Canon i960 Series User manual

i960
i965
SERVICE MANUAL
Revision 0
QY8-1392-000

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.
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 2003 by Canon Inc.
CANON INC.
Inkjet Products 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 i860 and i865:
Part 1: Maintenance
Information on maintenance and troubleshooting of the i860 and i865
Part 2: Technical Reference
New technology and technical information such as FAQ’s (Frequently Asked Questions) of the i860 and i865
Part 3: Appendix
Block diagrams and pin layouts of the i860 and i865
Reference:
This manual does not provide sufficient information of disassembly and reassembly procedures. Refer to the
graphics in the separate Parts Catalog.

II. TABLE OF CONTENTS
Page Part 1: MAINTENANCE
1-1 1. MAINTENANCE
1-1 1.1 Adjustment, Periodic Maintenance, Periodic Replacement Parts, and Replacement
Consumables by Service Engineer
1-2 1.2 Customer Maintenance
1-2 1.3 Product Life
1-3 1.4 Special Tools
1-3 1.5 Serial Number Location
1-4 2. LIST OF ERROR DISPLAY / INDICATION
1-4 2.1 Operator Call Errors (by LED Blinking in Orange)
1-5 2.2 Service Call Errors (by LED Blinking in Orange and Green Alternately, or Lit in
Orange)
1-6 2.3 Warnings
1-6 2.4 Troubleshooting by Symptom
1-8 3. REPAIR
1-8 3.1 Notes on Service Part Replacement (and Disassembling / Reassembling)
1-9 3.2 Special Notes on Repair Servicing
1-9 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
EEPROM initialization, EEPROM settings, Waste ink counter reset
Service test print, EEPROM information print
(7) Flash ROM upgrade
1-15 3.4 Verification Items
(1) Service test print
(2) EEPROM information print
1-17 4. PRINTER TRANSPORTATION METHOD
Part 2: TECHNICAL REFERENCE
2-1 1. NEW TECHNOLOGIES
2-1 2. CLEANING MODE AND AMOUNT OF INK PURGED
2-2 3. FAQ (Specific Problems and Solutions)
Part 3: APPENDIX
3-1 1. BLOCK DIAGRAM
3-2 2. CONNECTOR LOCATION AND PIN LAYOUT
3-2 2.1 Logic Board Ass’y
3-6 2.2 Carriage Board (Print Head Connector)

Part 1
MAINTENANCE

1 - 1
1. MAINTENANCE
1.1 Adjustment, Periodic Maintenance, Periodic Replacement Parts, and
Replacement Consumables by Service Engineer
(1) Adjustment
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
- On-arrival cleaning flag
- Waste ink counter
- Media sensor correction
value
- 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
- At bottom case unit
replacement
- At ink absorber
(QC1-2232 / 2233 /
2234 / 2235 / 2236)
replacement
To reset the waste ink
counter.
None. 1 min.
Media sensor
correction*1
(EEPROM settings)
- At logic board ass’y
replacement
- At sheet feeder unit
replacement
To correct the media
sensor.
Calibration media
kit (QY9-0064)*2
2 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)
1 min.
Print head alignment - At print head
replacement
- At logic board ass’y
replacement
To ensure accurate dot
placement.
Computer
(settings via the
printer driver)
3 min.
Paper feed motor
position adjustment*3
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 paper guide flapper
ass’y (QL2-0341)
replacement
- At lift cam base’s
(QL2-0340) gear
replacement
- At lift cam shaft unit
(QM2-0593)
replacement
- To maintain sliding
properties of the carriage,
carriage shaft, paper
guide flapper, and lift
cam shaft.
- To protect the lift cam
base gear.
- To maintain sliding
properties of the lift cam
shaft.
- FLOIL
KG-107A
(QY9-0057)
- MOLYKOTE
PG641
(CK-0562)
- EU-1
(QY9-0037)
2 min.
Note: DO NOT loosen the red screws on both sides of the main chassis, securing the carriage shaft positioning.
*1: Media sensor correction
This operation adjusts the correction value of the media sensor, installed in the sheet feeder unit, to the
EEPROM of the logic board ass’y. The adjustment is required when the sheet feeder unit or the logic board
ass’y is replaced, and values are automatically determined via use of calibration media kit (QY9-0064).
*2: Calibration media kit
The service tool for media sensor correction, consisting of 10 sheets of the reference plain paper, and 1

1 - 2
sheet of the reference white PET paper.
*3: 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.
1.2 Customer Maintenance
Adjustment Timing Purpose Tool
Approx.
time
Print head alignment At print head
replacement.
To ensure accurate
dot placement.
Computer (Automatic
settings via the printer
driver)
5 min.
Print head cleaning When print quality is
not satisfying.
To improve nozzle
conditions.
- Printer buttons
- Computer (settings
via the printer
driver)
30 sec. to
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)
1 to 1.5
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.
1.3 Product Life
(1) Printer
The value from (i) to (iv), whatever comes first.
(i) 10,000 pages of color printing
- Color: 7.5% duty per color pattern printing, A4
(ii) 1,200 disks of CD-R or DVD-R printing
- On a basis of monthly print volume of approx. 20 disks
(iii) 5,000 pages of printing using the photo paper tray
- On a basis of monthly print volume of approx. 83 pages
(iv) 5 years of use

1 - 3
(2) Print head
10,000 pages of color printing
- Color: 7.5% duty per color pattern printing, A4
(3) Ink tank
BCI-6BK: 600 pages (1,500 character pattern in black printing, plain paper, standard mode)
780 pages (ISO JIS-SCID No. 5 pattern, plain paper, standard mode)
BCI-6C: 880 pages (ISO JIS-SCID No. 5 pattern, plain paper, standard mode)
BCI-6M: 630 pages (ISO JIS-SCID No. 5 pattern, plain paper, standard mode)
BCI-6Y: 430 pages (ISO JIS-SCID No. 5 pattern, plain paper, standard mode)
BCI-6PC: 300 pages (ISO JIS-SCID No. 5 pattern, plain paper, standard mode)
BCI-6PM: 220 pages (ISO JIS-SCID No. 5 pattern, plain paper, standard mode)
(4) Auto duplex printing unit DPU-10 (option)
The value (i) or (ii), whichever comes first.
(i) 15,000 pages of printing
(ii) 5 years of use
(5) Paper feed cassette PFC-10 (option)
The value (i) or (ii), whichever comes first.
(i) 30,000 pages of printing
(ii) 5 years of use
1.4 Special Tools
Name Tool No. Purpose Remarks
MOLYKOTE PG641 CK-0562-000 To be applied to the lift cam
base gear and the sliding
portion of the lift cam shaft
In common with
conventional models
FLOIL KG-107A QY9-0057-000 To be applied to the sliding
portions of the carriage,
carriage shaft, and the paper
guide flapper
In common with
conventional models
EU-1 QY9-0037-000 To be applied to the sliding
portion of the carriage, and the
grease pad on the carriage
In common with
conventional models
Calibration media kit QY9-0064-000 To correct the media sensor New (in common with
the i860/i865)
1.5 Serial Number Location
On the carriage flexible cable holder (visible when the access cover is open).

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 LED Blinking in Orange)
LED
blinking
in orange
Error Solution Remarks
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 photo paper tray.
[1004]
Set the paper in the photo paper
tray, and press the Resume/Cancel
button.
2 times
No paper in the paper feed
cassette. [1003]*2
Set the paper in the paper feed
cassette, and press the
Resume/Cancel button.
Paper jam. [1300]
Paper jam in the auto duplex
printing unit. [1304]*3
3 times
Paper jam in the paper feed
cassette. [1303]*2
Remove the jammed paper, and
press the Resume/Cancel button.
4 times No ink.
[1601/1634/1635/1611/1612/1613]
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 front cover.
Or, with the print head installed,
turn the printer off and on.
No CD-R tray feeder (during
CD-R printing). [1850/1855]
Set the CD-R tray and tray feeder
properly, and press the
Resume/Cancel button.
6 times*1
Presence of the CD-R tray feeder
(during paper printing).
[1851/1856]
Remove the CD-R tray feeder, 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
feeder, and press the
Resume/Cancel button.
8 times Warning: The waste ink absorber
becomes almost full (approx. 95%
of the maximum capacity).
Pressing the Resume/Cancel button
will exit the error, and enable
printing.
In repair servicing, replace the
bottom case unit (QM2-0586), or
5-item set of the ink absorbers
(QC1-2232/2233/2234/2235/2236).
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.
When connected to a
Direct Print
supported camera,
the green LED blinks
2 times.

1 - 5
(Operator Call Errors - cont’d -)
LED
blinking in
orange
Error Solution Remarks
No auto duplex printing unit.
[1860]
Set the auto duplex printing unit,
and press the Resume/Cancel
button.
10 times*3
Automatic duplex printing
cannot be performed (paper
size not supported). [1310]
Set an automatic duplex printing
supported size of paper, and press
the Resume/Cancel button.
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).
*1: Only for the model supporting CD-R printing (i965).
*2: Only when the paper feed cassette PFC-10 (optional unit) is attached.
*3: Only when the auto duplex printing unit DPU-10 (optional unit) is attached.
2.2 Service Call Errors (by LED Blinking in Orange and Green Alternately, or Lit
in Orange)
LED
alternate blinking
in orange and
green
Error Solution
(Replacement of listed parts, which are likely to be faulty)
2 times Carriage error [5100] - Carriage unit (QM2-0729)
- Timing slit strip film (QA4-1053)
- Logic board ass’y (QM2-0786/QM2-0812)*1
- Carriage motor (QK1-0175)
3 times Paper feed error [6000] - Timing sensor unit (QM2-0596)
- Timing slit disk film (QC1-2511)
- Feed roller ass’y (QF4-01735)
- Platen unit (QM2-0310/QM2-0311)
- Logic board ass’y (QM2-0786/QM2-0812)*1
- Paper feed motor unit (QM2-0810)
4 times Purge unit error [5C00] - Purge unit (QM2-0730)
- Logic board ass’y (QM2-0786/QM2-0812)*1
6 times Internal temperature
error [5400]
- Logic board ass’y (QM2-0786/QM2-0812)*1
7 times Waste ink absorber full
[5B00]
- Ink absorbers (QC1-2232/2233/2234/2235/2236)
- Bottom case unit (QM2-0727)*4
8 times Print head temperature
rise error [5200]
- Print head (QY6-0043)
- Logic board ass’y (QM2-0786/QM2-0812)*1
9 times EEPROM error [6800] - Logic board ass’y (QM2-0786/QM2-0812)*1
10 times*2 Carriage lift mechanism
error [5110]
- Lift cam shaft unit (QM2-0593)
- Photo interrupter (WG8-5571)
- Sheet feeder unit (QM2-0589)
- Logic board ass’y (QM2-0786/QM2-0812)*1
11 times*3 Paper feed cassette error
[5900]
- Paper feed cassette PFC-10 (option)
- Logic board ass’y (QM2-0786/QM2-0812)*1
- Bottom case unit (QM2-0727)*4
12 times Media sensor error
[8000]
- Sheet feeder unit (QM2-0589)