Canon PIXMA iP4000 Service Manual

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PIXMA iP4000

SERVICE

MANUAL

Canon

Copyright 2004, Canon U.S.A. This technical publication is the proprietary and confidential information of Canon U.S.A. which shall be retained for reference purposes by Authorized Service Facilities of Canon U.S.A. Its unauthorized use is prohibited.

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.

Inkjet SFP 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 PIXMA iP4000:

Part 1: Maintenance

Information on maintenance and troubleshooting of the PIXMA iP4000

Part 2: Technical Reference

New technology and technical information such as FAQ's (Frequently Asked Questions) of the PIXMA iP4000

Part 3: Appendix

Block diagrams and pin layouts of the PIXMA iP4000

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

1-1. Adjustment, Periodic Maintenance, Periodic Replacement Parts, and Replacement Consumables by Service Engineer 1-2. Customer Maintenance

1-3. Product Life

1-4. Special Tools

1-5. Serial Number Location

2. LIST OF ERROR DISPLAY / INDICATION

2-1. Operator Call Errors

2-2. Service Call Errors

2-3. Warnings

2-4. Troubleshooting by Symptom

3. REPAIR

3-1. Notes on Service Part Replacement (and Disassembling / Reassembling) 3-2. Special Notes on Repair Servicing

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

Service test print, EEPROM initialization, Waste ink counter reset

Destination settings

3-4. 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. FAQ (Problems Specific to the iP4000 and Corrective Actions)

Part 3: APPENDIX

1. BLOCK DIAGRAM

2. CONNECTOR LOCATION AND PIN LAYOUT

2-1. Logic Board Ass'y

2-2. Carriage Board (Print Head Connector)

Part 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.
Adjustment	Timing	Purpose	Tool	time
				time
EEPROM	At logic board ass'y replacement	To initialize settings other than the following:	None.	1 min.
initialization		- USB serial number
(EEPROM settings)		- Destination setting
		- Waste ink counter
		- CD-R correction value
Destination settings	At logic board ass'y replacement	To set the destination.	None.	1 min.
(EEPROM settings)
Waste ink counter	- At bottom case unit replacement	To reset the waste ink counter.	None.	1 min.
resetting	- At ink absorber (QC1-4221 / 4222 / 4223 /
(EEPROM settings)	4224 / 4263 / 4264 / 4864 / 4257)
	replacement
CD-R sensor /	- At logic board ass'y replacement	To correct the CD-R and automatic print head	None. (Correction	2 min.
automatic print head	- At carriage unit replacement	alignment sensor.	performed through
alignment sensor			service test print)
correction (EEPROM
settings)
Print head alignment	- At print head replacement	To ensure accurate dot placement.	- None. (printer buttons)	2 min.
	- At logic board ass'y replacement		- Computer (settings via
	- At carriage unit replacement		the printer driver)
Paper feed motor	At paper feed motor unit replacement	To adjust the belt tension. (Position the paper	None.	2 min.
position adjustment*1		feed motor so that the belt is stretched tight.)
Grease application	- At carriage unit replacement	- To maintain sliding properties of the carriage,	- FLOIL KG-107A (QY9-	1 min.
	- At chassis' upper gear replacement	carriage shaft, and shaft lift.	0057)
	- At shaft lift (QC1-4331) replacement	- To protect the chassis' upper gear.	- MOLYKOTE HP300
			(QY9-0035)

Note: DO NOT loosen the red screws on both sides of the main chassis, securing the carriage shaft positioning.

*1: 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 - 1

1-2. Customer Maintenance

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

1-3. Product Life

(1)Printer

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

(I)Print volume

		PIXMA iP4000
		18,000 pages
Black	1,500 character pattern	7,200 pages
Color	A4, 7.5% duty per color pattern	5,400 pages
	A4, photo, borderless printing	300 pages
	4 x 6, photo, borderless printing	3,600 pages
	Postcard, photo, borderless printing	1,500 pages

(II) Years of use

PIXMA iP4000: 5 years of use

(2) Print head

Print volume:

Black

Color

	PIXMA iP4000
	18,000 pages
1,500 character pattern	7,200 pages
A4, 7.5% duty per color pattern	5,400 pages
A4, photo, borderless printing	300 pages
4 x 6, photo, borderless printing	3,600 pages
Postcard, photo, borderless printing	1,500 pages

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(3) Ink tank (target value)

PIXMA iP4000:

BCI-3eBK: 740 pages (1,500 character pattern, plain paper / standard mode) 1,500 pages (ISO JIS-SCID No. 5 / plain paper / standard mode)

BCI-6C: 550 pages (ISO JIS-SCID No. 5 / plain paper / standard mode) BCI-6M: 430 pages (ISO JIS-SCID No. 5 / plain paper / standard mode) BCI-6Y: 360 pages (ISO JIS-SCID No. 5 / plain paper / standard mode)

BCI-6BK: 2,000 pages (ISO JIS-SCID No. 5 / plain paper / standard mode)

1-4. Special Tools

Name	Tool No.	Application	Remarks
MOLYKOTE	QY9-0035-000	To be applied to the chassis' upper gear, and to the sliding	In common with other
HP300		portion of the shaft lift.	models.
FLOIL	QY9-0057-000	To be applied to the sliding portion of the carriage, and	In common with other
KG-107A		the carriage shaft.	models.

1-5. Serial Number Location

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

To the top

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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	Error [Error code]
	in orange	Error [Error code]
	in orange
	2 times	No paper. (ASF) [1000]
		No CD-R tray. [1001]*1
		No paper in the cassette. [1003]
		(No paper in the front paper feed cassette.)
	3 times	Paper jam. [1300]
		Paper jam in the under guide. [1304]
		Paper jam in the rear guide. [1303]
		Front door closed. [1250]
	4 times	No ink. [1601 / 1602 / 1611 / 1612 / 1613]

Solution

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

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

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

Remove the jammed paper, and press the Resume/Cancel button.

Open the paper output tray.

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

Remarks

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

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].

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

6 times	Inner cover open. [1841]*2
	Inner cover open (during printing on paper).
	[1846]*2
	CD-R tray guide closed (during CD-R printing).
	[1850 / 1855]*1
	CD-R tray guide open (during printing to paper).
	[1851 / 1856]*1
7 times*1	No CD-R or DVD-R. [1002]
8 times	Warning: The waste ink absorber becomes
	almost full (approx. 95% of the maximum
	capacity). [1700]

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

Open the CD-R tray guide, set the CD-R tray properly, and press the Resume/Cancel button.

Close the CD-R tray guide, and press the Resume/Cancel button.

After setting a CD-R or DVD-R in the tray, set the tray in the tray guide, and press the Resume/Cancel button.

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

In repair servicing, replace the bottom case unit (QM2-1205), or the ink absorbers (QC1-4222 / 4223 / 4224 / 4263 / 4264 / 4864 / 4221 / 4257).

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	After removing the cable between the camera and the printer,
	camera does not support Camera Direct Printing. press the Resume/Cancel button, and re-connect the cable.
	[2001]
10 times	Automatic duplex printing cannot be performed	Press the Resume/Cancel button to eject the paper being used
	(paper size not supported). [1310]	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, 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).
		- Protect the paper output slot from exposure to excessive
		light.
	Access cover open. [1200]	Close the access cover.
*1: Only for models supporting CD-R printing
*2: Only for models not supporting CD-R printing

1 - 4

2-2. Service Call Errors (by LED Blinking in Orange and Green Alternately, or Lit in Orange)

	LED alternate blinking	Error [Error code]
	in orange and green	Error [Error code]
	in orange and green
	2 times	Carriage error [5100]

Solution

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

-Carriage unit (QM2-1209)

-Timing slit strip film (QC1-4284)

-Logic board ass'y (QM2-1548)*1

-Carriage motor (QK1-0545)

3 times	Paper feed error [6000]	- Timing sensor unit (QM2-1213)
		- Timing slit disk film (QC1-4833)
		- Feed roller ass'y (QL2-0598)
		- Platen unit (QM2-1215)
		- Logic board ass'y (QM2-1548)*1
		- PAPER FEED MOTOR (QK1-0550)
4 times	Purge unit error [5C00]	- Purge unit (QM2-1210)
		- Logic board ass'y (QM2-1548)*1
5 times	ASF (cam) sensor error [5700]	- Sheet feed unit (QM2-1220)
6 times	Internal temperature error [5400]	- Logic board ass'y (QM2-1548)*1
7 times	Waste ink absorber full [5B00]	- Ink absorber (QC1-4222 / 4223 / 4224 / 4263 / 4264 / 4864 / 4221 / 4257)
		- Bottom case unit (QM2-1205)*2
8 times	Print head temperature rise error [5200]	- Print head (QY6-0049)
		- Logic board ass'y (QM2-1548)*1
9 times	EEPROM error [6800]	- Logic board ass'y (QM2-1548)*1
11 times	Carriage lift mechanism error [5110]	- Lift shaft(QC1-4331)
		- Photo interrupter (WG8-5624)
		- Sheet feed unit (QM2-1220)
		- Logic board ass'y (QM2-1548)*1
12 times	AP position error [6A00]	- Sheet feed unit (QM2-1220)
		- Logic board ass'y (QM2-1548)*1
13 times	Paper feed position error [6B00]	- Sheet feed unit (QM2-1220)
		- Logic board ass'y (QM2-1548)*1
14 times	Paper feed cam sensor error [6B10]	- Sheet feed unit (QM2-1220)
		- Logic board ass'y (QM2-1548)*1
15 times	USB Host VBUS overcurrent [9000]	- Logic board ass'y (QM2-1548)*1
16 times	Valve sensor error [6C00]	- Logic board ass'y (QM2-1548)*1
17 times	Motor driver error [6D00]	- Logic board ass'y (QM2-1548)*1
20 times	Other hardware error [6500]	- Logic board ass'y (QM2-1548)*1
Continuous alternate	ROM error	- Logic board ass'y (QM2-1548)*1
blinking
Lights in orange	RAM error	- Logic board ass'y (QM2-1548)*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 (QM2-1205) or the ink absorbers (QC1-4222 / 4223 / 4224 / 4263 / 4264 / 4864 / 4221 / 4257) when replacing the logic board ass'y.

[See Section 3-3. Adjustment / Settings, (6) Service mode, for details.]

*2: Reset the waste ink counter when replacing the bottom case unit.

[See Section 3-3. Adjustment / Settings, (6) Service mode, for details.]

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