38
Check Menu" p.5-25
9 Head slant check "5.7.3 Head Slant
Check Menu" p.5-28
Adjustment" p.5-33
Rev.-00 7-6
7.3 Working with Dedicated Network Software

On this plotter, adjustment parameters can be downloaded and installed, also, the firmware can be installed
via network by using dedicated software. In case of MAIN board replacement, work in the following order.
1. Setting up working environment: "7.3.3 Required Environment" p.7-8

2. Receiving parameters: "7.3.4 Receiving Parameters" p.7-11
3. Replacing MAIN board: "4.4.7 Replacing MAIN Board" p.4-49
4. Transferring firmware to plotter: "(1) Firmware Transfer" p.7-12
5. Confirming completion of installation to plotter: "(2) Confirming Completion of Installation to
Plotter" p.7-14
6. Sending parameters: "7.3.6 Sending Parameters" p.7-16
7.3.1 Parameter Backup

The NVRAM (Flash-ROM) installed on the MAIN board assembly stores various parameters for the system
operation.
The available backup parameters are as follows.
• . Panel setting parameters
• . Mechanism adjustment parameters
• . Main board-unique adjustment parameters
TIP
The MAIN board-unique adjustment parameters cannot be erased or modified.
If the MAIN board assembly is found to need replacement during maintenance operations, make sure to back
up the parameters. The backup data can be used to restore the original system status, omitting some
adjustment steps.
7.3.2 Jigs and Tools

The following jigs and tools are required for parameter backup.
• Windows PC:
• CPU: Pentium 400MHz or higher, Installed memory: 128MB or more
• With one of the following installed: Windows 98 / Windows 98 SE / Windows Me / Windows 2000 /
Windows XP
• Equipped with network port (RJ-45) (10M/100M Ethernet interface)
• With dedicated network software (MUTOH Maintenance Engineer Assistant) installed
• Network crossover cable (For hub connection, network straight cable)
7-7 Rev.-00
7.3.3 Required Environment

Before starting work, set up the following environment.
(1) Dedicated Network Software Startup and Plotter IP Address Check

Once "MUTOH Maintenance Engineer Assistant" is started, there is no need to exit it until a series of
processes completes.
1. Start "Mutoh Maintenance Engineer Assistant" from the shortcut on the desk top.
CAUTION
Never provide "MUTOH Maintenance Engineer Assistant" to users because the software
enables upload of plotter internal parameters to PCs.
2. From [Setup] menu, select [Option] and check if

the displayed address matches the plotter IP
address. The default plotter IP address is
"192.168.1.253". Then, click [OK].
NOTE
For the IP address, use the default value as much as possible. If you want to use other IP address,
consult with the network administrator of the network to be connected.
Rev.-00 7-8
(2) PC IP Address Setting

To set up on Windows XP with the default IP address on the plotter, follow the steps below.
1. From [Control Panel], open [Network Connections].

2. Right-click [Local Area Connection] and select [Properties].
3. Double-click [Internet Protocol

(TCP/IP)].
4. In [IP address], input

any value of
"192.168.1.1" to
192.168.1.252" or
"192.168.1.254".
Any numerical value between 1 and 252,

or 254.
7-9 Rev.-00
5. Click [OK] to finish the setting.
CAUTION
When the plotter and PC are not directly connected with crossover cable but connected via
hub, the IP address needs to be different from that of devices on the network to be
connected. To connect via hub, consult with the network administrator.
(3) Starting Board Manager Mode

1. Connect the plotter network port and PC network port with a network cable.
NOTE
When connecting the plotter and PC on a one-to-one basis, use a "crossover cable". When connecting
the plotter and PC via hub, use a "straight cable".
2. When the plotter is in the operation status or in

the menu display status, press [Power] key to
turn the plotter off.
3. While holding down [Back] key in the operation
panel, press [Power] key.
The LCD displays “Board Manager Mode”. If
[Back] key is released, the display turns to
“Waiting for command”.
NOTE
If "waiting for command" is not displayed, follow the steps below.
If IP address that is not default is displayed on the board, releasing [Back] key will display
[IP192.168.xxx.xxx] (depending on the set address) on the LCD. In this case, display either of the
default IP (IP 192.168.001.253) or the set IP address using [+] key and [-] key, and press [Enter].
Then, “Waiting for command” will be displayed.
Rev.-00 7-10
7.3.4 Receiving Parameters

This section describes the procedure to record backup parameters to the PC from the existing MAIN board
assembly. To download backup parameters, follow the steps below.
1. Click [Parameter Receive].
2. In the "Parameter receive check" window, click

[OK]. Installation will start.
3. In the "Receive completed" window, click [OK].

"Save of receive parameter file" window opens.
4. Confirm the location to save and click [Save] to

determine it.
7-11 Rev.-00
7.3.5 Firmware Installation

This section describes the procedure to install the firmware.
The NVRAM (Flash-ROM) on the MAIN board assembly stores the programs (firmware) that control the
machine operations.
When performing the following maintenance works, always install the firmware.
• Replacing the MAIN board assembly

• Updating the firmware
CAUTION
• Installing wrong firmware may disable plotter startup. In this case, reinstallation with
special jig is required. Pay careful attention to the transferred file types.
(1) Firmware Transfer

The following explains the procedure to transfer firmware.
Follow the steps below.
NOTE
When connecting the plotter and PC on a one-to-one basis, use "crossover cable". When connecting
the plotter and PC via hub, use "straight cable".
TIP
The extension of the firmware file is “.jfl”.
1. Click [Firmware Install].

The "Select of installation file" window is
displayed.
Rev.-00 7-12
2. Select a file to be transferred from the folder

where the firmware is saved, and click [Open].
3. In the "Firm installation check" window, click

[OK].
Installation will start.
4. If the "Transfer completed" window opens, click

[OK] to close the window.
CAUTION
Even after the "Transfer completed" window is closed, program installation to the plotter is
not completed. Never power off the plotter during the operation.
7-13 Rev.-00
(2) Confirming Completion of Installation to Plotter

Program installation to plotter continues even after the "Transfer completed" window is closed. Check
whether the program is properly installed from the operation panel.
1. When firmware transfer starts, the LCD display

on the plotter’s operation control panel changes
to [Program receiving].
The Data LED flashes.
㧼㨞㨛㨓㨞㨍㨙‫ޓ‬㨞㨑㨏㨑㨕㨢㨑㨕㨚㨓
2. The LCD display changes as follows:
Erasing ×× (×× is numeric)

Copying ×× (×× is numeric)
Comparing ×× (×× is numeric)
㧱㨞㨍㨟㨕㨚㨓‫ޓ‬㧜㧝
CAUTION
While the LCD display is in the Erasing to Comparing status, the power key is disabled. In
this situation, never disconnect the plug of the plotter. Doing so may disable plotter startup,
which will require reinstallation with special jig.
Rev.-00 7-14
3. If the LCD displays [transfer complete], the

buzzer sounds three times and only the Power
LED turns on among all LEDs.
㨠㨞㨍㨚㨟㨒㨑㨞‫ޓ‬㨏㨛㨙㨜㨘㨑㨠㨑
4. When [×××××× bytes recv (×× is numeric)] is

displayed, installation completes.
Turn off the plotter and restart it. Then check the
version number displayed on the LCD.
㨠㨞㨍㨚㨟㨒㨑㨞‫ޓ‬㨏㨛㨙㨜㨘㨑㨠㨑
NOTE
If an error occurs during installation, the buzzer sounds at intervals of 0.25 second, while the LCD
displays error message and all LEDs of Roll, Sheet, Color and Black & white flash. In this case,
follow the troubleshooting instructions. To stop the buzzer, press any key except for the power key
once. Pressing the key once again will return the LCD display to “waiting for command” and only
the Power LED on.
7-15 Rev.-00
7.3.6 Sending Parameters
NOTE
Before sending parameters, perform the following work.
• Receiving parameters: "7.3.4 Receiving Parameters" p.7-11
• Firmware installation: "7.3.5 Firmware Installation" p.7-12
TIP
The extension of the firmware file is .jfl.
1. Click [Parameter Send].
2. When the "Select of send parameter file" window

opens, select the parameter file to be transferred
and click [Open].
3. In the "Parameter Send check" window, click

[OK].
Sending will start.
Rev.-00 7-16
4. When sending completes and the "Send

completed" window opens, click [OK].
NOTE
Almost as soon as the "Send completed" window is displayed, writing to plotter also finishes. If
writing to plotter finishes successfully, the LCD displays the following:
Transfer complete
Buzzer sounds three times and only Power LED turns on. Then, when the LCD displays
16372 bytes recv
parameter writing completes.
7.3.7 Sub Controller Installation

This section describes installation procedures of HEATER_CONT board firmware.
TIP
The extension of the sub controller file is .mfl.
1. Click [Sub Controller Install].
7-17 Rev.-00
2. When the "Select of File to Install" window

opens, select the file to be installed and click
[Open].
3. In the "Sub Controller Install Confirm" window,

click [OK].
Sending will start.
4. When sending completes and the "Send

completed" window opens, click [OK].
5. When starting sub controller firmware

installation, LCD display on the plotter control
panel changes to [Subprogram receiving].
㧿㨡㨎㧼㨞㨛㨓㨞㨍㨙‫ޓ‬㨞㨑㨏㨑㨕㨢㨕㨚㨓
Rev.-00 7-18
6. When starting boot record installation on sub

controller board, LCD display on the plotter
control panel changes to [Sending boot code xx].
㧿㨑㨚㨐㨕㨚㨓‫ޓ‬㨎㨛㨛㨠‫ޓ‬㨏㨛㨐㨑‫ޓ‬㨤㨤
7. When starting system record installation on sub

controller board, LCD display on the plotter
control panel changes to [Sending sys code xx].
This process takes several minutes to complete.
㧿㨑㨚㨐㨕㨚㨓‫ޓ‬㨟㨥㨟‫ޓ‬㨏㨛㨐㨑‫ޓ‬㨤㨤
8. When completing sub controller firmware

s
installation, LCD display on the plotter control

panel changes to [Transfer complete].
Buzzer sounds three times.
㨀㨞㨍㨚㨟㨒㨑㨞‫ޓ‬㨏㨛㨙㨜㨘㨑㨠㨑
7-19 Rev.-00
9. When [xxxxxx bytes recv (xx is numerical

value)] is displayed, installation is completed.
Pressing any key goes back to [Waiting for
command] status.
㨤㨤㨤㨤㨤㨤‫ޓ‬㨎㨥㨠㨑㨟‫ޓ‬㨞㨑㨏㨢
7.3.8 RTC Date & Time Setting

* Normally, this function is not used because this setting should be made in the “Time setting“ of the self-
diagnosis function.
"5.10 Time Setting" p.5-46
This section describe the procedure to transfer time setting on a PC to the RTC (Real Time Clock) on the
MAIN board.
1. Click [Date & Time Install].
2. When the "Date & time installation check"

window opens, click [OK].
Installing will start.
Rev.-00 7-20
3. When installing completes and the "Install

completed" window opens, confirm that the
installed date is correct, and click [OK].
7-21 Rev.-00
7.4 Steel Belt Tension Adjustment

This section describes the procedure to adjust the tension of the steel belt.
When you have removed and installed the steel belt, always adjust the steel belt tension.

The jigs and tools required for steel belt tension adjustment are as follows.
• Tension gauge: for measuring Max. 2N (204gf)

• Adhesive material
TIP
Refer to"8.4 Jigs and Tools" p.8-6 for the details of jigs and tools required for this work.
7.4.2 Adjustment Procedure

To adjust the steel belt tension, follow the steps below.

3. Press the tension gauge at the center position of the steel belt.
2 3
No. Part name

1 Steel belt
2 Tension gauge
3 Y tension attachment
Rev.-00 7-22
TIP
• The steel belt tension specification is 0.98N ± 0.09N (100gf ± 10gf).
• The range where the steel belt moves up and down in the pulley is 1 mm or less.
4. If the tension of the steel belt does not agree to the specification, adjust the tension with a steel belt tension
screw.
No. Part name

1 Steel belt
2 Steel belt tension screw
CAUTION
Adjust the steel belt so that the steel belt is equally balanced. If not, the steel belt may be cut.
7-23 Rev.-00
No. Part name

1 Adhesive material applying surface
6. Close all the covers.
Rev.-00 7-24
7.5 PF Encoder Assembly Position Adjustment

This section describes the procedure to adjust the PF encoder assembly.
After replacing the PF encoder, adjust the PF encoder position.

To adjust PF encoder, follow the steps below.

2. Loosen the screws that retain PF encoder.
3. Align the PF encoder assembly so that the corner covers the periphery of the PF encoder scale, then retain
the PF encoder assembly with screws.
NOTE
Align the PF encoder so that the encoder scale slit periphery came very close to the corners of the PF
encoder.
PF encorder scale
come very close to
this point.
PF encorder scale
PF encorder
4. Attach the slit guide to the PF encoder assembly.

No. Part name
1 Slit guide
2 Scale
3 PF scale assembly
7-25 Rev.-00
5. Turn the scale around to check that the scale does not swing toward the speed reduction pulley from the
center of the encoder gap. If it swings, adjust the PF encoder assembly position again.
NOTE
There is no problem even if the scale hits the slit guide when turned around.
6. Close the side maintenance cover L.
Rev.-00 7-26
7.6 CR Speed Reduction Belt Tension Adjustment

This section describes the procedure to adjust the tension of the CR speed reduction belt.
When you have removed and installed the CR speed reduction belt, adjust the CR speed reduction belt
tension.

The jigs and tools required for CR speed reduction belt tension adjustment are as follows.
• Tension gauge: for measuring Max. 40N (4080gf)

7.6.2 Adjustment Procedures

3. Remove the panel to conversion board tape wire from the flat cramps (2 pieces) on the back of the
cartridge cover stay.
4 1
No. Part name

1 CR motor assembly
2 Cartridge cover stay
3 Panel to conversion board tape wire
4 Flat cramp
7-27 Rev.-00
4. Remove the screws (3 pieces) that retain cartridge cover stay R.
Upper 3 2 Lower
1 2 3
No. Part name

1 CR motor assembly
2 Cartridge cover stay R
3 Screws that retain cartridge cover stay R
(pan-head screw with spring washer and flat washer
M4 × 8)
5. Remove the cartridge cover stay R.

6. Loosen the hexagon bolts (4 pieces) that retain CR motor mounting plate.
1 3
2 2
No. Part name

1 CR motor assembly
2 Cartridge cover stay R
3 Screws that retain cartridge cover stay R
(pan-head screw with spring washer and flat washer
M4 × 8)
Rev.-00 7-28
7. Mount a tension gauge to CR motor mounting plate.
3 Enlarged view 3
1 1 2
No. Part name

1 Tension gauge
2 CR motor mounting plate
3 CR motor assembly
8. Pull the tension gauge in a direction perpendicular to CR motor assembly so that the tension of the CR
speed reduction belt equals the specification.
TIP
The tension specification of the CR speed reduction belt is 34.32N ± 3.42N (3,500gf ± 350gf).
9. Tighten the hexagon bolts (4 pieces) that retain the CR motor mounting plate.
10. Continue adjusting until the tension of the CR speed reduction belt equals the specification.
11. Remove the tension gauge from the CR motor mounting plate.
7-29 Rev.-00
7.7 Head Accuracy Adjustment

This section describes the procedure to adjust the head slant.
When you have removed and installed the head assembly, such as head assembly replacement, always adjust
the head slant following the steps below.
7.7.1 Head Alignment (Horizontal Height)

This section describes the procedure to adjust the head slant in horizontal direction.
When you have removed and installed the head assembly, such as for head assembly replacement, always
adjust the head slant and depth following the steps below.
NOTE
Before starting adjustment, remove the following parts.
• CR cover: "4.8.2 Removing CR Board Cover" p.4-106
• Adjust the horizontal height of the head alignment before adjusting the vertical alignment slant of
head alignment.
• In this procedure, align the print head in the direction shown below.
Print head
1. Start the plotter in the self-diagnosis function mode and print the adjustment patterns in "Head Slant:
Slant 1".
"5.7.3 Head Slant Check Menu" p.5-28
Rev.-00 7-30
2. Make adjustment based on the printed adjustment patterns.
5mm B
A
20mm
5mm
C D E
• A: Check the slant at this point

• B: Media feed direction
• C: OK
• D: Move the head adjusting cam upward
• E: Move the head adjusting cam downward
3. Move the head adjusting cam lever to adjust head slant.
No. Part name

1 Head adjusting cam
1 2 Head mounting plate
7-31 Rev.-00
7.7.2 Head Alignment (Vertical Slant)

This section describes the procedure to adjust the head slant in vertical direction.
After operation such as head assembly replacement, adjust the head slant according to the steps below.
NOTE
• Before starting adjustment, remove the following parts.
CR cover: "4.8.3 Replacing CR Board Assembly" p.4-106
• Before aligning print head in vertical direction, perform the alignment in horizontal direction.
"7.7.1 Head Alignment (Horizontal Height)" p.7-30
In this procedure, align the print head in the direction shown below.
Print head
1. Start the plotter in the self-diagnosis function mode and select "Head Slant: Slant 2".
"5.7.3 Head Slant Check Menu" p.5-28
Rev.-00 7-32
2. Make adjustment based on the printed adjustment patterns.
4-B 4-A 3-B 3-A 2-B 2-A 1-B 1-A
CCW
4-B 4-A 3-B 3-A 2-B 2-A 1-B 1-A
B CW
C D E
A: Check the point to check the vertical slant angle.

C: OK
D: Move the vertical-slant adjusting tab to the right.
E: Move the vertical-slant adjusting tab to the left.
7-33 Rev.-00
3. Loosen the head base mounting plate screw and move the head base mounting plate up and down to adjust
the head vertical angle.
No. Part name

1 Head base mounting plate
2 Head base mounting plate screw
7.8 PG Height Adjustment

This section describes the procedure to adjust the carriage height (distance between carriage and platen).

The following jigs and tools are required for carriage height adjustment.
• PG height check jig
TIP

To make adjustment, follow the steps below.

2. Unlock the head lock.
Rev.-00 7-34
3. Place the PG height check jig on the platen.
NOTE
Place the PG height check jig where print heads pass over the jig when moving the carriage.
No. Part name

1 PG height check jig
4. Move the carriage from the origin side with the lever “ON“.
5. Check if the carriage passes over the 1.37mm part of the PG height check jig, but not over the 1.42 mm
part.
2 Enlarged view 2
L R
1.42mm
1.37mm
3 1 1
No. Part name

1 PG height check jig
2 Print head
3 Platen
6. Reverse the jig and move the carriage from the opposite side of the jig.
7-35 Rev.-00
7. If the carriage passes over the 1.42mm part of the PG height check jig, loosen the screws (2 pieces on
each side) on the left and right side of the carriage that retain the head UD collar to lower the PG.
1 2 2 3
No. Part name

1 Head UD collar
2 Screws that retain the head UD collar (pan-head
screw with spring washer and flat washer M3 x 8)
3 Carriage
8. Loosen ths screws (2 pieces on each side) that retain the head UD collar to fix the height of the head.
9. Move the carriage back to the origin.
7.9 P_EDGE Sensor Sensitivity Adjustment

This section describes the procedure to adjust the P_EDGE sensor sensitivity.
When you have removed and installed the P_EDGE sensor or the MAIN board assembly, adjust the P_EDGE
sensor sensitivity.
NOTE
• When you adjust the P_EDGE sensor sensitivity, note the following;
• Any ambient light, such as sun light or room light, does not interfere with the sensor.
• Keep the media holding lever down so that the media is stable on the sensor during adjustment.
If media is not securely held, the sensor detection accuracy may be decreased.
• Use non-conductive screwdriver when operating the trimmer on the MAIN board assembly.
If a conductive screwdriver contacts with electronic component on the MAIN board or frame,
it may cause a short-circuit.
Rev.-00 7-36

The following jigs and tools are required for P_EDGE sensor sensitivity adjustment.
• Test media: MF-3G (A4)
TIP

To adjust the P_EDGE sensor, follow the steps below.
TIP
The adjustment parameters are as follows;
• HIGH level (with media): 216 to 226
• LOW level (without media): 0 to 80
1. Remove the board box cover.

NOTE
Start the self-diagnosis function before setting the test media. Otherwise, the suction fan does not
rotate and you cannot get correct setting value.
2. Start the system in self-diagnosis function mode.

"5.2.2 Starting Up" p.5-4
3. Select "Check 2: Test" from the self-diagnosis menu.
4. After confirming that the “Check 2: Test“ is displayed in the operation panel, set the test media on the
media base position and down the media hold lever to confirm that the suction fan starts rotating.
NOTE
The suction fan will not rotate if the [Enter] key is pressed before setting the test media. Make sure
to press the [Enter] key after setting the test media.
5. Select "Test 4: Sensor" from the inspection menu.

6. Select "Sen 8: EdgeAD" from the sensor menu.
7. Move the carriage to the center of the test media.
7-37 Rev.-00
8. Adjust the P_EDGE sensor adjusting volumes as shown below so that the value displayed in the operation
panel becomes between 216 and 226.
Counterclockwise: Sensitivity increases
Clockwise: Sensitivity decreases
• Trimmer R361: Rough adjustment
• Trimmer R365: Fine adjustment
Enlarged view
2 1
No. Part name

1 Trimmer R361
2 Trimmer R365
9. Move the carriage and adjust the P_EDGE sensor adjusting volumes so that the value displayed in the
operation panel becomes between 216 and 226.
10. Move the carriage so that the P_EDGE sensor is moved from the media setting position to the non
reflective tape area.
No. Part name

1 Platen
2 Non reflective tape
11. Check that the value displayed in the operation panel is "80" or less.
12. Move the carriage back to the origin.
Rev.-00 7-38
VJ-1604 　 Maintenance Manual 8 Maintenance
8 Maintenance
8.1 Introduction ............................................................................................. 8- 2
8.2 Periodical Services ................................................................................. 8- 3
8.3 Part Life Information............................................................................... 8- 4
8.4 Jigs and Tools......................................................................................... 8- 6
8.4.1 Required Tools............................................................................... 8-6
8.5 Lubrication/Bonding............................................................................... 8- 7
8.6 Transportation of Plotter...................................................................... 8- 10
8-1 Rev.-00
8 Maintenance VJ-1604 　 Maintenance Manual
8.1 Introduction
This chapter provides information about the periodical services, part life, lubrication/bonding, and transport.
WARNING
Before starting any maintenance work, always perform the following operations.
• Turn the printer power OFF.
• Remove the power cable from the power outlet.
Not doing so may cause electric shock or damage to the electric circuit.
• Unplug the cables connected to the printer.
Failure to do so could result in damage to the printer.
CAUTION
• Make sure there is sufficient space around the printer when performing maintenance
work.
• When servicing the machinery inside with some covers removed, pay special attention
not to be injured by the driving mechanisms.
• Maintenance must be done by more than two person for the following work.
• When disassembling or reassembling the printer and the optional stand
• When packing the printer for transportation
Rev.-00 8-2
8.2 Periodical Services

This section describes the periodical services required for this printer.
The periodical services ensures stable plotting quality of the printer.
Perform periodical inspections according to Table 8-1"Periodical Inspection Part List"(p.3) and perform
cleaning and part replacement as necessary.
TIP
• Operation manual
• Separate sheet “Exploded view” P.2-P.10
Table 8-1 Periodical Inspection Part List
Part Timing Check point Action

Media guide F Several times per • Media dust Clean it.
Platen front surface year accumulation
• Foreign objects If ink deposits are
• Damages present, remove them
with a dampened cloth
and wipe the area with a
clean dry cloth.
Timing fence Several times per • Media dust Clean it.

(CR encoder detection year accumulation
slit plate) • Foreign objects If any damages are found,
• Damages replace the part.
P_REAR sensor front Several times per • Media dust Clean it.
surface year accumulation
• Foreign objects
Cleaner head Several times per • Ink deposits Clean it.
(Cleaning wiper) year • Damages
Pressure roller Several times per • Ink deposits Clean it.
year • Damages
8-3 Rev.-00
8.3 Part Life Information

This section shows how to check the life of the service parts.
To know the life of the service parts, check the maintenance counter from the counter display menu in the
maintenance mode.
TIP
"6.3.1 Counter Display Menu" p.6-3
Part life information of this printer is shown in the table below.
Table 8-2 List of Parts Life Expectancy

Part Life expectancy Warning How to Replacement References
display restore parts
Cleaning unit 9,000 sheets *1 - Counter • Ink system "4.9.2
(Warning at 3,000 clear • Cleaner head Replacing
times of wiping) (Cleaning Cleaner
wiper) Head" p.4-121
• Flushing box "4.6.12
• Absorber Replacing
under the Flushing
maintenance Absorber"
base absorber p.4-82
CR motor Approx. 20,000 Check Life Counter At the first "4.7.2
sheets [CR motor] clear warning: Replacing CR
(4600,000 passes • CR motor Motor
*2) • CR Driven Assembly"
pulley p.4-87
(Check the ink "4.7.6
tube and the CR Replacing CR
cable.) Driven
At the next Pulley" p.4-96
warning: "4.7.10
• CR cable Replacing Ink
besides above Tube" p.4-102
"4.7.8
Replacing CR
Tape Wire"
p.4-99
PF motor Counted only, not Counter Replace as "4.6.2
displayed clear necessary Replacing PF
Motor
Assembly"
p.4-61
Rev.-00 8-4
Table 8-2 List of Parts Life Expectancy (Continued)

Part Life expectancy Warning How to Replacement References
display restore parts
Print head 6 billion dots Check Life Replace as "4.8.9
[Head] necessary Replacing
Print Head"
p.4-114
Pump 182,000 times Check Life Counter Replace as "4.9.3
[Pump] clear necessary Replacing
Maintenance
Assembly"
p.4-122
*1 Plotting on A1 sheet at 5% print ratio

*2 Continuous plotting on A0 sheet with “Plain Paper /Image /Speed-Mode”
8-5 Rev.-00
8.4 Jigs and Tools

This section provides lists of jigs and tools required for service operations.
8.4.1 Required Tools
(1) Tools for Part Replacement

Table 8-3 Tools for Part Replacement
No. Name Part number Remarks
1 Phillips driver No.2 Generic product More than 250mm shaft length is
recommended
2 Phillips driver No.2 Generic product Less than 50mm shaft length is
recommended
3 Phillips driver No.1 Generic product
4 Flat-head driver Generic product For replacing E rings
5 Box driver Generic product For replacing CR board assemblies
6 Ratchet Generic product
7 Long-nose pliers Generic product
8 Tweezers Generic product
9 Hex wrench (opposite side: 1.5 Generic product
to 6mm)
10 E ring holder (E-2.5) Generic product Name: JIS E-2.5
Manufacturer: Iwata Denko Co., Ltd
11 E ring holder (E-5) Generic product Name: JIS E-5
Manufacturer: Iwata Denko Co., Ltd
12 Penlight Generic product
13 C ring pliers Generic product For replacing take-up flange assemblies
(2) Tools for Adjustment

Table 8-4 Tools for Adjustment
1 Personal computer Generic product Printer port mounted
2 Cross cable Generic product For installing firmware
3 Tension gauge Generic product Max. 4,080gf (40N) for measurement
Manufacturer: Ohba Keiki Seisakusho Co.,
Ltd.
4 Tension gauge Generic product Max. 204gf (2N) for measurement
Manufacturer: Ohba Keiki Seisakusho Co.,
Ltd.
Rev.-00 8-6
Table 8-4 Tools for Adjustment (Continued)

5 Straight scale (100mm) Generic product
6 MF-3G Exclusive use media For P_EDGE sensor, for print accuracy
adjustment
7 PG height check tool (64) JD-42796
8.5 Lubrication/Bonding
This section covers the lubrication/bonding information.
After disassembling/assembling this plotter, always perform necessary lubrication/bonding according to
"Table 8-5 Lubricant List" p.8-7.
CAUTION
Only use specified lubricants and greases. The use of unauthorized lubricants and greases
may damage the components and shorten the plotter life.
Table 8-5 Lubricant List
Parts Item Manufacturer Type

PF drive section Up/down gear Apply to gear Kanto Kasei Co., FLOIL G-MK-1
on pressure Ltd.
lever
PF motor Apply to middle Kanto Kasei Co., FLOIL G-MK-1
bracket / gear inner diameter Ltd.
Middle gear
inner diameter
Speed Apply to drive Kanto Kasei Co., FLOIL G-MK-1
reduction pulley Ltd.
pulley
Medium tray Apply to the areas Kanto Kasei Co., FLOIL G-MK-1
slide, Grit the plates contact Ltd.
medium tray each other.
8-7 Rev.-00
Table 8-5 Lubricant List (Continued)

CR drive Y rail Apply to the hole Kanto Kasei Co., FLOIL G-MK-1
section machining securing Y drive Ltd.
diagram base.
Apply to the hole Kanto Kasei Co., FLOIL G-MK-1
securing the return Ltd.
pulley bracket.
Y rail and While inserting Kanto Kasei Co., FLOIL G-MK-1
roller guide roller guide, apply Ltd.
to the downside of
the roller guide.
Pressure shaft Apply to the upside Kanto Kasei Co., FLOIL G-MK-1
bearing and the shaft Ltd.
insertion part.
Pressure cam Apply to cam part. Kanto Kasei Co., FLOIL G-MK-1
Ltd.
Roller guide Apply to the front Mitsubishi Super multi-dia
surface of roller tetrat No.32
guide.
Drive pulley Apply to drive Kanto Kasei Co., FLOIL G-MK-1
pulley. Ltd.
Cursor section Head U/D Apply to head U/D Kanto Kasei Co., FLOIL G-MK-1
collar collar. Ltd.
Head U/D cam Apply to head U/D Kanto Kasei Co., FLOIL G-MK-1
cam. Ltd.
Slide gear Apply to gear. Kanto Kasei Co., FLOIL G-MK-1
Ltd.
Head base Head bracket Apply to the Kanto Kasei Co., FLOIL G-MK-1
section position of the Ltd.
screw hole securing
shoulder screw.
Head slide Apply to the part Kanto Kasei Co., FLOIL G-MK-1
base contacting with the Ltd.
CR cursor.
Rev.-00 8-8
Table 8-6 Adhesive List

PF drive section Set screw Apply screw- Three Bond Co., 1401
locking agent to Ltd.
the coupling set
screw.
CR drive section CR driven After adjusting Three Bond Co., 1401
pulley steel belt, apply Ltd.
adjusting screw-locking
screw agent.
Others Screw Apply to the area Three Bond Co., 1401
screw-locking Ltd.
agent is applied.
Table 8-7 Tape List

Others The areas Attach acetate Not specified
sharpened edge tapes to the tape
is likely to wires or harnesses
emerge where sharpened
edge is likely to
emerge.
8-9 Rev.-00
8.6 Transportation of Plotter

This section describes how to transport the plotter.
Before transporting the plotter, you must package it in the same manner as it was delivered using protective
materials and packaging materials so that the plotter will not be subject to excessive impact and vibrations
during the transportation.
Follow the steps below to package the plotter.
(1) Task Before Transportation

1. Start the Self-Diagnosis Mode.
"5.2.2 Starting Up" p.5-4
2. Start the Head Cleaning Menu 2.
3. Discharge ink of all heads.
4. Remove all ink cartridges.
5. Install the cleaning jigs.
6. Fill shipping liquid.
7. Remove the cleaning jigs.
8. Turn the plotter power off.
9. Remove all cables including the power cable.
10. Treat the waste fluid.
11. Fit the plotter with protective materials.
12. Package the plotter.
TIP
Operation manual
(2) Task After Transportation

1. Unpack, assemble, and install the plotter.
2. Make the plotter ready for operation.
Rev.-00 8-10
VJ-1604 　 Maintenance Manual 9 Troubleshooting
9 Troubleshooting
9.1 Introduction ............................................................................................. 9- 2
9.2 Troubleshooting with Error Messages ................................................. 9- 2
9.2.1 Operation Status ............................................................................ 9-3
9.2.2 Errors with Message ...................................................................... 9-5
9.2.3 Data Errors................................................................................... 9-12
9.2.4 Command Errors.......................................................................... 9-14
9.2.5 Errors Requiring Reboot .............................................................. 9-15
9.2.6 Error Messages During File Transmission................................... 9-29
9.3 Troubleshooting Without Error Messages ......................................... 9- 34
9.3.1 Initial Operation Problems............................................................ 9-34
9.3.2 Media Feed Problems.................................................................. 9-44
9.3.3 Printing Problems......................................................................... 9-46
9.3.4 Noise Problems............................................................................ 9-65
9.3.5 Online Function Problems............................................................ 9-68
9.3.6 Other Problems............................................................................ 9-70
9.3.7 Problems in Using Dedicated Network Software ......................... 9-72
9-1 Rev.-00
9 Troubleshooting VJ-1604 　 Maintenance Manual
9.1 Introduction
This chapter provides information on possible causes of machine errors/damage and recovery actions.
If the machine is malfunctioning and an error message is displayed on the operation panel, refer to "9.2
Troubleshooting with Error Messages" p.9-2. If the machine is malfunctioning but no error messages are
displayed, refer to "9.3 Troubleshooting Without Error Messages" p.9-34.
If cause of errors/damage and recovery actions are not found in this chapter, or the machine cannot restore to
normal status, please contact the distributor your purchased the product from or our customer support center.
9.2 Troubleshooting with Error Messages

This section describes the messages displayed in normal operation and upon an error occurrence as well as
how to correct the error.
The available messages are as follows.
Table 9-1 Error Message Type
Priority Message type Contents Reference

1 Operation status Displayed when the machine is operating normally. "9.2.1
Operation
Status" p.9-3
2 Error with Displayed when an abnormal condition occurs "9.2.2
message during normal operation. Errors with
Message" p.9-5
3 Data error Displayed when a data communication error occurs "9.2.3 Data
between PC and the machine. Errors" p.9-12
4 Command error Displayed when an abnormal condition occurs "9.2.4
during analysis of PC commands. Command
Errors" p.9-14
5 Error requiring Displayed when a serious error critical to the "9.2.5
reboot machine operation occurs. Errors
Requiring
Reboot" p.9-15
Rev.-00 9-2
9.2.1 Operation Status

This section describes the message contents, check items, and recovery actions for normal operation.
Table 9-2 Events and Check Items for Operation Status Messages
No. Message Event/ Check item Action Reference
symptom
1 Cover open Front cover is 1. Is cover sensor Tighten cover sensor "4.3.3
open. assembly loose? assembly screws. Replacing
Front Cover
Sensor" p.4-
32
2 Set media Media holding 1. Are front cover R Correctly connect front "4.4.7
lever is turned sensor assembly cover R sensor Replacing
backward. cable and front assembly cable to MAIN
cover L sensor MAIN board assembly Board" p.4-
assembly cable connector J38, and front 49
connected securely? cover L sensor assembly
cable MAIN board
assembly connector J40.
2. Does pressure lever Lubricate pressure cam. "8.5
move smoothly? Lubrication/
Bonding"
p.8-7
3. Is lever sensor Adjust lever sensor "4.6.6
assembly fitted assembly position. Replacing
correctly? Lever Up
Sensor" p.4-
67
4. Is sensor of lever Clean sensor face using "4.6.6
sensor assembly a swab. Replacing
contaminated? Lever Up
Sensor" p.4-
67
5. Is lever sensor Correctly connect lever "4.6.6
cable connected sensor assembly cables Replacing
securely? to MAIN board Lever Up
assembly connector J32. Sensor" p.4-
67
6. Panel unit assembly Replace panel unit "4.3.1
may be damaged. assembly. Replacing
Panel Unit"
p.4-30
7. Panel cable may be Replace panel cable. "4.3.1
damaged. Replacing
Panel Unit"
p.4-30
9-3 Rev.-00
Table 9-2 Events and Check Items for Operation Status Messages(Continued)
symptom
2 8. Check cover sensor Replace cover sensor "4.3.3
assembly operation assembly. Replacing
from "Sen: Cover" Front Cover
of self-diagnosis Sensor" p.4-
function. 32
9. Check lever sensor Replace lever sensor "4.6.6
operation from "Sen assembly. Replacing
7: Lever" of self- Lever Up
diagnosis function. Sensor" p.4-
67
10. Main board Replace MAIN board "4.4.7
assembly may be assembly. Replacing
damaged. MAIN
Board" p.4-
49
3 No media Displayed in 1. Is P_EDGE sensor Securely connect it to "4.8.3
the following assembly cable at CR board assembly Replacing CR
cases: the head section connector J208. Board
• When connected Assembly"
media is correctly? p.4-106
not set
2. Is P_REAR sensor Securely connect it to "4.4.7
assembly under MAIN board assembly Replacing
media guide R connector J42. MAIN
connected Board" p.4-
correctly? 49
3. Check sensor Adjust with MAIN "7.9
sensitivity from board assembly volume P_EDGE
"Sen 8:EdgeAD 3" (R361, R365). Sensor
of self-diagnosis Replace P_EDGE Sensitivity
function. sensor assembly. Adjustment"
p.7-36
4. CR board assembly Replace CR board "4.8.3
may be damaged. assembly. Replacing CR
Board
Assembly"
p.4-106
5. Check presence of When "No media" is "4.6.5
media from "Sen 9: displayed even if media Replacing
PaperRear" of self- is set, replace P_REAR P_REAR
diagnosis function. sensor assembly. Sensor
Assembly"
p.4-65
6. CR cable may be Replace CR cable. "4.7.8
broken. Replacing CR
Tape Wire"
p.4-99
Rev.-00 9-4
Table 9-2 Events and Check Items for Operation Status Messages(Continued)
symptom
3 7. Main board Replace MAIN board "4.4.7
damaged. MAIN
Board" p.4-
49
9.2.2 Errors with Message

This section describes the contents of errors with messages as well as the check items and recovery actions.
These messages are displayed when an abnormal condition occurs while the machine is running.
Upon an occurrence of an error with message, the machine stops its operation at the same time.
The error can be cancelled by removing the error causes. After that, the machine will restart its operation.
Table 9-3 Symptoms and Check Items for Errors with Message
symptom
1 Media Media 1. Is P_EDGE sensor Securely connect it to "4.8.3
detection error detection failed assembly cable at CR board assembly Replacing CR
head connected connector J208. Board
correctly? Assembly"
p.4-106
under media guide MAIN board assembly Replacing
R connected connector J42. MAIN
correctly? Board" p.4-
49
3. Check sensor • Adjust with MAIN "7.9
sensitivity from board assembly P_EDGE
"Sen 8:EdgeAD 3" volume (R361, Sensor
of self-diagnosis R365). Sensitivity
function. • Replace P_EDGE Adjustment"
sensor assembly. p.7-36
4. Is CR cable inserted Reconnect following "4.4.7

obliquely? connectors. Replacing
• Main board MAIN
assembly: J9 - J11 Board" p.4-
• CR board: J201 - 49
J205 "4.8.3
Replacing CR
Board
Assembly"
p.4-106
5. CR cable may be Replace CR cable. "4.7.8
broken. Replacing CR
Tape Wire"
p.4-99
9-5 Rev.-00
Table 9-3 Symptoms and Check Items for Errors with Message(Continued)
symptom
1 6. CR board assembly Replace CR board "4.8.3
Board
Assembly"
p.4-106
media from "Sen displayed even if media Replacing
7:PaperRear" of is set, replace P_REAR P_REAR
self-diagnosis sensor. Sensor
function. Assembly"
p.4-65
damaged. MAIN
Board" p.4-
49
2 Media skew Media is 1. Set media again and If this error is caused by -
error running check reappearance. user's inappropriate
obliquely. media setting, instruct
correct media setting
procedure.
2. Is suction fan - Check connection of "4.6.8
judged as normal following MAIN board Replacing
when checked assembly connectors. Suction Fan"
through "Test 6: • Suction fan 1 cable: p.4-76
Fan" of self- J25
diagnosis function? • Suction fan 2 cable:
J26
• Suction fan 3 cable:
J28
J29
• Replace suction fan
assembly.
• Replace cable of
suction fan that does
not operate
normally.
3. Is shielding material Remount it at specified -
secured at specified position.
position?
4. Check pressure Apply grease (G501) to "8.5
lever operation. pressure cam and make Lubrication/
adjustment. Bonding"
p.8-7
Rev.-00 9-6
symptom
3 Remove media Displayed if 1. Does the same If the message appears, -
lever is raised message appear if refer to the action in
during printing turning machine check item No. 2.
or cutting OFF and turn it ON
media and then again?
lowered
2. Is pressure lever Check that LCD "5.5.4
without
detected as normal monitor displays lever Sensor
removing
when checked status correctly when Menu" p.5-15
media.
through "Sen slowly raising/lowering
7:Lever" of self- pressure lever.
diagnosis function?
3. Check contact of • Reconnect MAIN "4.4.7
lever sensor board assembly Replacing
assembly. connector J30. MAIN
• If LCD displays as Board" p.4-
chattering, sensor 49
may be damaged. "4.6.6
Replace lever Replacing
sensor assembly. Lever Up
Sensor" p.4-
67
assembly under MAIN board assembly Replacing
media guide R connector J42. MAIN
connected Board" p.4-
correctly? 49
media from "Sen displayed even if media Replacing
7:PaperRear" of is set, replace P_REAR P_REAR
self-diagnosis sensor assembly. Sensor
function. Assembly"
p.4-65
damaged. MAIN
Board" p.4-
49
9-7 Rev.-00
symptom
4 [KCMY] Ink is running 1. Check which Remove all cartridges "5.5.4
Ink Near End short. Printing cartridge has no ink and lightly push the Sensor
[KCMY] is possible. from "Ctrl2: black resin lever of ink Menu" p.5-15
Ink End Ink has run out. Sensor" -> "Sen.3: sensor assembly (K, C,
Any printing etc" -> "12: Ink M, Y) to check that the
operation stops END" of self- display of "[KCYM]
immediately. diagnosis function. INK END" changes.
2. Check contact of the Reconnect following "4.4.7
ink sensor connectors. Replacing
assembly. MAIN board: J43 MAIN
HEATER JUNCTION Board" p.4-
board: 49
• Connector J5(K)
• Connector J6(C)
• Connector J7(M)
• Connector J8(Y)
3. For the ink color • If ink color display "4.10.3
that is displayed as changes after Replacing
"Ink Near End" or replacing Ink Cartridge
"Ink End", switch connector: Control
ink sensor assembly Ink sensor assembly Cable" p.4-
connector with that is damaged. 132
of normally Replace ink sensor
displayed ink color. assembly.
• If ink color display
does not change "4.4.7
after replacing Replacing
connector: MAIN
Main board Board" p.4-
assembly may be 49
damaged. Replace
MAIN board
assembly.
Rev.-00 9-8
symptom
5 [KCMY] Cartridge is not 1. Turn machine OFF. If message appears: -
No Cartridge installed. Turn it ON again Refer to action in check
and check if the item No. 2.
same message
appears.
2. Check presence of Remove all cartridges "5.5.4
ink cartridge from and lightly push the Sensor
"Ctrl 2:Sensor" -> switch of ink NOT Menu" p.5-15
"Sen.3: etc" -> sensor assembly (K, C,
"11:Ink NOT" of M, Y) with something
self-diagnosis with a flat tip such as
function. ballpoint pen to check
that the display of
"[KCYM] INK NOT"
changes.
3. Check contact of Reconnect following "4.4.7
ink NOT sensor connectors. Replacing
assembly MAIN board: J43 MAIN
connector. HEATER JUNCTION Board" p.4-
board: 49
• Connector J5(K)
• Connector J6(C)
• Connector J7(M)
• Connector J8(Y)
4. For the ink color If ink color displayed as "4.10.1
that is displayed as "No ink" changes after Replacing
"Little ink" or "No replacing connector: Ink ID Board
ink", switch ink Ink sensor assembly is Assembly"
NOT sensor damaged. Replace ink p.4-125
assembly connector sensor assembly.
with that of
If ink color displayed as "4.4.7
normally displayed
"No ink" does not Replacing
ink color.
change after replacing MAIN
connector: Board" p.4-
Main board assembly 49
may be damaged.
Replace MAIN board
assembly.
9-9 Rev.-00
symptom
6 Insert specified Specified ink 1. Check if the same If the message appears: -
cartridge cartridge is not message appear if Refer to the action in
installed. turning machine check item No. 2.
OFF and turn it ON
again.
2. Check if specified Replace ink cartridge Operation
ink cartridge is with specified one. Manual
used.
3. Check if ink If detection does not "4.10.1
cartridge status operate normally, Replacing
detection operates replace following parts. Ink ID Board
normally from "Ctrl • Ink sensor assembly Assembly"
2: Sensor" -> • Main board p.4-125
"Sen.3:etc" -> "7- assembly "4.4.7
10:[KCMY] Ink • Ink ID sensor Replacing
ID" of self- assembly MAIN
diagnosis function. Board" p.4-
49
4. Check contact of - Reconnect following "4.4.7
ink ID sensor MAIN board assembly Replacing
assembly connectors. MAIN
connector. MAIN board: J43 Board" p.4-
HEATER JUNCTION 49
board:
• Connector J5(K)
• Connector J6(C)
• Connector J7(M)
• Connector J8(Y)
If no change occurs,
proceed to step (5).
Rev.-00 9-10
symptom
6 5. For cartridge that is • If cartridge "4.10.1
displayed as NG in displayed as NG Replacing
"Ctrl 2: Sensor" -> changes: Ink ID Board
"Sen.3: etc" -> "7- Ink ID sensor Assembly"
10:[KCMY] Ink assembly displayed p.4-125
ID" of self- as NG is damaged.
diagnosis function, Replace defective
replace ink ID ink ID sensor
sensor assembly assembly.
connector with that
• If cartridge "4.4.7
of normally
displayed as NG Replacing
displayed cartridge.
does not change, or MAIN
all units are Board" p.4-
displayed as NG: 49
Main board
assembly may be
damaged. Replace
MAIN board
assembly.
7 Warning: Ink Ink tube life 1. Turn machine OFF. If the message appears: -
tube life has almost Turn it ON again Refer to the action in
expired. and check if the check item No. 2.
same message
appears.
2. Use of ink tube has Replace ink tube. "4.7.10
exceeded specified Replacing
level. Ink Tube"
p.4-102
damaged. MAIN
Board" p.4-
49
8 Out of memory Memory is 1. Check RAM size Memory size is 128MB. "5.5.1
DIMM 128MB insufficient for from "Test1:Ram If the displayed value is Memory Size
data analysis/ Capacity" of self- less than the memory Menu" p.5-12
printing. diagnosis function. size of the model, the
Required DIMM may be
memory size is damaged.
displayed. Replace the DIMM.
damaged. MAIN
Board" p.4-
49
9-11 Rev.-00
NOTE
• The square bracket pair in an error message contains the applicable ink color.
• If no ink and no cartridge occur at the same time, no cartridge message has priority to be displayed.
9.2.3 Data Errors

This section describes the message contents of data errors as well as the check items and recovery actions.
These errors are displayed when a communication error occurs between the PC and the machine.
Upon an occurrence of a data error, the machine stops its operation at the same time.
Table 9-4 Symptoms and Check Items for Data Errors

symptom
1 I 15-1 error Online frame 1. Attempt • Contact our
command [ ] error communication customer support
using PC and cable center.
2 I 15-2 error Overrun error
on hand.
command [ ]
3 I 15-3 error Online parity • Replace application
2. Is there any error
command [ ] error driver.
statement in "4.4.7
4 I 05 error Sum check printing data? Replacing
command [ ] error • Obtain printing MAIN
data. Board" p.4-
5 I 07 error ECS parameter 3. Does the symptom
command [ ] remain the same • Contact our 49
even if application customer support
driver is replaced? center.
4. Main board • Replace MAIN

assembly may be board assembly.
defective.
Rev.-00 9-12
Table 9-4 Symptoms and Check Items for Data Errors(Continued)

symptom
6 I 11 error Undefined 1. Attempt • Contact our
command [ ] ESC communication customer support
using PC and cable center.
7 I 12 error Unauthorized
on hand.
command [ ] character ESC
• Replace application
8 I 13 error Numeral driver.
2. Is there any error
command [ ] character ESC
statement in "4.4.7
9 I 14 error Parameter error printing data? Replacing
command [ ] ESC • Obtain printing MAIN
data. Board" p.4-
10 I 16 error Buffer 3. Does the symptom
command [ ] overflow remain the same • Contact our 49
even if application customer support
driver is replaced? center.
4. Main board • Replace MAIN

assembly may be board assembly.
defective.
NOTE
The square bracket pair in a message may contain the applicable command code.
9-13 Rev.-00
9.2.4 Command Errors

This section describes the message contents of command errors as well as the check items and recovery
actions.
These errors are displayed when an abnormal condition is found during analysis of PC command data.
Upon an occurrence of a command error, the machine stops its operation at the same time.
Table 9-5 Symptoms and Check Items for Command Errors

symptom
1 MH 01 Error Undefined 1. Attempt • Contact our "4.4.7
Command [ ] command: communication customer support Replacing
Command using PC and cable center. MAIN
being analyzed on hand. Board" p.4-
is not defined 49
in applicable
command
mode. 2. Is there any error • Replace application
statement in driver
2 MH 02 Error Parameter
Command [ ] error: printing data?
Number of
parameters
following • Obtain printing
3. Does the symptom
command is data.
inappropriate. remain the same
even if application • Contact our
3 MH 03 Error Numeral value driver is replaced? customer support
Command [ ] error: center.
Number of
parameters
following 4. Main board
command is assembly may be • Replace MAIN
inappropriate. defective. board assembly.
4 MH 04 Error Undefined
Command [ ] character set:
Unknown
character set is
present.
5 MH 07 Error Buffer
Command [ ] overflow:
Polygon buffer
or
downloadable
character
buffer
overflows.
Rev.-00 9-14
NOTE
• The square bracket pair in a message may contain the applicable command code.
• For the PC settings, refer to your PC's operation manual.
9.2.5 Errors Requiring Reboot

This section describes the contents of reboot-requiring errors as well as the check items and recovery actions.
These errors are issued when any of the following critical problems occurs.
• Obstacle that prevents the machine's operation
• Damage of electric circuits (boards, motors, sensors)
• Abnormal operation of control programs
When any of the above conditions occurs, the machine follows the steps shown below before stopping its
operation.
1. Turn OFF the driving system power automatically.
2. Flash all lamps in the operation panel and generate intermittent audible alarm.
3. Display the applicable error message on the LCD.
The error can be cancelled by removing the error causes and restarting the machine.
(1) CPU system serious error

Table 9-6 Symptoms and Check Items for CPU System Serious Errors
symptom
1 E 001 error Standard Main board assembly Replace MAIN board "4.4.7
DRAM DRAM error: may be defective. assembly. Replacing
Abnormal MAIN
condition in Board" p.4-
standard 49
memory
mounted on
MAIN board
assembly
9-15 Rev.-00
Table 9-6 Symptoms and Check Items for CPU System Serious Errors (Continued)
symptom
2 E 016 error Interruption 1. Check AC power Contact our customer Operation
CPU Err exception supply and printer support center. Manual
[00] error: surrounding
Abnormal equipment.
condition in
2. Check reappearance
interruption
by turning ON/OFF
process.
the machine power
3 E 016 error Command several times. Make
CPU Err border sure to perform this
[02] exception/TLB check repeatedly
exception (load even if no problems
or command seem to be present.
fetch) error: (Make the same
Abnormal condition as user's.)
condition in
command
border.
Or TLB
exception in
data load or
command
fetch.
4 E 016 error Data border 1. Check serial • Contact our "4.4.7
CPU Err exception/TLB number of the customer support Replacing
[03] exception printer. center. MAIN
(store) error: • Replace MAIN Board" p.4-
2. Main board
Abnormal board assembly. 49
assembly may be
condition in
defective.
data border.
Or TLB
exception in
data storing.
5 E 016 error Address
CPU Err exception error
[04] (load or
command
fetch):
Address error
in command
load or fetch.
6 E 016 error Address
CPU Err exception error
[05] (store):
Address error
in saving
process.
Rev.-00 9-16
symptom
7 E 016 error Address 3. Check serial • Contact our "4.4.7
CPU Err exception error number of the customer support Replacing
[06] (command printer. center. MAIN
fetch): • Replace MAIN Board" p.4-
4. Main board
Address error board assembly. 49
assembly may be
in command
defective.
loading or
storing
8 E 016 error Bus exception 1. Check serial • Contact our "4.4.7
CPU Err error (load or number of the customer support Replacing
[07] store): printer. center. MAIN
Bus error in Board" p.4-
2. Main board
command • Replace MAIN 49
assembly may be
loading or board assembly.
defective.
storing
9 E 016 error System call
CPU Err exception
[08] error:
Abnormal
condition in
system call
10 E 016 error Break point

CPU Err exception
[09] error:
Abnormal
condition in
break point
11 E 016 error Reserved
CPU Err command
[10] exception
error:
Abnormal
condition in
reserved
command
12 E 016 error Coprocessor
CPU Err disabled
[11] exception
error:
Abnormal
condition in
coprocessor
9-17 Rev.-00
symptom
13 E 016 error Arithmetic 1. Check AC power • Contact our
CPU Err overflow supply and printer customer support
[12] exception surrounding center.
error: equipment.
Overflow
2. Check reappearance
occurs
by turning ON/OFF
14 E 016 error Trap exception the machine power
CPU Err error: several times. Make
[13] Trap occurs sure to perform this
check repeatedly
15 E 016 error Floating point
even if no problems
CPU Err exception
seem to be present.
[15] error:
(Make the same
Abnormal
condition as user's.)
condition in
floating point 3. Check serial • Contact our
process number of the customer support
printer. center.
16 E 016 error Watch
"4.4.7
CPU Err exception 4. Main board • Replace MAIN Replacing
[22] error: assembly may be board assembly. MAIN
Abnormal defective. Board" p.4-
condition in
49
watch
17 E 016 error Watchdog
CPU Err time-out
[32] exception
error:
Time-out in
watchdog
18 E 016 error Abort error:
CPU Err Process
[33] aborted
19 E 237 error Transfer
Transfer memory error:
memory Abnormal
condition in
transfer of
analyzed
printer data.
NOTE
For the PC settings, refer to your PC's operation manual.
Rev.-00 9-18
(2) Mechanical Serious Errors

Table 9-7 Symptoms and Check Items for Mechanical Serious Errors
symptom
1 E 065 error Abnormal 1. Check error history - "5.5.7
PF motor condition in PF from "Test 7: History
motor (X-axis) Record" of self- Menu" p.5-18
during printer diagnosis function.
operation.
2. Set the number of
Displayed if "4.4.7
endurance running
the difference Replacing
cycles to 50 or more
between motor MAIN
from "Life 2: PF
command Board" p.4-
Motor" of self-
value and 49
diagnosis function,
feedback from Check connection of
and check if "X
encoder is following MAIN board
motor error" occurs.
large. assembly connectors.
3. Check "Encoder: • PF motor cable
PF" from "Check 2: assembly
Test" -> "Test 5: connector: J20
Encoder" of self- • PF_ENC assembly
diagnosis function. connector: J12
4. Check if Main • If NG, check
Power Board connection of "4.6.2
normally supplies MAIN board Replacing PF
DC24V. assembly Motor
connector: J12. Assembly"
5. PF motor assembly
may be defective. • Replace PF motor p.4-61
assembly.
"4.4.7
6. Main board Replacing
• Replace MAIN
assembly may be MAIN
board assembly.
defective. Board" p.4-
49
9-19 Rev.-00
Table 9-7 Symptoms and Check Items for Mechanical Serious Errors (Continued)
symptom
PF encoder condition in from "Test 7: History
media feed Record" of self- Menu" p.5-18
amount (X- diagnosis function.
axis) during
printer Check connection of "4.4.7
endurance running
operation. following MAIN board Replacing
Displayed if assembly connectors. MAIN
from "Life 2:PF
there is no • PF motor cable Board" p.4-
Motor" of self-
feedback from assembly 49
diagnosis function,
encoder. connector: J20
and check if "X
motor error" occurs. • PF_ENC assembly
connector: J12
3. Check "Encoder:
• If NG, check
PF" from "Check 2:
connection of
Test" -> "Test 5:
MAIN board
Encoder" of self-
assembly
diagnosis function.
connector: J12.
4. Check if Main
Power Board • Replace PF motor "4.6.2
normally supplies assembly. Replacing PF
DC24V. Motor
5. PF motor assembly • Replace MAIN Assembly"
may be defective. board assembly. p.4-61
"4.4.7
49
Rev.-00 9-20
symptom
3 E069 error Time-out 1. Check error history - "5.5.7
PF time-out condition in from "Test 7: History
media feed Record" of self- Menu" p.5-18
amount (X- diagnosis function.
axis) during
printer Check connection of "4.4.7
endurance running
operation. following MAIN board Replacing
Displayed if assembly connectors. MAIN
from "Life 2:PF
pressure roller • PF motor cable Board" p.4-
Motor" of self-
does not reach assembly 49
diagnosis function,
the defined connector: J20
and check if "X
position. • PF_ENC assembly
motor error" occurs.
connector: J12
3. Check "Encoder:
• If NG, check
PF" from "Check 2:
connection of
Test" -> "Test 5:
MAIN board
Encoder" of self-
assembly
diagnosis function.
connector: J12.
4. Check if Main
DC24V. Motor
"4.4.7
49
9-21 Rev.-00
symptom
4 E071 error Overload 1. Check error history - "5.5.7
PF overcurrent condition in PF from "Test 7: History
motor (X-axis) Record" of self- Menu" p.5-18
5 E079 error
during printer diagnosis function.
PF2
operation.
overcurrent 2. Set the number of
Check connection of "4.4.7
endurance running
following MAIN board Replacing
assembly connectors. MAIN
from "Life 2: PF
• PF motor cable Board" p.4-
Motor" of self-
assembly 49
diagnosis function,
connector: J20
and check if "X
motor error" occurs. • PF_ENC assembly
connector: J12
3. Check "Encoder:
• If NG, check
PF" from "Check 2:
connection of
Test" -> "Test 5:
MAIN board
Encoder" of self-
assembly
diagnosis function.
connector: J12.
4. Check if Main
DC24V. Motor
"4.4.7
49
Rev.-00 9-22
symptom
CR motor condition in from "Test 7: History
CR motor (Y- Record" of self- Menu" p.5-18
axis) during diagnosis function.
printer • Clean and lubricate "8.5
2. Move carriage in
operation. CR rail roller guide. Lubrication/
both directions
Displayed if Bonding"
while the printer is • Check connection
the difference of following p.8-7
turned off, and
between motor connectors.
check if there is any
command
position where Main board:
value and "4.4.7
carriage does not • CR motor assembly
feedback from Replacing
move smoothly. connector: J21
encoder is MAIN
large. 3. Set the number of • CR cable connector: Board" p.4-
endurance running J9 - J11 49
7 E 068 error Abnormal
CR encoder condition in cycles to 50 or more CR board:
head travel from "Life 1: CR • CR cable connector:
distance (Y- Motor" of self- J201 - J205
axis) during diagnosis function,
printer and check if "Y
operation. motor error" occurs.
Displayed if
there is no
feedback from
encoder.
9-23 Rev.-00
symptom
8 E 070 error Time-out 4. Check if T fence is • If grease or dust "4.7.4
CR time-out condition in contaminated or collect: Wipe fence Replacing T
head travel worn out. with a dry cloth. Fence" p.4-91
distance (Y- • If ink deposit
axis) during presents: Wipe it off
printer with cloth
operation. dampened with
Displayed if neutral detergent.
carriage does "4.7.4
not reach the • If contamination or Replacing T
defined deposit is too heavy: Fence" p.4-91
position. Replace T fence.
5. Check "Encoder: a) If NG:
9 E 072 error Overload
CR" from "Check 2: Check following cable
CR overcurrent condition in
Test" -> "Test 5: connection. "4.7.4
CR motor (Y-
10 E074 error Encoder" of self- • CR board assembly Replacing T
axis) during
CR2 diagnosis function. connector J207 Fence" p.4-91
printer
overcurrent b) Replace following "4.7.2
operation.
parts. Replacing CR
• T fence Motor
• CR motor assembly Assembly"
• CR board assembly p.4-87
• CR cable "4.8.3
Replacing CR
Board
• Replace MAIN Assembly"
board assembly. p.4-106
"4.7.8
6. Main board Replacing CR
assembly may be Tape Wire"
damaged. p.4-99
"4.4.7
Replacing
MAIN
Board" p.4-
49
Rev.-00 9-24
symptom
11 E 081 error CR_HP 1. Check CR_HP • Check connection "5.5.4
CR origin detection is not sensor from "Sen 1: of CR_HP sensor Sensor
possible. CR Origin" of self- cable assembly Menu" p.5-15
diagnosis function. connector.
2. CR_HP sensor may • Replace CR_HP "4.13.4
be damaged. sensor. Replacing
CR_HP
Sensor, Lever
Sensor" p.4-
150
3. Main board • Replace MAIN "4.4.7
assembly may be board assembly Replacing
damaged. MAIN
Board" p.4-
49
12 E 082 error Abnormal • Wiper sensor 1. Check connection "4.9.2
wiper sensor condition in assembly may be of wiper sensor Replacing
wiper sensor. faulty. connector. Cleaner
• Main board Head" p.4-
2. Replace wiper
assembly may be 121
sensor.
faulty. "4.4.7
3. Replace MAIN Replacing
board assembly. MAIN
Board" p.4-
49
9-25 Rev.-00
symptom
13 E 075 error Abnormal 1. Check connection Reconnect head cable. "4.8.9
head cable condition in of head cable Replacing
head cable or connectors on CR Print Head"
head board assembly side p.4-114
thermistor. and head side. "4.8.3
• Is head cable Replacing CR
inserted obliquely? Board
Assembly"
• Is it locked p.4-106
securely?
2. Is head cable Replace head cable. "4.8.9
broken? Replacing
Print Head"
p.4-114
"4.8.3
Replacing CR
Board
Assembly"
p.4-106
3. Head thermistor Replace Print head "4.8.9
may be faulty. assembly. Replacing
Print Head"
p.4-114
14 E 076 error Abnormal Disconnection of 1. Reconnect "4.6.7
pre-heater condition in connector, wrong connector of Replacing
system pre-heater wiring, or heater thermistor and Heater,
system malfunction of heater. Thermistor"
(thermistor, thermistor and heater p.4-68
2. Check connection
heater). may be occurred. "4.4.7
of board section.
Replacing
3. Replace heater. MAIN
Board" p.4-
49
15 E 077 error Abnormal Disconnection of 1. Reconnect "4.6.7
platen heater condition in connector, wrong connector of Replacing
system platen heater wiring, or heater thermistor and Heater,
system malfunction of heater. Thermistor"
(thermistor, thermistor and heater p.4-68
2. Check connection
heater). may be occurred.
of board section.
3. Replace heater.
after-heater condition in
system after-heater
system
(thermistor,
heater).
Rev.-00 9-26
symptom
17 E 079 error Abnormal • Communication 1. Check connection "4.4.7
communica- condition in cable may be faulty. between MAIN Replacing
tion error serial commu- • F/W on controller board to controller MAIN
nication board may be faulty. board. Board" p.4-
between MAIN 49
• Controller board 2. Check connection
board to "5.5.2
assembly may be between junction
controller Version
faulty. board to controller
board during Menu" p.5-13
board.
printing "7.3.5
operation. 3. Check firmware Firmware
version and install Installation"
the latest version. p.7-12
junction error condition in
serial commu- 4. Replace controller
nication board or MAIN
between board.
junction board
to controller
board during
printing
operation.
19 E 084 error Installed head Installed head is not Replace head. "4.8.9
head is incorrect. manufactured by other Replacing
identification vendor. Print Head"
p.4-114
20 E 085 error Abnormal Main board assembly Replace MAIN board "4.4.7
head overheat condition in may be damaged. assembly. Replacing
head driver. MAIN
Board" p.4-
49
21 E 086 error Abnormal Head or head cable may 1. Check connection "4.8
head OVP condition in be damaged. of head cable. Replacing
head driver Cursor
2. Replace head.
Section" p.4-
105
22 E 087 error Abnormal Temperature 1. Replace thermistor. "4.6.7
head transistor condition in abnormality of head Replacing
2. Replace MAIN
thermistor head transistor transistor on MAIN Heater,
board.
board or sensor Thermistor"
abnormality of p.4-68
thermistor may be "4.4.7
occurred. Replacing
MAIN
Board" p.4-
49
9-27 Rev.-00
symptom
23 E 093 error Abnormal Sub tank L sensor, two- 1. Replace sub tank L
sub tank L condition in way valve or junction sensor.
sensor error sub tank L board may be defective.
2. Replace two-way
sensor
valve.
3. Replace junction
board.
24 E 097 error Abnormal - Replace MAIN board "4.4.7
NVRAM condition in assembly. Replacing
NVRAM MAIN
Board" p.4-
49
25 E 118- E 121 Abnormal Sub tank Lo sensor, 1. Replace sub tank Lo
error condition in two-way valve or sensor.
sub tank Lo error sub tank junction board may be
2. Replace two-way
Lo sensor defective.
valve.
3. Replace junction
board.
Rev.-00 9-28
9.2.6 Error Messages During File Transmission

This section describes the error messages displayed when sending backup parameters and firmware using
dedicated online software, as well as their recovery actions.
Table 9-8 Error Messages During File Transmission

symptom
1 Transfer failed Firmware data Check if transferred After confirming it, "7.3.5
Data format format is firmware is an install firmware again. Firmware
error inappropriate. appropriate file. Installation"
p.7-12
2 Transfer failed Cancel button - Transfer firmware
Aborted by the on PC has been again.
HOST pressed.
3 Transfer failed Communication Check connection After resolving
Data timeout time-out between printer and PC. problem, transfer
occurred. firmware again.
4 Transfer failed File checksum - 1. Transfer firmware
Check-sum error. again.
error
2. If error message is
still displayed,
check if transferred
firmware is an
appropriate file.
5 Transfer failed Received Check if program file is After confirming it,
Wrong size wrong size appropriate. transfer data again.
xxxxxxxx data.
6 Transfer failed Incompatible Check if program file is After confirming it, "7.3.5
Incompatible firmware. appropriate. install firmware again. Firmware
F/W Installation"
p.7-12
7 Transfer failed ROM erase Board may be defective. Replace MAIN board. "4.4.7
Flash erase error. Replacing
error MAIN
Board" p.4-
8 Transfer failed ROM writing
49
Flash write error.
error
9 Transfer failed ROM
Flash compare comparing
error error.
10 Transfer failed FROM written Normally not detected.
Unknown in unknown FROM may be
Flash size method is defective.
detected.
9-29 Rev.-00
Table 9-8 Error Messages During File Transmission (Continued)

symptom
11 Internal Error No memory Normally not occurred. • Replace SODIMM. "4.4.7
Memory area is SODIMM may be • Replace MAIN Replacing
Exhausted available. defective. board. MAIN
Board" p.4-
49
12 Transfer failed “Block reply Check connection • Reconnect control "4.4.3
Block replay timeout” between control board board and MAIN Replacing
timeout occurred and MAIN board. board.
HEATER
during system • Replace the cable CONT
code transfer. connecting control Board" p.4-
13 Transfer failed Invalid value is board and MAIN
42
Block replay received during board.
"4.4.7
error xx system code • Replace control Replacing
transfer. board.
MAIN
14 Transfer failed “Final reply • Replace MAIN Board" p.4-
Final reply timeout“ board.
49
timeout occurred
during system
code transfer.
15 Transfer failed Invalid value is
Final reply received during
error xx final system
code transfer.
Rev.-00 9-30

symptom
16 Boot Transfer Opening • Check connection • Reconnect control "4.4.3
failed sequence of between control board and MAIN Replacing
Opening seq. boot code board and MAIN board. Otherwise, HEATER
failed transfer failed. board. replace the cable CONT
• Check if the green connecting control Board" p.4-
LED on control board and MAIN 42
board is lit. board. "4.4.7
• If the green LED on Replacing
• Check if the red MAIN
LED on control control board is off
after the power is Board" p.4-
board is blinking. 49
turned on, replace
the control board. " 7 . 3
• If the red LED is Working with
blinking and there is Dedicated
no problem at Network
connection between Software"
control board and p.7-7
MAIN board, try to
reinstall firmware.
• If the red LED is
off, perform the
following
procedures.
1. Turn off the power,
then switch the DIP
switch as follows:
1: ON
2: ON
3: ON
4: OFF
2. Start the board
manager mode.
3. Reinstall firmware.
4. Turn off the power,
then switch the DIP
switch as follows:
1: ON
2: OFF
3: ON
4: OFF
5. Turn on the power,
then check if the red
LED is blinking.
9-31 Rev.-00

symptom
17 Boot Transfer AA did not Check connection • Reconnect control "4.4.3
failed replied to Step between control board board and MAIN Replacing
55-AA 55 of boot code and MAIN board. board. HEATER
Timeout transfer. • Replace the cable CONT
connecting control Board" p.4-
18 Boot Transfer xx replied to
board and MAIN 42
failed Step 55 of boot
55-AA reply code transfer. board. "4.4.7
error xx • Replace control Replacing
board. MAIN
19 Boot Transfer An error (xx)
• Replace MAIN Board" p.4-
failed replied to
End code xx transfer end of board. 49
boot code.
20 Boot Transfer Transfer
failed sequence echo
Echo timeout of boot code
did not reply.
21 Boot Transfer Invalid transfer
failed sequence echo
Echo error xx of boot code
did not reply.
22 Internal error Failed in Normally not occurred. Replace MAIN board. "4.4.7
Parameter save writing FROM may be Replacing
error parameter. defective.
MAIN
23 Transfer failed Invalid year SODIMM or MAIN • Replace SODIMM. Board" p.4-
Wrong year data (xxxx) board may be defective. • Replace MAIN 49
xxxx received. board.
24 Transfer failed Invalid month
Wrong month data (xx)
xx received.
25 Transfer failed Invalid day
Wrong date data (xx)
xx received.
26 Transfer failed Invalid hour
Wrong hour data (xx)
xx received.
27 Transfer failed Invalid minute
Wrong min data (xx)
xx received.
Rev.-00 9-32

symptom
28 Transfer not Transfer is not Check if LED display Press any button on " 7 . 3
ready available. on operation panel is in operation panel to make Working with
waiting status of board the panel display
Dedicated
manager mode. waiting state. Then,
Network
reinstall the software.
Software"
p.7-7
9-33 Rev.-00
9.3 Troubleshooting Without Error Messages

This section describes the symptoms of errors without an error message as well as the check items and
recovery actions.
9.3.1 Initial Operation Problems
Table 9-9 Symptoms, Check Items and Actions for Initial Operation Problems
No. Symptom Check item Action Reference

1 Machine power 1. Is operation panel Replace panel cable. "4.3.1
cannot be turned ON unit assembly cable Replacing
broken or shorted? Panel Unit"
p.4-30
2. Panel unit assembly Replace panel unit "4.3.1
Panel Unit"
p.4-30
3. Inlet assembly may Replace inlet assembly. "4.4.9
be defective. Replacing
Inlet
Assembly"
p.4-55
4. Power board Replace power board "4.4.2
defective. Power Board
Assembly"
p.4-41
2 Abnormal LCD 1. Check power supply Replace power board "4.4.2
operation (no voltage (DC5V). assembly. Replacing
displays/garbled Power Board
characters) Assembly"
p.4-41
2. Check power supply Replace power board "4.4.2
voltage (DC24V). assembly. Replacing
Power Board
Assembly"
p.4-41
Rev.-00 9-34
Table 9-9 Symptoms, Check Items and Actions for Initial Operation Problems (Continued)

2 3. Check panel cable for Reconnect following "4.4.7
proper connection at connectors. Replacing
operation panel unit • Main board MAIN
assembly side and assemblyf: J5 Board" p.4-
MAIN board • Operation panel unit 49
assembly side. assembly
• Is the panel cable
inserted obliquely?
• Is the connector
securely locked?
4. Panel cable may be Replace panel cable. "4.3.1
damaged. Replacing
Panel Unit"
p.4-30
5. Is operation panel Replace panel board "4.3.1
unit assembly LCD assembly. Replacing
damaged? Panel Unit"
p.4-30
6. Main board assembly Replace MAIN board "4.4.7
MAIN
Board" p.4-
49
3 Initial ink charge not 1. Is "Sen: Cover open" • Check connection of "4.3.3
available displayed on LCD cover sensor assembly Replacing
with front cover connector. Front Cover
closed? • Replace cover sensor Sensor" p.4-
assembly. 32
9-35 Rev.-00

3 2. Check panel cable for Reconnect following "4.4.7
proper connection at connectors. Replacing
assembly side and assembly: J5 Board" p.4-
assembly side. assembly
• Is the panel cable
inserted obliquely?
• Is the connector
securely locked?
3. Is "Sen: Lever up" Adjust lever sensor. "4.7.4
displayed on LCD Replacing T
with media set lever Fence" p.4-
lowered? 91
4. Check MAIN board • Reconnect the "4.4.7
assembly connectors connector. Replacing
J30 for proper • Replace lever sensor MAIN
connection. assembly. Board" p.4-
49
5. Are the following • Follow the steps for the "4.4.7
self-diagnosis message "[KCMY] No Replacing
functions judged as Cartridge". MAIN
normal when • After adjustment/ Board" p.4-
checked with replacement, execute 49
specified cartridge initial ink charge from "(1) Head
securely inserted? "Update 1: Head Rank" Rank" p.5-50
• Detection of of self-diagnosis
presence of ink from function.
"Ctrl 2: Sensor" ->
"Sen.3: etc" -> "12:
Ink END".
• Detection of
presence of cartridge
from "Ink Not"
6. Is specified cartridge • Follow the steps for the "4.4.7
status judged as message "Insert Replacing
normal when specified cartridge". MAIN
checked through • After adjustment/ Board" p.4-
"Ctrl 2: Sensor" -> replacement, execute 49
"Sen.3: etc" -> "11: initial ink charge from "(1) Head
Ink NOT KCMY" of "Update 1: Head Rank" Rank" p.5-50
self-diagnosis of self-diagnosis
function with function.
specified cartridge
securely inserted?
Rev.-00 9-36

7. Main board assembly • Replace MAIN board "4.4.7
• After replacement, MAIN
execute initial ink Board" p.4-
charge from "Adj: 49
Input Rank" of self-
diagnosis function.
4 Though initial charge Is spring of ink system • If the part is detached, "4.10.1
has started, ink does assembly detached or remount it. Replacing
not reach head. damaged? • If the part is damaged, Ink ID Board
replace ink system Assembly"
assembly. p.4-125
5 Though ink reaches Is capping position • If ink inflow is Operation

head, ink is not appropriate? confirmed, execute Manual
discharged from head. initial ink charge.
9-37 Rev.-00

6 Ink is not discharged 1. Are damper • Remove head cover "4.2.4
though ink charge is assembly, ink tube and check damper Removing
finished. and SUS pipe joint assembly. Side
screws (K, Y, M, C) • Remove side cover (L, R) Maintenance
securely tightened? and cartridge cover, and Cover R"
Is O-ring properly check ink tube and SUS p.4-11
installed? pipe joint screws. "4.2.5
Removing
Side
Maintenance
Cover L" p.4-
12
"4.2.11
Removing
Cartridge
Cover
(lower)" p.4-
19
2. Does shield part of • Replace damper "4.8.9
damper assembly assembly and check if Replacing
have air leak? cleaning operation Print Head"
causes ink inflow. p.4-114
• If ink inflow is
confirmed, execute
initial ink charge.
3. Is ink tube in ink • Replace ink system "4.10.1
system assembly assembly and check if Replacing
bent? cleaning operation Ink ID Board
causes ink inflow. Assembly"
• If ink inflow is p.4-125
confirmed, execute
initial ink charge.
Rev.-00 9-38

6 4. Does pump motor • Reconnect MAIN "4.4.7
rotate during board assembly Replacing
cleaning operation? connector J22. MAIN
• Replace pump motor. Board" p.4-
49
• Replace MAIN board "4.2.2
assembly. Removing
Maintenance
Cover" p.4-9
5. When cleaning Replace maintenance base "4.2.2
operation is assembly. Removing
performed, are gears Maintenance
damaged or poorly Cover" p.4-9
engaged?
6. When cleaning Replace maintenance base "4.2.2
operation is assembly. Removing
performed, is Maintenance
transmission gear Cover" p.4-9
shaft damaged?
7. Does ink tube have • Replace damaged ink "4.7.10
bend, scratch, or tube and check if Replacing
leak? cleaning operation Ink Tube"
causes ink inflow after p.4-102
each replacement.
confirmed, execute
initial ink charge.
8. Check connection of Reconnect head cable. "4.8.9
head cable Replacing
connectors on CR Print Head"
board assembly side p.4-114
and head side. "4.8.3
• Is head cable inserted Replacing
obliquely? CR Board
Assembly"
• Is it locked securely? p.4-106
9-39 Rev.-00

6 9. Is head cable broken? Replace head cable. "4.8.9
Replacing
Print Head"
p.4-114
"4.8.3
Replacing
CR Board
Assembly"
p.4-106
10. Is print head Replace print head "4.8.9
assembly damaged? assembly. Replacing
Print Head"
p.4-114
11. Is CR board Replace CR board "4.8.3
assembly damaged? assembly. Replacing
CR Board
Assembly"
p.4-106
12. Check connection of Reconnect following "4.8.3
CR cable connectors connectors. Replacing
on CR board • CR board assembly CR Board
assembly side and connector: J201 - J205 Assembly"
MAIN board • Main board assembly p.4-106
assembly side. connector: J9 - J11 "4.4.7
• Is head cable inserted Replacing
obliquely? MAIN
Board" p.4-
• Is it locked securely? 49
13. Is CR cable broken? Replace CR cable. "4.7.8
Replacing
CR Tape
Wire" p.4-99
may be defective. assembly. Replacing
MAIN
Board" p.4-
49
Rev.-00 9-40

7 Machine makes no 1. Is "Sen: Cover open" • Check MAIN board "4.4.7
operations after displayed on LCD assembly connector Replacing
turned ON. with printer cover J38, J40. MAIN
closed? • Replace cover sensor Board" p.4-
Or, is cover sensor assembly. 49
assembly function "4.3.2
detected as normal Replacing
when checked Maintenance
through "Test 4: Cover
Sensor" of self- Sensor" p.4-
diagnosis function? 31
8 After turned ON, 2. Check panel cable Reconnect following "4.4.7
machine displays connectors at connectors. Replacing
"Initializing" and operation panel unit • Main board MAIN
resets itself. assembly and MAIN assembly: J5 Board" p.4-
board assembly. • Operation panel unit 49
• Is panel cable assembly: J1
inserted obliquely?
• Is it locked securely?
9 Machine does not 3. Is "Set Paper" • Check MAIN board "4.4.7
perform initialization displayed on LCD assembly connector Replacing
even if media is set. with pressure arm J30. MAIN
lowered? • Replace lever sensor Board" p.4-
assembly. 49
"4.6.6
Replacing
Lever Up
Sensor" p.4-
67
10 Machine does not 4. Is P_REAR sensor • Check MAIN board "4.4.7
start operation even if assembly judged as assembly connector Replacing
front cover is closed. normal when J42. MAIN
checked through • Replace P_REAR Board" p.4-
"Test 4: Sensor" of sensor Assembly. 49
self-diagnosis "4.6.5
function? Replacing
P_REAR
Sensor
Assembly"
p.4-65
9-41 Rev.-00

11 Machine does not stop 5. Check power supply Replace power board "4.4.2
even if front cover is voltage (DC5V). assembly. Replacing
opened. Power Board
Assembly"
p.4-41
voltage (DC24V, assembly. Replacing
DC42V). Power Board
Assembly"
p.4-41
7. Is DC cable assembly • Reconnect DC cable "4.4.2
connected correctly assembly. Replacing
between power board • Replace DC cable Power Board
assembly and MAIN assembly. Assembly"
board assembly? p.4-41
MAIN
Board" p.4-
49
Rev.-00 9-42

12 Ink cartridge cannot 1. Are the following • Follow the steps for the "(1) Head
be detected even if self-diagnosis message "[KCMY] No Rank" p.5-50
installed. functions detected as Cartridge".
normal when • After adjustment/
checked with replacement, execute
specified cartridge initial ink charge from
securely inserted? "Update 1: Head Rank"
• Detection of of self-diagnosis
presence of ink from function.
"Ctrl 2: Sensor" ->
"Sen.3: etc" -> "12:
Ink END"
• Detection of
presence of cartridge
from "Ctrl 2: Sensor"
-> "Sen.3: etc" ->
"11: Ink NOT
KCMY"
2. Is specified cartridge • Follow the steps for the "(1) Head
status detected as message "Insert Rank" p.5-50
normal when specified cartridge".
checked through • After adjustment/
"Ctrl 2: Sensor" -> replacement, execute
"Sen.3: etc" -> "7-10: initial ink charge from
[KCMY]Ink ID" of "Update 1: Head Rank"
self-diagnosis of self-diagnosis
function with function.
specified cartridge
securely inserted?
9-43 Rev.-00

13 Operation panel 1. Is operation panel Replace operation panel -
accepts no inputs. cover broken or cover.
contaminated?
2. Check panel cable Reconnect following "4.4.7
connectors at connectors. Replacing
assembly side and assembly: J5 Board" p.4-
assembly side. assembly: J1
• Is panel cable
inserted obliquely?
• Is it locked securely?
3. Operation panel unit Replace panel unit "4.3.1
damaged. Panel Unit"
p.4-30
may be assembly. Replacing
malfunctioning. MAIN
Board" p.4-
49
14 Machine prints 1. Refer to "9.3.5 - "9.3.5
nothing though it Online Function Online
receives data. Problem". Function
Problems"
p.9-68
Rev.-00 9-44
9.3.2 Media Feed Problems
Table 9-10 Symptoms, Check Items and Actions for Media Feed Problems

1 Media comes off 1. Are P_REAR sensor • Check following "4.4.7
during media set assembly and connectors. Replacing
initialization or P_EDGE sensor • Main board MAIN
printing. assembly detected as assembly: J42, J9 - Board" p.4-
normal when J11 49
checked through "4.8.3
"Test 4: Sensor" of • CR board assembly: Replacing
self-diagnosis J208, J201 - J203 CR Board
function? • Replace P_REAR Assembly"
sensor assembly and p.4-106
P_EDGE sensor "4.6.5
assembly. Replacing
P_REAR
Sensor
Assembly"
p.4-65
2 Media runs obliquely 2. Is suction fan run as • Check connection of "4.6.8
or meanders during normal when following MAIN board Replacing
media set checked through assembly connectors. Suction Fan"
initialization or "Test 6: Fan" of self- • Suction fan cable p.4-76
printing. diagnosis function? assembly: J25 - J29
3 Media crinkles during • Replace suction fan
media set assembly.
initialization or • Replace cable of
printing. suction fan that does
not operate normally.
4 Media jams during 3. When pressure lever Lubricate pressure cam. "8.5
media set is moved backward Lubrication/
initialization or and forward, does Bonding"
printing. pressure assembly p.8-7
move smoothly in
synchronization with
it?
5 Media is torn during 4. Does pressure roller If pressure roller collects Operation
media set drag when pressure media dust on itself, wipe Manual
initialization or lever is raised? dust away using a wet soft
printing. cloth.
5. Does media guide • If media guide collects
have large distortion media dust or other "4.2.17
or foreign objects? foreign objects on it, Removing
remove them. Media Guide
• Replace media guide. F (Upper)"
p.4-24
9-45 Rev.-00
Table 9-10 Symptoms, Check Items and Actions for Media Feed Problems (Continued)

6. When using roll Insert flanges correctly into Operation
media, are flanges core pipe of media roll. Manual
attached correctly?
6 Machine registers Is media in use a Set recommended media Operation
wrong media size recommended one? and check printout again. Manual
after media set With non-authorized
initialization. media, media sensor may
fail to detect media
correctly.
Rev.-00 9-46
9.3.3 Printing Problems

Table 9-11 Symptoms, Check Items and Actions for Printing Problems
1 Machine cannot print 1. printer driver may be Update printer driver. "7.3.5
sequentially. defective. Firmware
Installation"
p.7-12
2. Program ROM may be Update firmware. "7.3.5
defective. Firmware
Installation"
p.7-12
MAIN Board"
p.4-49
2 Media feed after 1. Is P_REAR sensor • Reconnect MAIN board "4.4.7
printing is excessive. assembly judged as assembly connector J42. Replacing
normal when checked • Replace P_REAR sensor MAIN Board"
through "Test 4: assembly. p.4-49
Sensor" of self- "4.6.5
diagnosis function? Replacing
P_REAR
Sensor
Assembly"
p.4-65
defective. Firmware
Installation"
p.7-12
MAIN Board"
p.4-49
9-47 Rev.-00
Table 9-11 Symptoms, Check Items and Actions for Printing Problems (Continued)
3 Missing dots in 1. Perform cleaning Operation
printing. twice consecutively. Manual
2. Is ink tube filled with Perform drop ink charge. Operation
ink? Manual
3. Perform "Check 4: If the nozzle check patterns "5.7.7 Test
Adjustment" -> "Adj are printed correctly, refer to Printing
1: NozzleChk" of the action in check item No. Menu" p.5-39
printer self-diagnosis 4.
or "Test Print".
4. Does pump motor • Reconnect MAIN board "4.4.7
rotate during cleaning assembly connector J22. Replacing
operation? • Replace Pump motor MAIN Board"
assembly. p.4-49
• Replace MAIN board
assembly.
5. Are gears and Replace maintenance base
transmission gear shaft assembly.
damaged or poorly
engaged during
cleaning operation?
4 Nozzle plugging or ink 1. Is spring of ink system • If the part is detached,
splash is not eliminated assembly detached or remount it.
even after cleaning. damaged? • If the part is damaged, "4.10.1
replace ink system Replacing Ink
assembly. ID Board
Assembly"
p.4-125
2. Check cleaning wiper • Wipe cleaning wiper Operation
condition. surface with accessory Manual
polynit wiper. After
wiping cleaning wiper,
perform cleaning twice
consecutively.
• If cleaning wiper is
sticky with ink, replace it "4.9.2
with a new one. Replacing
Cleaner Head"
p.4-121
Rev.-00 9-48
4 Nozzle plugging or ink 3. Is nozzle face wiped/ Check wiper installation "4.9.2
splash is not eliminated rubbed correctly? condition and secure it Replacing
even after cleaning. correctly. Cleaner Head"
(Continued) p.4-121
4. Is registered head rank Enter correct head rank. "(1) Head
different from actual Rank" p.5-50
head rank?
5. Does residual ink Clean head as follows. "5.7.8
collect on print head 1. Clean head from "Adj HeadWash
assembly or in 9: HeadWash" of printer Menu" p.5-40
nozzles? self-diagnosis.
2. Perform initial ink "(1) Head
charge from "Update 1: Rank" p.5-50
Head Rank".
3. Check printouts again.
6. Check if CR_ENC • If they contact with each
assembly and other, adjust CR_ENC
T fence contact with assembly and T fence
each other. positions.
• If problem remains even "4.8.3
after position Replacing CR
adjustment, replace CR Board
board assembly and T Assembly"
fence. p.4-106
"4.7.4
Replacing T
Fence" p.4-91
system assembly bent? assembly and check if Replacing Ink
cleaning operation ID Board
confirmed, execute
initial ink charge.
8. Is print head damaged? Replace damaged print head. "4.8.9
Replacing
Print Head"
p.4-114
MAIN Board"
p.4-49
9-49 Rev.-00
5 No printing. 1. Check power supply Replace power board "4.4.2
voltage (DC24V, assembly. Replacing
Particular color is DC42V). Power Board
missing. Assembly"
p.4-41
2. Is spring of ink system • If the part is detached, "4.10.1
assembly detached or remount it. Replacing Ink
damaged? • If the part is damaged, ID Board
assembly. p.4-125
3. Is CR cable inserted Reconnect MAIN board "4.4.7
obliquely? assembly connectors J9 - J11 Replacing
and CR board assembly MAIN Board"
connectors J201 - J205. p.4-49
"4.8.3
Replacing CR
Board
Assembly"
p.4-106
4. CR cable may be Replace CR cable assembly. "4.7.4
damaged. Replacing T
Fence" p.4-91
5. Are damper assembly, • Remove head cover and
ink tube and SUS pipe check damper assembly.
joint screws (K, C, M, • Remove side cover (L, "4.2.4
Y) securely tightened? R) and I/H cover, and Removing Side
Is O-ring properly check ink tube and SUS Maintenance
installed? pipe joint screws. Cover R" p.4-
11
"4.2.5
Removing Side
Maintenance
Cover L" p.4-
12
6. Does shield part of • Replace damper
damper have air leak? assembly and check if
cleaning operation
causes ink inflow.
confirmed, execute
initial ink charge.
confirmed, execute
initial ink charge.
Rev.-00 9-50
5 8. Does ink tube have • Replace damaged ink "4.7.10
bend, scratch, or leak? tube and check if Replacing Ink
cleaning operation Tube" p.4-102
causes ink inflow after
each replacement.
confirmed, execute
initial ink charge.
9. Are the following self- • Follow the steps for the "(1) Head
diagnosis functions message "[KCMY] No Rank" p.5-50
detected as normal Cartridge".
when checked with • After adjustment/
specified cartridge replacement, execute
securely inserted? initial ink charge from
• Detection of presence "Update 1: Head Rank"
of ink from "Ctrl 2: of self-diagnosis
Sensor" -> "Sen.3: etc" function.
-> "12: Ink END"
• Detection of presence
of cartridge from "Ctrl
2: Sensor" -> "Sen.3:
etc" -> "11: Ink NOT"
confirmed, execute
initial ink charge.
11. Does pump motor • Reconnect MAIN board "4.4.7
rotate during cleaning assembly connector J22, Replacing
operation? J23. MAIN Board"
• Replace Pump motor p.4-49
assembly.
assembly.
12. When cleaning Replace maintenance base
operation is assembly.
performed, does
transmission gear
rotate properly?
9-51 Rev.-00
5 13. When cleaning Replace maintenance base
performed, is
transmission gear shaft
damaged?
14. Check head cable Reconnect head cable. "4.8.9
connectors at CR Replacing
board assembly side Print Head"
and print head p.4-114
assembly side. "4.8.3
• Is head cable inserted Replacing CR
obliquely? Board
Assembly"
Replacing
Print Head"
p.4-114
16. CR board assembly Replace CR board assembly. "4.8.3
may be defective. Replacing CR
Board
Assembly"
p.4-106
MAIN Board"
p.4-49
Rev.-00 9-52
6 Machine outputs all 1. Check connection of Reconnect head cable. "4.8.9
black printing. head cable connectors Replacing
on CR board assembly Print Head"
side and print head p.4-114
side. "4.8.3
• Is head cable inserted Replacing CR
obliquely? Board
Assembly"
2. Is CR cable inserted Reconnect MAIN board "4.4.7
obliquely? assembly connectors J9 - J11 Replacing
and CR board assembly MAIN Board"
connectors J201 - J205. p.4-49
"4.8.3
Replacing CR
Board
Assembly"
p.4-106
3. CR cable assembly Replace CR cable assembly. "4.7.8
may be damaged. Replacing CR
Tape Wire"
p.4-99
4. Is print head damaged? Replace damaged print head "4.8.9
assembly. Replacing
Print Head"
p.4-114
may be Replacing CR
malfunctioning. Board
Assembly"
p.4-106
MAIN Board"
p.4-49
7 Blocky printing 1. Is working Use machine under specified "3.5
quality. environment environment. Choosing a
8 Blocky image printing. appropriate? Place for the
9 CR line seems dotted. Printer" p.3-6
10 White or black lines
appear. (No missing or
ink crooking in step
patters in location 1G -
7G in "Test Print")
9-53 Rev.-00
7 2. Have you started Printing just after initial Operation
8 printing immediately charge may cause following Manual
9 after initial charge? symptoms.
10 • Printed line blurs.
• White lines appear.
In such cases, perform
cleaning two or three times
and check printout again.
If symptoms remain even
after cleaning, leave machine
unused for 1 hour or more.
Then perform cleaning again
and check printout.
If symptoms still remains,
refer to Operation Manual to
contact the technical support.
3. Is suction fan run as • Check connection of "4.6.8
normal when checked following MAIN board Replacing
through "Test: Fan" of assembly connectors. Suction Fan"
self-diagnosis • Suction fan 1 - 4 p.4-76
function? assembly: J25 - 29
J127
• Suction fan L cable:
J126
assembly.
• Replace cable of suction
fan that does not operate
normally.
Rev.-00 9-54
7 4. Is shielding material Remount it at specified "4.6.8
8 secured at specified position. Replacing
9 position? Suction Fan"
10 p.4-76
5. If the media in Adjust roll receiver assembly "4.6.10
problem is roll media, position. Replace roll Replacing
does scroller rotate receiver assembly. Media Holder"
evenly? p.4-78
6. Is PF belt tension Adjust PF reduction belt "(2)
adjusted to tension. Confirming
specification? Completion of
Installation to
Plotter" p.7-14
polynit wiper. After
wiping cleaning wiper,
perform cleaning twice
consecutively.
• If cleaning wiper is
sticky with ink, replace it
with a new one.
8. Is nozzle face wiped/ Check wiper installation "4.9.2
rubbed correctly? condition and secure it Replacing
correctly. Cleaner Head"
p.4-121
9. Is T fence • Clean T fence.
contaminated? • If T fence is still
contaminated or "4.7.4
damaged, replace T Replacing T
fence. Fence" p.4-91
10. Does pressure roller If pressure roller collects Operation

rotate harder when media dust on itself, wipe Manual
pressure arm is raised? dust away using a wet soft
cloth.
9-55 Rev.-00
7 11. Does pump motor • Reconnect MAIN board "4.4.7
8 rotate during cleaning assembly connector J22. Replacing
9 operation? • Replace pump motor MAIN Board"
10 assembly. p.4-49
"4.4.7
• Replace MAIN board Replacing
assembly. MAIN Board"
p.4-49
performed, does
transmission gear
rotate properly?
performed, are gears
and transmission gear
shaft damaged?
assembly. p.4-125
confirmed, execute
initial ink charge.
16. Is registered head Enter correct head voltage. "(1) Head
voltage different from Rank" p.5-50
actual head voltage?
Rev.-00 9-56
7 17. Does residual ink Clean head as follows.
8 collect on head 1. Clean head through
9 assembly or in "Adj 9: HeadWash" of "5.7.8
10 nozzles? self-diagnosis function. HeadWash
2. Perform initial charge Menu" p.5-40
through "Update 1: Head
Rank".
3. Check plotouts again. "(1) Head
Rank" p.5-50
Replacing
Print Head"
p.4-114
19. Are the following self- • Follow the steps for the "(1) Head
diagnosis functions message "[KCMY] No Rank" p.5-50
judged as normal when Cartridge".
checked with specified • After adjustment/
cartridge securely replacement, execute
inserted? initial ink charge from
- Detection of presence "Update 1: Head Rank"
of ink from "Ctrl 2: of self-diagnosis
Sensor" -> "Sen.3: etc" function.
-> "11: Ink NOT"
- Detection of presence
of cartridge from "Ctrl
2: Sensor" -> "Sen.3:
etc" -> "12: Ink END"
may be Replacing CR
malfunctioning. Board
Assembly"
p.4-106
Board
Assembly"
p.4-106
9-57 Rev.-00
11 Printout borders blur. 1. Does purge correct Perform purge twice Operation
symptom? consecutively. Manual
2. Is media in use a Set recommended media and Operation
recommended one? check printout again. With Manual
non-authorized media, media
sensor may fail to detect
media correctly.
3. CR cable assembly Replace CR cable assembly "4.7.8
may be damaged. wire. Replacing CR
Tape Wire"
p.4-99
Replacing
Print Head"
p.4-114
may be Replacing CR
malfunctioning. Tape Wire"
p.4-99

MAIN Board"
p.4-49
Rev.-00 9-58
12 Many satellites 1. Is working Use machine under specified "3.5
(unnecessary dots) environment environment. Choosing a
appropriate? Place for the
Shaggy plotout Printer" p.3-6
2. Is the ink level Replace ink cartridge with Operation
Uneven lines (plotted
remained sufficient? new one. Manual
with stains)
3. Perform purge three Plot out drawing again. Operation
times consecutively. Manual
4. Perform test printing. If nozzle check patterns are
plotted correctly, refer to step
(6)
5. Have you started Be sure to wait 6 hours or Operation
plotouting more after initial ink charge. Manual
immediately after Plotouting before ink charge
initial charge? stabilization will not provide
adequate plotting quality.
6. Is CR belt tension Adjust CR belt tension. "7.6 CR
adjusted to Speed
specification? Reduction Belt
Tension
Adjustment"
p.7-27
7. Check if PF_ENC • If they contact with each
assembly and T fence other, adjust CR_ENC
contact with each assembly and T fence
other. positions.
• If problem remains even "4.8.3
after position Replacing CR
adjustment, replace CR Board
board assembly and T Assembly"
fence. p.4-106
"4.7.4
Replacing T
Fence" p.4-91
cleaning wiper cleaning
cloth dampened with
small amount of purified
water. After wiping
cleaning wiper, perform
cleaning twice
consecutively. "4.9.2
• If cleaning wiper is Replacing
sticky with ink, replace it Cleaner Head"
with a new one. p.4-121
9-59 Rev.-00
9. Is nozzle face wiped/ Check wiper installation "4.9.2
rubbed correctly? condition and secure it Replacing
correctly. Cleaner Head"
p.4-121
12 11. Does pump motor • Reconnect MAIN board "4.4.7
rotate during cleaning assembly connector J22. Replacing
operation? • Replace pump motor MAIN Board"
assembly. p.4-49
assembly.
performed, are gears
and transmission gear
shaft damaged?
assembly. p.4-125

confirmed, execute
initial ink charge.
15. Does residual ink Clean head as follows.
collect on print head 1) Clean head from "Adj "5.7.8
assembly or in 9: HeadWash" of printer HeadWash
nozzles? self-diagnosis. Menu" p.5-40
2) Perform initial ink
charge from "Update "5.7.4
1:Head Rank". Voltage
3) Check printouts again. Adjustment"
p.5-31
16. Is print head assembly Replace damaged print head "4.8.9
damaged? assembly. Replacing
Print Head"
p.4-114
Rev.-00 9-60
12 17. Main board assembly Replace MAIN board "4.4.7
MAIN Board"
p.4-49
13 Mixed color lines are 1. Is CR belt tension Adjust CR belt tension. "7.6 CR
not overlaid. adjusted to Speed
Tension
Adjustment"
p.7-27
3. Is head slant Adjust head slant. "7.6 CR
inappropriate? Speed
Reduction Belt
Tension
Adjustment"
p.7-27
4. Are bi-directional Align bi-directional printing "5.7.5 Uni-
printing positions positions. D/Bi-D Low/
aligned correctly? High
Adjustment"
p.5-33
5. Is CW adjustment Perform CW adjustment. "5.7.5 Uni-
inappropriate? D/Bi-D Low/
High
Adjustment"
p.5-33
14 Black and other colors 1. Check if CR_ENC • If they contact with each
do not align. assembly and T fence other, adjust CR_ENC
contact with each assembly and T fence
other. positions. "4.8.3
• If problem remains even Replacing CR
after position Board
adjustment, replace CR Assembly"
board assembly and T p.4-106
fence. "4.7.4
Replacing T
Fence" p.4-91
9-61 Rev.-00
15 Poor accuracy of 1. Is working Use machine under specified "3.5
segment length in head environment environment. Choosing a
travel direction (main appropriate? Place for the
scan direction). Printer" p.3-6
adjusted to Speed
Tension
Adjustment"
p.7-27
3. Is T fence • Clean T fence.
contaminated? • If T fence is still "4.7.4
contaminated or Replacing T
damaged, replace T Fence" p.4-91
fence.
4. Internal process of Initialize parameters and "5.11.1
MAIN board assembly reenter or modify them. Parameter
may be abnormal. Then, check machine Initialization
operation again. Menu" p.5-47
16 Poor linearity in head 1. Is suction fan run as • Check connection of "4.6.8
scan direction normal when checked following MAIN board Replacing
(straightness) through "Test 6: Fan" assembly connectors. Suction Fan"
of self-diagnosis • Suction 1 - 4 cable: p.4-76
function? J25 - J29
assembly.
normally.
2. Is PF driving pulley Replace PF motor assembly. "4.6.2
loose? Replacing PF
Motor
Assembly"
p.4-61
3. Is PF speed reduction Adjust PF speed reduction "(2)
belt tension adjusted to belt tension. Confirming
Installation to
Plotter" p.7-14
Rev.-00 9-62
16 4. If the media in • Adjust roll receiver "4.6.10
problem is roll media, assembly position. Replacing
does scroller rotate • Replace roll receiver Media Holder"
evenly? assembly. p.4-78

cloth.
17 Poor accuracy of 1. Is working Use machine under specified "3.5
segment length in environment environment. Choosing a
media feed direction appropriate? Place for the
(sub scan direction) Printer" p.3-6
2. Is PF driving pulley Replace PF motor assembly. "4.6.2
loose Replacing PF
Motor
Assembly"
p.4-61
3. Is PF belt tension Adjust PF speed reduction "(2)
adjusted to belt tension. Confirming
Installation to
Plotter" p.7-14
cloth.
5. Is rough surface of grid If grid roller is contaminated Operation
roller partially worn with media dust, clean roller Manual
out? with a nylon brush.
6. Is grid roller rotation
heavy? Does rattling
occur when it rotates?
7. If the media in Adjust roll receiver assembly "4.6.10
problem is roll media, position. Replacing
does scroller rotate Replace roll receiver Media Holder"
evenly? assembly. p.4-78
Change media to be used.
9-63 Rev.-00
18 Poor linearity in media 1. Is registered head Enter correct head voltage. "(1) Head
feed direction (media voltage different from Rank" p.5-50
splicing accuracy) actual head voltage?
2. Adjust head slant. Adjust head slant. "7.6 CR
Speed
Reduction Belt
Tension
Adjustment"
p.7-27
adjusted to Speed
Tension
Adjustment"
p.7-27
4. Are bi-directional Align two-way printing "5.7.5 Uni-
printing positions positions. D/Bi-D Low/
aligned correctly? High
Adjustment"
p.5-33
5. Is T fence Clean T fence. "4.7.4
contaminated? If T fence is still Replacing T
contaminated or damaged, Fence" p.4-91
replace T fence.
6. Check if vertical lines Replace steel bearer "4.7.8
plotted from "Adj 3: assembly. Replacing CR
HeadSlant" are not Tape Wire"
connected even though p.4-99
nozzle check pattern
from "Adj 1:
NozzleChk" of self-
diagnosis function is
adjusted properly.
7. Is carriage assembly Replace carriage assembly. -
loose?
19 Poor right angle 1. Is suction fan judged • Check connection of "4.6.8
accuracy as normal when following maintenance Replacing
checked through "Test board assembly Suction Fan"
6: Fan" of self- connectors. p.4-76
diagnosis function? • Suction fan 1 - 4
assembly: J25 - J29
assembly.
normally.
Rev.-00 9-64
2 2. Does pressure roller If pressure roller collects Operation
cloth.
3. Is rough surface of grid If grid roller is contaminated Operation
roller partially worn with media dust, clean roller Manual
out? with a nylon brush.
9.3.4 Noise Problems

Table 9-12 Symptoms, Check Items, and Actions for Noise Problems
1 Abnormal noise is 1. Are there any foreign Remove obstacles and "4.6.8
heard when media is objects or obstacles foreign objects. Replacing
suctioned. around rotating fin of Suction Fan"
suction fan assembly? p.4-76
2. Check damage of If damaged, replace damaged -
cables and connection part.
of connectors.
3. Suction fan assembly Replace suction fan "4.6.8
Suction Fan"
p.4-76
malfunctioning. Suction Fan"
p.4-76
5. Power board assembly Replace power board "4.4.2
Power Board
Assembly"
p.4-41
9-65 Rev.-00
Table 9-12 Symptoms, Check Items, and Actions for Noise Problems (Continued)
2 Abnormal noise in 1. Are there any foreign Remove obstacles and -
waiting mode objects or obstacles at foreign objects.
noise-generating
position?
2. Is abnormal noise Replace applicable one of the "4.4.2
heard from board? following board assemblies. Replacing
• Power board assembly Power Board
• Main board assembly Assembly"
p.4-41
• CR board assembly "4.4.7
• Print head assembly Replacing
MAIN Board"
p.4-49
"4.8.9
Replacing
Print Head"
p.4-114
3 Abnormal noise is 1. Does customer Explain machine operations. -
heard while head is recognize ink
moving laterally. discharge noise as
abnormal noise?
2. Is abnormal noise Additionally tighten screws. "4.2
caused by loose screw Removing
in covers? Covers" p.4-7
3. Is rattling noise heard • Remove dust from -
when moving carriage carriage bearing and
laterally? roller strip.
• After cleaning roller
strip, always apply thin
lubricant film over its
surface using a grease-
sprayed cloth.
4. Is abnormal noise • Remove twists from CR "4.7.8
heard from CR cable? cable. Replacing CR
• If abnormal noise sounds Tape Wire"
from between steel p.4-99
bearer and tube guide,
replace tube guide.
Rev.-00 9-66
Table 9-12 Symptoms, Check Items, and Actions for Noise Problems (Continued)
3 5. Does the cable • If they contact with each "4.7.8
connected to CR board other, adjust the cable Replacing CR
assembly on carriage position. Tape Wire"
contact with CR • If problem remains even p.4-99
cover? after position
adjustment, replace the
cable.
6. Is abnormal noise Replace it. "4.7.6
heard from CR driven Replacing CR
pulley bearing? Driven Pulley"
p.4-96
adjusted to Speed
Tension
Adjustment"
p.7-27
8. Is abnormal noise Replace CR motor assembly. "4.7.2
heard from CR motor Replacing CR
assembly? Motor
Assembly"
p.4-87
4 Abnormal noise is 1. Is PF speed reduction Replace PF speed reduction "4.6.2
heard during media belt slipping between belt. Replacing PF
feeding. PF speed reduction Motor
pulleys? Assembly"
p.4-61
2. Is abnormal noise Replace PF motor assembly. "4.6.2
heard from PF motor Replacing PF
assembly? Motor
Assembly"
p.4-61
3. Is rough surface of If grid roller is contaminated Operation
grid roller partially with media dust, clean roller Manual
worn out? with a nylon brush.
9-67 Rev.-00
9.3.5 Online Function Problems

Table 9-13 Symptoms, Check Items, and Actions for Online Function Problems
No. Event/symptom Check item Action Reference
1 Scaling does not work 1. Printer driver may be Update printer driver. Operation
correctly. defective. Manual
2 Mirror function does 2. Program ROM may be Update firmware. "7.3.5
not work correctly. defective. Firmware
Installation"
p.7-12
3 Other functions do not 3. Main board assembly Replace MAIN board "4.4.7
work correctly. may be damaged. assembly. Replacing
MAIN Board"
p.4-49
4 Printing position is 1. Is CW adjustment Perform adjustment. "5.7.5 Uni-
incorrect. inappropriate? D/Bi-D Low/
High
Adjustment"
p.5-33
2. Is adjustment of Perform adjustment. "7.9
P_EDGE sensor P_EDGE
inappropriate? Sensor
Sensitivity
Adjustment"
p.7-36
3. Printer driver may be Update printer driver. Operation
defective. Manual
defective. Firmware
Installation"
p.7-12
MAIN Board"
p.4-49
Rev.-00 9-68
Table 9-13 Symptoms, Check Items, and Actions for Online Function Problems(Continued)
5 Some data are not 1. Printer driver may be Update printer driver. Operation
printed (missing). defective. Manual
Some data change to 2. Program ROM may be Update firmware. "7.3.5

garbage. defective. Firmware
Installation"
p.7-12
3. Is T fence • If grease or dust collect:
contaminated or worn Wipe fence with a dry
out? cloth.
• If ink deposit presents:
Wipe it off with cloth
dampened with neutral
detergent.
• If contamination or "4.7.4
deposit is too heavy: Replacing T
Replace T fence. Fence" p.4-91
4. Check "Encoder CR" • Move carriage in both "4.4.7
from "Check 2: Test" - directions and check the Replacing
> "Test 5: Encoder" of numeral value on LCD. MAIN Board"
self-diagnosis If the numeral value p.4-49
function. doesn't change normally,
check MAIN board "4.7.4
assembly connector J12. Replacing T
• Replace T fence. Fence" p.4-91
• Replace CR motor
assembly. "4.7.2
Replacing CR
Motor
• Replace CR board Assembly"
assembly. p.4-87
"4.8.3
Replacing CR
• Replace CR cable. Board
Assembly"
p.4-106
"4.7.8
Replacing CR
Tape Wire"
p.4-99
malfunctioning. MAIN Board"
p.4-49
9-69 Rev.-00
Table 9-13 Symptoms, Check Items, and Actions for Online Function Problems(Continued)
6 Media feed after 1. Are print start position Update printer driver. Operation
printout is excessive. and layout method set Manual
properly?
2. Printer driver setting Modify the value to an Operation
may be unsuitable. appropriate value (Media Manual
size).
defective. Firmware
Installation"
p.7-12
MAIN Board"
p.4-49
9.3.6 Other Problems

Table 9-14 Symptoms, Check Items, and Actions
1 Machine hangs up. 1. Internal process of Initialize parameters and "7.3.1
MAIN board assembly reenter or modify them. Parameter
may be abnormal. Backup" p.7-7
MAIN Board"
p.4-49
2 Machine power is shut 1. Is power cable Check by a circuit tester. -
off during printing. shorted?
2. Is there any electric Check for short to chassis -
leakage? ground due to damaged cable
insulation.
Power Board
Assembly"
p.4-41
Power Board
Assembly"
p.4-41
Rev.-00 9-70
Table 9-14 Symptoms, Check Items, and Actions (Continued)

5. Power board assembly Replace power board "4.4.2
Power Board
Assembly"
p.4-41
3 Ink cartridge cannot be 1. Is pointer of ink sensor Replace ink sensor assembly. "4.10.4
inserted. assembly deformed or Replacing
damaged? Cartridge
Holder
Assembly"
p.4-132
2. Is ink NOT sensor Replace ink sensor assembly. "4.10.4
(black resin lever Replacing
switch) of ink sensor Cartridge
assembly damaged? Holder
Assembly"
p.4-132
4 Ink spills out of waste 1. Check inside of waste Replace waste ink absorber -
fluid box. fluid box. sheet.
2. Check presence of ink Remove all cartridges and "5.5.4
cartridge from "Ctrl 2: lightly push the switch of ink Sensor Menu"
Sensor" -> "Sen.3: etc" NOT sensor (BK, C, M, Y) p.5-15
-> "12: Ink END" of with something with a flat tip
self-diagnosis such as ballpoint pen to
function. check that the display of "12:
Ink END" changes.
3. Is waste fluid tube Reinstall it. "4.6.11
coming out of flushing Replacing
box bent? Flushing
Tray" p.4-80
5 Ink spills out of 1. Is flushing box • Remove dust. "4.6.11
flushing box. clogged with dust? • Replace flushing box Replacing
assembly. Flushing
Tray" p.4-80
2. Is waste fluid tube Reinstall waste fluid tube. -
coming out of flushing
box bent?
3. Does ink accumulate Replace flushing box "4.6.11
in ink absorber sheet in assembly. Replacing
flushing box? Flushing
Tray" p.4-80
9-71 Rev.-00
Table 9-14 Symptoms, Check Items, and Actions (Continued)

6 Ink spills around X rail. 1. Extension tube may be • Remove maintenance "4.4.7
disconnected under ink base assembly and check Replacing
system assembly. if extension tube is MAIN Board"
connected. p.4-49
• Replace pump motor
assembly.
"4.10.1
Replacing Ink
ID Board
• Replace ink system Assembly"
assembly. p.4-125
2. Ink tube may be cut. Replace ink tube. "4.7.10
Replacing Ink
Tube" p.4-102
3. Print head, MAIN After removing ink cartridge, "4.4.7
board assembly and check if each board operates Replacing
CR board assembly properly. MAIN Board"
may be defective. p.4-49
"4.8.9
Replacing
Print Head"
p.4-114
"4.8.3
Replacing CR
Board
Assembly"
p.4-106
9.3.7 Problems in Using Dedicated Network Software

Table 9-15 Problems in Using Dedicated Network Software
1 MUTOH Maintenance - Perform reinstallation and Network
Assistant does not start initial setting. Administration
up. Manual
2 "Transfer failed (Data 1. Are printer and PC Yes: Proceed to (2). "7.3.3
timeout)" is displayed connected correctly No: Connect printer and Required
during transfer. with network cable PC correctly. Environment"
(crossover cable for p.7-8
direct connection and
straight cable for
connection via hub)?
Rev.-00 9-72
Table 9-15 Problems in Using Dedicated Network Software (Continued)

2. Is PC IP address Yes: Proceed to (3). "7.3.3
appropriate? No: Adjust TCP/IP Required
properties from Environment"
[Properties] of [Local p.7-8
Area Connection] in
[Network Connections]
setting of PC. PC and
printer must have the same
subnet address (i.e.
192.168.1.1/24 and
192.168.1.253).
3. Is any device of the Yes: Disconnect the -
same IP address as PC applicable device from
or printer connected to network.
hub? No: Proceed to (4).
4. Is printer started in Yes: Proceed to (5). "7.3.3
board manager mode No: Start printer in board Required
and only POWER manager mode. If LCD Environment"
LED turned on? displays nothing, engine p.7-8
component may be
defective or firmware may
not be installed (including
power cutoff due to power
failure during installation
or other causes.)
5. Is printer IP address Yes: Proceed to (6). "4.4.7
appropriate? (Check No: Engine board may by Replacing
address according to defective MAIN Board"
Section 6.3.) p.4-49
6. Is LAN Yes: Connect PC with "4.4.7
communication other device with LAN Replacing
between PC and other cable and check with MAIN Board"
device available? method such as ping p.4-49
command.
No: PC or engine board
may by defective.
9-73 Rev.-00
Table 9-15 Problems in Using Dedicated Network Software (Continued)

3 "Error received: Buffer Firmware size is too large. Printer repeats buzzer "7.3.5
overflow." is displayed Check if transferred operation in short cycles as Firmware
during transfer. firmware is an appropriate well as display of the Installation"
file. message shown below on p.7-12
LCD. All LEDs of ROLL
MEDIA, CUT MEDIA,
COLOR and
MONOCHROME also
flash simultaneously.
Transfer failed
Data format error
To stop the buzzer, press

any key except for the
power key once.
To return to status in
which installation is
available, press any key
except for the power key
once again.
Rev.-00 9-74
VJ-1604 　 Maintenance Manual 10 Appendix
10 Appendix
10.1 Introduction ........................................................................................... 10- 2
10.2 Wiring Diagram ..................................................................................... 10- 2
10.3 Maintenance Part List........................................................................... 10- 2
10.4 Exploded View....................................................................................... 10- 7
10-1 Rev.-00
10 Appendix VJ-1604 　 Maintenance Manual
10.1 Introduction
This chapter provides referential information such as service data and exploded views.
10.2 Wiring Diagram

For wiring diagram, see information below.
TIP
Separate sheet “Wiring Diagram” p.1
10.3 Maintenance Part List

The following table lists the maintenance parts per unit. The part number below is identical to that of the
exploded view.
Table 10-1 X Rail Assembly
No. Part name Part number Remarks

1 X speed reduction belt DF-43883 Common with VJ26
2 Thermistor assembly DF-44115 For after-heater
3 Thermistor assembly DF-46639 For platen heater
4 AC inlet, large, 15A DF-48402 Common with VJ26
5 Power board assembly DF-48975 Common with VJ12
6 PF_ENC_A0_assembly DF-48985 Common with VJ26
7 PF motor assembly DF-49020 Common with VJ26
8 Cooling fan (24V) assembly DF-49022 Common in VJ series
9 CR_HP sensor, lever sensor DF-49471 Common parts for the CR
origin sensor and the lever
sensor
10 HEATER RELAY board DF-49661 Common in VJ series
assembly
11 MAIN board assembly DF-49658 Common with VJ12
12 HEATER CONT board DF-49660 Common with VJ12
assembly
13 Fuse DF-49683 Common in VJ series
14 Suction fan DG-40311 Common with VJ26
15 PF speed reduction pulley DG-40312 Common with VJ26
Rev.-00 10-2
Table 10-1 X Rail Assembly (Continued)

16 Media holder DG-40313 Common with VJ26
17 Flushing tray (VJ) DG-40317 Common with VJ26
18 Flushing absorber DG-40318 Common with VJ26
19 Platen nonreflective tape DG-40319 Common with VJ26
20 PF_ENC scale DG-40320 Common with VJ26
21 CONTROL to RELAY FFC1 DG-40321 Common with VJ26
(VJ26)
22 VJ16 platen heater assembly DG-40348
23 P_REAR_R sensor assembly DG-40349
(VJ16)
24 VJ16 after-heater assembly DG-40350
25 VJ16 pre-heater assembly DG-40351
26 Thermistor assembly DG-????? For pre-heater
27 Damper L_assembly DF-48141 Common with RH2
Table 10-2 Y Rail Assembly

1 CR driven pulley assembly DF-43868 Common with VJ26
2 CR motor assembly DF-43869 Common with VJ26
3 CR drive pulley assembly DF-43870 Common with VJ26
4 CR speed reduction belt DF-43940 Common with VJ26
5 Pressure roller DF-46666 Common with VJ26
6 CR_HP sensor, lever sensor DF-49471 Common parts for the CR
origin sensor and the lever
sensor
7 T fence (64) DF-43901 Common with 8000 series
8 Heater junction board DG-40135 Common in VJ series
assembly
9 VJ16_CR_FFC_assembly DG-40352
10 Steel belt (64) DF-43937 Common with 8000 series
10-3 Rev.-00
Table 10-3 Cursor Assembly

1 Cutter solenoid assembly DF-42234 Common with VJ12
2 O-ring, M6 DF-46671 Common with VJ26
4 Damper L_assembly DF-48141 Common with VJ26
5 CR_ENC assembly DF-48986 Common with VJ26
6 P_EDGE assembly DF-48983 Common with VJ12
7 Solenoid spring assembly DF-49062 Common with VJ12
8 CR board assembly DF-49659 Common with VJ12
9 Print head DF-49684 Common with VJ12
10 VJ cursor roller arm assembly DG-40326 Common with VJ26
11 VJ16 cursor head base DG-40353
assembly
12 Head FFC (VJ16) DG-40354
Table 10-4 Maintenance Assembly

1 Maintenance assembly DF-49686 Common with VJ12
2 Cleaner head assembly DF-49687 Common with VJ12
3 VJ16 flushing box assembly DG-40355
4 VJ16 maintenance assembly DG-40356
5 VJ16 pump absorber DG-40357
assembly
Table 10-5 IH Assembly

1 Ink ID board assembly DF-43968 Common with VJ26
4 Frame assembly, hook DF-46700 Common with VJ26
5 Two-way valve assembly DF-47837 Common with VJ26
Rev.-00 10-4
Table 10-5 IH Assembly (Continued)

6 VJ cartridge holder assembly DG-40339 Common with VJ26
7 Ink cartridge control cable DG-40340 Common with VJ26
(VJ26)
8 VJ subtank assembly DG-40341 Common with VJ26
9 VJ subtank lower absorber DG-40342 Common with VJ26
assembly
Table 10-6 Leg Assembly

1 Waste fluid level switch DF-44172 Common with VJ26
assembly
2 Waste fluid bottle DF-47867 Common with VJ26
Table 10-7 Roll Media Tray Assembly

1 VJ16_L roll media holder DG-40358
assembly
2 VJ16_R roll media holder DG-40359
assembly
Table 10-8 Cover Assembly

1 Cover sensor (C) assembly DF-47864 Common for the front cover
sensor and the maintenance
cover sensor
2 Panel unit assembly DF-48977 Common in VJ series
3 Cooling fan (24V) assembly DF-49022 Common with VJ26
4 Panel sheet DG-40170
5 Front cover gear DG-40347
6 Damper gear (sintered) DG-40346
7 Panel FFC (VJ16) DG-40360
8 F cover R sensor assembly DG-40361
(VJ16)
10-5 Rev.-00
Table 10-8 Cover Assembly (Continued)

9 F cover L sensor assembly DG-40362
(VJ16)
10 Maintenance cover sensor DG-40366
Table 10-9 Take-up Unit Assembly (Optional)

1 VJ take-up motor assembly DG-40471 Common with VJ12
2 Drive roller DG-40472 Common with VJ12
3 Holder roller DG-40473 Common with VJ12
4 Holder roller L DG-40474 Common with VJ12
5 Drive collar DG-40475 Common with VJ12
6 VJ take-up scroller 12 DG-40476 Common with VJ12
7 VJ take-up scroller 16 DG-40477 Common with VJ12
8 CR_HP sensor, lever sensor DF-49471 Common with VJ12
9 VJ take-up CNT board DG-40478 Common with VJ12
assembly
10 Power source (for foreign DF-44506 Common with RJ-8000
use)
11 VJ take-up SW board DG-40479 Common with VJ12
assembly
12 W_ON sensor assembly DG-40480 Common with VJ12
13 W_OFF sensor assembly DG-40481 Common with VJ12
14 AC cable assembly DG-40482 Common with VJ12
15 DC cable assembly DG-40483 Common with VJ12
16 Power cable 10A (for U.S. DG-40484 Common with VJ12
use)
17 Power cable 7A (for domestic DG-40485 Common with VJ12
use)
Rev.-00 10-6
10.4 Exploded View

For exploded views and the maintenance parts, see information below.
TIP
Separate sheet “Exploded View” p.2-p.10
10-7 Rev.-00
Rev.-00 10-8
VJ-1604 Maintenance Manual Supplement 　 Electric Diagram
Electric Diagram
SS-5GL13-F
J14 MAINTENANCE COVER SENSOR R
MAINTENANCE COVER
PANEL UNIT J1 FFC for Panel Unit (VJ16) J5
SENSOR ASS’Y (VJ16) SS-5GL13-F J5 S
PUMP1 J22 MOTOR DRIVER
J3
J15 INK SENSOR Cyan MAINTENANCE COVER SENSOR L HEATER INK CARTRIDGE
CONTROL CABLE (VJ26) INK
PUMP MOTOR 1 CABLE ASS’Y A3955SLB×2 Not
TR (VJ16)
DIMM(128M) J16 INK SENSOR Magenta J UNCTION SLOT1
CONNECTOR
J23 MOTOR DRIVER
LB1845
End K
J17 INK SENSOR Yellow E- SG2481
W_ORG J27 J 11
AC DC WIPER ORIGIN SENSOR
CABLE ASS’Y (VJ16) J18 Reserved connector 1 for Ink Sensor SUB TANK
SUB_TANK H
E- SG2481
CR_ORG J24 CONTROL CABLE (VJ26) SUB_TANK L
CR ORIGIN SENSOR J4
N +5V CABLE ASS’Y (VJ16)
CLKDV JTAG J19 Reserved connector 1 for Ink Sensor J1 2SOL
Connector Joint LEVER_Up J30
LEVER SENSOR Config CN
+12V CABLE ASS’Y (VJ16)
J2 J6 S
TRANSMISSION TYPE CONNECTOR (RESERVED) J37 INK CARTRIDGE
L +24V Config CN CONTROL CABLE (VJ26) Not INK
SLOT2
N/A TRANSMISSION TYPE CONNECTOR (RESERVED) J39 J20 M PF_MT
+42V MAIN Board Assembly PF MOTOR CABLE ASS’Y (VJ16)
E- 292156- 4
End C
J12 PF_ENC E- SG2481
AC_HEATER Waste_Fluid_Full_sensor J33 PF ENCORDER J12
WASTE FLUID SENSOR CABLE ASS’Y (VJ16) SUB_TANK H
Connector Joint CABLE ASS’Y (VJ16) J21 M CR_MT SUB TANK E- SG2481
(Optional) J35 CR MOTOR CABLE ASS’Y (VJ16) SUB_TANK L
WASTE FLUID BOX SENSOR L CONTROL CABLE (VJ26)
L,N CR_ENCODER 2SOL
J 207
ASS’Y
P_REAR_R J42 CR BOARD P_EDGE SENSOR J7 S
P_REAR SENSOR ASS’Y (VJ16) J 208 INK CARTRIDGE
J7 ASS’Y ASS’Y
CONTROL CABLE (VJ26) Not INK
SLOT3
Option IF J 209 PG_ORG
J8 PG ORIGIN SENSOR End M

TERMINAL ASS’Y (VJ16)
MAIN BOARD SIDE INLET to FUSE Option IF J 206 CUTTER SOLENOID E- SG2481
LAN J6
SOL
ASS’Y J13 SUB_TANK H
BOX CABLE ASS’Y (VJ26) CUTTER SOLENOID
MAIN BOARD SIDE FUSE to TERMINAL BLOCK CR_FFC (VJ16) x 3 RELAY ASS’Y (VJ16) SUB TANK E- SG2481
INLET (SMALL) CABLE ASS’Y (VJ26) USB J13 J44 For releasing CONTROL CABLE (VJ26) SUB_TANK L
E-F-66AD J11 J201 J204 J1 head lock
Noise CPLD HEAD (Cutter is not 2SOL
E-F-66BD ID380 attached.)

Filter FUSE
COVER_R J38 J10 J202 J205 J2
FRONT COVER R J8 S
SENSOR ASS’Y (VJ16) HEAD_FFC (VJ16) x 2 INK CARTRIDGE
HEATER SIDE FG COVER_L J40 J9 J203 CONTROL CABLE (VJ26) INK
FG FRONT COVER L HEAD FG CABLE ASS’Y (VJ16) Not SLOT4
CABLE ASS’Y (VJ26)
SENSOR ASS’Y (VJ16)
Terminal Stand
J 210
HEAD FAN CABLE 1
HEAD_FAN End Y
ASS’Y (VJ16)
COOLING FAN 㧝(5V) J32 J 211 HEAD_FAN
E- SG2481
HEAD FAN CABLE 2
J14 SUB_TANK H
ASS’Y (VJ16) FG SUB TANK E- SG2481
SHORT BAR COOLING FAN 㧞(5V) J34 CONTROL CABLE (VJ26) SUB_TANK L
J25 Vacum_FAN (#1)
SUCTION FAN CABLE 1 ASS’Y 2SOL
COOLING FAN 3 (24v) J36 (VJ16)
J26 Vacum_FAN (#2) J9 INK SLOT 5
POST HEADER ASS’Y COOLING FAN SUCTION FAN CABLE 2 ASS’Y
CABLE ASS’Y (24V) (VJ16)
TERMINAL BLOCK to POWER J28 Vacum_FAN (#3)
AC CABLE ASS’Y (VJ16) SUCTION FAN CABLE 3 ASS’Y J10 INK SLOT 6
PRESSURE ARM (VJ16)
TERMINAL BLOCK to CNT J29 Vacum_FAN (#4)
AC CABLE ASS’Y (VJ16) CN001 P/ S CN301 J1 SUCTION FAN CABLE 4 ASS’Y
J 11 SUB TANK 1
(VJ16)
MAIN BOARD SIDE INLET to FUSE
BOX CABLE ASS’Y (VJ26) J46
INLET (LARGE)
J12 SUB TANK 2
POW LVDS Debug CN
E-F-66AD
Noise J13 SUB TANK 3
E-F-66BD CNT BOARD to HEATER RLY BOARD J45 J43 J41
Filter FUSE
HEATER SIDE FUSE to RLY
AC CABLE ASS’Y (VJ26)
MAIN to CNT POWER CABLE ASS’Y (VJ16)
AC CABLE ASS’Y (VJ16)
MAIN to CNT SERIAL CABLE
FG J14 SUB TANK 4
HEATER SIDE FG CABLE ASS’Y (VJ26) J6 J4 J1
J10 J15 SUB TANK 5

Origin side Plt_Heat J2 J21 CNT to JC POWER CABLE ASS’Y (VJ16)
PLT_H1 CABLE ASS’Y HEATER
Oppositte side POW-ON J8 J2 DC IN J16 SUB TANK 6
to origin Plt_Heat
PLT_H2 CABLE ASS’Y J5 RELAY J22 AC㧙IN
J9 J3 Communi cat i on
PRE_H1 CABLE ASS’Y CONTROL to JUNCTION CABLE ASS’Y (VJ26) J18 EX_SLOT 1
Origin side Pre_Heat J7 J23 EXT-AC-OUT (for serial communication)
Pre_Heat
CNT to RLY FFC1 (VJ26) J4 JUNCTION TO JUNCTION
PRE_H2 CABLE ASS’Y J8 AC㧙OUT J20 J 20 EX_SLOT 2
Origin side J3 J6 RELAY A
Oppositte side PrAft_Heat
e_Heat J 25
to origin J9 J 23 EX_SLOT 3
AFT_H CABLE ASS’Y DC㧙IN J19
J7 RELAY B
Origin side Platen_thrm J12
PLT_T1 CABLE ASS’Y ???? J 24 EX_SLOT 4
Oppositte side S J12 SMART CARD
to origin Platen_thrm J13 J2 FEED-M
PLT_T2 CABLE ASS’Y J17 EX_ACT_1
Origin side Pre_thrm
PRE_T1 CABLE ASS’Y
J15 HEATER
Oppositte side J3 FEED-S J19 EX_ACT_2
to origin Pre_thrm
PRE_T2 CABLE ASS’Y
J16 CONTROL
Origin side After_thrm
AFT_T1 CABLE ASS’Y
J17 Debug J11 BOARD J4 WIND-M
J 21 EX_ACT_3
Oppositte side
to origin After_thrm J18 RSVIN1 J13 J 22 EX_ACT_4
AFT_T2 CABLE ASS’Y
J5 WIND-S
Rev1_thrm J19 RSVOUT1 J14
Rev2_thrm J20 J1
E-292156-2 RSVIN2 J16 Config CN
MIST FAN1 J11
MIST_FAN CABLE1
E-292156-2 ASS’Y (VJ16) RSVOUT2 J15
MIST FAN2
E-292156-2
MIST FAN3 EX THRM1 J17
J14
MIST_FAN CABLE2
ASS’Y (VJ16)
EX THRM2 J18
COOLING J10
1
Self-Diagnosis Function Configuration Diagram (1/3) for Ver. 1.05d
Adj.Platen
Test Ram Capacity

Version Firm
Parameter
DipSW
Board Rev.
Panel Key
LCD
LED
Sensor CR Origin
WasteTank
Wiper
Cover
M.Cover L
M.Cover R
Lever
EdgeAD
Rear
HeadGap
Head
Trans.1
Trans.2
Encorder CR
PF
Fan Vacum Fan

Cooling Fan
Head Fan
Record Maintenance Wiper

Error CR Motor
Error Init. PF Motor
PrintNumber
Cleaning
Fire 1-A
Fire 1-B
Fire 2-A
Fire 2-B
Fire 3-A
Fire 3-B
Fire 4-A
Fire 4-B
PUMP
LockSole
HeadSignal
InkCharge Normal
Little
Adjustment
Cleaning Refer to Self-Daignosis Function Configuration Diagram (2/4)
Print
SetTime
Parameter
Servo Refer to Self-Daignosis Function Configuration Diagram (3/4)
Endurance
PaperFeed
ExControl
PaperInitial
2
Adj.Platen
Test Self-Diagnosis Function Configuration Diagram(1/4)
InkCharge
Adjustment Nozzlcheck Cleaning Economy
Print Normal
Check Skew Strong
HeadSlant Slant
F and B
Adj. Volt 240CW

240CCW
320CW
320CCW
Uni/Bi Low Uni-D 240

Uni/Bi High Uni-D 320
Uni-D 240B
Uni-D 320B
Bi-D 240
Bi-D 320
Bi-D 240B
Bi-D 320B Setup
Print 1
Print 2
SideMargin Initialize
Check
TestPrint Adjust ALL

HeadWash Parameter
HeadWash2 Log Info
CountClear
SendPitch
FillPattern
Cleaning Economy
Normal
Strong
Print Adjust ALL

Parameter
SetTime Log Info
Parameter Initialize Adj. Volt 240CW

240CCW
320CW
320CCW

Head Uni-D 240B
Wiper Uni-D 320B
CR Motor Bi-D 240
PF Motor Bi-D 320
Pump Bi-D 240B
ALL Bi-D 320B
Update Head Rank

Adj. Volt 240CW
240CCW
320CW
320CCW

SideMargin Uni-D 240B
Charge Flg Uni-D 320B
SerialNo. Bi-D 240
ChipName Bi-D 320
Debug Bit Bi-D 240B
Bi-D 320B
Servo
Endurance Self-Daignosis Function Configuration Diagram (3/4)
PaperFeed
ExControl
PaperInitial
3
Adj.Platen
Test Refer to Self-Daignosis Function Configuration Diagram (1/4)
InkCharge
Adjustment
Cleaning Refer to Self-Daignosis Function Configuration Diagram (2/4)
Print
SetTime
Parameter Initialize
Refer to Self-Daignosis Function Configuration Diagram (2/4)
Update
Servo Servo1 (240cps CW)

Servo2 (240cps CCW)
Servo3 (320cps CW)
Servo4 (320cps CCW) GP
GI
GLPF
ＰＷＭ scale
ωC
Endurance CR Motor
PF Motor
Pump
Nozzle
Total Life
Check
PaperFeed
ExControl Version
Sensor Tank Status
MistFan Tank Valve Check
etc Pre1
Pre2
Heater Pre Platen1
Platen Platen2
After After1
After2
Record Pre.H K Ink ID
Platen.H C Ink ID
After.H M Ink ID
PaperInitial Top&Width Y Ink ID
Width Ink Not
Off Ink END
4
Maintenance Mode 2 Configuration Diagram for Ver.1.05d
Indication Used Ink K

Used Ink C
Used Ink M
Used Ink Y
PrintNumber
Waste Ink
CR Motor
PF Motor
Pump
Head K1
Head K2
Head C1
Head C2
Head M1
Head M2
Head Y1
Head Y2
Cleaner
InitCounter Print Num.

Ink
ALL
NVRAM
Timer
CR Motor
PF Motor
HeadUnit
Cleaning
Pump
Shipping
Print
PaperFeed
5
VJ-1604 Maintenance Manual Supplement 　 Exploded View
A-112 A-111 A-36

Exploded View A-110
A-109
A-35
A-97 A-114
A-117 B-5 A-19
DG-40317
A-120
DG-40320 A-249
A-18
A-118 A-41
A-25 A-28 A-31
DG-40312 A-251 A-43 A-30 A-34
A-121 A-24
A-97 A-116 DF-49020 A-252
H-7
A-115 B-5
DG-40313 DF-43883 A-248 DG-40318
A-26
DG-40319 A-122 DF-48985 A-20
A-41 A-27 A-35
A-21
A-80 A-129 A-130 A-37
A-81 A-124 A-22
A-126 A-23
A-125 A-253
A-131
A-130 A-19
A-129 A-254 A-247 A-14
A-82 A-43 A-18
A-84 B-5
A-16
A-85
A-92 A-86 A-94 A-97 A-13
A-83 A-87
A-69 DG-40313 A-41
A-91
H-5 A-15
DF-46639 A-16 A-245
A-84 A-246
A-12
A-60 A-85
A-86 A-226 A-231
A-217 A-5 A-49 A-48 A-224 B-28
A-87
A-58
A-90 A-230
A-59 A-5 DF-49471
DF-46639 A-215 A-234
A-68 A-222
DG-40311 A-5 A-13 A-223 A-235
A-82
A-225
A-92 A-239 A-236
A-67 A-66 A-237
DG-40348 A-216 A-16 A-241
A-75
A-83 H-3
A-77 A-10 A-240
A-243
A-70 A-76 A-74 A-244 H-1
A-8 A-15
A-298
A-56 A-12
A-299
DF-49658 A-9
A-69 A-270 A-4
A-269
A-71 A-261
A-95
A-260
A-261 DF-49683
A-264 A-294
A-260
A-295
A-68
A-265 A-274
A-280
A-55 A-278(A-279) A-100 A-1
A-285
H-2
A-51
A-101
DF-48402
X Rail Assy 1
A-257
A-52 2006.11.16 Rev.A Model Name: VJ-1604
6
X Rail Assy 1
Exploded View
A-180
A-188
A-181
A-190 A-186
A-184 A-183 A-202
A-208
A-196
A-206
A-209
A-185 A-214 A-108
A-183 DG-40349
A-107
A-190
A-184 A-106 DG-40???
A-187 A-211
DF-44115 A-105
A-205
A-182 A-207
A-206
A-209
A-137 A-203
A-196
A-194
A-204 A-214
A-193 A-136 A-210

DG-40350
DF-49022 A-211 DG-40351
A-177 A-135
A-134
A-174 A-175 A-138
A-176 A-140
A-168 A-170 DG-40321 A-141 A-200
A-162 A-192 A-213
A-167
A-161 A-137 A-212
A-153
A-152 A-191
A-145 DF-49661
DF-49660 A-149
A-148
DF-48975
A-173
X Rail Assy 2
A-192
A-146
2006.11.16 Rev.A Model Name: VJ-1604
7
X Rail Assy 2
Exploded View
B-125
A-112 A-111 B-128

A-110
A-109 B-122
A-118
A-114
DF-43868 B-52
B-127
A-117 B-54 B-119 B-122 DG-40352
B-53 B-114
A-120 B-126
B-101
B-106 B-105
B-55 B-120 B-119
B-93 B-51
A-121 A-118
B-50 B-118
A-116 B-104 B-131
B-102 B-92
A-115 B-117
B-103 B-94
B-100 B-95
A-122 B-99
B-95 B-117 B-115
B-5 B-165
B-11
A-129 A-130
B-12 B-121 B-116
A-124 B-113
A-126
B-24 A-125 B-33 B-112
B-23
DF-49471
A-131
B-24 A-130 B-6 DF-43901
B-9 B-39 B-114
B-23 A-129 B-45 DF-43869
B-40
B-24 B-47
B-46 B-38
B-23 B-37
B-44 B-71
B-15
B-24 B-43
B-36
B-23
B-76
B-74
B-18
B-19 B-2
B-61
B-17 B-27 B-60 B-75
B-72
B-1 B-59 B-73
B-157 B-84
B-16 B-155 B-85
B-12 B-82
B-153 B-80
B-60
B-20 B-156 B-83
B-65
B-66 DF-43870
B-2
B-29 B-11 B-154 DG-40135 B-81
B-2 B-153 B-11
B-88
B-8
B-109 DF-43940
B-5
B-28
DF-43937
B-6
DF-46666 C-62
Y Rail Assy
8
Y Rail Assy
C-67 C-157
Exploded View
C-69 C-68 C-164
C-111 C-151
C-109
C-145 C-155
C-69
C-111
C-110
C-154
C-151
C-153
C-156 DF-49659
C-112
C-150
C-144 C-152
C-126 DG-40354
DF-46672 C-106 C-93
C-147
C-121 C-104
C-162
C-125 C-105
C-102 C-161
C-143
C-124 C-115 DF-48141 C-144
C-103
DF-49062 DG-40353 C-134
C-117
C-96
C-122
C-98 C-140
C-99 C-36
DF-42234 C-116
C-97
C-25
DF-49684
C-123 C-33 C-143
C-200
C-92 C-12
C-120 C-21
DF-48986
C-10 C-9 C-34 C-62
C-132
C-87 C-11
C-29
C-132 C-35 C-4 C-60
C-131 C-82 C-66 C-6 C-36
C-33
C-88
C-119 C-32 C-5
DF-48983 C-77 C-22
C-30
C-31
C-75 C-6
C-130 C-9 C-62
C-12 C-4
C-74 C-51 C-61 C-5
C-76 C-53
C-73 C-31
C-1
C-44 C-52
C-86 C-10 C-11 C-9
C-54
C-10
C-32
C-45 C-11
C-46 C-9 C-30 C-12
C-85 C-80
C-47 C-61 C-10 C-22
C-12 C-11 C-20
C-194
C-180 C-48
C-179 C-45 C-57
C-81 DG-40326
C-16
C-178 C-19
C-46 C-17
C-47 C-18 C-16
C-184 C-48
D-2
C-186
C-15
C-19 C-17
C-18
Cursor Assy
C-185
9
Exploded View DG-40317

D-19
D-20 DG-40355
DG-40318 D-31
D-21
D-24
D-25 DG-40357
D-23 D-18 D-30
DG-40356
D-88
D-102
D-93
D-28
D-15 D-87
D-14
D-92
D-29
D-27
D-32
D-8
D-12 D-85
D-99 DG-40356
D-7
D-90
D-2
DF-49687
D-101 D-40
D-11
DG-40356 DF-49686
D-43 D-9
D-38 D-41
D-102 D-34
D-11 D-37
D-42
DG-40356
D-102
D-1
D-10
Maintenance Assy
10
Cursor Assy 1
Exploded View E-32
E-32 E-10
E-31
DG-40339
E-9
E-35 DF-46700
E-7
E-31
E-22 E-8
DF-46671
E-34 E-11
E-6
E-35
To Cartridge
E-33 DF-43968
E-81
E-17 E-22
E-34 E-76
E-33 E-76 E-16
E-70 E-79
E-69 E-19
E-68 E-21
E-78 E-2
E-66
DF-46672 E-75 E-12
E-67 E-48 E-14 E-13
E-74 DG-40340
E-65 DF-46671
E-58 E-50 DF-47837 E-29 E-4
E-87
E-59
E-63
E-64 E-60 E-28
E-3
E-44
E-49 E-77 E-25
DF-46671
E-42 E-75
E-75 E-73 E-24
E-57 E-61
K-76
DG-40341
E-51
E-1
E-62 DF-46671
E-53
E-60
E-55 E-64
E-63 E-42
E-56
E-61
E-53
DG-40342
E-88
E-56
E-84
E-90
E-25
E-88
E-41
E-83 E-27
E-25
E-39
RE
AR
E-41
E-40
E-39
E-85 I/H Assy
E-40
11
Cursor Assy 2
Exploded View
F-26 F-26 F-8

F-1
F-16
F-16
F-23
F-15
DF-44172
F-22 F-21
DF-47867
F-20
F-2
F-19
F-9
F-4
F-4
F-11
F-3
F-11
F-5
F-10 F-13
F-6
F-12 Leg Assy

12
Head Board Assy
Exploded View G-2
G-5
G-4
G-6
G-8
G-7 G-20
G-14 G-19
G-15
A-200
G-3
G-1
G-9
G-12
G-14
G-13
G-15
G-2
G-18
G-5
G-4
G-6
DG- 40359
G-18
G-7 G-8
G-13
G-12
G-3
DG- 40358
G-1
G-19
G-20
G-9
Roll Media Holder Assy
13
Foot Assy 1
Exploded View H-127 H-91

H-126 H-90
H-113
H-80
H-80
H-79
DG- 40170 DF- 48977

H-112
H-53 H-84
H-55
H-124 J-17
H-121 H-120 H-54 H-73
H-113 H-121 H-80
H-72
H-58 H-57 H-85
H-82
H-24 DG-40360 H-49
H-125
H-53 H-78 H-78
H-25 H-48
H-104 H-7 H-122 H-47
H-114
H-52 H-67
H-123 H-45
H-110 H-39 H-46 H-28

H-1 H-77
H-8 H-40
H-35 H-88
H-107 H-103 DG- 40362
H-36 H-180
H-187 H-178 DF- 47864 H-43 H-56
DF- 47864 H-2 H-89
H-111 H-181 DG-40347
H-184
H-108 H-186 H-183 H-44
H-179 H-32 H-31
H-10 H-67
H-181 H-23 H-33
DG-40346 H-176 H-177 H-170 H-27
H-60
H-174
H-165 H-173
H-168 H-21 H-28
H-105 H-167 H-172 K-28
H-166 H-171 H-66
H-15
H-106 H-20
H-198 H-14 DF- 49022
H-167
H-164 H-199 H-22
H-6
H-13
H-199 H-197
H-202
H-198 H-196
H-201
H-5
H-22 H-12
H-202
H-133
H-130 H-202
H-191 H-192
H-20
H-69 H-145
H-193 H-1 DG-40347
H-157
H-192 DF- 47864
H-193 H-142 H-146
H-190 DG-40361
H-4
H-153 H-152
H-131 H-71
H-3 H-154
H-143
H-204
H-203
H-144 H-150 H-161
H-149 H-69
H-205
H-98
H-160 DG-40346
H-97
O NT H-201
H-39 H-40 H-139
H-161
FR H-202
DF- 47864
H-136
H-70
Cover Assy
DG-40366 H-139 H-138
H-137 H-138 H-140 H-68 2006.11.29 Rev.A Model Name: VJ-1604
14
Exploded View +

+ +
+ + DG-36753
+ +
DG-40474 +
+ +
+
+ DG-40484
+ +
+
+ DG-40479
+
+
+ +
+ +
+
+
+ +
+ +
+ + + + +
DG-40482
+
+ + + +
+ + + DG-40483
+
+ +
+ + + + +
+
+ +
+ +
+
+ DG-40478 DG-40471
+
+ +
+ DF-40556
+ +
+ + +
+ + + DG-40473
+ + +
+
+ + + +
+
+ +
DG-40427 + +
+ +
+ +
+ +
+ +
+
+ +
+ +
+ + +
+ + +
+ + +
+ +
+
+ + +
+
+
DG-40477 +
+
+ + +
+
+ +
+ + + +
+ DG-40480 DG-40481 +
+
DF-49471
Feed Assy
+ DG-40475
15
16

Valuejet 1604 ServiceManual

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Valuejet 1604 ServiceManual

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MAINTENANCE

Full-Colour Inkjet Printer

Use this manual for the maintenance

1. For Users in Europe

2. For Users in the United States

3. Trademark Mentioned in this Manual

• No part of this product or publication may be reproduced, copied, or

About this Manual

1. Purpose and Target Readers

Must be observed to avoid slight or moderate bodily injury or damage to

Contains important information and useful tips on the operation of the

Indicates useful tips for operating or understanding the equipment

Indicates reference pages in this manual

General Table of Contents

1.2 Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.4 Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.5 Operation Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

2.2 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.3 Part Names and Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.4 Printer Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

3.2 Product Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.3 Interface Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.4 Options/Supplies List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.5 Choosing a Place for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

4.2 Removal of Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.4 Replacement of PF Driving Section Components. . . . . . . . . . . . . . . . . . 4-31

4.5 Replacement of CR Driving Section Components . . . . . . . . . . . . . . . . . 4-38

4.6 Replacement of Head Section Components . . . . . . . . . . . . . . . . . . . . . . 4-48

4.7 Replacement of Maintenance Section Components . . . . . . . . . . . . . . . . 4-57

4.8 Replacement of Ink Supply Section Components . . . . . . . . . . . . . . . . . . 4-66

4.9 Replacement of Frame Section Components . . . . . . . . . . . . . . . . . . . . . 4-73

4.10 Replacement of Cable Guide Section Components . . . . . . . . . . . . . . . . 4-75

5.3 Operations in Self-Diagnosis Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.4 Platen Adjustment Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.5 Inspection Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.5.7 History Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5.6 Ink Charging Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5.7 Adjustment Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

5.8 Cleaning Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

5.9 Sample Printing Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

5.10 Time Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

5.11 Parameter Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

5.12 Servo Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

5.14 Media Feed Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65

5.15 ExControl Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66

5.16 PaperInitial Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69

6.2 Operations in Maintenance Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.3 Maintenance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

7.2 Adjustment Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7.3 Working with Dedicated Network Software . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7.4 PF Speed Reduction Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . 7-20

7.5 PF Encoder Assembly Position Adjustment . . . . . . . . . . . . . . . . . . . . . . 7-22

7.6 CR Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

7.7 Head Alignment (Horizontal Height) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

7.8 Head Alignment (Vertical Slant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

7.9 Cutter Holder Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

7.10 PG Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31