Part 3: Operating Instructions

BJC-5000

3. PRINTER SERVICING FUNCTION

3.1 Error Indications
This printer notifies errors with the indicator lamp and beeper.
Indicator

POWER button

RESUME button

Figure 3-15 Control Panel Table 3-2 Error Indications

State [Errors that can be corrected by a user] Feed paper error/paper jam error Left-head recognition error Right-head recognition error High head temperature warning (during head replacement) Waste ink full warning [Errors that cannot be corrected by a user] Home position error Cleaning error Sheet feeder error Temperature sensor error Waste ink full error Head temperature error Sub-heater error BJ cartridge not found error EEPROM error ROM error RAM error Indicator Lights in orange Lights in orange Lights in orange Lights in orange Lights in orange Alternately blinks in green once and orange twice. Alternately blinks in green once and orange 3 times. Alternately blinks in green once and orange 4 times. Alternately blinks in green once and orange 5 times. Alternately blinks in green once and orange 6 times. Alternately blinks in green once and orange 7 times. Alternately blinks in green once and orange 8 times. Alternately blinks in green once and orange 9 times. Alternately blinks in green once and orange 10 times. Alternately blinks in green once and orange 11 times. Alternately blinks in green once and orange 12 times. Beeper Twice 3 times 4 times 5 times 6 times 7 times 7 times 7 times 7 times 7 times 7 times 7 times 7 times 7 times 7 times 7 times

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Part 4: Technical Reference

5. SENSOR FUNCTIONS
The printer has a pick-up roller sensor, paper end sensor, home position sensor, purge sensor, cover open sensor, printer temperature sensor, head temperature sensor, and auto-alignment sensor. The printer is also provided with a waste ink absorption amount detection function which counts and stores the waste ink absorption amount in the EEPROM and issues an error signal when the waste ink absorber becomes full.
Printer Temperature Sensor (TH1)

Cover Open Sensor

Home Position

TH1
Paper End Sensor (right) Pick-Up Roller Sensor (left)

Head Temperature Sensor (contact point) Auto-Alignment Sensor

Purge Sensor

Figure 4-30 Sensors 5.1 Pick-Up Roller Sensor

The photo interrupter-type pick-up roller sensor detects the initial position of the sheet feeder pick-up roller. When the initial position is detected, the flag interrupts the sensor and the sensor detection status is activated.

5.2 Paper End Sensor

The photo interrupter-type paper end sensor uses the paper sensor arms flag to detect the presence of paper when the front edge of the paper sheet passes through the paper feeding mechanism. The sensor is closed by the paper sensor arm when there is no paper, and opened (paper is recognized) when paper is detected.

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MAINTENANCE

Page 5- 1 5- 1 5- 1 5- 1 5- 2 5- 2 5- 3 5- 4 5- 4 5- 4 5- 6 5- 8 5- 8 5- 8 5- 9 5 -12 5 -12 5 -14 5 -34 5 -34 5 -37 5 -37 5 -39

1. Maintenance 1.1 Parts for Regular Replacement 1.2 Consumables 1.3 Periodic Maintenance 2. SERVICE TOOLS 2.1 List of Tools 3. GREASE APPLICATION 4. DISASSEMBLY AND REASSEMBLY 4.1 Disassembly and Reassembly 4.2 Disassembly and Reassembly Cautions 4.3 Logic Board and Waste Ink Absorber Replacement Cautions 5. ADJUSTMENTS 5.1 Adjustment Point 5.2 When Adjustment is Required 5.3 Adjustment Procedure 6. TROUBLESHOOTING 6.1 Troubleshooting 6.2 Error Condition Diagnostics 7. LOCATION AND SIGNAL ASSIGNMENT 7.1 Logic Board 8. CIRCUIT DIAGRAMS 8.1 Parts Layout 8.2 Circuit Diagrams

BJC-5000

Part 5: Maintenance

1. MAINTENANCE
1.1 Parts for Regular Replacement
Level User Service personnel Part None None

1.2 Consumables
Level User Consumable Black BJ cartridge (BC-23 and BC-20 [reference]) Color BJ cartridge (BC-21e) Photo BJ cartridge (BC-22e Photo) Ink cartridge (BCI-21 Black/BCI-21 Color) None

Service personnel

1.3 Periodic Maintenance

Level User Service personnel Periodic Maintenance None None

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BJC-5000

2. SERVICE TOOLS
2.1 List of Tools
Ordinary Tool Phillips screwdriver Blade screwdriver Tweezers Multi-meter Use For removing screws For removing plastic parts For installing and removing coil springs For troubleshooting

Special Tool (Parts Number) Gap gauge 1.9mm (QY9-0038-000) Tension spring (QY9-0039-000) Black BJ cartridge Grease MOLYKOTE PG641 (CK-0562-000)

Use For adjusting the head gap For adjusting the carriage belt tension Procure as special servicing tool. Do not use the black BJ cartridge of a user Apply to the specified place as shown in Figure 5-1

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BJC-5000

Part 5: Maintenance

3. GREASE APPLICATION
Use the special tool to apply the grease at the points and amounts shown below.
Sliding Section of Platen Gear (Approx. 22 to 46mg)

Shaft Sliding Section Surface (Approx. 12mg)

Cross-Sectional View of Gear and Sliding Section (Approx. 22 to 46mg)

Carriage Guide Frame Rear Surface (Evenly apply 30 to 50mg of grease on the entire surface.) Carriage Shaft (Evenly apply 300 to 500mg of grease on the entire surface.)

Sliding Section of Slide Lever (Approx. 18 to 36mg each at 2 locations) Sliding Section with LF Roller (Approx. 20mg) Sliding Section of Purge Unit (Approx. 40 to 60mg)

Sliding Section with Chassis (Approx. 20 to 40mg)

Sliding Section with Chassis (Approx. 20mg)

Sliding Section with Feed Roller (Approx. 20 to 40mg)

Figure 5-1 Grease Application Points

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Part 5: Maintenance

BJC-5000

4. DISASSEMBLY AND REASSEMBLY

4.1 Disassembly and Reassembly
When disassembling or reassembling the printer, refer to the parts catalog. The figure numbers in the parts catalog are provided in the order of disassembly. Close-up diagrams are also provided for parts where you need to exercise caution during disassembly and reassembly.

4.2 Disassembly and Reassembly Cautions

When disassembling or reassembling the printer, heed the following cautions.

4.2.1 Fastening screws of idler pulley assembly

When the screws of the idler pulley assembly are loosened during removal of the carriage or other maintenance services, be sure to use the tension spring (QY9-0039000) listed as a special tool for the installation procedure. Before fixing the screws, move the carriage 3 times sideways to stabilize the belt tension. After fixing the screw, be sure to remove the tension spring.

Carriage Belt Idler Pulley Assembly

Screw Tension Spring (QY9-0039-000)

Figure 5-2 Idler Pulley Assembly

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BJC-5000
4.2.2 Carriage guide frame installation

Part 5: Maintenance

The carriage guide frame adjusts the head gap between the BJ cartridge nozzles and platen to obtain optimum printing quality. It is mounted on the printer frame. The head gap must be adjusted only when the carriage guide frame position on the printer frame is changed. The screws fastening the carriage guide frame are painted red so that they are not loosened during servicing. If the carriage guide frame position is changed unintentionally, follow the procedure in 5. ADJUSTMENTS (page 5-8) to adjust the head gap.
Carriage Guide Frame

Screw

Screw

Figure 5-3 Carriage Guide Frame

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BJC-5000

4.2.3 Unlocking the carriage lock

The carriage is normally locked at the capping position when the printer is turned off. This feature is provided by the carriage lock mechanism in the purge unit. It prevents the carriage from moving from the capping position during transportation or being moved by hand to assure that normal printhead protection (capping) is performed. If the carriage moves when the printer turned on during servicing, unplug the AC power cord to unlock the carriage. If the printer is not turned on or the carriage does not move, follow the procedure below to unlock the carriage lock manually. You can also lock the carriage manually when you transport the printer.

3 2 1

Figure 5-4 Unlocking the Carriage Lock 4.3 Logic Board and Waste Ink Absorber Replacement Cautions 4.3.1 Logic board replacement cautions
The logic boards EEPROM stores the various settings, waste ink amount, total count of printed sheets, and other data related to the printer. The data stored in the logic boards EEPROM, excepting the total waste ink amount setting (25%, 50%, 75%), cannot be rewritten into the new EEPROM after the logic board is replaced. The data in the EEPROM installed on a replacement logic board is unclear. After the logic board/EEPROM is replaced, clear the EEPROM. After clearing the EEPROM, calibrate the auto-alignment sensor as described in Part 3: 3.4 Service Mode (page 318). When replacing the logic board (clearing the EEPROM), visually check the amount of waste ink in the waste ink absorber. Replace the waste ink absorber or set the total waste ink amount as required. Depending on the amount of waste ink already absorbed in the waste ink absorber, ink may leak from the printer even before a waste ink-full warning or waste ink-full error is output. (See Part 3: 3.4 Service Mode on page 3-18 for setting the waste ink amount.) However, it is not necessary to replace the waste ink absorber or set the waste ink amount if the printer has been in use for less than 2 weeks and less than 50 pages have been printed out.

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Part 5: Maintenance

NOTE

The waste ink absorber consists of three layers. When the printer is first used, most of the waste ink is absorbed by the lower waste ink absorber layer. The amount of waste ink in the upper layer of the waste ink absorber rises as the waste ink amount increases.

Absorber Cover Waste Ink Absorber

**

Figure 5-5 Waste Ink Absorber 4.3.2 Cautions after replacing the waste ink absorber
After a waste ink-full error (warning) occurs and the waste ink absorber is replaced, reset the waste ink counter in the Service Mode. (See Part 3: 3.4 Service Mode on page 3-18.) When a waste ink-full error (warning) occurs, it can be assumed that the printer has printed more sheets than its service life called for. However, this also depends on how many times the cartridge has been replaced and the usage conditions. When a color/photo BJ cartridge is used, more ink is consumed due to head maintenance compared to a black BJ cartridge. Therefore, the waste ink amount will also be more.

NOTE

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BJC-5000

5. ADJUSTMENTS
5.1 Adjustment Point
Only the distance (head gap) between the BJ cartridges nozzles and platen needs to be adjusted to the designated value (approximately 1.9mm) to ensure optimum printing quality. This adjustment is done by moving the cartridge guide frame fixing position forward or backward. The adjustment is necessary only when loosening the red screw which secures the carriage guide frame.

Carriage Guide Frame

Screw

BJ Cartridge

Head Gap

Platen

Figure 5-6 Head Gap Adjustment 5.2 When Adjustment is Required

If the carriage guide frame fixed to the printer frame is repositioned, the head gap must also be adjusted. The fixing screws are painted red so that they are not loosened unintentionally.

5.2.1 Tools required for adjustment Table 5-1 Tools Requied for Head Gap Adjustment
Tool Gap gauge 1.9 mm (QY9-0038-000) Black BJ cartridge Use For adjusting the head gap Procure as special servicing tool. Do not use the black BJ cartridge of a user.

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BJC-5000
5.3 Adjustment Procedure 5.3.1 Preparation

Part 5: Maintenance

1) Remove the upper case unit. 2) Turn on the printer under the condition where no BJ cartridge is installed in the carriage. (At this time, the carriage will move to position A.) 3) Disconnect the power cord. 4) Push in the carriage guide frame as indicated by arrows in Figure 5-7 and lightly fix the frame with screws A and B. 5) Install a black BJ cartridge (procured for servicing) on the left of the carriage.

CAUTION

Before making the adjustment, make sure that the gap gauge is not deformed and there are no foreign particles on it and the platen. The platen has a structure which enables it to move up and down vertically while maintaining a fixed distance between the head and paper depending on the paper thickness. When the printer is turned on and initialization starts, the LF motor rotates in the normal direction. This operation will set the platen in the normal position of no paper loaded condition. Do not press the platen down during adjustment.

Carriage Guide Frame

Carriage Belt Screw A

Screw B

Black BJ Cartridge

Position A Platen

Figure 5-7 Adjustment Preparation

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BJC-5000

5.3.2 Adjustment
1) 2) 3) 4) Place the gap gauge at position B. Move the carriage to position B. Gradually loosen screw A until the carriage guide frame moves forward under its own weight using screw B as a pivot. Lightly push the screw A end of the carriage guide frame once or twice and check that the carriage guide frame pivots around the screw B as indicated by arrows in Figure 5-9. If it does not return to the original position, you have fixed screw B too tight. If the screw B end moves as well, then screw B is too loose. Fix the carriage guide frame lightly again and repeat the procedure from step 1). Lightly fix screw A. Lightly push the screw A end of the carriage guide frame once or twice and check that the carriage guide frame moves around screw B as shown by the arrows figure 5-9. If it does not return to the original position, screw B is too tight. And if the screw B end moves as well, then the screw B is too loose. Refasten the carriage guide frame lightly again and repeat the procedure from step 1).

5) 6)

Carriage Guide Frame Carriage Belt Screw A

Screw B Position B

Position A

Position C

Nozzle Section Grade Difference Paper Guide

Position B

Gap Gauge

Position C

Figure 5-8 Head Gap Adjustment (1) 5-10

BJC-5000
6) 7) 8) 9)

Part 5: Maintenance

10) 11) 12) 13)

Move the carriage to position A, and then place the gap gauge at position C. Move the carriage to position C. Gradually loosen screw B until the carriage guide frame moves forward under its own weight using screw A as a pivot. Lightly push the screw B end of the carriage guide frame once or twice and check that the carriage guide frame pivots around screw A as indicated by the arrows shown in Figure 5-9. If it does not return to the original position, you have fixed screw A too tight. If the screw A end moves as well, then screw A is too loose. Fix the carriage guide frame lightly again and repeat the procedure from step 1). Lightly fix screw B. After moving the carriage to position A, place the gap gauge at position B. Repeat the procedure from 2) to 13) twice. Gradually tighten screws A and B alternately.

Figure 5-9 Head Gap Adjustment (2)

Do not use move the carriage by hand. It may cause the carriage guide frame to shift. To move the carriage, move the carriage belt manually instead.

CAUTION

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BJC-5000

6. TROUBLESHOOTING
6.1 Troubleshooting 6.1.1 Overview
This chapter consists of the following two sections on subsequent pages: Error condition diagnosis for diagnosing a problem when the cause is unknown and Symptoms for resolving problems whose causes are known. In the case of an unknown problem, diagnose the problem. If the cause is known, follow the corrective actions to resolve the problem.

6.1.2 Troubleshooting cautions

1. Before troubleshooting, make sure the connectors and ribbon cable are properly connected. Especially if a problem occurs at random, be sure to check the connections thoroughly. 2. When servicing the printer with its outer casing removed and the AC adapter connected, beware of electrical shocks and PCB short circuiting. 3. Troubleshooting is described in flowchart form. The following symbols are used in the flowcharts.

Start/End

Procedure

Judgement

Action/Replace

Jump

Stop

4. If there is a problem with the printing quality or paper feeding, first check whether the installation site and paper meet the required specifications. Also check whether the printer settings are correct and paper is loaded properly. 5. After replacing parts or repairing the printer, be sure to make a test print to confirm that the problem has been fixed. If the problem still persists, troubleshoot again without the steps already executed. Example 1

Print defects ? Yes 1. Replace the ink cartridge 2. Replace the BJ cartridge

No END

Print defects even after cartridge replacement? Yes

No

END

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BJC-5000

Part 5: Maintenance

6. In some cases, several corrective actions are successively indicated in Error condition diagnosis and Symptoms. These are steps that must be followed to resolve the problems. After you perform each corrective action step, make a test print to confirm whether the problem has been fixed. If the problem persists, perform the next step. Example 2 Corrective action 1: After replacing the BJ cartridge, execute a test printout to check whether the problem has been fixed. If the problem persists, perform the next step (corrective action 2), which calls for replacement of the logic board.

Remove and reinstall the BJ cartridge

Printer recognizes the cartridge ? Yes

No 1. Replace the BJ cartridge 2. Replace the logic board BJ Cartridgeis faulty Check th e BJ cartridge MPU is faulty

END

7. Ink cartridge replacement as a corrective action is only applicable when the color BJ cartridge has produced the Symptom. When using the black BJ cartridge for troubleshooting, advance to the next step. 8. After finishing troubleshooting, be sure to reconnect connectors and tighten any loosened screws.

CAUTION

When replacing the control board, be sure to execute the EEPROM all clear and AA sensor calibration and check the waste ink absorption amount of the waste ink absorber. In addition, replace the waste ink absorber or set the waste ink amount according to the requirement. Refer to Part 3: 3.4 Service Mode (page 3-18) and Part 5: 4.3 Logic Board and Waste Ink Absorber Replacement Cautions (page 5-6).

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Part 5: Maintenance

BJC-5000

6.2 Error Condition Diagnostics 6.2.1 Diagnostic flowcharts

Power ON Sequence Flowchart

Start

Connect power cable of AC adapter to wall outlet. (Hard power ON)

ROM/RAM/EEPROM Check

Turn Power ON. (Soft power ON)

ROM/RAM/EEPROM OK?

No
Beeper: Sounds 7 times Indicator: Blinks 11 times (orange) Beeper: Sounds 7 times Indicator: Blinks 12 times (orange) Beeper: Sounds 7 times Indicator: Blinks 10 times (orange)

Yes

ROM error

RAM error

EEPROM error Indicator blinks (green).

Paper check (Paper end sensor)

Is paper out?

No
Beeper: Sounds twice Indicator: Lights (orange)

Yes

Paper jam error

Detection of Heads

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BJC-5000

Part 5: Maintenance

OK?

No
Left-head recognition error Beeper: Sounds 3 times Indicator: Lights (orange) Beeper: Sounds 4 times Indicator: Lights (orange)

Yes

Right-head recognition error

Sub-heater error

Beeper: Sounds 7 times Indicator: Blinks 8 times (orange)

Purge unit initialization

OK?

No
Beeper: Sounds 7 times Indicator: Blinks 3 times (orange)

Yes

Cleaning error

Temperature sensor check

OK?

No
Beeper: Sounds 7 times Indicator: Blinks 5 times (orange)

Yes
Detection of carriage in home position

Temperature sensor error

OK?

No
Beeper: Sounds 7 times Indicator: Blinks twice (orange)

Yes
Auto sheet feeder initialization

Home position error

OK?

No
Beeper: Sounds 7 times Indicator: Blinks 4 times (orange)

Yes

Sheet feeder error

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Part 5: Maintenance

BJC-5000

Auto cleaning if needed

Waste ink check

OK?

No
Beeper: Sounds 6 times Indicator: Lights (orange) Beeper: Sounds 7 times Indicator: Blinks 6 times (orange)

Yes

Waste ink full warning Waste ink full error

Indicator lights (green).

End

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BJC-5000
6.2.2 Error recovery
a) Error display

Part 5: Maintenance

<Cause> During initialization, the contents in the ROM cannot

1. ROM Error

be read.

<Suspected Parts> Control ROM <Corrective Action> Replace the logic board. <Cause> RAM reading and writing is not being performed
properly.

2. RAM Error

<Suspected Parts> DRAM <Corrective Action> Replace the logic board. <Cause> EEPROM reading and writing is not being performed
properly. The auto alignment sensor has never been calibrated. <Suspected Parts> EEPROM <Corrective Action> Replace the logic board. Calibrate the auto-alignment sensor.

3. EEPROM Error

CAUTION

When a RAM error or ROM error occurs, the exact error may not be displayed correctly. When replacing the logic board, execute the EEPROM all clear function in Service mode, then calibrate the auto alignment sensor. In addition, check the amount of waste ink absorbed by the waste ink absorber in the bottom case unit. If necessary, also replace the waste ink absorber or set the waste ink counter value in Service mode. (See Part 5, 4.3 Logic Board and Waste Ink Absorber Replacement Cautions.)

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Part 5: Maintenance

BJC-5000
<Cause> The home position cannot be detected. <Suspected Parts> Home position sensor, carriage motor,
logic board, carriage ribbon cable, carriage belt, carriage shaft, idler pulley

4.Home Position Error

<Corrective Action>
Visual check of carriage drive mechanism

Check for any paper jams, carriage belt wear/deterioration/ dislocation, deformation of the carriage or carriage guide frame, scratching or bending in the carriage shaft, deterioration/damage of idler pulley, etc. Move the carriage with your hands and check to see if it moves smoothly. (See 4.2.3 Unlocking the Carriage for how to unlock the carria Check that there is no abnormal noise.

Correct ? Yes

No Repair/replace a faulty part(s). Does it turn during initialization? Is it out of synchronization?

Carriage motor operation check

Correct ? Yes

No Carriage motor check Measuring Pin No. Normal reading points 1-2 J2 Approximately10.5 3-4 Correct ? Yes No Replace the carriage motor.

Replace the logic board. Measuring Pin No. Sensor points Open J6 30 Closed

Normal reading Low level High level (Home position sensed)

Home position sensor check

While the power is on, manually move the carriage and check to see if it is sensed at the home position. Correct ? Yes No Replace the carriage unit The home position sensor is faulty The carriage ribbon cable is broken.

Replace the logic board.

The MPU and printer controller are faulty.

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BJC-5000

Part 5: Maintenance

<Cause> Cleaning or capping is not executed properly or not

5.Cleaning Error

detected.

<Suspected Parts> Purge unit, purge sensor, purge sensor

cable, paper feed motor, paper feed drive power transmission section, logic board

<Corrective Action>
Visual check of paper feed system operation During initialization, do the paper feed motor, feed roller, eject roller, etc., rotate? Any abnormal noises? Is the paper feed motor out of synchronization?

Correct ? Yes

No 1. Repair/Replace a faulty part(s). 2. Replace the logic board.

Purge sensor cable check

Check to see if the purge sensor cable connectors (which are located at both the purge sensor and the logic board) are connected properly and check the joint cable conductivity. No Re-connect/Replace the purge sensor cable. Remove the purge unit from the printer, and fully rotate the drive gear by hand in both directions to check that it moves smoothly. Check the purge sensor. Measuring Pin No. Sensor points Open J1 2, 3 Close Normal reading Low level High level

Correct ? Yes

Purge unit check

Correct ? Yes

No

While the power is on, remove the purge unit, then check the measuring points by rotating the drive gear manually to open and close the sensor. Replace the purge unit.

Check/Repair the paper feed motor drive switching mechanism

Check to see if each gear or slide lock lever is deformed or damaged and if any spring is dislocated. See Part 4 3.4.2 Paper Feed Motor Drive Switching Section on page 4-29.

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Part 5: Maintenance

BJC-5000
<Cause> The home position of the pick-up roller cannot be

6.Sheet Feed error

<Corrective Action>
Check the sheet feeder unit operation.

detected.

<Suspected Parts> Sheet feeder unit, pick-up roller, paper

feed motor drive transmission sensor, slide lock lever, logic board

Remove the sheet feeder unit, then manually rotate the drive gear fully to check to see if the parts such as the pick-up roller operate smoothly.

Correct ? Yes

No Repair/Replace the sheet feeder unit.

With your eyes, check the appearance and movement of the paper feed roller, which is the drive transmission section Check the paper feed of the paper feed motor, and the gear which is located on the motor drive transmission drive switching mechanism. gear located at the At the same time, check to see if the slide lock lever which platen section. locks the drive switching section operates smoothly. See Part 4 3.4.2 Paper Feed Motor Drive Switching Section on page 4-29. No Correct ? Yes Repair/Replace a faulty part(s).

Replace the logic board. The pick-up roller sensor is faulty. The MPU and printer controller are faulty.

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BJC-5000

Part 5: Maintenance

7.Machine Temperature Error

<Cause> The thermistor is abnormal. <Suspected Parts> Thermistor <Corrective Action> Replace the logic board.

8.Waste Ink-Full Warning/Error

<Corrective Action>
Visual check of the waste ink absorber

<Cause> The waste ink absorbers estimated waste ink amount

has reached 95% (Warning) or 100% (Error).

<Suspected Parts> Waste ink absorbers, logic board

Waste ink absorbed is 75 % or more of the limit ? Yes

Check to see how much ink the waste ink absorber has absorbed. (Check the rate of ink penetration for the entire waste ink absorber as a guideline to determine the waste ink counter setting value.) No 1. Reset the waste ink amount in the EEPROM. 2. Replace the logic board. 0% (clear), 25%, 50% or 75% (See Part 3 3.4 Service Mode.)

Replace the waste END ink absorber.

Clear the total of the waste ink amount saved in the EEPROM.

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Part 5: Maintenance

BJC-5000
<Cause> The head temperature is abnormally high. <Suspected Parts> BJ cartridge, logic board

9.Head Temperature Error

<Corrective Action>

When you use two BJ cartridges on both the right and left sides, follow the flow below for each BJ cartridge. Turn off the power with the POWER button, and wait several minutes. Since the head temperature may be very high, do not touch the carriage.

Remove/install the BJ cartridge.

Power on

Error displayed ? Yes

No END Faulty BJ cartridge connection

1. Replace the ink cartridge.

2. Replace the BJ cartridge.

Check the connector cable.

Carriage ribbon cable

Correct ? Yes

No Replace the carriage unit.

Replace the logic board.

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Part 5: Maintenance

<Cause> The sub heater which is located inside the BJ cartridge

10. Sub Heater error

<Corrective Action>

cannot be driven.

<Suspected Parts> BJ cartridge, logic board, carriage unit

When you use two BJ cartridges on both the right and left sides, follow the flow below for each BJ cartridge. Remove/install the BJ cartridge.

Error displayed? Yes Clean the contacts.

No END If the BJ cartridge or carriage contact side is soiled with ink mist and the like, clean or replace it.

Check the BJ cartridge conductivity.

14

2 1

Pin 1, 2, 14: GND terminals Pin 7: Sub heater drive signal terminal

Correct ? Yes

No Replace the BJ cartridge.

1. Replace the logic board.

2. Replace the carriage unit.

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BJC-5000
<Cause> The BJ cartridge is off from a position where the

11. Cartridge Displaced Error

<Corrective Action>

cartridge may not be replaced.

<Suspected Parts> BJ cartridge, logic board, carriage unit

When you use two BJ cartridges on both the right and left sides, follow the flow below for each BJ cartridge. Remove/install the BJ cartridge.

Error displayed ?

No

END Yes 1. Replace the BJ cartridge. 2. Replace the logic board. 3. Replace the carriage unit.

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Part 5: Maintenance

<Cause> The paper feed operation is executed but the paper

12. Paper Feed Error/Paper Jam

<Corrective Action>
Visual check of the paper feed mechanism

is not fed. The paper eject operation is executed but the paper is not ejected. <Suspected Parts> Sheet feeder unit, pick-up roller sensor, paper end sensor, logic board.

With your eyes, check for paper jams. Check for gear deformation or damage.

Correct ? Yes Check the paper feed operation.

No Repair/replace a faulty part(s). During initialization, do the paper feed motor, pick-up roller, feed roller, eject roller, etc., rotate? Any abnormal noises? Is the paper feed motor out of synchronization? No

Correct ? Yes Repair/replace a faulty part(s) Replace the logic board.

Check the paper feed operation.

Is the paper fed properly from the sheet feeder when the pick-up roller rotates?

Correct ? Yes

No

Check the sheet feeder unit. Remove the sheet feeder unit, and operate it with your hands to check. Check any contamination, wear or deterioration of the rubber ring or separation sheet of the pick-up roller, and deformation or damage of a gear, etc. No Correct ? Yes Replace the sheet feeder unit.

Next Page

Check/Replace the paper Check for deformation or damage feeder motor drive of each gear and the slide lock lever, switching section. and removed springs. See Part 4 3.4.2 Paper Feed Motor Power Switching Section on page 4-29.

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Pick-Up Roller Sensor Flag Paper

Previous Page

Pick-Up Roller Sensor

Check the pick-up roller sensor flag

Check for pick-up roller sensor flag deformation or damage. No Replace the pick-up roller. Measuring points PS2 Pin No. 3 and 4 Sensor

Pick-Up Roller

Paper End Sensor Sensor Flag

Correct ? Yes

Check the pick-up roller sensor.

Normal reading

Open Low level High level (Initial position) Close Remove the logic board, then turn on the PS2 NO.4 power to check the rear of the sensor. No Replace the logic board. Does it move smoothly when you move it with your hands? Is it deformed or damaged? No Replace the paper end sensor flag or repair/replace a faulty part(s). Measuring Pin No. points PS1 3 and 4
NO.3

Correct ? Yes

Check the paper end sensor flag.

Correct ? Yes

Check the paper sensor.

Sensor

Normal reading

Low level (with paper) Open Close High level (no paper) Remove the logic board, then turn on the PS1 power to check the rear of the sensor. No Replace the logic board.

NO.4 NO.3

Correct ? Yes

END

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Part 5: Maintenance

<Cause> 1. The BJ cartridge recognition ID error is detected.

13 Right Head Recognition Error 14. Left Head Recognition Error

<Corrective Action>

2. The rank resistance error of the head is detected. 3. The resistance error of the head temperature sensor is detected. <Suspected Parts> BJ cartridge, carriage unit, carriage cable, logic board

The right head recognition error is not displayed in the same manner as the left head recognition error is (see Part 3, 3.1 Error Indications). Check to see on which head the error occurred, then follow the flow below to perform the corrective action of the appropriate head. Check how the BJ cartridge is. No Is the combination of the installed cartridges appropriate? (See the table below.) Are the cartridges installed properly? Left BJ cartridge BC-23 BC-20 (reference) BC-21e BC-21e BC-21e BC-23 BC-20 (reference) BC-21e Right BJ cartridge BC-23 BC-20 (reference) BC-21e BC-23 (BC-20 as reference) BC-22e Photo None None None

Correct ? Yes Remove the BJ cartridge.

Is any ink or foreign substance stuck to Check the BJ cartridge the cartridge? contact section Is the contact (cartridge and both ends of the carriage). section deformed or positioned improperly? No Correct ? Yes Clean the contact section. Re-install the BJ cartridge.

Replace the BJ cartridge.

Does the same error occur again ? Yes 1. Replace the carriage unit. 2. Replace the logic board.

No END

5-27

Part 5: Maintenance

BJC-5000

Symptoms <Symptom> The power does not turn on even though you

1. The Power Does Not Turn On

<Corrective Action>
START

press the POWER button.

<Cause> The AC adapter and/or logic board is (are) faulty.

Check the DC plug and output voltage. DC+24V(VM) DC+24V(VH) DC+5V(Vcc) VHPWR

GND GND GND Does the DC plug output the proper voltage ? Yes Replace the logic board. No Replace the AC adapter.

GND

5-28

BJC-5000

Part 5: Maintenance

<Symptom> The cartridge installed is not recognized.

2.The Printer Does Not Recognize The Cartridge

<Corrective Action>

The cartridge installed is recognized incorrectly.

<Cause> Faulty contact between the cartridge and carriage.

The cartridge, carriage cable and/or logic board is (are) faulty. The combination of the right and left BJ cartridges installed is incorrect.

When you install two BJ cartridges on the right and left sides, follow the flow below to perform the corrective action for each cartridge respectively. Check to see how the Is the combination of the installed cartridges appropriate? BJ cartridge is installed. (See the table below.) Are the cartridges installed properly? Correct ? Yes Remove/install the cartridge. Re-install the cartridge.
BC-21e BC-23 BC-20 (reference) BC-21e

No

Left BJ cartridge BC-23 BC-20 (reference) BC-21e BC-21e

Does the printer recognize the cartridge ? Yes

Right BJ cartridge BC-23 BC-20 (reference) BC-21e BC-23 (BC-20 as reference) BC-22e Photo None None None

No 1. Replace the cartridge. 2. Replace the logic board. The cartridge is faulty. Check the cartridge. The MPU and printer controller are faulty.

END

3. Replace the carriage unit. To check to see if the cartridge is recognized properly, check for conductivity at the check points indicated in the diagram below.
29 28 26 25 24 21 22 23

20 27 15 3

19 18 17 16 11 12 13 14 10 9 4 8 7 6 5 2 1

Black BJ Cartridge (BC-23) Measuring points Normal reading 11-14 Approximately 0 Pin No. 12-14 Approximately 0 13-14 1-9 Approximately 60 to 750 Photo BJ Cartridge (BC-22e Photo) Measuring points Normal reading 11-14 Pin No. 12-14 13-14 Approximately 0 1-9 Approximately 60 to 750

Color BJ Cartridge (BC-21e) Measuring points Normal reading 11-14 12-14 Approximately 0 Pin No. 13-14 Approximately 0 1-9 Approximately 60 to 750 Black BJ Cartridge (BC-20 [reference]) Measuring points Normal reading 11-14 Approximately 0 Pin No. 12-14 13-14 1-9 Approximately 60 to 750

Pins No.10-29 should not be 0 . (This applies to all BJ cartridges.)

5-29

Part 5: Maintenance

BJC-5000
<Symptom> The printer does not print at all.

3. Faulty Printing <1>: No Printing

<Corrective Action>

<Cause>

Printing stops halfway. Only a certain color is not printed. The ink has run out or the BJ cartridge is faulty. The logic board, carriage cable and/or purge unit is (are) faulty.

When you install two BJ cartridges on the right and left sides, follow the flow below to perform the corrective action for each cartridge respectively. Check how the BJ cartridge is installed. Is the combination of the installed cartridges appropriate? (See the table below.) Are the cartridges installed properly? Left BJ cartridge Right BJ cartridge BC-23 BC-23 BC-20 (reference) BC-20 (reference) BC-21e BC-21e BC-21e BC-23 (BC-20 as reference) BC-21e BC-22e Photo BC-23 None BC-20 (reference) None BC-21e None While the printer is turned on, hold down the POWER button for one beep. Then release the POWER button to print out the test pattern. No END

Remove/install the BJ cartridge. Execute a test print.

Is the printing result defective ? Yes

1. Replace the ink cartridge. 2. Replace the BJ cartridge.

Is the printing result still defective even after cartridge replacement ? Yes 1. Replace the logic board. 2. Replace the carriage unit. 3. Replace the purge unit.

No

END

The carriage cable is faulty. The purge unit is faulty.

5-30

BJC-5000
<Symptom> There is blotching.

Part 5: Maintenance

4.Faulty Printing <2>: Stripes Appear

<Corrective Actions>

<Cause>

There are white stripes on the printed paper. There are certain dots not printed. The BJ cartridge or cartridge contacts is/are faulty. The carriage cable is faulty. The purge unit is faulty.

White stripe sample Check the environment and paper specifications. Troubleshooting consists of error condition diagnosis, which is required if the cause of an error is unknown, and error recovery, which is performed if the cause of an error is known. If the cause of an error is unknown, perform the error condition diagnosis, and if it is known, perform error recovery.

Do they meet the required specifications ? Yes Remove and re-install the BJ cartridge.

No

Use paper which meets the specifications.

Execute a test print.

While the printer is turned on, hold down the POWER button for one beep. Then release the POWER button to print out the test pattern. No

Is the printing result defective ? Yes 1. Replace the ink cartridge. 2. Replace the BJ cartridge.

END

Do blotches and/or stripes still appear on the printed paper even after cartridge replacement ? Yes Check the carriage cable conductivity.

No

END

Conduction cutoff ? Yes Replace the carriage unit.

No Replace the purge unit.

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Part 5: Maintenance

BJC-5000

5 Faulty Printing <3>: Other Print Problems

Symptom Paper contamination Check item Ink mist on the platen Ink has dried up around the head nozzles. (No paper stain occurs by paper feeding or ejecting but occurs during printing only.) Ink has clogged or paper bits have stuck around the head wiper or head capping area of the purge unit. Ink has adhered to the paper transport system (Paper is already contaminated before it reaches the platen.) Spur tracks appear. Ink has adhered to the spurs. The spurs are deformed. The BJ cartridge has been installed incorrectly. The head is not aligned properly. The problem occurs when your BJ cartridge (which may cause this problem) is installed in a normallyoperating printer. The head gap has not been adjusted to the regulated value (You cannot check to see if this gap is appropriate*). The carriage guide frame is deformed. Frictional wear between the carriage base and the carriage shaft. The head has not been aligned properly. Insufficient cleaning / Ink run-out / Faulty BJ cartridge The printout is either too light or too dark. The printing darkness is unbalanced. Check the printing mode. The BJ cartridge is faulty. The head has not been aligned properly. Corrective action Use a piece of soft cloth lightly damped with water to clean the platen. Clean the head nozzles and their surroundings several times. If the problem persists, replace the BJ cartridge. Replace the purge unit or wiper unit. Disassemble the paper transport system, then use a piece of soft cloth lightly damped with water to clean the platen. Use a soft toothbrush to clean the spurs. Replace the spurs. Reinstall the BJ cartridge correctly. Use the printer driver to perform the automatic head alignment operation. Replace the BJ cartridge.

Lines are not ruled properly.

Adjust the head gap (See 5. Adjustments on page 5-8).

Corrugated printing

Replace the carriage guide frame. Replace the carriage unit. Use the printer driver to perform the automatic head alignment operation. Perform the cleaning operation several times, then execute a test print. Replace the BJ cartridge. Set the desired printing mode. Replace the BJ cartridge. Use the printer driver to perform the automatic head alignment operation.

Print quality is not uniform.

* It is difficult to check the head gap. Readjust the head gap, then check whether it fixes this problem.

5-32

BJC-5000
<Symptom> No printing.

Part 5: Maintenance

6.Faulty Interface
<Corrective Action>
Execute a test print.

An unspecified color is printed.

<Cause> The printer driver is not set properly.

The interface cable is faulty. The logic board located at the printer is faulty.

While the printer is on, hold down the POWER button for one beep. Then release the POWER button to print the test pattern. No Replace the logic board.

Is the test pattern printed normally ?

Yes Check the printer driver settings.

Correct ? Yes

No Reset the printer driver.

1. Replace the interface cable. 2. Replace the logic board. The interface connector is faulty. The MPU and printer controller are faulty.

5-33

Part 5: Maintenance

BJC-5000

7. LOCATION AND SIGNAL ASSIGNMENT

7.1 Logic Board
1

J1
1

31

J7
1 2 1 2

3 32 31

J2
4

32

J6

J4
8

J3

1 4

1 1 19

J5
18 36

Figure 5-10 Logic Board J6 (Carriage cable connector)

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Signal name VHGND VHGND MCH0 MCH1 VH VH SUBH RSV1 RANK DIA ID0 ID1 IND LGND HENB0 EVENB HENB1 HENB3 ODENB BENB0 BENB1 BENB2 VCC DCLK DTLD DTRST HENB2 IDATA DIK HPO HHPG HPA IN/OUT ... ... IN IN OUT OUT OUT ... IN OUT IN IN ... ... OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT IN IN ... OUT Description GND for the head drive voltage VH GND for the head drive voltage VH Driver signal for the temperature control heater Driver signal for the temperature control heater Head drive voltage Head drive voltage Sub heater drive signal Not used Detection signal for rank resistance Head temperature sensor (diode) anode Cartridge detection signal Cartridge detection signal Cartridge detection signal GND for the head logic drive voltage HVdd Heat enable (Y) Even nozzle heat enable Heat enable (M) Heat enable (Black) Odd nozzle heat enable Signal for generating the block enable decoder output signal Signal for generating the block enable decoder output signal Signal for generating the block enable decoder output signal IC drive voltage (+ 5V) Print data transfer signal Timing signal for print data to be latched Latch reset signal Heat enable (C) Printing data Head temperature sensor (diode) cathode Home position sense signal High (sense)/Low GND Photo LED drive signal

5-34

BJC-5000
J7 (Carriage cable connector)
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Signal name VHGND VHGND MCH0 MCH1 VH VH SUBH RSV1 RANK DIA ID0 ID1 IND LGND HENB0 EVENB HENB1 HENB3 ODENB BENB0 BENB1 BENB2 VCC DCLK DTLD DTRST HENB2 IDATA DIK AAO AAA AAG IN/OUT ... ... IN IN OUT OUT OUT ... IN OUT IN IN ... ... OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT OUT IN IN OUT ...

Part 5: Maintenance

Description GND for the head drive voltage VH GND for the head drive voltage VH Driver signal for the temperature control heater Driver signal for the temperature control heater Head drive voltage Head drive voltage Sub heater drive signal Not used Detection signal for rank resistance Head temperature sensor (diode) anode Cartridge detection signal Cartridge detection signal Cartridge detection signal GND for the head logic drive voltage HVdd Heat enable (Y) Even nozzle heat enable Heat enable (M) Heat enable (Black) Odd nozzle heat enable Signal for generating the block enable decoder output signal Signal for generating the block enable decoder output signal Signal for generating the block enable decoder output signal IC drive voltage (+ 5V) Print data transfer signal Timing signal for print data to be latched Latch reset signal Heat enable (C) Printing data Head temperature sensor (diode) cathode AA sensor sense signal (Analog input) Photo LED drive signal GND

J1 (Purge sensor connector)

Pin No. 1 2 3 Signal name PSVCC GND U102(PB6) IN/OUT OUT ... IN Description Photo LED drive signal GND Purge sensor sense signal High (sense) / Low

J2 (Carriage motor connector)

Pin No. 1 2 3 4 Signal name CRA+ CRACRB+ CRBIN/OUT OUT OUT OUT OUT Description Carriage motor phase A+ Carriage motor phase A Carriage motor phase B + Carriage motor phase B -

J3 (Paper feed motor connector)

Pin No. 1 2 3 4 Signal name LFA+ LFALFB+ LFBIN/OUT OUT OUT OUT OUT Description Paper feed motor phase A + Paper feed motor phase A Paper feed motor phase B + Paper feed motor phase B -

5-35

Part 5: Maintenance

BJC-5000

J4 (DC power connector)

Pin No. 1 2 3 4 5 6 7 8 Signal name VH GND VM GND VCC GND VHPWR GND IN/OUT IN ... IN ... IN ... OUT ... Description +24 VDC GND +24 VDC GND +5 VDC GND VH power supply for the print head heater, ON (High)/OFF signal GND

J5 (Interface connector)
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Signal name STB DATA1 DATA2 DATA3 DATA4 DATA5 DATA6 DATA7 DATA8 ACK BUSY PE SLCT AFXT N.C. S-GND F-GND +5 V STB-GND D1-GND D2-GND D3-GND D4-GND D5-GND D6-GND D7-GND D8-GND ACK-GND BUSY-GND INT-GND INT FAULT S-GND N.C. +5 V PU SELIN IN/OUT IN IN IN IN IN IN IN IN IN OUT OUT OUT OUT IN ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... IN OUT ... ... ... IN Description See Part 2 for details.

5-36

BJC-5000

8.1 Parts Layout 8.1.1 Logic board

D18 D17 D16 D15 D14 D13

S2 RESET

0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
1 S1 POWER B 8 PS3 19 D3 U12 1 U11

Q23

31

32 J4 C62

J7

U2

J1

8. CIRCUIT DIAGRAMS

31 X1 B 53 208

J6

Q22

C77

52

C71

D4 1 ZD1

J2

C76
R

ZD2

PS2 F1 105 156 U9

PS1

18

BZ1

36

Figure 5-11 Logic Board (Top View)

D5

DAY INDX

FNCK

F2

U5 104

SCE -4 T
157

J5

5-37
QH1-9002-01 QG8-8002
J3 1

32

D12

D10

D11

D9

D8

D7

D6 4

Part 5: Maintenance

Part 5: Maintenance

BJC-5000

C46 R40 R132 Q10 Q9 R39 Q8 R16 R134 R133 R33 R131 R32 FB55 R81 R140 FB54 R149 R148 R21 R141 R146 R145 R91 R142 R139 R24 TP56 Q27 R60 C70 C49 FB52 R79 R137 FB51 R159 R157 R136 R155 R154 R90 R152 R138 Q25 R99 R123 R103 R105

TP4

R118

R114 R120 R115 R7 R110 R108 R106

R112 TP33

Q14 R98 R122 R101 R104 R100

R63 R66 R20 C68 R62 R65 R19 C67 C14 R41 R93 R92 C36 C15 R58 C10

Q15

C61

R96 Q18 U15 R52

U14

Q26 Q3 Q17

Q24 Q13

R102

R29

R26

R97 Q19 C37 R119 R113 R116 R121 R117 R126 R111 R109 R107 C85

LED1 Q2

R125

R38

R124

R95 LED2 LED3 R69 R68 R191 R70 TP58

R94 R61 C39 R144 R147 R143 FB56 R150 R78 R82 R130 R37 R36 R127

TP6

R23 R22

R28 R74 R77 R31 R27 R73 R76 R30

C78

R153 R156 R151 FB53 R158 R75 R80 R129 R35 R34 R128 C51 C86 TP7

TP57

R42

U3

R71 C7 C52 C53 C54 R38 TH1 R43 C4 C16 U10

Q11 R59 C83 R51 C66 C65 R50 C12 R54 R4 D2 TP34 R83 FB35 TP32 Q4 FB34 Q7 R170 R89 R88 TP25 TP26 TP22 TP23

R53 R57 R56 R55 C11 TP30 TP18 C28 TP19 TP10 TP27 TP3 C27 R13 R10 C42 C26 R45 C64 R47 R49 R46 R48 R44 C63 R86 R87 R167 R190 R84 R168 R171 1 2 3 4 5 6 7 8 9 XYZ TP5 Q6

C5 C40 R5

R8

C19 C20 C6 R9 R12 R17 C21 C9

R1 FB61 FB62 TP31 TP11

C44 FB1 TP8 TP9

C24 C23 R14 R15

FB3 C18 C43 R11

C22 C25

C8

C45

TP15 TP14 TP17

R64 R67 R25 C69 C87

TP13 TP16

FB7 FB8 FB9 FB10 FB11 FB12 FB13 FB14 FB58 FB59 FB60 FB23 FB24 FB25 FB26 FB28 C48 R166 R160

C17 FB22 FB21 FB20 FB19 FB18 FB17 FB16 FB57 FB4 FB31 FB30 FB29 FB27 C47

C13 ZD3 R72 C84 R175 R176 R177 R178 R179 R180 R181 R182 R183

R163 R164 R162 R165 R161

R169

VCC GND

GND

GND

VM

GND

VH

C72 R185 R184 R186 R187 C74 C75 R188 C73

ZD12

Figure 5-12 Logic Board (Bottom View)

FB32 FB50 FB49 FB48 FB46 FB47 FB45 FB44 FB33 FB37 FB36 FB38 FB39 FB42 FB43 FB40 FB41 R189

5-38

R6 R174 R85 R173 R172

FB15

C79 C80 C81 C82

98 M A

0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9

C56

C55

TP12

TP2

TP21 TP20

U6

BJC-5000
8.2 Circuit Diagrams 8
VCC VCC C7 0.1m F 16

Part 5: Maintenance

7
Multiplexer U3
4053
VCC X0 X1 Y0 Y1 Z0 Z1
INH A B C <02-A3> AASENS

5
VCC C26 0.1m F C42 1000PF C46 1000PF R16 10K,1/16W

4
R39 39K,1/16W VCC R10

3
PSVCC R40 390,1/16W

2
CNPG(for Purge Sensor)
1 2 3

1
LOGIC BOARD 01
TP27 EEDI TP10 EEDO

J1
TP18 EECS TP19 EECLK

VCC

EEPROM(1Kbit)

Temperature Senser
THI NTCCM20124AG473HC

THR

12 13 2 1 5 3 6 11 10 9 7 8

X Y Z

14 AN0 15 AN1 4 AN2

<03-D3> <03-D3> <03-C3> <03-C3> <03-C8> <03-C8> <03-C8> <03-C8>

R13 10K,1/16W

OPTIONAL DO NOT INSTALL

R43 3.3K,1/16W

AT93C46R-10SC
1 2 3 4

U10

<02-A4> DSR RANKR <02-B4> <02-A8> DSL <02-B8> RANKL

51PF

51PF

51PF

PSPWR <01-E2> IFPWR RNKPWR VDDPWR VHPWR CRBP CRB1 CRA1 CRAP CRB0 CRA0

C53

C52

C51

LFA0 LFAP HPSNS ASFSNS PESNS

BUZZER AALED

LFA1 LFBP LFB0 LFB1 FAULT SLCT PE BUSY BUSY PE SLCT

FAULT

IFPWR <03-F8> RNKPWR <02-B8,02-B4> VDDPWR <02-E3,02-E6> VHPWR <03-B1> LFA0 <03-D3> LFAP <03-D3> HPSNS <02-A6> <01-D1> <01-D1>

EECS EECLK

NC NC VCC GND CS DO DI SK

8 7 6 5

EEDO EEDI

C16
BUZZER <01-A4> AALED <02-A2>

C83 1000PF

VCC C28 C27

0.1m F

<03-E7>

BUSY PE SLCT FAULT LFPWR LFB1/SMC ST0 LFB0/SMC ST1 LFBP/SMC ST2 LFA1/SMC ST3 VREF AN3 AN2 AN1 AN0 AGND LFA0/SMC ST4 LFAP/SMC ST5 HPSNS(PA1)/SMC WR ASFSNS(PB3)/SMC RD PESNS(PB2)/SMC CS WDTOUT/SMC TEST A0/SMC GDIS CLK/SMC DTAD U1O2(PB6)/SMC EMPTY U1O1(P77)/SMC FULL U1O0(P65)/SMC TO PSPWR(P63)/SMC INTP IFPWR(P62)/SMC WAIT RNKPWR(P55)/SMC OE VDDPWR(P54)/SMC D0 VHPWR(P53)/SMC D1 CRBPWM(T03)/SMC D2 CRB(PG03)/SMC D3 CRB(PG01)/SMC D4 CRAPWM(TO1)/SMC D5 CRA(PG02)/SMC D6 CRA(PG00)/SMC D7 VSS TEST0 TEST1 TEST2 EEDO/EA VDD EEDI/AM816 EECS/SMC A0 EECLK/SMC A1 BUZZER/SMC A2 AALED/SMC A3 ASYNC DIS SCAN ENA ID1L(P83) ID0L(P82)

IFD[0....7]

<03-C8> ACK 157

156 155 154 153 152 151 150 149 148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125 124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105

0.01m F

<01-C3> R38 68K,1/16W,0.5%

AN3 AN2 AN1 AN0

ID1L ID0L

VCC C21 0.1m F

104 103 102 101 100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53

1 <01-F4> PSPWR 2 3

C54

MUXSEL

LFB1 LFB0 LFBP LFA1

CRBP <03-E3> CRB1 <03-E3> CRA1 <03-F3> CRAP <03-F3> <03-F3> <03-F3>

VCC

ID1L <02-D8> ID0L <02-D8>

VCC F 1000PF 0.1m Q6 FAIL4P OPTIONAL DO NOT INSTALL

VEE GND

C9 1000PF

VCC TP22 INT TP23 TP25 TP26 SLIN STB AFXT C22 1000PF C25 0.1m F

IFD7 158 IFD6 159 IFD5 160 IFD4 161 IFD3 162 IFD2 163
164 165 IFD1 166 IFD0 167 168 169 170 171 RA3 172 RA2 173 RA1 174 RA0 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 RA8 202 RA7 203 RA6 204 RA5 205 RA4 206 207 208

AFXT <03-C8> <03-D8> STB SLIN <03-C8> <03-B8> INT

BK1608LM152
<01-B8> RAS <01-B8> WE FB4 FB57

VCC VCC R14 10K,1/16W VCC R15 10K,1/16W RAMD7 RAMD6 RAMD5 RAMD4 RAMD3 RAMD2 RAMD1 RAMD0 RAMD15 RAMD14 RAMD13 RAMD12 RAMD11 RAMD10 RAMD9 RAMD8
<01-B8> LCAS <01-B8> UCAS <01-B8> OE FB58 FB59 FB60

RA[0....8]

DRAM(4Mbit) U11
TC514260C-70JS
BK1608LM152 26 RA8 FB23 25 RA7 FB24 24 RA6 FB25 23 RA5 FB26 22 RA4 FB28 19 RA3 FB27 18 RA2 FB29 17 RA1 FB30 16 RA0 FB31
13 14 29 28 27 1 6 20

A8 A7 A6 A5 A4 A3 A2 A1 A0

TP13 TP15 TP17 OE LCAS WE TP14 TP16 UCAS RAS

<01-D7> WE <01-D7> RAS <01-C6> LCAS <01-C6> UCAS <01-C6> OE

I/O16 I/O15 I/O14 I/O13 I/O12 I/O11 I/O10 I/O9 I/O8 I/O7 I/O6 I/O5 WE RAS I/O4 LCAS I/O3 UCAS I/O2 I/O1 OE VCC VSS VCC VSS VCC VSS VCC

BK1608LM152 39 FB7 RAMD15 RAMD14 38 FB8 RAMD13 37 FB9 RAMD12 36 FB10 34 FB11 RAMD11 33 FB12 RAMD10 32 FB13 RAMD9 31 FB14 RAMD8 10 FB15 RAMD7 9 RAMD6 FB16 8 RAMD5 FB17 7 RAMD4 FB18 5 RAMD3 FB19 4 RAMD2 FB20 3 RAMD1 FB21 2 RAMD0 FB22
40 35 21

BK1608LM152 VCC C23 1000PF C24 0.1m F VCC

NANDTREE D11 D4 D3 D12 D10 D5 D2 D13 VDD D9 D6 D1 D14 VSS D8 D7 D0 D15 RD ROMCS WR HWR A17 A1 A16 A2 A15 A3 A14 A4 A13 A5 A12 A6 A11 A7 VSS A10 A8 A9 A18 VDD A20 A19 A21 A22 A23 ERRLED(P61) PWRLED(P60) PWRSW(P74) RSMSW(P75)

ACK IFD7 IFD6 IFD5 IFD4 IFD3 IFD2 VSS VDD IFD1 IFD0 AFXT STB SLIN INIT RA3 RA2 RA1 RA0 RAS WE NMI RAMD7 RAMD6 RAMD5 RAMD4 RAMD3 RAMD2 RAMD1 RAMD0 PB0 PB1(INT5) RAMD15 RAMD14 RAMD13 RAMD12 RAMD11 RAMD10 RAMD9 RAMD8 LCAS UCAS OE VSS VDD RA8 RA7 RA6 RA5 RA4 TDI(SCANIN) TDOI(SCANOUT)

MPU & Printer Controller U12

T5L25

VCC C45 1000PF C8 0.1m F

IDATAL HENB2L HENB3L HENB1L HENB0L INDL SUBHL VDD VSS MCH1L MCH0L IDATAC HENB2C HENB3C HENB1C HENB0C INDC SUBHC MCH1C MCH0C ID1C(P85) ID0C(P84) IDATAR HENB2R HENB3R HENB1R HENB0R INDR SUBHR MCH1R MCH0R ID1R(P81) ID0R(P80) DTRST DTLD DCLK BENB2 BENB1 BENB0 EVENB ODENB MUXSEL(P64) DRSW(P76) VDD VSS RESET X2 X1 WAIT INT6 INT7 INT0

IDATAL HENB2L HENB3L HENB1L HENB0L INDL SUBHL MCH1L MCH0L

<02-D8> <02-C7> <02-C7> <02-C7> <02-C7> <02-B6> <02-F7> <02-E8> <02-E8>

C85 R59 47K,1/16W 1000PF

C86 1000PF

PSVCC <02-A6> R62 390 OHM,1W R65 39K,1/16W R19 10K,1/16W PESNS <01-F5> C67 100PF

R 17 VCC VCC VCC 10K,1/16W R12 10K,1/16W

TP20 ID1C TP21 ID0C

Paper End Sensor 3 1

2 4

PSI GP1SQ59C

R9 IDATAR <02-D4> 10K,1/16W HENB2R <02-C4> HENB3R <02-C4> HENB1R <02-C4> HENB0R <02-C4> INDR <02-B3> SUBHR <02-F4> MCH1R <02-E4> MCH0R <02-E4> ID1R <02-D4> ID0R <02-D4> DTRST <02-D7,02-D4> DTLD <02-D7,02-D4> DCLK <02-D8,02-D4> BENB2 <02-C7,02-C4> BENB1 <02-C7,02-C4> BENB0 <02-C7,02-C4> EVENB <02-D7,02-D4> ODENB <02-C7,02-C4> MUXSEL <01-E7> DRSW <01-C1>

D
R63 390 OHM,1/10W

Pick-UP Roller Sensor 1

3 2 4

R66 39K,1/16W R20 10K,1/16W ASFSNS C68 100PF

<01-F5>

PS2 TLP832

R64 390 OHM,1/10W

VCC

Cover Open Sensor 1

3 2 4

R67 39K,1/16W R25 10K,1/16W

C
DRSW C69 100PF
<01-C3>

C20 0.1m F

C6 1000PF

PS3 TLP832

Control ROM VCC

(8Mbit)

1 2 3 4 5 6 7 8 9 10 11 D9 12 D6 13 D1 D14 14 15 16 D8 17 D7 18 D0 D15 19 20 21 22 23 24 A17 A1 25 A16 26 27 A2 28 A15 29 A3 30 A14 A4 31 32 A13 33 A5 34 A12 35 A6 36 A11 A7 37 38 39 A10 40 A8 A9 41 42 A18 43 44 A20 45 A19 A21 46 A22 47 A23 48 ERRLED 49 PWRLED 50 PWRSW 51 RSMSW 52

U2
UPD23C8000 XCZ-187
22

C17 TP34 VH TP35 VM 0.1m F

C47 1000PF A[1....20]

A20 A19 A18 A17 A16 A15 A14 A13 A12 A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1

R11 10K,1/16W

TP12 X1 OPTIONAL DO NOT INSTALL R8 1M,1/16W

D11 D4 D3 D12 D10 D5 D2 D13

TP2 X2 TP7 RESET

VCC

VH TP4 VCC

VM TP5 VCC TP6 VCC TP30 GND TP31 GND TP32 GND TP33 MGND

VCC MT1 1 MT2 1 Linking mounting pads to GND TP11 RD R1

<01-B5> RD

VCC ROMCS <01-B4>

FB62 FB61

42 1 2 33 34 35 36 37 38 39 40 41 3 4 5 6 7 8 9 10 32 11 13 12 31

4.7K,1/16W

VCC A19 A18 D15 A17 D14 A16 D13 A15 D12 A14 D11 A13 D10 A12 D9 A11 D8 A10 D7 A9 D6 A8 D5 A7 D4 A6 D3 A5 D2 A4 D1 A3 D0 A2 A1 A0 BYTE / VPP CE OE VSS VSS

D[1....15]
30 28 26 24 21 19 17 15 29 27 25 23 20 18 16 14 D15 D14 D13 D12 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0

BLMHA1218 <01-A7> RD FB3 <01-A7> RMOCS FB1 WR HWR

VCC C43 1000PF C18 0.1m F

<01-A4> <01-A5>

A[1....20] TP8 HWR TP9 WR VCC C56 C19 VCC

1

CST25.0MX040
3 OUT OUT 1

Oscillator X1
GND 2

R5 1K,1/16W
1

Reset IC U6
OUT VOC MARES GND
3 4

TP3 VCC

VCC

PST592EMT
C5 C55 15PF R21 10K,1/16W VCC 0.1m F
2

C4

C40

C44 1000PF VCC 15PF

0.1m F 1000PF

VCC

0.1m F

Indicators
Q2 FAIL4P

<01-B3> PWRLED 2

<01-B3> ERRLED 2

Q3 FAIL4P

RESET S2 C61 0.022m F POWER

Beeper
R70 180 OHM,1/4W BZ1 CD11PA-Z R71 1.5K,1/16W Q11 FAIL4M

R69 150 OHM,1/4W

R68 150 OHM,1/4W

R191 180 OHM,1/4W

R24 10K,1/16W

VCC R22 10K,1/16W

Control Buttons
S1

LED3 ORENGE LED LED1 GREEN LED

<01-F3> LED2 ORENGE LED

BUZZER

2 1

R23 10K,1/16W

C78 0.022m F

BK1608HS330

5-39

BJC-5000

Part 5: Maintenance

8
VH

6
J6
R94 0.1m F,50V 2.7K, R124 3.9K,1/4W 1/16W
3 3

5
CNH (for Left Printhead)

4
VH

2
CNH (for Right Printhead)

1
LOGIC BOARD 02
J7

C76 2200m F,35V

C37 R26 12K,1/10W

C77 VH VH VHGND VHGND SUBH R76 100 1/16W 2200m F,35V

C38 0.1m F,50V R95 R29 12K,1/10W

5 6
1

5 6
1

VH VH VHGND VHGND SUBH

<01-E3>

SUBHL

2 1

Q13 FAIL4M

Q22 25B1443
2 2 4 1 3 D7

1 2 7

2.7K, R125 3.9K,1/4W 1/16W

3

SUBHR <01-D3>

Q17 FAIL4M

Q23 25B1443
2 2 4 1 3

1 2 7

HZM27FA
5

D13
5 HZM27FA

<01-E3>

MCH0L

R73 100 1/16W

3 Q24 25K1772

1 3

MCH0
<01-D3>

3 Q26 25K1772

MCH0R

1 3

MCH0

R27 10K,1/16W
MCH1L

R30 10K,1/16W 4 MCH1

<01-D3> MCH1R

R74 100 1/16W

<01-E3>

R77 100 1/16W

Q25 23K1772
2 <01-F4,02-E3> VDDPWR

VCC Q8 BLM11A601S FN1A4P FB53

3

4 Q27 23K1772
2 <01-F4,02-E6> VDDPWR 3

VCC Q9 BLM11A601S FN1A4P FB56 R61 47K,1/16W

MCH1

R28 10K,1/16W

23 VCC

R31 10K,1/16W

23

VCC

R60 47K,1/16W
<01-C3,02-D4> DTRST

14

LGND
<01-C3,02-D7>

R79 100 1/16W R80 100 1/16W 100 1/16W

D14
2 4 1 5 3

26 DTRST

DTRST

R81 100 1/16W R82 100 1/16W 100 1/16W

D14
2 4 1 5 3

14 LGND 26 DTRST

VCC

VCC
<01-C3,02-D4> EVENB R34 10K,1/16W

VCC

VCC

R35 10K,1/16W
<01-F3> <01-F3> <01-C3,02-D4>

16 11 12

EVENB ID0 ID1

<01-C3> ID0R <01-C3> ID1R <01-C3,02-D8> DCLK

R37 10K,1/16W

R36 <01-C3,02-D7> EVENB 10K,1/16W

R139 R142 R143 R144
<01-C3,02-D7> DTLD <01-D3> HENB0R <01-D3> HENB1R

16 EVENB 11 ID0

ID0L ID1L DCLK

R138 R152 R151 R153

<01-C3,02-D4> DTLD <01-E3> HENB0L <01-E3> HENB1L <01-E3> HENB2L

HZM6.8FA

HZM6.8FA

12 ID1 FB54 FB55 BLM11A601S

4 1 5

IDATAL <01-E3>

100 1/16W R137

R154 R155 R156

FB51 FB52 BLM11A601S

4

24 DCLK D9
2 1 3 5

<01-D3> IDATAR

24 D15
2 3

DCLK

28 IDATA 25 DTLD 15 HENB0

100 1/16W R140

R145 R146 R147

28 IDATA 25 DTLD 15 HENB0

HZM6.8FA

HZM6.8FA D16
2 3 5

<01-D3> HENB2R

VCC U14A
<01-E3>

D10
2 3 5

17 HENB1
<01-D3>

HENB3L

R136 R157 R158 R159

4 1

HENB3R

17 HENB1 27 HENB2 18 HENB3 20 BENB0

R141 R148 R150 R149

1 11

_ 2 +
3

<01-C3,02-C4> BENB0 <01-C3,02-C4> <01-C3,02-C4>

27 HENB2 18
1

U15A

4 1

_ 2 +
11 3

<01-C3,02-C7> BENB0 <01-C3,02-C7> <01-C3,02-C7>

BENB1 BENB2

HZM6.8FA

HENB3

BENB1 BENB2

HZM6.8FA D17
2 3 5

LM324

D11
2 3 5

20 BENB0 21 BENB1 22 BENB2 19 ODENB VCC VCC R128 10K, 1/16W 9 RANK 8 RSV1 13 IND 10 DIA

LM324

<01-C3,02-C4> ODENB <01-F4,02-B4> RNKPWR

R75 100 1/16W

4 1

<01-C3,02-C7> ODENB <01-F4,02-B8> RNKPWR

R78 100 1/16W

4 1

21 BENB1 22 BENB2

HZM6.8FA

HZM6.8FA VCC VCC R97 750 OHM, 1/10W 0.5W VCC R127 10K, 1/16W

R104

VCC R122 56K, 1/16W 0.5%

VCC R96 750 OHM, 1/10W 0.5W

3 2

R105

VCC R123 56K, 1/16W 0.5%

3

19 ODENB

R101 100K,1/16W 0.5% VCC

2 R98 39K, 1/16W 0.5%

Q14 FAIL4M

Q15 FAIL4M
INDL <01-E3>

11

11

LM324

LM324

<01-F7>

RANKL

510K,1/16W 1% R100 VCC 100K,1/16W 0.5% U14B _ 6

4 7

+ 5

R129 10K,1/16W

<01-F8> RANKR

510K,1/16W 1% R102 VCC 100K,1/16W 0.5% U15B _ 6

4 7

+ 5 R103 100K,1/16W 0.5% VCC R99 39K, 1/16W 0.5%

2

R130 10K,1/16W

B
9 RANK 8 RSV1 13 IND 10 DIA

R90 100,1/16W

Q18 FAIL4M

Q19 FAIL4M
<01-D3> INDR

R91 100,1/16W

R120 470K,1/16W 1%

CM324

R114 100K,1/16W 0.5%

100 OHM, 1/16W 0.5% R112 12K,1/16W 0.5%

11

11

11

LM324

R108 7.5K, 1/16W 0.5%

<01-E1>

R133 39K, 1/16W 30 HPO R134 32 HPA

11

<01-F7> DSL

14

R118 33K 1/16W 0.5% VCC R115 U14D 100K,1/16W 0.5% _ 13

4

VCC VCC R110 _ U14C 9 +

10 4

D12
2 4 1 5 3

R121 470K,1/16W 1%

R106 180K, 1/16W 0.5%

HZM6.8FA

29 DIK

+ 12

R7 1K,1/16W 0.5% VCC

PSVCC

<01-F8> DSR

14

R119 33K 1/16W 0.5% VCC R117 U15D 100K,1/16W 0.5% _ 13 + 12

CM324

VCC VCC R111 _ U15C 9 +

10 4

D18
2 4 1 5 3

R107 180K, 1/16W 0.5%

HZM6.8FA R126 1K,1/16W 0.5% VCC R131 22K, 1/16W

29

DIK

R116 100K,1/16W 0.5%

100 OHM, 1/16W 0.5% R113 12K,1/16W 0.5%

LM324

R109 7.5K, 1/16W 0.5% R32 10K,1/16W C39 0.1m F

30 32

AAO AAG

<01-F5> HPSNS

390 OHML 1/10W R33 C70 10K, 1/16W 100PF C49 1000PF

<01-F8> AASENS

31 HHPG

VCC

R132 1 FN1A4P3 180 OHM, 1/4W

2

Q10

31 AAA

<01-F3> AALED

5-40

BJC-5000

Part 5: Maintenance

8
IFPWR
<01-F4>

5
VM

4
F1 ICP-N25 + C62 100m F,35V

1
LOGIC BOARD 03

C13 VCC
1

0.1m F,50V Q7 FN1A4P 3.3K,1/16W D2 R166 R160 R163 R164 R162 R165 R161 R169 RB4 R83 100, 1/16W IFD[0....7]
<01-E6>

VCC C10 VCC 0.1m F

Carriage Motor Driver

2 3

U5
VSS VREF1 VREF2 PHASE I01 I11 VS OUT1A OUT1B OUT2A 24 1 21 2 5 22

F
CRA+ CRA CRB+ CRB

13 15 11 16 20 17 10 8 9 14

CNCR J2 CON4 Carriage Motor

1 2 3 4 C11 APPROX.10.5 / phase

CNIF (for Interface)

FCN-684J036-L/U#
FB32 BLM11A601S
D3 2 3

U5
2 3 4 5 6 7 8 9 1

R93 1K, 1/16W, 1%

CRAP <01-F4> CRA0 <01-F4> CRA1 <01-F4>

<01-F4> <01-F4> <01-F4>

2 1

Q4 FAIL3M

10 OHM,1/16W IFD0 R175 IFD1 R176 IFD2 R177 IFD3 R178

FB50

BLM11A601S

4 1 5 HZM6.8FA

FB49

BLM11A601S

D1 D2 D3 D4 D5 D6 D7 D8 STB

CRBP CRB0 CRB1

OUT2B PHASE2 I02 COMP1 I12 RC1 SENSE1

R56 1 OHM,1/4W,1%

R42 23 1K,1/16W

R41 1.5K, 1/16W, 1%

820PF

C15 470pF

R58 56K, 1/16W 12 RC2 GND GND

COMP2 SENSE2 GND GND L6219

4 R52

C14 820PF

R53 1 OHM,1/4W,1% R57 1 OHM,1/4W,1%

E
R55 1 OHM,1/4W,1%

FB48

BLM11A601S C36

3 19 18

1K,1/16W

FB46 10 OHM,1/16W IFD4 R179 IFD5 R180 IFD6 R181 IFD7 R182 FB45 FB47

BLM11A601S
D4 2 3

BLM11A601S
4 1 5 HZM6.8FA

BLM11A601S

11 10 12 13 32 36 14 31

BUSY ACK PE SLCT FAULT SELIN AFXT INT 15 N.C. 34 N.C. VCC

470pF

R92 56K, 1/16W

6 7

F2 ICP-N25

CNLF
VCC C12

Paper Feed Motor Driver

13 15 11 16 20 17 10 8 9 14

FB44 R6 1K,1/16W
<01-E7>

BLM11A601S ZD12 RD6.8SB BLM11A601S FB33 BLM11A601S FB36

2 D5 3

U9

0.1m F

VSS VREF1 VREF2 PHASE I01 I11

VS OUT1A OUT1B OUT2A

24 1 21 2 5 22 R44 23 4 R45 3 19 18 1K, 1/16W 1K, 1/16W C64 820PF C63 820PF C79 C80 C81

CON4 LFA+ 1 LFA 2 LFB+ 3 LFB 4

J3

Paper Feed Motor

APPROX. 2.7/phase

C82

STB C72 470PF BUSY ACK PE SLCT FAULT SLIN C73 470PF AFXT C74 470PF

R85 10 OHM,1/16W R183 R184 R185 R186 1K,1/16W

R54 1.8K, 1/16W, 1%

18 +5V 35 +5V PU 19 STB -GND 20 D1-GND 21 D2-GND 22 D3-GND 23 D4-GND 24 D5-GND 25 D6-GND 26 D7-GND 27 D8-GND 28 29 ACK-GND BUSY-GND 30 INT-GND 33 S-GND 16 S-GND 17 F-GND

<01-F5> LFA0 <01-F5> LFA1 <01-F6>

LFAP

1000PF 1000PF 1000PF 1000PF

<01-F6> <01-E6> <01-F6>

FB37

BLM11A601S

4 1 5 HZM6.8FA

FB38

BLM11A601S

R4 2K, 1/16W, 1%

LFBP <01-F6> LFB0 <01-F6> <01-F6> LFB1 C65 470pF

OUT2B PHASE2 I02 COMP1 I12 RC1 SENSE1

R48 10HM,1/4W

<01-F6> <01-F6> <01-D7>

10 OHM,1/16W R187 R188 R189 R190

FB39

BLM11A601S

R50 56K, 1/16W 12

RC2 GND GND

COMP2

R46 10HM,1/4W R49 10HM,1/4W

C
R47 10HM,1/4W

FB40

BLM11A601S
D6 2 3

SENSE2 GND GND

C66 470pF R51 56K, 1/16W

<01-E7>

FB41

BLM11A601S

6 7

4 1 5 HZM6.8FA

L6219

FB42 INT R84 10 OHM, 1/16W C75 470PF R174 R173 R172 R171 R170 R167 R168

BLM11A601S

OPTIONAL DO NOT INSTALL

FB43 BLM11A601S

<01-D7>

R72 C84 1000PF C71 C48 ZD3 RD6.2SB2 VCC 1K,1/16W C87 1000PF

VHPWR

<01-F4>

3.3K,1/16W

CNPS
CON8
R88 390 OHM,1/10W FB35 BLM11A601S FB34 BLM11A601S R86 0OHM,1/16W R87 0OHM,1/16W GND VHPWR VCCGND VCC(+5V) VHGND VM(+24V) VHGND VH(+24V)

+ 100m F, 1000PF 35V

J4
8 7 6 5 4 3 2 1

ZD1 VM RD36EB

R89 3.3K,1/16W

A
ZD2 VH RD36EB

5-41