Canon i960, i965 Service Manual

i960

SER VICE MANUAL

Canon

i960 i965 SERVICE MANUAL

Revision 0

QY8-1392-000

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) 1-9 3.2 Special Notes on Repair Servicing 1-9 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 1-15 3.4 Verification Items (1) Service test print (2) EEPROM information print 1-17 4. PRINTER TRANSPORTATION METHOD

2-1 1. NEW TECHNOLOGIES 2-1 2. CLEANING MODE AND AMOUNT OF INK PURGED 2-2 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.

3 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

- On-arrival cleaning flag

- 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 lift cam shaft.

- To protect the lift cam

base gear.

- To maintain sliding

properties of the lift cam shaft.

None. 1 min.

Calibration media kit (QY9-0064)

None. (Correction performed through service test print) Computer (settings via the printer driver)

None. 2 min.

- FLOIL KG-107A (QY9-0057)

- MOLYKOTE PG641 (CK-0562)

- EU-1 (QY9-0037)

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

Computer (Automatic 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)

5 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

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

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

(3) Ink tank

BCI-6BK: 600 pages (1,500 character pattern in black printing, plain paper, standard mode) 780 pages (ISO JIS-SCID No. 5 pattern, plain paper, standard mode) BCI-6C: 880 pages (ISO JIS-SCID No. 5 pattern, plain paper, standard mode) BCI-6M: 630 pages (ISO JIS-SCID No. 5 pattern, plain paper, standard mode) BCI-6Y: 430 pages (ISO JIS-SCID No. 5 pattern, plain paper, standard mode) BCI-6PC: 300 pages (ISO JIS-SCID No. 5 pattern, plain paper, standard mode) BCI-6PM: 220 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

EU-1 QY9-0037-000 To be applied to the sliding

portion of the carriage, and the grease pad on the carriage

Calibration media kit QY9-0064-000 To correct the media sensor New (in common with

In common with conventional models

the i860/i865)

1.5 Serial Number Location

On the carriage flexible cable holder (visible when the access cover is open).

1 - 3

+ 20 hidden pages