Canon PIXMA iP4200 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,

Destination settings

-4. Verification Items

(1) Service test print

(2) EEPROM information print

4. PRINTER TRANSPORTATION

EEPROM initialization, Waste ink counter reset

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

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

Replacement Consumables by Service Engineer

(1) Adjustment

Adjustment Timing Purpose Tool

Destination settings (EEPROM settings)

Waste ink counter resetting (EEPROM settings)

At logic board replacement To set the destination.

- At logic board replacement

- At waste ink absorber replacement

To reset the waste ink counter.

None. Perform in the

service mode.

None. Perform in the

service mode.

Approx.

time

1 min.

Paper feed motor position

adjustment

CD / DVD detection sensor light volume

correction

Grease application

Ink system function check

At paper feed motor replacement

- At logic board replacement

- At carriage unit replacement

- At PR shaft ass'y replacement

- At CL base / gear replacement

- At logic board replacement

- At platen unit replacement

- At carriage unit replacement

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

that the belt is stretched tight.)

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

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

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

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

None.

None. Perform in the

service mode.

FLOIL KG-107A 1 min.

None. Perform in the

service mode.

5 min.

2 min.

1 min.

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

1-2

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

Print head alignment

Print head cleaning

Print head deep cleaning

At print head replacement.

When print quality is not satisfying.

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

To ensure accurate dot placement.

To improve nozzle conditions. - Printer buttons

To improve nozzle conditions. Computer (settings

- Printer buttons

- Computer (automatic settings via the printer

driver)

- Computer (settings via the printer driver)

via the printer driver)

Approx.

time

3 min.

1 min.

2 min.

Ink tank replacement

Paper feed roller cleaning

CD / DVD print position

adjustment

Bottom plate cleaning

ASF sub- roller cleaning

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

When necessary To clean the paper feed

At CD / DVD printing, when necessary

When the back side of the paper is smeared

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

attached to the ASF sub-rollers.

rollers.

To correct CD / DVD print position.

To clean the platen ribs.

To clean the ASF sub-rollers.

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Printer buttons 2 min.

Computer (application software)

- Plain paper

- Computer (settings via the printer

driver)

2 min.

5 min.

1 min.

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- Plain paper

- Printer buttons

[See Part 2, 4. FAQ,

How to make and set the ASF subroller cleaning

sheet, for details]

1 min.

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1-3. Product Life

1-3

(1) Printer

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

(II) Years of use

(2) Print head

PIXMA iP4200: 18,000 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

PIXMA iP4200: 5 years of use

Print volume: 18,000 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

(3) Ink tank (target value)

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Pattern Ink tank used Print yield

Black text

Color chart

PGI-5BK Approx. 820 pages

CLI-8BK

CLI-8BK Approx. 2,000 pages

PGI-5BK Approx. 1,450 pages

CLI-8Y Approx. 540 pages

Photo chart

CLI-8M Approx. 600 pages

CLI-8C Approx. 850 pages

CLI-8BK Approx. 1,650 pages

CLI-8Y Approx. 310 pages

CLI-8M Approx. 290 pages

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1-4

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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.

CLI-8C Approx. 430 pages

1-4. Special Tools

Grease FLOIL KG-107A

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).

Name Tool No. Price Application Remarks

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.

To the top

2. LIST OF ERROR DISPLAY / INDICATION

1-5

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

2 times

Error [Error code]

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

No CD / DVD tray. [1001]

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

cassette.)

No CD / DVD. [1002]

Resume/Cancel button.

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

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

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.

Solution Remarks

3 times

4 times No ink. [1600] Replace the empty ink tank(s), or press the

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

Resume/Cancel button.

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

Paper jam in the under guide. [1304]

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

Resume/Cancel button.

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.

Error in paper feeding from the ASF.

printing unit.

Error in paper feeding from the cassette.

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

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

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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.

6 times

1-6

Inner cover open. [1841]

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

7 times

Inner cover open during printing on paper. [1846]

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

[1851]

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

[1856]

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

[1850]

Inner cover closed during CD / DVD printing (print NOT

continuable). [1855]

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

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

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.

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.

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.

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

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Ink tank in a wrong position. [1680]

8 times Warning: The waste ink absorber

becomes almost full. [1700]

9 times The connected digital camera or

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

10 times Automatic duplex printing cannot

be performed. [1310]

11 times

Failed in automatic print head alignment. [2500]

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

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

Remove the cable between the camera and the printer.

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.

Press the Resume/Cancel button.

- If paper is being fed at error occurrence,

- If the error occurs, the print head

- After exit from the error by the

the error is indicated after the paper is ejected.

alignment values are not changed.

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

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

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

Resume/Cancel button, the automatic print

1-7

head alignment will not be re-done.

is incorrect.

13 times

14 times

15 times

The remaining ink amount unknown. [1683]

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

Ink tank not recognized. [1410 to 1419]

Access cover open. [1200]

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

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

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

Close the access cover.

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.

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*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)

Cycles of

blinking in

orange (Alram

LED) and green

(Power LED)

2 times

3 times

Error [Error code]

Carriage error [5100]

Line feed error [6000]

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

- Carriage unit (QM2-2207)

- Timing slit strip film (QC1-6394)

- Logic board ass'y (QM2-2670)

- Carriage motor (QK1-1500)

- 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)

Solution

4 times

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

- Logic board ass'y (QM2-2670)

1-8

5 times

6 times Internal temperature error

7 times

8 times

9 times EEPROM error [6800]

11 times

12 times

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

[5400]

Waste ink absorber full [5B00]

Print head temperature rise error [5200]

Carriage lift mechanism error [5110]

AP position error [6A00]

- Logic board ass'y (QM2-2670)

- Ink absorber kit (QY5-0146)

- Print head (QY6-0059)

- Logic board ass'y (QM2-2670)

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

- Sheet feed unit (QM2-2211)

- Logic board ass'y (QM2-2670)

- Carriage lift sensor unit (QM2-2678)

- Sheet feed unit (QM2-2211)

- Logic board ass'y (QM2-2670)

- Purge unit (QM2-2208)

13 times

14 times

15 times

16 times Valve sensor error [6C00]

17 times

19 times Ink tank position sensor error

20 times

Continuous alternate blinking

Alarm LED lit RAM error

Paper feed position error [6B00]

Paper feed cam sensor error [6B10]

USB Host VBUS overcurrent [9000]

Motor driver error [6D00]

[6502]

Other hardware error [6500]

ROM error

- Sheet feed unit (QM2-2211)

- Logic board ass'y (QM2-2670)

- Sheet feed unit (QM2-2211)

- Logic board ass'y (QM2-2670)

- Purge unit (QM2-2208)

- Logic board ass'y (QM2-2670)

- Platen unit (QM2-2202)

- Logic board ass'y (QM2-2670)

*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.]

2-3. Warnings

1-9

Printer (no LED indications):

Displayed warning Remarks

Low ink

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

Protection of excess rise of the print head temperature

*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

Symptom Solution Remarks

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

after power-on.

Status indication only.

the warning is displayed

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,

Replace the

- AC adapter, or

- logic board ass'y*1.

Faulty operation

Paper feed

problems

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

removed part if any.

Printing stops mid-way.

Multiple sheets feed.

Paper does not feed. Remove foreign material, or replace

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

Replace the logic board ass'y*1.

Replace the

- sheet feed unit, or

- cassette.

the

- sheet feed unit, or

- cassette.

paper guide, or replace the

- sheet feed unit, or

- cassette.

No printing, or no color ejected. Replace the

- ink tank,

- print head*2, or

1-10

- logic board ass'y*1,

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

replace the purge unit.

Unsatisfactory

print quality

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.

Paper gets smeared.

A part of a line is missing on printouts.

Color hue is incorrect.

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

- ink tank,

- print head*2,

- purge unit, or

- logic board ass'y*1.

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

or cloth, or

clean the ASF sub-rollers.

Replace the

- ink tank, or

- print head*2.

Replace the

- ink tank, or

- print head*2, or

perform print head alignment.

Printing is incorrect.

No ejection of black ink.

Graphic or text is enlarged on printouts.

Replace the logic board ass'y*1.

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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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: Before replacement of the logic board ass'y, check the waste ink amount (by service test print or EEPROM

1-11

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

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

persists.

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

To the top

3. REPAIR

1-12

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

Service part

Logic board ass'y QM2-2670

Ink absorber kit QY5-0146

Carriage unit QM2-2207

Paper feed motor QK1-1502

Platen unit: QM22202

Notes on replacement

- 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.]

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

By attaching the tape at the

specified 2 locations,

Adjustment / settings Operation check

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.

After replacement:

1. Reset the waste ink counter.

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

At replacement:

1. Apply grease to the sliding portions.

[See 3 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.

At replacement:

1. Adjust the paper feed

[See 3 Settings, (1) Paper feed motor adjustment.]

At replacement:

-3. Adjustment /

motor.

-3. Adjustment /

- EEPROM information print

- Service test print

- Printing via USB connection

- Direct printing from a digital camera

- Service test print

- EEPROM information print

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

system function.)

After the printer unit is assembled in the bottom

Purge unit: QM2-

1-13

2208 Waste ink tube: QC1-

6458 Waste ink tube

holder: QC1-6460

Platen unit QM2-2202

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

QC1-6213

Timing slit strip film QC1-6394

Timing slit disk film

QC1-6229

secure the waste ink tube to

the waste ink tube holder.

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- 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

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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After replacement

1. Check the ink system function.

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

At replacement:

1. Apply grease to the sliding portions.

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

After replacement:

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

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.

- Service test print

Print head QY6-0059

*1: General notes:

- Make sure that the flexible cables and wires in the harness are in the proper position and connected correctly.

-2. Special Notes on Repair Servicing, (2) Flexible cable and harness wiring, connection, for details.]

[See 3

- 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.

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

[See 3

- 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.

After replacement:

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

- Service test print

- 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).

+ 39 hidden pages