Muton ValuejetVJ-1604 Maintenance Manual Download Page 109

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VJ-1604

Maintenance Manual

4 Parts Replacement

4-67

Rev.-00

4.6.6

Replacing Lever Up Sensor

1. Open the maintenance cover.

2. Remove the side maintenance cover R.

"4.2.4 Removing Side Maintenance Cover R" p.4-11

3. Remove the lever up sensor cable assembly.

4. Remove the lever up sensor assembly.

5. Replace the lever up sensor assembly.

No.

Part name

Lever up sensor cable assembly

Lever up sensor assembly

Cover stay RR

Rear view

Enlarged view

Summary of Contents for ValuejetVJ-1604

Page 1: ...Rev VJ 1604 Full Colour Inkjet Printer MAINTENANCE MANUAL VJ1604E M 00 Use this manual for the maintenance and inspection of machine ...

Page 2: ......

Page 3: ... 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 This is a Class A product approved fo...

Page 4: ...ure 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 ...

Page 5: ...verview 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 ...

Page 6: ...ng Must be followed carefully to avoid death or serious bodily injury Must be observed to avoid slight or moderate bodily injury or damage to your equipment Contains important information and useful tips on the operation of the product Indicates useful tips for operating or understanding the equipment Indicates reference pages in this manual WARNING CAUTION NOTE TIP ...

Page 7: ...on 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 ...

Page 8: ...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 Ass...

Page 9: ...g 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 Prepa...

Page 10: ...eed 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 ...

Page 11: ...are 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...

Page 12: ...leshooting 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 ...

Page 13: ...VJ 1604 Maintenance Manual 11 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 ...

Page 14: ...VJ 1604 Maintenance Manual 12 ...

Page 15: ...ctions 1 1 Rev 00 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 ...

Page 16: ...ed 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 Must be observed to avoid slight or moderate bodily injury or damage ...

Page 17: ...ausing 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 ...

Page 18: ...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 disc...

Page 19: ... 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 ...

Page 20: ...1 Safety Instructions VJ 1604 Maintenance Manual Rev 00 1 6 1 4 2 Locations and Types of Warning Labels 1 Main Body The locations of warning labels on the main body are shown below 4 3 2 1 5 6 6 8 9 7 ...

Page 21: ...604 Maintenance Manual 1 Safety Instructions 1 7 Rev 00 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 ...

Page 22: ...VJ 1604 Maintenance Manual Rev 00 1 8 5 Steel belt caution 6 High temperature caution 7 Electric shock caution 8 Ink handling caution 9 Waste fluid tube handling caution Table 1 2 List of Warning Labels No Warning label type ...

Page 23: ...VJ 1604 Maintenance Manual 1 Safety Instructions 1 9 Rev 00 2 Scroller Optional The locations of warning labels on the scroller are shown below No Warning label type 1 Catching caution 1 ...

Page 24: ...1 Safety Instructions VJ 1604 Maintenance Manual Rev 00 1 10 ...

Page 25: ...on 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 ...

Page 26: ...r 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 m...

Page 27: ...nual 2 Product Overview 2 3 Rev 00 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 Rear Right Upper Lower Left Front ...

Page 28: ...ter 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 Th...

Page 29: ...uid 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 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...

Page 30: ...ork interface cable 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 Sc...

Page 31: ... other functions The names and functions of the operation keys and status lamps are explained below TIP Operation manual 7 Scroller horizontal position adjustment screw Adjusts the horizontal position of the scroller 8 Power switch Turns the plotter on off Table 2 3 Part Names and Functions of Scroller Section Continued No Name Function 8 9 3 15 17 16 6 5 11 12 1 13 14 10 2 7 4 ...

Page 32: ...ng data During reception analysis Deletes the data that has been already received analyzed and ignores 1 file of data received after that Returns to the previous menu hierarchy Changed parameter values are disabled Changes the setup menu display status to normal status 4 key Changes the setting value in the following menu Origin setting menu Nozzle Check key If held down for 2 seconds or more star...

Page 33: ...et 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 lamp Green On The effect menu is set to either Fine or SuperFine Off The effect menu is set to Wave 15 Strong la...

Page 34: ...g 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 setu...

Page 35: ...0 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 ...

Page 36: ...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 ...

Page 37: ...racy 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 environment Without ink 20ºC 4F to 60ºC 140F 20 to 80 with no condensation With ink 10ºC 14F to 40ºC 104F 20 to 80 with no condensation Power source Voltage AC 90 132V Frequency 50Hz 60Hz 1Hz Power consumption During Plotting 1200W when heater is ON During standby 40W or ...

Page 38: ... Ink Cartridge 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 protocol TCP IP 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...

Page 39: ...VJ 1604 Maintenance Manual 3 Specifications 3 5 Rev 00 2 Other Supplies Name Model Sales units Waste ink bottle RJ8000 HET 1 box 1 piece per box ...

Page 40: ...m 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 specification s Voltage AC...

Page 41: ... 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...

Page 42: ...3 Specifications VJ 1604 Maintenance Manual Rev 00 3 8 ...

Page 43: ...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 G...

Page 44: ...ain 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...

Page 45: ...ence 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 Assemb...

Page 46: ...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 ...

Page 47: ...VJ 1604 Maintenance Manual 4 Parts Replacement 4 5 Rev 00 4 13 5 Replacing Peripheral Devices of VJ Take up Motor Assembly 4 153 ...

Page 48: ...s 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...

Page 49: ...Removing Covers This section describes the procedures to replace covers 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 2 3 1 4 5 6 7 8 10 11 12 13 5 9 8 14 20 21 19 18 15 13 16 17 ...

Page 50: ...p 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 Table 4 1 Cover Component List Continued No Part name ...

Page 51: ... 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 No Part name 1 Panel cover 2 Screws that retain the panel cover pan head screw with spring washer and flat washer M4 8 1...

Page 52: ...nit reverse the removal procedure 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 1 Remove the maintenance cover 4 2 2 Removing Maintenance Cover p 4 9 No Part name 1 Maintenance cover 1 ...

Page 53: ...ocedure 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 Maintenance cover U 2 Screws that retain the maintenance cover U pan head screw with spring washer and flat washer M4 8 No Part name 1 Side maintenance cover R 2 screws that retain the side maintenance cover R pan head screw with spring washer and flat washer M4 8 1 ...

Page 54: ... maintenance cover L 2 Lift up and remove the side maintenance cover L 3 To reassemble the unit reverse the removal procedure 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 No Part name 1 Side maintenance cover L 2 Screws that retain the side maintenance cover L pan...

Page 55: ...at retain the side top cover R 3 Remove the side top cover R to the direction shown in the picture below 4 To reassemble the unit reverse the removal procedure No Part name 1 Side top cover R 2 Screws that retain the side top cover R pan head screw with spring washer and flat washer M4 8 2 1 ...

Page 56: ...nce 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 3 Remove the side top cover L to the direction shown in the picture below 4 To reassemble the unit reverse the removal procedure No Part name 1 Side top cover L 2 Screws that retain the side top cover L pan head screw with spring washer and flat washer M4 8 2 1 ...

Page 57: ... 4 2 5 Removing Side Maintenance Cover L p 4 12 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 4 Remove the rear side cover 3 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 1 2 3 ...

Page 58: ...pieces on the left and right side of the rear side cover No Part name 1 Rear side cover 2 Screws that retain the rear side cover pan head screw with spring washer and flat washer M4 8 No Part name 1 Rear side cover 2 Screws that retain the rear side cover pan head screw with spring washer and flat washer M4 8 1 2 1 2 2 1 Rear right view Rear left view ...

Page 59: ...artridge 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 No Part name 1 Rear side cover No Part name 1 Cartridge cover Upper 2 Screws that retain the cartridge cover Upper pan head screw with spring washer and flat washer M4 8 1 2 1 1 2 Rear left view Rear right view ...

Page 60: ...ge Cover middle 1 Remove the cartridge cover upper 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 upper 2 Screws that retain the cartridge cover upper pan head screw with spring washer and flat washer M4 8 No Part name 1 Cartridge cover middle 2 Screws that retain the cartridge cover middle pan head scr...

Page 61: ...cartridge cover lower 2 Remove the cartridge cover lower 3 To reassemble the unit reverse the removal procedure 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 No Part name 1 Cartridge cover lower 2 Screws that retain the cartridge cover lower pan head screw with spring washer and flat washer M4 8 2 1 1 2 Left view Right view ...

Page 62: ...1 Remove the side top cover L 4 2 7 Removing Side Top Cover L p 4 14 2 Remove the screws 3 pieces that retain the switch cover L No Part name 1 Switch cover R 2 Screws that retain the switch cover R pan head screw with spring washer and flat washer M3 8 No Part name 1 Switch cover L 2 Screws that retain the switch cover L pan head screw with spring washer and flat washer M3 8 2 1 2 1 Rear view Rig...

Page 63: ...and right side of the front cover 4 pieces respectively 2 Remove the front cover 3 To reassemble the unit reverse the removal procedure 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 4 2 6 Removing Side Top Cover R p 4 12 2 Remove the Rear side cover 4 2 8 Removing Rear Side Cover p 4 15 No Part name 1 Front cover 2 Scr...

Page 64: ... 17 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 7 Remove the rear top cover 8 To reassemble the unit reverse the removal procedure No Part name 1 Rear top cover 2 Screws that retain the rear top cover pan head screw with spring washer and flat washer M4 8 3 Screws that retain the rear top cover cup screw M3 8 2...

Page 65: ...more persons 1 Remove the front cover 4 2 14 Removing Front Cover p 4 21 2 Remove the rear top cover 4 2 15 Removing Rear Top Cover p 4 21 3 Remove the screws 6 pieces that retain the back of the top cover No Part name 1 Top cover 2 Screws that retain the top cover pan head screw with spring washer and flat washer M3 8 2 1 Rear view ...

Page 66: ... reassemble the unit reverse the removal procedure 4 2 17 Removing Media Guide F Upper CAUTION Media guide F upper removal must be done by 2 or more persons 1 Remove the maintenance cover 4 2 2 Removing Maintenance Cover p 4 9 No Part name 1 Top cover 2 Screws that retain the top cover pan head screw with spring washer and flat washer M3 8 2 1 Front view ...

Page 67: ...es that retain the media guide FL 5 Remove the media guide FL No Part name 1 Media guide FR 2 Screws that retain the media guide FR pan head screw with spring washer and flat washer M4 8 No Part name 1 Media guide FL 2 Screws that retain the media guide FL pan head screw with spring washer and flat washer M4 8 2 1 Right upper view Lower view 2 1 Left upper view Lower view ...

Page 68: ...emove the screws 5 pieces that retain the media guide F upper 8 Lift up the media guide F upper No Part name 1 Media guide F upper 2 Screws that retain the media guide F upper pan head screw with spring washer and flat washer M4 8 No Part name 1 Media guide F upper 2 Screws that retain the media guide F upper binding small screw M3 6 1 2 1 2 ...

Page 69: ...de the media guide F upper 10 Remove the media guide F upper 11 To reassemble the unit reverse the removal procedure 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 No Part name 1 Media guide F upper 2 Media guide F lower 3 Connector to the after thermistor 4 Connector to the after heater 2 1 3 4 ...

Page 70: ...connectors to the pre thermistor that are in side the media guide R upper 5 Remove the media guide R upper 6 To reassemble the unit reverse the removal procedure No Part name 1 Media guide R upper 2 Screws that retain the media guide R upper pan head screw with spring washer and flat washer M4 8 No Part name 1 Rear top cover 2 Media guide R upper 3 Connector to the pre thermistor 4 Connector to th...

Page 71: ...ving 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 3 Remove the media guide R lower 4 To reassemble the unit reverse the removal procedure No Part name 1 Media guide R lower 2 Screws that retain the media guide R lower pan head screw with spring washer and flat washer...

Page 72: ... 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 4 Rem...

Page 73: ... pieces that retain the maintenance cover sensor assembly 4 Remove the maintenance cover sensor assembly 5 Replace the maintenance cover sensor assembly 6 To reassemble the unit reverse the removal procedure TIP The maintenance cover sensor looks like the following No Part name 1 Maintenance cover sensor assembly 2 Screws that retain the maintenance cover sensor assembly pan head screw with spring...

Page 74: ...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 6 Removing Side Top Cover R p 4 12 2 Remove the switch cover R 4 2 12 Removing Switch Cover R p 4 19 3 Detach the connector for the cover sensor C assembly_R ...

Page 75: ... The cover sensor looks like the following 2 L Side 1 Remove the Side top cover L 4 2 7 Removing Side Top Cover L p 4 14 2 Remove the switch cover L 4 2 13 Removing Switch Cover L p 4 20 3 Detach the connector for the cover sensor C assembly_L 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...

Page 76: ...y_L 5 Remove the cover sensor C assembly_L 6 To reassemble the unit reverse the removal procedure TIP The cover sensor looks like the following No Part name 1 Cover sensor C assembly_L 2 Screws that retain the cover sensor C assembly_L pan head screw with spring washer and flat washer M2 12 3 Damper cover L 2 1 3 Opened Closed ...

Page 77: ...emoving Switch Cover R p 4 19 2 Remove the screw 1 piece that retain the switch plate R 3 Remove the switch plate 4 Remove the screws 3 pieces that retain the damper cover R No Part name 1 Switch plate R 2 Screws that retain the switch plate R pan head screw with spring washer and flat washer M3 8 3 Front cover axis No Part name 1 Damper cover R 1 2 3 2 2 1 ...

Page 78: ...lace the front cover gear 8 Replace the damper gear sintered 9 To reassemble the unit reverse the removal procedure 2 Screws that retain the damper cover R pan head screw with spring washer and flat washer M4 8 No Part name 1 Flange bushing 2 Front cover gear 3 Front cover axis 4 Damper gear sintered No Part name 2 1 4 3 ...

Page 79: ...witch plate L 3 Remove the switch plate 4 Remove the screws 3 pieces that retain the damper cover L No Part name 1 Switch plate L 2 Screws that retain the switch plate L pan head screw with spring washer and flat washer M3 8 3 Front cover axis No Part name 1 Damper cover L 2 Screws that retain the damper cover L pan head screw with spring washer and flat washer M4 8 1 3 2 2 1 2 ...

Page 80: ...e the damper cover L 6 Remove the flange bushing 7 Replace the front cover gear 8 Replace the damper gear sintered 9 To reassemble the unit reverse the removal procedure No Part name 1 Flange bushing 2 Front cover gear 3 Front cover axis 4 Damper gear sintered 1 3 2 4 ...

Page 81: ...tion describes the procedure to replace the power supply or the board in the X rail section The boards are arranged as follows No Part name 1 HEATER RELAY board assembly 2 HEATER CONT board assembly 3 Power board assembly 4 Main board assembly 2 4 1 3 Inside view of board box 64 Inside view of paper guide F ...

Page 82: ...f 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 3 Open the board box 64 downwardly 4 To close the unit reverse the opening procedure No Part name 1 Board box 64 2 Screws that retain the board box 64 pan head screw with spring washer and flat washer M4 8 2 1 1 2 Left view Ri...

Page 83: ...the electrolytic capacitor Touching the board before the capacitor discharges may cause electric shock 1 Remove the media guide F upper 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 4 Remove the power board assembly 5 Replace the power board assembly 6 To reassemble the unit reverse the removal procedure No Part nam...

Page 84: ...ith 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 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 ...

Page 85: ...k 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 J3 LAN 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 ...

Page 86: ...t 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 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 co...

Page 87: ...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 ...

Page 88: ... 5 Replace the heater relay board 6 To reassemble the unit reverse the removal procedure 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 No Part name 1 Heater relay board 2 Screws that retain the heater relay board cup screw M3 6 2 1 2 ...

Page 89: ...sembly 4 Replace the cooling fan 24V assembly 5 To reassemble the unit reverse the removal procedure No Part name 1 Cooling fan 24V assembly 2 Screws that retain the cooling fan 24V assembly pan head screw with spring washer and flat washer M3 30 3 Connector to the cooling fan 24V assembly 2 1 3 Back of the leg holder base ...

Page 90: ...at retain the cooling fan 24V assembly 4 Remove the cooling fan mounting plate 5 Remove the screws 2 pieces that retain the cooling fan 24V assembly No Part name 1 Cooling fan 24V assembly 2 Cooling fan mounting plate 3 Screws that retain the cooling fan mounting plate pan head screw with spring washer and flat washer M4 6 4 Connector to the cooling fan 24V assembly No Part name 1 Cooling fan 24V ...

Page 91: ... 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 NOTE Be sure to back up the parameters before replacing the MAIN board assembly 7 3 1 Parameter Backup p 7 7 2 Screws that retain the cooling fan 24V assembly pan head screw with spring was...

Page 92: ...h sides 3 Remove the SODIMM 4 Replace the SODIMM NOTE Push in the SODIMM following the notches until click sound occurs 5 To reassemble the unit reverse the removal procedure 2 Replacing Main Board Assembly 1 Remove the board box 64 4 4 1 Opening Board Box 64 p 4 40 2 Remove the SODIMM 1 Replacing SODIMM p 4 50 No Part name 1 SODIMM 2 Main board assembly 1 2 ...

Page 93: ...moved up to 5 times Table 4 4 Connectors to Main Board Assembly No Connector No of Pins Colors Connect to Remark 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 10 J10 30 Black CR Board J202 FFC 11 J11 30 Black CR Board J20...

Page 94: ...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 Table 4 4 Connectors to Main Board Ass...

Page 95: ...ter Backup p 7 7 10 To reassemble the unit reverse the removal procedure 4 4 8 Replacing Fuse CAUTION Remove the AC inlet cable to replace the fuse before performing work You may suffer electric shock due to standby current 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 1 Open the board box 64 4 4 1 Open...

Page 96: ... Manual Rev 00 4 54 There are two fuses for one power supply four fuses in total CAUTION Don t touch the cap of a fuse with bare hands No Part name 1 Fuse main side 2 Fuse heater side 3 Fuse holder main side 4 Fuse holder heater side 1 2 3 4 ...

Page 97: ...cing Inlet Assembly CAUTION Remove the AC inlet cable to replace the fuse before replacing the AC inlet You may suffer electric shock due to standby current 1 Replacing AC Inlet Small Main Side 1 Open the board box 64 4 4 1 Opening Board Box 64 p 4 40 2 Remove the connectors 3 pieces No Function F1 MAIN LIVE F2 MAIN NEUTRAL F3 HEATER LIVE F4 HEATER NEUTRAL No Part name 1 AC inlet small 2 Connector...

Page 98: ...screws 2 pieces that retain the AC inlet small 4 Remove the AC inlet small from outside 5 Replace the AC inlet small 6 To reassemble the unit reverse the removal procedure No Part name 1 AC inlet small 2 Screws that retain the AC inlet small countersunk head screw M3 6 2 1 ...

Page 99: ...ectors 3 pieces 3 Remove the screws 2 pieces that retain the AC inlet large 4 Remove the AC inlet large from inside 5 Replace the AC inlet large 6 To reassemble the unit reverse the removal procedure No Part name 1 AC inlet large 2 Connector No Part name 1 AC inlet large 2 Screws that retain the AC inlet large pan head screw with spring washer and flat washer M3 8 1 2 2 1 ...

Page 100: ...to the opposite side of the origin 4 8 1 Releasing Head Lock p 4 105 2 Remove the side top cover R 4 2 6 Removing Side Top Cover R p 4 12 3 Remove the cartridge cover upper 4 2 9 Removing Cartridge Cover Upper p 4 17 4 Detach the connector to the heater junction board assembly Table 4 5 Connectors to Heater Junction Board Assembly No Connector No of Pins Color Connect to Remark 1 J1 Config CN 2 J2...

Page 101: ...ACT1 Not in use 18 J18 EX SLOT1 Not in use 19 J19 EX ACT2 Not in use 20 J20 EX SLOT2 Not in use 21 J21 EX ACT3 Not in use 22 J22 EX ACT4 Not in use 23 J23 EX SLOT3 Not in use 24 J24 EX SLOT4 Not in use 25 J25 EX DC OUT Not in use 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 Table 4 5 Connectors to Heater Junc...

Page 102: ...ht after starting up the plotter Otherwise you may be burned 1 Open the maintenance cover L 2 Remove the side maintenance cover L 4 2 5 Removing Side Maintenance Cover L p 4 12 3 Remove the rear side cover 4 2 8 Removing Rear Side Cover p 4 15 4 Loosen the screws 2 pieces that retain the PF motor 5 Confirm that the PF speed reduction belt has been loosened No Part name 1 PF motor 2 Screws that ret...

Page 103: ... Confirm that the PF speed reduction belt is not loosened 10 To reassemble the unit reverse the removal procedure 4 6 2 Replacing PF Motor Assembly CAUTION Do not touch the motor right after starting up the plotter Otherwise you may be burned 1 Initialize the PF motor counter 5 11 1 Parameter Initialization Menu p 5 47 2 Open the maintenance cover L 3 Remove the side maintenance cover L 4 2 5 Remo...

Page 104: ...PF motor 8 Remove the PF motor 9 Replace the PF motor 10 Lightly tighten the screws that retain the PF motor No Part name 1 PF motor 2 PF motor connector 3 PF motor cable assembly No Part name 1 PF motor 2 Screws that retain the PF motor pan head screw with spring washer and flat washer M4 8 3 PF speed reduction belt 4 PF drive mounting plate 2 1 3 2 1 3 4 ...

Page 105: ...F speed reduction belt is not loosened 14 To reassemble the unit reverse the removal procedure 4 6 3 Replacing PF Encoder Assembly 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 PF encoder assembly 3 Remove the PF encoder assembly 4 Replace the PF encoder assembly NOTE When reassemble the PF_ENC assembly and the PF ...

Page 106: ...aintenance Cover L p 4 12 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 Remove the ENC scale holder No Part name 1 PF_ENC scale 2 ENC scale holder 3 PF speed reduction pull...

Page 107: ...ment p 7 25 12 To reassemble the unit reverse the removal procedure 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 1 Remove the media guide R lower 4 2 19 Removing Media Guide R Lower p 4 29 2 Open the board box 64 4 4 1 Opening Board Box 64 p 4 40 3 Detach the connector MAIN J42 to the P_REAR_R sensor as...

Page 108: ...REAR_R sensor assembly 5 Remove the P_REAR_R sensor assembly 6 Replace the P_REAR_R sensor assembly 7 To reassemble the unit reverse the removal procedure 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 Enlarged view Rear view 1 2 3 ...

Page 109: ... Remove the side maintenance cover R 4 2 4 Removing Side Maintenance Cover R p 4 11 3 Remove the lever up sensor cable assembly 4 Remove the lever up sensor assembly 5 Replace the lever up sensor assembly No Part name 1 Lever up sensor cable assembly 2 Lever up sensor assembly 3 Cover stay RR 1 2 3 Rear view Enlarged view ...

Page 110: ...ce 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 No Part name 1 Lever up sensor assembl...

Page 111: ...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 No Part name 1 Pre heater 1 2 Pre heater 2 No Part name 1 Connectors to the pre heater thermistor 2 Connectors to the pre heater 3 Media guide R upper 1 2 3 1 2 ...

Page 112: ...uble 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 6 Replace the pre heater 7 Remove the thermistor film 8 Remove the pre thermistor No Part name 1 Media guide R upper 2 Pre heater 3 Pre heater heat insulator ...

Page 113: ...r is affixed using thermistor film 9 Remove the pre thermistor 10 Replace the pre thermistor 11 To reassemble the unit reverse the removal procedure No Part name 1 Media guide R upper 2 Pre thermistor 3 Pre heater heat insulator 4 Thermistor film 1 4 2 3 Back of paper guide R Upper ...

Page 114: ...n Heater Platen Thermistor The platen heater is arranged as follows 1 Open the front cover 2 Remove the screws 16 pieces that retain the platen 3 Lift up the platen No Part name 1 Platen heater 1 2 Platen heater 2 No Part name 1 Platen 2 Screws that retain the platen 1 2 1 2 2 ...

Page 115: ...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 12 To...

Page 116: ...Media Guide F Upper p 4 24 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 Remove the media guide F upper No Part name 1 After heater 1 2 After heater 2 No Part name 1 After heater heat insulator 2 Connectors to the after thermistor 3 Connectors to the after heater 1 2 2 1 3 Rear view of media guide F ...

Page 117: ... 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 7 Replace the after heater No Part name 1 Media guide F upper 2 After heater 3 After heater heat insulator 2 1 3 Rear view ...

Page 118: ...thermistor 11 To reassemble the unit reverse the removal procedure 4 6 8 Replacing Suction Fan The suction fan is arranged as follows No Part name 1 Media guide F upper 2 After heater thermistor 3 After heater heat insulator No Part name 1 Suction fan 1 2 Suction fan 2 3 Suction fan 3 4 Suction fan 4 2 1 3 Rear view of media guide F 1 2 3 4 ...

Page 119: ...s that retain the suction fan 4 Remove the suction fan 5 Replace the suction fan 6 To reassemble the unit reverse the removal procedure 4 6 9 Replacing Platen Non Reflective Tape 1 Open the front cover 2 Strip the platen non reflective tape No Part name 1 Suction fan 2 Screws that retain the suction fan pan head screw with spring washer and flat washer M4 10 3 Connector to the suction fan 3 2 1 2 ...

Page 120: ...ten non reflective tape is stripped it must not be reused 3 Replace the platen non reflective tape 4 6 10 Replacing Media Holder 1 Open the front cover 2 Remove the media guide F upper 4 2 17 Removing Media Guide F Upper p 4 24 No Part name 1 Platen 2 Platen non reflective tape ...

Page 121: ... stopper 5 Pull out the media holder from the left side the opposite side of the origin 6 Replace the media holder 7 To reassemble the unit reverse the removal procedure No Part name 1 Media holder stopper 2 Screws that retain the media holder stopper pan head screw with spring washer and flat washer M3 8 No Part name 1 Media holder 2 Platen 1 2 2 1 ...

Page 122: ...11 Replacing Flushing Tray The flushing tray is arranged as follows CAUTION When replacing the flushing tray wear rubber gloves 1 Replacing Flushing Tray R 1 Open the front cover 2 Open the maintenance cover R No Part name 1 Flushing tray R 2 Flushing tray L 2 1 2 ...

Page 123: ...flushing frame 5 Detach the flushing tray by pushing the flushing tray from behind the flushing frame 6 Replace the flushing tray 7 To reassemble the unit reverse the removal procedure No Part name 1 Flushing tray 2 Flushing frame 3 Flushing frame hook No Part name 1 Flushing tray 2 Flushing frame 1 2 3 1 2 ...

Page 124: ...flushing tray by pushing the flushing tray from behind the flushing frame 5 Replace the flushing tray 6 To reassemble the unit reverse the removal procedure 4 6 12 Replacing Flushing Absorber CAUTION When replacing the flushing absorber wear rubber gloves 1 Remove the flushing frame 4 6 11 Replacing Flushing Tray p 4 80 No Part name 1 Flushing tray 2 Flushing frame 3 Flushing frame hook 1 2 3 ...

Page 125: ...e Manual 4 Parts Replacement 4 83 Rev 00 2 Replace the flushing absorber 3 pieces TIP The flushing absorbers are three thicknesses 3 To reassemble the unit reverse the removal procedure No Part name 1 Flushing absorber 1 ...

Page 126: ...r more persons NOTE Pay close attention in handling the steel belt Bending or dust on the steel belt may cause steel belt breakage 1 Open the maintenance cover R 2 Open the maintenance cover L 3 Remove the side top cover R 4 2 6 Removing Side Top Cover R p 4 12 4 Remove the side top cover L 4 2 7 Removing Side Top Cover L p 4 14 5 Open the front cover 6 Move the carriage to the left side opposite ...

Page 127: ...ley 11 Insert the measure through the hole of the Y drive base to the inside of Y rail No Part name 1 CR driven pulley 2 Steel belt adjustment screws pan head screw with spring washer and flat washer M3 40 3 Steel belt 4 Return pulley mounting plate 5 Screw cap No Part name 1 Head cover 2 Steel belt 3 Screws that retain the belt 1 2 Left view Right view 1 2 3 3 ...

Page 128: ...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 No Part name 1 Measure 2 Y drive base 3 Return pulley mounting plate No Part name 1 Measure 2 Steel belt 3 Tape 3 2 1 View of origin side View of opposite...

Page 129: ...touch the motor after continuous operation You may get burned by the motor heated up 1 Remove the side maintenance cover R 4 2 4 Removing Side Maintenance Cover R p 4 11 2 Remove the side top cover R 4 2 6 Removing Side Top Cover R p 4 12 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 affixe...

Page 130: ...belt is loosened 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 No Part name 1 CR motor assembly 2 CR motor spacer 3 Hexagon socket screws M4 6 4 CR motor cable assembly No Part name 1 CR motor assembly 2 CR speed reduction belt 3 Y drive base 4 CR drive pulley 1 2 2 3 1 2 3 4 ...

Page 131: ... CR Speed Reduction Belt Tension Adjustment p 7 27 11 To reassemble the unit reverse the removal procedure 4 7 3 Replacing CR Drive Pulley Assembly 1 Remove the side maintenance cover R 4 2 4 Removing Side Maintenance Cover R p 4 11 2 Remove the side top cover R 4 2 6 Removing Side Top Cover R p 4 12 3 Loosen the hexagon socket screws 4 pieces that retain the CR motor assembly to loosen the CR spe...

Page 132: ...belt adjustment screws 2 pieces 6 Remove the CR drive pulley No Part name 1 CR motor assembly 2 CR speed reduction belt 3 Y drive base 4 CR drive pulley No Part name 1 CR driven pulley 2 Steel belt adjustment screws pan head screw with spring washer and flat washer M3 40 3 Steel belt 4 Return pulley mounting plate 1 2 3 4 2 1 3 4 5 5 ...

Page 133: ... speed reduction belt tension 7 6 CR Speed Reduction Belt Tension Adjustment p 7 27 11 Adjust the steel belt tension 7 4 Steel Belt Tension Adjustment p 7 22 4 7 4 Replacing T Fence 1 Open the maintenance cover R 2 Open the maintenance cover L 3 Remove the side top cover R 4 2 6 Removing Side Top Cover R p 4 12 4 Remove the side top cover L 4 2 7 Removing Side Top Cover L p 4 14 5 Open the front c...

Page 134: ... Manual Rev 00 4 92 8 Detach the T fence from the T fence spring 9 Detach the T fence from the T fence guide plate 3 pieces No Part name 1 T fence spring 2 T fence spring hook 3 T fence No Part name 1 T fence guide plate 2 T fence 1 2 3 2 1 ...

Page 135: ... 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 a...

Page 136: ...CR Origin Sensor 1 Open the maintenance cover R 2 Remove the side top cover R 4 2 6 Removing Side Top Cover R p 4 12 3 Move the carriage to the left side opposite side of the origin 4 8 1 Releasing Head Lock p 4 105 4 Remove the CR_ORG cable assembly No Part name 1 T fence guide plate 2 T fence 3 CR_ENC assembly 4 Carriage 3 1 2 4 ...

Page 137: ...emove the CR origin sensor 6 Replace the CR origin sensor 7 Apply adhesive material 8 To reassemble the unit reverse the removal procedure No Part name 1 CR origin sensor 2 CR_ORG cable assembly 3 Y rail No Part name 1 Adhesive material application surface 2 1 3 1 ...

Page 138: ...aintenance cover L 4 2 5 Removing Side Maintenance Cover L p 4 12 2 Remove the Side top cover L 4 2 7 Removing Side Top Cover L p 4 14 3 Remove the steel belt adjustment screws 2 pieces 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 No Part name 1 CR driven pulley 2 Adjustment screws pan head screw wi...

Page 139: ...he removal procedure 9 Adjust the steel belt tension 7 4 Steel Belt Tension Adjustment p 7 22 4 7 7 Replacing Steel Bearer 1 Remove the Side top cover R 4 2 6 Removing Side Top Cover R p 4 12 2 Remove the rear top cover 4 2 15 Removing Rear Top Cover p 4 21 3 Remove the screws 4 pieces that retain the steel bearer No Part name 1 Steel bearer 2 Screws that retain the steel bearer pan head screw wit...

Page 140: ...ain the cable guides 2 pieces 6 Remove the cable guide 7 Remove the steel bearer 8 Replace the steel bearer 9 To reassemble the unit reverse the removal procedure No Part name 1 Steel bearer 2 Film FFC retainer No Part name 1 Cable guide 2 Screws that retain the cable guide pan head screw with spring washer and flat washer M3 18 1 2 2 2 1 1 2 ...

Page 141: ...the connectors resulting in a breakdown of the on board devices The cables can be connected or removed up to 5 times 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 4 1 Opening Board Box 64 p 4 40 4 Detach CR FFC 3 pieces from the CR board assembly J201 J203 5 Detach CR FFC 3 pieces from the...

Page 142: ...ect 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 15 To reassemble the unit reverse the removal procedure No Part name 1 CR_FFC 2 Cable guide 3 Leg holder base 64 1 1 2 3 Cable guide Back of leg holder base 64 335 mm 330 mm 60 mm Fix the ferritic core with cable holder CR board side M...

Page 143: ...slightly with a finger and hold it 3 Pull down the other end of the pressure roller 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 8 To reassemble the unit reverse the removal procedure No Part name 1 Pressure roller 2 Pressure arm 2 1 ...

Page 144: ...ve the rear top cover 4 2 15 Removing Rear Top Cover p 4 21 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 5 Remove the tube guide plates 2 pieces 6 Remove the FFC guides 6 pieces No Part name 1 Cable guide plate 2 Screws that retain the cable guide plate P tight cup screws M3 8 2 2 1 1 2 2 ...

Page 145: ...tain the tube guide plate 9 Remove the tube guide plate 10 Detach the ink tube from the three way joint No Part name 1 Ink tube 2 Film FFC guide 3 Tube clamp No Part name 1 Tube guide plate 2 Screws that retain the tube guide plate pan head screw with spring washer and flat washer M3 8 3 Ink tube 2 1 3 Upper view Lower view 2 1 3 ...

Page 146: ...int screw on the tip of the sub tank 13 Detach the ink tube from the joint tube 14 Remove the ink tube 15 Replace the ink tube 16 To reassemble the unit reverse the removal procedure 17 Charge ink 5 6 Ink Charging Menu p 5 22 No Part name 1 Three way joint 2 Ink tube No Part name 1 Ink tube 2 Joint tube 3 Joint screw 1 2 1 2 3 ...

Page 147: ...position after the power is turned off This section describes the procedure to release head lock with the power turned off 1 Open the maintenance cover R 2 Push down the cap on the left side of carriage 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 wh...

Page 148: ...rent 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 Pulling or pushing them slantwise may damage short break the terminals in the connectors resulting in a breakdown of the on board devices The cables can be connected or removed up to 5 times 1 Remove the CR boa...

Page 149: ... board assembly 1 cup screw M3 6 6 Hexagon spacer Table 4 6 Connectors to CR board assembly No Connector No of Pins Color Connect to Remark 1 J201 30 Black MAIN J11 FFC 2 J202 30 Black MAIN J10 FFC 3 J203 30 Black MAIN J9 FFC 4 J204 30 Black MAIN J1 FFC 5 J205 30 Black MAIN J2 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_FA...

Page 150: ...ce 1 Move the carriage to the opposite side of the origin 2 Open the maintenance cover L 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 6 Remove the CR encoder assembly 7 Replace the CR encoder assembly 8 To reassemble the unit reverse the removal procedure No Part name 1 CR encoder assembly 2 Screws tha...

Page 151: ...er R 2 Open the side top cover R 4 2 6 Removing Side Top Cover R p 4 12 3 Remove the PG origin sensor relay assembly 4 Remove the PG origin sensor assembly 5 Replace the PG origin sensor assembly 6 To reassemble the unit reverse the removal procedure No Part name 1 PG origin sensor relay assembly 2 PG origin sensor assembly 2 1 ...

Page 152: ... cursor guide 4 Pull off the cursor roller arm to the direction shown below with the cursor arm spring being lifted up 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 6 To reassemble the unit reverse the removal procedure 4 8 7 Removing Print Head Co...

Page 153: ...y 4 Remove the screws 2 pieces that retain the print head cover 5 Remove the print head cover No Part name 1 Connector to the head fan assembly 2 Head fan relay assembly 3 CR board cover No Part name 1 Print head cover 2 Screws that retain the print head cover pan head screw with spring washer and flat washer M3 8 2 1 3 1 1 2 2 Left view Right view ...

Page 154: ...s 1 Perform ink discharge operation to discharge ink entirely from the ink paths 5 7 8 HeadWash Menu p 5 40 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 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 dam...

Page 155: ... on the side of the damper assembly L Place cotton waste under the detached damper to prevent residual ink discharging 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 10 To reassemble the unit reverse the removal procedure 11 Charge ink 5 6 Ink Charging Menu p 5 22 No Part name 1 Damper assembly L 2...

Page 156: ...ng 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 CR board cover 4 8 2 Removing CR Board Cover p 4 106 2 Remove the head cover 4 8 7 Removing Print Head Cover p 4 110 3 Remove the damper L assembly 4 8 8 Replacing Damper Assembly L_Assy p 4 112 4 Remove th...

Page 157: ... 115 Rev 00 6 Remove the print head 7 Remove the head FFC 2 pieces from the print head 8 Replace the print head 9 To reassemble the unit reverse the removal procedure No Part name 1 Print head No Part name 1 Head FFC 2 Print head 1 2 2 1 1 Front Back ...

Page 158: ... 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 Perform ink discharge operation to discharge ink entirely from the ink paths 5 7 8 HeadWash Menu p 5 40 2 Initialize the head counter 5 7 10 Software Counter Initialization Menu p 5 41 3 Remove the head cover 4 8 7 Removing Print Head Cover p 4 110 4 Remove the damper...

Page 159: ...nside 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 11 To reassemble the unit reverse the removal procedure No Part name 1 Flat core holder 2 Screws that retain the flat core holder 3 Flat core 4 Head FFC 1 2 3 1 4 CR board side 10 mm 10 mm 90 mm Print head side A B A Face the printed side front side A mounta...

Page 160: ...ssembly J208 4 8 3 Replacing CR Board Assembly p 4 106 3 Remove the screw 1 piece that retain the P_EDGE sensor assembly 4 Detach the cable of the P_EDGE sensor assembly from the clamp 4 pieces 5 Replace the P_EDGE sensor assembly No Part name 1 P_EDGE sensor assembly 2 Screws that retain the P_EDGE sensor assembly P tight cup screw M3 6 No Part name 1 Cable of the P_EDGE sensor assembly 2 Clamp 1...

Page 161: ... 1604 Maintenance Manual 4 Parts Replacement 4 119 Rev 00 TIP The cable of the P_EDGE sensor assembly is a stranded wire of red black blue and orange 6 To reassemble the unit reverse the removal procedure ...

Page 162: ...ance cover U 4 2 3 Removing Maintenance Cover U p 4 10 2 Move the carriage to the opposite side of the origin 4 8 1 Releasing Head Lock p 4 105 3 Remove the screws 4 pieces that retain the maintenance inside cover 4 Remove the maintenance inside cover No Part name 1 Maintenance inside cover 2 Screws that retain the maintenance inside cover pan head screw with spring washer and flat washer M3 8 2 2...

Page 163: ...ection and remove it upwardly 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 Insert the cleaner head into the holder to the full depth securely and hoo...

Page 164: ...7 8 HeadWash Menu p 5 40 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 6 Remove the screws 1 piece that retain ...

Page 165: ...te fluid tube 13 Remove the screws 4 pieces that retain the waste fluid guide 14 Replace the waste fluid guide No Part name 1 Flushing box holder 2 Screws that retain the flushing box holder pan head screw with spring washer and flat washer M3 6 3 Head lock holder 4 Screws that retain the head lock holder pan head screw with spring washer and flat washer M3 6 No Part name 1 Waste fluid guide cover...

Page 166: ...y 19 To reassemble the unit reverse the removal procedure 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 pan head screw with spring washer and flat washer M3 6 5 Waste fluid tube 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 spr...

Page 167: ...r middle 4 2 10 Removing Cartridge Cover middle p 4 18 3 Remove the screws 2 pieces 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 No Part name 1 Cartridge cable cover plate 2 Screws that retain the cartridge cable...

Page 168: ...name 1 I C slide 2 2 Screws that retain the I C slide 2 pan head screw with spring washer and flat washer M3 8 3 Cartridge side plate 4 Screws that retain the cartridge side plate pan head screw with spring washer and flat washer M3 8 No Part name 1 Cartridge side plate 2 Holder pressure spring 3 Screws that retain the holder pressure spring P tight cup screw M3 6 4 1 3 2 1 2 3 ...

Page 169: ...amp 12 Detach the ink cartridge control cable from the ink ID board assembly 13 Remove the ink ID board assembly 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 15 To reassemble the unit reverse the removal procedure No Part name 1 Ink ID board assembly 2 Ink cartridge control ...

Page 170: ... middle p 4 18 3 Remove the screws 2 pieces that retain the I C slide 2 4 Remove the I C slide 2 5 Remove the screws 2 pieces that retain the cartridge side plate 6 Remove the cartridge side plate No Part name 1 I C slide 2 2 Screws that retain the I C slide 2 pan head screw with spring washer and flat washer M3 8 3 Cartridge side plate 4 Screws that retain the cartridge side plate pan head screw ...

Page 171: ... Remove the joint screw M6 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 No Part name 1 Frame assembly needle 2 Joint screw M6 3 Cartridge side plate 4 Ink tube 1 3 2 4 ...

Page 172: ...idge slide to the direction shown below 10 Remove 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 No Part name 1 Cartridge slide 2 Frame assembly needle 3 Hook No Part name 1 Cartridge slide 2 Hook of the cartridge slide 1 3 2 1 2 ...

Page 173: ...ntrol cable to the frame assembly and the needle 15 Remove the ink cartridge control cable 16 To reassemble the unit reverse the removal procedure No Part name 1 Hook of the frame assembly and the needle 2 Clamp No Part name 1 Ink cartridge control cable 2 Screws that retain the ink cartridge control cable B tight band screw M2 x 8 3 Frame assembly needle 1 2 1 2 3 ...

Page 174: ... retains the ink cartridge control cable to the cartridge side plate 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 6 To reassemble the unit reverse the removal procedure 4 10 4 Replacing Cartridge Holder Assembly 1 Remove the cartridge cover upper 4 2 9 Removing Cartridge Cover Upper p 4 17 2 Remov...

Page 175: ... NOTE The cartridge holder assembly is composed of many parts Refer to exploded view for details 8 To reassemble the unit reverse the removal procedure 4 10 5 Replacing two way Valve 1 Remove the cartridge cover lower 4 2 11 Removing Cartridge Cover lower p 4 19 2 Remove the cartridge cover upper 4 2 9 Removing Cartridge Cover Upper p 4 17 3 Remove the screws 8 pieces that retain the two way valve...

Page 176: ... from the two way valve 7 Remove the two way valve 8 Replace the two way valve 9 To reassemble the unit reverse the removal procedure No Part name 1 Two way valve mounting plate 2 Screws that retain the two way valve pan head screw with spring washer and flat washer M3 6 No Part name 1 Two way valve 2 Ink tube 1 2 1 Left view Right view 2 2 1 K K C M Y K C M Y K C M Y K C M Y Rear view when replac...

Page 177: ...lace 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 5 To reassemble the unit reverse the removal procedure No Part name 1 Absorber mounting plate 2 Screws that retain the absorber mounting plate pan head screw with spring washer and flat washer M4 8 3 Screws...

Page 178: ...id 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 2 Remove the side maintenance cover R 4 2 4 Removing Side Maintenance Cover R p 4 11 3 Remove the connector to the level switch waste fluid 4 Remove the waste fluid tube 5 Loosen the cap of the waste fluid bottle No Part name 1 Connector to th...

Page 179: ...rom the connector side of the level switch waste fluid 8 Replace the waste fluid bottle 9 Replace the level switch waste fluid 10 To reassemble the unit reverse the removal procedure 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 No Part name 1 Cap of the waste fluid bottle 2 Nut of the level switch waste fluid 1 2 3 4 1 2...

Page 180: ...on the VJ16_L side 1 Remove the media guide R lower 4 2 19 Removing Media Guide R Lower p 4 29 2 Release the roll media fixing lever 3 Pull out the roll media holder assembly on the VJ16_L side from the left side 4 Replace the roll media holder assembly on the VJ16_L side No Part name 1 Roll media fixing lever No Part name 1 Roll media Holder assembly on the VJ16_L side 2 Roll media Holder assembl...

Page 181: ...he unit reverse the removal procedure 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 ...

Page 182: ... 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 2 Detach the lever from the release cam No Part name 1 Rubber foot 2 Screws that retain the rubber foot No Part name 1 Release cam 2 Lever 1 1 2 1 2 ...

Page 183: ...the removal procedure 4 13 2 Replacing Scroller 1 Replacing Holding Roller 1 Remove the E ring E 6 that retains the holding roller using a driver 2 Remove the holding roller and the bearing 3 Fit the E ring E 6 to the holding axis using a long nose pliers No Part name 1 Take up cover 2 Screws that retain the take up cover No Part name 1 holding roller 2 E ring that retains the holding roller 1 2 2...

Page 184: ...cedure 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 2 Remove the drive collar 3 To reassemble the unit reverse the removal procedure No Part name 1 Holding roller L 2 Screws that retain the holding roller L 3 Scroller receiver left No Part name 1 Drive collar 2 Screws that reta...

Page 185: ... on the chassis out 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 3 To reassemble the unit reverse the removal procedure No Part name 1 Board chassis 2 Screws that retain the board chassis 3 Chassis out No Part name 1 VJ take up CNT board assembly 2 Motor cable 3 W_ON sensor relay assembl...

Page 186: ...up CNT 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 3 Remove the VJ take up CNT board assembly 4 To reassemble the unit reverse the removal procedure No Part name 1 VJ take up CNT board assembly 2 DC cable assembly 3 VJ take up SW board assembly No Part name 1 VJ take u...

Page 187: ...n use 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 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 5 To reassemble the unit reverse the removal procedure No Part name 1 Power board a...

Page 188: ...assis p 4 143 1 Detach the cable of the VJ Take up SW Board Assembly from the connector to the VJ take up CNT board assembly 2 Remove the screws undersunk head screw M3 6 2 pieces that retain the SW mounting plate on the board chassis No Part name 1 VJ take up CNT board assembly 2 Cable of the VJ take up SW board assembly No Part name 1 SW mounting plate 2 Screws that retain the SW mounting plate ...

Page 189: ...placing AC Cable Assembly NOTE Remove the screws that retains the board chassis before replacing the AC cable assembly 1 Removing Board Chassis p 4 143 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 VJ take up SW board assembly 2 Screw that retains the VJ take up SW board assembly 3 SW mounting plate No Part name 1 VJ t...

Page 190: ...ble Assembly NOTE Remove the screws that retains the board chassis before replacing the DC cable assembly 1 Removing Board Chassis p 4 143 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 1 Power board assembly of take up section for foreign use 2 AC cable assembly No Part name 1 DC cabl...

Page 191: ...ard assembly of take up section for foreign use 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 No Part name 1 Power board assembly of take up section for foreign use 2 DC cable assembly 1 2 ...

Page 192: ... relay assembly and W_OFF sensor relay assembly from the connector to the VJ take up CNT board 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 3 Replace the W_ON sensor relay assembly and W_OFF sensor relay assembly 4 To reassemble the unit reverse the removal procedure No Part name 1 VJ take up CNT board assembly 2 Ca...

Page 193: ...nd W_OFF sensor relay assembly from the connector to the VJ take up CNT board assembly 2 Remove the screws pan head screw with spring washer and flat washer polished M3 6 2 pieces that retains the sensor mounting plate 87NX on the right of the inside chassis No Part name 1 VJ take up CNT board assembly 2 W_ON sensor relay assembly W_OFF sensor relay assembly No Part name 1 Sensor mounting plate 87...

Page 194: ...P sensor and lever sensor 4 Detach the CR_HP sensor and the lever sensor from the sensor mounting plate 87NX 5 To reassemble the unit reverse the removal procedure No Part name 1 CR_HP sensor the lever sensor 2 W_ON sensor relay assembly W_OFF sensor relay assembly No Part name 1 Sensor mounting plate 87NX 2 CR_HP sensor the lever sensor 1 1 2 2 1 2 ...

Page 195: ...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 2 Remove the drive roller 3 To reassemble the unit reverse the removal procedure No Part name 1 Drive roller 2 Screws that retain the drive roller 3 Drive axis C 3 1 2 ...

Page 196: ...up cover 4 13 1 Removing Take up Cover p 4 140 Screw for the board chassis 1 Removing Board Chassis p 4 143 1 Remove the screws pan head screw with spring washer and flat washer polished M4 10 3 pieces that retain the motor mounting plate on the right of the inside chassis 2 Detach the chain from the sprocket large No Part name 1 Motor mounting plate 2 Screws that retain the motor mounting plate 3...

Page 197: ...th spring washer and flat washer polished M4 6 2 pieces that retain the axis holder on the motor mounting plate 4 Remove the bearings 5 Replace the VJ take up motor assembly 6 To reassemble the unit reverse the removal procedure No Part name 1 Axis holder 2 Axis holder 3 Motor mounting plate 1 2 3 ...

Page 198: ...4 Parts Replacement VJ 1604 Maintenance Manual Rev 00 4 156 ...

Page 199: ...sis 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 Chec...

Page 200: ... 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 Prin...

Page 201: ...04 Maintenance Manual 5 Self Diagnosis Mode 5 3 Rev 00 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 ...

Page 202: ...tions 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 p...

Page 203: ...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 ...

Page 204: ...em 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 pr...

Page 205: ...ce Manual 5 Self Diagnosis Mode 5 7 Rev 00 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 ...

Page 206: ...ism 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...

Page 207: ...xt menu Next menu Test Menu InkCharge Menu Print Menu SetTime Menu Previous menu Enter key Cancel key Adj Platen Menu Parameter Menu Endurance Menu PaperFeed Menu Servo Menu ExControl Menu PaperInitial Menu ࠪࡦ ࠐࡦ㧦 ࠪࡈࠖ ࠐ Next menu Next menu Next menu Next menu Next menu Enter key Enter key Enter key Enter key Enter key Enter key Enter key Enter key Enter key Enter key Enter key Enter key Cancel key...

Page 208: ...be done in the condition This item displays platen temperature only Fig 5 1 If the heater temp does not reach 42 C 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 key key key key key PlatenHeater 1 PlatenHeater 2 Enter key Enter key Cancel key Cancel key key key key key key Platen Heater 1 Platen Heater 2 Enter key En...

Page 209: ...heck the functions of the operation panel keys LCD and LED 5 5 3 Operation Panel Menu p 5 14 Sensor Displays the status of the following sensors CR_ORG sensor 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 5 5 4 Sensor Menu p 5 15 Encoder Displays the detected values from the follo...

Page 210: ...s menu Previous menu Previous menu Next menu Next menu Next menu Next menu Previous menu Previous menu Next menu Next menu Ram Capacity Menu Version Menu Panel Menu Sensor Menu Encoder Menu Fan Menu History Menu Head Signal Menu Previous menu Enter key Cancel key Enter key Enter key Enter key Enter key Enter key Enter key Enter key Cancel key Cancel key Cancel key Cancel key Cancel key Cancel key ...

Page 211: ... 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 key key key Setting of DIP switches of main board assembly Revision of main board assemb key key key Firmware version Backup parameter version key ...

Page 212: ...e 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 key key key key key Operation Panel ...

Page 213: ...E sensor 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...

Page 214: ...ey key key key key key key key key key key Waste Tank Sensor Lever Sensor Cover Sensor Maintenance Cover L Sensor Maintenance Cover R Sensor Wiper Sensor P_EDGE Sensor P_REAR Sensor Head Gap Sensor H Transistor 1 H Transistor 2 Head Sensor key key key CR_HP Sensor key key key key key key ...

Page 215: ...in hexadecimal number 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 Previous menu Previous me...

Page 216: ...enance 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 Previous menu Previous men...

Page 217: ...F Motor driving Unit 220 pulse Frequenc of printing Frequenc of cleaning key key key Head 1 A Fire Unit Mdots Head 1 B Fire Unit Mdots Head 2 A Fire Unit Mdots Head 2 B Fire Unit Mdots Head 3 A Fire Unit Mdots Head 3 B Fire Unit Mdots Head 4 A Fire Unit Mdots Head 4 B Fire Unit Mdots Frequency of the lock solenoid moving down key key key key key key key key Frequenc of the pump operation Pump whee...

Page 218: ...he serious error history does not include CPU error The serious error history menu indicates the history up to 32 3 Error Initialization This menu is used to initialize the serious error history Previous menu Previous menu Next menu Previous menu Next menu Previous menu Next menu Next menu Next menu Previous menu Enter key ...

Page 219: ...ge of x1 1000000 Nozzle can be selected among A to H and ALL Previous menu Previous menu Next menu Previous menu Next menu Previous menu Previous menu Next menu Next menu Next menu Previous menu Next menu Previous menu Next menu Previous menu Next menu Next menu Next menu Next menu Next menu Previous menu Previous menu Previous menu Previous menu Enter key Enter key Enter key Enter key ...

Page 220: ...nk charging menu includes the following items In LittleCharge process the plotter charges a small amount of ink which is one fourth of InkCharge main suction steps Table 5 4 Ink Charging menu Charging item Contents InkCharge Performs initial ink charging LittleCharge Performs a small amount of ink charging key key key key Enter key ...

Page 221: ... D Bi D adjustment Low Prints out a printing to align the nozzle line distance Uni D of PG Low and the position of the repeated printing Uni D 240 240 cps Uni D 320 320 cps Uni D 240B 240 cps Banner Uni D 320B 320 cps Banner Bi D 240 240 cps Bi D 320 320 cps Bi D 240B 240 cps Banner Bi D 320B 320 cps Banner 5 7 5 Uni D Bi D Low High Adjustment p 5 33 Uni D Bi D adjustment High Prints out a printin...

Page 222: ...5 7 12 Solid Print Menu p 5 43 Table 5 5 Diagnosis Items in Adjustment Menu Continued Diagnosis item Contents Reference key key key key key key key key key key key key key key key key key key key key Nozzle Check Menu Check Skew Menu Head Slant Menu Voltage Adjustment Menu Uni D Bi D Low Adjustment Menu Side Margin Adjustment Menu Software Counter Initialization Menu Feed Pitch Check Menu key Ente...

Page 223: ...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 No...

Page 224: ...arge 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 Previous menu Previous menu Next menu Previous menu Next menu Next menu Media set Finish printing If media is not set Display during adjustment printing ...

Page 225: ... 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 Table 5 6 Skew Amount Specification C...

Page 226: ... a sample printing to check for head slant in the horizontal direction To perform head slant check follow the steps below 1 Set media as necessary 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 Table 5 7 Head slant checking items Items Contents Head slant in horizontal direction Head slant check in horizontal directio...

Page 227: ...the head adjustment cam upward E Move the head adjustment cam downward 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 5mm 5mm B A C E D 20mm Previous menu Next menu Previous menu Next menu Finish printing Display during adjustment printing Finish p...

Page 228: ...fter 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 B Media feed direction C OK D Move the vertical slant adjusting cam to the right E Move the vertical slant adjusting cam to the left A E D C B 1 A 1 B 2 ...

Page 229: ...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 320 CW Adjusts the VSD 3 S at 320 cps CW printing 320 CCW Adjusts the VSD 3 S at 320 cps CCW printing Previous menu ...

Page 230: ...tion C Executed adjustment item is printed like this Enter key If media is not set If head gap is PG Low Display during adjustment 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 Media set Change head gap to PG Low If the temperature of the pre heater and platen heater is below 42 C Pressing Cancel key stops contr...

Page 231: ...n Adjustment items are shown below Items Speed 240 CW CW 240 CPS 320 CW CW 320 CPS 240 CCW CCW 240 CPS 320 CCW CCW 320 CPS 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 24...

Page 232: ...t matches C Executed adjustment item is printed like this 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 Print 2 Print 2 is displayed only when Bi D is selected Prints pattern according to the selected item with the current parameter plus with the values of 2 4...

Page 233: ...nted like this Bi D 240 Bi Lo Hi 240 CPS Bi D 320 Bi Lo Hi 320 CPS Bi D 240B Bi Lo Hi 240 CPS Banner Bi D 320B Bi Lo Hi 320 CPS Banner Either Lo or Hi is displayed where explained as Lo Hi above The following shows a case for Bi D 240B Low Print 2 Prints the pattern by using 2A nozzle line Both Uni D Bi D High should be adjusted in the same procedure A Media feed direction B Adjust the setting val...

Page 234: ...e adjusted in the same procedure 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 ke...

Page 235: ...ng Displayed during adjustment printing If media is not 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 key key key key key key key key key key key key key key key key 2 A is not displayed because the position is referred as the basis when adjusting 2 is displayed if High menu...

Page 236: ...0 dpi If check is selected black replaces magenta 3 Check the printed side margin adjustment patterns for the measurement 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 key key key key Press Setting Value or Setting Value key to change unit to pulse ޓ 1 pulse 1 2880 inch Pulse range 400 VQ 400 Back to Uni㨺D Bi D Top me...

Page 237: ... follows 1 Set media as necessary 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 key key key key key Enter key Printing adjustment pattern Enter ...

Page 238: ... is charged remove the head cleaning jig 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 Remove cleaning jig and press Enter key to discharge shipping liquid After shipping liquid is charged Set cleaning jig an...

Page 239: ... counters that can be initialized through this menu are as follows 1 Pressing the Enter key in the operation panel performs the software counter initialization Pressing Cancel key cancels the initialization 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 p...

Page 240: ...w the steps below 1 Set media as necessary 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 A A Media feed direction Feed amount for one band key key key key key key key key key key key key key k...

Page 241: ...ries A and B Previous menu Previous menu Next menu Previous menu Previous menu Next menu Next menu Next menu Press Setting value or Setting value key to select color to check Previous menu Previous menu Next menu Previous menu Next menu Enter key Next menu Press Setting value or Setting value key to select nozzle to eject ink ALL All nozzles ODD Odd numbered nozzles EVEN Even numbered nozzles Prev...

Page 242: ...g 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 Previous menu Next menu Previous menu Next menu Enter key Cancel key Strong Cleaning Next menu Enter key Cancel key Enter key Cancel key Normal Cleaning Economy Cleaning ...

Page 243: ...er the number before you can start the adjustment variable printing Table 5 12 Diagnosis Items in Sample Printing Menu Diagnosis item Contents Adjust ALL Prints adjustment patterns Parameter ALL Prints out the set values of various adjustment items Error history Prints serious error history Enter key key key key key key key key key Enter key Enter key Enter key Adjust Pattern printing Adjust Param...

Page 244: ...e the Month setting value input 1digit input by pressing setting value or setting value Change the Date setting value input 1digit input by pressing setting value or setting value Change the Hour setting value input 1digit input by pressing setting value or setting value Change the Minute setting value input 1digit input by pressing setting value or setting value Previous menu Previous menu Previo...

Page 245: ...his menu are as follows Uni D Bi D parameter wiper CR motor PF motor pump waste ink Initialization of all items Table 5 13 Diagnosis Items in Parameter Menu Diagnosis item Contents Reference 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 key key Parameter Initializatio...

Page 246: ...meter Table 5 14 Voltage adjustment item 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 320 CW Adjusts the VSD 3 S at 320 cps CW printing 320 CCW Adjusts the VSD 3 S at 320 cps CCW printing Next menu Next menu Next menu Next menu Previous menu Previous menu Previous menu Previous menu key key key key key key key key key key key ...

Page 247: ...w Uni D Bi D High Side margin Not filled flag Serial number Smart chip name update DebugBit key key key key key key key key key key key key key key key key Head Voltage Offset Menu Head Parameter Update Menu Uni D Bi D Low Update Menu Uni D Bi D High Update Menu Side Margin Update Menu Ink Parameter Update Menu Chip name Serial No Update Menu Enter key Cancel key Enter key Cancel key Enter key Can...

Page 248: ...oltage 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 Enter key Enter key Enter key Enter key Enter key Enter key Enter key Error will occur if input value is wrong Press Enter key to retry Initial Ink ch...

Page 249: ... 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 Bi D 240 Adjusts Bi D at 240 CPS PG Low or High Bi D 320 Adjusts Bi D at 320 CPS PG Low or High Bi D 240B Adjusts Bi D at 240 CPS Banner PG Low or High Bi D 320B Adjusts Bi D at 320 CPS Banner PG Low or High key ke...

Page 250: ...pleted and ink is not charged User Init Charge Cleaning is completed and ink is charged NOTE When selecting Reset be sure to install the cartridge key key key key key key key key key key key key key key Enter If any value has been changed Press Setting Value or Setting Value key to change the set value Range 100 to 100 2A is not displayed because the value is the basis If High is selected the valu...

Page 251: ...or ordinary maintenance work key key key key key key key key key key key key Enter Serial Number digit by digit 㧲㧮㧢㧖㧜㧜㧜㧜㧜㧜㧲㧮㧢㧭㧖㧜㧜㧜㧜㧜㧲㧮㧢㧭㧝㧖㧜㧜㧜㧜㧲㧮㧢㧭㧝㧞㧖㧜㧜㧜㧲㧮㧢㧭㧝㧞㧟㧖㧜㧜㧲㧮㧢㧭㧝㧞㧟㧠㧖㧜㧲㧮㧢㧭㧝㧞㧟㧠㧡㧖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 MG MG MG MG MG MG MG MG MG Debug Bit Set digit by digit Press Settting Value or Setting Value key to ...

Page 252: ...W 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 ω C Sets ω C ...

Page 253: ...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 key key key key key key key key key key key key key key key key key Enter key key 㧔When selecting 240cps CW 㧕 Enter key Change the value unit to count by pressing setting value or setting value key ...

Page 254: ...eration 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 concurrently 5 13 5 General 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 Previous menu Next menu Previous menu Next menu Previous menu Previous menu Next menu Next ...

Page 255: ...o 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 Table 5 20 Set Items in CR Motor Endurance Menu Set it...

Page 256: ...ncel 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 Table 5 21 Set Items in PF Motor Endurance Menu Set item Contents Set value Remark Media feed amount Set the media feed amount per endurance running cycle 0 1 to 100 Unit mm Number of enduran...

Page 257: ... 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 Table 5 22 Set Items in Pump Motor Assembly Endurance Menu Set item Contents Set value Remark Running speed Set the running speed of pump motor assembly Super high High Normal Low Number of endurance running cycles Set the number of endura...

Page 258: ...ce 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 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 ...

Page 259: ...iven 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 Table 5 23 Set Items in General Endurance Menu Set item Contents Set value Remark Running speed CW CCW Set the carriage running speed CW direction CCW direction 240 320 400 400 CPS cannot be selected depend...

Page 260: ...cles just before the occurrence of the serious error 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 key key key key key key key key key key Number of endurance running cycles for the CR Motor Number of endurance running cycles for the PF Motor Number of endurance running cycles for ...

Page 261: ...X XX The controller board version is displayed in hex format 2 digits 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 ...

Page 262: ...sensors on the controller board is displayed 1 Tank Status Displays the status of sub tank and electromagnetic valve 2 Electromagnetic Valve Check Checks if the electromagnetic valve on the sub tank operates correctly key key key key key key key key key key key key key key key key key key key key key key ...

Page 263: ...idges Ink END sensor for 4 cartridges Cancel key Enter key key key key key key key key key key key key key key key key key key key key Pre heater1 condition display Pre heater2 condition display Platen Heater1 condition display Platen Heater2 condition display After Dryer heater1 condition display After Dryer heater2 condition display K Ink ID condition display M Ink ID condition display Y Ink ID ...

Page 264: ...cess Press Cancel key to stop the operation If the temperature reaches to the set value the plotter keeps the temperature control 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 n...

Page 265: ...al operation mode Select either Top Width Width Off When Off is selected you can set the media width in the media width setting menu s 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 Press Setting value or Setting value key to change the value Rang...

Page 266: ...5 Self Diagnosis Mode VJ 1604 Maintenance Manual Rev 00 5 68 ...

Page 267: ... 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 ...

Page 268: ...ection 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 ...

Page 269: ...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 Table 6 2 Diagnosis Items in Counter Display Menu Diagnosis item Contents Used Ink K Displays the ink consumptio...

Page 270: ...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 clea...

Page 271: ...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 Previous menu Previous menu Previous menu Next menu Next menu Life counter of the head nozzle C1 Life counter of the head nozzle Y2 Life counter of the head nozzle M2 Previous menu Previous menu Previous menu Next men...

Page 272: ...tializes 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 o...

Page 273: ...s menu Previous menu Next menu Previous menu Next menu Previous menu Next menu Next menu Next menu Next menu Previous menu Next menu Next menu Next menu Previous menu Next menu Next menu Next menu Previous menu Previous menu Previous menu Previous menu Previous menu Enter key Previous menu Previous menu Enter key After media is set ...

Page 274: ...nance Mode 2 VJ 1604 Maintenance Manual Rev 00 6 8 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 ...

Page 275: ... 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 A...

Page 276: ... Maintenance Manual Rev 00 7 2 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 ...

Page 277: ...nosis function referring to Table 7 1 Adjustment Item List p 7 3 Table 7 1 Adjustment Item List Part replaced or adjusted Adjustment order Adjustment item Reference Printer head 1 Head rank input including initial ink charge 1 Head Rank p 5 50 5 6 Ink Charging Menu p 5 22 2 Head nozzle check 5 7 1HeadNozzle Check Menu p 5 25 3 Head slant check 5 7 3 Head Slant Check Menu p 5 28 7 7 Head Accuracy A...

Page 278: ...ensor Sensitivity Adjustment p 7 36 8 Test printing 5 7 7 Test Printing Menu p 5 39 CR motor assembly 1 CR belt tension adjustment 7 6 CR Speed Reduction Belt Tension Adjustment p 7 27 2 Uni D Bi D Low Adjustment Uni D Bi D High Adjustment 5 7 5 Uni D Bi D Low High Adjustment p 5 33 3 Side margin adjustment 5 7 6 Side Margin Adjustment Menu p 5 38 4 Test printing 5 7 7 Test Printing Menu p 5 39 PF...

Page 279: ...Margin Adjustment Menu p 5 38 4 Test printing 5 7 7 Test Printing Menu p 5 39 T fence 1 CR encoder inspection 5 5 5 Encoder Menu p 5 17 2 Uni D Bi D Low Adjustment Uni D Bi D High Adjustment 5 7 5 Uni D Bi D Low High Adjustment p 5 33 3 Side margin adjustment 5 7 6 Side Margin Adjustment Menu p 5 38 4 Test printing 5 7 7 Test Printing Menu p 5 39 CR driven pulley 1 CR belt tension adjustment 7 6 C...

Page 280: ...ck 5 13 4 Print Head 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 7 Side margin adjustment 5 7 6 Side Margin Adjustment Menu p 5 38 8 Head nozzle check 5 7 1HeadNozzle Check Menu p 5 25 9 Head slant check 5 7 3 Head Slant Check Menu p 5 28 10 Uni D Bi D Low Adjustment Uni D Bi D High Adjustment 5 7 5 Uni D Bi D Low Hig...

Page 281: ...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 t...

Page 282: ...ntenance 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 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 2 From Setup menu select...

Page 283: ...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 ...

Page 284: ...n connecting the plotter and PC via hub use a straight cable 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 ...

Page 285: ...o 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 ...

Page 286: ...y 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 pl...

Page 287: ...allation to the plotter is not completed Never power off the plotter during the operation 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 ...

Page 288: ...CD 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 1 When firmware transfer starts the LCD display on the plotter s operation control panel changes to Program receiving The Data LED flashes 2 The LCD display changes as follows Er...

Page 289: ...tions 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 3 If the LCD displays transfer complete the buzzer sounds three times and only the Power LED turns on among all LEDs 4 When bytes recv is numeric is displayed installation completes Turn off the plotter and restart it Then che...

Page 290: ...arameters 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 ...

Page 291: ...llowing 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 4 When sending completes and the Send completed window opens click OK 1 Click Sub Con...

Page 292: ... 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 ...

Page 293: ...rting 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 8 When completing sub controller firmware installation LCD display on the plotter control panel changes to Transfer complete Buzzer sounds three times s 㧿㨑㨚㨐㨕㨚㨓 ޓ 㨎㨛㨛㨠 ޓ 㨏㨛㨐㨑 ޓ 㨤㨤㧿㨑㨚㨐㨕㨚㨓 ޓ 㨟㨥㨟 ޓ 㨏㨛㨐㨑 ޓ 㨤㨤㨀㨞㨍㨚㨟㨒㨑㨞 ޓ 㨏㨛㨙㨜㨘㨑㨠...

Page 294: ...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 9 When xxxxxx bytes recv xx is numerical value is displayed installation is completed Pressing any key goes back to Waiting for command status 1 Click Date Time Install 2 When the Date time installation check window opens click OK Installing will start 㨤㨤㨤㨤㨤㨤 ޓ 㨎㨥㨠㨑...

Page 295: ...VJ 1604 Maintenance Manual 7 Adjustment 7 21 Rev 00 3 When installing completes and the Install completed window opens confirm that the installed date is correct and click OK ...

Page 296: ...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 1 Open the front cover 2 Remove the side maintenance cover L 4 2 5 Removing Side Maintenance Cover L p 4 12 3 Press the tension g...

Page 297: ...teel 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 CAUTION Adjust the steel belt so that the steel belt is equally balanced If not the steel belt may be cut No Part name 1 Steel belt 2 Steel belt tension screw 2 1 ...

Page 298: ...7 Adjustment VJ 1604 Maintenance Manual Rev 00 7 24 5 Apply adhesive material 6 Close all the covers No Part name 1 Adhesive material applying surface 1 ...

Page 299: ...r L 4 2 5 Removing Side Maintenance Cover L p 4 12 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 4 Attach the slit guide to the PF encoder asse...

Page 300: ...heck 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 ...

Page 301: ... for CR speed reduction belt tension adjustment are as follows Tension gauge for measuring Max 40N 4080gf 8 4 Jigs and Tools p 8 6 7 6 2 Adjustment Procedures 1 Remove the side maintenance cover L 4 2 5 Removing Side Maintenance Cover L p 4 12 2 Remove the side top cover R 4 2 6 Removing Side Top Cover R p 4 12 3 Remove the panel to conversion board tape wire from the flat cramps 2 pieces on the b...

Page 302: ...eces that retain CR motor mounting plate 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 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 2 3 3 1 2 Upper Lower 1 2 2 3 ...

Page 303: ...ion 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 12 Close all the covers No Part name 1 Tension gauge 2 CR motor mountin...

Page 304: ...tion 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...

Page 305: ...djustment patterns 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 2 Head mounting plate 5mm 5mm B A C E D 20mm 1 2 ...

Page 306: ...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 1 Start the plotter in the self diagnosis function mode and select He...

Page 307: ...ted adjustment patterns A Check the point to check the vertical slant angle B Media feed direction C OK D Move the vertical slant adjusting tab to the right E Move the vertical slant adjusting tab to the left A E D C B 1 A 1 B 2 A 2 B 3 A 3 B 4 A 4 B 1 A 1 B 2 A 2 B 3 A 3 B 4 A 4 B CCW CW ...

Page 308: ...edure to adjust the carriage height distance between carriage and platen 7 8 1 Jigs and Tools The following jigs and tools are required for carriage height adjustment PG height check jig TIP 8 4 Jigs and Tools p 8 6 7 8 2 Adjustment Procedure To make adjustment follow the steps below 1 Open the front cover 2 Unlock the head lock 4 8 1 Releasing Head Lock p 4 105 No Part name 1 Head base mounting p...

Page 309: ...carriage 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 6 Reverse the jig and move the carriage from the opposite side of the jig No Part name 1 PG height check jig No Part name 1 PG height check jig 2 Print head 3 Platen 1 1 3 Enlarged view 2 1 37mm 1 42mm L R 1 2 ...

Page 310: ... 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 decre...

Page 311: ...st 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 f...

Page 312: ...stment 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 11 Check that the value displayed in the operation panel is 80 or less 12 Move the carriage back to the origin 13 Close all the...

Page 313: ...8 Maintenance 8 1 Rev 00 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 ...

Page 314: ...e 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 ...

Page 315: ... Part Timing Check point Action Media guide F Platen front surface Several times per year Media dust accumulation Foreign objects Damages Clean it If ink deposits are present remove them with a dampened cloth and wipe the area with a clean dry cloth Timing fence CR encoder detection slit plate Several times per year Media dust accumulation Foreign objects Damages Clean it If any damages are found ...

Page 316: ...00 sheets 1 Warning at 3 000 times of wiping Counter clear Ink system Cleaner head Cleaning wiper Flushing box Absorber under the maintenance base absorber 4 9 2 Replacing Cleaner Head p 4 121 4 6 12 Replacing Flushing Absorber p 4 82 CR motor Approx 20 000 sheets 4600 000 passes 2 Check Life CR motor Counter clear At the first warning CR motor CR Driven pulley Check the ink tube and the CR cable ...

Page 317: ...eed Mode Print head 6 billion dots Check Life Head Replace as necessary 4 8 9 Replacing Print Head p 4 114 Pump 182 000 times Check Life Pump Counter clear Replace as necessary 4 9 3 Replacing Maintenance Assembly p 4 122 Table 8 2 List of Parts Life Expectancy Continued Part Life expectancy Warning display How to restore Replacement parts References ...

Page 318: ... assemblies 6 Ratchet Generic product 7 Long nose pliers Generic product 8 Tweezers Generic product 9 Hex wrench opposite side 1 5 to 6mm Generic product 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 tak...

Page 319: ...eric product 6 MF 3G Exclusive use media For P_EDGE sensor for print accuracy adjustment 7 PG height check tool 64 JD 42796 Table 8 5 Lubricant List Parts Item Manufacturer Type PF drive section Up down gear on pressure lever Apply to gear Kanto Kasei Co Ltd FLOIL G MK 1 PF motor bracket Middle gear inner diameter Apply to middle gear inner diameter Kanto Kasei Co Ltd FLOIL G MK 1 Speed reduction ...

Page 320: ...o cam part Kanto Kasei Co Ltd FLOIL G MK 1 Roller guide Apply to the front surface of roller guide Mitsubishi Super multi dia tetrat No 32 Drive pulley Apply to drive pulley Kanto Kasei Co Ltd FLOIL G MK 1 Cursor section Head U D collar Apply to head U D collar Kanto Kasei Co Ltd FLOIL G MK 1 Head U D cam Apply to head U D cam Kanto Kasei Co Ltd FLOIL G MK 1 Slide gear Apply to gear Kanto Kasei Co...

Page 321: ...nd Co Ltd 1401 CR drive section CR driven pulley adjusting screw After adjusting steel belt apply screw locking agent Three Bond Co Ltd 1401 Others Screw Apply to the area screw locking agent is applied Three Bond Co Ltd 1401 Parts Item Manufacturer Type Others The areas sharpened edge is likely to emerge Attach acetate tapes to the tape wires or harnesses where sharpened edge is likely to emerge ...

Page 322: ... 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 5 7 8 HeadWash Menu p 5 40 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 fl...

Page 323: ...rors 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 So...

Page 324: ... 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 message Di...

Page 325: ...embly cable to MAIN board assembly connector J38 and front cover L sensorassembly cable MAIN board assembly connector J40 4 4 7 Replacing MAIN Board p 4 49 2 Does pressure lever move smoothly Lubricate pressure cam 8 5 Lubrication Bonding p 8 7 3 Is lever sensor assembly fitted correctly Adjust lever sensor assembly position 4 6 6 Replacing Lever Up Sensor p 4 67 4 Is sensor of lever sensor assemb...

Page 326: ...sembly p 4 106 2 Is P_REAR sensor assembly under media guide R connected correctly Securely connect it to MAIN board assembly connector J42 4 4 7 Replacing MAIN Board p 4 49 3 Check sensor sensitivity from Sen 8 EdgeAD 3 of self diagnosis function Adjust with MAIN board assembly volume R361 R365 Replace P_EDGE sensor assembly 7 9 P_EDGE Sensor Sensitivity Adjustment p 7 36 4 CR board assembly may ...

Page 327: ...edia detection failed 1 Is P_EDGE sensor assembly cable at head connected correctly Securely connect it to CR board assembly connector J208 4 8 3 ReplacingCR Board Assembly p 4 106 2 Is P_REAR sensor under media guide R connected correctly Securely connect it to MAIN board assembly connector J42 4 4 7 Replacing MAIN Board p 4 49 3 Check sensor sensitivity from Sen 8 EdgeAD 3 of self diagnosis func...

Page 328: ... s inappropriate media setting instruct correct media setting procedure 2 Is suction fan judged as normal when checked through Test 6 Fan of self diagnosis function Check connection of following MAIN board assembly connectors Suction fan 1 cable J25 Suction fan 2 cable J26 Suction fan 3 cable J28 Suction fan 4 cable J29 Replace suction fan assembly Replace cable of suction fan that does not operat...

Page 329: ...econnect MAIN board assembly connector J30 If LCD displays as chattering sensor may be damaged Replace lever sensor assembly 4 4 7 Replacing MAIN Board p 4 49 4 6 6 Replacing Lever Up Sensor p 4 67 4 Is P_REAR sensor assembly under media guide R connected correctly Securely connect it to MAIN board assembly connector J42 4 4 7 Replacing MAIN Board p 4 49 5 Check presence of media from Sen 7 PaperR...

Page 330: ...ors MAIN board J43 HEATER JUNCTION board Connector J5 K Connector J6 C Connector J7 M Connector J8 Y 4 4 7 Replacing MAIN Board p 4 49 3 For the ink color that is displayed as Ink Near End or Ink End switch ink sensor assembly connector with that of normally displayed ink color If ink color display changes after replacing connector Ink sensor assembly is damaged Replace ink sensor assembly If ink ...

Page 331: ...ly connector Reconnect following connectors MAIN board J43 HEATER JUNCTION board Connector J5 K Connector J6 C Connector J7 M Connector J8 Y 4 4 7 Replacing MAIN Board p 4 49 4 For the ink color that is displayed as Little ink or No ink switch ink NOT sensor assembly connector with that of normally displayed ink color If ink color displayed as No ink changes after replacing connector Ink sensor as...

Page 332: ...n 3 etc 7 10 KCMY Ink ID of self diagnosis function If detection does not operate normally replace following parts Ink sensor assembly Main board assembly Ink ID sensor assembly 4 10 1 Replacing Ink ID Board Assembly p 4 125 4 4 7 Replacing MAIN Board p 4 49 4 Check contact of ink ID sensor assembly connector Reconnect following MAIN board assembly connectors MAIN board J43 HEATER JUNCTION board C...

Page 333: ... OFF Turn it ON again and check if the same message appears If the message appears Refer to the action in check item No 2 2 Use of ink tube has exceeded specified level Replace ink tube 4 7 10 Replacing Ink Tube p 4 102 3 Main board assembly may be damaged Replace MAIN board assembly 4 4 7 Replacing MAIN Board p 4 49 8 Out of memory DIMM 128MB Memory is insufficient for data analysis printing Requ...

Page 334: ...by removing the error causes After that the machine will restart its operation Table 9 4 Symptoms and Check Items for Data Errors No Message Event symptom Check item Action Reference 1 I 15 1 error command Online frame error 1 Attempt communication using PC and cable on hand 2 Is there any error statement in printing data 3 Does the symptom remain the same even if application driver is replaced 4 ...

Page 335: ...ion driver is replaced 4 Main board assembly may be defective Contact our customer support center Replace application driver Obtain printing data Contact our customer support center Replace MAIN board assembly 4 4 7 Replacing MAIN Board p 4 49 7 I 12 error command Unauthorized character ESC 8 I 13 error command Numeral character ESC 9 I 14 error command Parametererror ESC 10 I 16 error command Buf...

Page 336: ... Command being analyzed is not defined in applicable command mode 1 Attempt communication using PC and cable on hand 2 Is there any error statement in printing data 3 Does the symptom remain the same even if application driver is replaced 4 Main board assembly may be defective Contact our customer support center Replace application driver Obtain printing data Contact our customer support center Re...

Page 337: ...l 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 ...

Page 338: ...etch error Abnormal condition in command border Or TLB exception in data load or command fetch 4 E 016 error CPU Err 03 Data border exception TLB exception store error Abnormal condition in data border Or TLB exception in data storing 1 Check serial number of the printer 2 Main board assembly may be defective Contact our customer support center Replace MAIN board assembly 4 4 7 Replacing MAIN Boar...

Page 339: ...umber of the printer 2 Main board assembly may be defective Contact our customer support center Replace MAIN board assembly 4 4 7 Replacing MAIN Board p 4 49 9 E 016 error CPU Err 08 System call exception error Abnormal condition in system call 10 E 016 error CPU Err 09 Break point exception error Abnormal condition in break point 11 E 016 error CPU Err 10 Reserved command exception error Abnormal...

Page 340: ...ustomer support center Contact our customer support center Replace MAIN board assembly 4 4 7 Replacing MAIN Board p 4 49 14 E 016 error CPU Err 13 Trap exception error Trap occurs 15 E 016 error CPU Err 15 Floating point exception error Abnormal condition in floating point process 16 E 016 error CPU Err 22 Watch exception error Abnormal condition in watch 17 E 016 error CPU Err 32 Watchdog time ou...

Page 341: ...cycles to 50 or more from Life 2 PF Motor of self diagnosis function and check if X motor error occurs 3 Check Encoder PF from Check 2 Test Test 5 Encoder of self diagnosis function 4 Check if Main Power Board normally supplies DC24V 5 PF motor assembly may be defective 6 Main board assembly may be defective Check connection of following MAIN board assembly connectors PF motor cable assembly conne...

Page 342: ...r of self diagnosis function 4 Check if Main Power Board normally supplies DC24V 5 PF motor assembly may be defective 6 Main board assembly may be defective Check connection of following MAIN board assembly connectors PF motor cable assembly connector J20 PF_ENC assembly connector J12 If NG check connection of MAIN board assembly connector J12 Replace PF motor assembly Replace MAIN board assembly ...

Page 343: ... 5 Encoder of self diagnosis function 4 Check if Main Power Board normally supplies DC24V 5 PF motor assembly may be defective 6 Main board assembly may be defective Check connection of following MAIN board assembly connectors PF motor cable assembly connector J20 PF_ENC assembly connector J12 If NG check connection of MAIN board assembly connector J12 Replace PF motor assembly Replace MAIN board ...

Page 344: ...ain Power Board normally supplies DC24V 5 PF motor assembly may be defective 6 Main board assembly may be defective Check connection of following MAIN board assembly connectors PF motor cable assembly connector J20 PF_ENC assembly connector J12 If NG check connection of MAIN board assembly connector J12 Replace PF motor assembly Replace MAIN board assembly 5 5 7 History Menu p 5 18 4 4 7 Replacing...

Page 345: ...urance running cycles to 50 or more from Life 1 CR Motor of self diagnosis function and check if Y motor error occurs Clean and lubricate CR rail roller guide Check connection of following connectors Main board CR motor assembly connector J21 CRcableconnector J9 J11 CR board CRcableconnector J201 J205 5 5 7 History Menu p 5 18 8 5 Lubrication Bonding p 8 7 4 4 7 Replacing MAIN Board p 4 49 7 E 068...

Page 346: ...mination or deposit is too heavy Replace T fence a If NG Check following cable connection CR board assembly connector J207 b Replace following parts T fence CR motor assembly CR board assembly CR cable Replace MAIN board assembly 4 7 4 Replacing T Fence p 4 91 4 7 4 Replacing T Fence p 4 91 4 7 4 Replacing T Fence p 4 91 4 7 2 ReplacingCR Motor Assembly p 4 87 4 8 3 ReplacingCR Board Assembly p 4 ...

Page 347: ...Lever Sensor p 4 150 3 Main board assembly may be damaged Replace MAIN board assembly 4 4 7 Replacing MAIN Board p 4 49 12 E 082 error wiper sensor Abnormal condition in wiper sensor Wiper sensor assembly may be faulty Main board assembly may be faulty 1 Check connection of wiper sensor connector 2 Replace wiper sensor 3 Replace MAIN board assembly 4 9 2 Replacing Cleaner Head p 4 121 4 4 7 Replac...

Page 348: ...thermistor heater Disconnection of connector wrong wiring or heater malfunction of thermistor and heater may be occurred 1 Reconnect connector of thermistor and heater 2 Check connection of board section 3 Replace heater 4 6 7 Replacing Heater Thermistor p 4 68 4 4 7 Replacing MAIN Board p 4 49 15 E 077 error platen heater system Abnormal condition in platen heater system thermistor heater Disconn...

Page 349: ...printing operation 19 E 084 error head identification Installed head is incorrect Installed head is not manufactured by other vendor Replace head 4 8 9 Replacing Print Head p 4 114 20 E 085 error head overheat Abnormal condition in head driver Main board assembly may be damaged Replace MAIN board assembly 4 4 7 Replacing MAIN Board p 4 49 21 E 086 error head OVP Abnormal condition in head driver H...

Page 350: ...on board 24 E 097 error NVRAM Abnormal condition in NVRAM Replace MAIN board assembly 4 4 7 Replacing MAIN Board p 4 49 25 E 118 E 121 error sub tank Lo Abnormal condition in error sub tank Lo sensor Sub tank Lo sensor two way valve or junction board may be defective 1 Replace sub tank Lo sensor 2 Replace two way valve 3 Replace junction board Table 9 7 Symptoms and Check Items for Mechanical Seri...

Page 351: ... Check connection between printer and PC After resolving problem transfer firmware again 4 Transfer failed Check sum error File checksum error 1 Transfer firmware again 2 If error message is still displayed check if transferred firmware is an appropriate file 5 Transfer failed Wrong size xxxxxxxx Received wrong size data Check if program file is appropriate After confirming it transfer data again ...

Page 352: ...rol board and MAIN board Replace the cable connecting control board and MAIN board Replace control board Replace MAIN board 4 4 3 Replacing HEATER CONT Board p 4 42 4 4 7 Replacing MAIN Board p 4 49 13 Transfer failed Block replay error xx Invalid value is receivedduring system code transfer 14 Transfer failed Final reply timeout Final reply timeout occurred during system code transfer 15 Transfer...

Page 353: ...oard If the red LED is blinking and there is no problem at connection between control board and 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...

Page 354: ...meout Transfer sequence echo of boot code did not reply 21 Boot Transfer failed Echo error xx Invalid transfer sequence echo of boot code did not reply 22 Internal error Parameter save error Failed in writing parameter Normally not occurred FROM may be defective Replace MAIN board 4 4 7 Replacing MAIN Board p 4 49 23 Transfer failed Wrong year xxxx Invalid year data xxxx received SODIMM or MAIN bo...

Page 355: ...on operation panel is in waiting status of board manager mode Press any button on operation panel to make the panel display waiting state Then reinstall the software 7 3 Working with Dedicated Network Software p 7 7 Table 9 8 Error Messages During File Transmission Continued No Message Event symptom Check item Action Reference ...

Page 356: ...ken or shorted Replace panel cable 4 3 1 Replacing Panel Unit p 4 30 2 Panel unit assembly may be damaged Replace panel unit assembly 4 3 1 Replacing Panel Unit p 4 30 3 Inlet assembly may be defective Replace inlet assembly 4 4 9 Replacing Inlet Assembly p 4 55 4 Power board assembly may be defective Replace power board assembly 4 4 2 Replacing Power Board Assembly p 4 41 2 Abnormal LCD operation...

Page 357: ...nel cable 4 3 1 Replacing Panel Unit p 4 30 5 Is operation panel unit assembly LCD damaged Replace panel board assembly 4 3 1 Replacing Panel Unit p 4 30 6 Main board assembly may be damaged Replace MAIN board assembly 4 4 7 Replacing MAIN Board p 4 49 3 Initial ink charge not available 1 Is Sen Cover open displayed on LCD with front cover closed Check connection of cover sensor assembly connector...

Page 358: ...ed with specified cartridge securely inserted Detection of presence of ink from Ctrl 2 Sensor Sen 3 etc 12 Ink END Detection of presence of cartridge from Ink Not Follow the steps for the message KCMY No Cartridge After adjustment replacement execute initial ink charge from Update 1 Head Rank of self diagnosis function 4 4 7 Replacing MAIN Board p 4 49 1 Head Rank p 5 50 6 Is specified cartridge s...

Page 359: ...does not reach head Is spring of ink system assembly detached or damaged If the part is detached remount it If the part is damaged replace ink system assembly 4 10 1 Replacing Ink ID Board Assembly p 4 125 5 Though ink reaches head ink is not discharged from head Is capping position appropriate If ink inflow is confirmed execute initial ink charge Operation Manual Table 9 9 Symptoms Check Items an...

Page 360: ...nance Cover L p 4 12 4 2 11 Removing Cartridge Cover lower p 4 19 2 Does shield part of damper assembly have air leak Replace damper assembly and check if cleaning operation causes ink inflow If ink inflow is confirmed execute initial ink charge 4 8 9 Replacing Print Head p 4 114 3 Is ink tube in ink system assembly bent Replace ink system assembly and check if cleaning operation causes ink inflow...

Page 361: ...gear shaft damaged Replace maintenance base assembly 4 2 2 Removing Maintenance Cover p 4 9 7 Does ink tube have bend scratch or leak Replace damaged ink tube and check if cleaning operation causes ink inflow after each replacement If ink inflow is confirmed execute initial ink charge 4 7 10 Replacing Ink Tube p 4 102 8 Check connection of head cable connectors on CR board assembly side and head s...

Page 362: ...le connectors on CR board assembly side and MAIN board assembly side Is head cable inserted obliquely Is it locked securely Reconnect following connectors CR board assembly connector J201 J205 Main board assembly connector J9 J11 4 8 3 Replacing CR Board Assembly p 4 106 4 4 7 Replacing MAIN Board p 4 49 13 Is CR cable broken Replace CR cable 4 7 8 Replacing CR Tape Wire p 4 99 14 Main board assem...

Page 363: ... securely Reconnect following connectors Main board assembly J5 Operation panel unit assembly J1 4 4 7 Replacing MAIN Board p 4 49 9 Machine does not perform initialization even if media is set 3 Is Set Paper displayed on LCD with pressure arm lowered Check MAIN board assembly connector J30 Replace lever sensor assembly 4 4 7 Replacing MAIN Board p 4 49 4 6 6 Replacing Lever Up Sensor p 4 67 10 Ma...

Page 364: ...ard assembly 4 4 2 Replacing Power Board Assembly p 4 41 7 Is DC cable assembly connected correctly between power board assembly and MAIN board assembly Reconnect DC cable assembly Replace DC cable assembly 4 4 2 Replacing Power Board Assembly p 4 41 8 Main board assembly may be defective Replace MAIN board assembly 4 4 7 Replacing MAIN Board p 4 49 Table 9 9 Symptoms Check Items and Actions for I...

Page 365: ...rtridge After adjustment replacement execute initial ink charge from Update 1 Head Rank of self diagnosis function 1 Head Rank p 5 50 2 Is specified cartridge status detected as normal when checked through Ctrl 2 Sensor Sen 3 etc 7 10 KCMY Ink ID of self diagnosis function with specified cartridge securely inserted Follow the steps for the message Insert specified cartridge After adjustment replac...

Page 366: ...s Main board assembly J5 Operation panel unit assembly J1 4 4 7 Replacing MAIN Board p 4 49 3 Operation panel unit assembly may be damaged Replace panel unit assembly 4 3 1 Replacing Panel Unit p 4 30 4 Main board assembly may be malfunctioning Replace MAIN board assembly 4 4 7 Replacing MAIN Board p 4 49 14 Machine prints nothing though it receives data 1 Refer to 9 3 5 Online Function Problem 9 ...

Page 367: ...cked through Test 6 Fan of self diagnosis function Check connection of following MAIN board assembly connectors Suction fan cable assembly J25 J29 Replace suction fan assembly Replace cable of suction fan that does not operate normally 4 6 8 Replacing Suction Fan p 4 76 3 Media crinkles during media set initialization or printing 4 Media jams during media set initialization or printing 3 When pres...

Page 368: ...ration Manual 6 Machine registers wrong media size after media set initialization Is media in use a recommended one Set recommended media and check printout again With non authorized media media sensor may fail to detect media correctly Operation Manual Table 9 10 Symptoms Check Items and Actions for Media Feed Problems Continued No Symptom Check item Action Reference ...

Page 369: ...p 7 12 3 Main board assembly may be damaged Replace MAIN board assembly 4 4 7 Replacing MAIN Board p 4 49 2 Media feed after printing is excessive 1 Is P_REAR sensor assembly judged as normal when checked through Test 4 Sensor of self diagnosis function Reconnect MAIN board assembly connector J42 Replace P_REAR sensor assembly 4 4 7 Replacing MAIN Board p 4 49 4 6 5 Replacing P_REAR Sensor Assembl...

Page 370: ... MAIN Board p 4 49 5 Are gears and transmissiongearshaft damaged or poorly engaged during cleaning operation Replace maintenance base assembly 4 Nozzle plugging or ink splash is not eliminated even after cleaning 1 Is spring of ink system assembly detached or damaged If the part is detached remount it If the part is damaged replace ink system assembly 4 10 1 Replacing Ink ID Board Assembly p 4 125...

Page 371: ...ank p 5 50 6 Check if CR_ENC assembly and T fence contact with each other If they contact with each other adjust CR_ENC assembly and T fence positions If problem remains even after position adjustment replace CR board assembly and T fence 4 8 3 Replacing CR Board Assembly p 4 106 4 7 4 Replacing T Fence p 4 91 7 Is ink tube in ink system assembly bent Replace ink system assembly and check if clean...

Page 372: ...eplacing T Fence p 4 91 5 Are damper assembly ink tube and SUS pipe joint screws K C M Y securely tightened Is O ring properly installed Remove head cover and check damper assembly Remove side cover L R and I H cover and check ink tube and SUS pipe joint screws 4 2 4 Removing Side Maintenance Cover R p 4 11 4 2 5 Removing Side Maintenance Cover L p 4 12 6 Does shield part of damper have air leak R...

Page 373: ... KCMY No Cartridge After adjustment replacement execute initial ink charge from Update 1 Head Rank of self diagnosis function 1 Head Rank p 5 50 10 Is ink tube in ink system assembly bent Replace ink system assembly and check if cleaning operation causes ink inflow If ink inflow is confirmed execute initial ink charge 4 10 1 Replacing Ink ID Board Assembly p 4 125 11 Does pump motor rotate during ...

Page 374: ...y Reconnect head cable 4 8 9 Replacing Print Head p 4 114 4 8 3 Replacing CR Board Assembly p 4 106 15 Is print head damaged Replace damaged print head 4 8 9 Replacing Print Head p 4 114 16 CR board assembly may be defective Replace CR board assembly 4 8 3 Replacing CR Board Assembly p 4 106 17 Main board assembly may be damaged Replace MAIN board assembly 4 4 7 Replacing MAIN Board p 4 49 Table 9...

Page 375: ...lace CR cable assembly 4 7 8 Replacing CR Tape Wire p 4 99 4 Is print head damaged Replace damaged print head assembly 4 8 9 Replacing Print Head p 4 114 5 CR board assembly may be malfunctioning Replace CR board assembly 4 8 3 Replacing CR Board Assembly p 4 106 6 Main board assembly may be damaged Replace MAIN board assembly 4 4 7 Replacing MAIN Board p 4 49 7 8 9 10 Blocky printing quality Bloc...

Page 376: ...ning again and check printout If symptoms still remains refer to Operation Manual to contact the technical support Operation Manual 3 Is suction fan run as normal when checked through Test Fan of self diagnosis function Check connection of following MAIN board assembly connectors Suction fan 1 4 assembly J25 29 Suction fan 2 cable J127 Suction fan L cable J126 Replace suction fan assembly Replace ...

Page 377: ...ning wiper surface with accessory polynit wiper After wiping cleaning wiper perform cleaning twice consecutively If cleaning wiper is sticky with ink replace it with a new one Operation Manual 8 Is nozzle face wiped rubbed correctly Check wiper installation condition and secure it correctly 4 9 2 Replacing CleanerHead p 4 121 9 Is T fence contaminated Clean T fence If T fence is still contaminated...

Page 378: ...damaged Replace maintenance base assembly 14 Is spring of ink system assembly detached or damaged If the part is detached remount it If the part is damaged replace ink system assembly 4 10 1 Replacing Ink ID Board Assembly p 4 125 15 Is ink tube in ink system assembly bent Replace ink system assembly and check if cleaning operation causes ink inflow If ink inflow is confirmed execute initial ink c...

Page 379: ...with specified cartridge securely inserted Detection of presence of ink from Ctrl 2 Sensor Sen 3 etc 11 Ink NOT Detection of presence of cartridge from Ctrl 2 Sensor Sen 3 etc 12 Ink END Follow the steps for the message KCMY No Cartridge After adjustment replacement execute initial ink charge from Update 1 Head Rank of self diagnosis function 1 Head Rank p 5 50 20 CR board assembly may be malfunct...

Page 380: ...peration Manual 3 CR cable assembly may be damaged Replace CR cable assembly wire 4 7 8 Replacing CR Tape Wire p 4 99 4 Is print head damaged Replace damaged print head 4 8 9 Replacing Print Head p 4 114 5 CR board assembly may be malfunctioning Replace CR board assembly 4 7 8 Replacing CR Tape Wire p 4 99 6 Main board assembly may be damaged Replace MAIN board assembly 4 4 7 Replacing MAIN Board ...

Page 381: ...te plotting quality Operation Manual 6 Is CR belt tension adjusted to specification Adjust CR belt tension 7 6 CR Speed Reduction Belt Tension Adjustment p 7 27 7 Check if PF_ENC assembly and T fence contact with each other If they contact with each other adjust CR_ENC assembly and T fence positions If problem remains even after position adjustment replace CR board assembly and T fence 4 8 3 Repla...

Page 382: ...maged If the part is detached remount it If the part is damaged replace ink system assembly 4 10 1 Replacing Ink ID Board Assembly p 4 125 14 Is ink tube in ink system assembly bent Replace ink system assembly and check if cleaning operation causes ink inflow If ink inflow is confirmed execute initial ink charge 4 10 1 Replacing Ink ID Board Assembly p 4 125 15 Does residual ink collect on print h...

Page 383: ...n Adjustment p 7 27 4 Are bi directional printing positions aligned correctly Align bi directional printing positions 5 7 5 Uni D Bi D Low High Adjustment p 5 33 5 Is CW adjustment inappropriate Perform CW adjustment 5 7 5 Uni D Bi D Low High Adjustment p 5 33 14 Black and other colors do not align 1 Check if CR_ENC assembly and T fence contact with each other If they contact with each other adjus...

Page 384: ...fy them Then check machine operation again 5 11 1 Parameter Initialization Menu p 5 47 16 Poor linearity in head scan direction straightness 1 Is suction fan run as normal when checked through Test 6 Fan of self diagnosis function Check connection of following MAIN board assembly connectors Suction 1 4 cable J25 J29 Replace suction fan assembly Replace cable of suction fan that does not operate no...

Page 385: ...ng PF Motor Assembly p 4 61 3 Is PF belt tension adjusted to specification Adjust PF speed reduction belt tension 2 Confirming Completion of Installation to Plotter p 7 14 4 Does pressure roller rotate harder when pressure arm is raised If pressure roller collects media dust on itself wipe dust away using a wet soft cloth Operation Manual 5 Is rough surface of grid roller partially worn out 6 Is g...

Page 386: ...is still contaminated or damaged replace T fence 4 7 4 Replacing T Fence p 4 91 6 Check if vertical lines plotted from Adj 3 HeadSlant are not connected even though nozzle check pattern from Adj 1 NozzleChk of self diagnosis function is adjusted properly Replace steel bearer assembly 4 7 8 Replacing CR Tape Wire p 4 99 7 Is carriage assembly loose Replace carriage assembly 19 Poor right angle accu...

Page 387: ... Action Reference 1 Abnormal noise is heard when media is suctioned 1 Are there any foreign objects or obstacles around rotating fin of suction fan assembly Remove obstacles and foreign objects 4 6 8 Replacing Suction Fan p 4 76 2 Check damage of cables and connection of connectors Ifdamaged replacedamaged part 3 Suction fan assembly may be defective Replace suction fan assembly 4 6 8 Replacing Su...

Page 388: ...moving laterally 1 Does customer recognize ink discharge noise as abnormal noise Explain machine operations 2 Is abnormal noise caused by loose screw in covers Additionally tighten screws 4 2 Removing Covers p 4 7 3 Is rattling noise heard when moving carriage laterally Remove dust from carriage bearing and roller strip After cleaning roller strip always apply thin lubricant film over its surface ...

Page 389: ...rmal noise heard from CR motor assembly Replace CR motor assembly 4 7 2 Replacing CR Motor Assembly p 4 87 4 Abnormal noise is heard during media feeding 1 Is PF speed reduction belt slipping between PF speed reduction pulleys Replace PF speed reduction belt 4 6 2 Replacing PF Motor Assembly p 4 61 2 Is abnormal noise heard from PF motor assembly Replace PF motor assembly 4 6 2 Replacing PF Motor ...

Page 390: ...2 3 Other functions do not work correctly 3 Main board assembly may be damaged Replace MAIN board assembly 4 4 7 Replacing MAIN Board p 4 49 4 Printing position is incorrect 1 Is CW adjustment inappropriate Perform adjustment 5 7 5 Uni D Bi D Low High Adjustment p 5 33 2 Is adjustment of P_EDGE sensor inappropriate Perform adjustment 7 9 P_EDGE Sensor Sensitivity Adjustment p 7 36 3 Printer driver...

Page 391: ... 4 Check Encoder CR from Check 2 Test Test 5 Encoder of self diagnosis function Move carriage in both directions and check the numeral value on LCD If the numeral value doesn t change normally check MAIN board assembly connector J12 Replace T fence Replace CR motor assembly Replace CR board assembly Replace CR cable 4 4 7 Replacing MAIN Board p 4 49 4 7 4 Replacing T Fence p 4 91 4 7 2 Replacing C...

Page 392: ...ence 1 Machine hangs up 1 Internal process of MAIN board assembly may be abnormal Initialize parameters and reenter or modify them 7 3 1 Parameter Backup p 7 7 2 Main board assembly may be damaged Replace MAIN board assembly 4 4 7 Replacing MAIN Board p 4 49 2 Machine power is shut off during printing 1 Is power cable shorted Check by a circuit tester 2 Is there any electric leakage Check for shor...

Page 393: ...om Ctrl 2 Sensor Sen 3 etc 12 Ink END of self diagnosis function Remove all cartridges and lightly push the switch of ink NOT sensor BK C M Y with something with a flat tip such as ballpoint pen to check that the display of 12 Ink END changes 5 5 4 Sensor Menu p 5 15 3 Is waste fluid tube coming out of flushing box bent Reinstall it 4 6 11 Replacing Flushing Tray p 4 80 5 Ink spills out of flushin...

Page 394: ...nkcartridge check if each board operates properly 4 4 7 Replacing MAIN Board p 4 49 4 8 9 Replacing Print Head p 4 114 4 8 3 Replacing CR Board Assembly p 4 106 Table 9 15 Problems in Using Dedicated Network Software No Event symptom Check item Action Reference 1 MUTOH Maintenance Assistant does not start up Perform reinstallation and initial setting Network Administration Manual 2 Transfer failed...

Page 395: ...oceed to 5 No Start printer in board manager mode If LCD displays nothing engine component may be defective or firmware may not be installed including power cutoff due to power failure during installation or other causes 7 3 3 Required Environment p 7 8 5 Is printer IP address appropriate Check address according to Section 6 3 Yes Proceed to 6 No Engine board may by defective 4 4 7 Replacing MAIN ...

Page 396: ...lay of the message shown below on 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 7 3 5 Firmware Installation p 7 12 Table 9 15 Problems in Using Dedicated Networ...

Page 397: ...VJ 1604 Maintenance Manual 10 Appendix 10 1 Rev 00 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 ...

Page 398: ...or 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 ...

Page 399: ...For pre heater 27 Damper L_assembly DF 48141 Common with RH2 Table 10 2 Y Rail Assembly No Part name Part number Remarks 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...

Page 400: ...mon with VJ12 10 VJ cursor roller arm assembly DG 40326 Common with VJ26 11 VJ16 cursor head base assembly DG 40353 12 Head FFC VJ16 DG 40354 Table 10 4 Maintenance Assembly No Part name Part number Remarks 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 absorbe...

Page 401: ...J26 Table 10 7 Roll Media Tray Assembly No Part name Part number Remarks 1 VJ16_L roll media holder assembly DG 40358 2 VJ16_R roll media holder assembly DG 40359 Table 10 8 Cover Assembly No Part name Part number Remarks 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 assembl...

Page 402: ...th 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 assembly DG 40478 Common with VJ12 10 Power source for foreign use DF 44506 Common with RJ 8000 11 VJ take up SW board assembly DG 40479 Common with VJ12 12 W_ON sensor assembly DG 40480 Common with VJ12 13 W_OFF sensor assembly DG 40481 Common with VJ12 14 AC cab...

Page 403: ...VJ 1604 Maintenance Manual 10 Appendix 10 7 Rev 00 10 4 Exploded View For exploded views and the maintenance parts see information below TIP Separate sheet Exploded View p 2 p 10 ...

Page 404: ...10 Appendix VJ 1604 Maintenance Manual Rev 00 10 8 ...

Page 405: ...REAR SENSOR ASS Y VJ16 FRONT COVER R SENSOR ASS Y VJ16 FRONT COVER L SENSOR ASS Y VJ16 POST HEADER ASS Y COOLING FAN CABLE ASS Y 24V PRESSURE ARM TERMINAL BLOCK to POWER AC CABLE ASS Y VJ16 TERMINAL BLOCK to CNT AC CABLE ASS Y VJ16 MAIN BOARD SIDE INLET to FUSE BOX CABLE ASS Y VJ26 MAIN BOARD SIDE INLET to FUSE BOX CABLE ASS Y VJ26 MAIN BOARD SIDE FUSE to TERMINAL BLOCK CABLE ASS Y VJ26 INLET SMAL...

Page 406: ...t Cleaning Print SetTime Parameter Servo Endurance PaperFeed ExControl PaperInitial Ram Capacity Version Panel Sensor Encorder Fan Record HeadSignal Refer to Self Daignosis Function Configuration Diagram 2 4 Refer to Self Daignosis Function Configuration Diagram 3 4 Firm Parameter DipSW Board Rev Key LCD LED CR Origin WasteTank Wiper Cover M Cover L M Cover R Lever EdgeAD Rear HeadGap Head Trans 1...

Page 407: ... D 320 Bi D 240B Bi D 320B Initialize Check Adjust ALL Parameter Log Info Adj Volt Uni Bi Low Uni Bi High Head Wiper CR Motor PF Motor Pump ALL Head Rank Adj Volt Uni Bi Low Uni Bi High SideMargin Charge Flg SerialNo ChipName Debug Bit Setup Print 1 Print 2 240CW 240CCW 320CW 320CCW Uni D 240 Uni D 320 Uni D 240B Uni D 320B Bi D 240 Bi D 320 Bi D 240B Bi D 320B 240CW 240CCW 320CW 320CCW Uni D 240 ...

Page 408: ...ialize Update Servo1 240cps CW Servo2 240cps CCW Servo3 320cps CW Servo4 320cps CCW CR Motor PF Motor Pump Nozzle Total Life Check Version Sensor MistFan Heater Record Top Width Width Off GP GI GLPF ＰＷＭ scale ωC Tank Status Tank Valve Check etc Pre Platen After Pre H Platen H After H for Ver 1 05d Pre1 Pre2 Platen1 Platen2 After1 After2 K Ink ID C Ink ID M Ink ID Y Ink ID Ink Not Ink END Self Diag...

Page 409: ...ed 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 Print Num Ink ALL NVRAM Timer CR Motor PF Motor HeadUnit Cleaning Pump Shipping Indication InitCounter Print PaperFeed Maintenance Mode 2 Configuration Diagram ...

Page 410: ...A 217 A 215 A 216 A 298 A 257 A 274 A 294 A 295 A 264 A 265 A 260 A 260 A 261 A 261 A 269 A 278 A 279 A 97 A 97 A 81 A 80 A 82 A 83 A 59 A 60 A 58 A 68 A 69 A 69 A 68 A 66 A 55 A 95 A 70 A 71 A 51 A 52 A 75 A 74 A 77 A 94 A 76 A 56 A 30 A 31 A 25 A 28 A 231 A 4 A 100 A 101 A 48 A 49 A 16 A 299 A 67 A 270 A 285 A 129 A 118 A 125 A 114 A 120 A 109 A 121 A 110 A 111 A 112 A 122 A 116 A 115 A 117 A 12...

Page 411: ...152 A 137 A 138 A 140 A 141 A 191 A 148 A 173 A 145 A 174 A 167 A 175 A 193 A 181 A 187 A 137 A 213 A 211 A 108 A 106 A 211 A 136 A 194 A 192 A 153 A 162 A 168 A 177 A 176 A 170 A 149 A 183 A 185 A 186 A 183 A 190 A 184 A 190 A 184 A 209 A 206 A 207 A 209 A 206 A 208 A 214 A 196 A 204 A 205 A 182 A 196 A 214 A 192 A 146 DF 44115 DG 40350 DG 40351 DG 40349 DF 48975 DF 49660 DF 49661 DG 40321 DF 490...

Page 412: ... 119 B 118 B 122 B 122 B 121 B 165 B 43 B 44 B 46 B 45 B 47 B 154 B 156 B 74 B 28 B 82 B 80 B 83 B 84 B 85 B 131 B 115 B 116 B 75 B 72 B 36 B 39 B 37 B 38 B 40 B 11 B 11 B 12 B 12 B 9 B 29 B 51 B 50 B 53 B 55 B 52 B 54 B 92 B 93 B 94 B 95 B 99 B 101 B 105 B 106 B 100 B 102 B 103 B 104 B 95 B 66 B 112 B 153 B 11 B 153 C 62 A 129 A 118 A 125 A 114 A 120 A 109 A 121 A 110 A 111 A 112 A 122 A 116 A 11...

Page 413: ...C 73 C 74 C 85 C 80 C 81 C 82 C 99 C 119 C 115 C 122 C 123 C 125 C 126 C 121 C 116 C 117 C 120 C 19 C 19 C 15 C 17 C 17 C 16 C 16 C 20 C 22 C 10 C 10 C 10 C 10 C 9 C 9 C 9 C 9 C 11 C 11 C 11 C 11 C 12 C 12 C 12 C 12 C 67 C 68 C 30 C 30 C 32 C 32 C 35 C 29 C 33 C 33 C 25 C 57 C 44 C 47 C 47 C 48 C 48 C 45 C 45 C 46 C 46 C 34 C 36 C 36 C 5 C 5 C 4 C 4 C 6 C 6 C 62 C 62 C 54 C 51 C 53 C 52 C 61 C 61 ...

Page 414: ... 11 14 Rev A D 101 D 102 D 102 D 102 D 20 D 18 D 23 D 14 D 15 D 92 D 93 D 99 D 90 D 38 D 11 D 11 D 7 D 12 D 24 D 25 D 27 D 32 D 28 D 29 D 30 D 31 D 34 D 9 D 37 D 10 D 42 D 2 D 1 D 85 D 87 D 88 D 40 D 43 D 41 D 8 D 19 D 21 DG 40317 DG 40318 DF 49687 DF 49686 DG 40355 DG 40356 DG 40356 DG 40356 DG 40356 DG 40357 ...

Page 415: ... 31 E 27 E 1 E 24 E 87 E 6 E 7 E 21 K 76 E 9 E 12 E 17 E 11 E 2 E 4 E 3 E 29 E 90 E 61 E 39 E 41 E 64 E 60 E 64 E 65 E 56 E 62 E 59 E 34 E 34 E 75 E 75 E 75 E 76 E 78 E 40 E 40 E 42 E 42 E 10 E 85 E 88 E 56 E 76 E 35 E 35 E 19 E 25 E 22 E 22 E 28 E 25 E 25 E 88 E 81 REAR E 16 E 63 E 63 E 8 E 77 To Cartridge E 67 E 66 E 68 E 69 E 70 E 13 E 14 DF 43968 DG 40340 DF 46671 DF 46671 DF 46671 DF 46700 DF...

Page 416: ...Supplement Exploded View 12 Cursor Assy 2 Model Name VJ 1604 Leg Assy Exploded View 2006 11 14 Rev A F 15 F 8 F 1 F 16 F 21 F 16 F 19 F 4 F 4 F 2 F 11 F 11 F 13 F 6 F 9 F 10 F 3 F 5 F 12 F 20 F 26 F 26 F 22 F 23 DF 47867 DF 44172 ...

Page 417: ... Head Board Assy Model Name VJ 1604 Roll Media Holder Assy Exploded View 2006 11 13 Rev A A 200 G 2 G 2 G 8 G 8 G 4 G 5 G 4 G 5 G 6 G 6 G 7 G 7 G 1 G 1 G 3 G 3 G 19 G 20 G 19 G 20 G 14 G 15 G 14 G 15 G 18 G 18 G 13 G 13 G 9 G 12 G 9 G 12 DG 40358 DG 40359 ...

Page 418: ...08 H 105 H 106 H 197 H 181 H 181 H 187 H 186 H 179 H 183 H 171 H 170 H 172 H 174 H 177 H 173 H 184 H 164 H 165 H 166 H 168 H 167 H 131 H 133 H 167 H 68 H 69 H 71 H 160 H 149 H 150 H 146 H 157 H 143 H 144 H 161 H 138 H 137 H 39 H 139 H 140 H 161 H 152 H 3 H 190 H 138 H 139 H 97 H 40 H 40 H 98 H 36 H 6 H 4 H 20 H 191 H 192 H 193 H 193 H 192 H 69 H 130 H 21 H 14 H 15 H 12 K 28 H 22 H 13 H 23 H 22 H 1...

Page 419: ...upplement Exploded View 15 Model Name VJ 1604 Feed Assy Exploded View 2006 11 22 Rev A DG 40480 DF 49471 DG 40481 DG 40477 DG 40475 DG 40471 DG 40479 DG 40478 DG 40473 DG 40427 DG 40474 DF 40556 DG 36753 DG 40482 DG 40483 DG 40484 ...

Page 420: ...VJ 1604 Maintenance Manual Supplement Exploded View 16 ...

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