Canon i860, i865 Service Manual

i860

SERVICE MANUAL

Canon

PIXUS 860i i860 i865 SERVICE MANUAL

Revision 0

QY8-1391-000

Scope

This manual has been issued by Canon Inc., to provide the service technicians of this product with the information necessary for qualified persons to learn technical theory, installation, maintenance, and repair of products. The manual covers information applicable in all regions where the product is sold. For this reason, it may contain information that is not applicable to your region.

Revision

This manual could include technical inaccuracies or typographical errors due to improvements or changes made to the product. When changes are made to the contents of the manual, Canon will release technical information when necessary. When substantial changes are made to the contents of the manual, Canon will issue a revised edition.

The following do not apply if they do not conform to the laws and regulations of the region where the manual or product is used:

Trademarks

Product and brand names appearing in this manual are registered trademarks or trademarks of the respective holders.

All rights reserved. No parts of this manual may be reproduced in any form or by any means or translated into another language without the written permission of Canon Inc., except in the case of internal business use.

I. MANUAL OUTLINE

This manual consists of the following three parts to provide information necessary to service the i860 and i865:

Part 1: Maintenance Information on maintenance and troubleshooting of the i860 and i865

Part 2: Technical Reference New technology and technical information such as FAQ’s (Frequently Asked Questions) of the i860 and i865

Part 3: Appendix Block diagrams and pin layouts of the i860 and i865

Reference: This manual does not provide sufficient information of disassembly and reassembly procedures. Refer to the graphics in the separate Parts Catalog.

II. TABLE OF CONTENTS

Page Part 1: MAINTENANCE 1-1 1. MAINTENANCE 1-1 1.1 Adjustment, Periodic Maintenance, Periodic Replacement Parts, and Replacement

Consumables by Service Engineer 1-2 1.2 Customer Maintenance 1-2 1.3 Product Life 1-3 1.4 Special Tools 1-3 1.5 Serial Number Location 1-4 2. LIST OF ERROR DISPLAY / INDICATION 1-4 2.1 Operator Call Errors (by LED Blinking in Orange) 1-5 2.2 Service Call Errors (by LED Blinking in Orange and Green Alternately, or Lit in

Orange) 1-6 2.3 Warnings 1-6 2.4 Troubleshooting by Symptom 1-8 3. REPAIR 1-8 3.1 Notes on Service Part Replacement (and Disassembling / Reassembling) 1-10 3.2 Special Notes on Repair Servicing 1-12 3.3 Adjustment / Settings (1) Paper feed motor adjustment (2) Gear phase adjustment (3) Grease application (4) Waste ink counter setting (5) User mode (6) Service mode EEPROM initialization, EEPROM settings, Waste ink counter reset Service test print, EEPROM information print (7) Flash ROM upgrade 1-19 3.4 Verification Items (1) Service test print (2) EEPROM information print 1-22 4. PRINTER TRANSPORTATION METHOD

2-1 1. NEW TECHNOLOGIES 2-4 2. CLEANING MODE AND AMOUNT OF INK PURGED 2-6 3. FAQ (Specific Problems and Solutions)

3-1 1. BLOCK DIAGRAM 3-2 2. CONNECTOR LOCATION AND PIN LAYOUT 3-2 2.1 Logic Board Ass’y 3-6 2.2 Carriage Board (Print Head Connector)

Part 2: TECHNICAL REFERENCE

Part 3: APPENDIX

Part 1 MAINTENANCE

1. MAINTENANCE

1.1 Adjustment, Periodic Maintenance, Periodic Replacement Parts, and Replacement Consumables by Service Engineer

(1) Adjustment

Approx.

time

2 min.

1 min.

2 min.

Adjustment Timing Purpose Tool

EEPROM initialization (EEPROM settings)

Destination settings (EEPROM settings) Waste ink counter resetting

Media sensor correction (EEPROM settings)

CD-R sensor / automatic print head alignment sensor correction (EEPROM settings) Print head alignment - At print head

Paper feed motor position adjustment

Grease application - At carriage unit

Note: DO NOT loosen the red screws on both sides of the main chassis, securing the carriage shaft positioning. *1: Media sensor correction This operation adjusts the correction value of the media sensor, installed in the sheet feeder unit, to the

EEPROM of the logic board ass’y. The adjustment is required when the sheet feeder unit or the logic board

ass’y is replaced, and values are automatically determined via use of calibration media kit (QY9-0064). *2: Calibration media kit The service tool for media sensor correction, consisting of 10 sheets of the reference plain paper, and 1

At logic board ass’y replacement

- At bottom case unit replacement

- At ink absorber (QC1-2232 / 2233 / 2234 / 2235 / 2236) replacement

- At logic board ass’y replacement

- At sheet feeder unit replacement

- At logic board ass’y replacement

- At carriage unit replacement

replacement

- At logic board ass’y replacement

At paper feed motor unit

replacement

- At paper guide flapper ass’y (QL2-0341) replacement

- At lift cam base’s (QL2-0340) gear replacement

- At lift cam shaft unit (QM2-0593) replacement

To initialize settings other than the following:

- USB serial number

- Destination setting

- Waste ink counter

- Media sensor correction value

- CD-R correction value

To set the destination. None. 1 min.

To reset the waste ink counter.

To correct the media sensor.

To correct the CD-R and automatic print head alignment sensor.

To ensure accurate dot placement.

To adjust the belt tension. (Position the paper feed motor so that the belt is stretched tight.)

- To maintain sliding

properties of the carriage, carriage shaft, paper guide flapper, and li ft cam shaft.

- To protect the lift cam

base gear.

None. 1 min.

Calibration media kit (QY9-0064)

None. (Correction performed through service test print)

- None. (printer buttons)

- Computer (settings via the printer driver)

None. 2 min.

- FLOIL KG-107A (QY9-0057)

- MOLYKOTE PG641 (CK-0562)

1 - 1

sheet of the reference white PET paper. *3: Red screws of paper feed motor The red screws securing the paper feed motor may be loosened only at replacement of the paper feed motor

unit.

(2) Periodic maintenance

No periodic maintenance is necessary.

(3) Periodic replacement parts

There are no parts in this printer that require periodic replacement by a service engineer.

(4) Replacement consumables

There are no consumables that require replacement by a service engineer.

1.2 Customer Maintenance

Adjustment Timing Purpose Tool

Print head alignment At print head

replacement.

Print head cleaning When print quality is

not satisfying.

Print head deep cleaning When print quality is

not satisfying, and not improved by print head cleaning.

Ink tank replacement When an ink tank

becomes empty.

(No ink error) Paper feed roller cleaning CD-R print position adjustment

When paper does not

feed properly.

At CD-R printing,

when necessary

1.3 Product Life (1) Printer

To ensure accurate dot placement.

To improve nozzle conditions.

----- -----

To clean the paper feed rollers. To correct CD-R print position

Approx.

time

- Printer buttons

- Computer (settings via the printer driver)

- Printer buttons

- Computer (settings via the printer driver)

Computer (settings via the printer driver)

Printer buttons 2 min.

Computer (application software)

3 min.

30 sec. to 1 min.

1 to 1.5 min.

2 min.

5 min.

The value from (i) to (iv), whatever comes first. (i) 10,000 pages of color printing, or 30,000 pages of black printing

- Color: 7.5% duty per color pattern printing, A4

- Black: 1,500 character pattern printing (ii) 1,200 disks of CD-R or DVD-R printing

- On a basis of monthly print volume of approx. 20 disks (iii) 5,000 pages of printing using the photo paper tray

- On a basis of monthly print volume of approx. 83 pages (iv) 5 years of use

1 - 2

(2) Print head

10,000 pages of color printing, or 30,000 pages of black printing

- Color: 7.5% duty per color pattern printing, A4

- Black: 1,500 character pattern printing

(3) Ink tank

BCI-3eBK: 740 pages (1,500 character pattern in black printing, plain paper, standard mode) 1,500 pages (ISO JIS-SCID No. 5 pattern, plain paper, standard mode) BCI-6C: 550 pages (ISO JIS-SCID No. 5 pattern, plain paper, standard mode) BCI-6M: 430 pages (ISO JIS-SCID No. 5 pattern, plain paper, standard mode) BCI-6Y: 360 pages (ISO JIS-SCID No. 5 pattern, plain paper, standard mode) BCI-6BK: 2,000 pages ((ISO JIS-SCID No. 5 pattern, plain paper, standard mode)

(4) Auto duplex printing unit DPU-10 (option)

The value (i) or (ii), whichever comes first. (i) 15,000 pages of printing (ii) 5 years of use

(5) Paper feed cassette PFC-10 (option)

The value (i) or (ii), whichever comes first. (i) 30,000 pages of printing (ii) 5 years of use

1.4 Special Tools

Name Tool No. Purpose Remarks

MOLYKOTE PG641 CK-0562-000 To be applied to the lift cam

base gear and the sliding portion of the lift cam shaft

FLOIL KG-107A QY9-0057-000 To be applied to the sliding

portions of the carriage, carriage shaft, and the paper guide flapper

Calibration media kit QY9-0064-000 To correct the media sensor New

In common with conventional models

1.5 Serial Number Location

On the carriage flexible cable holder (visible when the front cover is open, same as the i850).

1 - 3

2. LIST OF ERROR DISPLAY / INDICATION

Errors are indicated by the LED, and warnings are displayed on the monitor of the computer connected to the printer .

2.1 Operator Call Errors (by LED Blinking in Orange)

LED

blinking in

orange

2 times

No paper. (ASF) [1000] Set the paper in the ASF, and press

No CD-R tray. [1001]

No paper in the photo paper tray. [1004]

No paper in the paper feed cassette. [1003]

3 times

Paper jam. [1300] Paper jam in the auto duplex printing unit. [1304] Paper jam in the paper feed cassette. [1303]

4 times No ink.

[1601/1602/1611/1612/1613]

5 times The print head is not installed

[1401], or it is not properly installed (EEPROM data of the print head is faulty) [1403/1405].

6 times

No CD-R tray feeder (during CD-R printing). [1850/18 55]

Presence of the CD-R tray feeder (during paper printing) . [1851/1856]

7 times

No CD-R or DVD-R. [1002] After setting a CD-R or DVD-R in

8 times Warning: The waste ink

absorber becomes almost full (approx. 95% of the maximum capacity).

9 times The connected digital camera

or digital video camera does not support Camera Direct Printing. [2001]

Error Solution Remarks

the Resume/Cancel button. Set the CD-R tray, and press the Resume/Cancel button. Set the paper in the photo paper tray , and press the Resum e/Cancel button.

Set the paper in the paper feed cassette, and press the Resume/Cancel button. Remove the jammed paper, and

press the Resume/Cancel button.

Replace the empty ink tank(s), or press the Resume/Cancel button.

Pressing the Resume/Cancel button will exit the error without ink tank replacement, however, ink may run out during

printing. Install the print head properly, and close the front cover. Or, with the print head installed, turn the printer off and on.

Set the CD-R tray and tray feeder properly, and press the Resume/Cancel button. Remove the CD-R tray feeder, and press the Resume/Cancel button.

the tray, set the tray in the tray feeder, and press the Resume/Cancel button. Pressing the Resume/Cancel button will exit the error, and enable printing. In repair servicing, replace the

The service call error,

indicating the waste ink

absorber is full, is likely

to occur soon. bottom case unit (QM2-0586), or 5-item set of the ink absorbers (QC1-2232/2233/2234/2235/2236). After removing the cable between the camera and the printer, press the Resume/Cancel button, and re-connect the cable.

When connected to a

Direct Print supported

camera, the green LED

blinks 2 times.

1 - 4

(Operator Call Errors - cont’d -)

LED

blinking in

Error Solution Remarks

orange

10 times

No auto duplex printing unit. [1860]

Set the auto duplex printing unit, and press the Resume/Cancel

button.

Automatic duplex printing cannot be performed (paper size not supported). [1310]

11 times Failed in automatic print head

alignment. [2500]

Set an automatic duplex printing supported size of paper, and press the Resume/Cancel button. Press the Resume/Cancel button, and after confirming the following, perform print head alignment again:

- Set an appropriate type and size

of paper (plain paper, A4 or letter).

- Check that the nozzle check

pattern is properly printed (all

ink ejected, no faint printing). *1: Only for the model supporting CD-R printing (i865 / PIXUS 860i). *2: Only when the paper feed cassette PFC-10 (optional unit) is attached. *3: Only when the auto duplex printing unit DPU-10 (optional unit) is attached.

2.2 Service Call Errors (by LED Blinking in Orange and Green Alternately, or Lit in Orange)

LED

alternate blinking

in orange and

Error

(Replacement of listed parts, which are likely to be faulty)

green

2 times Carriage error [5100] - Carriage unit (QM2-0599)

- Timing slit strip film (QA4-1053)

- Logic board ass’y (QM2-0766/QM2-0767)

- Carriage motor (QK1-0175)

3 times Paper feed error [6000] - Timing sensor unit (QM2-0596)

- Timing slit disk film (QC1-2484)

- Feed roller ass’y (QF4-0155)

- Platen unit (QM2-0627/QM2-0634)

- Logic board ass’y (QM2-0766/QM2-0767)

- Paper feed motor unit (QM2-0810)

4 times Purge unit error [5C00] - Purge unit (QM2-0600)

- Logic board ass’y (QM2-0766/QM2-0767)

6 times Internal temperature

- Logic board ass’y (QM2-0766/QM2-0767)

error [5400]

7 times Waste ink absorber full

[5B00]

8 times Print head temperature

rise error [5200] 9 times EEPROM error [6800] - Logic board ass’y (QM2-0766/QM2-0767) 10 times

Carriage lift mechanism

error [5110]

- Ink absorbers (QC1-2232/2233/2234/2235/2236)

- Bottom case unit (QM2-0586)

- Print head (QY6-0049)

- Logic board ass’y (QM2-0766/QM2-0767)

- Lift cam shaft unit (QM2-0593)

- Photo interrupter (WG8-5571)

- Sheet feeder unit (QM2-0589)

- Logic board ass’y (QM2-0766/QM2-0767)

- Paper feed cassette PFC-10 (option)

- Logic board ass’y (QM2-0766/QM2-0767)

11 times

Paper feed cassette error

[5900]

- Bottom case unit (QM2-0586)

12 times Media sensor error

- Sheet feeder unit (QM2-0589)

[8000]

Solution

*1 *1

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+ 24 hidden pages