Service
Manual
ValueJet 1604
AP-74108 Rev. 1.6
Important Notice VJ-1604 Maintenance Manual
(1)
Important Notice
1. For Users in Europe
2. For Users in the United States
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant
to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial environment.
This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful interference to radio communications.
Operation of this equipment in a residential area is likely to cause harmful inte rference in which case the
user will be required to correct the interference at his own expense.
3. Trademark Mentioned in this Manual
• MUTOH, ValueJet, VJ-1604 are registered trademarks or product names of MUTOH INDUSTRIES
LTD.
• Centronics and BiCentronics are registered trademarks or product names of Centronics Data Computer
Corporation.
• Windows95, Windows98, Windows98SE, Windows NT4.0, Windows2000, Windows XP, and MS-
DOS are registered trademarks or product names of Microsoft Corporation.
• Intel and Pentium are trademarks or registered trademarks of Intel Corporation.
• Other company and product names may be registered trademarks or product names.
This is a Class A product approved for industrial environments. In a domestic environment this product may cause
radio interference in which case you may be required to take
adequate measures.
Important:
• No part of this product or publication may be reproduced, copied, or
transmitted in any form or by any means, except for personal use,
without the permission of MUTOH INDUSTRIES LTD.
• The product and the contents of this publication may be changed
without prior notification.
• MUTOH INDUSTRIES LTD. has made the best efforts to keep this
publication free from error, but if you find any uncertainties or
misprints, please call us or the shop where you bought this equipment.
• MUTOH INDUSTRIES LTD. shall not be liable for any damages or
troubles resulting from the use of this equipment or this manual.
VJ-1604 Maintenance Manual Warranty Limitations
(2)
Warranty Limitations
1. MUTOH INDUSTRIES LTD. warrants part repair or replacement as a sole measure only if a failure is
found in the system or in the materials and workmanship of the product the seller produced.
However, if the cause of failure is uncertain, decide the action after due mutual consultation.
2. The warranty shall not apply to any direct or indirect loss, or compensation for t he loss due to the product
that has been subject to misuse, neglect, or improper alternation.
About this Manual VJ-1604 Maintenance Manual
(3)
About this Manual
1. Purpose and Target Readers
This manual explains preparations needed before maintaining and checking operatio ns for MUTOH Full
Color Ink Jet Printer (VJ-1604A/VJ-1604E/VJ1604J/VJ-1604K2).
This manual is prepared for the maintenance personnel of this printer.
Before using this printer, fully understand the contents and directions in this manual.
2. Manual Configuration
Section Contents
1 Safety Instructions Explains types of warnings, cautions and warnings labeled o n the printer
for the both operators of the printer and maintenance personnel.
2 Product Overview Explains the features, part names, and functions of the printer.
3 Specifications Explains the specifications of the printer.
4 Parts Replacement Explains the procedures of replacement and removal of the service parts
of the printer.
5 Self-Diagnostic Mode Explains the self-diagnostic functions of the printer.
6 Maintenance Mode Explains the maintenance mode of the printer.
7 Adjustment Explains the adjusting procedures of the printer parts.
8 Maintenance Explains daily maintenance of the printer.
9 Troubleshooting Explains troubles that may occur when using the printer and ho w to
solve them.
10 Appendix Explains the maintenance information and the exploded views for this
printer.
Use the built-in self-diagnostic program to locate a defecti ve part and adjust/
check during maintenance.
VJ-1604 Maintenance Manual About this Manual
(4)
3. Manual Notation
The following symbols are used in this manual for easier understanding of the information.
4. Establishment Date of This Document
This document was established on July 10, 2007.
5. Firmware version covered by this document
Firmware version: V.1.08
Symbol Meaning
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
May 2008
VJ1604E-M-05a 1 MUTOH INDUSTRIES LTD.
Some contents of the Maintenance Manual are changed. Make sure the following list shown bellow.
Chapter Item Description
Chapter 8 Modified the descriptions in
“Table 8-1 Replacement
Target parts ”
False: VJ Periodic maintenance kit (DG-40075)
↓
True: VJ Periodic maintenance kit (DG-41030)
Chapter10 Modified the descriptions in
“ Table10-9 Others”
False: VJ Periodic maintenance kit (T.B.D.)
↓
True : VJ Periodic maintenance kit (DG-41030)
Chapter10 Modified the descriptions in
“Table 10-2 Y Rail
Assembly”
Add “No.11 Steel bare Assembly(VJ-1604) DG-41917”
Chapter10a-3 Modified the descriptions in
“ Y Rail Assy ”.
Add “ DG-41917 ”
Refer to sheet 1
Chapter10 Modified the descriptions in
“Table 10-2 Y Rail
Assembly”
Add “ No.12 Tube cramp Assembly DF-49041 ”
Chapter10a-3 Modified the descriptions in
“ Y Rail Assy ”
Add “ DF-49041”
Refer to sheet 1
VJ-1604 MAINTENANCE MANUAL ERRATA
ERRATA VJ-1604 Maintenance Manual
VJ1604E-M-05a 7
Exploded View
1ޓޓޓޓޓޓޓޓޓ 2ޓޓޓޓޓޓޓޓޓ3ޓޓޓޓޓޓޓޓޓ 4ޓޓޓޓޓޓޓޓ ޓ5ޓޓޓޓޓޓޓޓޓ6ޓޓޓޓޓޓޓޓޓ 7ޓޓޓޓޓޓޓޓ 8
㧭
㧮
㧯
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㧱
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㧭
㧮
㧯
㧰
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㧲
2008.05.21 Rev.D
1ޓޓޓޓޓޓޓޓޓ 2ޓޓޓޓޓޓޓޓޓ3ޓޓޓޓޓޓޓޓޓ 4ޓޓޓޓޓޓޓޓ ޓ5ޓޓޓޓޓޓޓޓޓ6ޓޓޓޓޓޓޓޓޓ 7ޓޓޓޓޓޓޓޓ 8
Model Name : VJ-1604
Y Rail Assy
B-162
B-92
FRONT
B-71
B-74
B-76
B-60
B-75
B-72
B-73
B-84
B-85
B-82
B-80
B-83
B-81
B-88
B-28
B-11
B-61
B-60
B-65
B-66
B-154
B-156
C-62
B-6
B-5
B-8
B-153
B-11
B-2
B-1
B-29
B-2
B-2
B-153
B-12
B-155
B-157
B-59
B-109
B-27
B-33
B-113
B-39
B-40
B-38
B-37
B-36
B-45
B-47
B-46
B-44
B-43
B-6
B-9
B-50
B-51
B-54
B-55
B-53
B-52
B-23
B-24
B-105
B-101
B-106
B-104
B-93
B-94
B-95
B-95
B-12
B-11
B-100
B-5
B-99
B-103
B-102
A-118
A-114
A-118
A-130
A-126
A-129
A-130
A-131
A-125
A-124
A-129
A-122
A-115
A-116
A-121
A-120
A-117
A-109
A-110
A-111
A-112
B-23
B-24
B-23
B-24
B-24
B-23
B-20
B-16
B-17
B-19
B-18
B-15
B-114
B-131
B-119
B-126
B-125
B-115
B-116
B-112
B-119
B-114
B-121
B-122
B-122
B-127
B-128
B-120
B-165
B-117
B-117
B-118
DF-43868
DF-43869
DF-43870
DF-43940
DF-46666
DF-49471
DF-43901
DG-40135
DG-40352
DF-43937
DF-49041
DG-41917
VJ-1604 Maintenance Manual
5
General Table of Contents
1 Safety Instructions
1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 Warning Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.4.1 Handling the Warning Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.4.2 Locations and Types of Warning 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 Winding Unit Section (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.3.4 Operation Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.4 Plotter Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.4.1 Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.4.2 Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.4.3 Self-Diagnosis Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.4.4 Maintenance Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.4.5 Selecting Panel Language and Panel Temperature. . . . . . . . . . . . . . . 2-11
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
VJ-1604 Maintenance Manual
6
3.5 Choosing a Place for the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
4 Parts Replacement
4.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.2 Removing Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.2.1 Removing Panel Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.2.2 Removing Maintenance Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.2.3 Removing Maintenance Cover U. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.2.4 Removing Side Maintenance Cover R. . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.2.5 Removing Side Maintenance Cover L . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.2.6 Removing Side Top Cover R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.2.7 Removing Side Top Cover L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.2.8 Removing Rear Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.2.9 Removing Cartridge Cover (Upper) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.2.10 Removing Cartridge Cover (Middle). . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.2.11 Removing Cartridge Cover (Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.2.12 Removing Switch Cover R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.2.13 Removing Switch Cover L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.2.14 Removing Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.2.15 Removing Rear Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.2.16 Removing Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.2.17 Removing Media Guide F (Upper). . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4.2.18 Removing Media Guide R (Upper). . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
4.2.19 Removing Media Guide R (Lower). . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
4.3 Replacing Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
4.3.1 Replacing Panel Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
4.3.2 Replacing Maintenance Cover Sensor. . . . . . . . . . . . . . . . . . . . . . . . . 4-31
4.3.3 Replacing Front Cover Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
4.3.4 Replacing Front Cover Gear, Damper Gear (Sintered) . . . . . . . . . . . . 4-35
4.4 Replacing Board Base (X Rail Section) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
4.4.1 Opening Board Box 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
4.4.2 Replacing Power Board Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
4.4.3 Replacing HEATER CONT Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
4.4.4 Replacing HEATER RELAY Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
4.4.5 Replacing Cooling Fan (24V) Assembly (for Main Board). . . . . . . . . . 4-46
4.4.6 Replacing Cooling Fan (24V) Assembly (in Media Guide F) . . . . . . . . 4-48
4.4.7 Replacing MAIN Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
4.4.8 Replacing Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
4.4.9 Replacing Inlet Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
VJ-1604 Maintenance Manual
7
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
4.6.3 Replacing PF Encoder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
4.6.4 Replacing PF_ENC Scale, PF Speed Reduction Pulley . . . . . . . . . . . 4-65
4.6.5 Replacing P_REAR Sensor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 4-66
4.6.6 Replacing Lever Up Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
4.6.7 Replacing Heater, Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69
4.6.8 Replacing Suction Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
4.6.9 Replacing Platen Non-Reflective Tape . . . . . . . . . . . . . . . . . . . . . . . . 4-79
4.6.10 Replacing Media Holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
4.6.11 Replacing Flushing Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
4.6.12 Replacing Flushing Absorber. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
4.7 Replacing Y Rail Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85
4.7.1 Replacing Steel Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85
4.7.2 Replacing CR Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
4.7.3 Replacing CR Drive Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 4-90
4.7.4 Replacing T Fence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92
4.7.5 Replacing CR Origin Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95
4.7.6 Replacing CR Driven Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97
4.7.7 Replacing Steel Bearer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-98
4.7.8 Replacing CR_FFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-100
4.7.9 Replacing Pressure Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-102
4.7.10 Replacing Ink Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-103
4.8 Replacing Cursor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-106
4.8.1 Releasing Head Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-106
4.8.2 Removing CR Board Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-107
4.8.3 Replacing CR Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-107
4.8.4 Replacing CR Encoder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-109
4.8.5 Replacing PG Origin Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . 4-110
4.8.6 Replacing Cursor Roller Arm Assembly. . . . . . . . . . . . . . . . . . . . . . . 4-111
4.8.7 Removing Print Head Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-111
4.8.8 Replacing Damper Assembly L_Assy . . . . . . . . . . . . . . . . . . . . . . . . 4-113
4.8.9 Replacing Print Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-115
4.8.10 Replacing Head FFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-117
4.8.11 Replacing P_EDGE Sensor Assembly. . . . . . . . . . . . . . . . . . . . . . . . 4-119
VJ-1604 Maintenance Manual
8
4.9 Replacing Maintenance Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-121
4.9.1 Removing Maintenance Inner Cover . . . . . . . . . . . . . . . . . . . . . . . . . 4-121
4.9.2 Replacing Cleaner Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-122
4.9.3 Replacing Maintenance Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-123
4.10 Replacing IH Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-133
4.10.1 Replacing Ink ID Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-133
4.10.2 Replacing Frame Assembly, Needle . . . . . . . . . . . . . . . . . . . . . . . . . 4-136
4.10.3 Replacing Ink Cartridge Control Cable. . . . . . . . . . . . . . . . . . . . . . . . 4-140
4.10.4 Replacing Cartridge Holder Assembly. . . . . . . . . . . . . . . . . . . . . . . . 4-140
4.10.5 Replacing Two-Way Valve NX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-141
4.10.6 Replacing SMC Two-Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-143
4.10.7 Replacing Sub-Tank Lower Absorber Assembly . . . . . . . . . . . . . . . . 4-144
4.10.8 Replacing Sub-Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-145
4.11 Replacing Leg Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-147
4.11.1 Replacing Waste Fluid Bottle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-147
4.12 Replacing Roll Media Holder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 4-149
4.12.1 Replacing Roll Media Holder Assembly on the VJ16_L Side. . . . . . . 4-149
4.12.2 Replacing Roll Media Holder Assembly on the VJ16_R Side . . . . . . 4-150
4.13 Replacing Winding Unit Section (Option) . . . . . . . . . . . . . . . . . . . . . . . 4-151
4.13.1 Removing Tension Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-151
4.13.2 Removing Take-up Holding Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-152
4.13.3 Removing Take-up Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-153
4.13.4 Replacing Scroller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-155
4.13.5 Replacing VJ Take-up CNT Board Assembly . . . . . . . . . . . . . . . . . . 4-157
4.13.6 Replacing CR_HP Sensor, Lever Sensor . . . . . . . . . . . . . . . . . . . . . 4-163
4.13.7 Replacing Peripheral Devices of VJ Take-up Motor Assembly . . . . . 4-166
5 Self-Diagnosis Mode
5.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.2.1 Preparations on Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.2.2 Starting Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3 Operations in Self-Diagnosis Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.1 Operating Self-Diagnosis Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.2 Diagnosis Items in Self-Diagnosis Menu . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.4 Platen Adjustment Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
VJ-1604 Maintenance Manual
9
5.5 Inspection Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.5.1 Memory Size Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.5.2 Version Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.5.3 Operation Panel Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.5.4 Sensor Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.5.5 Encoder Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.5.6 Fan Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.5.7 History Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.5.8 Head Waveform Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5.6 Ink Charging Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.7 Adjustment Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5.7.1 Head Nozzle Check Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5.7.2 Skew Check Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5.7.3 Head Slant Check Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
5.7.4 Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
5.7.5 Uni-D/Bi-D Low/High Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
5.7.6 Side Margin Adjustment Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
5.7.7 Test Printing Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
5.7.8 HeadWash Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
5.7.9 HeadWash Menu 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
5.7.10 Software Counter Initialization Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
5.7.11 Feed Pitch Check Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
5.7.12 Solid Print Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
5.8 Cleaning Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
5.9 Sample Printing Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
5.10 Time Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
5.11 Parameter Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
5.11.1 Parameter Initialization Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
5.11.2 Parameter Update Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
5.12 Servo Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
5.13 Endurance Running Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
5.13.1 CR Motor Endurance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
5.13.2 PF Motor Endurance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
5.13.3 Pump Endurance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5.13.4 Print Head Endurance (Nozzle Print) Menu . . . . . . . . . . . . . . . . . . . . . 5-69
5.13.5 General Endurance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
5.13.6 Endurance Running Check Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71
VJ-1604 Maintenance Manual
10
5.14 Media Feed Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71
5.15 ExControl Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
5.15.1 Version. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
5.15.2 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
5.15.3 Mist Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
5.15.4 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
5.15.5 History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
5.16 PaperInitial Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
6 Maintenance Mode 2
6.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Operations in Maintenance Mode 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.1 Starting Up the Maintenance Mode 2. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.2 Operating Maintenance Mode 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Maintenance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3.1 Counter Display Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3.2 Counter Initialization Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3.3 Counter Print Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3.4 Media Feed Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
7 Adjustment
7.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2 Adjustment Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.3 Working with Dedicated Network Software . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.3.1 Parameter Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.3.2 Jigs and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.3.3 Required Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.3.4 Receiving Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.3.5 Firmware Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7.3.6 Sending Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7.3.7 Sub Controller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7.3.8 RTC Date & Time Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
7.4 Steel Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
7.4.1 Jigs and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
7.4.2 Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
VJ-1604 Maintenance Manual
11
7.5 PF Speed Reduction Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . 7-29
7.5.1 Jigs and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
7.5.2 Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
7.6 PF Encoder Assembly Position Adjustment . . . . . . . . . . . . . . . . . . . . . . 7-30
7.6.1 Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
7.7 CR Speed Reduction Belt Tension Adjustment. . . . . . . . . . . . . . . . . . . . 7-32
7.7.1 Jigs and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
7.7.2 Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
7.8 Head Accuracy Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
7.8.1 Head Alignment (Horizontal Height). . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
7.8.2 Head Alignment (Vertical Slant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
7.9 PG Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
7.9.1 Jigs and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
7.9.2 Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
7.10 P_EDGE Sensor Sensitivity Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
7.10.1 Jigs and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
7.10.2 Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
7.11 P_REAR Sensor Sensitivity Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 7-44
7.11.1 Jigs and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
7.11.2 Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
8 Maintenance
8.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2 Periodical Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.2.1 Periodic Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.2.2 Parts Which Require Inspection/Replacement. . . . . . . . . . . . . . . . . . . . 8-3
8.3 Part Life Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4 Jigs and Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.4.1 Required Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.5 Lubrication/Bonding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.6 Transportation of Plotter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
VJ-1604 Maintenance Manual
12
9 Troubleshooting
9.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2 Troubleshooting with Error Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2.1 Operation Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2.2 Errors with Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.2.3 Errors Requiring Reboot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.2.4 Error Messages During File Transmission. . . . . . . . . . . . . . . . . . . . . . 9-26
9.3 Troubleshooting Without Error Messages. . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.3.1 Initial Operation Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.3.2 Media Feed Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
9.3.3 Printing Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
9.3.4 Noise Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-61
9.3.5 Online Function Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-64
9.3.6 Other Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-66
9.3.7 Problems in Using Dedicated Network Software . . . . . . . . . . . . . . . . . 9-68
10 Appendix
10.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.2 Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.3 Maintenance Part List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.4 Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
VJ-1604 Maintenance Manual 1 Safety Instructions
1-1 Rev.-05
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- 9
1.4.1 Handling the Warning Labels......................................................... 1-9
1.4.2 Locations and Types of Warning Labels...................................... 1-10
1 Safety Instructions VJ-1604 Maintenance Manual
Rev.-05 1-2
1.1 Introduction
This chapter explains the meaning of safety terms for personnel who installs, operates, or maintains this
equipment, important safety inst ructions, and the warning labels attach ed to the equipment.
Make sure to follow all instructions and warnings on this manual when installing, operating,
or maintaining the equipment.
1.2 Warnings, Cautions and Notes
Safety terms in this manual and the contents of warning lab els attached to the printer are cat egorized 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 to
whole or part of the product
Contains important information and useful tips on the operation of the
product
Indicates useful tips for operating or understanding the printer
Indicates “prohibited” operations
Indicates required operations
Indicates reference page in this manual
WARNING
DANGER
NOTE
TIP
VJ-1604 Maintenance Manual 1 Safety Instructions
1-3 Rev.-05
1.3 Important Safety Instructions
General safety instructions that must be observed to use the equipment safely are explained below.
Do not install this printer in the following locations:D oing so may resul t in the printer
tipping or falling over and causing injury.
• Unstable surfaces
• Angled place
• Areas subject to vibration by other equipment
Do not stand on or place heavy objects on your printer. Doing so may result in the
printer tipping or falling over and causing injury.
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.
Do not use damaged power supply cables. Doing so may cause electric shock or
fires.
Do not connect or disconnect the power supply plug with wet hands. Doing so may
cause electric shock.
Make sure that the following is performed before parts replacement.
• Turn off the power of the printer.
• Remove the power cable from the power outlet.
Not doing so may cause electric shock or damage to the electric circuit.
• Unplug the cables connected to the printer.
Failure to do so could result in damage to the printer.
Do not connect ground lines to the following locations.
• Gas piping
There will be a possibility of causing fires or exploding.
• Phone ground lines and lightning rods
A large current may flow if there is a lightning strike.
• Water piping and faucets
If a part of the piping is plastic, it will not serve as a ground.
During heater operation, do not place flammable objects on top of the platen. Doing
so may cause fires.
Do not spill flammable fluids on the platen. Doing may cause fires.
1 Safety Instructions VJ-1604 Maintenance Manual
Rev.-05 1-4
Do not insert or drop metal objects or flammable objects inside the printer through
openings such as air holes. Doing so may cause electric shock or fires.
If foreign objects or fluids such as water enter the product internals, do not use the
unit as is. Doing so may cause electric shock or fires. Turn off the power supply
switch immediately, and disconnect the power plug from the power outlet.
Make sure to always use the provided power supply cable. If a power supply cable
other than the one supplied with the unit is used, it may cause electric shock or fires.
Always use the specified power supply (AC100V-120V or AC220V-240V). If a
power supply that is outside specificat ions is used, it may cause electric shock or
fires.
Supply power directly from a power supply outlet (AC100V-120V or AC 220V240V). Do not use extensions or splitters. Doing so may cause electric shock or
fires.
Always use the dedicated power plug with ground termin al, and make sure to
connect the ground to a ground line. If the ground line is not connected, it can cause
electric shock or fires.
Waste fluid produced from the printer corresponds to waste oil (waste ink) in
industrial waste (out of the 19 business related items). A proper waste fluid
processing is required by law based on the industrial waste processing law and
regulations of individual local governments. Please contract a waste fluid
processing company for disposal.
VJ-1604 Maintenance Manual 1 Safety Instructions
1-5 Rev.-05
Assembling and disassembling of the printer are possible only for the parts that
disassembling procedures are shown in this manual. Do not disassemble any frame
parts or parts that disassembling procedures are not shown in this manual.
Doing so may cause trouble that cannot be restored, as the printer is originally
assembled in the factory with a high accuracy of 1/100 mm.
Do not touch the elements on the circuit board with bare hands.
Doing so may cause static electricity and break the elements.
Do not press the transparent film on the damper assembly with your hands. Doing so
may discharge the ink filled inside the damper assembly.
Be careful not to damage the transparent film on the damper assembly.
Do not touch the nozzles of the print head. Make sure that the nozzles do not get any
dust.
There are some remaining ink in the tubes. Be careful that the ink is not spilled from the
tube outlet onto the printer or items close to the printer.
If you need to operate the printer with the cover removed for maintenance, be careful
not to get hurt by the driving parts.
Never lube the printer mechanism with lube other than that designated by MUTOH.
Doing so may damage the parts or shorten the lifetime.
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.
When connecting or removing an FFC type cable on a MAIN board assembly
connector, make sure to connect or remove the cable perpendicular to the connector.
Connecting or removing at a slant angle may damage, break or short circuit the inner
terminal of the connector. That may damage the elements on the board.
When connecting or removing the FFC type cables (tape wire) on the main board
assembly connector, always insert or remove the cables perpendicularly into or from
the connector.
Connecting or removing at a slant angle may damage, break or short circuit the inner
terminal of the connector. That may damage the elements on the board.
Make sure there is sufficient space around the printer when performing maintenance
work.
Maintenance must be done by more than two person for the following work.
• When disassembling or reassembling the product and the dedicated stand
• When packing the printer for transportation
1 Safety Instructions VJ-1604 Maintenance Manual
Rev.-05 1-6
When handling power supply cables, be careful for the following:
• Do not modify the power supply cable.
• Do not place heavy objects on top of the power supply cable.
• Do not excessively bend, twist or pull on the power supply cable.
• Do not route the power supply cable near heater devices.
When handling the power supply plug, be careful for the following: If handled
improperly, it will be a cause for fires.
• Do not insert the power supply plug when it is dusty or when there are any foreign
objects attached to it.
• Insert the power supply plug all the way to the base of the pins.
When opening or closing the front cover and maintenance cover, be careful not to
get fingers caught.
When handling the ink cartridge, be careful so that the ink does not come into
contact with eyes or skin. If the ink comes into contact with skin or the eyes, wash
off immediately with water. If left al on e, it can cause bloodshot eyes or ligh t
inflammations. If there is an abnormal condition, consul t a doctor immediately.
Do not disassemble the ink cartridge. If disassembled, there will be a danger of the
ink coming into contact with the eyes or skin.
During initialization operation of the product, do not operate the media set lever. The
print head section and pressure roller sections may interfere with one another, and
lead to damage of the unit.
Do not touch the media guide during printing. The media guide will be extremely hot,
and may cause burns.
During operation of the winding unit, be careful not to get fingers caught in the drive
section.
When cutting roll media, be careful for the following: If mishandled, there is a
possibility of cutting fingers or hands on the cutter blade.
• When holding the media, do not place fingers on top of the media cut groove.
• Move the cutter blade slowly along the media cut groove.
Excluding the locations specified below, do not use volatile chemicals such as jet
wash fluid, thinner, benzene, alcohol, etc. Doing so can cause damage to the unit.
• Inside of maintenance cover
• Print head surface
Be careful so that no moisture enters inside the product. If moisture enters the
product, electrical circuits inside the product may short.
When replacing the flushing box absorption material, take appropriate care so that
the waste fluid is not spilled. If the waste fluid adheres to the grid roller, the grid roller
surface may be intruded, and cause an adverse effect to media feeding.
VJ-1604 Maintenance Manual 1 Safety Instructions
1-7 Rev.-05
When cleaning the cleaning wiper
• Do not touch the cleaning wiper and head cap unit.
Oil becoming attached may make it impossible to perform proper head cleaning.
• Always use a clean stick, and wipe off with a dry cloth.
If water, etc. comes into contact with the clean stick, it may cause the print head
to become clogged.
• Do not reuse the clean stick.
Any attached dust, etc. may damage the head.
When cleaning the outer perimeter of the print head
• Never touch the nozzle surface of the print head.
Doing so may damage the print head.
• Do not touch the tip of the clean stick.
Oil becoming attached may damage the print head.
• Never apply water, etc. on the tip of the clean stick.
Doing so may damage the print head.
• Do not reuse the clean stick.
Any attached dust, etc. may damage the print head.
Do not place the product on an incline, stand against another object, or flip upside
down. Doing so may spill the ink inside the product. Also, it will not be possible to
guarantee proper operation after moving.
When unpacking or moving the product, make sure to always work with 2 or more
persons.
When taking the product out of the packaging box, always remove the vinyl bag, and
hold the side of the product. If lifted while still in the vinyl bag, there will be a danger
of the product slipping out of one's hands, and falling and becoming damaged.
When not using the product for extended periods of time, always disconnect the
power supply plug from the wall outlet for safety.
Always connect the ground line to a ground line that satisfies the following
specifications:
• Ground terminal of the power supply socket
• A ground line where a copper piece is buried over 650mm or more into the
ground.
• A ground terminal for which class D grounding work has been performed.
Make sure to ventilate the work area. The odor may cause nausea, and may
potentially cause fires.
When performing the following work, make sure to always work with 2 or more
persons.
• Setting the winding unit
Immediately after completing printing, the media guide and platen will be extremely
hot. Perform any work after the media guide and platen have adequately cooled.
1 Safety Instructions VJ-1604 Maintenance Manual
Rev.-05 1-8
When performing cleaning, make sure to turn the power supply OFF, and pull out
the power supply plug from the power outlet.
Make sure that the product maintains a horizontal position when moving.
Before performing installation work for various options, make sure to perform the
following.
• Turn the power supply of the product OFF.
• Pull out the power supply plug from the power outlet.
• Disconnect cables connected to the product.
If work is performed with these connected, damage to the product or computer
may result.
• Touch the metallic sections of the product to remove any static electricity charged
in clothing or on one's body.
The electronic parts such as the memory, etc. are susceptible to damage by static
electricity.
When installing various options, make sure not to touch any elements on the
circuitboard. Elements on the circuitboard become very hot, and may cause burns.
VJ-1604 Maintenance Manual 1 Safety Instructions
1-9 Rev.-05
1.4 Warning Labels
The handling, attachment locations, and types of warning labels are explained below.
Warning labels are attached to areas where care should be taken. Read and understand the positions and
contents thoroughly before maintenance operation.
1.4.1 Handling the Warning Labels
Make sure to note the following when handling the warning labels.
• Make sure that all warning labels can be recogn ized. If text or illustrations cannot be seen clearly,
clean or replace the label.
• When cleaning warning labels, use a cloth with water or neutral detergent. Do not use a solvent or
gasoline.
• If a warning label is damaged, lost, or cannot be recognized, replace the label.
1 Safety Instructions VJ-1604 Maintenance Manual
Rev.-05 1-10
1.4.2 Locations and Types of Warning Labels
(1)Main Body
The locations of warning labels on the main body are shown below.
321
4
5
5
8
7
6
VJ-1604 Maintenance Manual 1 Safety Instructions
1-11 Rev.-05
Table 1-2 List of Warning Labels
No. Warning label type
1
(Front cover open/close caution)
2
(Head nozzle drying caution)
3
(Cleaning caution)
4
(Steel belt caution)
1 Safety Instructions VJ-1604 Maintenance Manual
Rev.-05 1-12
5
(High temperature caution)
6
(Electric shock caution)
7
(Ink handling caution)
8
(Waste fluid tube handling caution)
Table 1-2 List of Warning Labels (Continued)
No. Warning label type
VJ-1604 Maintenance Manual 1 Safety Instructions
1-13 Rev.-05
(2)Winding Unit Section (Optional)
The locations of warning labels on the scroller are shown below.
No. Warning label type
1
(Catching caution)
1
1 Safety Instructions VJ-1604 Maintenance Manual
Rev.-05 1-14
VJ-1604 Maintenance Manual 2 Product Overview
2-1 Rev.-05
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 Winding Unit Section (Optional)..................................................... 2-6
2.3.4 Operation Panel............................................................................. 2-7
2.4 Plotter Status......................................................................................... 2- 10
2.4.1 Normal......................................................................................... 2-10
2.4.2 Setup Menu ................................................................................. 2-10
2.4.3 Self-Diagnosis Function............................................................... 2-10
2.4.4 Maintenance Mode...................................................................... 2-10
2.4.5 Selecting Panel Language and Panel Temperature.................... 2-11
2 Product Overview VJ-1604 Maintenance Manual
Rev.-05 2-2
2.1 Introduction
This chapter explains the features, part names, and functions of the plotter.
2.2 Features
The features of the plotter are explained below.
(1)Fast Print
This model uses the new head prints images faster.
Realizing printing width of 1615 mm in uni-direction printing mode.
(2)Variety of Print Media
The height of the print head position can be set high/ low, so that th is model can prin t on th e media of wh ich
thickness is between 0.08 and 0.3 mm.
(3)Vivid Color Reproduction
For Vivid color reproduction, this model has high-capacity (220 ml) 4 color ink cartridges with exclusive
smart IC chip on it. With the IC chip, you can manage the ink level of the cartridges and can get better
productivity.
Also, With variable dot mechanism, this model enhances the level of color expression.
(4)Multi-Heater System
The media-heating system which have been equipped to PJ series is changed to match the solvent ink. There
are 3 heaters on Pre / Platen / After positions and improved the ink fixability and drying property.
(5)Effective Utilization of Media
The JOG function for setting print start position o n purpose is equipp ed. Yo u can pr int on t he ma rgin(s) o f a
media which is already printed.
VJ-1604 Maintenance Manual 2 Product Overview
2-3 Rev.-05
2.3 Part Names and Functions
Part names and functions are explained below.
For the directions described in this document, refer to the following figure.
Rear
Right
U
pper
Lower
Left
Front
2 Product Overview VJ-1604 Maintenance Manual
Rev.-05 2-4
2.3.1 Front Section
Table 2-1 Part Names and Functions of Front Section
No. Name Function
1 Media set lever Used for fixing or releasing the media
• Lower the lever to fix the media
• Lower the lever further to fix the media firmly
Used to improve the accuracy of media feeding
* The accuracy of media feeding may decline depending on media.
• Raise the lever to release the media
2 Operation panel Used to set operational conditions, the status of the plotter, and other
functions
3 Front cover Keeps the operator safe from the drive parts of the plotter while it is
operating. Opened and closed when media is set or jammed. It is normally
closed.
4 Waste fluid tank Used to store waste ink discharged from print head
5 Stand Used to set the plotter on the level surface of the floor
6 Media guide Used to feed media smoothly when setting media and printing
The heater (after-heater) for drying ink is installed inside.
7 Platen Installed inside the front cover
The heater (platen heater) for drying ink is installed.
8 Pressure roller Installed inside the front cover
Used to press the media from above and hold it when printing
13
1
4
12
2
133
10
11
5
8
9
6
5
10
7
12
VJ-1604 Maintenance Manual 2 Product Overview
2-5 Rev.-05
2.3.2 Rear Section
9 Media cut g roove Installed inside of the front cover
Used to cut printed media straight
10 Maintenance cover Used to protect users from the mechanical parts inside the plotter in the
following cases:
- Cleaning the cleaning wiper
- Cleaning around the print head
This cover must usually be closed.
11 Waste fluid cock Opened/closed when discharging waste fluid from waste fluid tank. This
cover must usually be closed.
12 Adjuster Used to keep the plotter level
13 Media holding plate Installed inside the front cover
By attaching media holder plates to both sides of the media, it is possible
to prevent media warp.
Table 2-2 Part Names and Functions of Rear Section
No. Name Function
1 Roll media holders Used to load the roll media
Include flanges where roll media is attached, and the levers that fix the roll
media holders.
2 Media feed slot Insert media from here when feeding media
3 Ink cartridge slot Holds the ink cartridge
Table 2-1 Part Names and Functions of Front Section (Continued)
No. Name Function
24
1
5 6 7 1
3
2 Product Overview VJ-1604 Maintenance Manual
Rev.-05 2-6
2.3.3 Winding Unit Section (Optional)
4 Media guide Used for feeding media smoothly when the media is set or printed.
The heater (pre-heater) to warm media is installed.
5 AC inlet Used for connecting the power cable
6 USB connector Not used for this printer
7 Network interface
connector
Connector to connect a network interface cable
Table 2-3 Part Names and Functions of Winding Unit Section
No. Name Function
1 Winding unit 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 winding unit here
4 Scroller release lever Used to poise the scroller when rotating the scroller manually
5 Scroller Used to take up printed media
6 Scroller height
adjustment screw
Adjusts the height of scroller receiver
Table 2-2 Part Names and Functions of Rear Section (Continued)
No. Name Function
1
2
3
4
8
5
7
6
VJ-1604 Maintenance Manual 2 Product Overview
2-7 Rev.-05
2.3.4 Operation Panel
The operation panel is used to set operational conditions, display the status of the plotter, and set other
functions.
The names and functions of the operation keys and status lamps are explained below.
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 Winding Unit Section (Continued)
No. Name Function
8, 9
3
15
17
16
6
5
11
12
1
13
14
10
27
4
2 Product Overview VJ-1604 Maintenance Manual
Rev.-05 2-8
(1)Operation Keys
Some keys have multiple functions and names depending on the plotter status (normal or setup menu
display). See "2.4 Plotter Status" p.2-10 for more details.
No. Name Normal Setup menu display
1
[Menu] key
Changes the LCD monitor display to
setup menu status.
Changes the setup menu display
status to normal status.
2 [Ent er] key - - Selects the menu to be set and shifts
to the next hierarchy.
- Determines and saves the parameter
value.
[Cleaning] key If held down for 2 seconds or more,
starts cleaning the plotter head.
-
3 [Cancel] key - During plotting: Terminates printing
forcibly and deletes 1 file of
remaining data.
- During reception/analysis: Deletes
the data that has been already
received/analyzed and ignores 1 file
of data received after that.
- During ink drying time wait status:
Releases the ink drying time wait
status and ejects the media.
- Returns to the previous menu
hierarchy. Changed parameter values
are disabled.
- Changes the setup menu display
status to normal status.
4 [<] key Sets the media type.
- The lamp for the type that is set
lights on (green).
-Changes the setting value in the
following menu:
• Origin setting menu
[Nozzle Check] key If held down for 2 seconds or more,
starts checking the plotter nozzle.
-
5 [>] key Sets the cleaning mode.
- The lamp for the cleaning mode
lights on (green).
Displays lower rank menu items.
6 [Backward ↑ ] key Feeds the media in the reverse
direction.
-
[+] key - -Changes the menu in forward order.
-Changes the setting value in forward
order.
-Increases the value when inputt ing
setting value.
VJ-1604 Maintenance Manual 2 Product Overview
2-9 Rev.-05
(2)LCD Monitor and Status Lamps
7[Forward ↓] key Feeds the media in the forward
direction.
-
[-] key - - Changes the menu in the reverse
direction.
- Decreases the value when inputting
values.
8 [Power] key Turns the plotter on and off. Turns the plotter on and off.
No. Name Color Status Function
9 Power lamp Green On The plotter is switched on.
Blinking An error has occurred. The contents will be displayed on the
LCD monitor.
Off The plotter is switched off.
10 Data lamp Orange On - The plotter is analyzing received data.
- The plotter is printing data.
Blinking The plotter is receiving data.
Off The plotter is not receiving, analyzing or printing data.
11 High lamp Green On The print head height is set to High position.
Off The print head height is set to Low position.
12 Low lamp Green On The print head height is set to Low position.
Off The print head height is set to High position.
13 Wave lamp Red On The effect menu is set to Wave.
Off The effect menu is set to either Fine or SuperFine.
14 Fine & S.Fine
lamp
Red On The effect menu is set to either Fine or SuperFine.
Off The effect menu is set to Wave.
15 Strong lamp Green On - The cleaning mode is set to Strong.
- When the Normal lamp is also on, t he cleaning mode is set
to Economy.
Off - The cleaning mode is set to Normal.
16 Normal lamp Green On - The cleaning mod e is set to Normal.
- When the Strong lamp is also on, the cleaning mode is set
to Economy quality.
Off The cleaning mode is set to Strong.
17 LCD monitor - - This monitor displays the operation status and error
messages of the plotter.
No. Name Normal Setup menu display
2 Product Overview VJ-1604 Maintenance Manual
Rev.-05 2-10
2.4 Plotter Status
The status of the plotter is explained below.
2.4.1 Normal
Indicates that the plotter can print when media is loaded.
Each setup concerning printing can be operated by using operation panel.
Operation manual
2.4.2 Setup Menu
Each setup concerning printing can be operated by using operation panel.
The settings required for normal printing are usually made on the plotter driver or application, but can also
be made using the operation panel.
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.
"5 Self-Diagnosis Mode" p.5-1
2.4.4 Maintenance Mode
Indicates that each setup concerning to the life counter o n this plotter can be operated by using the operation
panel. Names and functions of the operation panel keys are the same as those of setup menu display.
"6 Maintenance Mode 2" p.6-1
VJ-1604 Maintenance Manual 2 Product Overview
2-11 Rev.-05
2.4.5 Selecting Panel Language and Panel Temperature
This section describes how to select the language and temperature displayed in the operation panel.
Follow the steps below to select the language.
You can choose the following display.
Language: English or Japanese.
Temperature: Centigrade (C) or Fahrenheit (F)
1. Press [Power] key in the operation panel while
pressing [Cancel] key.
2. Press [Setting/value +] key or [Setting/value -]
key in the operation panel to modify the value.
3. To save the modified value, press [Enter] key in
the operation panel.
2 Product Overview VJ-1604 Maintenance Manual
Rev.-05 2-12
VJ-1604 Maintenance Manual 3 Specifications
3-1 Rev.-05
3 Specifications
3.1 Introduction............................................................................................. 3- 2
3.2 Product Specifications........................................................................... 3- 2
3.3 Interface Specifications.......................................................................... 3- 4
3.3.1 Network Interface Specifications.................................................... 3-4
3.4 Options/Supplies List............................................................................. 3- 4
3.4.1 Options .......................................................................................... 3-4
3.4.2 Supplies......................................................................................... 3-4
3.5 Choosing a Place for the Printer ........................................................... 3- 6
3 Specifications VJ-1604 Maintenance Manual
Rev.-05 3-2
3.1 Introduction
This chapter explains the specifications of the product, optional parts, and supplies. Installation environment
requirements are also explained.
3.2 Product Specifications
(1) Main Unit Specifications
Item Specifications
Model name
VJ-1604
Plotting method
On-demand piezo drive
Motor driving method
Firmware servo / DC motor drive
Media feeding method
Multi-point pressure grid roller method
Media fixing method
Pressurizing roller manual-down method
Media supply and
ejection
Roll media
Rear feeding / front ejection
Roll media outer diameter
150 mm (5.9 in.) or less
Roll media weight
30 kg (66 lb.) or less
Maximum media length
50 m (164 ft.)
Maximum media width
1625 mm (63.9 in.)
Maximum media thickness
0.3 mm (0.01 in.)
Maximum plot length
18 m (59.1 ft.)
Maximum plot width
1615 mm (63.6 in.)
Plotting margins
Top: 15 mm, Bottom: 5 mm, Left: 5-25 mm, Right: 5-25 mm
Media cutting method
Horizontal manual cut
Head height adjustment
2 levels: Normal / High
Distance accuracy The larger value either ± 0.25 mm or ± 0.1% of moving distance
•Used media: Roll MF-3G
• Plot length: 1219 mm (4 ft.)
• Operating temperature: 22ºC to 30ºC (71.6ºF to 86ºF)
• Operating humidity: 40% to 60%
•PG: Low
• Plot mode: Graphics1
Right angle accuracy ±0.1 mm or less against the moving distance (500.0 mm)
•Used media: Roll MF-3G
• Operating temperature: 22ºC to 30ºC (71.6ºF to 86ºF)
• Operating humidity: 40% to 60%
• Plot mode: Graphics1
CPU
64Bit RISC CPU
Memory
256MB
VJ-1604 Maintenance Manual 3 Specifications
3-3 Rev.-05
Command
MH-RTL (RTL-PASS)
Interface
Network Interface (Ethernet IEEE802.3)
Ink Suppl y method
Tube supply from four separate cartridges
Cartridge
Black, cyan, magenta, yellow: 220 ml ± 5 ml for each color
Environmental conditions Temperature Humidity
Operation environment
20ºC (68ºF) to 32ºC (89.6ºF) 40% to 60%, with no condensation
Plotting accuracy warranty range
22ºC (71.6ºF) to 30ºC (86ºF) 40% to 60%, with no condensation
Rate of change
2ºC/hour or less 5%/hour or less
Storage
environment
Without ink
-20ºC (-4ºF) to 60ºC (140ºF) 20% to 80%, with no condensation
With ink
-10ºC (14ºF) to 40ºC (104ºF) 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 less (when standby heater is OFF)
Outer dimensions Height
1262 mm (49.7 in.) * including dedicated stand
Width
2698 mm (106 in.)
Depth
845 mm (33.3 in.)
Weight
173 kg (380.6 lb.) * including dedicated stand
Item Specifications
3 Specifications VJ-1604 Maintenance Manual
Rev.-05 3-4
3.3 Interface Specifications
This section explains the specification of the interfaces Supported for this printer.
3.3.1 Network Interface Specifications
3.4 Options/Supplies List
3.4.1 Options
For more information about the winding unit (optional), contact the following:
• MUTOH distributor
• MUTOH sales office
3.4.2 Supplies
(1)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 ml)
VJ-MSINK3-MA220
1 box (1 piece per box)
Ink cartridge Y (Yellow: 220 ml
± 5 ml)
VJ-MSINK3-YE220
1 box (1 piece per box)
Cleaning cartridge (220 ml
± 5 ml)
VJ-MSINK3-CL220
1 box (1 piece per box)
VJ-1604 Maintenance Manual 3 Specifications
3-5 Rev.-05
(2)Other Supplies
Name Model Sales units
Waste ink bottle
RJ8000-HET
1 box (1 piece per box)
3 Specifications VJ-1604 Maintenance Manual
Rev.-05 3-6
3.5 Choosing a Place for the Printer
• Do not place the printer in a location under the following conditions. Doing so may cause
the product to fall, become damaged, or cause injury.
• Unstable surfaces
• Slanted areas
• Locations that are subject to vibration from other product
• Do not stand on the printer or place any heavy objects on it.
Doing so may cause it to fall over, become damaged, or cause injury.
• Do not cover the ventilation hole of the printer with cloth, such as a blanket or table cloth.
Doing so could prevent the printer from ventilating and cause fire.
• Keep the printer away from humid and dusty areas. Failure to do so may result in
electrical shock or fire.
(1) Installation Environment Requirements
Choose a place for printer installation following the requirements of the table below.
Table 3-1 Installation Environment Requirements List
Floor loading capability 2940Pa (300kgf/m
2
) or over
Electrical
specification
s
Voltage AC 90-132 V
Frequency 50/60Hz ± 1Hz
Capacity Main side: 8.5 A, Heater side: 8.5A
Environmental conditions Temperature Humidity
Operation
environment
20ºC (68ºF) - 32ºC (89.6ºF) 40% - 60%, with no condensation
Plotting accuracy
warranty range
22ºC (71.6ºF) - 30ºC (86ºF) 40% - 60%, with no condensation
Rate of change 2ºC/hour or less 5%/hour or less
Storage
environment
-20ºC (-4ºF) - 60ºC (104ºF) 20% - 80%
No condensation (when ink is not
charged)
VJ-1604 Maintenance Manual 3 Specifications
3-7 Rev.-05
• Avoid the following temperature and humidity conditions. Otherwise, Plotted images may appear
differently from what you expect.
• Places where sudden changes in temperature and humidity are expected, even though the
condition is within the range specified
• Places where direct sunlight or excessive lighting are expecte d
• 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 dedicated stand should have enough loading capacity.
For the printer and the dedicated stand, refer to"3.2 Pr oduc t Specifications" p.3-2.
* Do not use VJ-1604 without stand.
e
a
d
b
c
a= 600 mm
b=1000 mm
c=1000 mm
d=1000 mm
e=1550 mm
3 Specifications VJ-1604 Maintenance Manual
Rev.-05 3-8
VJ-1604 Maintenance Manual 4 Parts Replacement
4-1 Rev.-05
4 Parts Replacement
4.1 Introduction............................................................................................. 4- 6
4.2 Removing Covers ...................................................................................4- 7
4.2.1 Removing Panel Cover.................................................................. 4-9
4.2.2 Removing Maintenance Cover....................................................... 4-9
4.2.3 Removing Maintenance Cover U................................................. 4-10
4.2.4 Removing Side Maintenance Cover R......................................... 4-11
4.2.5 Removing Side Maintenance Cover L......................................... 4-12
4.2.6 Removing Side Top Cover R....................................................... 4-12
4.2.7 Removing Side Top Cover L........................................................ 4-14
4.2.8 Removing Rear Side Cover......................................................... 4-15
4.2.9 Removing Cartridge Cover (Upper)............................................. 4-17
4.2.10 Removing Cartridge Cover (Middle) ............................................ 4-18
4.2.11 Removing Cartridge Cover (Lower)............................................. 4-19
4.2.12 Removing Switch Cover R........................................................... 4-19
4.2.13 Removing Switch Cover L............................................................ 4-20
4.2.14 Removing Front Cover................................................................. 4-21
4.2.15 Removing Rear Top Cover.......................................................... 4-21
4.2.16 Removing Top Cover................................................................... 4-23
4.2.17 Removing Media Guide F (Upper)............................................... 4-24
4.2.18 Removing Media Guide R (Upper)............................................... 4-27
4.2.19 Removing Media Guide R (Lower)............................................... 4-29
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-2
4.3 Replacing Covers ..................................................................................4- 30
4.3.1 Replacing Panel Unit.................................................................... 4-30
4.3.2 Replacing Maintenance Cover Sensor......................................... 4-31
4.3.3 Replacing Front Cover Sensor..................................................... 4-32
4.3.4 Replacing Front Cover Gear, Damper Gear (Sintered)................ 4-35
4.4 Replacing Board Base (X Rail Section)...............................................4- 39
4.4.1 Opening Board Box 64................................................................. 4-40
4.4.2 Replacing Power Board Assembly............................................... 4-41
4.4.3 Replacing HEATER CONT Board................................................ 4-42
4.4.4 Replacing HEATER RELAY Board............................................... 4-44
4.4.5 Replacing Cooling Fan (24V) Assembly (for Main Board)............ 4-46
4.4.6 Replacing Cooling Fan (24V) Assembly (in Media Guide F)........ 4-48
4.4.7 Replacing MAIN Board................................................................. 4-49
4.4.8 Replacing Fuse............................................................................. 4-53
4.4.9 Replacing Inlet Assembly............................................................. 4-55
4.5 Replacing Board Base Section (Y Rail Section) .................................4- 58
4.5.1 Replacing Heater Junction Board Assembly................................ 4-58
4.6 Replacing X Rail Section ......................................................................4- 60
4.6.1 Replacing PF Speed Reduction Belt............................................ 4-60
4.6.2 Replacing PF Motor Assembly..................................................... 4-62
4.6.3 Replacing PF Encoder Assembly................................................. 4-64
4.6.4 Replacing PF_ENC Scale, PF Speed Reduction Pulley .............. 4-65
4.6.5 Replacing P_REAR Sensor Assembly......................................... 4-66
4.6.6 Replacing Lever Up Sensor.......................................................... 4-68
VJ-1604 Maintenance Manual 4 Parts Replacement
4-3 Rev.-05
4.6.7 Replacing Heater, Thermistor...................................................... 4-69
4.6.8 Replacing Suction Fan................................................................. 4-77
4.6.9 Replacing Platen Non-Reflective Tape........................................ 4-79
4.6.10 Replacing Media Holder............................................................... 4-79
4.6.11 Replacing Flushing Tray.............................................................. 4-81
4.6.12 Replacing Flushing Absorber....................................................... 4-83
4.7 Replacing Y Rail Section...................................................................... 4- 85
4.7.1 Replacing Steel Belt..................................................................... 4-85
4.7.2 Replacing CR Motor Assembly.................................................... 4-88
4.7.3 Replacing CR Drive Pulley Assembly.......................................... 4-90
4.7.4 Replacing T Fence....................................................................... 4-92
4.7.5 Replacing CR Origin Sensor........................................................ 4-95
4.7.6 Replacing CR Driven Pulley......................................................... 4-97
4.7.7 Replacing Steel Bearer................................................................ 4-98
4.7.8 Replacing CR_FFC.................................................................... 4-100
4.7.9 Replacing Pressure Roller......................................................... 4-102
4.7.10 Replacing Ink Tube.................................................................... 4-103
4.8 Replacing Cursor Section.................................................................. 4- 106
4.8.1 Releasing Head Lock................................................................. 4-106
4.8.2 Removing CR Board Cover....................................................... 4-107
4.8.3 Replacing CR Board Assembly.................................................. 4-107
4.8.4 Replacing CR Encoder Assembly.............................................. 4-109
4.8.5 Replacing PG Origin Sensor Assembly..................................... 4-110
4.8.6 Replacing Cursor Roller Arm Assembly..................................... 4-111
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-4
4.8.7 Removing Print Head Cover....................................................... 4-111
4.8.8 Replacing Damper Assembly L_Assy........................................ 4-113
4.8.9 Replacing Print Head.................................................................. 4-115
4.8.10 Replacing Head FFC.................................................................. 4-117
4.8.11 Replacing P_EDGE Sensor Assembly....................................... 4-119
4.9 Replacing Maintenance Section.........................................................4- 121
4.9.1 Removing Maintenance Inner Cover.......................................... 4-121
4.9.2 Replacing Cleaner Head ............................................................ 4-122
4.9.3 Replacing Maintenance Assembly ............................................. 4-123
4.10 Replacing IH Section...........................................................................4- 133
4.10.1 Replacing Ink ID Board Assembly.............................................. 4-133
4.10.2 Replacing Frame Assembly, Needle .......................................... 4-136
4.10.3 Replacing Ink Cartridge Control Cable....................................... 4-140
4.10.4 Replacing Cartridge Holder Assembly........................................ 4-140
4.10.5 Replacing Two-Way Valve NX ................................................... 4-141
4.10.6 Replacing SMC Two-Way Valve ................................................ 4-143
4.10.7 Replacing Sub-Tank Lower Absorber Assembly........................ 4-144
4.10.8 Replacing Sub-Tank Assembly .................................................. 4-145
4.11 Replacing Leg Section........................................................................4- 147
4.11.1 Replacing Waste Fluid Bottle ..................................................... 4-147
4.12 Replacing Roll Media Holder Assembly............................................4- 149
4.12.1 Replacing Roll Media Holder Assembly on the VJ16_L Side..... 4-149
4.12.2 Replacing Roll Media Holder Assembly on the VJ16_R Side .... 4-150
VJ-1604 Maintenance Manual 4 Parts Replacement
4-5 Rev.-05
4.13 Replacing Winding Unit Section (Option)......................................... 4- 151
4.13.1 Removing Tension Arm ............................................................. 4-151
4.13.2 Removing Take-up Holding Plate.............................................. 4-152
4.13.3 Removing Take-up Cover.......................................................... 4-153
4.13.4 Replacing Scroller...................................................................... 4-155
4.13.5 Replacing VJ Take-up CNT Board Assembly............................ 4-157
4.13.6 Replacing CR_HP Sensor, Lever Sensor.................................. 4-163
4.13.7 Replacing Peripheral Devices of VJ Take-up Motor Assembly.. 4-166
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-6
4.1 Introduction
This chapter provides information on removal and replacement of service parts.
• Before starting part replacement, always perform the following operations.
• Turn OFF the machine power.
• Remove the power plug from the outlet.
Otherwise, you may suffer electric shock or the system circuit may be damaged.
• Remove any cables connected to the plotter.
Otherwise, the plotter may be damaged.
The components in the plotter can be disassembled only if so instructed in this manual. Do
not disassemble the frame components and other components that are not instructed to
disassemble in the manual.
The plotter has been assembled in the MUTOH factory with extremely high precision up to
1/100mm. If disassembled inappropriately, it may not restore its normal functionality.
After replacing any service parts, perform necessary lubrication and bonding following the
instructions in section "8.5 Lubrication/Bonding" p.8-6.
VJ-1604 Maintenance Manual 4 Parts Replacement
4-7 Rev.-05
4.2 Removing Covers
This section describes the procedures to replace covers.
Table 4-1 Cover Component List
No. Part name
1 Panel cover
2 Main tenance 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
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-8
5 Side top cover R
6 Maintenance cover L
7 Maintenance cover U_L
8 Side top cov er 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
VJ-1604 Maintenance Manual 4 Parts Replacement
4-9 Rev.-05
4.2.1 Removing Panel Cover
1. Open the maintenance cover R.
2. Remove the screws (2 pieces) that retain the panel cover.
3. Remove the panel cover.
4. To reassemble the unit, reverse the removal procedure.
4.2.2 Removing Maintenance Cover
The procedure to remove the maintenance cover R is the same as the one for the mainten ance 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
2
2
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-10
4. To reassemble the unit, reverse the removal procedure.
4.2.3 Removing Maintenance Cover U
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
VJ-1604 Maintenance Manual 4 Parts Replacement
4-11 Rev.-05
2. Remove the screws (2 pieces) that retain the maintenance cover U.
3. Remove the maintenance cover U.
4. To reassemble the unit, reverse the removal procedure.
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
1
2
1
2
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-12
2. Lift up and remove the side maintenance cover R.
3. To reassemble the unit, reverse the removal procedure.
4.2.5 Removing Side Maintenance Cover L
1. Remove the screws (2 pieces) that retain the side 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
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
2 Screws that retain the side maintenance cover R
(pan-head screw with spring washer and flat washer M4
×
8)
No. Part name
1 Side maintenance cover L
2 Screws that retain the side maintenance cover L
(pan-head screw with spring washer and flat washer M4
×
8)
No. Part name
1
2
VJ-1604 Maintenance Manual 4 Parts Replacement
4-13 Rev.-05
2. Remove the screws (2 pieces) that 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
1Side 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
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-14
4.2.7 Removing Side Top Cover L
Before removing the side top cover L, close the front cover.
1. Remove the side maintenance cover L.
"4.2.5 Removing Side Maintenance Cover L" p.4-12
2. Remove the screws (2 pieces) that retain the side top cover L.
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
VJ-1604 Maintenance Manual 4 Parts Replacement
4-15 Rev.-05
4.2.8 Removing Rear Side Cover
1. Remove the side maintenance 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 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
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-16
5. Remove the screws (2 pieces) on the lower part of the rear side cover.
6. Remove the screws (3 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
VJ-1604 Maintenance Manual 4 Parts Replacement
4-17 Rev.-05
7. Remove the rear side cover.
8. To reassemble the unit, reverse the removal procedure.
4.2.9 Removing Cartridge Cover (Upper)
1. Remove the ink cartridge (6 pieces).
2. Remove the screws (4 pieces) that retain the left and right part of the cartridge cover (upper).
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
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-18
3. Remove the screws (2 pieces) on the upper part of the cartridge cover (upper).
4. Remove the cartridge cover (upper).
5. To reassemble the unit, reverse the removal procedure.
4.2.10 Removing Cartridge 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)
1
2
2
1
VJ-1604 Maintenance Manual 4 Parts Replacement
4-19 Rev.-05
3. Remove the cartridge cover (middle).
4.2.11 Removing Cartridge Cover (Lower)
1. Remove the screws (4 pieces) that retain the cartridge cover (lower).
2. 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
2 Screws that retain the cartridge cover (middle)
(pan-head screw with spring washer and flat washer M3
×
8)
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)
No. Part name
2
1
1
2
Left view
Right view
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-20
2. Remove the screws (3 pieces) that retain the switch cover R.
3. Remove the switch cover R.
4. To reassemble the unit, reverse the removal procedure.
4.2.13 Removing Switch Cover L
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
1
2
1
Rear view
Right view
2
1
1
2
Rear view
Left view
VJ-1604 Maintenance Manual 4 Parts Replacement
4-21 Rev.-05
3. Remove the switch cover L.
4. To reassemble the unit, reverse the removal procedure.
4.2.14 Removing Front Cover
Front cover removal must be done by two or more persons.
1. Remove the screws that retain the left and right side of the front cover (4 pieces respectively).
2. Remove the front cover.
3. To reassemble the unit, reverse the removal procedure.
4.2.15 Removing Rear Top Cover
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 Screws that retain the switch cover L
(pan-head screw with spring washer and flat washer M3
×
8)
No. Part name
1 Front cover
2 Screws that retain the front cover
(Trusco screw M4
× 6)
No. Part name
1
2
2
1
Left view
Right view
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-22
2. Remove the rear side cover.
"4.2.8 Removing Rear Side Cover" p.4-15
VJ-1604 Maintenance Manual 4 Parts Replacement
4-23 Rev.-05
3. Remove the side top cover L.
"4.2.7 Removing Side Top Cover L" p.4-14
4. Remove the cartridge cover (upper).
"4.2.9 Removing Cartridge Cover (Upper)" p.4-17
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
1
3
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-24
4.2.16 Removing Top Cover
Top cover removal must be done by 2 or more persons.
1. Remove the front cover.
"4.2.14 Removing Front Cover" p.4-21
2. Remove the rear top cover.
"4.2.15 Removing Rear Top Cover" p.4-21
3. Remove the screws (5 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
VJ-1604 Maintenance Manual 4 Parts Replacement
4-25 Rev.-05
4. Remove the screws (5 pieces) that retain the front of the top cover.
5. Remove the top cover.
6. To reassemble the unit, reverse the removal procedure.
4.2.17 Removing Media Guide F (Upper)
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
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-26
2. Remove the screws (2 pieces) that retain the media guide FR.
3. Remove the
media guide FR.
4. Remove the screws (2 pieces) that retain the media guide FL.
5. Remove the media guide FL.
No. Part name
1Media guide FR
2 Screws that retain the media guide FR
(pan-head screw with spring washer and flat washer M4
×
8)
No. Part name
1Media 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
VJ-1604 Maintenance Manual 4 Parts Replacement
4-27 Rev.-05
6. Remove the screws (5 pieces) that retain the bottom of the media guide F (upper).
7. Remove 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
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-28
9. Remove the two connectors to the after-heater and the two connectors to the after-thermistor that are
inside 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)
Media guide R (upper) removal must be done by 2 or more persons.
1. Remove media.
No. Part name
1 Media gu ide F (upper)
2 Media guid e F (lower)
3 Connector to the after-thermistor
4 Connector to the after-heater
2
1
3
4
VJ-1604 Maintenance Manual 4 Parts Replacement
4-29 Rev.-05
2. Remove the screws (4 pieces) that retain the media guide R (upper).
3. Push backward the
media guide R (upper).
4. Remove the two connectors to the pre-heater and the two connectors to the pre-thermistor that are inside
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 (up per)
(pan-head screw with spring washer and flat washer M4
×
8)
No. Part name
1Rear top cover
2 Media guide R (upper)
3 Connector to the pre-thermistor
4 Connector to the pre-heater
1
2
2
1
3
4
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-30
4.2.19 Removing Media Guide R (Lower)
Media guide R (lower) removal must be done by 2 or more persons.
1. Remove the media guide R (upper).
"4.2.18 Removing Media Guide R (Upper)" p.4-27
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 M4
×
8)
2
2
1
VJ-1604 Maintenance Manual 4 Parts Replacement
4-31 Rev.-05
4.3 Replacing Covers
This section describes the procedures to replace the covers.
4.3.1 Replacing Panel Unit
• When replacing the panel unit, first pull out the AC cable.
Power may be turned on depending on how the cable is connected, and that may damage
the board.
• When connecting and removing the FFC type cables (panel tape wires), always pull or
push the cables perpendicularly.
Pulling or pushing them slantwise may damage/short/break the terminals in the
connectors, causing a breakdown of the on-board devices.
• The cables can be connected or removed up to 5 times.
1. Remove the panel cover.
"4.2.1 Removing Panel Cover" p.4-9
2. Remove the panel to conversion board tape wire.
3. Release the four panel unit back tabs (4 pieces) from the panel stay.
4. Remove the
panel unit.
5. Replace the panel unit.
6. To reassemble the unit, reverse the removal procedure.
No. Part name
1 Panel unit
2 Panel unit tab
3 Panel stay
4 Panel FFC
2
1
2
3
2
2
2
1
3
4
Front view
Rear view
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-32
4.3.2 Replacing Maintenance Cover Sensor
(1)Replacing Maintenance Cover Sensor R
1. Remove the maintenance cover U.
"4.2.3 Removing Maintenance Cover U" p.4-10
2. Detach the connector for the maintenance cover sensor assembly.
3. Remove the screws (2 pieces) that retain the maintenance cover sensor assembly.
4. Remove the maintenance cover sensor assembly.
5. Replace the maintenance cover sensor assembly.
6. To reassemble the unit, reverse the removal procedure.
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 washer and flat washer M2
×
6)
3 Connector for the maintenance cover sensor assembly
1
2
3
Opened
Closed
VJ-1604 Maintenance Manual 4 Parts Replacement
4-33 Rev.-05
(2)Replacing Maintenance Cover Sensor L
The procedure to replace the maintenance cover sensor L is the same as the one for the maintenance cover
sensor R.
4.3.3 Replacing Front Cover Sensor
(1)R Side
1. Remove the side top cover R.
"4.2.6 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.
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-34
4. Remove the screws (2 pieces) that retain the cover sensor (C) assembly_R.
5. Remove the cover sensor (C) assembly_R.
6. To reassemble the unit, reverse the removal procedure.
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 cover R
2
1
3
Opened
Closed
VJ-1604 Maintenance Manual 4 Parts Replacement
4-35 Rev.-05
4. Remove the screws (2 pieces) that retain the cover sensor (C) assembly_L.
5. Remove the cover sensor (C) assembly_L.
6. To reassemble the unit, reverse the removal procedure.
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
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-36
4.3.4 Replacing Front Cover Gear, Damper Gear (Sintered)
(1)R Side
1. Remove the switch cover R.
"4.2.12 Removing Switch Cover R" p.4-19
2. Remove the screw (1 piece) that retains 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 Screw that retains 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
VJ-1604 Maintenance Manual 4 Parts Replacement
4-37 Rev.-05
5. Remove the damper cover R.
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.
2 Screws that retain the damper cover R
(pan-head screw with spring washer and flat washer M4
×
8)
No. Part name
1 Fla nge bushing
2 Fr ont cover gear
3 Front cover axis
4 Damper gear (sintered)
No. Part name
2
1
4
3
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-38
(2)L Side
1. Remove the switch cover L.
"4.2.13 Removing Switch Cover L" p.4-20
2. Remove the screw (1 piece) that retains the switch 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 Screw that retains 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
1
3
2
2
1
2
VJ-1604 Maintenance Manual 4 Parts Replacement
4-39 Rev.-05
5. Remove 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.
2 Screws that retain the damper cover L
(pan-head screw with spring washer and flat washer M4
×
8)
No. Part name
1 Flange bushing
2 Fr ont cover gear
3 Front cover axis
4 Damper gear (sintered)
No. Part name
1
3
2
4
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-40
4.4 Replacing Board Base (X Rail Section)
This section describes the procedure to replace the power supply or the board in the X rail section.
The boards are arranged as follows.
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 media guide F
VJ-1604 Maintenance Manual 4 Parts Replacement
4-41 Rev.-05
4.4.1 Opening Board Box 64
1. Remove the AC inlet cables (2 pieces), and the other cables (LAN, USB).
2. Remove the screws (5 pieces) that retain the board box 64.
If you remove the screws that retain the board box 64, the box opens downwards because
of it's weight. Remove the last screw while holding the box by hand, or you may be injured.
3. Open the board box 64 downwards.
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
Right view
Rear view
1
2
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-42
4.4.2 Replacing Power Board Assembly
If the power board assembly needs to be removed, remove the power cable and wait for 5
minutes or more before dismount the assembly; this will discharge the residual electrical
charge of the electrolytic capacitor.
Touching the board before the capa citor 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 name
1 Power board assembly
2 Screws that retain the power board assembly
(cup screw M3
× 6)
2
1
2
VJ-1604 Maintenance Manual 4 Parts Replacement
4-43 Rev.-05
4.4.3 Replacing HEATER CONT Board
• Before you replace a board assembly, remove the AC inlet cable.
You may suffer electric shock due to standby current.
• When you handle a circuit board, do not touch any elements on it with bare hands.
Doing so may cause electrostatic discharge and damage the elements.
• 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 elements.
• The cables can be connected or removed up to 5 times.
1. Remove the media guide F (upper).
"4.2.17 Removing Media Guide F (Upper)" p.4-24
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-44
2. Detach the connectors listed below from the HEATER CONT board.
No. Connector
No.
# of
Pins
Color Connect to Remark
1 J1 8 Black Config CN
2 J2 2 White Feeder Motor
3 J3 6 White Feeding Unit Sensor
4 J4 4 White Roll Motor
5 J5 7 White Roll Unit Sensor
6 J6 40 Black HEATER RELAY A (J3) FFC
7 J7 40 Black Not in use
8 J8 4 White DC IN [HEATER JUNCTION (J2)]
9 J9 8 Gray Communication [HEATER JUNCTION
(J3)]
LAN
10 J10 8 Gray LVS [MAIN (143)] LAN
11 J11 5 White Debug
12 J12 5 Yellow SMART CARD Not in use
13 J13 RSV IN 1 Not in use
14 J14 RSV OUT 1 Not in use
15 J15 RSV OUT 2 Not in use
16 J16 RSV IN 2 Not in use
17 J17 THRM 1 Not in use
18 J18 THRM 2 Not in use
19 J19 8 White DC IN -> [MAIN J46]
20 J20 2 White AC OUT -> DC5V/24V (CN1)
21 J21 3 Red POW-ON -> POW [MAIN (J45)]
22 J22 2 White AC-IN -> Terminal Stand
23 J23 2 White EXT-AC-OUT -> HEATER RELAY A (J1)
VJ-1604 Maintenance Manual 4 Parts Replacement
4-45 Rev.-05
3. Remove the screws (4 pieces) that retain the HEATER CONT board.
4. Replace the HEATER CONT board.
5. To reassemble the unit, reverse the removal procedure.
6. Install the firmware to the HEATER_CONT board.
"7.3.7 Sub Controller Installation" p.7-23
4.4.4 Replacing HEATER RELAY Board
• Before you replace a board assembly, remove the AC inlet cable.
You may suffer electric shock due to standby current.
• When you handle a circuit board, do not touch any elements on it with bare hands.
Doing so may cause electrostatic discharge and damage the elements.
• 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 elements.
• The cables can be connected or removed up to 5 times.
1. Remove the media guide F (upper).
"4.2.17 Removing Media Guide F (Upper)" p.4-24
No. Part name
1 HEATER CONT board
2 Screws that retain th e HEATER CONT board.
(cup screw M3
× 6)
2
2
1
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-46
2. Detach the connectors listed below from the heater relay board.
Table 4-2 Connectors to Heater Relay Board
No. Connector
No.
# of
Pins
Color Connect to Remark
1 J1 2 White EX-AC-OUT [HEATER CONT (J23)]
2 J2 4 White Plt_Heat 1
3 J3 40 Black HEATER CONT (J6) FFC
4 J4 2 White Not in use
5 J5 4 White Plt_Heat 2
6 J6 2 White Inlet (Large)
7J7 2 White Pre_Heat
8 J8 2 White Pre_Heat
9J9 4 White Aft_Heat
10 J10 2 Blue Cooling FAN
11 J11 4 White Vacum FAN (#1, #2)
12 J12 2 White Platen_Thrm 1
13 J13 2 Black Platen_Thrm 2
14 J14 4 Black Vacum FAN (#3, #4)
15 J15 2 Red Pre_Thrm 1
16 J16 2 Yellow Pre_Thrm 2
17 J17 3 White Aft_Thrm 1
18 J18 3 Black Aft_Thrm 2
19 J19 3 Red Reserve 1 Thrm
20 J20 3 Yellow Reserve 2 Thrm
VJ-1604 Maintenance Manual 4 Parts Replacement
4-47 Rev.-05
3. Remove the screws (6 pieces) that retain the heater relay board.
4. Remove the heater relay board.
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
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-48
3. Remove the screws (2 pieces) that retain the cooling fan (24V) assembly.
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
VJ-1604 Maintenance Manual 4 Parts Replacement
4-49 Rev.-05
4.4.6 Replacing Cooling Fan (24V) Assembly (in Media Guide F)
1. Remove the media guide F (upper).
"4.2.17 Removing Media Guide F (Upper)" p.4-24
2. Remove the connector to the coo ling fan (24V) assembly.
3. Remove the screws (2 pieces) that 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 S crews that retain the cooling fan mounting plate
(pan-head screw with spring washer and flat washer M4 ×
6)
4 Connecto r to the cooling fan (24V) assembly
No. Part name
1 Cooling fan (24V) assembly
2
1
3
Inside view of media guide F
4
2
1
Inside view of media guide F
4 Parts Replacement VJ-1604 Maintenance Manual
Rev.-05 4-50
6. Remove the cooling fan (24V) assembly.
7. To reassemble the unit, reverse the removal procedure.
4.4.7 Replacing MAIN Board
• Before you replace a board assembly, remove the AC inlet cable.
You may suffer electric shock due to standby current.
• When you handle a circuit board, do not touch any elements on it with bare hands.
Doing so may cause electrostatic discharge and damage the elements.
Be sure to back up the parameters before replacing the MAIN board assembly.
"7.3.1 Parameter Backup" p.7-9
2 Screws that retain the cooling fan (24V) assembly
(pan-head screw with spring washer and flat washer M3
×
30)
No. Part name
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