MUTOH ValueJet VJ-1604 User manual

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

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 interference in which case the
user will be required to correct the interference at his own expense.
3. Trademark Mentioned in this Manual
• MUTOH, ValueJet, VJ-1604 are registered trademarks or product names of MUTOH INDUSTRIES
LTD.
• Centronics and BiCentronics are registered trademarks or product names of Centronics Data Computer
Corporation.
• Windows95, Windows98, Windows98SE, Windows NT4.0, Windows2000, Windows XP, and MS-
DOS are registered trademarks or product names of Microsoft Corporation.
• Intel and Pentium are trademarks or registered trademarks of Intel Corporation.
• Other company and product names may be registered trademarks or product names.
This is a Class A product approved for industrial environ-
ments. In a domestic environment this product may cause
radio interference in which case you may be required to take
adequate measures.
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 the 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 operations for MUTOH Full
Color Ink Jet Printer (VJ-1604).
This manual is prepared for the maintenance personnel of this printer.
Before using this printer, fully understand the contents and directions in this manual.
2. Manual Configuration
Section Contents
1 Safety Instructions Explains types of warnings, cautions and warnings labeled on the printer
for the both operators of the printer and maintenance personnel.
2 Product Overview Explains the features, part names, and functions of the printer.
3 Specifications Explains the specifications of the printer.
4 Parts Replacement Explains the procedures of replacement and removal of the service parts
of the printer.
5 Self-Diagnostic Mode Explains the self-diagnostic functions of the printer.
6 Maintenance Mode Explains the maintenance mode of the printer.
7 Adjustment Explains the adjusting procedures of the printer parts.
8 Maintenance Explains daily maintenance of the printer.
9 Troubleshooting Explains troubles that may occur when using the printer and how to
solve them.
10 Appendix Explains the maintenance information and the exploded views for this
printer.
Use the built-in self-diagnostic program to locate a defective part and adjust/
check during maintenance.

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.
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

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General Table of Contents
1 Safety Instructions
1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.4.1 Handling the Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.4.2 Locations and Types of Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.5 Operation Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.5.1 Handling the Operation Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.5.2 Locations and Types of Operation Labels . . . . . . . . . . . . . . . . . . . . . . 1-10
2 Product Overview
2.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Part Names and Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3.1 Front Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3.2 Rear Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.3 Operation Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4 Printer Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.4.1 Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.4.2 Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.4.3 Self-Diagnosis Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.4.4 Maintenance Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
3 Specifications
3.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Product Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Interface Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3.1 USB Interface Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3.2 Network Interface Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

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3.4 Options/Supplies List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4.1 Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4.2 Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.5 Choosing a Place for the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
4 Parts Replacement
4.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.2 Removal of Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.2.1 Removing R Side Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.2.2 Removing Operation Panel Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.2.3 Removing L Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.2.4 Removing Ink Holder (I/H) Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.2.5 Removing Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.2.6 Removing Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.2.7 Removing Media Guide F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.2.8 Removing Media Guide R2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.2.9 Removing Scroller Receiver (L, R). . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.3 Replacement of Board Base Section Components. . . . . . . . . . . . . . . . . 4-17
4.3.1 Removing Connector Panel and Cooling Fan . . . . . . . . . . . . . . . . . . . 4-17
4.3.2 Removing Main Board Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.3.3 Replacing Main Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.3.4 Replacing HEATER CONT board assembly . . . . . . . . . . . . . . . . . . . . 4-22
4.3.5 Replacing HEATER RELAY board assembly . . . . . . . . . . . . . . . . . . . 4-25
4.3.6 Replacing Power Board Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
4.3.7 Replacing Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
4.3.8 Replacing Inlet Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
4.4 Replacement of PF Driving Section Components. . . . . . . . . . . . . . . . . . 4-31
4.4.1 Replacing PF Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
4.4.2 Replacing PF_ENC Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
4.4.3 Replacing PF_ENC Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
4.4.4 Replacing Heater and Thermistor Assembly . . . . . . . . . . . . . . . . . . . . 4-34
4.5 Replacement of CR Driving Section Components . . . . . . . . . . . . . . . . . 4-38
4.5.1 CR Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
4.5.2 Replacing CR_HP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
4.5.3 Replacing Lever Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
4.5.4 Replacing T Fence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
4.5.5 Replacing CR Driven Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
4.5.6 Replacing Pressure Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

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4.6 Replacement of Head Section Components . . . . . . . . . . . . . . . . . . . . . . 4-48
4.6.1 Replacing Print Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
4.6.2 Replacing Cutter Holder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
4.7 Replacement of Maintenance Section Components . . . . . . . . . . . . . . . . 4-57
4.7.1 Removing Maintenance Base Assembly . . . . . . . . . . . . . . . . . . . . . . . 4-57
4.7.2 Replacing Pump Cap Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61
4.7.3 Replacing Cleaner Head (Cleaning Wiper) . . . . . . . . . . . . . . . . . . . . . 4-63
4.7.4 Replacing Flushing Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
4.8 Replacement of Ink Supply Section Components . . . . . . . . . . . . . . . . . . 4-66
4.8.1 Replacing Ink Holder (I/H) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
4.8.2 Replacing Ink Sensor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
4.8.3 Replacing Cover Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
4.8.4 Replacing Heater Junction Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
4.9 Replacement of Frame Section Components . . . . . . . . . . . . . . . . . . . . . 4-73
4.9.1 Replacing Suction Fan Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
4.9.2 Replacing P_REAR Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
4.10 Replacement of Cable Guide Section Components . . . . . . . . . . . . . . . . 4-75
4.10.1 Replacing CR Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
4.10.2 Replacing Ink Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76
4.10.3 Replacing CR Tape Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
5 Self-Diagnosis Mode
5.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.2.1 Preparations on Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.2.2 Starting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3 Operations in Self-Diagnosis Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.1 Operating Self-Diagnosis Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.3.2 Diagnosis Items in Self-Diagnosis Menu . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.4 Platen Adjustment Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.5 Inspection Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.5.1 Memory Size Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.5.2 Version Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.5.3 Operation Panel Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.5.4 Sensor Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.5.5 Encoder Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.5.6 Fan Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

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5.5.7 History Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5.5.8 Head Waveform Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5.6 Ink Charging Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.7 Adjustment Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5.7.1 Head Nozzle Check Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5.7.2 Skew Check Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5.7.3 Head Slant Check Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
5.7.4 Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
5.7.5 Uni-D / Bi-D Low Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
5.7.6 Uni-D / Bi-D High Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
5.7.7 Side Margin Adjustment Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
5.7.8 Test Printing Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
5.7.9 HeadWash Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
5.7.10 Software Counter Initialization Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
5.7.11 Feed Pitch Check Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
5.7.12 Solid Print Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
5.8 Cleaning Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
5.9 Sample Printing Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
5.10 Time Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
5.11 Parameter Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
5.11.1 Parameter Initialization Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
5.11.2 Parameter Update Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
5.12 Servo Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
5.13 Endurance Running Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
5.13.1 CR Motor Endurance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
5.13.2 PF Motor Endurance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
5.13.3 Wiper Motor Endurance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
5.13.4 Pump Endurance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
5.13.5 Print Head Endurance (Nozzle Print) Menu . . . . . . . . . . . . . . . . . . . . . 5-63
5.13.6 General Endurance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
5.13.7 Endurance Running Check Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
5.14 Media Feed Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
5.15 ExControl Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
5.15.1 Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
5.15.2 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
5.15.3 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5.15.4 History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69

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5.16 PaperInitial Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
6 Maintenance Mode
6.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Operations in Maintenance Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.1 Starting Up the Maintenance Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.2 Operating Maintenance Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.3 Maintenance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3.1 Counter Display Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3.2 Counter Initialization Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3.3 Counter Print Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3.4 Media Feed Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
7 Adjustment
7.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2 Adjustment Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.3 Working with Dedicated Network Software . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.3.1 Parameter Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.3.2 Jigs and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.3.3 Required Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.3.4 Receiving Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.3.5 Firmware Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.3.6 Sending Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7.3.7 Sub Controller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.3.8 RTC Date & Time Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7.4 PF Speed Reduction Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . 7-20
7.4.1 Jigs and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7.4.2 Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7.5 PF Encoder Assembly Position Adjustment . . . . . . . . . . . . . . . . . . . . . . 7-22
7.5.1 Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7.6 CR Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
7.7 Head Alignment (Horizontal Height) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
7.8 Head Alignment (Vertical Slant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
7.9 Cutter Holder Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
7.9.1 Jigs and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
7.9.2 Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

VJ-1604 Maintenance Manual
10
7.10 PG Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
7.10.1 Jigs and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
7.10.2 Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
7.11 Media Sensor Sensitivity Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
7.11.1 P_EDGE Sensor Sensitivity Adjustment . . . . . . . . . . . . . . . . . . . . . . . 7-32
7.11.2 P_REAR Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
8 Maintenance
8.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2 Periodical Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3 Part Life Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4 Lubrication/Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.5 Transportation of Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
9 Troubleshooting
9.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2 Troubleshooting with Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2.1 Operation Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2.2 Errors with Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.2.3 Data Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.2.4 Command Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
9.2.5 Errors Requiring Reboot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
9.2.6 Error Messages During File Transmission. . . . . . . . . . . . . . . . . . . . . . 9-29
9.3 Troubleshooting Without Error Messages. . . . . . . . . . . . . . . . . . . . . . . . 9-33
9.3.1 Initial Operation Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
9.3.2 Media Feed Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
9.3.3 Printing Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
9.3.4 Noise Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-62
9.3.5 Online Function Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-65
9.3.6 Other Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-68
9.3.7 Problems in Using Dedicated Network Software . . . . . . . . . . . . . . . . . 9-71
10 Appendix
10.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.2 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

VJ-1604 Maintenance Manual
11
10.3 Maintenance Part List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.4 Jigs and Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10.4.1 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10.5 Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10

VJ-1604 Maintenance Manual
12

VJ-1604 Maintenance Manual 1 Safety Instructions
1-1 Rev.-00
1 Safety Instructions
1.1 Introduction ............................................................................................. 1- 2
1.2 Warnings, Cautions and Notes.............................................................. 1- 2
1.3 Important Safety Instructions ................................................................ 1- 3
1.4 Warning Labels ....................................................................................... 1- 6
1.4.1 Handling the Warning Labels......................................................... 1-6
1.4.2 Locations and Types of Warning Labels........................................ 1-7

1 Safety Instructions VJ-1604 Maintenance Manual
Rev.-00 1-2
1.1 Introduction
This chapter explains the meaning of safety terms for personnel who installs, operates, or maintains this
equipment, important safety instructions, and the warning labels attached to the equipment.
WARNING
Make sure to follow all instructions and warnings on this manual when installing, operating,
or maintaining the equipment.
1.2 Warnings, Cautions and Notes
Safety terms in this manual and the contents of warning labels attached to the printer are categorized into the
following three types depending on the degree of risk (or the scale of accident).
Read the following explanations carefully, and follow the instructions in this manual.
Table 1-1 Safety Terms Descriptions
Safety terms Details
Must be followed carefully to avoid death or serious bodily injury
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.-00
1.3 Important Safety Instructions
General safety instructions that must be observed to use the equipment safely are explained below.
WARNING
Do not place the printer in the following areas. Doing so may result in the printer
tipping or falling over and causing injury.
• Unstable surfaces
• Angled place
• Areas subject to vibration by other equipment
Do not stand on or place heavy objects on your printer. Doing so may result in the
printer tipping or falling over and causing injury.
Doing so could obstruct ventilation and cause fire.
Do not cover the ventilation hole of your printer with cloth, such as a blanket or table
cloth.Doing so may result in fire.
Do not place the printer in humid and dusty areas. Doing so may result in electrical
shock or fire.
Make sure to use the power cable packed with the printer you purchased. Not doing
so may result in electrical shock or fire.
Make sure that the following is performed before parts replacement.
• Turn off the power of the printer.
• Remove the power cable from the power outlet.
Not doing so may cause electric shock or damage to the electric circuit.
• Unplug the cables connected to the printer.
Failure to do so could result in damage to the printer.

1 Safety Instructions VJ-1604 Maintenance Manual
Rev.-00 1-4
CAUTION
Assembling and disassembling of the printer are possible only for the parts that
disassembling procedures are shown in this manual. Do not disassemble any frame
parts or parts that disassembling procedures are not shown in this manual.
Doing so may cause trouble that cannot be restored, as the printer is originally
assembled in the factory with a high accuracy of 1/100 mm.
Do not touch the elements on the circuit board with bare hands.
Doing so may cause static electricity and break the elements.
Do not press the transparent film on the damper assembly with your hands. Doing so
may discharge the ink filled inside the damper assembly.
Be careful not to damage the transparent film on the damper assembly.
Do not touch the nozzles of the print head. Make sure that the nozzles do not get any
dust.
Never lube the printer mechanism with lube other than that designated by MUTOH.
Doing so may damage the parts or shorten the lifetime.
There are some remaining ink in the tubes. Be careful that the ink is not spilled from the
tube outlet onto the printer or items close to the printer.
If you need to operate the printer with the cover removed for maintenance, be careful
not to get hurt by the driving parts.
If the power board assembly needs to be removed, remove the power cable and wait
for 5 minutes or more before taking it out; this will discharge the residual electrical
charge of the electrolytic capacitor.
Touching the board before the capacitor discharges may cause electric shock.
When connecting or removing an FFC type cable on a MAIN board assembly
connector, make sure to connect or remove the cable perpendicular to the connector.
Connecting or removing at a slant angle may damage, break or short circuit the inner
terminal of the connector. That may damage the elements on the board.
When connecting or removing an FFC type cable on the CR board assembly connector,
make sure to connect or remove the cable perpendicular to the connector.
Connecting or removing at a slant angle may damage, break or short circuit the inner
terminal of the connector. That may damage the elements on the board.
Make sure there is sufficient space around the printer when performing maintenance
work.
Maintenance must be done by more than two person for the following work.
• When disassembling or reassembling the product and the optional stand
• When packing the printer for transportation

VJ-1604 Maintenance Manual 1 Safety Instructions
1-5 Rev.-00
1.4 Warning Labels
The handling, attachment locations, and types of warning labels are explained below.
Warning labels are attached to areas where care should be taken. Read and understand the positions and
contents thoroughly before maintenance operation.
1.4.1 Handling the Warning Labels
Make sure to note the following when handling the warning labels.
NOTE
• Make sure that all warning labels can be recognized. If text or illustrations cannot be seen clearly,
clean or replace the label.
• When cleaning warning labels, use a cloth with water or neutral detergent. Do not use a solvent or
gasoline.
• If a warning label is damaged, lost, or cannot be recognized, replace the label.

1 Safety Instructions VJ-1604 Maintenance Manual
Rev.-00 1-6
1.4.2 Locations and Types of Warning Labels
(1) Main Body
The locations of warning labels on the main body are shown below.
43215
6
6
8
9
7