Canon PIXMA iP4200 Service Manual

Name: Canon PIXMA iP4200
Brand: Canon
SKU: 195963
Rating: 4 (1 reviews)

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PIXMA iP4200

SERVICE MANUAL

Revision 0

QY8-13A9-000

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.

Inkjet Device Quality Assurance Div. 2

451, Tsukagoshi 3-chome, Saiwai-ku, Kawasaki-shi, Kanagawa 212-8530, Japan

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

New 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

1-1. 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)Grease application

(3)Waste ink counter setting

(4)User mode

(5)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. PRINT MODE

4. 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)

PIXMA iP4200 Specifications

Part 1

MAINTENANCE

1. MAINTENANCE

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

(1) Adjustment

Adjustment	Timing
Destination	At logic board replacement
settings
(EEPROM
settings)

Waste ink	- At logic board replacement
counter	- At waste ink absorber
resetting	replacement
(EEPROM
settings)

Paper feed	At paper feed motor
motor position	replacement
adjustment

CD / DVD	- At logic board replacement
detection sensor	- At carriage unit replacement
light volume
correction*1

Grease	- At carriage unit replacement
application	- At PR shaft ass'y replacement
	- At CL base / gear replacement

Ink system	- At logic board replacement
function check	- At platen unit replacement
	- At carriage unit replacement

Purpose

Tool

To set the destination.

To reset the waste ink counter.

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.

Perform in the service mode.

None.

Perform in the service mode.

None.

Perform in the service mode.

FLOIL KG-107A

None.

Perform in the service mode.

Approx.

time

1 min.

5 min.

2 min.

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.

(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.
Adjustment	Timing	Purpose	Tool	time
				time
Print head	At print head replacement.	To ensure accurate dot	- Printer buttons	3 min.
alignment		placement.	- Computer
			(automatic settings
			via the printer
			driver)
Print head	When print quality is not	To improve nozzle conditions.	- Printer buttons	1 min.
cleaning	satisfying.		- Computer (settings
			via the printer
			driver)

Print head deep	When print quality is not	To improve nozzle conditions.
cleaning	satisfying, and not improved by
	print head cleaning.
Ink tank	When an ink tank becomes	-----
replacement	empty. ("No ink error" via the
	computer, or ink tank LED
	flashing fast in red)
Paper feed roller	When necessary	To clean the paper feed
cleaning		rollers.
CD / DVD print	At CD / DVD printing, when	To correct CD / DVD print
position	necessary	position.
adjustment
Bottom plate	When the back side of the paper	To clean the platen ribs.
cleaning	is smeared

Computer (settings	2 min.
via the printer driver)
-----	2 min.
Printer buttons	2 min.

Computer (application 5 min. software)

- Plain paper

1 min.

-Computer (settings via the printer

driver)

ASF subroller	When the paper fed from the	To clean the ASF sub-rollers. - Plain paper	1 min.
cleaning	ASF is smeared due to ink mist	- Printer buttons
	attached to the ASF sub-rollers.	[See Part 2, 4. FAQ,
		How to make and
		set the ASF sub-
		roller cleaning
		sheet, for details]

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
		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
	(II) Years of use
		PIXMA iP4200: 5 years of use
(2)	Print head
		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)

Pattern

Black text

Color chart

Photo chart

Ink tank used	Print yield
PGI-5BK	Approx. 820 pages
CLI-8BK
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
CLI-8BK	Approx. 1,650 pages
CLI-8Y	Approx. 310 pages
CLI-8M	Approx. 290 pages

1-3

CLI-8C

Approx. 430 pages

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.

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

Name	Tool No.	Price	Application	Remarks
Grease FLOIL	QY9-0057-000	US$2.00	To be applied to the sliding portions	In
KG-107A			of the carriage shaft and lift cam	common
			shaft.	with the
				S500
				and
				S520.

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

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

2 times

Error [Error code]

No paper. (ASF) [1000]

No CD / DVD tray. [1001]*1

No paper in the cassette. [1003]

(No paper in the front paper feed cassette.)

No CD / DVD. [1002]*1

Solution

Remarks

Set the paper in the ASF, and press the

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.

3 times

4 times

5 times

Paper jam. [1300]

Paper jam in the rear guide. [1303]

Paper jam in the under guide. [1304]

Front door close error. [1250]

No ink. [1600]

Ink tank not installed. [1660]

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.

Install the applicable ink tank(s) properly, and confirm that the LED's of all the ink tanks light red.

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

Error in paper feeding from the ASF.

Error in the duplex printing unit.

Error in paper feeding from the cassette.

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.

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

6 times

Inner cover open. [1841]*2

Inner cover open during printing on paper. [1846]*2

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

[1851]*1

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

[1856]*1

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

[1850]*1

Inner cover closed during CD / DVD printing (print NOT

continuable). [1855]*1

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

	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]

Close the inner cover, and press the

Resume/Cancel button.

Close the inner cover, and press the

Resume/Cancel button.

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).

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

Pressing the Resume/Cancel button will	The service call
exit the error, and enable printing.	error, indicating
	the waste ink
	absorber is full, is
	likely to occur
	soon.

Remove the cable between the camera and the printer.

10 times

11 times

Automatic duplex printing cannot be performed. [1310]

Failed in automatic print head alignment. [2500]

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, 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

1-6

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	is incorrect.
		head alignment will not be re-done.
13 times	The remaining ink amount	An ink tank which has once been empty is	Printing with a
	unknown. [1683]	installed. Replace the applicable ink tank	once-empty or
		with a new one.	refilled ink tank
			can damage the
			print head.
			If printing is
			continued without
			replacing the "no-
			good" 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.

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).

Access cover open. [1200] Close the access cover. *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 Error [Error code] LED) and green

(Power LED)

2 times

Carriage error [5100]

Solution

(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)*1

-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)*1
		- PAPER FEED MOTOR (QK1-1502)
4 times	Purge cam sensor error [5C00]	- Purge unit (QM2-2208)
		1-7

		- Logic board ass'y (QM2-2670)*1
5 times	ASF (cam) sensor error [5700]	- Sheet feed unit (QM2-2211)
6 times	Internal temperature error	- Logic board ass'y (QM2-2670)*1
	[5400]
7 times	Waste ink absorber full	- Ink absorber kit (QY5-0146)
	[5B00]
8 times	Print head temperature rise	- Print head (QY6-0059)
	error [5200]	- Logic board ass'y (QM2-2670)*1
9 times	EEPROM error [6800]	- Logic board ass'y (QM2-2670)*1
11 times	Carriage lift mechanism error	- PR lift shaft ass'y (QL2-0936)
	[5110]	- Sheet feed unit (QM2-2211)
		- Logic board ass'y (QM2-2670)*1
		- Carriage lift sensor unit (QM2-2678)

12 times	AP position error [6A00]
13 times	Paper feed position error
	[6B00]
14 times	Paper feed cam sensor error
	[6B10]
15 times	USB Host VBUS overcurrent
	[9000]

-Sheet feed unit (QM2-2211)

-Logic board ass'y (QM2-2670)*1

-Purge unit (QM2-2208)

-Sheet feed unit (QM2-2211)

-Logic board ass'y (QM2-2670)*1

-Sheet feed unit (QM2-2211)

-Logic board ass'y (QM2-2670)*1

16 times	Valve sensor error [6C00]	- Logic board ass'y (QM2-2670)*1
		- Purge unit (QM2-2208)
17 times	Motor driver error [6D00]	- Logic board ass'y (QM2-2670)*1
19 times	Ink tank position sensor error	- Platen unit (QM2-2202)
	[6502]	- Logic board ass'y (QM2-2670)*1
20 times	Other hardware error [6500]	- Logic board ass'y (QM2-2670)*1
Continuous	ROM error	- Logic board ass'y (QM2-2670)*1
alternate
blinking
Alarm LED lit	RAM error	- Logic board ass'y (QM2-2670)*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 ink absorber kit (QY5-0146) when replacing the logic board ass'y.

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

1-8

2-3. Warnings

Printer (no LED indications):

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*1.
	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,

*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

The power does not turn on.

The power turns off immediately after power-on.

Faulty operation A strange noise occurs.

Printing stops mid-way.

Multiple sheets feed.

Paper does not feed.

Paper feed problems

Paper feeds at an angle.

No printing, or no color ejected.

Solution	Remarks
Replace the
- AC adapter, or
- logic board ass'y*1.

Remove foreign material, or attach a removed part if any.

Replace the logic board ass'y*1.

Replace the

-sheet feed unit, or

-cassette.

Remove foreign material, or replace the

-sheet feed unit, or

-cassette.

Remove foreign material, adjust the paper guide, or replace the

-sheet feed unit, or

-cassette.

Replace the

- ink tank,

1-9

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.

Printing is incorrect.

No ejection of black ink.

Graphic or text is enlarged on printouts.

-print head*2, or

-logic board ass'y*1,

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

replace the purge unit.

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.

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.

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

[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

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*1

-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.]

Adjustment / settings

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.]

-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,

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.

At replacement:

1. Adjust the paper feed motor.

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

At replacement:

1-12

Operation check

-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: QM22208

Waste ink tube: QC16458

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

Print head

QY6-0059

*1: General notes:

secure the waste ink tube to the waste ink tube holder.

-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.]

After replacement:

1.Check the ink system function.

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

At replacement:

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

1.Apply grease to the sliding portions.

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

After replacement: - Service test print

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

After replacement:

- Service test print

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

-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 positioning (they are not adjustable in servicing).

1-13

+ 39 hidden pages