Canon iPF9000 series User manual

Aug 8 2007
Service Manual
iPF9000 series

Application
This manual has been issued by Canon Inc. for qualified persons to learn technical theory, installation, maintenance, and repair
of products. This manual covers all localities where the products are sold. For this reason, there may be information in this
manual that does not apply to your locality.
Corrections
This manual may contain technical inaccuracies or typographical errors due to improvements or changes in products. When
changes occur in applicable products or in the contents of this manual, Canon will release technical information as the need
arises. In the event of major changes in the contents of this manual over a long or short period, Canon will issue a new edition
of this manual.
The following paragraph does not apply to any countries where such provisions are inconsistent with local law.
Trademarks
The product names and company names used in this manual are the registered trademarks of the individual companies.
Copyright
This manual is copyrighted with all rights reserved. Under the copyright laws, this manual may not be copied, reproduced or
translated into another language, in whole or in part, without the written consent of Canon Inc.
COPYRIGHT © 2001 CANON INC.
Printed in Japan
Caution
Use of this manual should be strictly supervised to avoid disclosure of confidential information.

Introduction
Symbols Used
This documentation uses the following symbols to indicate special information:
Symbol Description
Indicates an item of a non-specific nature, possibly classified as Note, Caution, or Warning.
Indicates an item requiring care to avoid electric shocks.
Indicates an item requiring care to avoid combustion (fire).
Indicates an item prohibiting disassembly to avoid electric shocks or problems.
Indicates an item requiring disconnection of the power plug from the electric outlet.
Indicates an item intended to provide notes assisting the understanding of the topic in question.
Indicates an item of reference assisting the understanding of the topic in question.
Provides a description of a service mode.
Provides a description of the nature of an error indication.
Memo
REF.

Introduction
The following rules apply throughout this Service Manual:
1. Each chapter contains sections explaining the purpose of specific functions and the relationship between electrical and mechanical systems with refer-
ence to the timing of operation.
In the diagrams, represents the path of mechanical drive; where a signal name accompanies the symbol , the arrow indicates the
direction of the electric signal.
The expression "turn on the power" means flipping on the power switch, closing the front door, and closing the delivery unit door, which results in
supplying the machine with power.
2. In the digital circuits, '1'is used to indicate that the voltage level of a given signal is "High", while '0' is used to indicate "Low".(The voltage value, how-
ever, differs from circuit to circuit.) In addition, the asterisk (*) as in "DRMD*" indicates that the DRMD signal goes on when '0'.
In practically all cases, the internal mechanisms of a microprocessor cannot be checked in the field. Therefore, the operations of the microprocessors
used in the machines are not discussed: they are explained in terms of from sensors to the input of the DC controller PCB and from the output of the
DC controller PCB to the loads.
The descriptions in this Service Manual are subject to change without notice for product improvement or other purposes, and major changes will be com-
municated in the form of Service Information bulletins.
All service persons are expected to have a good understanding of the contents of this Service Manual and all relevant Service Information bulletins and be
able to identify and isolate faults in the machine."

Contents
Contents
Chapter 1 PRODUCT DESCRIPTION
1.1 Product Overview .......................................................................................................................................1- 1
1.1.1 Product Overview....................................................................................................................................................1- 1
1.2 Features .....................................................................................................................................................1- 3
1.2.1 Features ..................................................................................................................................................................1- 3
1.2.2 Features ..................................................................................................................................................................1- 3
1.2.3 Features ..................................................................................................................................................................1- 3
1.2.4 Printhead.................................................................................................................................................................1- 3
1.2.5 Ink tank....................................................................................................................................................................1- 4
1.2.6 Ink tank....................................................................................................................................................................1- 5
1.2.7 Cutter unit................................................................................................................................................................1- 6
1.2.8 Roll holder ...............................................................................................................................................................1- 6
1.2.9 Stand.......................................................................................................................................................................1- 6
1.2.10 Media take-up unit.................................................................................................................................................1- 7
1.2.11 Hard disk drive.......................................................................................................................................................1- 8
1.2.12 Hard disk drive.......................................................................................................................................................1- 8
1.2.13 Consumables.........................................................................................................................................................1- 8
1.2.14 Consumables.......................................................................................................................................................1- 10
1.3 Product Specifications..............................................................................................................................1- 11
1.3.1 General Specifications...........................................................................................................................................1- 11
1.3.2 Product Specifications...........................................................................................................................................1- 12
1.3.3 Product Specifications...........................................................................................................................................1- 13
1.4 Detailed Specifications .............................................................................................................................1- 14
1.4.1 Printing mode ........................................................................................................................................................1- 14
1.4.2 Print Speed and Direction......................................................................................................................................1- 15
1.4.3 Print Speed and Direction......................................................................................................................................1- 22
1.4.4 Interface Specifications .........................................................................................................................................1- 28
1.5 Names and Functions of Components .....................................................................................................1- 29
1.5.1 Front......................................................................................................................................................................1- 29
1.5.2 Rear.......................................................................................................................................................................1- 30
1.5.3 Top Cover (Inside).................................................................................................................................................1- 31
1.5.4 Carriage.................................................................................................................................................................1- 32
1.5.5 Ink Tank Cover (Inside).........................................................................................................................................1- 32
1.5.6 Ink Tank Cover (Inside).........................................................................................................................................1- 33
1.6 Basic Operation........................................................................................................................................1- 34
1.6.1 Operation Panel.....................................................................................................................................................1- 34
1.6.2 Main Menu.............................................................................................................................................................1- 35
1.6.3 Main Menu.............................................................................................................................................................1- 50
1.6.4 Basket Unit............................................................................................................................................................1- 71
1.7 Safety and Precautions ............................................................................................................................1- 77
1.7.1 Safety Precautions ................................................................................................................................................1- 77
1.7.1.1 Moving Parts..........................................................................................................................................................................1- 77
1.7.1.2 Adhesion of Ink ...................................................................................................................................................................... 1- 78
1.7.1.3 Electrical Parts.......................................................................................................................................................................1- 80
1.7.2 Other Precautions..................................................................................................................................................1- 81
1.7.2.1 Printhead................................................................................................................................................................................ 1- 81
1.7.2.2 Ink tank ..................................................................................................................................................................................1- 82
1.7.2.3 Handling the Printer............................................................................................................................................................... 1- 83
1.7.3 Precautions When Servicing Printer......................................................................................................................1- 85
1.7.3.1 Notes on the Data Stored in the Printer................................................................................................................................. 1- 85
1.7.3.2 Confirming the Firmware Version ..........................................................................................................................................1- 85

Contents
1.7.3.3 Precautions against Static Electricity.....................................................................................................................................1- 85
1.7.3.4 Precautions for Disassembly/Reassembly............................................................................................................................. 1- 85
1.7.3.5 Self-diagnostic Feature.......................................................................................................................................................... 1- 85
1.7.3.6 Disposing of the Lithium Battery ............................................................................................................................................1- 85
Chapter 2 TECHNICAL REFERENCE
2.1 Basic Operation Outline .............................................................................................................................2- 1
2.1.1 Printer Diagram........................................................................................................................................................2- 1
2.1.2 Printer Diagram........................................................................................................................................................2- 1
2.1.3 Print Signal Sequence .............................................................................................................................................2- 3
2.1.4 Print Signal Sequence .............................................................................................................................................2- 4
2.1.5 Print Driving .............................................................................................................................................................2- 5
2.1.6 Print Driving .............................................................................................................................................................2- 7
2.1.7 Print Driving .............................................................................................................................................................2- 9
2.2 Firmware ..................................................................................................................................................2- 11
2.2.1 Operation Sequence at Power-on..........................................................................................................................2- 11
2.2.2 Operation Sequence at Power-off..........................................................................................................................2- 12
2.2.3 Print Control...........................................................................................................................................................2- 13
2.2.4 Print Control...........................................................................................................................................................2- 13
2.2.5 Print Control...........................................................................................................................................................2- 21
2.2.6 Print Position Adjustment Function........................................................................................................................2- 28
2.2.7 Head Management ................................................................................................................................................2- 28
2.2.8 Printhead Overheating Protection Control.............................................................................................................2- 28
2.2.9 Pause between Pages...........................................................................................................................................2- 28
2.2.10 White Raster Skip ................................................................................................................................................2- 28
2.2.11 Sleep mode..........................................................................................................................................................2- 28
2.2.12 Hard disk drive.....................................................................................................................................................2- 28
2.3 Printer Mechanical System.......................................................................................................................2- 30
2.3.1 Outline....................................................................................................................................................................2- 30
2.3.1.1 Outline....................................................................................................................................................................................2- 30
2.3.2 Ink Passage...........................................................................................................................................................2- 31
2.3.2.1 Ink Passage...........................................................................................................................................................................2- 31
2.3.2.2 Ink Tank Unit..........................................................................................................................................................................2- 32
2.3.2.3 Carriage Unit.......................................................................................................................................................................... 2- 34
2.3.2.4 Printhead................................................................................................................................................................................ 2- 37
2.3.2.5 Purge Unit.............................................................................................................................................................................. 2- 38
2.3.2.6 Maintenance Cartridge........................................................................................................................................................... 2- 43
2.3.2.7 Air Flow..................................................................................................................................................................................2- 44
2.3.3 Paper Path.............................................................................................................................................................2- 45
2.3.3.1 Outline....................................................................................................................................................................................2- 45
2.3.3.2 Paper Path............................................................................................................................................................................. 2- 46
2.3.3.3 Cutter Unit.............................................................................................................................................................................. 2- 46
2.4 Printer Electrical System ..........................................................................................................................2- 47
2.4.1 Outline....................................................................................................................................................................2- 47
2.4.1.1 Overview................................................................................................................................................................................ 2- 47
2.4.1.2 Overview................................................................................................................................................................................ 2- 47
2.4.2 Main Controller.......................................................................................................................................................2- 50
2.4.2.1 Main controller PCB components .......................................................................................................................................... 2- 50
2.4.2.2 Main controller PCB components .......................................................................................................................................... 2- 52
2.4.3 Carriage Relay PCB...............................................................................................................................................2- 54
2.4.3.1 Carriage relay PCB components ........................................................................................................................................... 2- 54
2.4.4 Head Relay PCB....................................................................................................................................................2- 54
2.4.4.1 Head relay PCB components................................................................................................................................................. 2- 54
2.4.4.2 Head relay PCB components................................................................................................................................................. 2- 55
2.4.5 Motor Driver...........................................................................................................................................................2- 56
2.4.5.1 Media take-up PCB components ........................................................................................................................................... 2- 56
2.4.6 Maintenance Cartridge Relay PCB........................................................................................................................2- 56

Contents
2.4.6.1 Maintenance cartridge relay PCB components......................................................................................................................2- 56
2.4.7 Power Supply ........................................................................................................................................................2- 56
2.4.7.1 Power supply block diagram..................................................................................................................................................2- 56
2.5 Detection Functions with Sensors ............................................................................................................2- 57
2.5.1 Sensors for covers.................................................................................................................................................2- 57
2.5.2 Ink passage system...............................................................................................................................................2- 58
2.5.3 Carriage system ....................................................................................................................................................2- 60
2.5.4 Paper path system.................................................................................................................................................2- 62
2.5.5 Paper path system.................................................................................................................................................2- 62
2.5.6 Media take-up Unit ................................................................................................................................................2- 63
2.5.7 Others....................................................................................................................................................................2- 63
Chapter 3 INSTALLATION
3.1 Installation ..................................................................................................................................................3- 1
3.1.1 Making Pre-Checks.................................................................................................................................................3- 1
3.1.1.1 Making Pre-Checks.................................................................................................................................................................. 3- 1
3.1.1.2 Making Pre-Checks.................................................................................................................................................................. 3- 2
3.1.1.3 Making Pre-Checks.................................................................................................................................................................. 3- 3
3.1.2 Unpacking and Installation ......................................................................................................................................3- 4
3.1.2.1 Checking the Contents............................................................................................................................................................. 3- 4
3.1.2.2 Checking the Contents............................................................................................................................................................. 3- 7
3.1.2.3 Assembling the Stand............................................................................................................................................................3- 10
3.1.2.4 Installing the Printer............................................................................................................................................................... 3- 13
3.1.2.5 Installing the Media Take-up Unit ..........................................................................................................................................3- 19
3.1.2.6 Installing the Basket............................................................................................................................................................... 3- 23
3.1.2.7 Removing Protection Materials..............................................................................................................................................3- 27
3.1.3 Checking the Images/Operations..........................................................................................................................3- 29
3.1.3.1 Checking the Image and Operation .......................................................................................................................................3- 29
3.2 Transporting the Printer............................................................................................................................3- 30
3.2.1 Transporting the Printer.........................................................................................................................................3- 30
3.2.1.1 Transporting the Printer ......................................................................................................................................................... 3- 30
3.2.1.2 Transporting the Printer ......................................................................................................................................................... 3- 43
3.2.2 Reinstalling the Printer ..........................................................................................................................................3- 56
3.2.2.1 Reinstalling the Printer...........................................................................................................................................................3- 56
Chapter 4 DISASSEMBLY/REASSEMBLY
4.1 Service Parts ..............................................................................................................................................4- 1
4.1.1 Service parts............................................................................................................................................................4- 1
4.2 Disassembly/Reassembly...........................................................................................................................4- 2
4.2.1 Diassembly/Reassembly.........................................................................................................................................4- 2
4.3 Points to Note on Disassembly and Reassembly.......................................................................................4- 5
4.3.1 Note on locations prohibited from disassembly.......................................................................................................4- 5
4.3.2 Moving the carriage manually .................................................................................................................................4- 5
4.3.3 Units requiring draining of ink..................................................................................................................................4- 5
4.3.4 External Covers.......................................................................................................................................................4- 6
4.3.5 Drive Unit...............................................................................................................................................................4- 13
4.3.6 Carriage Unit .........................................................................................................................................................4- 14
4.3.7 Ink Tube Unit.........................................................................................................................................................4- 18
4.3.8 Feeder Unit............................................................................................................................................................4- 20
4.3.9 Purge Unit..............................................................................................................................................................4- 21
4.3.10 Ink Tank Unit........................................................................................................................................................4- 22
4.3.11 Linear Encoder ....................................................................................................................................................4- 25
4.3.12 Head Management Sensor .................................................................................................................................4- 26
4.3.13 PCBs....................................................................................................................................................................4- 27
4.3.14 Opening the cap and moving the wiper unit ........................................................................................................4- 28

Contents
4.3.15 Opening and closing ink supply valves................................................................................................................4- 29
4.3.16 Draining the ink....................................................................................................................................................4- 30
4.4 Applying the Grease.................................................................................................................................4- 31
4.4.1 Applying the Grease ..............................................................................................................................................4- 31
4.5 Adjustment and Setup Items ....................................................................................................................4- 34
4.5.1 Adjustment Item List ..............................................................................................................................................4- 34
4.5.2 Action to take after replacing the Carriage Unit or Multi Sensor............................................................................4- 34
4.5.3 Action to take after replacing the Feed Roller Encoder or Feed Roller..................................................................4- 34
4.5.4 Action to take after replacing the Head Management Sensor ...............................................................................4- 34
Chapter 5 MAINTENANCE
5.1 Periodic Replacement Parts.......................................................................................................................5- 1
5.1.1 Periodic Replacement Parts ....................................................................................................................................5- 1
5.2 Consumable Parts......................................................................................................................................5- 1
5.2.1 Consumable Parts ...................................................................................................................................................5- 1
5.2.2 Consumable Parts ...................................................................................................................................................5- 2
5.2.3 Consumable Parts ...................................................................................................................................................5- 3
5.3 Periodic Maintenance.................................................................................................................................5- 4
5.3.1 Periodic Maintenance ..............................................................................................................................................5- 4
Chapter 6 TROUBLESHOOTING
6.1 Troubleshooting..........................................................................................................................................6- 1
6.1.1 Outline......................................................................................................................................................................6- 1
6.1.1.1 Outline of Troubleshooting....................................................................................................................................................... 6- 1
6.1.2 Troubleshooting When Warnings Occur..................................................................................................................6- 1
6.1.2.1 Ink Level: Check ......................................................................................................................................................................6- 1
6.1.2.2 Check maint cartridge capacity................................................................................................................................................6- 1
6.1.2.3 Ink tank is empty. Replace the ink tank. .................................................................................................................................. 6- 1
6.1.2.4 No ink tank loaded. Check ink tank.......................................................................................................................................... 6- 1
6.1.2.5 Close Ink Tank Cover .............................................................................................................................................................. 6- 2
6.1.2.6 End of paper feed. Cannot feed paper more. ......................................................................................................................... 6- 2
6.1.2.7 Paper Type Wrong...................................................................................................................................................................6- 2
6.1.2.8 GARO W12xx .......................................................................................................................................................................... 6- 2
6.1.2.9 Check printed document..........................................................................................................................................................6- 2
6.1.2.10 Prepare for parts replacement. Call for service...................................................................................................................... 6- 3
6.1.2.11 Parts replacement time has passed. Call for service.............................................................................................................6- 3
6.1.3 Troubleshooting When Errors Occur .......................................................................................................................6- 3
6.1.3.1 03870001-2015 Cutter error ....................................................................................................................................................6- 3
6.1.3.2 03010000-200C/03010000-200E/03010000-200F/03010000-2017/03010000-2018/03016000-2010 multi sensor...............6- 3
6.1.3.3 03031000-2E0F Upper cover sensor error.............................................................................................................................. 6- 4
6.1.3.4 03031101-2E10 Ink tank cover switch error ............................................................................................................................ 6- 4
6.1.3.5 03031000-2E11 Carriage cover sensor error ..........................................................................................................................6- 4
6.1.3.6 03031000-2E12 Defective paper release lever ....................................................................................................................... 6- 4
6.1.3.7 03010000-2016/03010000-2E27 Paper feed error.................................................................................................................. 6- 5
6.1.3.8 03010000-200D Cut media end error...................................................................................................................................... 6- 5
6.1.3.9 03010000-2E1F/03060000-2E14/03060A00-2E00/03061000-2E15/03063000-2E08/03860002-2E02/03860002-2E0A/
03860002-2E0C Path mismatch error............................................................................................................................................6- 5
6.1.3.10 03862000-2E09 Insufficient roll media error.......................................................................................................................... 6- 5
6.1.3.11 03890000-2920 Media take-up motor error ...........................................................................................................................6- 6
6.1.3.12 03890000-2921 Media take-up paper detection sensor error................................................................................................6- 6
6.1.3.13 03060A00-2E1B Roll media end error................................................................................................................................... 6- 6
6.1.3.14 03861001-2405/03861001-2406 Borderless printing error.................................................................................................... 6- 6
6.1.3.15 03810104-2500/03810101-2501/03810102-2502/03810103-2503/03810112-2504/03810113-2505/03810106-2506/
03810105-2508/03810115-2509/03810107-250A/03810109-250B/03810108-250C No ink error................................................ 6- 6
6.1.3.16 03830104-2520/03830101-2521/03830102-2522/03830103-2523/03830112-2524/03830113-2525/03830106-2526/
03830105-2528/03830115-2529/03830107-252A/03830109-252B/03830108-252C Ink tank is not installed. ( This error occurs
when the ink tank is replaced.).......................................................................................................................................................6- 7