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This manual may include technical inaccuracies or typographical errors due to improvements or changes in the products. When amendments are made to the content of this manual, Canon will issue technical information as the need arises. In the event of major alterations to the content of this manual over a long or short period, Canon will publish a revised version of the manual.
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PREFACE This Service Manual describes fundamental field service for the BJ-W3000/BJ-W3050 large format printer. This Manual is composed of the following chapters: Chapter 1 General Description: Features, specifications and operating procedures Chapter 2 Basic Operation: Operation of mechanical and electric functions...
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PREFACE Descriptions in this manual are based on the following conventions. 1. In the Basic Operation section, the roles of each function, relationships between electrical and mechanical systems, and the timing for each part are summarized. The mark indicates mechanical drive transmission. The mark accompanying a signal name indicates the flow of electrical signals.
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PREFACE • In order to remedy a problem, check the Steps in order. Answer the first "Check item" question. If your answer matches that given in the "Result", follow the corresponding proce- dure in the "Remedy" column. If your answer is not the same, go on to the next step and repeat the same procedure.
PREFACE CONTENTS CHAPTER 1 GENERAL DESCRIPTION I. SPECIFICATIONS ..........1-1 E. Paper Thickness Adjustment Lever ... 1-31 1. Type ............. 1-1 IV. CARTRIDGE REPLACEMENT ....... 1-32 2. Exterior ............1-1 A. Replacing the BJ Print head ....... 1-32 3. Mechanism ..........1-2 B.
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PREFACE 3. Maintenance jet ........2-53 F. Remaining Ink Detection ......2-35 4. Suction ..........2-54 1. Outline ..........2-35 D. Waste Ink Absorber Unit ......2-56 2. Method of detecting remaining ink ..2-36 1. Waste ink absorber unit ....... 2-56 G.
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PREFACE CHAPTER 4 MAINTENANCE AND SERVICING I. PERIODIC PARTS REPLACEMENT ....4-1 IV. MAINTENANCE AND INSPECTION ....4-2 II. STANDARD SERVICE LIFE OF A. Cleaning/Inspection Points ......4-2 CONSUMABLES ..........4-1 B. Lubrication Points ........4-3 III. PERIODIC SERVICE ........4-1 CHAPTER 5 TROUBLESHOOTING I.
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CHAPTER 1 GENERAL DESCRIPTION I. SPECIFICATIONS ..........1-1 V. SIMM REPLACEMENT ........1-36 II. NAMES OF COMPONENTS ......1-7 A. About SIMM ..........1-36 A. External View ..........1-7 B. SIMM Installation ........1-36 B. Carriage ............1-8 C. SIMM Removal .......... 1-37 C.
CHAPTER 1. GENERAL DESCRIPTION I. SPECIFICATIONS 1. Type Type: Bubble jet printer Purge system: Suction with tube pump Paper feeding method: Cut sheet media; Manually set to the front. Roll media; Automatic feeding (When manually set to the rear.) Sheet feeder capacity: Cut sheet media;...
CHAPTER 1. GENERAL DESCRIPTION 3. Mechanism Print mode/Resolution (No.) Mode Pass * Resolution Drive frequency Dot size * Monochrome draft 1 pass/Bi 180dpi x 360dpi 14.4kHz Monochrome normal 1 pass/Uni 360dpi x 360dpi 7.2kHz Monochrome enhanced 2 pass/Uni 360dpi x 360dpi 7.2kHz Monochrome high enhanced 4 pass/Uni 360dpi x 360dpi 7.2kHz...
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CHAPTER 1. GENERAL DESCRIPTION Cartridge construction Head/Ink tank separation type 1 row of 160 nozzles (144 nozzles used) x 4 colors Ink type Black: Pigment, Cyan/Magenta/Yellow: dye Ink tank capacity Black: Approx. 23g, Cyan/Magenta/Yellow: Approx. 20g BJ print head service life A0 size: Approx.
CHAPTER 1. GENERAL DESCRIPTION Ink tank detection Provided Remaining ink detection Provided Waste-ink full detection Provided Media out detection Provided Remaining roll media detection Not provided Roll media end detection Provided Media size detection Cut sheet media: Automatic vertical/horizontal detection Roll media: Vertical;...
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CHAPTER 1. GENERAL DESCRIPTION Printable papers Paper standard A1 model A0 model inch Vertical Horizontal Vertical Horizontal ISO A 841.0 × 33.1 × 1189.0 46.8 594.0 × 23.4 × 841.0 33.1 420.0 × 16.5 × 594.0 23.4 297.0 × 11.7 × 420.0 16.5 210.0 ×...
CHAPTER 1. GENERAL DESCRIPTION 5. Others Power source AC: 100 ~ 240 V (-15%, +10%) Frequency 50/60Hz Power consumption Max.: 120W or less At stand-by: 22W or less Noise Sound pressure level (Complies with ISO 9296.) When operating: Approx. 52dB (A) or less At stand-by: Approx.
CHAPTER 1. GENERAL DESCRIPTION II. NAMES OF COMPONENTS A. External View [1] Front cover [5] Wiper (Cleaner blade) [2] Carriage [6] Cutter unit [3] Operation panel [7] Platen [4] Paper release lever [8] Pinch roller Figure 1-201 1–7...
CHAPTER 1. GENERAL DESCRIPTION B. Carriage [1] Ink tank [4] BJ Cartridge [2] BJ print head release hook [5] Ink tank release hook [3] Paper thickness adjustment lever [6] Cutter unit Figure 1-202 C. Cable Connections [1] Parallel interface connector [4] Earth wire terminal [2] Serial interface connector [5] Power switch...
CHAPTER 1. GENERAL DESCRIPTION D. Rear Side of Main Unit [1] Roll media stopper [4] Parallel interface connector [2] Spindle [5] AC inlet [3] Serial interface connector [6] Power switch Figure 1-204 E. Printing Direction Paper feed backward direction Paper feed forward direction Figure 1-205 1–9...
CHAPTER 1. GENERAL DESCRIPTION III. OPERATION A. Operation Panel DATA POWER ONLINE ENTER Figure 1-301 Name Function Data reception lamp Green when receiving data. Blinks if data is transmitted when the printer cannot receive it. Message display Menus, parameters, error messages and other conditions are displayed.
CHAPTER 1. GENERAL DESCRIPTION B. Printer States Printer states and key operation are shown below. Data received Printing Online After printing on roll media Menu setup screen Menu setup screen Sleep Pause Offline (Black arrows) : Change of printer states when the Online key is pressed. *1.
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CHAPTER 1. GENERAL DESCRIPTION State Printer state Online ¥ This machine can receive, analyze and print data. When printing is started, "Printing" appears on the message display. ¥ While online, only the online key is functional. To use the other keys, this machine should be offline or in the menu state.
C. User Mode Menu Menu guide The following diagram shows the menu hierarchy of this printer. Normal menu Printing Menu : Indicates the menu (Select the item using the up and down arrow keys.) Emulation Line Type Interface Setup Main Menu (The shaded items are indicated only in the roll media mode.) Main menu *1: Can be set as a printer driver property, This fares priority...
CHAPTER 1. GENERAL DESCRIPTION . Menu and parameter setup Menus and parameters are selected as described below. 1) By pressing the online key in the offline or pause state, the printer enters the menu state. 2) Select a menu item by pressing the right and left arrow keys. 3) After selecting a menu, move to the parameter menu by pressing the down arrow key.
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CHAPTER 1. GENERAL DESCRIPTION [2] Head Cleaning [5] Print Mode Used to clean the cartridge heads. a. Print Quality • All [Default: Normal] All heads are cleaned. The print quality can be selected for the • Black type of data or paper. Only the black head is cleaned.
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CHAPTER 1. GENERAL DESCRIPTION [6] Media Setup [7] Auto Cut Used to change paper settings. a. Cut Type a. Roll/Cut Sheet [Default: Cut] [Default: Previous setting preserved] Select the type of cut for roll media after completion of printing. Select roll media or cut sheet. •...
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CHAPTER 1. GENERAL DESCRIPTION CAUTION • HP RTL In the draft mode, the ink may not Should only be used when printing dry, depending on the environment. raster data. After the raster data is Set the drying time as required. received and 1 band is analyzed, print- ing is started.
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CHAPTER 1. GENERAL DESCRIPTION [10] Line Type b. Modify Table The pen setup (pen table) stored in the a. Line Intersect printer can be changed. [Default: Overlay] • Pen Table (1 to 3) Color processing method for overlapping • Pen lines or figures can be set.
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CHAPTER 1. GENERAL DESCRIPTION Default values of pen table 1 to 3 at the time of Factory settings. No. of dots Approximate thickness (mm/inch) Pen No. Width(* Color Joint 0.07/0.003 0.14/0.005 0.21/0.008 0.28/0.011 0.35/0.014 0.49/0.019 0.63/0.025 0.78/0.031 0.92/0.036 1.06/0.042 1.20/0.047 1.34/0.052 1.48/0.058 1.62/0.063...
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CHAPTER 1. GENERAL DESCRIPTION • Media Save [11] Plot layout Automatic paper saving layout. Con- Printed data layout can be set. tinuous data is rotated clockwise so that paper feeding rate is minimized. The a. Auto Layout (roll media only) image data is printed to the left end of [Default: Off] the paper.
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CHAPTER 1. GENERAL DESCRIPTION A=5mm Nesting Best Media Save A=5mm A=5mm Figure 1-304 1–21...
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CHAPTER 1. GENERAL DESCRIPTION c. Rotation e. Layout Size (roll media only) [Default: 0°] [Default: ISO A] Data can be rotated on the paper when Paper size can be set. • ISO A printed. • ISO B • Auto (cut paper only) •...
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CHAPTER 1. GENERAL DESCRIPTION [12] Interface Setup [13] System Setup a. RS-232C Configuration of the system setting menu Used to set up the RS-232C interface. as follows: • Baud Rate [default: 9600] a. Language Sets the data transfer speed. 2400bps, 4800bps, 9600bps, [Default: previos setting preserved] 19200pbs, 38400bps Language to be indicated on the message...
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CHAPTER 1. GENERAL DESCRIPTION c. Feed Priority [14] Self-test Print A self-test pattern can be printed to check [Default: Print Length] the printer operation. Select between paper feeding accuracy • Demonstration over distance, or feeding with less band A built-in demonstration pattern is variation.
CHAPTER 1. GENERAL DESCRIPTION 4. Using the setup list The setup list is used when the printer is not working correctly, to determine whether the problem is attributable to the printer or the computer. The current menu settings, service mode values and a history of the last 4 errors which occurred are printed in the setup list, and can be filed for reference or faxed to the service depart- ment.
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CHAPTER 1. GENERAL DESCRIPTION Description Description User-defined size setting I/C: Image controller PCB version Length setting E/C: Engine controller PCB version Width setting I/Boot: Image controller PCB ROM Nesting timer setting version Line intersecton setting E/Boot: Engine controller PCB ROM Line shading setting version Baud rate setting...
CHAPTER 1. GENERAL DESCRIPTION 5. Dump mode This machine is provided with a dump test function to print the input data in hexadecimal and ASCII code as an online test. Select "Dump mode" on the system setting menu, and then set the printer online. When data is transferred from the computer in this state, the data is first printed normally.
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Relation between data size recognition and image processing The printer recognizes the size of the data received and lays it out as listed below. When printing using the Canon printer driver, PS (Plot Size) commands are always provided. Data size...
CHAPTER 1. GENERAL DESCRIPTION D. Basic Operation • When the paper inserted below the pinch roller unit is detected by the PE 1) Turn the power switch ON. sensor, the suction fan runs and the • The power lamp is lit and the initializa- paper is sucked to the platen.
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CHAPTER 1. GENERAL DESCRIPTION CAUTION CAUTION • If the roll media is forcibly aligned to After printing, take care not to touch the the paper matching line on the platen, ink with wet hands. skewed feeding may result. When the printer is not to be used for a •...
CHAPTER 1. GENERAL DESCRIPTION E. Paper Thickness Adjustment Lever When printing, depending on the print media used or its thickness, the paper may become wavy, causing it to rub the head. To prevent this, the distance between the head and platen can be adjusted in 3 stages Paper thickness using the paper thickness adjustment lever.
CHAPTER 1. GENERAL DESCRIPTION IV. CARTRIDGE REPLACEMENT The printer is provided with a mechanism Electrode to detect the ink remaining in the ink tank. When the tank becomes empty, the ink head Head state indication on the message display Figure 1-401 becomes “...
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CHAPTER 1. GENERAL DESCRIPTION 8) Pressing as shown in figure1-405, install 6) Remove the protection cap and protection seal. the BJ print head in the carriage. Protective cap Protective seal Figure 1-403 CAUTION Figure 1-405 Take care not to touch the BJ print head and carriage electrodes.
CHAPTER 1. GENERAL DESCRIPTION B. Replacing the Ink Tank 5) Twist the protective cap of the ink tank in the direction of the arrow mark and re- CAUTION move it. Replace the ink tank only at the cartridge replacement position. 1) Press the right and left keys in the offline or pause state to move the carriage to the cartridge replacement position.
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CHAPTER 1. GENERAL DESCRIPTION 6) Install the ink tank. Figure 1-411 CAUTION • Push the ink tank in until it clicks. 7) Close the front cover. • The carriage returns to the home position and head cleaning is carried out. 1–35...
CHAPTER 1. GENERAL DESCRIPTION CAUTION V. SIMM • When handling SIMMs, be careful REPLACEMENT to avoid static electricity discharge. • Before installing the SIMM, be A. About SIMM sure to turn off the printer power. The printer's memory can be increased. If •...
CHAPTER 1. GENERAL DESCRIPTION C. SIMM Removal 3) With the edge of the SIMM in the slot, roll the SIMM to the left until the hooks 1) Using the installation tools supplied with [3] at both ends of the slot click into the the printer, remove the 4 screws [1] and holes at both ends of the SIMM.
CHAPTER 1. GENERAL DESCRIPTION VI. CAUTIONS ON HANDLING When handling the printer, pay attention Electrodes to the following points. A. Cartridges Head 1. Cautions on handling the BJ print Figure 1-601 head 2. Cautions on handling ink tanks • Do not touch the head surface, or wipe with cloth or paper.
CHAPTER 1. GENERAL DESCRIPTION D. After Printing B. Paper Storage Environment • Since the ink may still be wet, do not • Store the paper in wrapping paper, in a touch it immediatly after printing. If the place free from high humidity and direct ink is not completely dry, ink may be sun light.
CHAPTER 1. GENERAL DESCRIPTION 1) Pinch roller/Paper feed roller VII. USER Load plain paper of the maximum width MAINTENANCE which can be printed by your printer (A1 size A. Head Cleaning or A0 size) and feed the paper manually several times to remove any ink. The printer has a head cleaning function to maintain image quality.
CHAPTER 1. GENERAL DESCRIPTION • Locations where there might be alcohol, VIII. INSTALLATION thinner, etc. nearby. ENVIRONMENT • Places where temperature or humidity Avoid the following when choosing a fluctuates often. location for the printer. • Air from an air conditioning system or •...
CHAPTER 1. GENERAL DESCRIPTION IX. PACKAGE CON- FIGURATION The package configuration of the printer when shipped from the factory is shown in the figure below. [1] Printer [2] Spindle/Roll media stopper [3] BJ print heads (black, cyan, magenta, yellow) [4] Accessory box Figure 1-901 1–42...
CHAPTER 1. GENERAL DESCRIPTION X. TRANSPORTING Clip Linear scale THE PRINTER Carriage belt When transporting the printer by truck etc., or moving the printer, follow the procedures below. CAUTION • Pack the printer in the original box. If the original box is not avaiable, pack the machine with sufficient shock absorbing material.
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CHAPTER 2 BASIC OPERATION I. BASIC OPERATION ......... 2-1 A. BJ Cartridge ..........2-39 A. Functional Configuration ......2-1 B. BJ Print head Drive ........2-43 B. Interface Input/Output ........2-2 IV. PURGE UNIT ..........2-46 C. Image Controller .......... 2-7 A.
CHAPTER 2. BASIC OPERATION I. Basic operation A. Functional Configuration The printer functional diagram is composed of 5 blocks; image processing/control system, carriage, BJ cartridge unit, purge unit and feeder unit. Image processing/control system Carriage External Engine Image interface controller controller BJ cartridge unit...
CHAPTER 2. BASIC OPERATION B. Interface Input/Output 1. Parallel interface The parallel interface conforms to IEEE1284-B and is applicable to the compatible mode and nibble mode (2-way interface). a. Input/output signal and pin assignment Signal Signal direction Signal Signal direction No.
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CHAPTER 2. BASIC OPERATION b. Compatible mode The compatible mode is applicable to cases as shown below. The compatible mode can be switched by changing the BUSY and ACKNLG timing in the Centro timing setting mode. • A - B(Defaut) [Ack-in-Busy] DATA1-8 STROBE BUSY...
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CHAPTER 2. BASIC OPERATION Data is transferred 8 bits at a time in the compatible mode. The data is transferred by hand- shaking the STROBE, ACKNLG, and BUSY signals. The computer sets 8 bits of data and outputs the STROBE signal to the printer. The printer receives the data with the STROBE signal and responds by setting the BUSY signal to "H".
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CHAPTER 2. BASIC OPERATION c. Nibble mode In the nibble mode, 8-bit data is transmitted from the printer to the computer in two pieces, 4 bits at a time. When data transmission is possible, the printer sets the DataAvail signal to "L" and the com- puter sets the HostBusy signal to "L"...
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CHAPTER 2. BASIC OPERATION 2. Serial interface The serial interface conforms to RS-232C. The printer side is set up as the DCE (Data Circuit Terminating Equipment) and the computer side as DTE (Data Terminal Equipment). The serial interface connector is a D-Sub 9-pin female. Table 2-102 shows the connector pin assignment and input/output signals.
CHAPTER 2. BASIC OPERATION C. Image Controller Figure 2-104 is a block diagram of the image controller. Image controller External parallel interface FIFO External serial DRAM (U622) SRAM interface Serial (U602,606, (U628) U611,U616) controller (U632) Y601 Timer 14.7MHz (U610) Communication Serial Gate array controller...
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CHAPTER 2. BASIC OPERATION [5] Timer (U610) Major functions of the ICs on the image Uses the by external clock of 14.7MHz controller are as follows. divided by 2. Functions as a baud rate clock for the [1] Serial controller (U632) Uses the external clock of 14.7MHz serial controllers.
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CHAPTER 2. BASIC OPERATION [8] FLASH ROM (XU601) [14]Timer (U609) 1 Mbyte boot ROM used to initialize the Uses the external clock of 14.7MHz CPU at power ON. Stores the divided by 2. downloaded program. Functions as a timer for : •...
CHAPTER 2. BASIC OPERATION D. Engine Controller Figure 2-105 is a block diagram of the engine controller. The printer is controlled mainly by the CPU (U221), which is run by the 16MHz external clock. Engine controller Y202 16MHz (U221) Command Reset IC communic- (U227)
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CHAPTER 2. BASIC OPERATION [7] Gate array (U208) Major functions of the ICs on the engine Provided with an 8-bit parallel input port controller are as follows. for the image data from the image controller. Processes the image data [1] CPU (U221) Connected to the DRAM (U216), before sending it to the gate array (U212).
CHAPTER 2. BASIC OPERATION E. Engine controller Input/Output 1. Engine controller input/output (1/3) Engine controller J211 Front cover When the front cover DOOR_IN switch is opened, "1". J212 +26V Wiper solenoid When "0", SOL_CONT* SL1 turns on. Pump position When the guide roller is sensor PURHP_IN at home position, "1".
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CHAPTER 2. BASIC OPERATION 2. Engine controller input/output (2/3) Engine controller +26V J203 See the section on the "Paper feed Motor" Paper feed motor (P. 2-58). J201 +26V See the section on the "Carriage Motor" Carriage motor (P. 2-24). J202 PG_OUT1 PG_OUT2 Rotation control signal...
CHAPTER 2. BASIC OPERATION F. Summary of Operation 1. When the power switch is turned ON AC connection Power switch (SW1) • CPU initialization Software initial check • ROM/RAM check • EEPROM check Error indication Normal? •E011xx •E012xx •E051xx BJ print head presence •...
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CHAPTER 2. BASIC OPERATION • Linear encoder check • Home position detection • Pump position detection Initial operation • Ink tank presence detection • Remaining ink detection • BJ print head reference position detection Error indication Normal? •E003xx •E005xx •E007xx •...
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CHAPTER 2. BASIC OPERATION 2. When media is loaded Set media Media presence detection Message indication Present? Set media. Suction fan (FM1) • Always detect while the fan is rotating. Cooling fan (FM2) • Rotates for 60 sec. after detection of media. Rotation Error indication Normal?
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CHAPTER 2. BASIC OPERATION 3. Printing Data reception Check communication condition Error indication Normal? •E052xx •E053xx Front cover open/close detection Message indication Closed? Close the front cover. Media presence detection Present? Message indication Set media. Load the media • See page 2-30 for details. Error indication Normal? •E001xx...
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CHAPTER 2. BASIC OPERATION Checking the time having been left Less than 72 hours from the Purge action • See page 2-48, 49, 50 for details. previous purging? Error indication Normal? •E005xx Suction fan (FM1) • Always detected when rotating Cooling fan (FM2) Rotation Normal?
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CHAPTER 2. BASIC OPERATION Printing started • Always detected while printing Check print head Normal? Error indication •E004xx •W004xx End of printing Cutting operation • See page 2-38 for details. Cut sheet media? Error indication Normal? •E008xx Feed the media to the printing end position. Move the carriage to the home position Suction fan (FM1) and cooling fan (FM2) stopped.
CHAPTER 2. BASIC OPERATION II. CARRIAGE UNIT A. Outline Figure 2-201 shows the composition of the carriage and its driving components. The driving force from the carriage motor (M2) is transmitted to the carriage through the carriage belt , causing the carriage to move back and forth over the paper. The distance it moves is controlled by counting the number of pulses of the signal transmitted from the engine control- ler to the carriage motor.
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CHAPTER 2. BASIC OPERATION Name Function Linear scale Reference of printing position and print timing. Carriage motor (M2) Moves the carriage back and forth. Home position sensor (PS2) * Detects the home position. Remaining ink sensor (PS3) * Detects the ink level remaining in the ink tank. Ink tank sensor (PS4) * Detects presence of ink tank.
CHAPTER 2. BASIC OPERATION B. Carriage Motor Control 1. Outline The carriage motor (M2) of this machine is a 2-phase stepping motor. It controls the back and forth movement of the carriage. The carriage motor (M2) is controlled by the engine controller, the main functions of which are shown below.
CHAPTER 2. BASIC OPERATION b. Direction control The output timing of the motor drive pulses (YMA, YMAN, YMB, YMBN) from the carriage motor driver is changed by the carriage motor driver control signals (MTP12-15) output from the CPU, to control the direction of the carriage motor (M2). c.
CHAPTER 2. BASIC OPERATION C. Linear Encoder 1. Outline A linear encoder is installed on the printer to allow checking the carriage operation and ad- justing the dot placement position on the paper. When the carriage is returning, after the home position sensor (PS2) turns ON and the carriage has travelled an additional 12mm, that position is considered the home position.
CHAPTER 2. BASIC OPERATION Carriage controller Engine controller Linear sensor Light sensing unit Light emitting unit J502 Photo Comparator J214 diode Gate array Lens Linear scale Position Position When carriage is advancing When carriage is retracting Figure 2-204 4. Control b.
CHAPTER 2. BASIC OPERATION D. Media Sensor 1. Outline The printer is provided with a media sensor to detect the width and skew of the paper, the internal temperature, and to enable automatic head adjustment. The media sensor is located on the carriage unit and composed of a red and a blue LED and one reflective photo sensor.
CHAPTER 2. BASIC OPERATION 3. Skew detection By comparing the detected right edge position of the paper after a certain volume of paper has been fed, with the position of the right edge detected during the paper width detection operation, paper skew can be detected.
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CHAPTER 2. BASIC OPERATION If the skew value is more than the specified amount, the paper is determined to be skewed. The skew value here is the divergence between the paper's right edge at the time of paper width detection and the right edge at the time of skew detection. When paper skew is detected, the printer returns the carriage to the home position and stops operation.
CHAPTER 2. BASIC OPERATION 4. Light compensation The media sensor brightness is automatically compensated for at the time of paper width detection and automatic print position adjustment. The carriage is advanced for approx. 200mm, the light quantity on the paper is compensated for in the order of blue and red, and then the light quantity on the platen is compensated for in the order of blue and red.
CHAPTER 2. BASIC OPERATION 6. Automatic print position adjustment When cartridges are installed on the carriage, the nozzle positions of the cartridges may be displaced, causing displacement of dots of different colors on the paper. The automatic print position adjustment compensates for this displacement. The head is automatically adjusted vertically (paper feeding) and horizontally (carriage move- ment) as follows.
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CHAPTER 2. BASIC OPERATION CAUTION Whenever a BJ print head is removed and reinstalled, or the head-to-paper gap is adjusted, the automatic print position adjustment must be conducted. Vertical adjustment Backforwad printing : Black Forward printing : Cyan : Magenta : Yellow Forward Forward...
CHAPTER 2. BASIC OPERATION E. Detection of the Ink Tank 1. Outline The printer has an ink tank detection function. When an ink tank is not installed, an error message appears on the message display and the ink and head condition is indicated by a blink- ing hyphen ("–").
CHAPTER 2. BASIC OPERATION F. Remaining Ink Detection 1. Outline The printer has a remaining ink detection function. The remaining ink is detected at 2 levels. When the ink in the ink tank chamber is used up, the ink condition on the message display is shown in lower case letters.
CHAPTER 2. BASIC OPERATION 2. Method of detecting remaining ink The ink remaining in the ink chamber is detected by the remaining ink sensor (PS3) installed on the purge unit, in the order of yellow, magenta, cyan, and black when the carriage returns to the home position.
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CHAPTER 2. BASIC OPERATION Ink tank detection Is there an Error Message indication ink tank? Remaining ink detection Ink tank's ink chamber empty? • State indication is displayed in lower-case letters. Dot counting started Dot count (gate array) Counted dot values added (CPU) •...
CHAPTER 2. BASIC OPERATION G. Cutter Unit 2. Cutting operation When roll media is cut, the carriage 1. Outline advances to the left side of the platen and the The Cutter unit is installed on the carriage. cutter hook is released by the cutter guide at As the carriage moves, the cutter lowers, the left edge of the guide rail.
CHAPTER 2. BASIC OPERATION III. BJ CARTRIDGE A. BJ Cartridge 1. Overview Four colors of BJ cartridges are used in this printer: black (Bk), cyan (C), magenta (M), and yellow (Y). The BJ print head and ink tank are separable for each color. 2.
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CHAPTER 2. BASIC OPERATION Name Function Tank packing Seals between the ink tank and ink pipe to prevent leakage. Ink filter Filters the ink to prevent foreign matter from entering the ink passage. Cartridge body A case accommodating and connecting the head unit and ink tank.
CHAPTER 2. BASIC OPERATION 3. BJ print head Ink from the ink sponge is filtered through the mesh-like ink filter and fed to the head unit through the ink pipe of the cartridge body. The ink is then sent to the nozzle through the joint pipe. When head drive current flows to the heater plate in the nozzle, the ink boils in multiple bubbles, which soon become one bubble.
CHAPTER 2. BASIC OPERATION 4. Nozzle arrangement 160 nozzles are arranged vertically in one line at a spacing of 1/360 in. Nozzle arrangement on the BJ print head is shown below. Nozzle 1 Nozzle 160 Figure 2-303 In the monochrome mode, 1 band is printed at a maximum width of 160 nozzles (approxi- mately 11.3mm) .
CHAPTER 2. BASIC OPERATION B. BJ Print head Drive 1. Construction of electric head unit The figure below is a block diagram of the BJ print head drive control circuit. Rank resistance RANK GNDH SUBH Sub-heater X2 EVEN Heater 1A ODATA Heater 1B Heater 2A...
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CHAPTER 2. BASIC OPERATION • 160-bit shift register • Sub-heater The serial ODATA signal from the engine Head temperature adjusting heater for controller is converted to parallel image data stable ink efection. using the DCLK signal timing. The engine controller drives the sub- heater according to the temperature detected •...
CHAPTER 2. BASIC OPERATION 2. Print signal The BJ print head is controlled as follows. Approx. 70µs (14.4kHz)/ Approx. 130µs (7.7kHz) LTCLK ODATA Data transfer to shift register DCLK EVEN 1(0) 0(1) 1(0) 0(1) 1(0) 0(1) 1(0) 0(1) BENB 0 Drive of head divided into 8 1(0) 0(1)
CHAPTER 2. BASIC OPERATION IV. PURGE UNIT A. Outline The purge unit provides both a capping function to prevent the head from drying out, and to prevent dust and other foreign substances from attaching, as well as a head cleaning function to maintain the print head's condition.
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CHAPTER 2. BASIC OPERATION The purge unit is composed of the units below. Name Function Wiper Lifts up when the carriage returns and wipes ink off the head surfaces (C, M, Y, Bk). Remaining ink sensor (PS3) Detects ink remaining in the ink tank. Ink tank sensor (PS4) Detects presence of ink tank.
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CHAPTER 2. BASIC OPERATION Purge operation is carried out in the following steps. b. Purge sequence when user cleaning a. Purge sequence when powered is executed (Ink consumed: approx. 0.16g) (Ink consumed: approx. 0.5g) Power switch (SW1) User cleaning Suction Is carriage at home position? Uncapping...
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CHAPTER 2. BASIC OPERATION c. Purge sequence when printing (Ink consumed: approx. 0.16g) Data reception 72 hours elapsed after the last discharge Printing started Wiping Suction Wiping Uncapping Maintenance jet Maintenance jet Suction Capping Printing ended Stand by for 2 sec. Wiping Wipe twice Maintenance jet...
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CHAPTER 2. BASIC OPERATION d. Purge sequence at the time of head re- placement/ink tank replacement (Ink consumed : approx, 0.65g) Replace the head or ink tank Suction of appropriate head Wiping Maintenance jet Uncapping Suction Suction Capping Capping Stand-by Stand by for about 2 sec.
CHAPTER 2. BASIC OPERATION B. Capping Function 1. Outline The carriage of this machine stands by at the home position. Duming this time, the caps of the purge unit are pressed against the BJ print heads to prevent the nozzles from drying out and to keep out dust.
CHAPTER 2. BASIC OPERATION C. Head Cleaning b. Operation 1. Outline 1) Before starting the printing process, the Head cleaning consists of wiping ink and carriage is moved to the specified position dust from the head face plate, maintenance on the left side of the wiper. The wiper jet to adjust the head conditions, and sucking solenoid (SL1) is turned ON and the wiper up the ink and air bubbles in the nozzles.
CHAPTER 2. BASIC OPERATION 3) The carriage continues moving in c. Timing backward direction, wiping the Y head, M Wiping is conducted under the following head, C head and Bk head. conditions. [1] Before printing 4) After wiping the Bk head, the wiper Before the printing process is started, the solenoid is turned OFF and the wiper is wiping is carried out once.
CHAPTER 2. BASIC OPERATION b. Timing 4. Suction a. Outline Ink is ejected into the caps in the order of the heads (Bk, C, M and Y) under the follow- The cap is pressed against the head and ing conditions. the thickened ink and air bubbles in the [1] When printing is to be started nozzles are removed by suction.
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CHAPTER 2. BASIC OPERATION After the guide roller has rotated 160 de- c. Timing grees, it is stopped for about 2 seconds. The [1] User cleaning 1 waste ink carriage tube which was squeezed The user can perform the cleaning recovers during this period, and suction is operation for all heads.
CHAPTER 2. BASIC OPERATION D. Waste Ink Absorber Unit [6] Suction by timer If 72 hours elapse with no suction 1. Waste ink absorber unit operations, head cleaning will be car- Waste ink is removed from the head ried out in the next standby mode. nozzles by the suction operation, sent to the •...
CHAPTER 2. BASIC OPERATION V. FEEDER UNIT A. Outline The paper feed motor (M1) drives the paper feed roller to feed the paper. The existence of paper is detected by the PE sensor (PS6). A diagram of the feeder unit is shown below. [1] Paper feed roller [2] Pinch roller unit [3] PE sensor (PS6)
CHAPTER 2. BASIC OPERATION B. Paper Feed Motor Control 1. Outline The paper feed motor (M1) is a 2-phase stepping motor. It controls the rotation of the paper feed roller. The paper feed motor is controlled by the engine controller. Its major functions are shown below.
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CHAPTER 2. BASIC OPERATION b. Control of rotation direction The output timing of the motor drive pulses (XMA, XMAN, XMB, XMBN) from the paper feed motor driver is controlled by the paper feed motor driver control signals (MTP 4 to 7) output by the CPU to the paper feed motor driver, in order to control the rotation direction of the paper feed motor (M1).
CHAPTER 2. BASIC OPERATION C. Feeding Operation 3) The carriage is returned to the home position and the paper width is detected. 1. Outline 4) The carriage is advanced to a position Paper feeding is classified into three about 200mm to the left of the home modes as follows : position, the paper is fed backward, and •...
CHAPTER 2. BASIC OPERATION b. Roll media REFERENCE 1) When the paper is set and the media • Paper length detection is not con- trailing edge sensor detects the paper, the ducted for roll media. suction fan operates to suck the paper on •...
CHAPTER 2. BASIC OPERATION 4. Feeding operation For cut sheets, the paper is fed until the paper rear edge reaches a position 3mm behind the pinch roller, after printing is completed. When roll media is cut, the paper is fed to the position to be cut.
CHAPTER 2. BASIC OPERATION VI. FAN The two fans shown in the figure below function as shown in Table 2-601. Figure 2-601 Symbol Name Fan direction Function Suction fan Suction Pulls the paper onto the platen to prevent it from floating up. Cooling fan Suction Discharges the heat generated by the DC power...
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CHAPTER 2. BASIC OPERATION • Suction fan (FM1) When the PE sensor detects the paper, the fan drive signal (FAN_CONT) changes to "1" and the suction fan (FM1) runs. The suction fan continues to run constantly while the paper is being transported during the printing operation, to prevent the paper from floating away from the platen.
CHAPTER 2. BASIC OPERATION VII. POWER SUPPLY A. Power Supply Outline Figure 2-701 is a block diagram which shows the power supply system for the printer. Power switch AC100 to 240 V Switch +26V Paper Feed motor +26V Carriage motor +26V Purge motor +26V...
CHAPTER 2. BASIC OPERATION B. Power Circuit C. Power Circuit Protection 1. AC power supply On the DC power supply, fuse F1 is By plugging in the power cord and turning provided on the primary side as a safety measure. On the secondary side, overcurrent the power switch (SW1) ON, AC power is protection and overvoltage protection circuits supplied to the DC power supply PCB.
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CHAPTER 3 MECHANICAL SYSTEM DISASSEMBLY AND ASSEMBLY ......3-1 B. Operation Panel ........... 3-9 1. List of Main Parts ......... 3-2 C. Fan ............. 3-10 2. Outline of disassembly and assembly of II. CARRIAGE UNIT ..........3-13 main parts ............ 3-3 III.
CHAPTER 3. MECHANICAL SYSTEM DISASSEMBLY AND ASSEMBLY The disassembly and assembly list for the main parts and the related outlines are shown here. The outlines give the procedures for removing the main parts from the main unit. However, the directions for removing the connectors and the disassembly procedures for other parts are omitted.
CHAPTER 3. MECHANICAL SYSTEM 1. List of Main Parts Disassembly and assembly of : • operation panel • right cover • lower cover • upper cover • front cover • front cover switch • purge unit • waste-ink absorber unit •...
CHAPTER 3. MECHANICAL SYSTEM 2. Outline of disassembly and assembly of main parts Main Unit Operation panel Cover plate (4) Left cover (3) Right cover (3) Image controller (12) Engine controller (5) Right cover stay plate (4) Mount plate (5) Purge unit (3) Cooling fan (2) Front cover switch...
CHAPTER 3. MECHANICAL SYSTEM PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY 1. Do not loosen or remove screws which are not included in the disassembling procedures in this manual. In particular, never disassemble the points fixed with red screws as shown below. Readjustment is prohibited since they have been adjusted to the optimum position at the factory.
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CHAPTER 3. MECHANICAL SYSTEM 4. When lifting this machine, be sure that 2 people hold it as shown in Figure 3-003. Electrode Head Figure 3-002 Figure 3-003 5. Before carrying out disassembly or reassembly, be sure to turn OFF the power switch and disconnect the power cord and interface cable.
CHAPTER 3. MECHANICAL SYSTEM 1. Removing the right cover I. EXTERNALS 1) Remove the operation panel (See page 3- A. External Cover 2) Remove 3 screws [1] and take off the right cover [2]. Figure 3-101 Figure 3-102 [1] Front cover 2.
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CHAPTER 3. MECHANICAL SYSTEM 3) Remove 2 screws [3]. 3. Removing the lower cover 1) Remove the right cover and left cover (See page 3-7). 2) Open the front cover and lower the paper release lever. 3) Remove 6 set screws [1] and take off the lower cover [2].
CHAPTER 3. MECHANICAL SYSTEM B. Operation Panel 4. Removing the front cover switch 1) Remove the right cover (See page 3-7). 1. Removing the operation panel 2) Open the front cover. 1) Open the front cover, and holding the 3) Remove 4 screws [1] and take off the green part, move the carriage to the right cover stay plate [2].
CHAPTER 3. MECHANICAL SYSTEM C. Fan 3) Remove 3 connectors [3] (CN701, CN702, CN704) from the operation panel 1. Removing the cooling fan and take off the operation panel [2]. 1) Remove the image controller (See page 3- 32). 2) Remove the engine controller (See page 3-33).
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CHAPTER 3. MECHANICAL SYSTEM 6) Remove 5 set screws [3] and take off the 8) Remove 2 screws [6] and take off the mount plate [4]. cooling fan [7]. Figure 3-114 Figure 3-112 CAUTION 7) Disconnect the connector [5] • To prevent the heads from drying out, return the carriage promptly to the capping position upon completion of the work and close the front cover.
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CHAPTER 3. MECHANICAL SYSTEM 2. Removing the suction fan 1) Remove the PE sensor (See page 3-27). 2) Remove 2 screws [1] and remove the suction fan cover [2]. Figure 3-115 3) Disconnect the connector [3] and remove the suction fan [4]. Figure 3-116 3–12...
CHAPTER 3. MECHANICAL SYSTEM 3) Remove the front cover and upper cover II. CARRIAGE UNIT (See pate 3-7). 4) Holding the green part, move the carriage CAUTION to the center, and remove the BJ Before disassembling or reassembling cartridges. the carriage unit, remove the BJ car- 5) Disconnect 2 connectors [3] (J501, J502) tridge and cutter unit.
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CHAPTER 3. MECHANICAL SYSTEM 6) Remove the idler roller holder tension 8) Remove 7 screws [9] and take off the left spring [4] and remove the idler roller [5] frame plate [10]. and idler roller holder [6]. [10] Figure 3-205 9) Remove the carriage unit [11] from the Figure 3-203 left side of the printer.
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CHAPTER 3. MECHANICAL SYSTEM CAUTION 2. Removing the carriage belt When installing the carriage unit, check 1) Remove the carriage unit (See page 3-13). that the linear scale passes through the 2) Remove 2 belt stoppers [1] at the back linear scale sensor.
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CHAPTER 3. MECHANICAL SYSTEM 3. Installing the carriage belt 1) Matching the belt stopper [1] and carriage belt [2], insert the belt stopper into the CAUTION hole at the back side of the carriage. Install the carriage belt so that the belt 2) Pull the carriage belt in the direction stopper and the carriage belt joint shown in the figure below and check that...
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CHAPTER 3. MECHANICAL SYSTEM 4. Removing the linear scale 3) Unlatch the hook [2] and remove the 1) Remove the carriage unit (See page 3-13). linear scale [3]. 2) Remove the tension spring [1] of the linear scale. Figure 3-211 Figure 3-210 CAUTION When removing the linear scale, be...
CHAPTER 3. MECHANICAL SYSTEM 5. Replacing the flexible cable 6) Holding the green part, move the carriage 1) Remove the image controller (See page 3- to the center and remove 2 connectors [3] 32). (J501, J502) of the flexible cable on the carriage controller.
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CHAPTER 3. MECHANICAL SYSTEM 7) Peel off the fixing sheet [4] of the ferrite 9) Remove 5 screws [9] from the noise core and remove the ferrite core [5]. protection sheet [8]. Figure 3-214 Figure 3-216 10) Peel off the flexible cable [10] from the 8) Remove 4 screws [6] and take off the flexible cable cover [7].
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CHAPTER 3. MECHANICAL SYSTEM 11) Fold the new flexible cable as shown in the figure below, and attach double-faced tape to positions [A]. Figure 3-218 12) Stick double-faced tape over the flexible guide and attach the new flexible cable, aligning the mark [B] with the flexible guide edge [12].
CHAPTER 3. MECHANICAL SYSTEM 4) Cap the pipe [2] and the end of the waste III. PURGE UNIT ink tube [2] using the waste ink tube caps [3]. CAUTION • Do not touch the wiper or caps. • Since waste ink accumulates on the bottom of the purge unit, hold the sides of the purge unit when removing •...
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CHAPTER 3. MECHANICAL SYSTEM 5) Disconnect 4 connectors [4] and remove 6) Remove 3 screws [5] and take off the the wiring harness from the wiring harness purge unit [6]. guide. Figure 3-304 Figure 3-303 3–22...
CHAPTER 3. MECHANICAL SYSTEM 2. Removing the waste ink absorber 5) Remove 2 screws [4]. unit 1) Remove the right cover (See page 3-7). 2) Remove the lower cover (See page 3-8). 3) Remove the tube clamp [1] and discon- nect the waste ink tube from the pipe [2].
CHAPTER 3. MECHANICAL SYSTEM CAUTION IV. FEEDER UNIT • When installing the pinch roller shaft, be careful about the position. 1. Removing the pinch roller unit • Install the pinch roller unit with the 1) Remove the lower cover (See page 3-8).
CHAPTER 3. MECHANICAL SYSTEM 2. Removing the platen 1) Remove the pinch roller unit (See page 3- 24). 2) Remove the front cover and upper cover (See page 3-7). 3) Remove 2 screw [1] and remove the left stay [2]. Figure 3-403 Figure 3-405 4) Remove screws [3] (A0 size model: 16,...
CHAPTER 3. MECHANICAL SYSTEM < A0 size model > 3. Installing the platen Top view of platen 1) Tighten screw [11] ([7] on the A1 size model) temporarily. 2) Adjust the platen position so that the screw hole [1] is aligned with the platen [2] [16] [14] [12]...
CHAPTER 3. MECHANICAL SYSTEM 5. Removing the PE sensor 4. Removing the paper feed roller 1) Remove the platen (See page 3-25). 1) Remove the platen (See page 3-25). 2) Remove the screw [1] and disconnect the 2) Remove the lower cover (See page 3-8).
CHAPTER 3. MECHANICAL SYSTEM V. DRIVING UNIT 3) Remove the PCB box (See page 3-34). 4) Remove 4 screws [4] and remove the carriage motor [5]. 1. Removing the carriage motor 1) Remove the right cover and left cover (See page 3-7).
CHAPTER 3. MECHANICAL SYSTEM 2. Removing the paper feed motor 5) Remove 3 screws [2] and remove the 1) Remove the purge unit (See page 3-21). motor holder [3] from the bearing. 2) Remove the platen (See page 3-25). 6) Disconnect the connector [4], rotate the 3) Remove the lower cover (See page 3-8).
CHAPTER 3. MECHANICAL SYSTEM 3. Installing the paper feed motor 4. Fastening the paper feed roller set screws 1) Install the paper feed motor on the motor a. When the marks are aligned between side board, pushing down the front of the paper feed motor in the direction shown in the set screw positions Figure 3-506, and tighten 3 screws [1].
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CHAPTER 3. MECHANICAL SYSTEM b. When the marks coincide with the set screw position 1) Match the marks on the paper feed motor side and paper feed roller side. 2) Tighten set screw [1] at the mark slightly. 3) Tighten set screws [2] and [3] slightly. 4) Loosen set screw [1].
CHAPTER 3. MECHANICAL SYSTEM 2) Remove the connector [3] (CN602) and VI. ELECTRICAL PART remove 12 screws [4]. 3) Remove the image controller [5]. 1. Removing the image controller CAUTION When replacing the image controller, see "Chapter 5 II. C. 3. Replacing the image controller and engine controller"...
CHAPTER 3. MECHANICAL SYSTEM 3. Removing the PCB box 5) Remove 7 screws [5]. 1) Remove the right cover (See page 3-7). 2) Remove the engine controller (See page 3-33). 3) Remove the screw [1] and remove the noise protection sheet [2]. Figure 3-606 6) Remove the harness [6] and remove the PCB box [7].
CHAPTER 3. MECHANICAL SYSTEM 4. Removing the power switch 5. Removing the DC power supply 1) Remove the PCB box (See page 3-34). 1) Remove the power switch. 2) Remove the screw with a crown washer 2) Disconnect the connector and the DC [1] and the 2 screws [2].
CHAPTER 4 MAINTENANCE AND SERVICING I. PERIODIC PARTS REPLACEMENT ....4-1 IV. MAINTENANCE AND INSPECTION ....4-2 II. STANDARD SERVICE LIFE OF A. Cleaning/Inspection Points ......4-2 CONSUMABLES ..........4-1 B. Lubrication Points ........4-3 III. PERIODIC SERVICE ........4-1...
CHAPTER 4. MAINTENANCE AND SERVICING I. Periodic parts replacement The printer contains no parts which require periodic replacement. II. Standard service life of consumables The printer contains no parts which require replacement. III. Periodic service The printer contains no parts which require periodic service. 4–1...
CHAPTER 4. MAINTENANCE AND SERVICING IV. MAINTENANCE AND INSPECTION A. Cleaning/Inspection Points Figure 4-401 Parts Cleaning Tool Service/caution Pinch roller Plain paper (A1 or A0) Feed the paper until the stains are removed from it. Platen Moistened cloth Clean Check or replace Waste ink absorber unit —...
CHAPTER 4. MAINTENANCE AND SERVICING B. Lubrication Points Figure 4-402 Position Lubricant Remarks Paper feed motor gear Permalub G2 Apply approx. 500mg of grease uniformaly to the tooth surfaces. Grit roller bearing Permalub G2 Apply approx. 40mg of grease to each bearing surface. Table 4-402 4–3...
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CHAPTER 5 TROUBLESHOOTING I. SERVICE MODE ..........5-1 IV. CORRECTION OF OPERATION DEFECTS .. 5-32 A. Outline ............5-1 V. CORRECTION OF IMAGE DEFECTS .... 5-43 B. Service Mode Operation ......5-1 A. Initial Inspection ......... 5-43 C. Service Mode Map ........5-2 B.
CHAPTER 5. TROUBLESHOOTING B. Service Mode Operation I. SERVICE MODE 1. How to enter the service mode A. Outline 1) While pressing the up and down arrow For the purpose of adjustment in the field, keys, turn ON the power switch. 5 service modes are provided as shown 2) Confirm the "Initializing"...
CHAPTER 5. TROUBLESHOOTING C. Service Mode Map The hierarchy of service mode items is as shown below. Refer to "D. Service Mode" for details on each item. The service mode items are displayed in English regardless of which language is selected. Main Menu ∆...
CHAPTER 5. TROUBLESHOOTING D. Service Mode 1. Control display mode • Display items: Left or right arrow key • Select an item: Down arrow key • Execute an item: Enter key • Reset the mode: Up arrow key D I S P L A Y ∆...
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CHAPTER 5. TROUBLESHOOTING < "System" details > Name of item Contents Remarks TYPE A0/A1 size model Indicates the engine controller SW201 setting. Units: °C Internal temperature Units: °C H-TMP K1 Compensated temperature of the head temperature sensor (Bk) (Proper value: 0±80°C) H-TMP K2 Unused H-TMP C...
CHAPTER 5. TROUBLESHOOTING 2. Adjusting mode • Display items and change values: Left or right arrow key • Select an item: Down arrow key • Registration of values and execution of actions: Enter key • Reset mode or item: Up arrow key A D J U S T ∆...
CHAPTER 5. TROUBLESHOOTING 3. Operation/inspection mode • Display an item: Left or right arrow key • Execute an item: Enter key • Reset mode or item: Up arrow key F U N C T I O N P A N E L L E D / L C D Name of item Contents...
CHAPTER 5. TROUBLESHOOTING 4. Counter mode • Indication of items: Left or right arrow key • Reset the mode: Up arrow key C O U N T E R W - I N K : 0 0 0 0 0 0 Name of item Contents Remarks...
CHAPTER 5. TROUBLESHOOTING 5. Initialization mode • Display items: Left or right arrow key • Initialization of counter: Down arrow key + Enter key • Reset the mode: Up arrow key I N I T I A L I Z E W - I N K : 0 0 0 0 0 0 Name of item...
CHAPTER 5. TROUBLESHOOTING II. ADJUSTMENTS AND SETTINGS A. About Adjustments and Settings The message display language (Factory setting: English) can be changed using the operation panel keys, corresponding to each sales territory. There are no parts that require mechanical adjustment when assembling them as described in the service manual.
CHAPTER 5. TROUBLESHOOTING C. Adjustment and Setting Procedures Some of the adjustments and settings must be carried out after the machine has been booted up in the specific methods described below. Mode Operating procedure Service mode Turn on the power while pressing both the Up arrow and Down arrow keys.
CHAPTER 5. TROUBLESHOOTING 1. Automatic printing position adjustment and automatic band adjustment (User- settable) Select and execute the "Auto Adjust" or "Auto Band-adj." from the "Adjustment" menu within the Main menu. (See P. 1-15.) 2. Waste ink counter reset (for exclusive use in service mode) Select and execute "W-INK"...
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CHAPTER 5. TROUBLESHOOTING 3.3 Replacing the engine controller Before replacing the engine controller, the data such as the waste ink amount, carriage driving time, and paper feed accuracy compensation value stored in the EEPROM of the engine controller must be copied into the EEPROM of the image controller, and then be automatically updated through internal communication.
CHAPTER 5. TROUBLESHOOTING 4. Paper feed accuracy compensation 5) Measure the length of the printed scale value adjustment adjustment pattern in the paper feed direction. Media feed accuracy can be adjusted as • Specified value: 380±0.5mm follows. 1) Set up the service mode and select the "ADJUST"...
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CHAPTER 5. TROUBLESHOOTING CAUTION When changing the paper feed accuracy compensation value ("X-SCALE" value), be sure to write the new value in the "H/W X" item on the label attached to the left frame (under the left cover). At the factory, each printer is adjusted and the value is written on this label. Figure 5-202 shows the label on the left panel of the printer.
CHAPTER 5. TROUBLESHOOTING 4) Press the ENTER key to confirm the . Changing the parallel interface displayed mode. communication mode • When a "*" mark is displayed after the With some types of computers which com- name of communication mode, execute municate in the compatible mode, the timing of the initial operation and return to the the Busy and Ack signals may need to be...
CHAPTER 5. TROUBLESHOOTING 6. Image controller/engine controller 7) Type the following from the command upgrade procedure prompt (when the computer output port Upgrade the image controller and/or LPT1 has been selected). engine controller by downloading the COPY/B file name LPT1: firmware following the procedure below.
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CHAPTER 5. TROUBLESHOOTING • Upon completion of data reception, one of the following messages is displayed. Download Mode a: For both the image controller and Erasing.. engine controller : Download Mode I:XX.XX E:XX.XX Writing.. [Press Online Ke [Press Online Key to Write File on Flash] Download Mode b: For only the image controller : Verifying..
CHAPTER 5. TROUBLESHOOTING B. List of Error and Warning III. ERROR/WARNING Codes CODES A. Outline • Error/warning code configuration This machine has a self-diagnostic Numeric Alphabetic function by means of the engine controller and image controller. Diagnosis is carried digit 2 digit 1 digit digit 4...
CHAPTER 5. TROUBLESHOOTING • Errors and warning codes The errors and warning codes are shown below. Detailed information on the codes (meaning, detecting timing, major causes) are described in the following pages. Codes * Diagnostic part 001xx Media/feeding system 003xx Drive system 004xx BJ Print head system...
CHAPTER 5. TROUBLESHOOTING 1. 001xx (Media/feeding system) Refer to "CORRECTION OF OPERATION DEFECTS" (P. 5-32) for remedies. Code Meaning Detection timing Major cause (W00111) • PE sensor (PS6) detected • While loading (roll media • No roll media the roll media trailing mode) •...
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CHAPTER 5. TROUBLESHOOTING Code Meaning Detection timing Major cause (W00161) • Media sensor (PS9) • When skewed feeding is • Improper loading of media detected skewed feed of detected. • Defective media roll media exceeding the • Defective media sensor (PS9) specified value.
CHAPTER 5. TROUBLESHOOTING 2. 003xx (Drive system) Code Meaning Detection timing Major cause E00311 • Carriage does not oper- • During initial operation • Improper installation of carriage ate. • During purging operation belt • When the carriage is • Defective carriage home position moving backward for a sensor (PS2) reason other than above...
CHAPTER 5. TROUBLESHOOTING 3. 004xx (BJ Print head system) Code * Meaning Detection timing Major cause (E00401) * • No BJ print head • During initial operation • There is no BJ print head. • Improper installation of BJ print (W00402) * head •...
CHAPTER 5. TROUBLESHOOTING 4. 005xx (Ink tank system) Code * Meaning Detection timing Major cause (E00501) • The ink tank sensor (PS4) • At the time of the home • No ink tank cannot detect the ink tank position detection •...
CHAPTER 5. TROUBLESHOOTING 6. 008xx (Cutter system) Code Meaning Detection timing Major cause E00801 • Media could not be cut. • While detecting the • No cutter media leading edge after • Improper installation of cutter being cut. • Defective cutter •...
CHAPTER 5. TROUBLESHOOTING 11. 051xx (Image controller) Code Meaning Detection timing Major cause E05102 • No EEPROM • Constant • Defective DRAM • Error writing to • Defective added memory EEPROM • Defective image controller E05105 • No on board DRAM •...
CHAPTER 5. TROUBLESHOOTING 14. 060xx (Internal data processing system) Code Meaning Detection timing Major cause W06011 • Data missing due to • While data is being • Insufficient memory insufficient memory analyzed • Defective setting of parallel interface communication mode W06012 •...
CHAPTER 5. TROUBLESHOOTING 15. 061xx (GL command system) Code Meaning Detection timing Major cause W06100 • Unsupported command • While data is being • Incorrect data from computer analyzed • Defective image controller W06111 • Incorrect number of parameters W06120 •...
CHAPTER 5. TROUBLESHOOTING 18. 064xx (ESC command system) Code Meaning Detection timing Major cause W06400 • Unsupported command • While data is being • Improper communication data analyzed. from computer W06411 Incorrect number of • Defective image controller parameters W06420 •...
CHAPTER 5. TROUBLESHOOTING 21. 097xx (Direct error code from the image controller) Code Meaning Detection timing Major cause E097xx* • Undefined error on image • Constant • Defective image controller controller * The last 2 digits of the code are hexadecimal. 22.
CHAPTER 5. TROUBLESHOOTING IV. CORRECTION OF OPERATION DEFECTS 1. 001xx (Media/feeding system) Problem/Unit Step Check item Result Remedy Media jam Has media jam occurred? Remove media jam. Incorrect media Is the media loaded properly? Instruct the user to load the media setting correctly according to the specified media loading procedure.
CHAPTER 5. TROUBLESHOOTING 2. 003xx (Drive system) Problem/Unit Step Check item Result Remedy Foreign substance on Can the carriage be moved Check for foreign substance, or rail smoothly by hand? some part in contact with the rail surface. Carriage belt Is the carriage belt correctly installed? Reinstall correctly.
CHAPTER 5. TROUBLESHOOTING 3. 004xx (BJ Print head system) Problem/Unit Step Check item Result Remedy BJ print head instal- Is the BJ print head properly Install the BJ print head correctly. lation problem installed? BJ print head Is the trouble corrected by replac- Completed.
CHAPTER 5. TROUBLESHOOTING 5. 007xx (Purge unit) a. E00701 Problem/Unit Step Check item Result Remedy Pump home position Does the purge motor (M3) rotate Check the wiring from the sensor to sensor (PS1) when the power switch is turned the engine controller and the wiring from the purge motor to the engine controller.
CHAPTER 5. TROUBLESHOOTING 6. 008xx (Cutter system) a. E00801 Problem/Unit Step Check item Result Remedy Is the code "001xx (Media/feeder Refer to step 7 onwards of Table 1. system)" displayed when new 001xx (Media/feeder system) media is loaded? (P.5-32). Foreign substance in Are there any foreign substances in Clean the groove.
CHAPTER 5. TROUBLESHOOTING 8. 012xx (Internal communication system) Problem/Unit Step Check item Result Remedy Malfunction Is the trouble corrected by turning Completed. the power switch OFF and ON? Engine controller Is the trouble corrected by replac- Completed. ing the engine controller? Image controller Replace the image controller.
CHAPTER 5. TROUBLESHOOTING 12. 052xx (Serial interface communication system) 13. 053xx (Parallel interface communication system) Problem/Unit Step Check item Result Remedy Improper printer- Is the printer-computer communi- Set the communication mode computer communi- cation setting proper? properly. cation setting Image controller Replace the image controller.
CHAPTER 5. TROUBLESHOOTING 24. No power Problem/Unit Step Check item Result Remedy Unplugged power Is the power cord properly con- Connect the power cord correctly to source nected to the receptacle on the the printer and outlet. printer and the outlet? Power source failure Is the proper voltage available at Explain to the customer that the...
CHAPTER 5. TROUBLESHOOTING 25. Nothing is indicated on the operation panel Problem/Unit Step Check item Result Remedy Disconnected Are the connectors on the operation Connect the connectors properly. connector panel and image controller con- nected correctly? Operation panel Is the trouble corrected by replac- Completed.
CHAPTER 5. TROUBLESHOOTING 28. Media is not fed Problem/Unit Step Check item Result Remedy Loose set screw Are the set screws fixing the paper Tighten the paper feed roller with feed roller tightened firmly? set screws. Paper feed motor (M1) Turn OFF the power switch and Replace the paper feed motor.
CHAPTER 5. TROUBLESHOOTING V. CORRECTION OF IMAGE DEFECTS A. Initial Inspection The causes of poor images can be loosely classified into the following four cases : • Installation environment • Type or condition of media • BJ cartridge • Main unit problem Check the installation environment, media and other conditions in the initial inspection.
CHAPTER 5. TROUBLESHOOTING B. Corrective Procedures for Image Defects 1. Non-ejection of ink Normal Abnormal Problem/Unit Step Check item Result Remedy No ink Is there ink in the ink tank chamber of the Replace the ink tank of that applicable color? color.
CHAPTER 5. TROUBLESHOOTING 2. Vertical misalignment 1 Normal Abnormal Problem/Unit Step Check item Result Remedy BJ print head Is it corrected by reinstalling the BJ print Completed. installation problem head of the applicable color and doing the following? • Load the recommended type of media (plain paper or coated paper) larger than A3 and execute the "Auto Adjust"...
CHAPTER 5. TROUBLESHOOTING 3. Vertical misalignment 2 Normal Abnormal Problem/Unit Step Check item Result Remedy Printing position Is it corrected by loading the recom- Completed. adjustment problem mended type of media (plain paper or coated paper) larger than A3 and execut- ing the "Auto Adjust"...
CHAPTER 5. TROUBLESHOOTING 4. Low resolution Problem/Unit Step Check item Result Remedy Clogged nozzle, foreign Execute the [Head Cleaning] for the If the problem persists after substance stuck to the applicable color. corrective steps have been Is the nozzle check pattern of that color head attempted 3 times, check the proper when printing the "Nozzle Check"...
CHAPTER 5. TROUBLESHOOTING 6. Dot misalignment Normal Abnormal Problem/Unit Step Remedy Check item Result Foreign substance stuck If the problem persists after Execute [Head Cleaning] for that color. to the head corrective steps have been Is the nozzle check pattern of that color proper when the "Nozzle Check"...
CHAPTER 5. TROUBLESHOOTING 7. Lines (Carriage direction) Normal Abnormal Normal Abnormal Problem/Unit Step Remedy Check item Result Main menu settings If the problem persists after setting Is the "Band Joint" selected in "Feed Priority" in the [System Setup] menu? "Band Joint", check the following. Clogged nozzles Carry out the [Head Cleaning] for the If the problem persists after...
CHAPTER 5. TROUBLESHOOTING 8. White lines (Paper feed direction) Normal Abnormal Problem/Unit Check item Result Step Remedy Linear scale Is it corrected by replacing the linear Completed. scale and executing the following? Engine controller • Load the recommended type of media Replace the engine controller.
CHAPTER 5. TROUBLESHOOTING 9. Bleeding DENSITY 1 DENSITY 1 Normal Abnormal Problem/Unit Remedy Step Check item Result Media smudges easily. Use the recommended type of Is the recommended type of media being used? media (coated paper or other smudge resistant paper). Printable side reversed.
CHAPTER 5. TROUBLESHOOTING 11. Blotting boundary between filled images Normal Abnormal Problem/Unit Check item Result Step Remedy Poor moisture absor- Is the recommended type of media being Explain to the user to use the bency of media used? recommended type of media (media with high absor- bency).
CHAPTER 5. TROUBLESHOOTING VI. ELECTRICAL COMPONENTS ARRANGEMENT/ FUNCTIONS A. Sensors and Switches Figure 5-601 Name Symbol Function Photo-interrupter Pump position detection Home position detection Detection of remaining ink in the ink chamber Detection of the ink tank presence Media trailing edge detection Sensor Printing position detection Media leading edge detection, media width detection,...
CHAPTER 5. TROUBLESHOOTING B. Motors, Fans, and Solenoids Figure 5-602 Name Symbol Function Motor Paper feed drive Carriage drive Pump drive Hold paper during printing Heat dispersion Solenoid Wiper (cleaner blade) lifting Table 5-602 5–54...
CHAPTER 5. TROUBLESHOOTING C. Logic boards Figure 5-603 Name Symbol Function Sequence control/motor control Engine controller Image controller Data communication to host/raster conversion Carriage controller Head drive signal/sensor signal relay DC power supply DC power supply Operation panel controller Operation key, LED and message display control Table 5-603 5–55...
CHAPTER 5. TROUBLESHOOTING E. Image Controller DSW601 CN607 CN604 CN605 CN603 CN606 Figure 5-605 SW No. Function Remarks For factory adjustment DSW601-1 Set to OFF before shipment from factory For factory adjustment DSW601-2 Set to OFF before shipment from factory For factory adjustment DSW601-3 Set to OFF before shipment from factory...
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CHAPTER 6 CIRDUIT DIAGRAM A. GENERAL CIRCUIT DIAGRAM ......6-1 D. CARRIAGE CONTROLLER ......6-33 B. IMAGE CONTROLLER ........6-4 E. PAPER SENSOR ..........6-41 C. ENGIN CONTROLLER ........6-16 F. OPERATION PANEL CONTROLLER ..... 6-42...
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Part 6: Circuit Diagram BJ-W3000 / BJ-W3050 A. GENERAL CIRCUIT DIAGRAM General circuit diagram (1/3) CARRIAGE MOTOR PAPER FEED MOTOR SUCTION FAN COOLING FAN PE SENSOR FRONT COVER SENSOR J201 J203 J206 J214 J204 J211 J202 PPOW_CONL PPOW_CONL PG_OUT4 J202...
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Part 6: Circuit Diagram BJ-W3000 / BJ-W3050 General circuit diagram (2/3) LINEAR SCALE/LINEAR SENSOR PAPER SENSOR ENGINE CONTROLLER J208 J207 J510 J509 J501 J502 CARRIAGE CONTROLLER J505 J504 J503 J506 HEAD(3) HEAD(2) HEAD(1) HEAD(0)