PIXMA iP4200 SERVICE MANUAL Revision 0 QY8-13A9-000 COPYRIGHT©2005 CANON INC. CANON PIXMA iP4200 072005 XX 0.00-0 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.
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.
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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.
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. 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.
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.
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.
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.
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 3 times 4 times 5 times Solution Error [Error code] No paper. (ASF) [1000] Set the paper in the ASF, and press the Resume/Cancel button. No CD / DVD tray. [1001]*1 Set the CD / DVD tray, and press the Resume/Cancel button. No paper in the cassette.
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. Inner cover open during printing on paper (print continuable). [1851]*1 Close the inner cover, and press the Resume/Cancel button. Inner cover open during printing Close the inner cover, and press the on paper (print NOT continuable). Resume/Cancel button to clear the error.
Resume/Cancel button, the automatic print head alignment will not be re-done. is incorrect. 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. 13 times The remaining ink amount unknown.
- Logic board ass'y (QM2-2670)*1 5 times ASF (cam) sensor error [5700] - Sheet feed unit (QM2-2211) 6 times Internal temperature error [5400] Waste ink absorber full [5B00] - Logic board ass'y (QM2-2670)*1 8 times Print head temperature rise error [5200] - Print head (QY6-0059) - 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 [5110] - PR lift shaft ass'y (QL2-0936) - Sheet feed unit (QM2-2211) - Logic board ass'
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.
- 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 Remove and re-install the print head, appear on printouts even after print or replace the head cleaning. - ink tank, Line(s) not included in the print - print head*2, data appears on printouts. - purge unit, or - logic board ass'y*1. Paper gets smeared.
*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
3. REPAIR 3-1. Notes on Service Part Replacement (and Disassembling / Reassembling) Notes on replacement*1 Adjustment / settings - 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).
Purge unit: QM2secure the waste ink tube to 2208 the waste ink tube holder. Waste ink tube: QC16458 Waste ink tube holder: QC1-6460 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.] case unit, the tube conditions are not visible.
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3-2. Special Notes on Repair Servicing (1) External cover removal (I) Release the 2 hooks on the rear side of the printer (indicated by the blue circles). (II) Release the hooks on the left and right side of the main case (indicated by the blue circle). (III) While inserting the flat-blade screwdriver in the slots on the left and right sides of the printer front shown in the figures below, release the hooks to remove the main case from the bottom case.
(2) Flexible cable and harness wiring, connection Be careful of wiring of the flexible cables and harness. Improper wiring or connection may cause breakage of a line, leading to ignition or emission of smoke.
(II) Paper feed motor side wiring (3) Printer unit and bottom case unit assembly In assembling the printer unit chassis into the bottom case unit, be cautious of the following points to protect the waste ink tube from being pinched: (I) At replacement of the platen unit (QM2-2202), purge unit (QM2-2208), waste ink tube (QC1-6458), or waste ink tube holder (QC1-6460), fix the waste ink tube to the printer chassis and waste ink tube holder with tape (at 2 locations).
(II) After securing the waste ink tube with tape, be careful not to damage the tube in installing the printer unit chassis in the bottom case unit. With the units assembled, the tube conditions are not visible. To confirm the tube is free from damage, perform the manual purging 3 or 4 times, and confirm that no strange noise is heard. [Example: The tube is pinched and blocked as it is not fixed with tape.] To the top
3-3. Adjustment / Settings (1) Paper feed motor adjustment Perform the following adjustments when the paper feed motor unit is replaced: 1) When attaching the motor, fasten the screws so that the belt is properly stretched (in the direction indicated by the blue arrow in the figure below). 2) After replacement, be sure to perform the service test print, and confirm that no strange noise or faulty print operation (due to dislocation of the belt or gear, or out-of-phase motor, etc.) occurs.
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2) CL base / CL gear 3) PR shaft / LF roller bushing To the top
(3) Waste ink counter setting When the logic board ass'y is replaced, reset the waste ink counter. In addition, according to the waste ink amount, replace the waste ink absorber (ink absorber kit). The standard amount for waste ink absorber replacement is given in the table below. Waste ink amount*1 Ink absorber kit replacement Less than 7% Not required. 7% or more Required. *1: Check the waste ink amount by service test print or EEPROM information print. [See 3.3.
setting). 3 times Paper feed roller cleaning 4 times Automatic print head alignment Set a sheet of plain paper (A4 or letter) in the ASF. 5 times Bottom plate cleaning Fold a sheet of plain paper (A4 or letter) in half crosswise, then unfold and set it in the ASF with the folded ridge facing down.
according to the function listed in the table below. (Each time the Resume/Cancel button is pressed, the Alarm and Power LEDs light alternately, Alarm in orange and Power in green, starting with Alarm LED.) Time(s) LED indication 0 times Green (Power) Power off When the print head is not installed, the carriage returns and locks in the home position capped. 1 time Orange (Alarm) Service test print See 3-4. Verification Items, (1) Service test print.
6 times Green (Power) 7 times Orange (Alarm) China Supported 8 times Green (Power) Supported 9 times Orange (Alarm) Return to the menu selection Asia Supported Taiwan Note: After setting the destination, confirm the model name and destination in service test print or EEPROM information print. [See 3.4. Verification Items, (1) Service test print, or (2) EEPROM information print.] To the top
3-4. Verification Items (1) Service test print On the service test print (sample below), confirm the EEPROM information as shown below. (The information is given in the upper portion of the printout.) iP4200: Model name JPN: Destination Vx.xx: ROM version USB (xxxxxx): USB serial number FA = xx xx xx: Reserved for plant use D = xxx.x: Waste ink amount (%) CDR (+xxxxx, +yyyyy): CD / DVD sensor position correction value AB (K = OK Y = ...
(2) EEPROM information print Print sample: iP4200 JPN V1.04 IF(USB2=1) D=004.
WP=0024 CDIN(LG=001 PB=000) MSD(015) PAGE(All=00083 PP=00035 HR+MP=00003 PR+SP+SG =00000 GP =00000 PC=00000 EV=00000) UCPAGE(All=00083 PP=00035 HR+MP=00003 PR+SP+SG =00000 GP =00000 PC=00000 EV=00000) BPPAGE(All=00083 BSSP=00003 PC=00000) CDPAGE(All=000) EDGE=00083 L=00000 CDR=00000 CDRP=(-00005,-00029) CDRS=(000) LM=(ASF_R:00 UT_F:00 UT_R:00) Head TempBK=18.5 Head TempC=17.5 Env Temp=30.
4. PRINTER TRANSPORTATION This section describes the procedures for transporting the printer for returning after repair, etc. 1) In the service mode, press the Power button to finish the mode, and confirm that the paper lifting plate of the sheet feeder unit is raised. 2) Keep the print head and ink tanks installed in the carriage. [See Caution 1 below.] 3) Turn off the printer to securely lock the carriage in the home position. (When the printer is turned off, the carriage is automatically locked in place.
Part 2 TECHNICAL REFERENCE
1. NEW TECHNOLOGIES (1) New ink tank system (PGI-5, CLI-8) An LED is installed in each ink tank. By the LED indication, wrong installation of the ink tanks will be prevented, and the remaining ink level can be visually recognized with the ink tanks seated in the carriage.
2. CLEANING MODE AND AMOUNT OF INK PURGED To prevent printing problems due to bubbles, dust, or ink clogging, print head cleaning is performed before the start of printing (when the cleaning flag is on), except in the following cases: - Cleaning on arrival: Performed when the access cover is closed. - Manual cleaning / deep cleaning: Performed manually. Black: Pigment-based black Color: Dye-based black, cyan, magenta, yellow Condition On arrival of the printer Amount of ink used Est.
If 2,160 to 4,320 hours have elapsed since 1.58 (Black) the previous Black/Color cleaning till the 1.00 (Color) start of the next printing. 80 If 4,320 to 8,640 hours have elapsed since 1.58 (Black) the previous Black/Color cleaning till the 1.00 (Color) start of the next printing. 80 80 (All in sequence) If 8,640 or longer hours have elapsed since the previous Black/Color cleaning till the start of the next printing. At print head replacement When the print head is removed and installed.
3. PRINT MODE 3-1.
(3) Borderless printing (4) Duplex printing (5) Camera Direct printing To the top
4. FAQ (Problems Specific to the iP4200 and Corrective Actions) No. * Function Phenomenon Skewed paper feeding 1 2 3 B Print results B Paper feed C Print results Condition Cause - Paper feeding from the cassette, Photo Paper Plus Double Sided, 5 x 7 size Due to its mechanism, contact of the PF pinch rollers to the 5 x 7 size paper is uneven, which is likely to cause skewed paper feeding. Corrective action Possible call or complaint Change the paper - Paper feeds at feeding method an angle.
4 A as A4) is printed. - With Photo Paper Plus Double Sided or postcards, the phenomenon is likely to be noticeable and to be complained of by users, as printing is performed on both sides of such paper. Print results Soiling on paper - Automatic duplex in automatic printing (Photo duplex printing Paper Plus Double (lines or streaks Sided, postcards, perpendicular to plain paper) the paper feed direction) 5 B paper is absorbed 2. If soiling on the by the platen's ink paper still absorber.
the auto sheet feeder, manually print each side of paper. 6 C Print results - PP-101D, PP-101, PR-101, SG-101, etc. - Paper feeding from the ASF - Multiple number of sheets loaded Soiling on paper The printer has been used for a long period of time with the ASF cover closed before printing is performed using the ASF.
*3: How to prepare and set the ASF sub-roller cleaning sheet: 1) Fold a sheet of plain paper lengthwise in half.
2) Fold the paper at approx. 60 mm from the end, and fold the folded end in half backward, as shown below. 3) Moisten the folded end portion (indicated by the blue circle in the figure below) using a wipe, and set the paper in the ASF so that the moistened edge of the paper contacts the 2 sub-rollers. Then, fold the other end of the paper along the ASF cover edge to hook the paper to the ASF cover, as shown below.
* Occurrence level: A: The symptom is likely to occur frequently. (Caution required) B: The symptom may occur under certain conditions, but likeliness is assumed very low in practical usage. C: The symptom is unlikely to be recognized by the user, and no practical issues are assumed. To the top
Part 3 APPENDIX
1. BLOCK DIAGRAM 1-1. PIXMA iP4200 To the top
2. CONNECTOR LOCATION AND PIN LAYOUT 2-1. Logic Board Ass'y CN101 Not used CN201 (Print head 1/2 [Carriage unit]) No.
21 H_EEPROM_SK Head EEPROM serial clock signal OUT 22 H_D10 Head data (SM2) OUT 23 LOGIC_GND Logic GND 24 H_CLK Head data transfer clock signal OUT 25 H_EEPROM_DIO Head EEPROM data signal OUT 26 H_D12 Head data (SC2) OUT 27 H_D6 Head data (PBK1) OUT 28 LOGIC_GND Logic GND 29 CR_ENCB CR encoder phase B 30 LOGIC_GND Logic GND 31 CR_ENCA CR encoder phase A 32 LOGIC GND Logic GND 33 DIA1 Diode sensor anode 1 34 LOGIC GND Logic GND 35 H_D7 Head data (PBK2) OUT
CN301 (AC adapter) No. Signal name Function 1 VH2 Head power supply 2 H2_GND Head GND 3 VH1 Head power supply 4 H1_GND Head GND 5 VM Motor power supply 6 M_GND Motor GND 7 PW_CONT Power supply control signal Input / Output IN IN IN OUT CN302 (USB I/F) No. Signal name Function Input / Output 1 SNS_USB USB: VBUS power supply sense IN 2 D- USB: D- signal BUS 3 D+ USB: D+ signal BUS 4 GND GND - 5 to 9 GND GND - CN303 (DSC harness) No.
8 GND GND - 9 PF_ENCA PF encoder phase A 10 VSEN_3.3V Power supply for sensor 3.3V 11 PF_ENCB PF encoder phase B IN OUT IN CN403 (Operation panel ass'y) No.
CN501 (Motor multi harness) No. Signal name Function Input / Output 1 CR_M CR motor + OUT 2 CR_MN CR motor - OUT 3 PF_MN PF motor - OUT 4 PF_M PF motor + OUT 5 AP_M AP motor + OUT 6 AP_MN AP motor - OUT 7 LF_M LF motor + OUT 8 LF_MN LF motor - OUT To the top
2-2. Carriage Board (Print Head Connector) No.
31 HD13_C2 Head data C2 OUT 32 B_VH_16V Head drive power supply 16V OUT 33,34 A_VH_24V Head drive power supply 24V OUT 35 HVDD_3.3V Head logic power supply 3.3V OUT 36 ROM_SK Head EEPROM serial clock signal OUT 37 ROM_DIO (I) Head EEPROM data signal OUT 38 DIA1 Diode sensor anode 1 39 VHT Head drive power supply 24V OUT 40 B_VH_24V Head drive power supply 24V OUT IN To the top
PIXMA iP4200 Specifications Type Desktop serial color bubble jet printer Paper feeding method Auto sheet feed (ASF, cassette, automatic duplex printing, CD / DVD printing*1) Resolution 9,600 x 2,400dpi (Max.) Throughput (target value) - 4 x 6, borderless printing: Approx. 51 sec. (standard mode, PP-101, Full Page SCID No. 2) - Camera Direct Printing: Approx. 1 minute and 35 sec. (4 x 6, borderless printing, PP-101, default settings) For reference: Fast Standard 29ppm 14.
detection Available (automatic detection by optical method and dot count, enabled at default) Paper type detection Not available Print head alignment Available (automatic or manual alignment via driver utilities, or the Resume/Cancel button in Camera Direct Printing, automatic alignment at default) *1: Only for CD / DVD printing supported regions Type Single head with 5 removable ink tanks (each color) Print head Black: 320 nozzles (600dpi), 30pl (pigment-based black) Color: 256 nozzle