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Not sure if it will resolve the issue, but you could try Uni-directional and slowing down the print head speed and see if this gives better results. Of course it will take much longer to print, but might stop the need to replace the head. You could also try replacing the cap top, if it's been a...

A 0380 error is a timing error in which the machine tries and fails after a set time frame to fill a damper. The 0008 indicates what damper. Usually the small sensors fail. It is good to keep them on hand. The usual sign for this is ink leaking out of the printhead. Of course they are also in...

If you did want to upgrade, I'd recommend trying to pick up a VS-i model, they are quick, good quality and easy enough to service yourself. Only real downside is the 1 head setup. However, as long as you treat it right, it will treat you right. It's our most used printer. We still have our old...

Although the nozzle test doesn't look bad, there are a few deflections and a few missing nozzles, which might be causing trouble. Have you tried doing solid blocks of CMYK with PMS colors and setting them up as Pure 100% of each and seeing if there is 1 color that is worse. From your photos...

Happy 4th of July to all our friends to the south.

Unfortunately not. Hopefully someone else with more knowledge then me might have some more suggestions.

It's the cut carriage that detects the position of the pinch rollers.

No sensor in there. You typically don't need to clean them, unless you have some stuff on the little wheels, those are usually the things that go. Are those little wheels in good shape?

It tells the printer where the limits are. Not sure if it will help, but it might. It will give you instructions on the screen of what do do. Because if you'd done all the linear encoder setups and calibrations and then did the adjust Bi-Dir and the print and cut calibration in the user menu and...

No, it's a different procedure. Sorry, it's called limit position & cut down position initialize, which secondary power off, you press the left, up and right keys at the same time and press power button while holding those keys. It's in the service menu if you have it.

If you just replaced the linear encoder, you could always try another linear initialization. *Edit: Looks like you actually haven't done that yet, based on what you mentioned above.

Sorry, didn't mean files, meant have you tried other types of vinyl, other then the Oracal 751?

What kind of material are you using and does it give you this issue on all medias you try?

Does it do it on all medias you print on or just one specific kind? Doesn't really appear to be a damper problem, as it is were it, you'd expect it to be very faded or have fine lines, but those lines are very thick, my guess is that maybe the edge of the media is lifting slightly and it can't...

Might be a stupid question, but have you adjusted the Bi-dir and done the calibration from the menu on the user side? Also, make sure that the pinch rollers aren't broken and that the media isn't moving side to side.

Have you made sure the blade wasn't broken? Also, make sure the blade holder is securely locked into the carriage.

Do you have a photo? What about the cap tops and dampers, replaced recently? From that photo you posted, there is overspray, which is usually due to a deflecting nozzle.

Looks to be a little more then that, how are your nozzle test prints? Have your cap tops and dampers been replaced recently?

As mentioned above, how is the nozzle test print? Also, do you have photos, which might also shed light on possible problems.

Have you tried to setup a special file setting PMS colors for C,M,Y & K and then setting in the Spot color in Versawork 100%C only for Cyan , 100& M only for Magenta and so on and trying to see if it's actually printing black, as typically when you print something it doesn't always use K, a lot...