Canon iP4200 - PIXMA Photo Printer Service Manual

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PIXMA iP4200 SERVICE MANUAL

Revision 0

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QY8-13A9-000

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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.

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I. MANUAL OUTLINE

This manual consists of the following three parts to provide information necessary to service the PIXMA iP4200:

Part 1: Maintenance Information on maintenance and troubleshooting of the PIXMA iP4200

Part 2: Technical Reference

ew technology and technical information such as FAQ's (Frequently Asked Questions) of the PIXMA iP4200

Part 3: Appendix Block diagrams and pin layouts of the PIXMA iP4200

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

II. TABLE OF CONTENTS

Part 1: MAINTENANCE

1. MAINTENANCE

-1. Adjustment, Periodic Maintenance, Periodic Replacement Parts, and Replacement Consumables by

Service Engineer

-2. Customer Maintenance

-3. Product Life

-4. Special Tools

-5. Serial Number Location

2. LIST OF ERROR DISPLAY / INDICATION

-1. Operator Call Errors

-2. Service Call Errors

-3. Warnings

-4. Troubleshooting by Symptom

3. REPAIR

-1. Notes on Service Part Replacement (and Disassembling / Reassembling)

-2. Special Notes on Repair Servicing

-3. Adjustment / Settings

(1) Paper feed motor adjustment

(2) Grease application

(3) Waste ink counter setting

(4) User mode

(5) Service mode

Service test print,

EEPROM initialization, Waste ink counter reset

Destination settings

-4. Verification Items

(1) Service test print

(2) EEPROM information print

4. PRINTER TRANSPORTATION

Part 2: TECHNICAL REFERENCE

1. NEW TECHNOLOGIES

2. CLEANING MODE AND AMOUNT OF INK PURGED

3. PRINT MODE

. FAQ (Problems Specific to the iP4000 and Corrective Actions)

Part 3: APPENDIX

1. BLOCK DIAGRAM

2. CONNECTOR LOCATION AND PIN LAYOUT

-1. Logic Board Ass'y

-2. Carriage Board (Print Head Connector)

PIXMA iP4200 Specifications

art 1

MAINTENANCE

1. MAINTENANCE

1-1. Adjustment, Periodic Maintenance, Periodic Replacement Parts, and

Replacement Consumables by Service Engineer

(1) Adjustment

Adjustment Timing Purpose Tool

Approx.

time

Destination settings (EEPROM settings)

At logic board replacement To set the destination.

None. Perform in the

service mode.

1 min.

Waste ink counter resetting (EEPROM settings)

- At logic board replacement

- At waste ink absorber replacement

To reset the waste ink counter.

None. Perform in the

service mode.

1 min.

Paper feed motor position

adjustment

At paper feed motor replacement

To adjust the belt tension. (Position the paper feed motor so

that the belt is stretched tight.)

None.

5 min.

CD / DVD detection sensor light volume

correction

- At logic board replacement

- At carriage unit replacement

To correct the light volume for the CD / DVD detection sensor.

None. Perform in the

service mode.

2 min.

Grease application

- At carriage unit replacement

- At PR shaft ass'y replacement

- At CL base / gear replacement

- To maintain sliding properties of the carriage shaft and the lift cam shaft.

- To protect the printer's sliding portions (gears).

FLOIL KG-107A 1 min.

Ink system function check

- At logic board replacement

- At platen unit replacement

- At carriage unit replacement

To maintain detection functionality for presence of the ink tanks and each ink tank position.

None. Perform in the

service mode.

1 min.

1-1

Note: DO NOT loosen the red screws at both ends of the carriage shaft, securing the print head position, as they are

not re-adjustable. The red screws securing the paper feed motor may be loosened only at replacement of the paper feed motor unit.

*1: Only for CD / DVD printing supported regions.

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(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

Approx.

time

Print head alignment

At print head replacement.

To ensure accurate dot placement.

- Printer buttons

- Computer (automatic settings via the printer

driver)

3 min.

Print head cleaning

When print quality is not satisfying.

To improve nozzle conditions. - Printer buttons

- Computer (settings via the printer driver)

1 min.

Print head deep cleaning

When print quality is not satisfying, and not improved by print head cleaning.

To improve nozzle conditions. Computer (settings

via the printer driver)

2 min.

Ink tank replacement

When an ink tank becomes empty. ("No ink error" via the computer, or ink tank LED flashing fast in red)

----- -----

2 min.

Paper feed roller cleaning

When necessary To clean the paper feed

rollers.

Printer buttons 2 min.

CD / DVD print position

adjustment

At CD / DVD printing, when necessary

To correct CD / DVD print position.

Computer (application software)

5 min.

Bottom plate cleaning

When the back side of the paper is smeared

To clean the platen ribs.

- Plain paper

- Computer (settings via the printer

driver)

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1 min.

ASF sub- roller cleaning

When the paper fed from the ASF is smeared due to ink mist

attached to the ASF sub-rollers.

To clean the ASF sub-rollers.

- Plain paper

- Printer buttons

[See Part 2, 4. FAQ,

How to make and set the ASF subroller cleaning

sheet, for details]

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1 min.

1-2

1-3. Product Life

(1) Printer

Specified print volume (I) or the years of use (II), whichever comes first. (I) Print volume

PIXMA iP4200: 18,000 pages

(II) Years of use

PIXMA iP4200: 5 years of use

(2) Print head

Print volume: 18,000 pages

(3) Ink tank (target value)

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Black 1,500 character pattern 8,300 pages

Color

A4, 7.5% duty per color pattern 5,400 pages

A4, photo, borderless printing 400 pages

4 x 6, photo, borderless printing 3,200 pages

Postcard, photo, borderless printing 700 pages

Black 1,500 character pattern 8,300 pages

Color

A4, 7.5% duty per color pattern 5,400 pages

A4, photo, borderless printing 400 pages

4 x 6, photo, borderless printing 3,200 pages

Postcard, photo, borderless printing 700 pages

Pattern Ink tank used Print yield

Black text

PGI-5BK Approx. 820 pages

CLI-8BK

Color chart

CLI-8BK Approx. 2,000 pages

PGI-5BK Approx. 1,450 pages

CLI-8Y Approx. 540 pages

CLI-8M Approx. 600 pages

CLI-8C Approx. 850 pages

Photo chart

CLI-8BK Approx. 1,650 pages

CLI-8Y Approx. 310 pages

CLI-8M Approx. 290 pages

1-3

CLI-8C Approx. 430 pages

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Black text:󲩷 When printing the Canon standard pattern (1,500 characters per page) on A4 size plain paper, with

the default settings in the Windows XP driver, using Word 2003.

Color chart:󲩷 When printing the ISO/JIS-SCID N5 pattern on A4 size plain paper in bordered printing, with the

default settings in the Windows XP driver, using Photoshop 7.0.

Photo chart:󲩷 When printing the Canon standard pattern on 4" x 6" Photo Paper Plus Glossy in borderless

printing, with the default settings in the Windows XP driver, using Windows XP Photo Printing Wizard.

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The print yield in the table above is an average value measured in continuous printing, using the ink tank immediately after it is unsealed, until the ink is out. Ink yield may vary depending on texts and photos printed, application software, print mode, and type of paper used.

1-4. Special Tools

1-5. Serial Number Location

On the carriage flexible cable holder (visible on the right of the carriage after the printer is turned on, the access cover is opened, and the carriage moves to the center).

To the top

Name Tool No. Price Application Remarks

Grease FLOIL

KG-107A

QY9-0057-000 US$2.00 To be applied to the sliding portions

of the carriage shaft and lift cam shaft.

In common with the S500 and S520.

1-4

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 Alarm LED Blinking in Orange)

Alarm

LED

blinking

in orange

Error [Error code]

Solution Remarks

2 times

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

Resume/Cancel button.

No CD / DVD tray. [1001]

Set the CD / DVD tray, and press the Resume/Cancel button.

No paper in the cassette. [1003] (No paper in the front paper feed

cassette.)

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

No CD / DVD. [1002]

Set a CD or DVD in the CD / DVD tray (which is ejected at error occurrence), and insert the CD / DVD tray in the proper position. Then, press the Resume/Cancel button.

3 times

Paper jam. [1300] Remove the jammed paper, and press the

Resume/Cancel button.

Error in paper feeding from the ASF.

Paper jam in the rear guide. [1303] Error in the duplex

printing unit.

Paper jam in the under guide. [1304]

Error in paper feeding from the cassette.

Front door close error. [1250] Open the paper output tray. The error is

indicated if the paper output tray is closed at start of a print job, or while a print job is being performed.

4 times No ink. [1600] 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.

Ink tank not installed. [1660] Install the applicable ink tank(s) properly,

and confirm that the LED's of all the ink tanks light red.

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5 times The print head is not installed

[1401], or it is not properly installed (Print head temperature sensor error [1403] / Faulty EEPROM data of the print head [1405]).

Install the print head properly.

1-5

6 times

Inner cover open. [1841]

Close the inner cover, and press the Resume/Cancel button.

Inner cover open during printing on paper. [1846]

Close the inner cover, and press the Resume/Cancel button.

Inner cover open during printing on paper (print continuable).

[1851]

Close the inner cover, and press the Resume/Cancel button.

Inner cover open during printing on paper (print NOT continuable).

[1856]

Close the inner cover, and press the Resume/Cancel button to clear the error. The paper being printed at error occurrence will be ejected without printing the remaining data for the ejected paper, then printing will resume from the next page.

Inner cover closed during CD / DVD printing (print continuable).

[1850]

Open the inner cover which functions as the CD / DVD tray feeder, set the CD / DVD tray in the feeder, and press the Resume/Cancel button.

Inner cover closed during CD / DVD printing (print NOT

continuable). [1855]

Open the inner cover, and press the Resume/Cancel button to clear the error. The CD or DVD being printed at error occurrence will be ejected without printing the remaining data for the ejected CD or

DVD, then the next print job will be done.

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7 times

Multiple ink tanks of the same color installed. [1681]

Replace the wrong ink tank(s) with the correct one(s).

Ink tank in a wrong position. [1680]

Install the ink tank(s) in the correct position.

8 times Warning: The waste ink absorber

becomes almost full. [1700]

Pressing the Resume/Cancel button will exit the error, and enable printing.

The service call error, indicating the waste ink absorber is full, is likely to occur soon.

9 times The connected digital camera or

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

Remove the cable between the camera and the printer.

10 times Automatic duplex printing cannot

be performed. [1310]

Press the Resume/Cancel button to eject the paper being used at error occurrence. Printing will resume from on the front side of the next page.

Data which was to be printed on the back side of paper at error occurrence is skipped (not printed).

11 times

Failed in automatic print head alignment. [2500]

Press the Resume/Cancel button.

- If paper is being fed at error occurrence, the error is indicated after the paper is ejected.

- If the error occurs, the print head alignment values are not changed.

- After exit from the error by the

The error is indicated when the pattern is not printed due to no ink or non-ejection of ink, or when the sensor's AD value

1-6

*1: Only for models supporting CD / DVD printing

*2: Only for models not supporting CD / DVD printing

2-2. Service Call Errors (by Cyclic Blinking in Orange (Alarm LED) and Green

(Power LED), or Alarm LED Lit in Orange)

Resume/Cancel button, the automatic print

head alignment will not be re-done.

is incorrect.

13 times

The remaining ink amount unknown. [1683]

An ink tank which has once been empty is installed. Replace the applicable ink tank with a new one.

Printing with a once-empty or refilled ink tank can damage the print head.

If printing is continued without replacing the "nogood" ink tank, press the Resume/Cancel button for 5 sec. or longer to record the use of a refilled ink tank.

Note:

After the above operation, the function to detect the remaining ink amount is disabled.

14 times

Ink tank not recognized. [1684] A non-supported ink tank is installed (the

ink tank LED is turned off). Install the supported ink tanks.

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15 times

Ink tank not recognized. [1410 to 1419]

An error occurred in an ink tank (the ink tank LED is turned off). Replace the ink tank(s).

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Access cover open. [1200]

Close the access cover.

Cycles of

blinking in

orange (Alram

LED) and green

(Power LED)

Error [Error code]

Solution

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

2 times

Carriage error [5100]

- Carriage unit (QM2-2207)

- Timing slit strip film (QC1-6394)

- Logic board ass'y (QM2-2670)

- Carriage motor (QK1-1500)

3 times

Line feed error [6000]

- Timing sensor unit (QM2-2683)

- Timing slit disk film (QC1-6229)

- Feed roller ass'y (QL2-0925)

- Platen unit (QM2-2202)

- Logic board ass'y (QM2-2670)

- PAPER FEED MOTOR (QK1-1502)

4 times

Purge cam sensor error [5C00] - Purge unit (QM2-2208)

1-7

*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 ink absorber kit (QY5-0146) when replacing the logic board ass'y.

[See Section 3

-3. Adjustment / Settings, (5) Service mode, for details.]

- Logic board ass'y (QM2-2670)

5 times

ASF (cam) sensor error [5700] - Sheet feed unit (QM2-2211)

6 times Internal temperature error

[5400]

- Logic board ass'y (QM2-2670)

7 times

Waste ink absorber full [5B00]

- Ink absorber kit (QY5-0146)

8 times

Print head temperature rise error [5200]

- Print head (QY6-0059)

- Logic board ass'y (QM2-2670)

9 times EEPROM error [6800]

- Logic board ass'y (QM2-2670)

11 times

Carriage lift mechanism error [5110]

- PR lift shaft ass'y (QL2-0936)

- Sheet feed unit (QM2-2211)

- Logic board ass'y (QM2-2670)

- Carriage lift sensor unit (QM2-2678)

12 times

AP position error [6A00]

- Sheet feed unit (QM2-2211)

- Logic board ass'y (QM2-2670)

- Purge unit (QM2-2208)

13 times

Paper feed position error [6B00]

- Sheet feed unit (QM2-2211)

- Logic board ass'y (QM2-2670)

14 times

Paper feed cam sensor error [6B10]

- Sheet feed unit (QM2-2211)

- Logic board ass'y (QM2-2670)

15 times

USB Host VBUS overcurrent [9000]

- Logic board ass'y (QM2-2670)

16 times Valve sensor error [6C00]

- Logic board ass'y (QM2-2670)

- Purge unit (QM2-2208)

17 times

Motor driver error [6D00]

- Logic board ass'y (QM2-2670)

19 times Ink tank position sensor error

[6502]

- Platen unit (QM2-2202)

- Logic board ass'y (QM2-2670)

20 times

Other hardware error [6500]

- Logic board ass'y (QM2-2670)

Continuous alternate blinking

ROM error

- Logic board ass'y (QM2-2670)

Alarm LED lit RAM error

- Logic board ass'y (QM2-2670)

1-8

2-3. Warnings

Printer (no LED indications):

*1: If the warning is displayed, the carriage does not move to the ink tank replacement position when the access

cover is opened.

2-4. Troubleshooting by Symptom

Displayed warning Remarks

Low ink

Status indication only.

Print head temperature rise If the print head temperature is high when the access cover is opened,

the warning is displayed

When the print head temperature falls, the warning is released.

Protection of excess rise of the print head temperature

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

Symptom Solution Remarks

Faulty operation

The power does not turn on. The power turns off immediately

after power-on.

Replace the

- AC adapter, or

- logic board ass'y*1.

A strange noise occurs. Remove foreign material, or attach a

removed part if any.

Printing stops mid-way.

Replace the logic board ass'y*1.

Paper feed

problems

Multiple sheets feed.

Replace the

- sheet feed unit, or

- cassette.

Paper does not feed. Remove foreign material, or replace

the

- sheet feed unit, or

- cassette.

Paper feeds at an angle. Remove foreign material, adjust the

paper guide, or replace the

- sheet feed unit, or

- cassette.

No printing, or no color ejected. Replace the

- ink tank,

1-9

Unsatisfactory

print quality

- print head*2, or

- logic board ass'y*1,

remove foreign material from the purge unit caps, if any, or

replace the purge unit.

Printing is faint, or white lines appear on printouts even after print head cleaning.

Line(s) not included in the print data appears on printouts.

Remove and re-install the print head, or replace the

- ink tank,

- print head*2,

- purge unit, or

- logic board ass'y*1.

Paper gets smeared.

Feed several sheets of paper, perform bottom plate cleaning, clean the paper path with cotton swab

or cloth, or

clean the ASF sub-rollers.

A part of a line is missing on printouts.

Replace the

- ink tank, or

- print head*2.

Color hue is incorrect.

Replace the

- ink tank, or

- print head*2, or

perform print head alignment.

Printing is incorrect.

Replace the logic board ass'y*1.

No ejection of black ink.

Replace the

- ink tank, or

- print head*2, or

remove foreign material from the purge unit caps, if any, or

replace the purge unit.

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Graphic or text is enlarged on printouts.

When enlarged in the carriage movement direction, clean 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 disk film, or replace the

- timing slit disk film,

- timing sensor unit, or

- logic board ass'y*1.

1-10

*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 ink absorber kit (QY5-0146) when replacing the logic board ass'y.

[See Section 3

-3. Adjustment / Settings, (5) Service mode, for details.]

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

persists.

To the top

1-11

3. REPAIR

3-1. Notes on Service Part Replacement (and Disassembling / Reassembling)

Service part

Notes on replacement

Adjustment / settings Operation check

Logic board ass'y QM2-2670

- Before removal of the logic board ass'y, remove the power cord, and allow for approx. 1 minute (for discharge of capacitor's accumulated charges), to prevent damages to the logic board ass'y.

- Before replacement, 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 ink absorber kit when replacing the logic board ass'y.

[See 3-3. Adjustment / Settings, (5) Service mode, for details.]

After replacement:

1. Initialize the EEPROM.

2. Reset the waste ink counter.

3. Set the destination in the EEPROM.

4. Correct the CD / DVD and automatic print head alignment sensors.

5. Check the ink system function.

[See 3-3. Adjustment / Settings, (5) Service mode, for details of 1 to 5]

6. Perform the print head alignment in the user mode.

- EEPROM information print

- Service test print

- Printing via USB connection

- Direct printing from a digital camera

Ink absorber kit QY5-0146

After replacement:

1. Reset the waste ink counter.

[See 3.3. Adjustment / Settings, (5) Service mode.]

- Service test print

- EEPROM information print

Carriage unit QM2-2207

At replacement:

1. Apply grease to the sliding portions.

[See 3

-3. Adjustment /

Settings, (2) Grease application.]

After replacement:

1. Correct the CD / DVD and automatic print head alignment sensors.

[See 3.3. Adjustment / Settings, (5) Service mode.]

2. Check the ink system function.

[See 3.3. Adjustment / Settings, (5) Service

mode.]

3. Perform the print head alignment in the user mode.

- Service test print (Confirm CD / DVD and automatic print head alignment sensor correction, and ink

system function.)

Paper feed motor QK1-1502

- The red screws securing the paper feed motor are allowed to be loosened. (DO NOT loosen any other red screws.)

At replacement:

1. Adjust the paper feed motor.

[See 3

-3. Adjustment /

Settings, (1) Paper feed motor adjustment.]

Platen unit: QM22202

By attaching the tape at the

specified 2 locations,

At replacement:

After the printer unit is assembled in the bottom

1-12

*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, (2) Flexible cable and harness wiring, connection, for details.]

- Protect the waste ink tube from being pinched when assembling the printer unit chassis into the bottom case unit.

Since the tube conditions after assembly are not visible, perform the manual purging 3 or 4 times to confirm that no strange noise is heard.

[See 3

-2. Special Notes on Repair Servicing, (3) Printer unit and bottom case unit assembly, 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 the 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

ositioning (they are not adjustable in servicing).

Purge unit: QM22208

Waste ink tube: QC16458

Waste ink tube holder: QC1-6460

secure the waste ink tube to

the waste ink tube holder.

1. To protect the waste ink tube from being pinched when reassembling the printer unit chassis into the bottom case unit, tape the tube (at 2 locations).

[See 3-2. Special Notes on Repair Servicing, (3) Printer unit and bottom case unit assembly.]

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case unit, the tube conditions are not visible. For confirmation of the tube conditions, perform the manual purging 3 or 4 times, and confirm that no strange noise is heard.

Platen unit QM2-2202

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After replacement

1. Check the ink system function.

[See 3-3. Adjustment / Settings, (5) Service mode.]

- Service test print

PR lift shaft ass'y QL2-0936 CL input gear

QC1-6213

At replacement:

1. Apply grease to the sliding portions.

[See 3.3. Adjustment / Settings, (2) Grease application.]

- Service test print

Timing slit strip film QC1-6394

- Upon contact with the film, wipe the film with ethanol.

- Confirm no grease is on the film. (Wipe off any grease thoroughly with ethanol.)

- Do not bend the film

After replacement:

1. Perform the print head alignment in the user mode.

- Service test print

Timing slit disk film

QC1-6229

Print head QY6-0059

After replacement:

1. Perform the print head alignment in the user mode.

- Service test print

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+ 39 hidden pages

Canon iP4200 - PIXMA Photo Printer Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual