Canon QY8-1360-000 User Manual

QY8-1360-000

REVISION 0

COPYRIGHT 1998 CANON INC. CANON BJC-7100 1098 AB 5.00-0 PRINTED IN JAPAN (IMPRIME AU JAPON)

OCT. 1998

1098 AB 5.00-0

Target Readers

This manual is published by Canon Inc. for qualified persons and contains the necessary technical
information for technical theory, installation, maintenance, and repair of products. This manual covers
all localities where the products are sold. For this reason, it may contain information that does not
apply to your locality.

Revisions

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.

The following paragraph does not apply to any countries where such provisions are
inconsistent with the local law.

Trademarks

The product names and company names appearing in this manual are the registered trademarks or
trademarks of the individual companies.

Copyright

This manual is copyrighted and all rights reserved. Under the copyright laws, this manual may not be
copied, reproduced, or translated into other languages, in whole or in part, without the express written
consent of Canon Inc. except in the case of internal business use.

Copyright  1998 by Canon Inc.
CANON INC.
BJ Products Quality Support Dept.
16-1, Shimonoge 3-chome, Takatsu-ku, Kawasaki, Kanagawa 213, Japan

This manual was produced on an Apple Macintosh Power Mac 7300/180 personal computer and Apple
LaserWriter II NTX-J laser beam printer; final pages were printed on Agfa SelectSet Avantra 25.
A YANO 640MO drive system NJ640MO with MITSUBISHI MO disk cartridge MR230M1 were used for
storing large volumes of page layout and graphic data for this manual.
All graphics were produced with MACROMEDIA FREEHAND 7.0J.
All documents and all page layouts were created with QuarkXPress 3.3J.

I

I. ABOUT THIS MANUAL

This manual is divided into five parts containing the information required for servicing the BJC­7100 printer.

Part 1: Safety and Precautions

This part contains information on how to service the unit safely. It is very important, and
must be read.

Part 2: Product Specifications

This part outlines the product and its specifications.

Part 3: Operating Instructions

This part explains how to operate the unit properly, how it is installed, and how to use
the service mode.

Part 4: Technical Reference

This part outlines the unit operation giving a technically.

Part 5: Maintenance

This part explains maintenance of the unit. It includes details of disassembly/assembly,
adjustments required when assembling, troubleshooting procedures, and wiring/circuit
diagrams, etc.

This manual does not contain complete information required for
disassembling and assembling the BJC-5500 printer. Please also refer to the
separate Parts Catalog.

II. TABLE OF CONTENTS

Page

Part 1: SAFETY AND PRECAUTIONS

1 - 1 1. SAFETY PRECAUTIONS
1 - 1 1.1 Moving Parts
1 - 2 1.2 Front Cover
1 - 3 1.3 Ink Stains
1 - 3 1.3.1 Ink path
1 - 4 1.3.2 Ink mist
1 - 5 1.4 Live Parts
1 - 6 1.5 BJ Cartridge Metal Plate
1 - 7 2. MACHINE PRECAUTIONS
1 - 7 2.1 BJ Cartridge Handling
1 - 7 2.1.1 Unpacking the BJ cartridge
1 - 7 2.1.2 BJ cartridge protection
1 - 8 2.1.3 Power on/off
1 - 8 2.1.4 When not using the printer
1 - 9 2.1.5 Ink electroconductivity
1 - 9 2.2 Ink Tank Handling
1 - 9 2.2.1 Unpacking the ink tank
1 - 9 2.2.2 Preventing clogging
1 -10 2.3 Printer Handling
1 -10 2.3.1 Spurs
1 -10 2.3.2 Damage due to static electricity
1 -11 2.3.3 Ink Leakage and dry-out
1 -11 2.3.4 Carrying the printer
1 -12 3. NOTES ON SERVICING
1 -12 3.1 EEPROM Data
1 -13 3.2 Service Mode of Printer Driver
1 -13 3.3 Protecting the Power Supply
1 -14 3.4 Static Electricity
1 -15 3.5 Disassembly and Assembly
1 -15 3.5.1 Parts that cannot be disassembled
1 -15 3.5.2 Parts requiring careful attention during disassembly and assembly
1 -15 3.6 Self-Diagnosis

Part 2:

PRODUCT SPECIFICATIONS

2 - 1 1. PRODUCT OUTLINE
2 - 1 1.1 Outline
2 - 2 1.2 Features
2 - 3 1.3 BJ Cartridge
2 - 3 1.3.1 Black BJ cartridge (BC-60)
2 - 4 1.3.2 Photo BJ cartridge (BC-62e Photo)
2 - 5 1.3.3 Color BJ cartridge (BC-61)
2 - 5 1.3.4 BJ cartridge vs print mode
2 - 6 1.4 SB-60 BJ Cartridge Container
2 - 6 1.5 Consumables
2 - 6 1.5.1 BJ cartridge
2 - 6 1.5.2 Ink tank
2 - 7 2. SPECIFICATIONS
2 - 7 2.1 General Specifications
2 -10 2.2 Paper Specifications
2 -10 2.2.1 Paper types

II

Page
2 -11 2.2.2 Printing range
2 -12 2.3 Interface Specifications

Part 3: OPERATING INSTRUCTIONS

3 - 1 1. PRINTER SETUP
3 - 1 1.1 Unpacking
3 - 2 1.2 Installation Location
3 - 3 1.3 Installation
3 - 3 1.3.1 Connecting the interface cable
3 - 3 1.3.2 Connecting the power supply
3 - 4 1.3.3 Installing the BJ cartridge
3 - 6 1.3.4 Replacing the ink tanks
3 - 7 1.3.5 Cartridge container [SB-60]
3 - 8 1.4 Turning Printer Power On and Off
3 - 8 1.4.1 Turning the power on
3 - 8 1.4.2 Turning the power off
3 - 9 1.5 Loading Printer Paper
3 -10 1.6 Names of Parts and Their Functions
3 -12 2. TRANSPORTING THE PRINTER
3 -12 2.1 Transporting the Printer
3 -13 2.2 Manual Capping
3 -14 3. PRINTER SERVICING FUNCTIONS
3 -14 3.1 Error Indications
3 -14 3.1.1 Operator call errors
3 -15 3.1.2 Service calls
3 -16 3.2 Warning Indications
3 -17 3.3 Function Settings
3 -17 3.3.1 Items set by control function
3 -18 3.3.2 Service mode of printer driver
3 -19 3.4 EEPROM
3 -19 3.5 Cleaning the BJ Cartridge
3 -20 3.6 Test Printout
3 -20 3.7 Pickup Roller Cleaning Function (HR-101)
3 -21 3.8 Service Mode
3 -22 3.8.1 Final factory test pattern
3 -22 3.8.2 Resetting EEPROM data
3 -23 3.8.3 Printing EEPROM data
3 -23 3.8.4 Setting destination country
3 -24 3.8.5 Other Function

Part 4: TECHNICAL REFERENCE

4 - 1 1. OVERVIEW
4 - 1 1.1 Printer Block Diagram
4 - 2 1.2 Initial Flowchart
4 - 3 1.3 Print Signal Sequence
4 - 4 1.4 BJ Cartridge Drive
4 - 4 1.4.1 Print drive control
4 - 5 1.5 Power-Off Sequence Flowchart
4 - 6 2. FIRMWARE
4 - 6 2.1 Interface
4 - 6 2.1.1 Compatible mode
4 - 7 2.1.2 Nibble mode
4 - 7 2.1.3 ECP mode

III

Page
4 - 8 2.2 Print Modes
4 - 9 2.2.1 Plain paper optimized printing mode (P-POP)
4 - 9 2.2.2 Economy print mode (Draft mode)
4 - 9 2.2.3 Standard mode
4 - 9 2.2.4 High quality and fine mode
4 -10 2.2.5 Print mode settings
4 -11 2.3 Smoothing Function
4 -11 2.4 Print Optimization Controls
4 -11 2.4.1 Power monitor
4 -11 2.4.2 Head sticking prevention
4 -11 2.4.3 Ink smear prevention
4 -12 2.5 Head Overheat Protection
4 -13 3. PRINTER'S MECHANICAL SYSTEM
4 -13 3.1 Overview
4 -14 3.1.1 Structure of printer's mechanical system
4 -15 3.2 BJ Cartridge
4 -15 3.2.1 BJ Cartridge structure
4 -19 3.2.2 Structure of BJ head unit
4 -21 3.2.3 Nozzle arrays
4 -22 3.2.4 Signal contacts
4 -24 3.2.5 Drive circuit
4 -28 3.2.6 BJ cartridge detection
4 -29 3.3 Purge Unit
4 -29 3.3.1 Function of purge unit
4 -30 3.3.2 Structure of purge unit
4 -33 3.4 Carriage
4 -33 3.4.1 Carriage functions
4 -34 3.4.2 Carriage structure
4 -36 3.5 Paper Feed/Sheet Feeder Mechanism
4 -36 3.5.1 Paper feed/sheet feeder mechanism functions
4 -38 3.5.2 Paper feed/sheet feeder mechanism structure
4 -39 4. PRINTER ELECTRICAL SYSTEM
4 -39 4.1 Overview of Printer Electrical System
4 -40 4.2 Logic
4 -40 4.2.1 Logic block diagram
4 -41 4.2.2 Logic components
4 -45 4.3 Electrical System
4 -45 4.3.1 Input power supply (AC adaptor)
4 -45 4.3.2 Output voltages
4 -46 5. DETECTION FUNCTIONS
4 -46 5.1 Sensor-based Detection Functions
4 -48 5.2 Miscellaneous Detection Functions
4 -48 5.2.1 Waste-ink amount detection
4 -48 5.2.2 BJ cartridge detection
4 -48 5.2.3 Ink-out detection

Part 5: MAINTENANCE

5 - 1 1. MAINTENANCE
5 - 1 1.1 Parts for Periodic Replacement
5 - 1 1.2 Consumable Parts
5 - 1 1.3 Consumables
5 - 1 1.4 Periodic Maintenance
5 - 2 2. SERVICING TOOLS

IV

Page
5 - 2 2.1 List of Tools
5 - 3 3. APPLYING GREASE
5 - 4 4. DISASSEMBLY AND REASSEMBLY
5 - 4 4.1 Disassembly and Reassembly
5 - 4 4.2 Notes on Disassembly and Reassembly
5 - 4 4.2.1 Main cover
5 - 4 4.2.2 Carriage unit
5 - 5 4.2.3 Bearings at ends of support shaft
5 - 5 4.2.4 Purge unit and bottom case assembly
5 - 5 4.2.5 Securing idler pulley assembly screw
5 - 6 4.3 Waste Ink Absorbers
5 - 7 4.4 Assembling the Chassis
5 - 8 5. ADJUSTMENTS
5 - 8 5.1 Adjustment Locations
5 - 8 5.1.1 Adjusting registration
5 - 8 5.1.2 Checking and adjusting the head gap
5 -13 6. TROUBLESHOOTING
5 -13 6.1 Troubleshooting Overview
5 -13 6.1.1 Overview
5 -13 6.1.2 Troubleshooting cautions
5 -14 6.2 Diagnosis
5 -14 6.2.1 Diagnostic flow
5 -16 6.2.2 Action
5 -37 7. CONNECTOR LAYOUT AND SIGNAL ASSIGNMENT
5 -37 7.1 Logic Board
5 -39 7.2 Carriage Board
5 -44 8. CIRCUIT DIAGRAMS
5 -44 8.1 Parts Layout
5 -44 8.1.1 Logic board
5 -45 8.1.2 Carriage board
5 -47 8.2 Circuit Diagrams
5 -47 8.2.1 Logic board

V

III. ILLUSTRATION INDEX

Page

Part 1: SAFETY AND PRECAUTIONS

1 - 1 Figure 1 - 1 The Printer's Moving Parts
1 - 2 Figure 1 - 2 Front Cover
1 - 3 Figure 1 - 3 Ink Path
1 - 4 Figure 1 - 4 BC-62e Photo and BC-61
1 - 4 Figure 1 - 5 Ink Mist
1 - 5 Figure 1 - 6 AC Adapter
1 - 6 Figure 1 - 7 BJ Cartridge Metal Plate
1 - 7 Figure 1 - 8 Removing the BJ Cartridge Cap and Tape
1 - 8 Figure 1 - 9 BJ Cartridges
1 - 9 Figure 1 -10 Removing the Ink Tank Cap
1 - 9 Figure 1 -11 The Ink Outlets on Ink Tank
1 -10 Figure 1 -12 Spurs
1 -10 Figure 1 -13 Contacts
1 -11 Figure 1 -14 Capping Position
1 -11 Figure 1 -15 Carrying the Printer
1 -13 Figure 1 -16 Protecting the Power Supply
1 -14 Figure 1 -17 Electrical System of Printer
1 -15 Figure 1 -18 Parts that Cannot be Disassembled

Part 2: PRODUCT SPECIFICATIONS

2 - 1 Figure 2 - 1 Printer Appearance
2 - 3 Figure 2 - 2 Black BJ Cartridge (BC-60)
2 - 4 Figure 2 - 3 Photo BJ Cartridge (BC-62e Photo)
2 - 5 Figure 2 - 4 Color BJ Cartridge (BC-61)
2 - 6 Figure 2 - 5 BJ Cartridge (SB-60)
2 - 6 Figure 2 - 6 Ink Tanks
2 -11 Figure 2 - 7 Printing Area
2 -18 Figure 2 - 8 Compatible Mode
2 -18 Figure 2 - 9 Nibble Mode
2 -18 Figure 2 -10 ECP Mode

Part 3: OPERATING INSTRUCTIONS

3 - 1 Figure 3 - 1 Packaging
3 - 2 Figure 3 - 2 Printer Dimensions
3 - 3 Figure 3 - 3 Connecting the Interface Cable
3 - 3 Figure 3 - 4 Connecting the Power Supply
3 - 4 Figure 3 - 5 Removing Cap and Tape from BJ Cartridge
3 - 4 Figure 3 - 6 Installing BJ Cartridges
3 - 5 Figure 3 - 7 Checking Print Head Alignment
3 - 6 Figure 3 - 8 Replacing the Ink Tank
3 - 6 Figure 3 - 9 Removing Protective Cap from Ink Tank
3 - 7 Figure 3 -10 Cartridge Container SB-60
3 - 8 Figure 3 -11 Incorrect Method of Powering Off
3 - 9 Figure 3 -12 Paper Settings
3 -10 Figure 3 -13 Names of Parts and Their Functions (1)
3 -11 Figure 3 -14 Names of Parts and Their Functions (2)
3 -12 Figure 3 -15 Transporting the Printer
3 -13 Figure 3 -16 Manual Capping Method
3 -14 Figure 3 -17 Control Panel
3 -17 Figure 3 -18 Windows 95 Driver Control Sheet (Sample)

VI

Page
3 -18 Figure 3 -19 Hidden Control Sheet (Sample)
3 -20 Figure 3 -20 Nozzle Check Pattern (Sample)
3 -22 Figure 3 -21 Service Mode Test Print (Sample)
3 -23 Figure 3 -22 EEPROM Data Print (Sample)

Part 4: TECHNICAL REFERENCE

4 - 1 Figure 4 - 1 Printer Block Diagram
4 - 2 Figure 4 - 2 Flowchart of Initialization Sequence
4 - 3 Figure 4 - 3 Print Signal Sequence
4 - 5 Figure 4 - 4 Power-Off Sequence Flowchart
4 - 6 Figure 4 - 5 Bidirectional Centronics Specifications Selection Sequence
4 - 6 Figure 4 - 6 Interface Timing (Compatible Mode)
4 - 7 Figure 4 - 7 Interface Timing (Nibble Mode)
4 - 7 Figure 4 - 8 Interface Timing (ECP Mode)
4 - 9 Figure 4 - 9 Photo Print Mode (Image)
4 -10 Figure 4 -10 Print Mode Main Sheet (Sample)
4 -11 Figure 4 -11 Print Mode Detail Quality Sheet (Sample)
4 -13 Figure 4 -12 Printer's Mechanical System
4 -15 Figure 4 -13 Structure of BC-60
4 -16 Figure 4 -14 Structure of BC-61
4 -17 Figure 4 -15 Structure of BC-62e Photo
4 -19 Figure 4 -16 Structure of BC-60 BJ Head Unit
4 -19 Figure 4 -17 Structure of BC-61 BJ Head Unit
4 -20 Figure 4 -18 Structure of BC-62e Photo BJ Head Unit
4 -21 Figure 4 -19 Nozzle Arrays
4 -22 Figure 4 -20 Signal Contacts
4 -24 Figure 4 -21 Block Diagram of BC-60 Drive Circuit
4 -25 Figure 4 -22 Block Diagram of BC-61/BC-62e Photo Drive Circuit
4 -32 Figure 4 -23 Purge Unit
4 -33 Figure 4 -24 Carriage
4 -35 Figure 4 -25 Paper Feed Motor Drive Switching
4 -36 Figure 4 -26 Auto Platen-Head Gap Adjustment
4 -37 Figure 4 -27 Paper Feed Mechanism
4 -38 Figure 4 -28 Paper Separator
4 -39 Figure 4 -29 Printer Electrical System
4 -40 Figure 4 -30 Logic Board Block Diagram
4 -43 Figure 4 -31 Printer Block Diagram
4 -44 Figure 4 -32 Motor Drive Circuit
4 -45 Figure 4 -33 AC Adaptor Output Voltages
4 -46 Figure 4 -34 Sensor Positions

Part 5: MAINTENANCE

5 - 3 Figure 5 - 1 Grease Points
5 - 4 Figure 5 - 2 Main Cover and Connector Cover
5 - 4 Figure 5 - 3 Releasing the Carriage Lock
5 - 5 Figure 5 - 4 Bearings at Ends of Support shaft
5 - 5 Figure 5 - 5 Purge Unit and Bottom Case Assembly
5 - 5 Figure 5 - 6 Tightening Idler Pulley Assembly Screw
5 - 6 Figure 5 - 7 Maintenance Jet and Waste Ink Absorbers
5 - 7 Figure 5 - 8 Tightening the Chassis Fixing Screws
5 - 8 Figure 5 - 9 Screws Influencing Head Gap
5 - 9 Figure 5 -10 Measuring Sheet Setting 1
5 - 9 Figure 5 -11 Measuring Sheet Setting 2

VII

Page
5 -10 Figure 5 -12 Thickness Gauge Setting
5 -10 Figure 5 -13 Check the Head Gap
5 -11 Figure 5 -14 Adjust the Head Gap 1
5 -12 Figure 5 -15 Adjust the Head Gap 2
5 -37 Figure 5 -16 Logic Board
5 -39 Figure 5 -17 Carriage Board
5 -44 Figure 5 -18 Logic Board (Face)
5 -44 Figure 5 -19 Component Board (Back)
5 -45 Figure 5 -20 Carriage Board (Face)
5 -45 Figure 5 -21 Carriage Board (Back)

VIII

IV. TABLE INDEX

Page

Part 2: PRODUCT SPECIFICATIONS

2 - 5 Table 2- 1 BJ Cartridge vs Print Mode
2 -10 Table 2- 2 Paper Specifications
2 -12 Table 2- 3 IO Signals Compatible Mode
2 -13 Table 2- 4 IO Signals in Nibble Mode
2 -13 Table 2- 5 IO Signals in ECP Mode

Part 3: OPERATING INSTRUCTIONS

3 - 9 Table 3- 1 Printer Paper Settings
3 -14 Table 3- 2 Operator Calls
3 -15 Table 3- 3 Service Calls
3 -21 Table 3- 4 Service Mode

Part 4: TECHNICAL REFERENCE

4 - 8 Table 4- 1 Number of Passes vs Number of Operational Head Nozzles
4 -10 Table 4- 2 Main Default Print Mode Settings
4 -22 Table 4- 3 BJ Head Input and Output Signals
4 -27 Table 4- 4 AND Gate Contacts and IDATA Order
4 -27 Table 4- 5 Electrode Connection Pins
4 -28 Table 4- 6 Index Connections
4 -28 Table 4- 7 Index Sensor Signals and BJ Cartridge Detection
4 -30 Table 4- 8 Cleaning Conditions and Ink Consumption (Average)
4 -48 Table 4- 9 Ink-out Detection Timing

Part 5: MAINTENANCE

5 -39 Table 5- 1 Contacts (DARK COL and LIGHT COL)

IX

Part 1

SAFETY AND
PRECAUTIONS

Page
1 - 1 1. SAFETY PRECAUTIONS
1 - 1 1.1 Moving Parts
1 - 2 1.2 Front Cover
1 - 3 1.3 Ink Stains
1 - 5 1.4 Live Parts
1 - 6 1.5 BJ Cartridge Metal Plate
1 - 7 2. MACHINE PRECAUTIONS
1 - 7 2.1 BJ Cartridge Handling
1 - 9 2.2 Ink Tank Handling
1 -10 2.3 Printer Handling
1 -12 3. NOTES ON SERVICING
1 -12 3.1 EEPROM Data
1 -13 3.2 Service Mode of Printer Driver
1 -13 3.3 Protecting the Power Supply
1 -14 3.4 Static Electricity
1 -15 3.5 Disassembly and Assembly
1 -15 3.6 Self-Diagnosis

1. SAFETY PRECAUTIONS

1.1 Moving Parts

Be careful not to let your fingers, hair, clothing, accessories, etc., become caught up in
the moving parts of the printer.
There are moving parts associated with the carriage motor and paper feed motor.

Carriage motor

Carriage belt, idler pulleys, and carriage

Paper feed motor

Paper feed roller, pressure rollers, spurs, pick-up roller, slow down gear, paper output

guide, and purge unit.
Be sure that the front cover is closed so that there is no risk of contacting the moving
parts, except when checking operation during servicing.
Note that the spurs are made of metal with a sharp edge. Be careful not to touch the
spurs with your bare hands.

1-1

BJC-7100

Part 1: Safety and Precautions

Figure 1-1 The Printer's Moving Parts

Pickup Roller

Carriage Belt

Idler Pulley

Paper Feed Motor

Slow Down Gear

Carriage

Carriage Motor

Purge Unit

Spur Unit

Page Eject Roller

Feed Roller

Pressure Roller

1.2 Front Cover

Hold the front part of the front cover to open and close the cover.
Be careful not to pinch your fingers between the front and main cover when closing the
front cover.

Part 1: Safety and Precautions

BJC-7100

1-2

Figure 1-2 Front Cover

1.3 Ink Stains

1.3.1 Ink path

Be careful not to touch the ink path as it may stain your hands, clothes, printer, work

table etc., during servicing.

The ink path consists of the BJ cartridge nozzles, head cap, waste ink tube, head

wiper, cleaner unit, maintenance jet receiving section, and waste ink absorber.

CAUTION

Although the ink and ink optimizer for plain paper are not harmful to the
human body, they contain organic solvents indicated on the package.
Avoid getting the ink into your mouth and eyes, and store out of reach of
children.
If ink does get into your eyes, wash with plenty of water and consult a
doctor. If for some reason a large amount of ink is swallowed, consult a
doctor immediately.
Give the doctor the information on the BJ cartridge package.
This ink contains dyes, that cannot be removed from clothing, etc.

1-3

BJC-7100

Part 1: Safety and Precautions

Figure 1-3 Ink Path

Wiper for Plain Paper
Ink Optimizer

Maintenance Jet Receiving
Section for Plain Paper
Ink Optimizer

Maintenance Jet
Receiving Section
for Ink

Maintenance Jet Absorber
for Plain Paper Ink Optimizer

BJ Cartridge

Carriage

Color: Photo Head (Nozzles)

Black: Ink Optimizer Head (Nozzles)

Cleaner Unit

Head Cap

Purge Unit

Waste Ink Tube

Waste Ink & Waste Ink Optimizer Absorber

Head Wiper

Maintenance Jet
Absorber for Ink

The joints and ink outlets of the respective ink tanks of the photo BJ cartridge [BC­62e Photo] and color BJ cartridge [BC-61] are also part of the ink path and must be
handled with care.
Unless absolutely necessary, do not remove the ink tanks from a BJ cartridge, since
air may enter the ink path and have a negative effect on print quality.

The BJC-7100 uses a variety of inks and an ink optimizer for printing on
plain paper. The ink optimizer is an almost colorless, transparent fluid.
We will refer to the ink optimizer for plain paper simply as ink optimizer or
just optimizer for simplicity purposes. We will also refer to the various
colored inks and the ink optimizer for plain paper simply as "inks".

1.3.2 Ink mist

The BJ cartridge ejects ink onto the paper. After prolonged or heavy-duty use of the
printer, a small amount of ink mist splattered during printing can dirty the printer
such as the platen.
Turn off the power, open the front cover, and clean the dirty parts with a soft moist
cloth. This is to prevent dirtying the paper, your hands, and clothing from touching
these parts.

Part 1: Safety and Precautions

BJC-7100

1-4

Figure 1-4 BC-62e Photo and BC-61

Figure 1-5 Ink Mist

Ink Outlets
Joints

Head (Nozzles)

Ink Outlets
Joints

Head (Nozzles)

BC-62e Photo BC-61

Front Cover

Platen

Paper Output

1.4 Live Parts

When the plug of the printer's AC adapter is plugged into a live power outlet, the power
supply unit of the printer is live regardless of the power being set to ON or OFF using
the

POWER

button.
Be careful not to get on electric shock if you are checking the printer operation with the
covers off.

CAUTION

Do not attempt to dismantle the AC adapter. The mains AC voltage is
supplied to the primary side of the AC adapter. To prevent risk of electric
shock, do not attempt to dismantle the AC adapter to check its operation,
etc.

If faulty, the AC adapter must be replaced as one unit (service part). The
structural components, including the case, are not available individually
as service parts. Do not attempt to dismantle the AC adapter.

1-5

BJC-7100

Part 1: Safety and Precautions

Figure 1-6 AC Adapter

1.5 BJ Cartridge Metal Plate

Do not touch the BJ cartridge's metal plate as it may be very hot. The metal plate
heats up during printing and becomes particularly hot during heavy duty printing.

CAUTION

Danger! High Temperature!
Do not touch.

The printer has the following protective mechanisms to detect overheating:

1. Overheat detection when replacing cartridge

If overheating is detected, a beeper sounds four times and the carriage
does not return to the replacement position. This is to prevent the user
from touching the BJ cartridge's metal plate.
Resume the cartridge replacement after leaving the cartridge to cool for
several minutes.

2. Overheat detection during normal printing

The carriage movement and the paper eject operation are continued
while the printing is stopped. Depending on the outcome of the ink-out
detection after completion of printing a page, a beeper sounds to
indicate the status of the error.

Ink available: BJ cartridge overheat error (beeper sounds 7 times)

Ink out: Ink-out error (beeper sounds 3 or 4 times)
When a BJ cartridge overheat error occurs, leave the cartridge to cool
for several minutes then press the

RESUME

button.
These protective mechanisms are based on the temperatures detected by
the sensors in the BJ head.

If the protective mechanism is activated and normal operation cannot be
resumed after cooling the head for several minutes, see

"Part 5: 6.

TROUBLESHOOTING" (page 5-13)

.

For details of ink-out detection, see

"Part 4: 5.2.3 Ink-out detection" (page 4-48)

.

Part 1: Safety and Precautions

BJC-7100

1-6

Metal Plate

Figure 1-7 BJ Cartridge Metal Plate

2. MACHINE PRECAUTIONS

2.1 BJ Cartridge Handling

2.1.1 Unpacking the BJ cartridge

Do not unpack the BJ cartridge until you are ready to use it.
Before installing the BJ cartridge in the printer, remove the cap protecting the nozzles
and gently peel off the protective tape.
Do not attempt to reuse the cap or the tape after they have been removed, as doing so
may cause faulty printing.

If you replace the cap on the color BJ cartridge or photo BJ cartridge, the
sponge in the cap may cause the colors to bleed into each other. The
nozzles may also become clogged.

Always move the carriage to the BJ cartridge replacement position before
attempting to remove or install a cartridge. Failure to do so may result in
damage to the BJ cartridge.

2.1.2 BJ cartridge protection

To prevent the nozzles from clogging, never touch or wipe the nozzles, joint pipes, or
ink tank outlets with your bare hands or with tissue paper, etc. After removing the
cap and peeling off the protective tape from a BJ cartridge, promptly install the
cartridge in the printer or store it in the cartridge holder. If the BJ cartridge is not
capped or stored in the cartridge holder, the nozzles may clog due to dried out ink or
dust, etc.
Do not attempt to leave color BJ cartridges or photo BJ cartridges with their ink tanks
removed.
BJ cartridges cannot be disassembled, reassembled, or washed.

Clogged nozzles cause faulty printing. If this problem persists even after
the nozzles are cleaned, replace the BJ cartridge.

1-7

BJC-7100

Part 1: Safety and Precautions

Figure 1-8 Removing the BJ Cartridge Cap and Tape

BC-60

BC-62e Photo

Head Cap

Protective Tape

BC-61

2.1.3 Power on/off

When the printer is turned off with the

POWER

button, the printer automatically caps
the BJ cartridge's nozzles for protection and to prevent ink leakage.
If the AC adapter is unplugged before the printer is turned off with the

POWER

button, the nozzles may not be capped. In this case, plug the AC adapter again, start
up the printer and turn off the printer with the

POWER

button before unplugging the
power cord. Note that, if you unplug the power during the recovery operation and
then leave the printer, the purge unit may be damaged.

If the nozzles are not capped, the ink might dry out and clog the nozzles or
leak from the cartridge.

2.1.4 When not using the printer

Keep the BC-60 BJ cartridge installed in the printer even when the printer is not in
use. The BC-62e Photo and BC-61 BJ cartridges can be left installed in the printer or
stored in the cartridge holder. This also applies when carrying, transporting, or
storing the printer.

If the BJ cartridge is taken out of the printer, dried ink or dust may clog
the nozzles, resulting in inconsistent printing.
If the printer is moved or transported with no cartridge installed, ink may
leak from the cap mechanism.

Part 1: Safety and Precautions

BJC-7100

1-8

Figure 1-9 BJ Cartridges

BC-60 BC-62e Photo

Ink Outlets

Joints

BC-61

Ink Outlets

Joints

2.1.5 Ink electroconductivity

The ink used in the BJ cartridge can conduct electricity. If any ink leaks into the
printer's mechanical parts, use paper towels, etc., to wipe clean. If the ink leaks onto
the printer's electrical components, use tissue paper, etc., to wipe clean. If the ink
gets to the IC chips on the PCB, or if it is too difficult to thoroughly clean off the ink,
replace the respective parts.

Never connect the printer's power cord if ink has leaked inside the printer.
It may damage the circuitry.

2.2 Ink Tank Handling

2.2.1 Unpacking the ink tank

Do not unpack the ink tank until you are ready to use it.
Before installing it in the color BJ cartridge, remove the cap covering the ink outlets.

2.2.2 Preventing clogging

To prevent poor ink suction due to clogging of the joints in the BJ cartridge, never
touch the ink tank's ink outlets. After removing the cap from the ink tank, promptly
install the ink tank in the BJ cartridge to prevent the nozzles from clogging due to
dried-out ink, dust, etc. Do not remove an ink tank from a BJ cartridge unless you
are replacing it.

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Figure 1-10 Removing the Ink Tank Cap

Figure 1-11 The Ink Outlets on Ink Tank

BCI-62 Photo

Photo Cyan Ink Outlet

Photo Magenta Ink Outlet

Photo Yellow Ink Outlet

Yellow Ink Outlet

Magenta Ink Outlet

Cyan Ink Outlet

BCI-61 Color

Cyan Ink Outlet

Magenta Ink Outlet

Yellow Ink Outlet

2.3 Printer Handling

2.3.1 Spurs

Take care not to bend the tips of the spurs.
The spurs that transport and eject the paper after printing are very small and can
easily be deformed.
If a spur is deformed, its contacting surface with the printed paper increases, creating
a dotted line.

2.3.2 Damage due to static electricity

The static charge accumulated by your body from clothing can damage electrical
components and alter their electrical characteristics.
Never touch the carriage contacts or BJ cartridge contacts.

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Figure 1-12 Spurs

Figure 1-13 Contacts

Double Spurs

Spur Cleaner

Spurs

Contacts

2.3.3 Ink leakage and dry-out

Make sure a BJ cartridge is installed before turning off the power, using the

POWER

button.
When you turn off the printer using the

POWER

button, the printer automatically

performs the following operations:

Cleaning

Any ink left in the purge unit or in the nozzles of the BJ cartridge is removed.

Capping

To prevent ink dry-out, the BJ cartridge's nozzles are capped automatically and the

carriage is locked in position.
If you unplug the AC adapter by mistake, plug the power cord again, turn the power
on and then off again using the

POWER

button, then unplug the AC adapter.
If you turn the power off or unplug the AC adapter when the BJ cartridge has been
removed, the nozzles will not be automatically capped or the carriage locked in
position, and hence there is a risk of ink leaking or dry-out.

If the power cannot be turned on due to some failure, manually move the
carriage belt or the carriage itself to the capping position. For details, see

"Part 3: 2.2 Manual Capping" (page 3-13).

2.3.4 Carrying the printer

Hold both sides of the bottom of the printer to carry it. Note that inserting your hand
into the paper outlet may dislodge or damage the paper guides.

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BJC-7100

Part 1: Safety and Precautions

Figure 1-14 Capping Position

Figure 1-15 Carrying the Printer

BJ Cartridge

Head Cap

3. NOTES ON SERVICING

3.1 EEPROM Data

The printer stores the function settings and keeps track of various information
including the total sheets printed, the number of cartridge replacements, the total
waste ink amount, and the head position adjustment values. The data is stored in the
EEPROM on the logic board.
Note the following precautions during servicing:

1) Before servicing

You can check the EEPROM data with a test print. The total sheets printed can give
you an idea of how much the printer has been used.

2) During logic board replacement

Always replace the waste ink absorber when replacing the EEPROM.
If you do not replace the waste ink absorber, the data on waste ink amount will differ
from the amount of ink that can be absorbed by the waste ink absorber. There is
therefore a risk of ink leaking.
When replacing the logic board, be sure to reset all the data. Because the data on
new EEPROMs is undefined, they cannot be used until they are reset. For details of
handling EEPROMs, see

"Part 3: 3.4 EEPROM" (page 3-19)

.

3) After waste ink absorber replacement

After replacing full waste ink absorbers, reset the EEPROM's waste ink counter.

4) If you accidentally reset the EEPROM's waste ink amount data or all data

Once reset, the EEPROM data cannot be restored. If you accidentally reset the
EEPROM, you must take the same steps as when replacing the logic board.

After the EEPROM is reset, the data it contained cannot be printed out
with a test print. If you want to check the stored data, be sure to make a
test print before resetting the EEPROM.
Note that you cannot reenter the data from the printer's control panel or
by using a computer.
If the EEPROM is faulty, or all data is reset, all data is lost. Whenever
possible, restore all data such as the head alignment to the user's
settings.

During operation, the waste ink amount (EEPROM data) is automatically
updated. An error message is displayed and operation halted when the
waste ink absorber is nearly full. If this occurs, refer to

"Part 5: 6.

TROUBLESHOOTING" (page 5-13)

.

See

"Part 3: 3.8.3 Printing EEPROM data" (page 3-23)

for how to make a test
print of the stored data.
You can choose to either reset the waste ink counter or all data. See

"Part

3: 3.8.2 Resetting EEPROM data" (page 3-22)

for details.

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3.2 Service Mode of Printer Driver

There are certain printer driver control functions, described below, that are, in
principle, hidden from the end user. These service mode functions, which must be
used with caution, are provided for service purposes only.
See

"Part 3: 3.3.2 Service mode of printer driver" (page 3-18)

for details.

3.3 Protecting the Power Supply

The power supply for the BJC-7100 printer consists of an AC adapter and a power supply
circuit on the logic board. Provided the AC supply is connected, the printer power supply
is live whether or not the power is set ON or OFF using the

POWER

button.
Always unplug the AC adapter from the power outlet before connecting it to or
disconnecting it from the printer. Ignoring this warning can result in damage and
failure of the printer power supply.

When moving the carriage by hand when, for example, manually capping the
ink nozzles or releasing the carriage lock, do so slowly while paying attention
to the operation of the carriage motor; the back electromotive force generated
by moving the carriage horizontally may damage the motor control board.
If it is necessary to move the carriage horizontally fairly frequently, such
as when replacing or adjusting the carriage, temporarily disconnect the
carriage motor connector from the control board.

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Part 1: Safety and Precautions

Figure 1-16 Protecting the Power Supply

STEP 1-1

USA Only

or

STEP 2

STEP 1-2

3.4 Static Electricity

The electrostatic charge accumulated in clothing can damage electrical components
and alter their electrical characteristics.
Before disassembling the printer to service it, use a wriststrap or other grounded metal
object to discharge the static electricity. The following parts must not be touched
before you have discharged the static electricity from your body:

• Logic board, carriage board

• Motor control board

• Cable connectors and contacts

• BJ cartridge signal contacts

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1-14

Figure 1-17 Electrical System of Printer

Static Damage!

Carriage Motor

Carriage Board

BJ Cartridge Signal Contacts

Logic Board

Paper Feed Motor