BJ-W7200 TRM

Canon
imagePROGRAF 7200/7250
and BJ-W7000
Technical
Reference
Manual
Systems & Technical Support Division

W7000 and imagePROGRAF 7200/7250
Technical Reference Manual
Version 201
October 2002
This Manual was produced and published in its entirety by:
Canon USA, Inc.

One Canon Plaza, Bldg. B
Lake Success, NY 11042
For Questions concerning any Canon Systems & Technical Support

Division, Educational Services training programs, call (516) 328-5620.
Disclaimer
Information in this Manual is based on material available prior to
publication.
Copyright 2002 by Canon U.S.A., Inc.

This Manual is for private use only. Any other use, reproduction or
transmission of this Manual, in any form or by means including,
without limitation, storage in a database or retrieval system, without
the prior written permission of an authorized representative of Canon
U.S.A., Inc. is prohibited. All rights reserved.
All trademarks appearing in this Manual are trademarks of their

respective owners.
Introduction to the Course
Introduction to the Course
To the student:
The purpose of this self-paced training program is to provide Service Technicians

with information required to install, service and support the Wide Format Bubble
Jet printers BJ-W7000 and imagePROGRAF 7200/7250 models.
The course is based on the Technical Reference Manual (TRM) as an interface

with the printer’s Service Manual. Together they provide comprehensive
technical information supplemented by lab exercises, culminating in a Final
Exam. Further technical information of value to can be found in the printer’s
Parts Catalog and User’s Guides (Setup, Users and Network Guides).
The TRM provides many direct references to corresponding or supporting

material in the Service Manual. It is recommended that the student refer to and
review in the Service Manual, all topical areas introduced by the TRM, for detail
of the technology processes and service procedures of the printer.
Course Overview
This training program provides certification on two similar products. It includes

training for service technicians on the servicing of the existing W7000 and the
newly released imagePROGRAF 7200/7250, both wide-format inkjet printers.
The student is required to read and review all of the material in each of 16
chapters of the TRM and complete all portions of the Lab exercises possible (all
parts if working with a printer). If a printer is available, the complete Lab for that
printer’s section is to be done.
Lab exercises are for review only, are not graded and can be done
as chapters are completed or all together, at the discretion of the student.
Upon completion of this training program, with a passing score of 70 percent or

greater, successful candidates will be certified to provide quality service in the field
on the BJ-W7000 and imagePROGRAF 7200/7250 printers.
imagePROGRAF 7200/7250 and BJ-W7000 - 201
Required Items
The following items are required, or recommended, to complete this training program:
Required:
• BJ-W7000/imagePROGRAF 7200/7250 Technical Reference Manual
• BJ-W7000 and imagePROGRAF 7200/7250 Service Manual (both needed for Final Exam)
Recommended:
• BJ-W7000 or imagePROGRAF 7200/7250 Series Machine
• Common service tools as needed
• BJ-W7000 or imagePROGRAF 7200/7250 Parts catalog and User’s Guides
How the Course is Structured
The student is required to read and review all of the material in each of 16 chapters of the TRM
and complete all portions of the Lab exercises possible (all parts if working with a printer). If a
printer is available, the complete Lab for that printer’s section is to be done. Then complete the
Online Final Exam available on the Canon e-Learning Center.
The TRM contains the following breakdown of material:
Section 1: BJ-W7000
• Chapter 1: Product Overview with Product Introduction Lab
• Chapter 2: Installation
• Chapter 3: Control Panel with Control Panel Lab
• Chapter 4: Sequence of Operations with Sequence of Operations Lab
• Chapter 5: Print Carriage withPrint Carriage Lab
• Chapter 6: Purge Unit Purge Unit Lab
• Chapter 7: Media Transport with Media Transport Lab
• Chapter 8: Troubleshooting
Section 2: imagePROGRAF 7200/7250

• Chapter 9: Product Introduction with Product Introduction Lab
• Chapter 10: Installation
• Chapter 11: Operations and Controls with Operations and Controls Lab
• Chapter 12: Print Head and Print Carriage Assembly with Print Head and Carriage Lab
• Chapter 13: Ink Supply and Recovery with Ink Supply and Recovery Lab
• Chapter 14: Print Media and Media Transport with Print Media and Media Transport
• Chapter 15: Service and Maintenance
• Chapter 16: Troubleshooting
CHAPTERS
Section 1
1 Product Introduction
W7000
2 Installation
3 Control Panel Chapters one through eight cover the

W7000 model Wide Format Printer
Sequence of
4 Lab exercises follow chapters:
Operations
1, 3, 4, 5, 6 and 7
5 Print Carriage
6 Purge Unit
7 Media Transport
8 Troubleshooting
Table of Contents i
Section 1 – BJ-W7000
Table of Contents
1) Product Introduction ............................................................................................................. 1-1
1.1) Applications of Wide Format Printing ........................................................................... 1-1
1.1.1) Types of Wide Format Printing ............................................................................... 1-1
1.1.2) Comparing Printers with Built-in Interpreters to Straight Raster Printers................ 1-1
1.2) Specifications................................................................................................................. 1-2
1.2.1) Different Media For Different Purposes .................................................................. 1-2
1.2.2) BJ-W7000 Media .................................................................................................... 1-3
1.2.3) Media Quality and Print Quality Issues ................................................................... 1-4
1.2.4) Ink Supply ............................................................................................................... 1-5
1.3) Component Identification............................................................................................... 1-7
1.3.1) Overview................................................................................................................. 1-7
1.3.2) Cross Sectional View .............................................................................................. 1-8
1.3.3) Print Carriage .......................................................................................................... 1-9
1.3.4) Roll Media Installation Unit ...................................................................................1-10
1.3.5) Cable Connector.....................................................................................................1-10
1.3.6) Print Scanning Direction ........................................................................................1-10
2) Installation ............................................................................................................................ 2-1

2.1) Installation Procedure..................................................................................................... 2-1
2.2) Unpacking and Setup ..................................................................................................... 2-2
2.3) Loading Print Drivers................................................................................................... 2-26
2.4) Site Inspection Checklist.............................................................................................. 2-30
3) Control Panel ........................................................................................................................ 3-1

3.1) Buttons and LCD Messages ........................................................................................... 3-1
3.2) Operational Modes and Printer Status ............................................................................ 3-3
3.3) User Mode...................................................................................................................... 3-4
4) Sequence of Operations......................................................................................................... 4-1

4.1) Start-up Sequence........................................................................................................... 4-1
5) Print Carriage........................................................................................................................ 5-1

5.1) Print Carriage Operations............................................................................................... 5-1
5.3) Ink Tank, Caterpillar and Ink Supply Tubes................................................................... 5-5
6) Purge Unit............................................................................................................................. 6-1

6.2) Print Head Symptoms..................................................................................................... 6-4
6.3) Clearing the Waste Ink Counter ..................................................................................... 6-5
Educational Services Systems and Technical Support Division

ii imagePROGRAF 7200/7250 and BJ-W7000 - 201
7) Media Transport.................................................................................................................... 7-1

7.1) Media Types................................................................................................................... 7-1
7.2) Media Handling.............................................................................................................. 7-2
7.3) Media Storage ................................................................................................................ 7-3
7.4) Media Movement ........................................................................................................... 7-4
8) Troubleshooting .................................................................................................................... 8-1
Systems and Technical Support Division Educational Services

CHAPTER HIGHLIGHTS Chapter 1
Applications of Wide
1.1
Format Printing
Product Overview
1.2 Specifications
and Introduction
Component
1.3
Identification
This chapter introduces the W7000 printer and
its main features and specifications
Chapter 1: Product Introduction 1-1
1) Product Introduction
1.1) Applications of Wide Format Printing
Wide format printers are most commonly found in:
Print shops (Pay for Print).

Graphic art design locations.
Advertising agencies.
Architectural and engineering locations.
Corporate locations.
Wide format printers are a special class of printers that have the ability to print on media greater
than 24 inches wide. These printers have are generally found in print shops that offer pay for
print services to walk up customers. Customers that are making banners or presentations. The
advertising industry uses wide format printers to produce life size, graphics with stunning color
to promote a product at the Point of Purchase PoP.
Wide format printers are also used to produce litigation materials that are commonly used to
displayed statistical information and evidence in a court of law.
Engineering and Architectural firms rely on wide format printers to produce engineering
drawings and renderings.
1.1.1) Types of Wide Format Printing
Wide format printers generally use one of three printing technologies. They are electrostatic, ink-
jet and thermal transfer. The BJ-W7000 uses bubble jet technology thus, placing it into the
popular ink-jet category.
1.1.2) Comparing Printers with Built-in Interpreters to Straight Raster Printers
Interpreter Based Printers
Examples of interpreter based printers are printer equipped with PostScript or PCL. Such printers
use a printer driver in the computer that send either PostScript or PCL code to the printer. The
printer has a circuit that interprets PostScript or PCL code converting it to raster data the printer
engine understands. These types of printers are generally dependent on constructing the print
data in an onboard memory location then sending the job in raster to the print engine. That’s why
printer performance may be adversely effected by the amount of memory it has.

1-2 imagePROGRAF 7200/7250 and BJ-W7000 - 201
If a wide format printer does have an built-in interpreter, generally it will be HP-GL, HP-GL/2 or
HP RTL. These formats were originally designed to work with CAD programs using pen
plotters. As electrostatic, ink-jet and thermal transfer print processes became more mainstream,
the HP-GL language evolved to HP-GL/2 and HP RTL specifically for newer print technologies.
Raster Printers
The BJ-W7000 is capable of printing raster only. It does not have a built-in interpreter. Raster
data can be looked as pixel data that is done on the fly, line by line. The printer will print as fast
as the host computer can deliver the raster data.
The BJ-W7000 printer is equipped with 8mb of RAM. This RAM configuration can
accommodate 2 full color print lines and cannot be upgraded. Actually, there is no need to
increase the amount of RAM as image data is not being interpreted or RIPPED. Increasing the
RAM capacity will not increase print performance.
1.2) Specifications
1.2.1) Different Media For Different Purposes
Wide format printing is used in a variety of applications from indoor to outdoor retail signs and
displays in public places. The type of media used is dependent on the application of the print.
For example, an outdoor print must be impervious to the elements such as sunlight, rain, snow
and ice. The print should not fade due to exposure to the sun.
Oppositely, standard media for indoor use does not have to be as durable as media for outdoor
print thus costing less.
One of the definitions of media is ‘an intervening substance through which something else is
transmitted or carried on’. BJ-W7000 media is not just paper, the printer can run:
Plain paper
Coated paper
Heavyweight coated paper
Glossy paper
Semi-gloss paper
Glossy film
Back print film
Graphic matte canvas
Inks are specially formulated for indoor and outdoor usage. The BJ-W7000 inks are designed for
indoor usage only.

1.2.2) BJ-W7000 Media
Wide format printers typically used two types of media feed systems. The first being most
common is roll-based and the second is pre-cut sheets.
Roll Based Paper Supply
A Roll-based media feed system simply feeds a continuous supply of media into the printer. In
the case of the BJ-W7000 the roll can be 24 to 36 inches wide and the length can be up 50
meters. This does not mean a print can be 50 meters long. The Printed image sizes are standard
ANSI, ARCH, ISO and JIS B sizes printed on the rolled media. After the last print line is printed,
the media is advanced in the paper path and cut. The BJ-W7000 cutter resembles an X-acto®
blade which is customer replaceable. The blade is spring loaded and capable of automatically
cutting up to 40 pound media. Media heavier than 40 pounds requires manual cutting.
Pre-Cut Sheet Paper Supply
Pre-cut paper can be loaded into the BJ-W7000 one sheet at a time. The CAD industry has
American and International standards for media sizes (paper and Mylar are common media
types). The tables on the next page will list the 3 most popular standards and show the media
sizes for each in inches and in millimeters. They are:
ANSI = American National Standards Institute for Engineering Drawing

ARCH = Architectural Standard
ISO = International Standards Organization for Engineering Drawings
ANSI Media Sizes, as established by the ANSI Standards:
Media Size Inches Millimeters

A 8.5 x 11 216 x 279
B 11 x 17 279 x 432
C 17 x 22 432 x 559
D 22 x 34 559 x 864
E 34 x 44 864 x 1118
ARCH Media Sizes, established by the Architectural Standards:

ARCH 1 9 x 12 229 x 305
ARCH 2 12 x 18 305 x 457
ARCH 3 18 x 24 457 x 610
ARCH 4 24 x 36 610 x 914
ARCH 5 30 x 42 762 x 1067
ARCH 6 34 x 44 914 x 1219

ISO Media Sizes, established by the International National Institute for Engineering Standards:

A4 8.27 x 11.69 210 x 297
A3 11.69 x 16.54 297 x 420
A2 16.54 x 23.35 420 x 594
A1 23.35 x 33.11 594 x 841
A0 33.11 x 46.81 841 x 1189
The W7000 also prints to the following Japanese Industrial Standards B (JIS B) sizes:

B1 28.66 x 40.55 728 x 1030
B2 20.28 x 28.66 515 x 728
B3 14.33 x 20.28 364 x 515
B4 10.12 x 14.33 257 x 364
Media
1.2.3) Media Quality and Print Quality Issues
When a dot of ink strikes paper it is absorbed into the paper and the ink dries. After the drying of
ink the dot will be a certain size. The desirable size of the ink dot must be in the range of 90 to
120? (microns). Using Canon recommended paper will ensure correct dot size. If incorrect paper
is used, the dot size may be too small or large resulting in pint quality issues such as banding,
blurred or bleeding images.
Recommended Monthly Volume
To obtain optimum printer performance, the recommended monthly volume for the BJ-W7000
must be in the following range:
Ideal
100 Minimum 200 Average 400 Maximum
The above print counts are based on A0 (36” x 48”) size prints.
The ideal print volume is approximately 20 ‘A0’ size sheets a day. Although the monthly volume
ranges from 100 to 400 prints a month; it is not recommended to run the printer for extended
uninterrupted periods of time. The primary reason for this is the print heads tend to build up
excessive heat during extended printing operations. If the heads get too hot, this could cause

print quality problems, practically banding. After the head has overheated, the head is damaged
and requires replacement.
1.2.4) Ink Supply
Each ink head is capable of holding 44ml (milliliters) of ink. When the ink head ink supply get
low it is replenished by a ink replenishment system. Each color ink in the ink replenishment
system contains 330ml of ink. The total ink capacity (per color) for the BJ-W7000 is 374ml. The
operator is warned when there is approximately 6ml of ink left in the replenishment reservoir to
replenish the ink supply.
Ink Yield
The approximate ink yield for the BJ-W7000 is:
Color Ink A0 size page count

Black 112
Cyan 124
Magenta 124
Yellow 124
The above are estimates based on the following conditions:
- Temperature range of 59 to 86? Fahrenheit

- Relative humidity range of 10 to 80%
- Color, Standard mode (3-pass unidirectional printing)
- 25% coverage
- Consumption of the entire supply (330ml replenishment reservoir is empty)
Item Description
Printer Type Wide format bubble jet mounted on a special stand
Print Technology Bubble-Jet
Print Head Configuration 128 nozzles for each of the 4 colors
Head Drive Frequency 10, 8 and 6.75 kHz
Print Mode Draft, Normal and Enhanced
Color Mode/ Monochrome Modes Provided
Resolution 360 dpi x 360 lpi
Computer Interface Parallel Port (Conforming to IEEE 1284-B with ECP
mode enabled in CMOS)
Data Format SRL (Selex Raster Language)
Internal Memory 8 Mb (two lines of full color data) Not expandable
Media Type Cut sheet and roll

Media Material Plain, Gloss, Semi-Gloss and, Heavyweight Coated

papers, Glossy Film and Back Print Film
Media Width 210 mm, 8 ½ inch letter (cut sheet)
to 914 mm, 36 inch (roll feed)
Maximum Media Length (Cut Sheet 1250 mm, 49.2 inches
Media)
Media Size Cut Sheet:
ISO A0, A1, A2, A3, and A4
ISO Over A0, A1, A2, and A3
JIS B1, B2, B3 and B4
ANSI 34” x 44”, 22” x 34”, 17” x 22”, 11” x 17” and
8 ½” x 11”
ARCH 36” x 48”, 36” x 24”, 18” x 24”, 12” x 18”, 9”
x 12” and 30” x 42”
Roll Media
A0, A1, 36” and 24” the roll outer diameter must be
100 mm/ 4” or less.
The inner (hub) diameter: 51 mm/ 2”
Auto Cutter Provided (Y-axis) Customer replaceable cutting blade
Media Discharge Face up
Media Stacking Capacity Maximum 25 Sheets (Roll, A0 or less), Maximum 1
Sheet (Cut Sheet)
Cartridge Type Head with 44ml ink tank capacity
Ink Color Black, Cyan, Magenta and Yellow
Ink System Capacity (Per color) Cartridge: 44 ml
Ink Bottle: 330 ml
Total: 374 ml
Remaining ink and waste full detection Provided
Dimensions (including stand) 1500 mm x 760 mm x 1200 mm
or
59 5/8” x 29 7/8” x 47 1/4” (W x D x H)
Weight (Including stand) 82 kg/ 180.8 lbs.
Power Requirements 100 to 240 VAC (universal), 50 to 60 cycles
Power Consumption 150 watts or less
Standby Power Consumption 35 watt hours
Noise (by ISO) 50 dB or less during printing
35 dB or less during standby
Operating Environment Temperature - 63.5 to 95.0°F
Humidity 10 to 90%
Recommended Operating Environment Temperature - 63.5 to 81.5°F
Humidity 25 to 75%
Printer Storage Environment Temperature - 41.0 to 95.0°F
(without condensation) Humidity 10 to 90%
Cartridge Storage Environment Temperature - 14.0 to 95.0°F

Humidity 10 to 95%
1.3) Component Identification
1.3.1) Overview
1 - Carriage 7 - Roll Media Cover

2 - Purge Unit 8 - Media Discharge Upper Cover
3 - Right Cover 9 - Power Switch
4 - Feeder Release Lever 10 - Left Cover
5 - Control Panel 11 - Dust Cover
6 - Media Guide
1 - Ink Bottle Case 6 - Buffer Cap

2 - Right Rear Cover 7 - Cap
3 - Ink Supply Tube 8 - Ink Bottle
4 - Rear Cover 9 - Jig Head Exchange Tool
5 - Left Rear Cover 10 - Jig Air Vent

1.3.2) Cross Sectional View
1 - MR Sensor
2 - Dust Cover
3 - Carriage
4 - Spur
5 - Spur Cleaner
6 - Spur Unit
7 - Media Discharge Sensor (PS6)
8 - Media Discharge Roller
9 - Cut Sheet Trailing Edge Sensor (PS7)
10 - Path Change Plate
11 - Roll Media Shaft
12 - Roll Media
13 - Roll Media Feed Guide
14 - Media Guide 1
15 - Roll Media Detection Sensor (PS2)
16 - Roll Media Pressure Roller
17 - Cut Sheet Detection Switch (PS1)
18 - Pinch Roller 1
19 - Feed Roller
20 - Media Guide 2
21 - Media Retainer
22 - Pinch Roller 2
23 - Carriage Rail

1.3.3) Print Carriage
1 - Long Flexible Cable

2 - Bubble Jet Cartridge (BK)
3 - Bubble Jet Cartridge (C)
4 - Bubble Jet Cartridge (M)
5 - Bubble Jet Cartridge (Y)
6 - Carriage Cover
7 - Carriage Rail
8 - Ink Supply Tube
9 - Tube Cock
10 - Joint Stand
11 - Head Joint
12 - Cartridge Angle Adjustment Lever (rear)
13 - Cartridge Angle Adjustment Lever (front)
14 - Cartridge Cap
15 - Cartridge Height Adjustment Lever
16 - Y - Cutter
17 - Cartridge Fixing Knob
18 - Media Sensor

1.3.4) Roll Media Installation Unit
1 - Roll Media Cover

2 - Roll Media
3 - Roll Sheet
1.3.5) Cable Connector
1 - Power Cord Receptacle

2 - Parallel Interface Connector (ECP Configured)
1.3.6) Print Scanning Direction
1 - Left Edge 3 - Trailing Edge

2 - Right Edge 4 - Leading Edge

LAB - CH 1
Product L-1
Introduction
Objective:
Reinforce familiarity with the components and subsystems of the printer
Instructions:
Given a list of wide format printer attributes and specifications, match the correct specifications and
attributes to the stated BJ-W7000 characteristics. All your responses must match the information
contained in this module.
Place the number of each Attribute next to the correctly matching Description (in the # column).
W7000 Attribute Description #

1 Wide Format Print ISO media size
Technologies
2 Printer Interpreter On the fly, line by line printing
Languages
3 Raster Printers Electrostatic, Ink-jet and
Thermal Transfer
4 Paper Size A0 ANSI media size
5 Paper Sixe B HP-GL, HP-GL/2 and HPRTL

L-2
Product Introduction Lab
Using your service documentation, place the number of each Specification beside the correct
Description (in the # column).
Specification Description #
1 Recommended monthly volume 330 ml
(Ideal)
2 Number of ink nozzles per row Bubble-Jet
3 Approximate ink yield for the black 124 A0 size prints
ink bottle (size A0 at 25% coverage)
4 Data format 36 inches
5 The computer interface, parallel port 374 ml
must be set to this mode
6 Minimum roll media width 200 A0 size prints
7 Print resolution 112 A0 size prints
8 Approximate ink yield for the cyan ECP
ink bottle (size A0 at 25% coverage)
9 Smallest cut size sheet 128
10 Print Technology SRL Selex Raster Language
11 Maximum cut sheet media length 100 to 400 A0 size prints
12 Total ink capacity (per color) for the 49.2 inches
BJ-W7000
13 Maximum roll media width 24 inches
14 Monthly volume range 8 1/2 x 11 inches
15 Ink bottle capacity for the BJ- 360 x 360
W7000
Instructor Initials:__________

2.1 Installation Procedure
2.2 Unpacking and Setup

Installation
2.3 Loading Print Drivers
Site Inspection
2.4
Checklist
Objective
To present the steps to properly unpack,
assemble and prepare a new unit and its
operating environment, including setup and
configuration of the hardware, loading of
system software and computer connectivity.
Chapter 2: Installation 2-1
2) Installation
2.1) Installation Procedure
So far, you have learned about the basics of wide format printing market and the BJ-W7000
specifications. Before we learn about how to operate the BJ-W7000 we must examine the aspects
of installing and de-installing the BJ-W7000 for shipment. Additionally, we will examine how
the printer driver is installed on the PC computer.
To obtain optimum printer performance, the customer’s site must meet specific environmental
criteria. It is important to know what they are. Additionally, de-installing and shipping the printer
from one location to another requires specific printer preparation. If the shipping preparations are
not done the printer could be damaged during transit.
In this module, you may install the BJ-W7000 printer and stand (if they are new in the box) or
review the installation procedure and perform a site inspection. Additionally, you will have a
chance to perform a printer de-installation and a print driver installation.
When installing the printer and stand:
1. Installation Manual is packed in the Individual Equipment box in the printer’s box.
2. The stand’s locking casters must be facing the rear of the printer.
3. Two people are required to lift the printer onto the stand.
4. Save the fixing plate and setscrew securing the print carriage for future transport.
To prepare the printer for shipment:
1. Before shutting the printer’s power OFF, take the printer Offline and press the
ROLL/SHEET key selecting Roll media; otherwise, the feeder roller might be damaged.
2. The ink bottle case must be removed and prepared for shipment. This helps prevent ink
spillage. If any spilled ink finds its way onto any of the printer’s electrical circuits, they
could be shorted out as the ink is conductive. The ink bottle case may require some
draining before inserting the buffer caps.
3. If your printer and stand are new in their original boxes install them. If they are already
installed, simply review the installation procedure found in this module.
4. Review the Site Inspection Checklist found at the end of this module.
5. Install the print driver on the PC. The procedure can be found in this module.
6. Review and perform the Transporting the Printer, part B, procedure in your BJ-W7000
Service Manual, chapter 1, section VIII.
7. Please do not re-install the ink tank. And disconnect connector J212 on the engine
controller PCB. This will enable you to operate the printer during the later modules
without the ink tank.

2.2) Unpacking and Setup
This installation procedure is a modified version of the installation procedure packaged with the
printer. This procedure is not in your service manual.
All the graphic reference numbers in this procedure are represented in boldface.
Installation Environment:
• Avoid locations where temperature and humidity are too high or too low.
Operating temperature range 17.5° C to 27.5° C, Humidity range: 25% to 75%
• Avoid locations exposed to direct sunlight. (If direct sun light cannot avoid, shield
the light with curtains or blinds).
• Avoid locations where temperature changes are suddenly.
• Avoid locations that are dusty.
• Avoid locations where vibrations frequently occur.
• Install the printer in a horizontal and stable location.
Installation Space:
As shown in the diagram below, allow sufficient space that is required for mechanical operation.
Confirm that the following accessories were included with the printer:

Item descriptions:
1 - AC Power Cord (NEMA 5-15) 14 - Ink Tank (Yellow)

2 - Operation Panel (For USA market) 15 - Tube Cover
3 - Operator’s Manual 16 - Tube Holder
4 - Printer Driver Disk Set for Windows 95/NT and Mac 17 - Ink-Tank Case
5 - Driver Installation Manual Set for Win95/NT and Mac 18 - Head Changing Jig
6 - Warranty package 19 - Relay Cable
7 - BJ cartridge (Black) 20 - Buffer caps
8 - BJ cartridge (Cyan) 21 - Air Vent Tool
9 - BJ cartridge (Magenta) 22 - Glove
10 - BJ cartridge (Yellow) 23 - Joint Caps
11 - Ink Tank (Black) 24 - Dowel Pins
12 - Ink Tank (Cyan) 25 - Screws (M4x6) (2)
13 - Ink Tank (Magenta) 26 - Screws (M3x6) (3)

Check the contents of the main box. The BJ-W7000 Installation Manual is located in the
accessory kit box, item number 2 below.
1 - Printer main body

2 - Accessory kit box
3 - Media roll shaft
4 - Roll Media stopper
Open the package of the stand. Referring to the Installation procedure enclosed in the package,
check that everything listed is included in the package.
Instructions for assembly follow below.
Note:
The right and left leg stands are different. When the stand is assembled, follow this installation
procedure, and be certain the right and left parts are not mixed up.
The steps for assembly of the printer out of the shipping container are outlined below. Note that
the <numbers> in brackets correspond to the diagram callouts of the illustrations, usually
following the reference in the text.

Lay down the stand leg (left) <1> and attach the pedestal (left) <2> with four screws (M5 x 12)
<3>.
Note the position of the caster with lock <4> and metal plate <5> of the pedestal (left).
Lay down the stand leg (right) <1> and attach the pedestal (right) <2> with four screws (M5 x
12) <3>.
Note:
Pay attention to the position of the caster with lock <4> and metal plate <5> of the pedestal
(right).

Insert the horizontal stay <1> into the (right) leg <3> with the opening of the stay facing towards
the locking casters and secure it with three screw (M4 x 8) <2>.
Stand up the stand leg (right) <1>4. Insert the stand leg (left) <15> and secure it with three
screws (M4 x 8) <16>.

Check the following:
1. The caster with stoppers <17> are located in the rear of the stand.
2. The opening <18> of horizontal stay is facing the rear of the stand.
This completes the assembly of the printer stand.
Open the plastic bag. Insert your hands as illustrated below and firmly hold the bottom of the
printer, and lift the printer out of the box.
Note:
The printer weighs about 121 pounds. Two people are required to lift the printer.

When lifting the printer, be sure to hold it at the positions illustrated below.
Read the following precautions carefully:
1. Orient the printer on the stand so the control panel is on the right side of the stand.
When done properly, the printer will be facing you and the locking casters on the printer
stand will be in the back.
2. Place the printer so the pins 1 of the stand (four pins on each side) enter the holes at the
bottom of the printer. The rule of thumb is to align the mark 2 on the rear of the printer to
pedestal of the stand.
When you have completed reading numbers <1> and <2> place the printer on the stand.

Secure the printer to the stand with four screws (M6 x 16) <3> on both right and left sides.
Attach the basket to the printer stand, referring to the Installation Procedure on the next page. A
copy of the procedure is also included with the printer stand.
Remove all the securing tape <1> and cushioning materials <2> from the printer.
Peel off the clear film from the message display. Peel off the paper from the back of the control
panel sheet <3> and attach the sheet to the control panel mounting surface.

Open the dust cover <1>.
Remove the securing tape <2> and the setscrew <3>, and detach the carriage fixing plate <4>.
Remember to store the setscrew and the fixing plate in a safe place so they can be used again
when re-locating the printer.

Close the dust cover and insert the AC power cord <5> into the printer and a suitable AC outlet.
Turn the power switch <6> ON.
After the power switch has been turned ON, the LCD display will display an Offline status.

The pilot lamps on the control panel lights. The print carriage moves to the center of the printer.
At this time "Not Installed: Black, Cyan, Magenta, Yellow" is displayed in the LCD on the
control panel.
Open the dust cover. Turn the cartridge-fixing knob <1> clockwise to the "FREE" position while
pressing it down to release the cartridge attachment section.
Open the box of the BJ cartridge and remove the cartridge <2>. Remove the orange-colored cap
<3> at the head and remove the protective seal <4>.
Note: Do not shake or drop cartridge or touch the head <5> or electrode section <6> of
cartridge.

Detach the cartridge cap <8> on the BJ cartridge, using the head changing tool <7>. Use gloves
to prevent ink stains on your fingers.
Insert the cartridge <10> into the carriage, while opening the cartridge attachment section <9> by
hand. The cartridge positions are black, cyan, magenta and yellow from the left to right.
Notes:
1. Insert the cartridge with the label <11> facing you and the head side down.
2. Once the cartridge is opened, immediately install it into the carriage.
3. Do not force the cartridge into the carriage.
4. Do not touch the electrode section <12> (cartridge contacts) of the carriage.

Repeat the same procedure, set the remaining cartridges into the carriage. Then return the
cartridge fixing knob to the operational position.
Install the Head Joints <13> into ink inlet holes <14> for all the BJ cartridges. Ensure all the
Tube Cocks <12> are released allowing ink flow to the BJ cartridges.
Close the dust cover.
When the dust cover is closed, the carriage moves to the right of the printer and stops. At this
time, "Ink Bottle Near Empty: Black, Cyan, Magenta, Yellow" is displayed in the LCD on the
control panel. Do not open the dust cover while this message is displayed.
Note:
If the cartridge-setting position is incorrect, the carriage stops in the center of the printer. Check
the cartridge-setting position (the cartridge-fixing knob).

Turn OFF the power switch.
Install the tank holder <3> on the rear of the printer by using screw <1> and the two screws <2>
(M4 x 6) to fasten the rear cover.
Slide the shouldered screws in the ink-tank case <4> onto the hooks on the tank holder. Fix the
ink-tank case, using the two screws <5> (M3 x 6).
Attach the four ink-supply tubes <6> securely onto the tube joints <7> on the ink-tank case.
Then, connect the relay cable <8>.
Note:
Connect the ink-supply tubes to the tube joints on the ink-tank case so the tube with the tape
marking is connected to the top tube joint.

Install the tube cover <9> on the rear printer cover using screws <10> (M3 x 6). (As shown in
the figure, before installing the tube cover, insert the hooks on the tube cover into the holes on
the rear cover of the printer and slide the tube cover to the left).
Open a new ink-tank and remove the ink-cap.
Open the ink-tank case. Insert the ink-tank <3> into the ink-tank case. Place the removed ink cap
<4> on the cap stand inside the ink-tank case. Repeat this for all the colors, placing them in their
proper places.

Place the head-changing tool <5> in the ink-tank case. Close the cover of the ink-tank case and
turn the printer power switch ON.
Open the roll-media cover <1>.
Paying attention to the roll direction of the roll media <2>, insert the media into the roll shaft
<3> until the roll media contacts the stopper <4>.
Note: Use roll media with an internal diameter of two inches.

Insert the stopper <5> onto the roll shaft to secure the roll media.
When loading roll media ensure the edge of the roll media is perfectly straight.
If the media core sticks out or is too far in, adjust it by hand so it is straight as shown above.
If the media roll is uneven (stepped), adjust it by hand so it is straight as shown above

Attach the roll media to the roll holder <6> with the stopper fixed to the roll shaft to the right.
Install the roll shaft starting with the left side first.
Close the roll media cover.
With the printer Offline, press the ROLL/SHEET key on the control panel to select roll media.
Open the roll media cover. Hold the roll media at both ends and insert the leading edge along
line <1> illustrated below until it feeds into the printer.

The leading edge of media is fed through and comes out the top of the printer and stops. At this
time, the "Straighten Media" message is displayed on the control panel LCD.
Open the dust cover <2> and pull down the feeder unit release lever <1>.
Straighten the roll media by holding both the right and left ends that came out of the printer by
slightly shifting it to either the right or left, aligning the media with the roll.

Push the feeder-unit release lever <1> back to the original position and close the dust cover <2>.
When the dust cover is closed, the printer checks whether the roll media has been fed in straight.
If the roll media is straight, the end of the roll will be cut and the printer will switch to an
"Online" condition.
If the roll media has not been fed straight, the media will not be cut and a "Straighten Media"
message will be displayed in the LCD. If this is the case, open the dust cover, release the media
with the release lever and straighten the media again. Then close the dust cover.
When the "Online" status is present, close the roll-media cover.
With the printer in the Offline mode, press the ROLL/SHEET key on the control panel to select
the cut-sheet media.

Insert 8.5" x 11.0" or larger-sized media into printer. Use media guide <1> to feed media
straight.
When 8.5" x 11.0" cut-sheet media is used, insert the media landscape (lengthwise).
If the media has been fed straight, "Online" will be displayed in the control panel LCD.
If the media has not been fed straight, take the following actions, depending on the media size.
For media shorter than 20 inches:
The media will be fed out of the printer and the control panel LCD will display the message
"Please Remove Media". At this point, remove the media and re-feed it.

For media 20 inches or longer:
The media will be fed out of the printer and the control panel LCD will display the message
"Straighten Media". At this point straighten the media according to the following procedure.
1. Open the dust cover <2> and pull down the feeder-unit release lever <3>.
2. Straighten the media. Hold both right and left ends of the media that came out of the printer,
slightly shift it to either the right or left aligning the media leading to the trailing edge.

3. After aligning the media, push the feeder-unit release lever back to its original position and
close the dust cover. Note: When dust cover <2> is closed, printer checks the media for skew
again.
If the media has been fed straight, "Online" will be displayed in the control panel LCD.
When the print is complete the message below will be displayed in the control panel LCD. Then
remove the media.

The printer operation check is now complete. Shut the printer AC power OFF for the next step.
Connect a standard parallel printer cable from the computer to the bottom of the printer.
The printer uses a standard parallel cable (IEEE1284).
For optimum printer performance, the computer’s parallel port must be set to ECP mode. The
customer should change this setting referencing the computer’s user manuals.
Installation Notes:
Before installing the print driver ensure the computer’s parallel port is set to ECP (Extended
Capabilities Port) to reduced pauses between printed scan lines.
The following procedure shows basic installation of Windows 95 print driver. If Windows NT 4
or Mac print driver is required, refer to their respective manuals, shipped with the printer. Each
manual contains detailed information about specific print driver settings and configurations.

2.3) Loading Print Drivers
Load the Windows 95 print driver floppy disk into the computer. With Window 95 running,
shutdown any unnecessary programs and press the Start button in the lower left corner.
Select Settings then Printers.
Select Add Printer
Select Next

Select Next for a Local Printer
Select Have Disk
Select browse

Select the file bwrstr.inf then OK
Next, Select OK
Select Next confirming the Canon BJ-W7000

Select LPT#: ECP Printer Port to choose connected port and confirm parallel port is set to ECP.
Select a printer name or leave BJ-W7000; select if BJ-W7000 is to be default printer or not.
Next, the question is asked, would you like to print a test page? Select Yes then Finish.

Lastly, ‘Did the test page print correctly?” is displayed If the print output looks good, select Yes.
2.4) Site Inspection Checklist
Site preparation is important to determine that the required environmental conditions are
available for the optimal running of the printer over its operating life, throughout all seasons.
The following checklist is provided to ascertain that those minimum environmental conditions
will be met at the installation site.

BJ-W7000 Site Inspection
Checklist
Space Requirements
The Printer must be installed so that it is at least 20 inches away from all walls to allow
for machine operation and maintenance work.
Measured Distances
1. ____________
2. ____________
3. ____________
4. ____________
The floor must be level so that all feet of the printer stand are in contact with the floor
and the machine is level.
Power Requirements
The specifications for the electrical outlet are a standard NEMA 5-15R.
Actual Voltages:
G
H1 to G = ___________
115VAC H1 H2 0VAC
H2 to G = ___________
H1 to H2 = ___________
115VAC
Environmental Requirements
Avoid dusty areas, direct exposure The operating tempera- Humidity (%)
to the sun, and areas near: ture and humidity should 90
fall within the shaded are
-water faucets -water boilers- in the figure on the right.
-sources of fire -refrigerators
-humidifiers
10
°F
63 95
Buttons and LCD
3.1
Messages
Operational Modes
3.2
and Printer Status Control Panel
3.3 User Mode
Objective
Familiarize with the Control Panel
functions, basic operations, adjustments
and customer maintenance items.
Chapter 3: Control Panel 3-1
3) Control Panel
The BJ-W7000 control panel operations are for the most part straight forward. The important
things to know are:
• how to load media.

• control panel indications such as a low ink supplies.
• what certain adjustments do and when they must be done.
Additionally, it is important to know how to do customer maintenance.

In this module, you practice operating the control panel along with loading media and
performing various printer adjustments. Additionally, you will practice head cleaning along with
a media cutter and wiper blade replacement.
3.1) Buttons and LCD Messages
With the printer power ON, familiarize yourself with the control panel. Examine the following
buttons, indicators and LCD displays according to the explanations found in your service
manual, chapter 1, III Explanation of Operation, A. Control Panel.
The control panel operational functions are shown in the Figure above and the functional
descriptions, as numbered, are outlined in the following table:

No. Function Description

1 Message Display Displays menus, parameters, error messages, warnings and
printer status
2 Print Mode Indicator Displays the print mode selected by the PRINT MODE key
3 Color Mode Indicator Lights in the color mode when the four color cartridges are
attached
4 Data Reception Indicator Lights when data is being received
5 Error Indicator Lights when an error has occurred
6 Pilot Lamp Lights when power is ON
7 Up Arrow Key • Press to select menu
• Press to discharge cut sheet media in OFFLINE
8 Down Arrow Key • Pressing Up in OFFLINE mode feeds roll media in
reverse direction; Down feeds forward
9 Right Arrow Key • Press to select parameters
• Press to move the carraige to the cartridge replacement
10 Left Arrow Key position in the OFFLINE or PAUSE modes
•
11 MENU Key Press to display the Menu screen
12 ONLINE Key Press to switch between ONLINE and OFFLINE modes
13 PRINTMODE Key Press to switch the print mode (valid in OFFLINE mode only)
14 CANCEL Key Press to cancel printing (valid in PAUSE mode only)
15 ROLL/SHEET Key Press to select media type (valid in OFFLINE mode only)
16 Media Selection Indicator Displays the currently selected media
17 CUT Key Press to cut roll media (valid in OFFLINE mode only)
Items to note when operating the Control Panel:
1. When the ONLINE key is pressed during printing, the printer goes into a pause mode.
The data stream from the computer is temporarily halted along with the data contained in
the printer’s 8-MB buffer. Pressing the ONLINE key will allow the data to flow again.
2. Canceling a print job must be done at the computer first. This stops the data stream
going to the printer. Then, press the CANCEL key. Doing so will clear the data in the
printer’s 8 megabyte buffer.
3. The KCMY characters in the LCD display indicate amount of ink remaining in the ink
bottles. The indications are:
KCMY - Upper case characters indicates at least 6 ml ink in each ink bottle.
KcMY - Lower case characters indicates less than 6 ml in a given ink bottle (c).
K-MY - A slash or hyphen indicate the ink bottle is out of ink. In this case cyan.
4. When the Waste Ink tank is full, a C8 is displayed. To clear the error code, a service
person must replace the Waste Ink tank and reset the Waste Ink Counter in service mode.

Chapter 3: Control Panel 3-3
3.2) Operational Modes and Printer Status
The following table describes the different functional modes of the printer and the operating
states of the printer when each is selected.
Mode Printer State

Online • The printer can receive and print data. When printing is carried outin
the ONLINE mode, the display shows “Printing”
• Keys on the Control Panel cannot be operated in the ONLINE mode.
To operate keys on the Control Panel in this mode, the printer must
first be set to the OFFLINE or MENU mode.
Offline • Received data is not printed even though the printer can receive
data. If the print buffer becomes nearly full in the OFFLINE mode,
the printer is set internally to the mode in which data is received at a
rate of one byte per second.
Pause • Data is not analyzed during printing and printing is paused. If the
print buffer becomes nearly full in the PAUSE mode, the printer is
set internally to the mode in which data is received at a rate of one
byte per second.
• In the PAUSE mode, the PRINTING mode can be returned to
resume printing by pressing the ONLINE key, and printing can be
canceled by pressing the CANCEL key.
Menu • Menus and parameters can be set. Menu items vary according to the
printer being in the OFFLINE or PAUSE mode.
Printing • Printing operations are being carried out.
• Control Panel keys cannot be operated. To operate Control Panel
keys, the printer must be set to the PAUSE or MENU mode.
The following displays migration between printer status and Control Panel key operation.

3.3) User Mode
Review the following User Mode Menu options with supplemental comments and explanations
found in the service manual, chapter 1, III Explanation of Operation, F. User Mode Menu.
• Version (Engine and Image Controller Firmware).

• Auto Cut (Factory set to Yes. Can be set to No if heavy media is being used
and Automatic cutting is not cutting all the way through the media).
• Head Cleaning (Factory set to No. The printer cleans the heads at regular
intervals thus, not requiring manual cleaning. This mode is used to unclog
ink nozzles regular cleaning does not).
• Print Frequency (Factory set to 10Khz. The frequency at which ink is
ejected from the nozzles, generally set to 10Khz. The only time this value
might be altered is to help reduce regularly occurring lines in the 1-pass
print mode (as only one layer of ink is applied to the media).
• Media Type (Factory set to Coated Paper).
• EOP Timer (Factory set to 30 seconds. This setting relates to the speed in
which the computer sends data to the printer. Faster computers send data
quicker with less pauses. If the printer detects a pause greater than the EOP
Timer setting, it may try to park the print carriage and start a head cleaning).
Slower computers may require a setting greater than 30 seconds.
• Alarm Set (Factory set to On. Enables printer beeps for errors/warnings).
• Adjustment (Factory set to No. Adjustments primarily used when the ink
head(s) are replaced. We will practice these adjustment later in this module).
• Setup List (Factory set to No. This prints the Setup List).

LAB - CH 3
Control L-1
Panel
Objective:
Review the Control Panel functions and operations.
Instructions:
1. User Mode Setup and Adjustments
Place a check √ mark next to each completed printer operation below.
√ Printer Operation
Load roll media (page 1-25 in the service manual).
Practice removing and replacing one of the ink cartridges
(page 1-16 in your service manual).
Run a Setup List print in user mode and check the
information contained in the list by referencing page 1-24
in your service manual.
Practice the Cartridge Height Adjustment Lever
Adjustment (page 1-27 in your service manual).
Practice the Auto Head Adjustment. (Remember, this is
done after an ink cartridge replacement. The procedure is
on page 1-27 in your service manual). Use either roll or A3
size media when performing this adjustment. 11 x 17
media is not large enough. 11 x 17 media is incorrectly
called out in the service manual and will not work with this
adjustment.
After practicing the Auto Head Adjustment, perform the
Manual Head Adjustment. (This is done after an ink
cartridge replacement and the Auto Head Adjustment. The
procedure is on page 1-28 in your service manual). It is
okay to use 11 x 17, A3 or roll media when performing this
adjustment.
Practice the Media Feed Adjustment (Band Adjustment)
The procedure is on page 1-29 in your service manual. This
adjustment must be done after a Y-axis motor replacement
or if banding occurs with unusual media.
Practice the Cartridge Angle Adjustment Lever. (This is
done after an ink cartridge replacement. The procedure is
on page 1-30 in your service manual).

L-2
Control Panel Lab
2. Head Cleaning and Blade Replacements
√ Maintenance Item
Practice a Head Cleaning in User Mode (page 1-20 in your
service manual).
Practice removing and replacing the wiper blade (page 1-36
in your service manual).
Practice removing and replacing the cutter (page 1-34 in
your service manual).
Practice the general cleaning procedure (page 1-37 in your
service manual).
Review the handling precautions of the bubble jet cartridge
and media (page 1-35 in your service manual).

4.1 Start-up Sequence
Sequence of
Operations
Objective
The objective of this chapter is to identify
the proper printer initialization sequence
Chapter 4: Sequence of Operations 4-1
4) Sequence of Operations
One of the most efficient ways of diagnosing printer start-up problems is to know the steps or
items the printer goes through to get to a Ready or Online state. The start-up sequence can be
broken down into Power ON and Media Loading.
In this module, you will review a start-up sequence list and compare it to the printer’s operation.
4.1) Start-up Sequence
The following is a list of major events that take place during the BJ-W7000 start-up sequence.
This list is helpful as there are no general timing charts in your service manual.
When reviewing the following list, observe the printer’s operation. Get familiar with the printer’s
sounds and movement of the print carriage, purge unit and media. Pay attention to the Media
Sensor (the sensor on the print carriage that has a visible light) and the Media Retainer. The
Media Retainer resembling a transparent shade, attaches itself to the print carriage keeping the
leading edge of the media down as it travels to the spur unit.
With the printer’s AC power OFF, remove the right, left and dust covers. The procedure can be
found on page 3-2 in your service manual. Bypass the Dust Cover Switch (SW2) with a cheater
key to enable printer operation.


LAB - CH 4
Sequence of L-1
Operations
Objective:
Review and reinforce the correct sequence of system start-up and printer operations.
Instructions:
1. Startup Subroutine Checklist
Arrange the start-up subroutines in their proper sequence. Using your service documentation,
place the appropriate number beside the start- up subroutines below, properly sequencing them.
Sequence No. Start-up Subroutine Step

The Y-Axis motor (M2) turns ON to move the print carriage to the left
grabbing the Media Retainer. While the print carriage goes to grab the
Media Retainer the media is checked (with the media sensor) for width
and skew.
If the AC power has been OFF for 12 hours or more the leading edge of
the roll media is trimmed with the cutter.
X-Axis motor (M1) turns ON advancing the media 300 millime ters past
the media discharge sensor (PS6). Then, the media stops and the user is
prompted to align it.
The leading edge of the media is advanced to the print standby position.
Purge motor (M3) turns ON to de-cap the print heads.
Turn the printer AC power ON.
Y-Axis motor (M2) turns ON moving the print carriage to detect the
print carriage home position.
Wiper blade solenoids SL1 and SL2 are turned ON. Then, the print
heads are cleaned and capped when media is not loaded.

L-2
Sequence of Operations Lab
2. Power On Sequence Checklist
Place a check √ mark next to each observed printer operation.
√ Power On Sequence
Turn the printer AC power ON.
Purge motor (M3) turns ON to de-cap the print heads.
(page 2-37 and 2-41 in your service manual). If the:
• Purge motor (M3)
• Cap Cam Home Position Sensor (PS5)
• Pressure Cam Home Position Sensor (PS4)
were to fail, error C4 code will be displayed.
Y-Axis motor (M2) turns ON moving print carriage to detect print
carriage Home Position. Service Manual pages 2-15 thru 2-17
If the:Y-axis motor (M2) Carriage Home Position Sensor (PS3) or
Defective linear encoder were to fail, error CO code displays.
The print carriage cannot then find home position.
Sometimes, this error code can be caused by the Carriage Home
Position Sensor (PS3) being out of position.
Wiper blade solenoids SL1 and SL2 turn ON moving the wipers to
clean the passing print heads. If media is not loaded the print heads
are capped. When media is loaded, proceed to the following steps.

L-3
3. Media Loading Operations Checklist
Place a Check √ mark next to each observed printer operation when completed.
√ Media Loading
For either cut sheet or roll media
(Cut sheets) X-Axis motor (M1) turns ON advancing the media to the
print standby position. (page 2-49 in your service manual). Or,
(Roll media) X-Axis motor (M1) turns ON advancing the media 300
millimeters past the media discharge sensor (PS6). Then, the media stops
and the user is prompted to align it. (page 2-50 in your service manual).
After the user aligns the media it is retracted so the leading edge is
returned to the platen.
For both cut and roll media
The Y-Axis motor (M2) turns ON to move the print carriage to the left
grabbing the Media Retainer. While the print carriage goes to grab the
Media Retainer the media is checked (with the media sensor) for width
and skew. (page 2-25 in your service manual. If the: Media Retainer
Detection Switch (MSW3) or Media Retainer Solenoid (SL3) were to fail,
error code 54 will be displayed.
Sometimes the Media Retainer Detection Switch (MSW3) fails due to

grease in the switch contacts or the Media Retainer Solenoid (SL3) falls
out of adjustment preventing the Media Retainer from being grabbed.
Please note: If the media slips in the paper path, error code C1 will be
displayed. In this case, the media is not suitable, change the media.
(For roll media)
The leading edge of the media is trimmed with the cutter. (If the AC
power has been OFF for 12 hours or more). (page 2-26 and 2-27 in your
service manual).
(For roll media)
The leading edge of the media is advanced to the print standby position.
√ The printer is now Online.

L-4

Print Carriage
5.1
Operations
5.1
Component Print Carriage
Identification
Ink Tank, Caterpillar
5.3
and Ink Supply Tubes
Objective
To examine and understand the components
and operations of the print carriage and to
facilitate removal and replacement of select
print carriage components.
Chapter 5: Print Carriage 5-1
5) Print Carriage
5.1) Print Carriage Operations
We will now learn about the BJ-W7000 print carriage. Additionally, the ink replenishment
system will be included in the module.
The print carriage is responsible for delivering ink to the media. However, the print carriage
performs other tasks besides ink delivery including the following:
Checks the placement of the media in the media path with a Media Sensor.
Holds down the leading edge of the media with the Media Retainer.
Cuts standard roll media.
This module covers component identification, removing and replacing key print carriage
components and specific adjustments as they relate to the print carriage drive mechanism, print
heads, Media Sensor and Retainer.
Print Carriage, Print Carriage Drive, Media Cutter, Media Sensor and Retainer
With the printer’s AC power OFF, remove all the exterior covers. All the procedures can be
found on in the service manual starting on page 3-2.
Locate the following components:

Y-Axis Drive Motor and Linear Encoder
The print carriage is moved by the Y-Axis motor via a drive belt. If the dust cover is opened
while the Y-Axis motor is ON, it will be shut OFF by the Dust Cover Switch (SW2) disabling
the motor controller drive circuit.
The print carriage location is always monitored by both the Carriage Home Position Sensor
(PS3) and the Linear Encoder.
The Linear Encoder is a magnetic sensing device, much like Hall effect device. The Linear
Encoder is mounted on the print carriage. The encoder has a memory write threaded through it
that is magnetized. Actually, the memory wire has alternating north/south polarity that changes
360 times an inch. This is what makes the DPI in the Y-Axis print direction.
The Linear Encoder is extremely susceptible to foreign magnetic fields. For example, if your
screwdriver is magnetic and you are working near the encoder, the memory wire may be
damaged. This may cause the print carriage to lose its location as it monitors north/south polarity
in the memory wire. If the memory wire is damaged in certain areas (due to a magnetic screw
driver) you will see blank areas in the print scan lines in those damaged areas.
Additionally, if the memory wire has been replaced or installed incorrectly (the memory wire has
a flat spot on the end lug) the print carriage can get lost, resulting in error code C0.
Media Sensor Operation and Abnormalities
The media sensor is mounted on the print carriage and is primarily used for detecting media
width and skew. Additionally, it is used for User Auto Head Adjustments. The sensor works by

reflecting focused white light off the media to two photo-sensors. This happens while the print
carriage is passing over the media.
If the Media Sensor is defective or has been replaced and the sensor gain has not been adjusted,
the User Auto Head Adjustment routine could fail.
Another (Tricky) problem causing a constant Load Paper condition or error 5F, or less likely
error 60 is the rail the print carriage travels on drops during shipping or servicing. The rail, if it
does drop, generally, drops on the side opposite of the carriage home position in the front side of
the printer. This causes the Media Sensor to lose sight of the media.
See the graphic below. This graphic is in your parts catalog page B-7. If this happens, the rail
needs to be raised to its original position and a Media Sensor requires re-adjustment.

Media Retainer Operation and Abnormalities
The Media Retainer holds the leading edge of the media down so it can feed into the spur unit.
How it works is simple. When the print carriage travels across the media (for the first time
sampling media size and position) it travels all the way to the left grabbing the media retainer.
The media retainer is like a window shade attaching itself (being lifted by the media retainer
solenoid SL3) to the print carriage.
Common issues with media retainer is the media retainer solenoid SL3 does not raise the retainer
high enough or if the Media Retainer Switch (MSW3) is defective causing error 54.
Media Cutter Operation
The media cutter is capable of cutting stock up to 40 pounds. If the stock is heavier and the cutter
is not cutting completely through the printer can be set to manual cutting in User Mode Auto
Cut. Cutter sensor PS13 detects media that cannot be cut by monitoring the cutting blade
position. This condition will result in a error 42 code.
Cartridge Angle Adjustments
If you notice alternating offsets or jagged areas in straight lines or edges the Cartridge Angle
Adjustment in User Mode must be performed. Generally, this adjustment should be done after
replacement of the Y-Axis motor (M2) or the ink heads.
Head Ranking / Compensation of the Head Temperature Sensor
If either the carriage PCB or the DC power supply has been replaced the ink cartridge head
temperature must be re- established. This is primarily due to the variance in the electronic
characteristics on the newly replaced carriage PCB or the DC power supply. The procedure
utilizes Head Temperature Sensor Adjustment Jig which emulates the ideal ink cartridge by
providing a known Rank Resistive value. The Circuit uses a fixed rank resistor value to tune the
circuit in service mode. When an ink cartridge is installed the Rank Resistor is evaluated to set
the proper head temperature.

5.3) Ink Tank, Caterpillar and Ink Supply Tubes
The BJ-W7000 supplies ink to each of the ink cartridges via the following method:
Print Carriage
Ink Flexible Caterpillar Ink
Bottle
Cartridge
1. (When required) Ink is drawn out of ink bottle.
2. The ink travels through the ink tank reservoirs to the flexible caterpillar. The flexible
caterpillar protects the ink supply tubes from kinking when the print carriage moves.
3. The ink is drawn to the ink cartridges in the print carriage. Note that ink is drawn into the ink
cartridges only when the ink cartridge level is low. The ink cartridge capacity is 44 milliliters.
Ink Supply Tips and Nice to Knows
If the printer is left unused for an extended period of time the ink supply system should be
purged to prevent the ink solidification. If the ink tubes become clogged, they must be removed
from the printer and water should be used to unclog any obstructions. Any remaining water
should be squeezed out of the tubes.
If (while servicing the printer) you need to run the printer without the ink tank unit, it can be
done by disconnecting J58 the 5 pin connector at the ink tank unit. Doing so will permit printer
operation. Typically this will cause the upper case KCMY characters in the LCD display will
switch to lower case.
Lastly, when handling the ink detection electrodes, remember to disconnect them at the Ink
Detection PCB connector J605. This helps to prevent electrostatic discharge from damaging the
Ink Detection and Engine Controller PCBs.


LAB - CH 5
Print L-1
Carriage
Objective:
Identify components and practice disassembly of the Print Carriage Assembly.
Instructions:
1. Unit Identification
Shut the printer’s AC power OFF. Do each practice procedure and refer to the indicated page in
the Service Manual, listed after each procedure, if needed
Place a check √ mark next to each completed procedure below.
√ Procedure
Practice Uncapping the print heads. (3-7).
Remove the Cover Caterpillar Unit (3-7).
Remove the Linear Encoder (non-magnetic screwdriver) (3-9).
Remove the Carriage Unit (3-12).
Remove the Cutter Unit (3-15).
Remove the Cover Tubes (3-19).
Remove the Ink Supply Tubes (service manual, page 3-20).
Re-install all the above items back into the printer and turn the printer power ON.
Some procedures may require the use of Service Mode. Service Mode is accessed by pressing
and holding both Up and Down arrow keys down on the control panel while turning the printer’s
AC power ON. Refer to page 5- 43 of the Service Manual for additional information.
Refer to the Service Manual (page) indicated after each procedure, if needed.
Place a check √ mark next to each completed adjustment below.
√ Procedure
Practice Adjustment of Media Illumination Lamp Optical Axis. (5-2).
Practice Adjustment of Carriage Drive Belt Tension. (5-4).
Practice Adjustment of Media Retainer Hook Position. (5-6).
Practice Media Sensor Gain. (5-6).
Practice Adjustment of Media Sensor Light Intensity. (5-8).
Practice Compensation of Room Temperature Thermistor (page 5-12).
Review ALL Procedures after replacing the various components (5-14)

L-2
Print Carriage Lab
2. Print Carriage Component Identification
Place a check √ mark next to the component after identifying it.
√ Component
1 - Y-Axis Motor (M2)
2 - Carriage PCB
3 - Linear Encoder
4 - Carriage
5 - Carriage Home Position Sensor (PS3)
6 - Carriage Drive Belt
7 - Cartridge Lock Detection Sensor (PS14)
8 - Volume PCB
9 - Cartridge Height Adjustment Lever
10 - Cutter Sensor (PS13)
11 - Y Cutter (roll media cutter)
12 - Media Sensor
13 - Media Retainer
14 - Media Retainer Solenoid (SL3)
15 - Media Retainer Detection Switch (MSW3)
3. Head Adjustment
Refer to the Service Manual and print out a Head Adjustment Pattern test print. Determine the
values displayed by the test print according to the criteria outlined in the Service Manual.

Component
6.1
Identification
6.2 Print Head Symptoms Purge Unit

Cleaning and Waste
6.3
Ink Counter
Objective
and operations of the Purge Unit to facilitate
removal and replacement of selected
components.
Chapter 6: Purge Unit 6-1
6) Purge Unit
The purge unit ensures that all the print heads remain clean and all the print nozzles in the heads
are unobstructed throughout all phases of the print process. This is done by:
Capping the print heads when they are not in use. This prevents ink drying in the nozzles
and attraction of dust and any other foreign debris.
Cleaning the print heads by wiping, suction and pre-discharges.
The capping and cleaning of the print heads alleviate unwanted ink and blank lines in the prints.
If faults are to develop in the purge unit, blotches or streaks of ink may appear from a dirty print
head. Conversely, it is possible to see recurring light or blank lines in the print scan direction
from clogged ink nozzles. All of these symptoms are indications of improper print head
maintenance.
In this module, you practice identifying, removing and replacing key purge unit components.
Additionally, you will practice resetting the waste ink counter in service mode.
Additionally, you will find out what the current field issues are as they relate to the purge unit
and their countermeasures.
Exterior Purge Unit
With the printer AC power OFF and the print carriage un- capped and away from home position.
The print heads can be manually un-capped by following the How to Cancel Capping for the
Purging Unit procedure on page 3-7 in your service manual.
Locate the following Exterior Purge Unit components.

Interior Purge Unit
Locate the following interior Purge Unit components. To identify Pressure and Cap Cam Home
Position sensors follow their removal procedures found on page 3-22 and 3-23 in your service
manual. Also, practice removing wiper blades 1 and 2.
After examining the Pressure and Cap Cam Home Position sensors re-install them back into the
purge unit.
Cap Cam and Guide Roller Position Detection
Both the Cap Cam and the Guide Rollers are driven by the stepper Purge Motor (M3). A stepper
motor is used to control the exact position of both the Cap Cam and the Guide Rollers.
The Cap Cam position is critical as the four print heads can be capped (or un-capped)
individually or all at the same time. During the printer startup the purge motor rotates and the cap
cam position is established via the PS5 the cap cam home position sensor. The print heads are
then uncapped for printing. If the sensor gets ink in it or slips out of it’s holder, error code C4
will be displayed.
The Guide roller positions are equally important. They are monitored to produce the correct
amount of suction. During the printer startup the purge motor rotates and the guide roller (cam)
position is established via the PS4 the pressure cam home position sensor. Just like PS5, if the
sensor gets ink in it or slips out of its holder, error code C4 will be displayed.
Wiper, Pre-discharge and Suction
Wiper
While a print is being delivered the print carriage returns to home position. While returning to
home position, wipers 1 and 2 rise up removing any ink or dirt from the print heads. The wipers
themselves are cleaned by blade cleaner pads mounted on the underside of the print carriage. The
blade cleaner pads may appear to be dirty and require cleaning or replacement. Generally,

cleaning or replacement is not necessary. Solvents such as alcohol must not be used to clean the
wiper blades or the blade cleaners. Solvents can permanently damage the print heads.
Pre-discharge
Before and after each print, the ink nozzles discharge about 0.14ml of ink. This helps reduce ink
nozzle clogging. The pre-discharged ink travels through the pre-discharge receptacle to the
absorbent pads in the pre-discharge tank.
Print Carriage Wiper Blade Units 1 & 2

B C M Y Head Caps
Purge Unit
Print
Heads
Suction Unit Waste Ink
Pre-discharge Tubes
Receptacle Pre-discharge Tank
Pre-discharged Waste Ink
Ink (Yellow) Absorbent Pads Tank
Suction
Suction is when ink is sucked out of the nozzles. This is done when the print heads are capped
and the print carriage is in home position under the following conditions:
• User cleaning 1 - this is where all heads are cleaned by the key operator to
correct lines in the print.
• User cleaning 2 - this is where a specified head is cleaned by the key
operator to correct lines in the print.
• Cartridge Replacement Suction 1 - this is where two suction operations
are performed on the replaced print head.
• Cartridge Replacement Suction 2 - this is where one suction operation is
performed on all print heads after the carriage fixing knob has been rotated.
• Timer Suction - this is where one suction operation is performed if the
printer is left in standby or on-line mode for 72 hours.
Waste ink suction is provided by the suction unit located in the purge unit. During suction
operations you can see ink traveling (in the tubes) from the suction unit to the waste ink tank.

6.2) Print Head Symptoms
When your print heads are cleaned properly the print will not have any lines or blotches of ink. If
you see any of the symptoms on the following page suspect wiper blade problems or the ink
nozzles are not being cleaned properly.
Do not rule out the media being out of specification in terms of thickness. If the media is too
thick it can cause ink streaks in the print scan direction. With some types and thickness of print
media, the media rises up from the platen and comes in contact with the print cartridge when
high-density areas of the image is being printed. This not only impairs image quality, but also
may damage the print heads. To prevent this from occurring, adjust the gap between the print
cartridge head and the media by using the cartridge height adjustment lever. The adjustment
procedure can be found on page 8-20 and 8-21 in the BJ-W7000 Operator’s Manual.
Defective wiper blades, clogged nozzles or defective print heads.
Try head cleaning 1 or 2 twice, clean or replace the wiper blades. If the problem persists replace
the defective print head(s). For the last sample a Media Feed Adjustment may be needed. See
page 1-29 in your service manual for additional information regarding the Media Feed
Adjustment.

6.3) Clearing the Waste Ink Counter
The amount of waste ink in the waste ink tank is calculated by the number of scan lines. The
number of scan lines are kept track by the engine controller PCB. If both engine and image
controller PCBs are replaced at the same time, the waste ink tank must be replaced. This will
prevent the waste ink from overfilling.
Now, in service mode, practice clearing the waste ink counter. The procedure can be found in the
Service Manual on page 5-13.


LAB - CH 6
Purge L-1
Unit
Objective:
Identify Purge Unit subassemblies and components.
Instructions:
Place a check √ mark next to the component after identifying it.
√ Component
1 - Wiper Blade 1
2 - Wiper Blade 2
3 - Caps
4 - Waste Ink Absorbers
5 - Pressure Cam Home Position Sensor (PS4)
6 - Purge Motor (M3)
7 - Waste Ink Tank
8 - Pre-discharge Tank (slide it out to examine the
absorbent material).
9 - Pre-discharge Receptacle
10 - Wiper Solenoid (SL1)
11 - Wiper Solenoid (SL2)
12 - Cap Cam Home Position Sensor (PS5)
13 - Cap Cam
14 - Feeder Tubes
15 - Suction Unit

L-2
Purge Unit Lab

7.1 Media Types
7.2 Media Handling Media Transport

7.3 Media Storage
7.4 Media Movement Objective

To define and familiarize the Service Technician
with the processes involved in the maintenance
and servicing of the Media Transport system,
including removal and replacement of selected
components.
Chapter 7: Media Transport 7-1
7) Media Transport
We will now learn about the BJ-W7000 media transport system, the handling and the
characteristics of acceptable media types.
The BJ-W7000 is capable of printing on a variety of media. Media can be fed from a large roll or
individual pre-cut sheets. As you know, we covered the media standard sizes earlier in the
Introduction Module. Now, we will focus on what types of media exists and media handling
precautions. Additionally, we will look at the media transport system, how the printer feeds and
moves roll and pre-cut sheets through the media path.
It is important to know what types of media is available and how to handle them. Knowing
ensures optimum print quality. Equally important, knowing how the media transport system
works for roll and pre-cut sheets will help you resolve any media transport problems.
In this module, you will learn about various media types. Then practice loading roll and pre-cut
sheets. Additionally, you will identify media transport components and learn about their
operation and current field issues.
7.1) Media Types
Print Media can be broken down into the following categories:
Plain paper
Glossy paper
Semi-glossy paper
Coated paper
Heavyweight coated paper
Glossy film
Black print film
Graphic mstte canvas
The quality of a print is dependent on the quality of the media, which will determine the ink dot
size. Improper ink dot size can result in a variety of print quality issues ranging from lightness to
blotchy print scan lines. For suspected media problems, try switching media. If the problem goes
away or changes, the media is more than likely the source of the problem.
Plain Paper
This media is best suited for printing low-resolution images or making test prints. Plain paper,
however, is easily affected by temperature and humidity, which makes plain paper less stable
than the other media types.

Glossy Paper
This paper has a glossy surface like photographic printing paper used for prints. Use this paper to
give graphics and full- color images a high-quality finish like that of photo prints.
Semi-gloss Paper
This white paper has a glossy finish that is less reflective than glossy paper. It is best suited for
making prints of graphics. This paper allows you to reproduce graphics with a soft look to them.
Heavyweight Paper
This white paper has a coated surface. It is best suited for making well-defined prints for POP
(point -of-purchase) tools graphics and full-color images.
Glossy Film
This film has a glossy surface like photographic printing paper, and is glossier than glossy paper.
This film allows you to reproduce graphics and full-color images with more defined and brighter
colors. It also offers good durability for indoor use.
Back Print Film
This white semi-transparent film is for electrically illuminated signs. It allows you to reproduce
prints with a beautiful, glossy surface almost like photographs.
Graphic Matte Canvas
Coated on one side, this media is supplied in a 36-inch wide by 35-foot long roll.
7.2) Media Handling
Always load media with the printing surface facing down. The coated side of the paper is
the printing surface, the surface that you see after unpacking the paper
When using curled plain paper, load it in the printer with the curled section facing up.
Loading curled plain paper facing down may result in media jams.
When handling media, hold it by its edges. If you hold the print area surface, sweat or oil
from you skin may transfer to the media, preventing ink from adhering to the media.
Ensure that the ink has dried completely before removing the print from the stacker.
As ink on glossy paper is difficult to dry, only use such paper in environments with
humidity levels of 70% or less.

7.3) Media Storage
Remember the following points when storing media:
When storing opened media, ensure it is stored in its original wrapping. This helps
protect it from direct sun light and moisture. Also, store it on its side.
Storing roll media on end will damage the roll end; store roll media on its side.
Keep all printed media out of direct sun light. This will help to prevent the ink on the
print from fading or discoloring.
Make sure to confirm the ink has completely dried before handling glossy film(s). Be
especially careful when using paper to separate the glossy print(s) as the printed surface
of the film may adhere to the paper.
Read Load Roll and Cut Sheet Media sections of the BJ-W7000 Operator’s Manual
Roll Media
Remove any exterior covers from the printer. Shut the printer’s AC power OFF and locate the
components in the roll media path listed below.

Selecting Roll or Pre-Cut Sheet Media
The BJ-W7000 selects roll or pre-cut sheet media by changing the position of the Path Change
Plate. Path Change Motor (M4) moves the plate position based on the mode selected. The Roll
Media Position Switch (MSW2) and Cut Sheet Position Switch (MSW1) lets the engine
controller know the position of the Path Change Plate.
Servicing Tips/Field Issues
If you have to replace the change path motor (M4), ensure the motor gears mesh to the gears
inside the printer. You can confirm proper Path Change Motor operation by pressing the
ROLL/SHEET button on the control panel with the printer power ON. When doing so, you will
hear the Path Change Plate change position. If you do not hear the plate change position, error
code C7 may occur.
As mentioned in the Installation module, when moving the printer, it must be set to ROLL mode.
If the printer is shipped in CUT SHEET mode, the Path Change Plate may come in contact with
the feed roller, damaging it.
7.4) Media Movement
To prevent continuous printing in the same spot of media the BJ-W7000 is equipped with a
Media Feed Detection sensor. The sensors (PS8) detects the movement of a perforated disk that
is in constant contact with the feed roll. Print media passes between the perforated disk and the
feed roller. If the media stops, say for example the media supply is at the end of its roll and the
end is secured to the roll core with tape. The media movement will stop. This will cause error C1
to appear. Actually, any media slippage will general error C1. If error C1 occurs; check the
media and the condition of the Media Feed Detection sensor (PS8) and the perforated disk.

Servicing Tips/Field Issues
If the X-Axis motor (M1) requires replacement in the field; remember, when installing the X-
Axis motor, the worm gear collar must be against the motor housing. If not, the media
movement through the printer maybe inconsistent. This will cause the Media Feed Adjustment
problems. (You will not be able to get consistent Media Feed Adjustment results). Additionally.
overlapping or spaces may appear between printed scan lines.
It is strongly suggested you perform a Media Feed Adjustment (on page 1-29 in your service
manual) after replacing the X-Axis motor.

Cut Sheet Media
With the printer’s AC power OFF locate the components in the cut sheet media path listed
below.

LAB - CH 7
Media L-1
Transport
Objective:
Component identification and hands-on practice operating the Media Transport assembly
Instructions:
1. Media Product Identification
Match each of the Media Name items by entering the correct beside the matching Media
Description in the (#) column. After completing this exercise, review it with the course
administrator.
Media
Name Media Description #
1 Glossy Paper This white paper has a coated surface. It is best suited for
making well-defined prints for POP (point -of-purchase)
tools graphics and full-color images.
2 Semi-gloss This media is best suited for printing low-resolution
Paper images or making test prints. Plain paper, however, is
easily affected by temperature and humidity, which
makes plain paper less stable than the other media types.
3 Plain Paper This white semi-transparent film is for electrically
illuminated signs. It allows you to reproduce prints with a
beautiful, glossy surface almost like photo graphs.
4 Glossy Film This white paper has a glossy finish that is less reflective
than glossy paper. It is best suited for making prints of
graphics. This paper allows you to reproduce graphics
with a soft look to them.
5 Heavyweight This film has a glossy surface like photographic printing
Paper paper, and is glossier than glossy paper. This film allows
you to reproduce graphics and full- color images with
more defined and brighter colors. It also offers good
durability for indoor use.
6 Back Print This paper has a glossy surface like photographic printing
Film paper used for prints. Use this paper to give graphics and
full-color images a high-quality finish like that of photo
prints.

L-2
Media Transport Lab
2. Media Transport Assembly Components
Place a check √ mark next to each identified component below.
√ Component
X - Axis Motor (M1) (Refer to page 5-37 in your service
manual for the exact location).
PS2 - Roll Sheet Set Detection sensor (Refer to page 5-36
in your service manual for the exact location).
PS6 - Paper Out Detect/Media Discharge sensor (Refer to
page 5-36 in your service manual for the exact location).
PS8 - Media Transport Detection sensor (Refer to page 5-
36 in your service manual for the exact location)
Path Change Motor (M4) Changes the Path Change Plate
between roll and pre-cut sheets (Refer to page 5-37 in your
service manual for the exact location).
Cut Sheet Position Switch (MSW1) (Refer to page 5-37 in
your service manual for the exact location).
Roll Media Position Switch (MSW2) (Refer to page 5-37
PS1 - Cut Sheet Detection sensor (Refer to page 5-36 in
your service manual for the exact location).
PS7 - Cut Sheet Trailing Edge sensor (Refer to page 5-36

L-3
Media Transport Lab
3. Component Removal and Replacement
With the printer AC power OFF, practice removing and replacing the following components.
Place a check √ mark next to each removed and replaced component.
√ Component
* X-Axis Motor (M1) (Refer to page 3-40 in your service
manual for the procedure).
** Path Change Motor (M4) (Refer to page 3-39 in your
service manual for the procedure).
Cut Sheet Trailing Edge Sensor (PS7) (Refer to page 3-37
in your service manual for the procedure).
Roll Media detection Sensor (PS2) and Cut Sheet
Detection Sensor (PS1) (Refer to page 3-37 in your service
manual for the procedure).
After replacing all the above components, turn the printer’s AC power ON and perform the
following:
* After removal and replacement of the X-Axis motor (M1) perform the Media Feed
Adjustment found on page 1-29 in the Service Manual.
** After removal and replacement of the Path Change motor (M4) confirm proper
operation by listening for the Path Change Plate moving when pressing the
ROLL/SHEET button on the control panel with the printer Off-line.
4. Media Feed Adjustment
Refer to the Service Manual and print out a Media Feed Adjustment Pattern test print. Determine
the values displayed by the pattern according to the Service Manual.

L-4
Media Transport Lab

Troubleshooting
Objective
To enable the technician to troubleshoot system
problems and to successfully diagnosis and
solve the problems.
Chapter 8: Troubleshooting 8-1
8) Troubleshooting
The objectives of this module are to enable you to troubleshoot two separate printer problems,
make the correct diagnosis and successfully solve the problems. When finished, print a printer
setup list print, Automatic and Manual Head Adjustment prints. All the prints must be free from
any defects.
Given a BJ-W7000 printer, a basic tool kit, Canon documentation, and two troubleshooting
faults. You must find and correct both faults. When ready, inform your Course Manager you are
ready to start the troubleshooting process so he or she can install the printer faults. Use the two
troubleshooting sheets in this module to list all the troubleshooting steps you make.
Remember to list all the steps you take to resolve the problem as you will be graded on those
parts.
When you have completed both troubleshooting problems and your Course Manager has given
the okay, reassemble the printer and print a printer setup list. Also do Automatic and Manual
Head Adjustment prints. All the prints must be free from any defects.


CHAPTERS
Section 2
9 Product Introduction ImagePROGRAF
10 Installation
7200/7250
Operations and
11 Chapters nine through sixteen cover the
Controls
imagePROGRAF 7200 and 7250 models
Print Head and Print
12 Lab exercises follow chapters:
Carriage Assembly
9, 11, 12, 13 and 14
Ink Supply and
13
Recovery
Print Media and Media
14
Transport
Service and
15
Maintenance
16 Troubleshooting
Table of Contents i
Section 2 – imagePROGRAF 7200/7250

Table of Contents
9) Product Introduction ............................................................................................................. 9-1
9.1) Overview........................................................................................................................ 9-1
9.2) Features.......................................................................................................................... 9-1
9.2.1) Print Head ............................................................................................................... 9-1
9.2.2) Ink Tanks................................................................................................................. 9-2
9.2.3) Media Roll Holder................................................................................................... 9-2
9.3.1) Overview................................................................................................................. 9-3
9.3.2) Internal View, Print Carriage Unit........................................................................... 9-4
9.3.3) Roll Media Tray Unit .............................................................................................. 9-5
10) Installation ........................................................................................................................ 10-1

10.1) Printer Setup............................................................................................................... 10-1
10.2) Site Preparation .......................................................................................................... 10-1
10.3) Unpacking the Unit .................................................................................................... 10-2
10.4) Installing the Printer................................................................................................... 10-3
10.5) Preparing the Printer for Use...................................................................................... 10-4
10.5.1) Unit Preparation .................................................................................................. 10-4
10.5.2) Installing the Print Head...................................................................................... 10-5
10.5.3) Installing the Ink Tanks ....................................................................................... 10-5
10.5.4) Settings and Adjustments .................................................................................... 10-6
10.5.5) Loading Paper ..................................................................................................... 10-6
10.6) Transporting the Printer.............................................................................................. 10-7
10.7) Network Environments............................................................................................... 10-7
10.7.1) TCP/IP Network Printing .................................................................................... 10-7
10.7.2) AppleTalk Network Printing ............................................................................... 10-7
10.7.3) Network Interface Specifications......................................................................... 10-8
11) Operations and Controls.................................................................................................... 11-1

11.1) Printer Operations ...................................................................................................... 11-1
11.1.1) Print Modes ......................................................................................................... 11-1
11.1.2) Print Data Processing .......................................................................................... 11-2
11.1.3) Print Drivers ........................................................................................................ 11-3
11.1.4) Print Position Adjustment.................................................................................... 11-4
11.1.5) Overheating Protection Control of Print Head..................................................... 11-4
11.1.6) Additional Features ............................................................................................. 11-5
11.2) Controls and Displays ................................................................................................ 11-6
11.3) Main Menu................................................................................................................. 11-8
11.3.1) Main Menu Operations........................................................................................ 11-9
11.3.2) Map of the Main Menu........................................................................................ 11-9
11.3.3) Main Menu Contents ........................................................................................... 11-9

ii imagePROGRAF 7200/7250 and BJ-W7000 - 201
12) Print Head and Print Carriage Assembly........................................................................... 12-1

12.1) Configuration ............................................................................................................. 12-1
12.2) The Print Carriage ...................................................................................................... 12-1
12.2.1) Carriage Controls ................................................................................................ 12-1
12.2.2) Print Carriage System Sensors............................................................................. 12-2
12.2.3) Head Cleaning..................................................................................................... 12-4
12.3) The Print Heads.......................................................................................................... 12-4
12.3.1) Nozzle Arrays...................................................................................................... 12-5
12.3.2) Print Head Life Cycle/Replacement .................................................................... 12-5
12.4) Print Head Sensors and Adjustments.......................................................................... 12-6
12.4.1) Media Thickness Adjustment .............................................................................. 12-6
12.4.2) Paper Width/Skew Detection............................................................................... 12-6
12.4.3) Gap Adjustment Unit........................................................................................... 12-6
12.4.4) Media Sensor Unit............................................................................................... 12-7
12.4.5) Internal Temperature Detection ........................................................................... 12-7
12.4.6) Carriage Home Position Edge ............................................................................. 12-7
13) Ink Supply and Recovery .................................................................................................. 13-1

13.1) Overview.................................................................................................................... 13-1
13.2) Ink Tank Unit ............................................................................................................. 13-2
13.3) Purge Unit .................................................................................................................. 13-4
14) Print Media and Media Transport...................................................................................... 14-1

14.1) Print Media Types ...................................................................................................... 14-1
14.2) Installing Print Media................................................................................................. 14-1
14.2.1) Installing Roll Media........................................................................................... 14-2
14.2.2) Loading Cut Sheets ............................................................................................. 14-5
14.3) Paper Path .................................................................................................................. 14-5
14.3.1) Overview............................................................................................................. 14-5
14.3.2) Paper Path Sensors .............................................................................................. 14-6
14.3.3) Media Feeding..................................................................................................... 14-7
14.4) Paper Feed Operations ............................................................................................... 14-8
15) Service and Maintenance .................................................................................................. 15-1

15.1) Service Mode ............................................................................................................. 15-1
15.2) Draining the Ink Supply (when required) ................................................................... 15-1
15.3) Adjustment and Setup ................................................................................................ 15-3
15.4) Upgrading the Printer’s Firmware .............................................................................. 15-4
16) Troubleshooting ................................................................................................................ 16-1

16.1) Outline ....................................................................................................................... 16-1
16.2) Notice for Troubleshooting ........................................................................................ 16-1
16.3) Troubleshooting When Warnings are Displayed ........................................................ 16-2
16.4) Troubleshooting When Error Codes are Displayed .................................................... 16-3
16.5) Troubleshooting When Service Call Errors Occur ..................................................... 16-7
16.6) Troubleshooting for Other Problems Indicated on the Display................................... 16-7
16.7) Troubleshooting for Problems Not Indicated on the Display...................................... 16-8

9.1 Overview
9.2
The imagePROGRAF Product Overview
7200/7250 Printers
Component
and Introduction
9.3
Identification
Objective
This chapter introduces the W7200/7250
printer and its main features and specifications
9) Product Introduction
9.1) Overview
This printer is a BJ large format printer capable of high-speed, photo-quality printing on large-
size paper up to 36 inches wide (A0 size with index lines) for the W7200 and up to 24 inches
wide (A1 size with index lines) for the W7250.
The W7200 is stand-mounted and the W7250 is a desktop-type printer. Both printers are capable
of output to either roll media or cut sheet.
9.2) Features
Both models feature 1200 x 600 dpi resolution, high-quality photo printing with six color inks
(black, photo-cyan, cyan, photo-magenta, magenta and yellow). They employ bi-directional
printing control for high-speed printing output.
The print heads are completely separated from the high-capacity ink tank (330 ml for W7200 and
130 ml for W7250). Ink is supplied to each print head from the ink tank through its own tube, to
the one-inch print.
Roll media is fed automatically from the roll media tray and cut sheets can also be fed manually
from the tray. Paper feeding capabilities are up to 36 inches for the W7200 and up to 24 inches
for the W7250. They can printing long sheets of up to 18 meters in length
An automatic cutter is provided for cutting media up to a certain weight, for heavier media the
automatic cutter is disabled and the media cut manually.
User functions such as feeding and delivery of media and replacement of ink tanks can be
conveniently controlled and operated from the front panel controls.
9.2.1) Print Head
The disposable Print Head are installed on the Print Carriage, each of which contains six rows of
integrated nozzles (noe row per color). Each row consists of 1280 nozzles, arranged in a
staggered pattern of two rows of 640 nozzles, for printing efficiency. Generally, it is
recommended that the print head be replaced about 12 months after installation. The number of
printable pages for each model is shown below.

W7200:
Approx. 1,100 sheets in Standard mode (8-pass, Bi-directional)
A0 size, 20% duty pattern for each color)
W7250:
Approx. 3,000 sheets in Standard mode (8-pass, Bi-directional)
A1 size, 15% duty pattern for each color)
The print head for this printer is a consumable. This consumable print head is the same as the
print head shipped with the printer. Refer to page 2-6 of the Service Manual for detailed print
head specifications.
9.2.2) Ink Tanks
The ink tanks are disposable and contain dye based Black (Bk), Photo-Cyan (PC), Cyan (C),
Photo-Magenta (PM), Magenta (M) and Yellow (Y) inks. The printers feature a mechanism by
which only the correct color ink tank will fit in its given slot.
When the “No Ink” message is displayed, replace the ink tank with a new one (tanks should
generally be replaced six months after installation). The approximate number of printable pages
for each model is shown below.
W7200:
Black - 1,780 sheets, Photo-Cyan - 194 sheets, Cyan - 882 sheets,
Photo-Magenta - 171 sheets, Magenta - 619 sheets, Yellow - 272 sheets
In Standard Mode (8-pass, Bi-directional), A0 size, Bicycle (ISO No.5) pattern)
W7250:
Black - 1,148 sheets, Photo-Cyan - 170 sheets, Cyan - 663 sheets,
Photo-Magenta - 136 sheets, Magenta - 502 sheets, Yellow - 213 sheets
In Standard mode (8-pass, Bi-directional), A1 size, Bicycle (ISO No.5) pattern)
Consumable ink tanks are the same as the ink tanks shipped with the printer except for the
package. Each bottle has a life of six-months from the time the package is opened. Refer to page
2-6 of the Service Manual for detailed specifications of the ink supply components.
9.2.3) Media Roll Holder
One roll holder can be installed in the roll media tray. The roll holder for a 2-inch inner diameter
paper tube is shipped with the printer. The roll holder locks into the cardboard tube of roll media
with an outer diameter not more than 130mm.
Refer to page 2-6 of the Service Manual for all other electrical and mechanical specifications.

9.3.1) Overview

9.3.2) Internal View, Print Carriage Unit

9.3.3) Roll Media Tray Unit

LAB - CH 9
Product L-1
Introduction
Objective:
Reinforce familiarity with the components and subsystems of the printer
Instructions:
Given a list of wide format printer attributes and specifications, match the correct specifications and
attributes to the stated imagePROGRAF 7200/7250 characteristics.
Place the number of each Attribute next to the correctly matching Description (in the # column).
7200/7250 Attribute Description #

1 Wide Format Print ISO media size
Technologies
2 Printer Interpreter On the fly, line by line printing
Languages
3 Raster Printers Electrostatic, Ink-jet and
Thermal Transfer
4 Paper Size A0 ANSI media size
5 Paper Sixe B HP-GL, HP-GL/2 and HPRTL

L-2
Product Introduction Lab
Using your service documentation, place the number of each Specification beside the correct
Description (in the # column).
Specification Description #
1 Ideal monthly vol ume 130 ml
2 Acceptable paper thicknesses Bubble-Jet
3 Media cutter type 882 A0 size prints
4 Data format 36 inches
5 Maximum operatring humidity level 330 ml
6 Minimum roll media width 200 A0 size prints
7 Print resolution Automated replaceable cartridge
8 Approx ink yield - cyan ink bottle 80%
9 Smallest cut size sheet 80 to 500µm
10 Print Technology GARO
11 Maximum cut sheet media length 100 to 400 A0 size prints
12 Ink capacity (per color) for the 7250 55.1 inches
13 Maximum roll media width, 7200 24 inches
14 Monthly volume range 1 sheet
15 Ink tank capacity for the BJ- W7200 1200 x 600

10.1 Printer Setup
10.2 Site Preparation
10.3 Unpacking the Unit

Installation
10.4 Installing the Printer
Preparing the Printer

10.5
for Use
Objective
Transporting the Familiarize with the processes and requirements
10.6
Printer involved in setting up and configuring a new
printer, including the considerations of site
10.7 Network Environments selection and preparation.
10) Installation
10.1) Printer Setup
In addition to the printer unit, an accessory kit is needed when installing the printer, which also
includes regional components. Take the following precautions when installing the printer.
• Always hold the handles when lifting and moving the printer; never by any other part.
• The printers weighs approximately 141 lbs for the W7200 and approximately 112 lbs
for the W7250. At least two people are required to remove the printer from the box.
10.2) Site Preparation
Refer to the Service Manual, page 3-6, for exact specifications of the space required to ensure
easy operation and maintenance of the printer.
Follow the precautions below when choosing the location.
• Do not subject the printer to extremes of temperature or humidity (operating

temperature - 40°-95°F; humidity range 10% - 90% RH).
• Avoid direct sunlight. Use curtains if there is no alternative.
• Avoid abrupt changes in temperature.
• Avoid dusty locations.
• Avoid placing it in the vicinity of an air conditioner or an electric fan (air currents may
damage the printer).
• Avoid places prone to vibrations.

Install the unit on a stable floor or table which safely supports the printers’ approx. 194 lbs for
the W7200 (including stand), and 112 lbs for the W7250, and will not subject the printer to
vibrations. Do not install on a carpeted floor or other surface where it cannot remain level and
stable. Doing so can harm the print quality.
10.3) Unpacking the Unit
Open the package and the enclosed accessory kit and ensure that the items displayed in the
Figure below have been included:

Unpack the printer stand (optional with W7250), if included, and assemble in accordance with
the instructions in the Service Manual, page 3-10.
10.4) Installing the Printer
Place the printer on a stand or table.
Grasp the handles on the bottom of the printer, and place the printer on the stand or table. If
placing on a stand, proceed with the following steps (and refer to the Figure below).
1) Use the screws supplied with the stand to secure the printer to the stand.
2) Mount the right cover and left mount attachment cover.
3) Assemble and install the Print Stacker

When installing the printer on a tabletop, align the front edge of the tray lid with the edge of the
table. See page 3-12 of the Service Manual for a detailed diagram of printer placement.
10.5) Preparing the Printer for Use
10.5.1) Unit Preparation
Refer to the Service Manual, page 3-5, for detailed procedures or illustrations needed to
complete the following setup processes.
Removing Packing Materials
After installing the printer on a stand or table, remove all of the packing materials attached to the
printer.
Removing the Belt Stopper
Remove the belt stopper (one screw). The belt stopper is needed when transporting the printer;
store the belt stopper by screwing it to the left side of the roll media tray. When removing the
belt stopper, be careful not to bring it into contact with the linear scale. If the linear scale is
scratched, the printer may not operate properly.
CAUTION
Connecting the Power Supply
Connect the power supply as follows:
1) Connect the power cord and the ground wire to the printer.
2) Connect the ground wire to a grounded terminal. Connect the power plug to an
electrical outlet.
Be sure to connect the ground wire of the power cord. Failure to properly connect the ground
wire can result in electric shocks. Connect the ground wire to:
1. Grounding terminals of electrical outlets.

2. Terminals used to make a connection to a ground.
Connecting the Interface Cable
The printer is provided with a USB port, an IEEE-1394 parallel port (optional for W7250), and
LAN port interfaces. Connect to these ports according to the computer being used and the
connection method.

Note: This printer does not include an interface cable. Obtain a suitable cable
(available commercially) for the required length and connection method used.
10.5.2) Installing the Print Head
Follow the steps below to install the print head.
1) Check that all covers are closed.

2) Press the Power button to turn on the printer.
3) Open the upper cover.
4) Remove the tape from the carriage cover and cutter.
5) Open carriage cover, print head lock lever, and print head lock cover until they stop.
6) Open the package containing the print head.
7) Remove the orange protective cap on the print head.
8) Install the print head in the carriage.
9) Close the lock cover, lock lever and the carriage cover, in that order.
10) Lock the print head into position.
11) Close the upper cover.
Take the following precautions when handling the print head.
• Unseal the package of the print head only when you are ready to install it.
• Do not replace the orange protective cap once you have removed it from the print head.
If there is foreign matter stuck to the protective cap, it may scratch the print head.
• Never put a print head on racks or tables with the nozzles facing downward. If the head
becomes scratched or dirty, it may result in poor quality printing.
• Never touch the head area or the electrodes. If those areas become soiled by dirt or
finger grease, it may result in poor quality printing.
10.5.3) Installing the Ink Tanks
Follow the steps below to install the ink tanks.
1) After installing the print head, open the right cover.

2) Open the package containing the ink tank.
3) Install the ink tank while holding up the ink tank lever.
4) Press down the ink tank cover firmly it clicks as the ink tank is locked into position.
5) Repeat steps 2) to 4) until the ink tanks are installed for all six colors.
6) Close the right cover. The message "Ink Filling" is displayed, and the initial filling of
the ink is started automatically (taking about eight minutes to complete).
7) In the case of the W7250, "Stand" is displayed. Use the right/left arrow buttons to
select "Use" when the stand is installed and "No use" when the stand is not
installed. Then press the ENTER button (not displayed in the case of the W7200).

The ink tank covers have a mark which indicates which ink color goes in a particular slot, and
each tank can be installed only in the correct slot. Never try to force a tank into a wrong slot, as
this may damage the printer. Install Black (BK), Photo-Cyan (PC), Cyan (C), Magenta (M),
Photo-magenta (PM) and Yellow (Y), in order, from left to right.
10.5.4) Settings and Adjustments
Language Setting
This feature allows the user to specify which language should be used for message display.
Select from the following six languages:
English German
Japanese Italian
French Spanish
Follow the steps in the Service Manual, page 3-18, to specify the language selection for user
display.
Checking and Adjusting the Print Status
After installing the printer, perform a nozzle check print and print position adjustment to confirm
that the printer is operating properly.
The printer may not produce satisfactory printing results when printing on paper types other than
those used for the adjustment or when the vertical position of a print head has been changed. It is
recommended that you make the "Adjustment" setting before a print job for producing optimum
print quality when a new paper type has been selected or when the vertical position of a print
head has been changed.
Refer to the Service Manual, page 3-19, for the detailed steps to accomplish the following
adjustments:
a) Nozzle Check
b) Adjusting the Print Head Position
c) Adjusting the Sheet Feeding Rate
10.5.5) Loading Paper
Roll media and cut sheet media are available for this printer. Refer to page 3-27 of the Service
Manual for detailed instructions on how to load the various print media.

10.6) Transporting the Printer
Refer to the Service Manual, page 3-21 before moving the printer. When moving the unit,
several critical precautions must be taken, depending on the conditions and distance of the move;
for example, the heads must be capped and stay in the carriage during transporting. Print the
"Nozzle Check" before and after moving the printer, and compare the two printouts. If any
deterioration is evident in the output quality, replacement of the print head with new ones may be
required.
10.7) Network Environments
The following section provides an outline of the system requirements for connecting the W7200
printer to a network. Complete connectivity specifications and detailed setup procedures are
provided in the Network Setup Guide, included with each delivered printer.
10.7.1) TCP/IP Network Printing
Compatible Server Operating Systems:
Windows XP Professional
Windows 2000 Server
Windows 2000 Professional
Windows NT Server 4.0
Windows NT Workstation 4.0
Compatible Client Computers - IBM compatible PC running:
Windows Me
Windows 95/98
Windows XP
Windows 2000
Windows NT (for NT 4.0, with Service Pack 6 or later installed)
10.7.2) AppleTalk Network Printing
Compatible Computer:
Macintosh Series computer equipped with a Power PC processor.
Compatible Operating Systems:

Mac OS 8.6 or later

Mac OS x 10.1 or later
Compatible AppleTalk:
EtherTalk Phase 2
Required Memory:
24 MB or more for Mac OS 8

32 MB or more for Mac OS 9
10.7.3) Network Interface Specifications
Interface Format
Ethernet CAT 5 interface complying with IEEE802.3 standards
Data Transfer
10Base-T/100Base-TX
Signal level
Input threshold
100 Base-TX: turn-on +1000mV diff pk-pk

turn-off +200mV diff pk-pk
10 Base-T : max +585mV

min +300mV
Output:
100 Base-TX : +0.95V ~ +1.05V
10 Base-T : +2.2V ~ +2.8V
4) Interface cable
Category 5 (STP or UTP) cable, 100 meters max.

Compliance with EIA/TIA-568A or EIA/TIA-568B standards

5) Interface connector
Printer side: IEEE802.3 standards, and compliance with ANSI X3.263 standards
Cable side: IEEE802.3 standards, RJ-45 type
6) Input/output signals and pin configuration
Refer to Connector Position and Pin Arrangement (Service Manual, page 5-74).


CHAPTER HIGHLIGHTS
11.1 Printer Operations

Chapter 11
Controls and
11.2
Displays Operations and
11.3 Main Menu Control
Objective
Familiarize with the printers basic operations
and the Control Panel functions, adjustments
and customer maintenance items.
Chapter 11: Operations and Controls 11-1
11) Operations and Controls
11.1) Printer Operations
The printer requires approximately two minutes (not including the time required to supply ink, or
for cleaning after an extended storage period) to perform the power-on initialization sequence.
After this initialization sequence is complete, the printer displays an ‘Online’ status on the
display panel with all print functions fully operational.
The W7200/7250 printers are capable of fast, high-quality printing without blurring or
inconsistent ink density by changing the carriage operation, sheet feeding operation, and other
printing methods according to the selected paper, print quality, and print data.
Printing is performed using a multi-pass technique for each color. This allows not only a faster
print speed, but also reduces the inconsistency in ink density due to different amounts of ink
discharged from the print head nozzles. Blurring is also prevented since the multi-pass printing
technology shifts the print timing so that the ink discharged onto the paper in the previous pass is
nearly dry before the next ink discharge occurs in the next pass.
The printer supports a maximum of 8-pass printing according to the required print quality.
11.1.1) Print Modes
Draft Mode
In high-speed draft print mode, image data is thinned out and a single band (equivalent to the height
of a nozzle array) is printed in a two-pass operation (by selecting the "Draft" option under Print
Quality settings in the printer driver).
The image data is allocated for each color by the mask pattern control, divided into two parts by
the nozzle block control, and then printed by a two-pass bi-directional.
Standard Mode
In normal print mode, a single band (equivalent to the height of a nozzle array) is printed using a
four-pass or eight-pass operation (by selecting the "Standard" option under Print Quality settings
in the printer driver).
The printing operation varies depending on the sheet settings in the printer driver. If Plain Paper
is selected in the sheet settings, the image data is allocated for each color by the mask pattern

control, divided into four parts by the nozzle block control, and then printed by a four-pass
single-directional carriage 2x-speed movement.
If a media other than Plain Paper is selected in the sheet settings, the image data is allocated for
each color by the mask pattern control, divided into eight parts by the nozzle block control, and
then printed by an eight-pass bi-directional.
High Mode
In high quality print mode, a single band is printed using an 8-pass operation (by selecting the
"High" option under Print Quality settings in the printer driver).
The image data is allocated for each color by the mask pattern control, divided into eight parts by
the nozzle block control, and then printed by an eight-pass bi-directional.
Highest Mode
In super-high quality print mode, a single band is printed using an eight-pass operation (by
selecting the "Highest" Fine option under Print Quality settings in the printer driver).
The image data is allocated for each color by the mask pattern control, divided into eight parts by
the nozzle block control, and then printed by an 8-pass single-directional.
11.1.2) Print Data Processing
The print process sequence within the W7200 occurs from the printer’s receipt of print data signals
from the host computer until print output starts. This process is illustrated in Figure 4-2 of the
Service Manual.
The printer driver in the host PC compresses the image data, and then sends the command data
and other print data to the printer. Resolution conversion, color conversion process, and six-color
binary conversion process for the image data are not performed by the print driver. The image
process table data is used in the color conversion process, binary conversion process, and other
operations of the image data to achieve a high-quality image output. This data is created and sent
as command data based on the Paper Type setting specified in the printer driver.
An optional software RIP performs resolution conversion of the image and then sends this image
data to the printer together with the command data after a color conversion process or six-color
binary conversion is performed.
This printer receives the print data from the interfaces controlled by the interface unit of the
system controller. The received print data is sent to the CPU or Application-Specific Integrated
Circuit (ASIC).

The system controller extracts the print data that was sent to the CPU or ASIC, and then
performs resolution conversion, color conversion process, and six-color binary conversion while
storing the data in the SDRAM or FCRAM at the optimal timing.
The ASIC in the system controller converts the print data to six-color binary image data and
command data and sends the data to the ASIC in the engine controller.
The ASIC in the engine controller stores the received image data in the SDRAM at the optimal
timing, and the data is combined with the mask data in the ASIC and output in coordination with
the discharge timing. The ASIC also sends the command data from the system controller to the
CPU.
The CPU in the engine controller obtains the mask pattern data from the FLASH ROM based on
the command data, print head information from the EEPROM in the print head, and internal
temperature from the latch IC on the head relay PCB, and sends this data to the ASIC.
The ASIC in the engine controller sends the image data combined with the mask pattern to the
print head as print signals while converting to data corresponding to the print head information
and internal temperature. During this operation, heat pulses are sent to the print head for
performing the optimal head driving.
The print signals undergo differential processing by the driver ASIC to reduce noise and then are
restored by the receiver ASIC.
The print heads convert the received print signals internally, which are in serial format, into the
parallel data used by a single nozzle array, and then perform heat pulse and AND processing to
carry out the printing.
The CPU in the engine controller manages the overall print drive operations while controlling the
motor driver and monitoring the status of the printer components based on the adjustment values
stored in the EEPROM. The SDRAM is used as work memory.
The CPU in the system controller manages the overall image processing operations while
controlling key operation and message display based on the adjustment values stored in the
EEPROM. The firmware is stored in the FLASH ROM.
11.1.3) Print Drivers
In the W7200, the print signals and control signals pass through the carriage relay PCB and head
relay PCB and are output to the print heads. This allows the print heads to perform printing
operations by discharging ink from the print head nozzles.
Each print head has six nozzle arrays (Bk, PC, C, PM, M, and Y from the left with the carriage
installed).

The print signals received by each print head include odd and even nozzle data. The two data
types are sent according to the timing determined by the data transfer clock and data latch pulse.
The drive control signals include heat enable signals for ejecting ink from the print head nozzle
and sub-heat enable signals for maintaining stable ink discharge rates by raising the temperature
of the head when it is lower than the optimum operating temperature.
Print Drive Control
Each nozzle array on a print head has 1280 nozzles. The nozzles used for discharging ink are
selected by the block enable information in the even nozzle data and odd nozzle data and are
separated into 24 blocks. (The 1280th nozzle ends at block number 15.) There are 54 nozzles in
blocks 0 to 15, and 52 nozzles in blocks 16 to 23.
In the print head nozzles in the selected block, heat enable signals and sub-heat enables signals
are applied to adjust the pulse width according to the head rank, head temperature, internal
temperature, and other factors to ensure optimal ink discharge, and then the heat board in the
print head nozzle is driven so that ink is discharged.
11.1.4) Print Position Adjustment
This printer incorporates a print position adjustment function for manual adjustment of the
vertical/horizontal positions, bi-directional printing position, and sheet feeding rate of the print
heads installed on the carriage.
Adjusted is made by first printing the print position adjustment patterns with slightly modified
conditions and then setting the adjustment values observed visually from the operation panel.
The print position adjustment requires a roll media or cut sheet that is A3 size or larger.
11.1.5) Overheating Protection Control of Print Head
This printer is provided with an overheating protection control function that detects abnormally
high temperatures in the print heads. The print heads can overheat, for instance, when the
printing process continues for some time with no ink supplied to the print head nozzles. The
overheating protection control function prevents a print head nozzle from becoming permanently
clogged or damaged due to excessive heat.
The overheating protection control process is based on the detected temperature of the head
temperature sensors in each nozzle array. If overheating is detected in a single nozzle array,
control is performed in one of the two stages below according to the temperature.

Protection Level 1:
If the head temperature sensor detects a temperature above 175°F, the printer allows the carriage
to continue in the direction of its scanning pass and then stops it at the scan end position. The
wait control is activated to allow the heat to dissipate. Printing resumes when the temperature
drops below 175°F or 30 seconds have passed in the wait state.
Protection Level 2:
If the head temperature sensor detects a temperature above 250°F, the printer immediately stops
printing and the carriage returns to the home position where capping is performed. An error
message is shown on the display.
11.1.6) Additional Features
Pause Between Pages
To prevent in-blots from forming, this printer discharges printed pages so that they hang down
from the platen and dry and is provided with a Pause between Pages function for discharging
sheets after a specified wait time. The user can set the wait time from the printer driver. This
function is particularly useful for film-type and other sheets that need extra time to dry.
White Raster Skip
To improve printing throughput, this printer incorporates a White Raster Skip function for
skipping the carriage scan operation for continuous blank segments of print data.
Sleep Mode
This printer has a Sleep mode for reducing the standby power; it automatically enters this Power
Save mode when there are no user operations and no print data has been received for a preset
period of time in the Online or Offline mode. The printer wakes from Sleep mode whenever the
user performs any key operations on operation manual or print data is received from the host
computer.
Whenever the roller trace preventive sequence starts automatically, the printer temporarily
switches to the normal power mode and then returns to Sleep mode again once the operation is
finished. The time until the printer enters Sleep mode can be changed from the operation panel.

11.2) Controls and Displays
This section describes the function of the buttons and the meaning of the LED displays on the
printer’s operation panel.
Refer to the Figure below and the button lamp and display functional descriptions that follow.
Further details for some functions are provided in the Service Manual, page 3-38.
Operational Panel Buttons, Lamps and Display
Buttons (1-9)
1) PAPER SOURCE
Offline status: Switches paper source between roll media and cut sheets; if sheets are
loaded on the take-up reel, the paper source is fixed at roll media.
2) CANCEL
Offline status: Holding down this button for 0.5 seconds or longer aborts the job in
progress or ink drying and then discharges the media.
Pause status: Holding down this button for 0.5 seconds or longer aborts the paused job
and discharges the media.
3) LEFT ARROW
Offline status: Carriage moves left when upper cover is closed. When menu is displayed,
it functions as selector and is used to display the previous option.

4) LOWER ARROW
Offline status: When roll media is loaded, this button functions as a manual feed button
and feeds the media. When a cut sheet is loaded, the sheet is discharged. When menu is
displayed, this button moves to the next lower-level menu.
5) RIGHT ARROW
Offline status: The carriage moves to the left when the upper cover is close. When a
menu is displayed, this button functions as a selector button and is used to display the
next option.
6) UPPER ARROW
Offline status: When roll media is loaded, this button activates manual feed and reverse-
feeds the media. When a cut sheet is loaded, the sheet is discharged. When a menu is
displayed, this button returns to the next higher-level menu.
7) ENTER
When setting values are displayed, sets or executes selected value or operation.
8) POWER
This button is used to turn the printer ON and OFF. When the power is OFF, pressing this
buttons turns power ON. When the power is ON, holding down this button for about 2.5
or more seconds turns power OFF.
9) ONLINE
Switches between online status, offline status, and menu display.

Online status: Switches to offline status.
Offline status: Switches to menu display.
Menu display: Cancels the menu operation and switches to online status.
Lamps and Display (10-15)

10) ROLL MEDIA
On: Indicates that roll media has been selected as the paper source.

11) CUT SHEET
On: Indicates that cut sheets have been selected as the paper source.
12) DATA
On: This indicates that a job is being received or processing.

Flashing: This indicates that there is a job that has been stopped in pause status.
Off: This indicates that there are no jobs.
13) MESSAGE
On: This indicates that a warning is displayed.

Flashing: This indicates that an error has occurred.
Off: This indicates that operation is normal.
14) ONLINE
On: This indicates that the printer is in online status or job processing status. Flashing:
This indicates that media are being loaded or a job that cannot be processed is being
received.
Off: This indicates that the printer is in offline status, pause status, or turned off.
15) DISPLAY
The display presents the printer status, menu options and error codes. It display data in
two lines of 16 characters each.
11.3) Main Menu
The printer’s User mode provides access to various adjusting and configuring features, for
example: adjusting print position; performing cleaning or other maintenance features; auto-
cutting, ink drying period and other print settings; message language and other parameter
settings.

11.3.1) Main Menu Operations
a) To enter the Main Menu, press the printer's Online button several times.
b) To exit the Main Menu, press the Online button once to exit the User mode.
c) Keys used in the Main Menu
• Select menu and parameter: Left/Right arrow key
• Confirm menu/parameter, or decrease entered value: Down arrow key
• Return to menu on upper level, or increase entered value: Up arrow key
11.3.2) Map of the Main Menu
The hierarchy of menus and parameters in the Main Menu is mapped out in the Service Manual,
page 3-40.
11.3.3) Main Menu Contents
The available options in the main menu are listed as follows (detailed in the Service Manual on
page 3-43):
1) Head Cleaning - cleans the print heads to prevent nozzles from getting clogged and to
recover nozzles that are already clogged.
2) Force Cutting - is displayed only when "Cutter" is set to "Enable" in Roll Media mode.
The operation will end without cutting if the media is not fed to the cutting position.
3) Auto Feed - is displayed in the W7200 only when "Take-up Reel" is set to "Enable"
and the roll media is already loaded in Roll Media mode.
4) Take-up Reel - is set when the take-up reel is used. When the "Enable" setting is made,
the "Auto Feed" option is displayed in the Main menu.
5) Cut Sheet Type - is displayed only in Cut Sheet mode and is used to select the media
type loaded in the cut sheet tray.
6) Roll Media Type - is used to select the media type loaded in the roll media tray.
7) Rep. Ink Tank – is selected when replacing the ink tank. It unlocks and opens the right
cover so that the ink tank can be replaced.

8) Auto Cut - is displayed only in Roll Media mode and is used to select the operation
that is performed at the trailing edge of each media after printing is finished.
9) System Setup:
a. Cutter - prohibits all cutting operations when "Disable" is set.
b. Buzzer - is selected, whenever the buzzer sounds a warning or an error occurs.
c. Sleep Timer - sets the time until the device enters the sleep state.
d. EOP Timer - sets the timeout time for a printing job.
e. Replace P Head - selected when replacing print head. This operation uncaps
the print head and moves the carriage over the platen so that the heads can be
replaced.
f. Adjust Printer - allows user to check if the nozzles are discharging normally or
if the discharge positions are misaligned.

LAB - CH 11
Operations L-1
and
Controls
Objective:
Review the printer’s User Mode setup and adjustments, operating functions and service
procedures.
Instructions:
These exercises may be performed on a new printer undergoing initial setup or on an operating
machine. If performed on an operating system, remove and replace components to simulate
installation, where indicated. When lab is done as part of a new system setup, follow the User’s
Guide (Setup volume) to ensure that all initial settings and adjustments are properly entered.
√ Printer Operation
Load roll media (page 3-27 in the Service Manual).
Installation of the ink cartridges (page 3-17 in the service Manual).
Installation of the Print Head (page 3-16 in the Service Manual).
Locate grease points on the upper cover, Print Carriage, pinch roller
unit and feed roller assembly (page 5-4 and 5-5 in the Service Manual).
Input Language Setting selection at the Control Panel (page 3-18 of the
Service Manual).
Check settings of system controller DIP swithh settings (page 5-40 of
the Service Manuall).
Check the operation and tension adjustment of the feed roller drive belt
(page 5-16 in the Service Manual).
Practice the removal and replacement of the ink tank tube unit. The
procedure is outlined on page 5-17 in the Service Manual.
Practice the procedure for cleaning the Print Head (page 7-31 in the
User’s Guide).
Practice Print Head Alignment procedure (page 7-33, User’s Guide).
Review the Precautions When Servicing the Printer section of the
Service Manual, page 1-12.
Perform Power On startup and observe sequence. Refer to page 4-7 of
the Service Manual.

L-2
Operations and Controls Lab

12.1 Configuration
Print Head and
12.2 The Print Carriage
Print Carriage
12.3 The Print Heads Assembly
Print Head Sensors
12.4
and Adjustments
Objective
Familiarize with the components and
operations of the print head unit and print
carriage assembly.
Chapter 12: Print Head and Print Carriage Assembly 12-1
12) Print Head and Print Carriage Assembly
12.1) Configuration
12.2) The Print Carriage
The print carriage assembly holds and mechanically locks the print heads in position, connecting
them to the terminals on the head relay PCB. The toothed carriage drive belt moves the carriage
back and forth on the platen, in the sheet horizontal direction, driven by the carriage motor, with
the relay PCB connected to the engine controller by flexible cable.
The print heads are mounted to the carriage by the print head lock cover and print head lock
lever. When the print heads are fixed to the carriage, the signal contact point of the head relay
PCB contacts the signal contact points of the print heads, enabling the transmission of print
signals.
12.2.1) Carriage Controls
The carriage relay PCBs are connected to the head relay PCBs by short flexible cables. The
flexible cable between the engine controller and carriage relay PCB is mounted on a frame-
shaped caterpillar and moves in coordination with the carriage.

Ink supply is passed from the ink tank through the ink tubes connected to the print heads. The
ink tubes run through the joints and inside the frame-shape caterpillar and move in coordination
with the carriage.
The carriage relay PCB and encoder, installed on the carriage assembly, work in concert to time
the movement of the carriage in the print cycles The carriage relay PCB communicates the drive
signal of the print head while the encoder detects the carriage position and generates print timing
signals. A photo-coupler-type sensor is mounted at the bottom of the rear of the carriage for
reading the linear encoder scale during carriage movement. The encoder consists of a fixed-
position marked strip that passes through a slot in the sensor, constantly reading the position
markings on the strip over the length of the carriage sweep.
The carriage home position, which is also the capping position, is detected by the carriage home
position edge, on the right (home) side of the carriage and by the photo interrupter on the
carriage right-side plate. The position on the linear scale that corresponds to the detected carriage
home position is recorded as the home position, and this position is set as the reference point for
position control. The carriage motor is then driven and controlled using the control signals
generated by the engine controller.
Mechanical misalignment of the installed print heads in the vertical/horizontal direction and in
bi-directional printing can be corrected by using the Adjustment command in the Main Menu to
shift the print timing.
12.2.2) Print Carriage System Sensors

Media Sensor
The photo reflection-based media sensor detects the edges of the media. The sensor detects the
edges by monitoring the change in voltage with respect to changes in the reflection density from
the media. Since the sensor light uses infrared light, light emission cannot be confirmed visually
(see Figure below).
Carriage Cover Sensor
The photo interrupter-based carriage cover sensor detects opening and closing of the carriage
cover.
When the carriage cover is closed, the sensor light is cut off by the sensor arm, notifying the
sensor that the carriage cover is closed.
Carriage Home Position Sensor
The photo interrupter-based carriage home position sensor detects the home position of the
carriage.
The sensor, located on the right-side plate, detects the carriage home position edge on the
carriage unit during carriage traveling.
The carriage home position is defined based on the location where the edge is detected.
Linear Encoder
The linear encoder, installed on the rear of the carriage, detects the position of the carriage using
the slits on the linear scale while the carriage is moving.
Environment Temperature Sensor
The environment temperature sensor (thermistor) installed on the head relay PCB detects the
environment temperature in the vicinity of the carriage.

The resistance measured by the thermistor, which varies as the temperature inside the printer
changes, is sent to the engine controller after passing through the carriage relay PCB.
The environment temperature is used to calibrate the head temperature sensor and to detect
abnormal internal printer temperatures.
Head Temperature Sensor
A set of two diode head temperature sensors are installed at the top and bottom of the nozzle
arrays of print head to detect the temperature of the print head.
The voltage produced by each diode, which varies as the temperature near the nozzle array
changes, is sent to the engine controller after passing through the carriage relay PCB.
The head temperature information is used to control the operation of the head and to detect
abnormal head temperatures.
Print Head Contact Detection
The status of direct contact between the contact faces of the print head and the carriage is
checked by testing the electrical conductivity.
The contact status between the two faces is detected from the voltage changes of the flexible
cable connecting two separate terminals on the contact surface of the print head, the +18 V
power supply terminal, and the GND terminal.
12.2.3) Head Cleaning
The printer performs cleaning operations of the print heads at the carriage home position. In the
wiping operation, the print heads installed in the carriage are wiped as the purge motor rotates at
the point when the carriage is stopped at the carriage home position. The maintenance jets are
discharged when the carriage passes through the maintenance jet tray, located at the right side of
the platen, while the carriage is moving forward. The suction operation is performed using the
suction cap of the purge unit.
12.3) The Print Heads
The print head contains six arrays of integrated nozzles. Signal contact points on the print head
are connected to the signal contact points on the head relay PCB to transfer print signals and
other information from the carriage relay PCB through the print head to the ink nozzles.

12.3.1) Nozzle Arrays
Each array consists of 1280 nozzles arranged in a two-column staggered pattern for printing
efficiency. Each column is comprised of 640 nozzles separated by an interval of 1/600 inch and
is arranged in a staggered pattern to form 1280 nozzles separated by an interval of 1/1200 inch.
Each nozzle can be controlled individually so that a six-color discharge action is performed by a
single print head. Thermistors installed in the print head relay PCBs detect the internal
temperature in the vicinity of the print head.
12.3.2) Print Head Life Cycle/Replacement
The life cycle of the W7200 print head is approximately one year. Generally, it is recommended
that the print head be replaced about 12 months after the printer has been unpacked.

If white lines appear on the printed image, it is possible that ink is not being discharged due to
clogging of the nozzles in the print head.
In this case, enter the Main menu, and perform the "Cleaning" operation two or three times, and
then select "Nozzle Check" under "Test Print" to print the check pattern. Verify the check
pattern, and then replace the print head if there are any clogged nozzles.
If print quality does not improve despite carrying out cleaning, the print head should be replaced
with a new one. The number of printable pages for each model is shown below.
W7200: Approx. 1,100 sheets (Standard mode (8-pass, Bi-directional), A0 size, 20% duty
pattern for each color)
W7250: Approx. 3,000 sheets (Standard mode (8-pass, Bi-directional), A1 size, 15% duty
pattern for each color)
12.4) Print Head Sensors and Adjustments
12.4.1) Media Thickness Adjustment
The gap between the bottom face of the print heads and the media surface can be adjusted
according to the media thickness. Although the print quality is higher when the gap is narrow,
inkblots may form on the print surface due to contact of the media with the print head face, or the
print head nozzles may be damaged.
In this printer, the user can use the print head height adjustment lever to select the gap width
according to the media thickness (3 positions).
12.4.2) Paper Width/Skew Detection
A media sensor is installed at the bottom left of the carriage for detecting the paper width and
skewing of the paper on the platen.
12.4.3) Gap Adjustment Unit
The paper thickness lever located on the right side of the carriage works in
coordination with the height adjustment cam. The height adjustment rollers located at the
bottom-right edge of the carriage front are moved up and down by this mechanism, and this

moves the head holder position up or down to change the gap between the face of the print heads
and the media.
12.4.4) Media Sensor Unit
The media sensor located at the bottom left of the carriage consists of an LED and photo-sensor.
The sensor is protected by a transparent cover, which prevents the adhesion of dust, and other
foreign substances, due to ink mist.
12.4.5) Internal Temperature Detection
A thermistor for measuring the internal temperature is installed on the head relay PCB on the
rear of the head holder.
12.4.6) Carriage Home Position Edge
The carriage home position is determined to be the position on the linear scale measured when
the carriage home position edge has been detected.


LAB – CH 12
Print Head L-1
and Print
Carriage
Objective:
Identify components and practice disassembly of the Print Carriage Assembly.
Instructions:
1. Unit Identification
Shut the printer’s AC power OFF. Review each procedure in the Service Manual and identify the
applicable components for each procedure. Simulate ink flow procedures and accomplish unit
removal and replacement wherever ink drainage is not a prerequisite operation. The
corresponding Service Manual (page) is indicated beside each procedure.
Place a check √ mark next to each completed procedure below.
√ Procedure
Opening and Closing the Ink Supply Valve (5-34).
Manual Carriage Movement (5-11).
Remove the Cable Mount (5-19).
Mounting the Carriage Belt (5-23).
Remove the Carriage Unit (5-22).
Remove the Head Holder (5-24).
Check Print Head Adjustment Lever (5-26).
Re-install all the above items back into the printer.

L-2
Print Head and Print Carriage Lab
2. Component Identification – refer to Part 4 of the Service Manual for parts breakdown
Place a check √ mark next to the component after identifying it.
√ Component
1 - Carriage Motor
2 - Carriage Relay PCB
3 - Linear Encoder
4 – Carriage Assembly
5 - Carriage Home Position Sensor
6 - Carriage Drive Belt
7 - Cartridge Cover Sensor
8 – Head Relay PCB
9 - Print Height Adjustment Lever
10 - Contacts
11 – Ink Supply Joint
12 - Media Sensor
13 – Ink Tube
14 – Print Head Lock Lever
15 – Print Head Lock Cover
3. Head Cleaning and Head Alignment Test Patterns
Refer to the Service Manual and User’s Guide to print out a set of Test Pattern A (Head
Cleaning) and Test Pattern B (Head Alignment) test prints and evaluate their data. Perform the
correction indicated on the Control Panel.

13.1 Overview
13.2 Ink Tank Unit

Ink Supply and
Recovery
13.3 Purge Unit
Objective
Examine and understand the components and
operations of the ink supply system, to
facilitate operation and maintenance of the
system.
Chapter 13: Ink Supply and Recovery 13-1
13) Ink Supply and Recovery
13.1) Overview
The ink supply system consists of the ink tanks, print heads, caps, maintenance jet tray, waste ink
absorber, ink tubes for connecting the mechanical components, and ink suction pump that is
activated when ink is removed. These components are used to perform the supply, circulation,
and suction/removal of waste ink.
A diagram of the ink supply flow path (for one color) is shown below.

The ink tanks supply ink to the print head. Ink flows from the tank to the ink supply valve due to
the fluid level difference. Although ink flows from the ink tank to the sub buffer due to the fluid
level difference, air also enters from the air passage of the sub buffer to maintain the pressure
inside the ink tank at a fixed level. If the ink inside the sub buffer exceeds a certain level, the ink
passes through the air passage and flows to the waste ink absorber.
Ink is supplied to the print head by opening the ink supply valve, capping the heads and then
driving the suction pump. The ink removed from the caps flows to the waste ink absorber.
During the printing operation, ink is constantly filling the print heads from the ink tank due to the
negative pressure applied to the print head nozzle by the opening of the ink supply valve and
discharging of the print ink. Waste ink removed by the cleaning operation and waste ink in the
right maintenance jet tray flows to the waste ink absorber.
13.2) Ink Tank Unit
The ink tanks contain approximately 11 ounces for W7200; (4.5 ounces for W7250) of ink for
each color.
The amount-of-ink data is stored in the EEPROM mounted on the ink tank. The remaining ink
level in the ink tank is detected using a dot count based on the EEPROM information. When the
electrodes mounted to the hollow needle detect that there is no electrical current, a message
appears on the display indicating that the ink is nearly empty. If the dot count reaches the
prescribed value from this state, the ink tank is considered to be empty.
Ink Port
The hollow needle enters the ink port (covered by a rubber plug) when the ink tank lever of the
printer is pressed down to the ink tank fixing position, and this establishes an ink passage
between the printer and ink tank.
Air passage
The open hollow needle enters the air passage (covered by a rubber plug) when the ink tank lever
of the printer is pressed down to the ink tank fixing position, and the internal pressure of the ink
tank is opened so that the internal pressure is maintained at a fixed level.
Notches for preventing incorrect installation
The ink tanks have notches for preventing incorrect installation. The wrong ink tanks cannot be
inserted and set because of these notches.

The ink tank lever can be lowered only when the ink tank has been installed in the set position,
and the ink supply will not start unless the ink tank lever is lowered.
Ink supply valve
The ink supply valve is located between the ink tank and ink tube. This valve presents ink
leakage from occurring when the ink tube on the ink tank side is opened during replacement of
the ink tank.

13.3) Purge Unit
To maintain high print quality, the purge unit performs maintenance of the nozzles in the print
heads. The functions of the purge unit include capping, cleaning, and ink supply.
Capping
The caps are activated during the capping operation to protect the nozzle arrays. Each print head
(six nozzle arrays) installed in the carriage has two caps. The rubber section of the cap touches
the face plate of the nozzle array The caps are raised by the cap cams and operated by the purge
motor, to cover the arrays when the carriage has moved to the home position. Capping is also
performed during the cleaning operation, and the suction pump is then used to remove ink from
the print heads.
Capping prevents nozzle drying and dust adhesion by pressing the cap of the purge unit to the
faceplate on the nozzle section of the print head. It is performed when printing is completed, at
the start of the suction operation, and when switching to the standby state due to an error. The
capping operation also connects the ink passage between the print head and purge unit.
Cleaning
Cleaning includes a wiping operation for removing paper fibers and dried ink deposits adhering
to the nozzle face plates of the print heads, a suction operation for removing ink from the nozzles
and drawing new ink to refresh the nozzles, and a maintenance jet operation where ink is sprayed
from the nozzles to the cap or maintenance jet tray to remove bubbles in the nozzles and dust and

other foreign particles near the nozzles. The combination of these three maintenance operations
improves nozzle discharge performance. Refer to the Service Manual, page 4-26, for details of
the cleaning functions.
Ink supply
The suction pump of the purge unit operates in coordination with the ink supply valve to deliver
the ink in the ink tank to the print heads during the initial refilling and ink level adjustment.
Wipers
The wipers are operated by the purge motor and perform the wiping of six nozzle arrays
simultaneously of the print heads. One pairs of wiper blades are used to provide improved
wiping performance. The wiping operation is performed in a "slide wipe" style where the wiper
blades slide based on the forward rotation of the purge motor. This action is performed after the
printing or suction operations using a constant-speed movement in the front direction as viewed
from the printer front. The wiper cam raises the wiper unit to the wiping position. The wiper
blade, which is positioned perpendicular to the print head, wipes the entire faceplate of the print
head, and then the narrow blade is used to wipe the nozzle array.
After wiping, the wiper blades are cleaned before they are set at the wiping position
so that maximum wiping performance can be maintained.
In the wiper blade cleaning, ink wiped from the head section is rubbed off by an ink-scraping
receptacle connected to the waste ink absorber. The blades are then wiped off by a blade cleaner.

Pumps
In this printer, tube pumps press on the ink tubes using push rollers to produce negative pressure
and enable suction of the ink. Two rollers are used to press a single tube one after the other to
allow flexible control over the ink suction volume.
The rotation timing of the push rollers in the suction pump is detected by the pump home
position sensor, and the rotation speed is controlled by the driving of the pump motor (stepping
motor).

Ink Passage Sensors
Sensors are located in the purge unit for detecting the status of the printer components. The
sensors for ink passage detection are located in the purge unit as shown in the Figure below.
Cap sensor
The photo interrupter-based cap sensor detects the status of the caps on the purge unit. The
sensor determines that the cap is closed when the rotary flag, which operates in conjunction with
the cap camshaft, cuts off the sensor light. The other states are determined by the number of
pulses from the pulse motor based on the timing when the sensor light is cut off.
Pump home position sensor
The photo interrupter-based pump sensor detects the home position of the suction pump rollers.
The home position of the pump is defined as the position where the rotary flag, which operates in
conjunction with the drive gear shaft of the rollers, cuts off the sensor light.
Waste Ink Absorber
The waste ink absorber can hold approx. three pints of waste ink in the W7200 and approx. two
and a half pints in the W7250.
Waste ink absorber full detection

The waste ink absorber full detection is calculated based on the dot count. When waste ink
remains accumulate from the expenditure of a predetermined volume of ink, a warning message
appears on the display indicating that the waste ink receptacle is nearly full. Once the maximum
allowable waste ink is calculated to have accumulated, an error occurs when the current printing
operation is completed and further operation is halted.
Air Flow
Ink mist that floats inside the printer or splashes from the paper during printing is collected by
the waste ink absorber at the right side and the mist tank at the left side of the printer through the
air flow inside the printer.
The suction fans at the right and left sides of the printer create an air current that carries the ink
mist to the waste ink absorber and mist tank.



LAB - CH 13
Ink Supply L-1
and Recovery
Objective:
Identify Ink Supply and Recovery system subassemblies and components.
Instructions:
Place a check √ mark next to the component after identifying it.
√ Component
1 - Wiper Blades
2 - Wiper
3 - Caps
4 - Waste Ink Absorbers
5 - Ink Scraping Receptacle
6 - Pump Motor
7 - Waste Ink Tank
8 - Purge Motor
9 - Blade Cleaner
10 - Carriage Lockpin
11 - Wiper
12 - Pump Home Position Sensor
13 - Push Rollers
14 - Feeder Tubes
15 - Suction Unit

L-2
Ink Supply and Rcovery Lab

14.1 Print Mdia Types
14.2 Installing Print Media

Print Media and
14.3 Paper Path
Media Transfer
14.4 Paper Feed Operations
Objective
and operations of the Media Transport
system to facilitate operation and
maintenance of the system.
Chapter 14: Print Media and Media Transport 14-1
14) Print Media and Media Transport
14.1) Print Media Types
A variety of print media can be used with this printer. The types of paper or special media are
described below. For more details about Canon print media, always refer to the instructions
provided with each media package.
Plain Bond Paper
An inexpensive paper for printing monochrome proofs and low res color images. Its stability is
slightly lower than other media, being more susceptible to change by temperature and humidity.
Coated Paper
Specially coated for use with Bubble Jet printers, coated paper reproduces brilliant colors
without blurring.
Heavy Coated Paper
Specially coated for use with Bubble Jet printers, heavy coated paper is thicker than coated
paper, making it suitable for printing POP artwork and other graphic designs.
Glossy Paper
Provided with a brilliant bright base coat on its print side, it is suitable for printing high-density
graphic images like photographs and other images that require extremely high quality finishing.
Glossy Film
Coated with a film base that reproduces color even more brilliantly than glossy paper. Ideal for
reproducing brilliant colors for the demanding requirements of graphic and photographic images.
Graphic Matte Canvas
A canvas media coated on one side and having a 17 millimeter thickness.
14.2) Installing Print Media
The printer can load roll media and cut sheet. When loading the print media, always hold the
paper edges, outside the print area. Holding the print area can cause finger grease or foreign
matter to adhere to the paper surface, which may affect the print quality.

14.2.1) Installing Roll Media
1) On the operation panel select roll media as source.

2) Pull out the roll media tray until it moves no more. Wind back the media, and then hold both
ends of the roll holder to remove it from the roll cassette.
3) Remove the holder stopper from the roll holder, and then pull out the roll holder from the roll
cassette.
4) Prepare a new media roll.

5) Insert the roll holder while paying attention to the winding direction of the roll media.
6) Attach the holder stopper.
7) Load the roll holder with the mounted roll media into the roll media tray.
8) Flip the roll release lever to the back to release the paper guide.

9) Pull out the roll media with the leading end facing up, and then insert it between the paper
guides.
10) Pull out the media edge evenly up to the roll media so that the right and left edges are
parallel. Using the edges of the roll media as a guide, pull out the right and left edges evenly.
11) While holding down the center of the roll media, turn the roll holder in the direction shown
in the figure below to take up any slack.
12) Pull the roll release lever forward while pressing down the roll holder to lock the paper
guides.
13) Turn the right and left roll holders in the direction of the arrows, and wind the leading edge
of the media so that approximately 1 to 2 mm is visible from the edge of the paper guides.

Make sure that the leading edge of the loaded media is straight and clean. If it is not, unwind and
trim the media as necessary. Slide a cutter along the guide plate to cut the media.
14) Close the roll media tray. The message display will ask you to specify the type of media to
be loaded in the media tray. Select the media type, and then press the [ENTER] button. The
printer feeds the paper forward, cuts off about four inches (about 12 inches if the W7250 is being
used as a desktop) from the leading edge, and then winds it back to the print starting position
over the platen.
• The selected media type can be checked on the printer driver screen.
• If the roll media tray is pulled out the printer assumes that the media has been
changed, and it will display the screen for selecting the media type.

14.2.2) Loading Cut Sheets
1) Press the Online button, and then select either "Offline" or "Main Menu".
2) Press the Paper Source button so that the Cut Sheet lamp turns on. The paper release lever
raises up, and the roll media is automatically rewound to the standby position. If the W7250 is
used without a stand, raise the paper release lever, pull out the roll media tray, and then manually
wind up the roll media.
3) Open the upper cover.
4) With the printing surface of the cut sheets facing upward, insert the sheet flatly into the pinch
roller, load in alignment with the right-side guide and rear-side guides, and then close the upper
cover.
5) Closing the upper cover shows the screen on the display for selecting the media
type that is loaded. Select the media type, and then press the ENTER button. You can not load
the cut sheet media and print on the roll media. If the roll media has been selected but cut sheet
media is loaded, the printer will eject the cut sheet automatically. Likewise it is impossible to
load the cut sheet media while the roll media is being fed.
14.3) Paper Path
14.3.1) Overview
The paper path includes the following components: roll media tray, roll drive unit, roll feed unit,
feed rollers, pinch roller drive unit for pressing and releasing the pinch rollers, and sensors for

detecting the media feeding status. The paper path performs automatic feeding for the roll media
and manual feeding, transport, and delivery for the cut sheets.
The diagram below presents an overview of the paper path and its operations.
14.3.2) Paper Path Sensors
Roll media set sensor
The photo interrupter-based roll media set sensor detects the opening and closing of the paper
holder by the paper release lever.
When the paper holder is closed and the roll media tray is closed, the sensor light is transmitted
through the sensor arm, and this notifies the sensor that the paper holder is closed.
Roll media end sensor
The photo interrupter-based roll media end sensor detects the feed of paper from the roll media
tray. The sensor light is blocked by the sensor arm when the paper is fed, and this notifies the
sensor that paper is available in the tray.

Roll feed sensor
The photo interrupter-based roll feed sensor detects the slit of the rotary flag that turns as the roll
media is fed. If the feed of roll media cannot be detected when the feeding operation is being
performed, the printer determines that a media feeding error has occurred.
Feed sensor
The photo reflection-based feed sensor detects if paper is on the platen.

The sensor detects the presence of paper by receiving the sensor light reflected from
the paper.
14.3.3) Media Feeding
Roll media tray feeding
Roll media fed in the roll media tray are transported by the roll media supply rollers, and feed
rollers.
If roll media is fed when the roll media tray feeding option is selected, the roll drive motor and
feed motor start operating once the roll media tray and tray are closed.
When the roll media leading edge is detected by the feed sensor and moves a pre-determined
length from the feed sensor, the feeding operation is stopped momentarily. Next, to remove the
slack from the roll media, temporarily release the pinch roller unit, increase the suction rate of
the suction fan, run the feed motor in reverse to rewind the prescribed amount, and apply
pressure with the pinch roller to pause the feeding operation.
After performing calibration of the media sensor in this state, perform media leading edge
detection, media width detection, and skewing detection, and then stop the roll media at the print
standby position.
The roll media is then fed by a length equivalent to the margin of the leading edge, and the
printing operation is started. Feeding of the roll media during printing is performed by
controlling the rotation of the feed rollers according to the printing mode.
Tray feeding
Cut sheets that are loaded on the platen are transported by the feed rollers. If the cut sheets are
loaded when the tray feeding option is selected, the feed motor starts operating once the upper
cover is closed. The trailing edge of the cut sheets loaded on the platen is detected by the feed
sensor. After performing calibration of the media sensor in this state, perform media leading
edge detection, media width detection, and skewing detection, and then stop the cut sheet at the
print standby position. The cut sheets are then fed by a length equivalent to the margin of the

leading edge, and the printing operation is started. Feeding of the cut sheets during printing is
performed by controlling the rotation of the feed rollers according to the printing mode.
Paper delivery
If the cutter is enabled when using roll media, the media is fed to the cut position after printing
and cut using the cutter. Then, the roll media on the platen is fed by approximately 100 mm, and
the cut roll media is pushed out. The discharged sheet is stacked on the stacker (optional in the
W7250) with the printed side face down.
The roll media on the platen is wound back to the print standby position. In continuous banner
printing with roll media, the paper is not cut and waits in pause mode for maintenance operations
such as cleaning.
The printed cut sheets stop on the platen, and a message is displayed when printing is finished.
14.4) Paper Feed Operations
Roll media replacement sequence
This printer assumes that the roll media has been replaced when the sensor detects that the tray is
opened and closed.
When the roll media is replaced, the roll media is fed over the platen where the media leading
edge detection, media width detection, and skewing detection is performed. If no skewing is
detected, approximately 100 mm of the media leading edge is trimmed, and the roll media is
wound back to the print standby position on the platen.
Media leading edge detection, media width detection, and skewing detection are performed by
the media sensor.
In media width detection, the media edges at the carriage home position side and at the opposite
side are detected at the position where the media leading edge is fed approximately 50 mm from
the media sensor to find the media width.
In skewing detection, the skewing amount is found using the media edge at the carriage home
position side found by media width detection and the shift of the media edge at the same position
when the media leading edge is fed approximately 300 mm from the media sensor.
Roll media trailing edge detection sequence
The roll media is handled in the following manner according to the paper type.

Recommended roll media
When the roll media end sensor detects the roll media trailing edge during the roll media feeding
operation, the feeding operation is stopped, and a warning message is shown on the display.
Non-recommended roll media
If the roll media trailing edge is secured by strong adhesive tape, the roll media trailing edge
cannot be detected by the roll media end sensor. In this case, the roll feed sensor detects a media
feeding error, the feeding operation is stopped, and a warning message is shown on the display.
Pinch roller trace prevention sequence
Pinch roller traces can form on the roll media when the roll media is left at the print standby
position for an extended period of time. As a result, the following sequence is performed to
prevent roller traces from forming.
While the power is on, the media is fed by about 2 mm at 100-minute intervals four times, and
then the media is rewound back to the roll media tray for standby.
If printing is started during the roller trace prevention sequence, the media is rewound back to
the print standby position before printing starts.
If printing is started after the roller trace prevention sequence, the roll media is reloaded before
printing starts.
Roll media load unit
One roll media can be loaded in the roll media tray with the roll holder as the shaft. The roll
drive motor transmits its power to the roll media load unit through the gear train, and feeding of
the roll media is performed.
Roll media detection unit
The paper feed unit includes sensors for monitoring the media feeding status and sensors for
monitoring the status of the component parts of the paper path. The roll media is detected by the
roll media end sensor of the roll media load unit and the roll media feed sensor of the roll feed
unit.
The remaining amount of roll media can be checked visually from the small window at the right
side of the tray.

a) Paper feed unit
The paper feed unit consists of paper path parts, including the paper guides and platen; and
media feeding mechanisms, including feed rollers driven by the feed motor and the pinch roller
unit operating in conjunction with the feed rollers.
To ensure that no waves form on the media, the paper remains flat as it passes over the platen so
that it is carried horizontally as it passes under the print heads of the carriage.
Sheet cutter
When "Autocut: Yes" is selected in the Main Menu, the cutter mounted on the left side of the
carriage automatically cuts the roll media.

The cutter home position is on the left side. Once the sheet is fed to the cut position, the sheet is
cut when the carriage moves from the left to the right in the backward movement.


LAB - CH 14
Print Media L-1
and
Media Transport
Objective:
Component identification and hands-on practice operating the Media Transport assembly
Instructions:
1. Media Product Identification
Match each of the Media Name items by entering the correct beside the matching Media
Description in the (#) column. Media types are defined in the User’s Guide.
Media
Name Media Description #
1 Glossy Paper This white paper has a coated surface. It is best suited for making
well-defined prints for POP (point -of-purchase) tools graphics and
full-color images.
2 Semi-gloss This media is best suited for printing low-resolution images or
Paper making test prints. Plain paper, however, is easily affected by
temperature and humidity, which makes plain paper less stable than
the other media types.
3 Plain Paper This paper has a glossy surface like photographic printing paper used
for prints. Use this paper to give graphics and full-color images a
high-quality finish like that of photo prints.
4 Glossy Film This white paper has a glossy finish that is less reflective than glossy
paper. It is best suited for making prints of graphics. This paper
allows you to reproduce graphics with a soft look to them.
5 Heavyweight This film has a glossy surface like photographic printing paper, and is
Paper glossier than glossy paper. This film allows you to reproduce
graphics and full- color images with more defined and brighter
colors. It also offers good durability for indoor use.

L-2
Print Media and Media Transport Lab
2. Media Transport Assembly Components
Place a check √ mark next to each identified component below.
√ Component
Feed Roller
Upper Cover Sensor Left
Upper Cover Sensor Right
Right Cover Sensor
Tray sensor
Roll Media Tray Set Sensor
Cutter
Pinch Roller
Paper Guide
Roll Feed Sensor
Roll Drive Unit
Roll Media Tray
Pinch Roller Drive Unit

15.1 Service Mode
15.2
Draining the Ink
Supply
Service and
Maintenance
15.3 Adjustment and Setup
Objective
To familiarize the Service Technician with the
processes involved in the maintenance and
servicing of the printer, including removal and
replacement of selected components.
Chapter 15: Service and Maintenance 15-1
15) Service and Maintenance
15.1) Service Mode
This mode is used for servicing the printer and is accessed and controlled from the operation
panel. Refer to the Service Manual, page 3-40, for a complete map of the Service Mode menus
and options.
Entering Service mode
1) Turn off the printer.
2) Turn on the printer while holding down the [PAPER SOURCE] button and [Online] button.
3) Check that "Canon W72xx" is shown on the display, and then release the buttons.
4) Next, "SERVICE MODE" is shown on the display. (If sheets are inserted, this will be
displayed after the sheets are loaded.)
5) Use the [down arrow] button to make a selection. Service mode is added to the options in the
Main menu.
Service mode can be entered even during error status (when Exxxx and Wxxxx are shown on the
display) by turning the power off and then using the above key operation.
Buttons Used to Navigate Service Mode
• Selecting menus and parameters: [Left arrow] button and [right arrow] button
• Entering a lower-level menu: [Down arrow] button
• Entering a higher-level menu: [Up arrow] button
• Setting menus and parameters: [ENTER] button
Exiting Service Mode
To exit Service mode, turn off the printer.
15.2) Draining the Ink Supply (when required)
Some service procedures and the transporting of the printer will require that the ink be drained
from the ink flow path to avoid spillage and leakage within the printer during the move.

When disassembling the following units of the ink passage, drain the filled ink to prevent an ink
leak. There are two methods of removing the ink, using a manual method or automatic method.
When the ink is drained, the ink inside the ink passage totaling approximately seven and a half
ounces (one and a half ounce x six colors) is drained as waste ink.
To prevent ink leaks, be sure to always remove the ink inside the ink passage when
disassembling or transporting the parts of the ink passage section.
Automatic ink drainage
Automatic ink drainage is performed by selecting:
Main Menu --> System Setup --> Move Printer
from the operation panel. It takes about 4 minutes for automatic ink drainage to be performed.
Perform automatic ink drainage again if a power outage or other cause shuts off the power during
the operation for automatic ink drainage.

Chapter 15: Service and Maintenance 15-3
Manual ink drainage
A syringe or other implement is used to remove the ink inside the ink passages one color at a
time in the event of a printer electrical failure, firmware error, or malfunction in supplying power
to the printer.
Preparation
Prepare the following items before starting the manual ink drainage procedure.
Syringe having approximately one and two thirds ounces capacity (CK-0541-000)
Connecting tube (QA2- 6161-000)
If possible, use a separate syringe for each color.
If syringes are severely stained or tubes attached to different color needles, flush and wash
tubes/syringes with water and fully dry to prevent mixing of ink colors.
15.3) Adjustment and Setup
System Controller DIP Switch Settings
These settings are made during assembly, disassembly, and replacement of the system controller.
Engine Controller Short Connector Settings
These settings are made during assembly, disassembly, and replacement of the engine
controller.
Adjustment of Head Holder Tilt Lever
This procedure is performed when the edge sections of the image are not sharp when
printing in Fast mode (2-pass).
System Controller DIP Switch Settings
Be careful that you do not move the DIP switch setting positions during assembly and
disassembly of the system controller.

Make the settings as shown in the figure below if the setting positions of the DIP switches are
inadvertently moved or a system controller installed as a service part has different DIP switch
setting positions.
Engine Controller Short Connector Settings
Be careful that you do not move the short connector setting positions during assembly and
disassembly of the engine controller.
Make the settings as shown in the figure below if the setting positions of the short connector are
inadvertently moved or a system controller installed as a service part has different short
connector setting positions.
Adjustment of the Head Holder Tilt Lever
This adjustment is performed when the edge sections of the image are not sharp when printing in
Fast mode (2-pass).
After adjusting the head holder tilt lever, mark the number visible from the window of the head
holder tilt lever with the number inside the sensor cover.
15.4) Upgrading the Printer’s Firmware
The service tools can be used to update the versions of the firmware for the system controller and
engine controller installed in the printer. They can also be used to access various types of
information from the printer.
In Windows NT, 2000, and XP, use the lpr.exe file that is provided in the standard Windows
installation. This is a software tool that connects the LAN cable to the LAN port on the system
controller and allows the software to upgrade the firmware for the system controller and engine
controller contained the printer.
Refer to page 3-74 of the Service Manual for further details and for step-by-step procedures to
accomplish the firmware upgrade ptocess.

16.1 Outline
Notice for
16.2
Troubleshooting Troubleshooting
Troubleshooting When
16.3
Warnings Display
Troubleshooting When
16.4
Error Codes Display Objective
Troubleshooting
16.5 To enable the technician to troubleshoot
Service Call Errors
system problems and to successfully diagnosis
Troubleshooting Other and solve the problems.
16.6
Displayed Indications
Troubleshooting
16.7 Problems Not
Displayed
16) Troubleshooting
16.1) Outline
There are two types of system problems to be corrected; those reported by the messages
indicated on the display, including "Operator Call," "Warning," "Error," and "Firmware Error",
and those problems not indicated on the message display.
In this manual, a colon (:) is used to distinguish the first and second lines of the message. The
alphanumeric code indicating the type of error, that is the "warning", or "error," will be displayed
on the printer's display. The letters at the end of the code indicates the following: W for the
"warning" and E for the "error".
Refer to the Service Manual, page 3-63, for a list of the problems that can be detailed on the
message display.
16.2) Notice for Troubleshooting
1. Obtain information about the system environment and the type of media used for printing.
2. Before performing troubleshooting, make sure that all cables are connected properly.
3. When servicing the printer with the external cover is removed and the AC power connected,
pay special attention when handling the electrical parts or the boards to avoid an electric shock or
short circuit.
4. In the following sections, the troubleshooting steps (action) are described such that the
component related to the most probable cause of the problem will be repaired or replaced first,
following by components with less failure probability. If multiple components are the same
probability of predicted failure, the steps are indicated based on how easy the servicing is.
After performing a step, check to see if the problem has been solved by executing a
test print. If not resolved, proceed with the next step.
5. When the service has been completed, check to ensure that all connectors/cables
are reinstalled and screws are firmly tightened.
6. After performing replacement or repair services, run test prints to check whether the problem
has been solved.

16.3) Troubleshooting When Warnings are Displayed
Codes in parentheses are not displayed when a warning occurs. These codes can be checked in
the warning history by using SERVICE MODE>DISPLAY>WARNING.
Ink Check: (W01000, W01001, W01002, W01003, W01004, W01005)
Displayed when the electrodes mounted to the hollow needle in the ink tank unit detect that the
ink is below the prescribed level.
Waste-Ink Full Soon: (W01006)
Displayed when a nearly full (approx. 95% capacity of the waste ink absorber) waste ink level is
detected in the waste ink absorber.
Memory Overflow: (W0100C)
Displayed when a data fault occurs due to insufficient memory.
Feed Limit: (W0100F)
Displayed when the engine controller has detected the feed limit of the media during manual
feeding. During back feeding, the print standby position (on feed roller) is the feed limit. During
forward feeding, the feed limits are as follows.
Roll media: 700 feet

Cut sheet: Detected size when sheets are loaded
Incorrect Media: (W01021)
During data reception, this is displayed when the media type required by the received data is
different from the media type that is currently loaded.
W01030/W01031/W01032/W01033/W01034/W01035/W01036/
W01037/W01038/W01039: GARO W0103x (number is indicated by x)
During data reception, this is displayed when an error occurs in the data reception GARO
command.

16.4) Troubleshooting When Error Codes are Displayed
Roll Media End Sensor Error: E02000
Displayed when a roll media end sensor has detected the roll media trailing edge during printing
or loading of the roll media.
Feed Sensor Error: E02005/E0200D/E02016
Displayed:
When the feed sensor could not detect the roll media even after feeding the prescribed
length during loading of the roll media.
When the feed sensor could not detect the cut sheet trailing edge even after feeding the
prescribed length during cut sheet loading.
During printing when the feed sensor has detected the cut sheet trailing edge at a different
position from the media loading position.
Media Sensor Error:

E0200A/E0200B/E0200C/E0200E/E0200F/E02010/E02015/E02017/E02018
Displayed when:
The light intensity of the media sensor could not be adjusted during media loading.
The media sensor has detected a media loading position error during detection of the
media right edge.
The media sensor could not detect the media leading edge during detection of the media
leading edge.
The media sensor has detected a media smaller than the prescribed size during media
loading:
Media width: Less than eight inches

Media length: Less than four inches
The media sensor has detected a media larger than the prescribed size during media
loading:
Media width: more than 36.5 inches (W7200)/25.4 inches (W7250)

Media length (roll media): more than 708 feet
Media length (cut sheet): more than 63 inches (W7200)/55 inches (W7250)

The media sensor detects slanting that exceeds the prescribed amount during media
loading.
The media sensor could not detect the media leading edge during detection after cutting
of the roll media.
The media sensor could not detect the media right edge during media loading.
The media sensor could not detect the media left edge during media loading.
Roll Media Tray Set Sensor Error: E02011
Displayed when a roll media tray set sensor has detected that the roll media tray unit has been
pulled out during printing or loading of the roll media.
Path Mismatch Error: E02400/E02401/E02402/E02403
Displayed when:
The loaded media is cut sheet and the received data is designated for roll media.
The roll media is not loaded and the received data is designated for roll media.
The cut sheet is not loaded and the received data is designated for cut sheet.
Printing the adjustment pattern if the loaded media is smaller than the prescribed size of
the adjustment pattern.
Ink Empty Error: E02500/E02501/E02502/E02503/E02504/E02505
Displayed when no ink is detected in the ink tank.
Ink Tank Uninstalled Error (during tank replacement):

E02506/E02507/E02508/E02509/E0250A/E0250B
Displayed when the sensor detects that the right cover is closed with an ink tank removed during
ink tank replacement.
Print Head Error: E02800/E02801/E02802/E02803/E02811
Displayed when:
No print head is detected.

Unusually high temperatures are detected in the print head.
Installation of an incorrect print head is detected.
A checksum error occurs in the print head EEPROM.
A DI correction failure is detected in the print head.
Ink Tank Error:

E02804/E02805/E02806/E02807/E02808/E02809/E0280A/E0280B/E0280C
E0280D/E0280E/E0280F
Displayed when:
Installation of an incorrect ink tank is detected.
A checksum error occurs in the ink tank EEPROM.
Engine Controller Internal Error: E02812/E02A00/E02A01/E02A02/E02A03
Displayed when:
An error occurs in the engine controller EEPROM.
An error occurs in the firmware of the engine controller.
A error occurs in the FLASH ROM of the engine controller.
Tray Sensor Error: E02B01
Displayed when the tray sensor has detected that the tray is open during media loading or
printing.
Upper Cover Sensor Error: E02B04
Displayed when the upper cover sensor has detected that the upper cover is open while the upper
cover is locked.
Right Cover Sensor Error: E02B05
Displayed when the right cover sensor has detected that the right cover has been opened not
using operations from the main menu.

Carriage Cover Sensor Error: E02B06
Displayed when the carriage cover sensor has detected that the carriage cover is open while the
upper cover is locked.
Sensor Error in Purge Unit: E02D00/E02D01
Displayed when sensors in the purge unit could not detect the positions of the motors within the
prescribed time.
Carriage Home Position Error: E02D02
Displayed when the carriage home position sensor could not detect the carriage within the
prescribed time.
Feed Motor Error: E02D03
Displayed when the feed motor could not reach the prescribed speed within the prescribed time
or the feed roller sensor could not detect the prescribed number of steps from the encoder slit.
Roll Media Feed Motor Error: E02D04
Displayed when the roll media feed motor could not reach the prescribed speed within the
prescribed time.
Air Flow Fan Error: E02D05
Fan rotation could not be detected while the air flow fan was running.
Carriage Motor Error: E02E01/E02E05
Displayed when:
A jam or other physical problem puts an excessive load on the carriage motor so that the
carriage could not operate.
The carriage motor could not reach the prescribed speed within the prescribed time.
Roll Media Set Sensor Error: E02E02
Displayed when the roll media set sensor could not detect positional changes by the paper guide
during the paper guide opening and closing operations.
Pinch Roller Up/Down Sensor Error: E02E03

Displayed when the pinch roller up/down sensor could not detect positional
changes by the pinch roller during the pinch roller up/down operations.
Roll Feed Sensor Error: E02E04
Displayed when the roll feed sensor has detected stoppage of the rotary flag during supplying or
feeding of the roll media.
IEEE1394 Error: E02E10
Displayed when an error has occurred in the IEEE1394 interface.
System Controller Internal Error: E02F00
Displayed when an error has occurred in the firmware of the system controller.
16.5) Troubleshooting When Service Call Errors Occur
Codes in parentheses are not displayed when a service call error occurs. These codes can be
checked in the error history by using SERVICE MODE>DISPLAY>ERROR.
Print Head Error: (E04000)
Displayed when a drive voltage error occurs in the print head.
Waste Ink Full: (E04001)
Displayed when a full waste ink absorber is detected.
Scale Read Error: (E04002)
Displayed when the carriage sensor could not read the linear scale.
16.6) Troubleshooting for Other Problems Indicated on the Display
Incorrect Value: Check Value
Displayed when it is detected that the default G/W input value does not match the IP address.

Offline: Load Roll Media
Displayed when the roll media end sensor does not detect any roll media in roll media mode.
Offline: Load Cut Sheet Offline: Remove Cut Sheet
Displayed when:
The feed sensor does not detect any sheets in cut sheet mode.
The feed sensor detects sheets when switching from cut sheet mode to roll media mode.
Offline: Open Upper Cover
Displayed when the upper cover sensor detects that the upper cover is closed when switching
from roll media mode to cut sheet mode.
Offline: Open Tray
Displayed when the roll media end sensor detects that there is no roll media in roll media mode,
and the tray sensor detects that the tray is closed.
Off line: Open Roll Tray
Displayed when the roll media end sensor detects that there is no roll media in roll media mode,
and the roll media tray set sensor detects that the roll media tray is closed.
Printer Setup: Install Print Head
Displayed when no print head is detected when the power is turned on.
Printer Setup: Ins. Ink Tank OK
Displayed when no ink tank is detected when the power is turned on.
16.7) Troubleshooting for Problems Not Indicated on the Display
Printer does not turn on (No display when the Power button is pressed)
Broken connection in connector, faulty inlet unit, faulty power supply, faulty
operation panel, faulty engine controller, faulty system controller

Network is not connected (Printing cannot be performed from the network)
Cable is not connected properly, incompatibility with hub, system controller fault
Right cover does not open (Right cover does not open; no error message displayed)
Connector is not connected properly, engine controller fault
Printing problems (ink is full)
Step 1
Interface is not recognized.
A test print can be printed, but printing from the host computer is not functioning
normally.
Step 2
No printing can be performed.
Printing of the test print and from the host computer are not functioning normally.
Textures appear in the image.
Cause
Faulty host computer, faulty interface cable, dirty carriage rail, improper position
for head tilt lever, faulty print head, faulty purge unit, faulty linear scale, faulty
carriage unit, faulty carriage relay PCB, faulty engine controller, faulty system
controller.
Printing problems (ink is not full)
No printing can be performed.

A specific ink is not printed.
Ink is not filled to the ink tube for the print head lock lever.
Ink is not filled to the ink tube before the ink tank unit.
Cause
Faulty ink tank, faulty print head, faulty purge unit, faulty ink tank unit, faulty ink
tube unit, faulty engine controller, faulty system controller

Other printing problems
Soiled media
Cause
Soiling due to ink mist or other substances.

Canon

Educational Services – (516) 328-5620
Technical Support Centers:
Lake Success, NY – (800) 528-2830
Jamesburg, NJ – (800) 528-2830
Irvine, CA – (800) 528-2830
WWW Access:
Canon USA, Inc. – http://www.cusa.canon.com
Canon e-Support Center– http://www.support.cusa.canon.com

BJ-W7200 TRM

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Canon

Systems & Technical Support Division

This Manual was produced and published in its entirety by:

Canon USA, Inc.

For Questions concerning any Canon Systems & Technical Support

Copyright 2002 by Canon U.S.A., Inc.

All trademarks appearing in this Manual are trademarks of their

Introduction to the Course

The purpose of this self-paced training program is to provide Service Technicians

The course is based on the Technical Reference Manual (TRM) as an interface

The TRM provides many direct references to corresponding or supporting

This training program provides certification on two similar products. It includes

Upon completion of this training program, with a passing score of 70 percent or

How the Course is Structured

Section 2: imagePROGRAF 7200/7250

3 Control Panel Chapters one through eight cover the

2) Installation ............................................................................................................................ 2-1

3) Control Panel ........................................................................................................................ 3-1

4) Sequence of Operations......................................................................................................... 4-1

5) Print Carriage........................................................................................................................ 5-1

6) Purge Unit............................................................................................................................. 6-1

Educational Services Systems and Technical Support Division

7) Media Transport.................................................................................................................... 7-1

8) Troubleshooting .................................................................................................................... 8-1

Systems and Technical Support Division Educational Services

1.1) Applications of Wide Format Printing

Wide format printers are most commonly found in:

Print shops (Pay for Print).

1.1.1) Types of Wide Format Printing

1.1.2) Comparing Printers with Built-in Interpreters to Straight Raster Printers

Interpreter Based Printers

Educational Services Systems and Technical Support Division

1.2.1) Different Media For Different Purposes

Systems and Technical Support Division Educational Services

1.2.2) BJ-W7000 Media

Roll Based Paper Supply

Pre-Cut Sheet Paper Supply

ANSI = American National Standards Institute for Engineering Drawing

ANSI Media Sizes, as established by the ANSI Standards:

Media Size Inches Millimeters

ARCH Media Sizes, established by the Architectural Standards:

Media Size Inches Millimeters

Educational Services Systems and Technical Support Division

Media Size Inches Millimeters

Media Size Inches Millimeters

1.2.3) Media Quality and Print Quality Issues

Recommended Monthly Volume

Systems and Technical Support Division Educational Services

1.2.4) Ink Supply

The approximate ink yield for the BJ-W7000 is:

Color Ink A0 size page count

The above are estimates based on the following conditions:

- Temperature range of 59 to 86? Fahrenheit

Educational Services Systems and Technical Support Division

Media Material Plain, Gloss, Semi-Gloss and, Heavyweight Coated

Systems and Technical Support Division Educational Services

1.3) Component Identification

1 - Carriage 7 - Roll Media Cover

1 - Ink Bottle Case 6 - Buffer Cap

Educational Services Systems and Technical Support Division

1.3.2) Cross Sectional View

Systems and Technical Support Division Educational Services

1.3.3) Print Carriage