Canon i900, i905 Service Manual

i900D

SERVICE MANUAL

Canon

i900D

i905D

PIXUS 900PD SERVICE MANUAL

Revision 0

QY8-1394-000

COPYRIGHT©2003 CANON INC. CANON PIXUS 900PD / i900D / i905D 092003 XX 0.00-0

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.

Copyright

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.

Copyright 2003 by Canon Inc. CANON INC.

Inkjet Products Quality Assurance Div.

16-1, Shimonoge 3-chome, Takatsu-ku, Kawasaki, Kanagawa 213-8512, Japan

I.MANUAL OUTLINE

This manual consists of the following three parts to provide information necessary to service the i900D/i905D:

Part 1: Maintenance

Information on maintenance and troubleshooting of the i900D/i905D

Part 2: Technical Reference

New technology and technical information such as FAQ’s (Frequently Asked Questions) of the i900D/i905D

Part 3: Appendix

Block diagrams and pin layouts of the i900D/i905D

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

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

1-2	1.2	Customer Maintenance
1-3	1.3	Product Life
	1.4	Special Tools
	1.5	Serial Number Location
1-4	2. LIST OF ERROR DISPLAY / INDICATION
	2.1	Operator Call Errors (by LED Blinking in Orange)
1-5	2.2	Service Call Errors
1-6	2.3	Warnings
1-7	2.4	Troubleshooting by Symptom
1-8	3. REPAIR

3.1Notes 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
		(7)	Flash ROM upgrade
1-20	3.4	Verification Items
		(1)	Service test print
		(2)	EEPROM information print

1-22 4. PRINTER TRANSPORTATION METHOD

Part 2: TECHNICAL REFERENCE

2-1	1.	NEW TECHNOLOGIES
2-4	2.	CLEANING MODE AND AMOUNT OF INK PURGED
2-5	3.	PRINT MODE
2-7	4.	PHOTO DIRECT PRINT FUNCTION
		4.1	Host PC Memory Card Access Function with the Memory Card Startup Utility
2-8		4.2	Memory Card Direct Printing Function
2-10		4.3	File Search
2-11		4.4	File Sort
		4.5	Date Print
2-12		4.6	Bubble Jet Direct Function
2-14		4.7	PictBridge Function
2-15		4.8	Exclusive Processes
2-16		4.9	LCD Viewer
2-17		4.10	Card Slot-related Operations and Display
2-18		4.11	DPOF Settings in the Memory Card Direct Printing Function
2-19		4.12	Print Layout (Details)
2-21		4.13	Date Print Specifications
2-22		4-14	Photo Number Printing Specifications
2-23	5.	FAQ (Specific Problems and Solutions)
	Part 3:		APPENDIX
3-1	1.	BLOCK DIAGRAM
3-2	2.	CONNECTOR LOCATION AND PIN LAYOUT
		2.1	Logic Board Ass’y
3-6		2.2	USB I/F Board (DCC Cover Unit) for Camera Direct Printing
3-7		2.3	Operation Panel Board
3-8		2.4	Memory Card Board
3-12		2.5	Carriage Board (Print Head Connector)

Part 1

MAINTENANCE

1.MAINTENANCE

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

(1)Adjustment

	Adjustment	Timing	Purpose	Tool	Approx.
					time
	EEPROM	At logic board ass’y replacement	To initialize settings other than the	None.	1 min.
	initialization		following:
	(EEPROM settings)		- USB serial number
			- Destination setting
			(The language to be displayed on
			the LCD viewer is set to the default
			setting for each destination.)
			- Waste ink counter
			- Media sensor correction value
			- CD-R correction value
	Destination settings	At logic board ass’y replacement	To set the destination.	None.	1 min.
	(EEPROM settings)
	LCD viewer	At logic board ass’y replacement	To set the language to be displayed	None.	1 min.
	language settings		on the LCD viewer.
	Waste ink counter	- At bottom case unit	To reset the waste ink counter.	None.	1 min.
	resetting	replacement
		- At ink absorber (QC1-2232 /
		2233 / 2234 / 2235 / 2236)
		replacement
	Media sensor	- At logic board ass’y	To correct the media sensor.	Calibration media	2 min.
	correction*1	replacement		kit (QY9-0064)
	(EEPROM settings)	- At sheet feeder unit
		replacement
	CD-R sensor /	- At logic board ass’y	To correct the CD-R and automatic	None.	1 min.
	automatic print head	replacement	print head alignment sensor.	(Correction
	alignment sensor	- At carriage unit replacement		performed
	correction			through service
	(EEPROM settings)			test print)
	Print head alignment	- At print head replacement	To ensure accurate dot placement.	- None.	2 min.
		- At logic board ass’y		(printer buttons)
		replacement		- Computer
				(settings via the
				printer driver)
	Paper feed motor	At paper feed motor unit	To adjust the belt tension. (Position	None.	2 min.
	position	replacement	the paper feed motor so that the belt
	adjustment*2		is stretched tight.)
	Grease application	- At carriage unit replacement	- To maintain sliding properties of	- FLOIL	2 min.
		- At paper guide flapper ass’y	the carriage, carriage shaft, paper	KG-107A
		(QL2-0341) replacement	guide flapper, and lift cam shaft.	(QY9-0057)
		- At lift cam base’s (QL2-0340)	- To protect the lift cam base gear.	- MOLYKOTE
		gear replacement		PG641
		- At lift cam shaft unit		(CK-0562)
		(QM2-0593) replacement

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: 10 sheet of reference plain paper and one sheet of reference white PET paper).

*2: 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.

1 - 1

(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.

1.2Customer Maintenance

	Adjustment	Timing	Purpose	Tool	Approx.
					time
	Print head alignment	At print head	To ensure accurate	- Printer buttons	3 min.
		replacement.	dot placement.	- Computer (settings
				via the printer
				driver)
	Print head cleaning	When print quality is	To improve nozzle	- Printer buttons	30 sec. to
		not satisfying.	conditions.	- Computer (settings	1 min.
				via the printer
				driver)
	Print head deep cleaning	When print quality is	To improve nozzle	- Printer buttons	1 to 1.5
		not satisfying, and	conditions.	- Computer (settings	min.
		not improved by		via the printer
		print head cleaning.		driver)
	Ink tank replacement	When an ink tank			2 min.
		becomes empty.	-----	-----
		(No ink error)
	Paper feed roller	When paper does not	To clean the paper	Printer buttons	2 min.
	cleaning	feed properly.	feed rollers.
	CD-R print position	At CD-R printing,	To correct CD-R	Computer (application	5 min.
	adjustment	when necessary	print position	software)
	LCD viewer contrast	When adjusting the	To adjust the	Printer buttons	1 min.
	adjustment	contrast	contrast

1 - 2

1.3Product Life

(1)Printer

The value (i) or (ii), whichever comes first.

(i)5,000 pages of printing

- Black:	1,500 pages	(A4,	1,500 character pattern)
- Color:	3,500 pages	(A4,	7.5% duty per color pattern:	1,300 pages
		A4, 30% duty per color pattern:		400 pages
		Postcard, 30% duty per color pattern:		800 pages
		L-size, 30% duty per color pattern:		1,000 pages)

(ii)5 years of use

(2)Print head

5,000 pages (in the above print modes)

(3)Ink tank

BCI-6BK:	540 pages (JEIDA standard pattern J1, plain paper, standard mode)
	520 pages (1,500 character pattern in black printing, plain paper, standard mode)
	540 pages (ISO JIS-SCID No. 5 pattern, plain paper, standard mode)
BCI-6C:	780 pages (ISO JIS-SCID No. 5 pattern, plain paper, standard mode)
BCI-6M:	580 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-6PC:	410 pages (ISO JIS-SCID No. 5 pattern, plain paper, standard mode)
BCI-6PM:	260 pages (ISO JIS-SCID No. 5 pattern, plain paper, standard mode)

1.4 Special Tools

Name	Tool No.	Purpose	Remarks
MOLYKOTE PG641	CK-0562-000	To be applied to the lift cam base’s	In common with
		upper gear and the sliding portion	conventional models
		of the lift cam shaft
FLOIL KG-107A	QY9-0057-000	To be applied to the sliding	In common with
		portions of the carriage, carriage	conventional models
		shaft, and the paper guide flapper
GREASE EU1	QY9-0037-000	To be applied to the carriage shaft	In common with
		bearing	conventional models
Calibration media kit	QY9-0064-000	To correct the media sensor	In common with
			conventional models

1.5Serial Number Location

Visible when the access cover is open.

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.

(1)Errors are indicated by the number of times the LED blinks.

(2)Errors are indicated in the LCD viewer on the operation panel.

(3)Warnings are displayed in the Status Monitor of the printer driver.

2.1Operator Call Errors (by LED Blinking in Orange)

LED	Error	Solution	Remarks
blinking
in orange
2 times	No paper. (ASF) [1000]	Set the paper in the ASF, and press the
	No CD-R tray. [1001]*1	Resume button.
		Set the CD-R tray, and press the Resume
		button.
	No paper in the photo paper tray.	Set the paper in the photo paper tray, and
	[1004]	press the Resume button.
3 times	Paper jam. [1300]	Remove the jammed paper, and press the
	No ink.	Resume button.
4 times		Replace the empty ink tank(s), or press the	Pressing the Resume
	[1601/1602/1611/1612/1613/1634/	Resume button.	button will exit the
	1635]		error without ink tank
			replacement, however,
			ink may run out during
			printing.
5 times	The print head is not installed	Install the print head properly, and close the
	[1401], or it is not properly	front cover.
	installed (EEPROM data of the	Or, with the print head installed, turn the
	print head is faulty) [1403/1405].	printer off and on.
6 times*1	No CD-R tray feeder (during	Set the CD-R tray and tray feeder properly,
	CD-R printing). [1850/1855]	and press the Resume button.
	Presence of the CD-R tray feeder	Remove the CD-R tray feeder, and press the
	(during paper printing).	Resume button.
	[1851/1856]
7 times*1	No CD-R or DVD-R. [1002]	After setting a CD-R or DVD-R in the tray,
		set the tray in the tray feeder, and press the
		Resume button.
8 times	Warning: The waste ink absorber	Pressing the Resume button will exit the	The service call error,
	becomes almost full (approx. 95%	error, and enable printing.	indicating the waste
	of the maximum capacity). [1700]	In repair servicing, replace the bottom case	ink absorber is full, is
		unit (QM2-0663), or 5-item set of the ink	likely to occur soon.
		absorbers
		(QC1-2232/2233/2234/2235/2236).
9 times	The connected digital camera or	After removing the cable between the camera	When connected to a
	digital video camera does not	and the printer, press the Resume button, and	Direct Print supported
	support Camera Direct Printing.	re-connect the cable.	camera, the green LED
	[2001]		blinks 2 times.
11 times	Automatic print head alignment	Press the Resume button, and after
	failure. [2500]	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)

-Check that the paper output slot is not exposed to light.

*1: Only for the model supporting CD-R printing (i905D only)

1 - 4

2.2Service Call Errors

-LED Blinking in Orange and Green Alternately, or Lit in Orange

-LCD viewer displaying error codes

	LED
	alternate blinking	Error	Solution
	in orange and		(Replacement of listed parts, which are likely to be faulty)
	green
	2 times	Carriage error [5100]	- Carriage unit (QM2-0662)
			- Timing slit strip film (QA4-1053)
			- Logic board ass’y (QM2-0813/QM2-0814)*1
			- Carriage motor (QK1-0175)
	3 times	Paper feed error [6000]	- Timing sensor unit (QM2-0596)
			- Timing slit disk film (QC1-2511)
			- Feed roller ass’y (QF4-0155)
			- Platen unit (QM2-0670/QM2-0675)
			- Logic board ass’y (QM2-0813/QM2-0814)*1
			- Paper feed motor (QK1-0224)
	4 times	Purge unit error [5C00]	- Purge unit (QM2-0656)
			- Logic board ass’y (QM2-0813/QM2-0814)*1
	6 times	Internal temperature	- Logic board ass’y (QM2-0813/QM2-0814)*1
		error [5400]
	7 times	Waste ink absorber full	- Ink absorbers (QC1-2232/2233/2234/2235/2236)
		[5B00]	- Bottom case unit (QM2-0663)*3
	8 times	Print head temperature	- Print head (QY6-0050)
		rise error [5200]	- Logic board ass’y (QM2-0813/QM2-0814)*1
	9 times	EEPROM error [6800]	- Logic board ass’y (QM2-0766/QM2-0767)*1
	10 times*2	Carriage lift mechanism	- Lift cam shaft unit (QM2-0593)
		error [5110]	- Photo interrupter (WG8-5571)
			- Sheet feeder unit (QM2-0589)
			- Logic board ass’y (QM2-0813/QM2-0814)*1
	12 times	Media sensor error	- Sheet feeder unit (QM2-0589)
		[8000]
	13 times	USB Host VBUS	- Logic board ass’y (QM2-0813/QM2-0814)*1
		overcurrent [9000]
	15 times	Other hardware error	- Logic board ass’y (QM2-0813/QM2-0814)*1
		[6500]
	Continuous	Flash ROM error	- Logic board ass’y (QM2-0813/QM2-0814)*1
	alternate blinking
	Lights in orange	RAM error	- Logic board ass’y (QM2-0813/QM2-0814)*1

*1: Before replacement of the logic board ass’y, check the waste ink amount (by service test print or EEPROM information print). If the waste ink amount is 7% or more, also replace the bottom case unit (QM2-0586) or the 5-item set of the ink absorbers (QC1-2232/2233/2234/2235/2236) when replacing the logic board ass’y. See Section 3.3. Adjustment / Settings, (6) Service mode, for details.

*2: Only for models supporting CD-R printing (i905D only).

*3: Reset the waste ink counter when replacing the bottom case unit (QM2-0586). See Section 3.3. Adjustment / Settings, (6) Service mode, for details.

1 - 5

Printer (LCD viewer displaying)

Displayed warning

Low ink of 6BK, 6C, 6M, 6Y, 6PC or 6PM (at detection of no liquid ink remaining)

Print head temperature rise warning

Protection of excess rise of the print head temperature

Presence of the CD-R tray feeder*2

2.3Warnings

Remarks

If the print head temperature is high when the front cover is opened, the warning is displayed*1. When the print head temperature falls, the warning is released.

If the print head temperature exceeds the specified limit, a Wait is inserted during printing,

If the CD-R tray feeder is attached when the front cover is opened, the warning is displayed.*1 When the CD-R tray feeder is removed, and the front cover is closed, the warning is released.

*1: If the warning is displayed, the carriage does not move to the ink tank replacement position when the front cover is opened.

*2: Only for models supporting CD-R printing (i905D only).

1 - 6

2.4 Troubleshooting by Symptom

	Symptom	Solution	Remarks
Faulty	The power does not turn on.	Replace the
	The power turns off immediately	- AC adapter, or
		*1
	after power-on.	- logic board ass’y .
operation
	The print head is not recognized.	Remove and re-install the print head, or replace the
	The print head does not move to	- print head, or
	the home position.	- logic board ass’y*1.
	A strange noise occurs.	Remove foreign material, or attach a displaced part if
		any.
	Printing stops mid-way.	Replace the logic board ass’y*1.
Paper	Multiple sheets feed.	Replace the
		- sheet feeder unit, or
		- photo paper tray.
feed
	Paper does not feed.	Remove foreign material, or replace the
problems		- sheet feeder unit, or
		- photo paper tray.
	Paper feeds at an angle.	Remove foreign material, adjust the paper guide, or
		replace the
		- sheet feeder unit, or
		- photo paper tray.
Unsatisfactory	No printing, or no color ejected.	Replace the
		- ink tank,
		- print head*2,
		- logic board ass’y*1, or
	Printing is faint, or white lines	- purge unit.
		Remove and re-install the print head, or replace the
print
	appear on printouts even after	- ink tank,
	print head cleaning.	- print head*2,
quality
	Line(s) not included in the print	- purge unit, or
	data appears on printouts.	- logic board ass’y*1.
	Paper gets smeared.	Feed several sheets of paper, or clean the paper path with
		cotton swab or cloth.
	A part of a line is missing on	Replace the
	printouts.	- ink tank, or
		- print head*2.
	Color hue is incorrect.	Replace the
		- ink tank, or
		- print head*2, or
		correct the media sensor.
	Printing is incorrect.	Replace the logic board ass’y*1.
	No ejection of black ink.	Replace the
		- ink tank, or
		- print head*2.
	Graphic or text is enlarged on	When enlarged in the carriage movement direction, clean
	printouts.	grease or oil off the timing slit strip film, or replace the
		- timing slit strip film,
		- carriage unit, or
		- logic board ass’y*1.
		When enlarged in the paper feed direction, clean grease
		or oil off the timing slit strip film, or replace the
		- timing slit disk film,
		- timing sensor unit, or
		- logic board ass’y*1.

*1: Before replacement of the logic board ass’y, check the waste ink amount (by service test print or EEPROM information print). If the waste ink amount is 7% or more, also replace the bottom case unit (QM2-0663) or the 5-item set of the ink absorbers (QC1-2232/2233/2234/2235/2236) when replacing the logic board ass’y. See Section 3.3. Adjustment / Settings, (6) Service mode, for details.

*2: Replace the print head only after the print head deep cleaning is performed 2 times, and the problem persists.

1 - 7

3.REPAIR

3.1Notes on Service Part Replacement (and Disassembling / Reassembling)

Service part	Notes on replacement*1			Adjustment / settings	Operation check
			After replacement:
Logic board ass’y	- Before removal of the				- EEPROM
(QM2-0813/0814)	logic board ass’y, remove	1.		Initialize the EEPROM.	information print
	the power cord, and allow	2.		Reset the waste ink	- Service test print
	for approx. 1 minute (for			counter.	- Printing via USB
	discharge of capacitor’s	3.		Set the destination in	connection
	accumulated charges), to			the EEPROM.	- Direct printing
	prevent damages to the		4. Set the LCD viewer’s		from a digital
	logic board ass’y.			language.	camera
	- Before replacement,	5.		Correct the media
	check the waste ink			sensor.
	amount (by service test	6.		Correct the CD-R and
	print or EEPROM			automatic print head
	information print). If the			alignment sensor.
	waste ink amount is 7%		For details of 1 to 5, see
	or more, also replace the		3.3. Adjustment / Settings,
	bottom case unit or the		(6) Service mode.
	ink absorbers when
	replacing the logic board	7.		Perform the print head
	ass’y. See 3.3. Adjustment			alignment in the user
	/ Settings, (6) Service			mode.
	mode, for details.
Bottom case unit			After replacement:		- Service test print
(QM2-0663)		1.		Reset the waste ink
Ink absorber				counter. See 3.3.
(QC1-2232/2233/				Adjustment / Settings,
2234/2235/2236)				(6) Service mode.
Sheet feeder unit			After replacement:		- Service test print
(QM2-0589)		1.		Correct the media	(Confirm media
				sensor. See 3.3.	sensor correction.)
				Adjustment / Settings,
				(6) Service mode.
Carriage unit			At replacement:		- Service test print
(QM2-0662)		1.		Apply grease to the	(Confirm CD-R
				sliding portions. See	and automatic print
				3.3. Adjustment /	head alignment
				Settings, (3) Grease	sensor correction.)
				application.
			After replacement:
		1.		Correct the CD-R and
				automatic print head
				alignment sensor. See
				3.3. Adjustment /
				Settings, (6) Service
				mode.
		2.		Perform the print head
				alignment in the user
				mode.
Paper feed motor	- The red screws securing		At replacement:
(QK1-0224)	the paper feed motor are	1.		Adjust the paper feed
	allowed to be loosened.			motor. See 3.3.
	(DO NOT loosen any			Adjustment / Settings,
	other red screws.)			(1) Paper feed motor
				adjustment.

1 - 8

(Notes on Service Part Replacement and Disassembling / Reassembling - cont’d-)

	Service part	Notes on replacement*1	Adjustment / settings	Operation check
			At replacement:
	Lift cam shaft unit			- Service test print
	(QM2-0593)		1. Apply grease to the
			sliding portions. See
			3.3. Adjustment /
			Settings, (3) Grease
			application.
			2. Adjust the phase of the
			lift shaft gear
			(QC1-2297). See 3.3.
			Adjustment / Settings,
			(3) Grease application.
	Timing slit strip film	- Upon contact with the	After replacement:	- Service test print
	(QA4-1053)	film, wipe the film with	1. Perform the print head
		ethanol.	alignment in the user
		- Confirm no grease is on	mode.
		the film. (Wipe off any
	Timing slit disk film
		grease thoroughly with
	(QC1-2511)
		ethanol.)
		- Do not bend the film.
	Print head		After replacement:	- Service test print
	(QY6-0050)		1. Perform the print head
			alignment in the user
			mode.
*1: General notes:

-Make sure that the flexible cables and wires in the harness are in the proper position and connected correctly. See 3.2. Special Notes on Repair Servicing, (1) Flexible cable and harness wiring, connection, for details.

-Do not drop the ferrite core, which may cause damage.

-Protect electrical parts from damage due to static electricity.

-Before removing a unit, after removing the power cord, allow the printer to sit for approx. 1 minute (for capacitor discharging to protect the logic board ass’y from damages).

-Do not touch the timing slit strip film and timing slit disk film. No grease or abrasion is allowed.

-Protect the units from soiled with ink.

-Protect the housing from scratches.

-Exercise caution with the red screws, as follows:

i.The red screws of paper feed motor may be loosened only at replacement of the paper feed motor unit (DO NOT loosen them in other cases).

ii.DO NOT loosen the red screws on both sides of the main chassis, securing the carriage shaft positioning (they are not adjustable in servicing).

1 - 9

3.2Special Notes on Repair Servicing

(1)Flexible cable and harness wiring, connection

Use caution with the flexible cable and harness wiring. Improper wiring or connection may cause line breakage, possibly leading to ignition or emission of smoke.

(I)

(II)

(III)

(I)DSC direct connector harness wiring

DSC direct connector

Ground line

1 - 10