Canon Pixma IP4000 printer service and repair manual

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. Copyright 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. Copyright © 2004 by Canon Inc. CANON INC. 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 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. Adjustment Timing Purpose Tool Approx. time EEPROM initialization (EEPROM settings) At logic board ass'y replacement To initialize settings other than the following: - USB serial number - Destination setting - Waste ink counter - CD-R correction value None. 1 min. Destination settings (EEPROM settings) At logic board ass'y replacement To set the destination. None. 1 min. Waste ink counter resetting (EEPROM settings) - At bottom case unit replacement - At ink absorber (QC1-4221 / 4222 / 4223 / 4224 / 4263 / 4264 / 4864 / 4257) replacement To reset the waste ink counter. None. 1 min. CD-R sensor / automatic print head alignment sensor correction (EEPROM settings) - At logic board ass'y replacement - At carriage unit replacement To correct the CD-R and automatic print head alignment sensor. None. (Correction performed through service test print) 2 min. Print head alignment - At print head replacement - At logic board ass'y replacement - At carriage unit replacement To ensure accurate dot placement. - None. (printer buttons) - Computer (settings via the printer driver) 2 min. Paper feed motor position adjustment *1 At paper feed motor unit replacement To adjust the belt tension. (Position the paper feed motor so that the belt is stretched tight.) None. 2 min. Grease application - At carriage unit replacement - At chassis' upper gear replacement - At shaft lift (QC1-4331) replacement - To maintain sliding properties of the carriage, carriage shaft, and shaft lift. - To protect the chassis' upper gear. - FLOIL KG-107A (QY9- 0057) - MOLYKOTE HP300 (QY9-0035) 1 min. 1 - 1

1-2. Customer Maintenance 1-3. Product Life (1) Printer Specified print volume (I) or the years of use (II), whichever comes first. (I) Print volume (II) Years of use PIXMA iP4000: 5 years of use (2) Print head Print volume: 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) ----- ----- 2 min. Paper feed roller cleaning When paper does not feed properly. To clean the paper feed rollers. Printer buttons 2 min. CD-R print position adjustment At CD-R printing, when necessary To correct CD-R print position. Computer (application software) 5 min. Bottom plate cleaning When the back side of the paper is smeared To clean the platen ribs. Computer (application software) 1 min. 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 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 1 - 2

(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 1-5. Serial Number Location On the carriage flexible cable holder (visible when the access cover is open). To the top Name Tool No. Application Remarks MOLYKOTE HP300 QY9-0035-000 To be applied to the chassis' upper gear, and to the sliding portion of the shaft lift. In common with other models. FLOIL KG-107A QY9-0057-000 To be applied to the sliding portion of the carriage, and the carriage shaft. In common with other models. <Part 1: 1. MAINTENANCE> 1 - 3

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) *1: Only for models supporting CD-R printing *2: Only for models not supporting CD-R printing 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-R tray. [1001] *1 Set the CD-R 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. 3 times Paper jam. [1300] Remove the jammed paper, and press the Resume/Cancel button. Paper jam in the under guide. [1304] Paper jam in the rear guide. [1303] Front door closed. [1250] Open the paper output tray. 4 times No ink. [1601 / 1602 / 1611 / 1612 / 1613] 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. 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 Close the inner cover, and press the Resume/Cancel button. Inner cover open (during printing on paper). [1846] *2 Close the inner cover, and press the Resume/Cancel button. CD-R tray guide closed (during CD-R printing). [1850 / 1855] *1 Open the CD-R tray guide, set the CD-R tray properly, and press the Resume/Cancel button. CD-R tray guide open (during printing to paper). [1851 / 1856] *1 Close the CD-R tray guide, and press the Resume/Cancel button. 7 times *1 No CD-R or DVD-R. [1002] After setting a CD-R or DVD-R in the tray, set the tray in the tray guide, and press the Resume/Cancel button. 8 times Warning: The waste ink absorber becomes almost full (approx. 95% of the maximum capacity). [1700] 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 camera does not support Camera Direct Printing. [2001] After removing the cable between the camera and the printer, press the Resume/Cancel button, and re-connect the cable. 10 times Automatic duplex printing cannot be performed (paper size not supported). [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, 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 - 4

2-2. Service Call Errors (by LED Blinking in Orange and Green Alternately, or Lit in Orange) *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.] LED alternate blinking in orange and green Error [Error code] Solution (Replacement of listed parts, which are likely to be faulty) 2 times Carriage error [5100] - 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 blinking ROM error - Logic board ass'y (QM2-1548) *1 Lights in orange RAM error - Logic board ass'y (QM2-1548) *1 1 - 5

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Canon Pixma IP4000 printer service and repair manual

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