MP540 / MP545 SIMPLIFIED SERVICE MANUAL

MP540 / MP545 SIMPLIFIED SERVICE MANUAL

MP540 / MP545

SIMPLIFIED SERVICE MANUAL

1. LIST OF ERROR DISPLAY

2. ADJUSTMENT / SETTINGS

3. EXTERNAL VIEW / PARTS LIST

QY8-13CA-000

Rev.00

July 31, 2008

Canon Inc.

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1. LIST OF ERROR DISPLAY

Errors and warnings are displayed by the following ways:

- Operator call errors are indicated by the Alarm LED lit in orange, and the error and its solution are displayed on the LCD in text and by icon.

- Messages during printing from a computer are displayed on the MP driver Status Monitor.

- Error codes (the latest 10 error codes at the maximum) are printed in the "operator call/service call error record" area in EEPROM information print.

Buttons valid when an operator call error occurs:

- ON button: To turn the machine off and on again.

- OK button: To clear and recover from an error. In some operator call errors, the error will automatically be cleared when the cause of the error is eliminated, and pressing the OK button may not be necessary.

- Stop button: To cancel the job at error occurrence, and to clear the error.

1-1. Operator Call Errors (Alarm LED Lit In Orange)

Error

Error code

U No. Message on the LCD Solution

No paper in the rear tray.

No paper in the cassette.

There is no paper. Load paper and press [OK].

[1003] --- Cassette.

There is no paper. Load paper and press [OK].

Print head not installed, or not properly installed.

[1401] U051 Print head is not installed.

Install the print head.

Faulty print head ID.

Print head [1403]

U052 The type of print head is incorrect. Install the correct temperature sensor error. print head.

Confirm that the rear tray is selected as the paper source. Set the paper in the rear tray, and press the OK button.

Confirm that the cassette is selected as the paper source. Set the paper in the cassette, and press the OK button.

Note: Only plain paper can feed from the cassette.

Remove the jammed paper, and press the OK button.

Paper jam. [1300] --- The paper is jammed. Clear

Paper jam in the rear [1303] --- the paper and press [OK]. guide.

Ink may have run out.

[1600] U041 The following ink may have run out. Replacing the ink tank is recommended.

Replace the applicable ink tank, or press the OK button to clear the error without ink tank replacement. When the error is cleared by pressing the OK button, ink may run out during printing.

Ink tank not installed. [1660] U043 The following ink tank cannot Install the applicable ink tank(s) properly, be recognized.

(Applicable ink tank icon) and confirm that the LED's of all the ink tanks light red.

Install the print head properly.

Re-set the print head. If the error is not cleared, the print head may be defective.

Replace the print head.

Faulty EEPROM data [1405] of the print head.

Multiple ink tanks of the same color installed.

Ink tank in a wrong position.

[1681] U071 More than one ink tank of the Replace the wrong ink tank(s) with the following color is installed. correct one(s).

[1680] U072 Some ink tanks are not installed in place.

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

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Error

Error code

U No. Message on the LCD Solution

Warning: The ink absorber becomes almost full.

[1700,

1701]

--- Contact the support center or Replace the ink absorber, and reset its service center for ink counter. Pressing the OK button will exit absorber replacement. Press the error, and enable printing without

[OK] to continue printing. replacing the ink absorber. However, when the ink absorber becomes full, no further printing can be performed unless the applicable ink absorber is replaced.

Remove the cable between the camera The connected digital [2001] --- The device may be camera or digital video camera does incompatible. Remove the device and check the manual and the machine. not support Camera

Direct Printing. supplied with the connected device.

The remaining ink amount unknown.

Ink tank not recognized.

[1683] U130 (Applicable ink tank icon)

The remaining level of the following ink cannot be correctly detected. Replace the ink tank.

An ink tank which has once been empty is installed. Replace the applicable ink tank with a new one. Printing with a once-empty ink tank can damage the machine.

To continue printing without replacing the ink tank(s), press the Stop button for

5 sec. or longer to disable the function to detect the remaining ink amount. After the operation, it is recorded in the machine EEPROM that the function to detect the remaining ink amount was disabled.

[1684] U140 The following ink tank cannot A non-supported ink tank (an ink tank be recognized.

(Applicable ink tank icon) that is sold in a different region from where the machine was purchased) is installed (the ink tank LED is turned off).

Install the supported ink tanks.

Ink tank not recognized.

[1410 U150 The following ink tank cannot A hardware error occurred in an ink tank to

1419] be recognized.

(Applicable ink tank icon)

(the ink tank LED is turned off). Replace the ink tank(s).

No ink (no raw ink). [1688] U163 Printer detected ink out condition of the following ink.

Replace the empty ink tank(s), and close the scanning unit (cover).

Replace the ink tank.

(Applicable ink tank icon)

Printing with an empty ink tank can damage the machine.

To continue printing without replacing the ink tank(s), press the Stop button for

5 sec. or longer to disable the function to detect the remaining ink amount. After the operation, it is recorded in the machine that the function to detect the remaining ink amount was disabled.

Non-supported hub [2002] --- An unsupported USB hub is connected. Remove the hub.

Remove the applicable USB hub from the PictBridge (USB) connector.

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Error

Error code

U No. Message on the LCD Solution

Time-out for the scanner device

[2700] --- Timeout error has occurred.

Press [OK].

The buffer became full in the middle of scanning operation, and 60 minutes have elapsed since then, making re-scanning unstable. Press the OK button to clear the error.

1-2. Service Call Errors (by Cyclic Blinking of Alarm and Power LEDs)

Service call errors are indicated by the number of cycles the Alarm and Power LEDs blink, and the corresponding error code with the message, "Printer error has occurred. Turn off power then back on again. If problem persists, see the manual." is displayed on the LCD.

Cycles of blinking of Error

Error Conditions

Alarm and

Power LEDs code

Solution

(Check points and replacement items)

2 times

3 times

4 times

Carriage error

Line feed error [6000] An error occurred in the LF encoder signal.

Purge cam sensor error

[5100] An error occurred in the carriage encoder signal.

[5C00] An error occurred in the purge unit.

1) Smearing or scratches on the carriage slit film;

clean the timing slit film.

2) Foreign material or paper debris that obstructs the carriage movement;

remove foreign material.

3) Ink tank conditions;

re-set the ink tanks.

4) Cable connection

5) Part replacement:

- Timing slit disk film

- Carriage unit

- Logic board

- Carriage motor

1) Smearing or scratches on the LF slit film;

clean the LF slit film.

2) Foreign material or paper debris in the

LF drive;

remove foreign material.

3) Cable connection

4) Part replacement:

- LF slit film

- LF timing sensor unit

- Paper feed roller unit

- Logic board

- Paper feed motor

1) Foreign material or paper debris around the purge drive system unit;

remove foreign material.

2) Cable connection

3) Part replacement:

- Purge drive system unit

- Logic board

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Cycles of blinking of

Alarm and

Power LEDs

5 times

6 times

7 times

8 times

9 times

10 times

11 times

12 times

14 times

Error

Error code

Conditions

Solution

(Check points and replacement items)

ASF (cam) sensor error

[5700] An error occurred in the

ASF cam sensor.

1) Cable connection

2) Part replacement:

- ASF unit

- PE sensor board unit

- Logic board

Internal temperature error

[5400] The internal temperature is

Ink absorber full [5B00]

[5B01] not normal.

1) Cable connection

2) Part replacement:

- Carriage unit

- Logic board

The ink absorber is supposed to be full.

Message on the LCD:

- Print head

1) Ink absorber condition

2) Part replacement:

- Ink absorber kit

Ink absorber full. Service 3) Ink absorber counter value in the required.

Error codes:

5B00: Main ink absorber is full (non-Japan).

EEPROM;

reset the ink absorber counter.

5B01: Main ink absorber is full (Japan).

Print head temperature rise

[5200] The print head temperature 1) Print head condition exceeded the specified 2) Cable connection error value. 3) Part replacement:

- Print head

EEPROM error [6800]

[6801]

A problem occurred in reading from or writing to the EEPROM.

- Logic board

1) Part replacement:

- Logic board

VH monitor error [B200] The internal temperature exceeded the specified value.

Carriage lift mechanism error

[5110] The carriage did not move up or down properly.

1) Part replacement:

- Print head and logic board

(Replace them at the same time.)

- Power supply unit

1) Foreign material or paper debris that obstructs the carriage movement;

remove foreign material.

2) Part replacement:

- Switch system unit

- Carriage unit

APP position error

APP sensor error

[6A80] An error occurred in the

APP motor.

[6A90] An error occurred during paper feeding or purging.

1) Foreign material or paper debris around the purge drive system unit;

remove foreign material.

2) Foreign material or paper debris around the ASF unit;

remove foreign material.

3) Cable connection

4) Part replacement:

- Purge drive system unit

- Logic board

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Cycles of blinking of

Alarm and

Power LEDs

Error

Error code

Conditions

Solution

(Check points and replacement items)

15 times

16 times

19 times

20 times

21 times

22 times

USB Host VBUS overcurrent

Pump roller sensor error

Ink tank position sensor error

Other errors

Drive switch error

Scanner error

[9000] The USB Host VBUS is overloaded.

[5C20] The pump roller position cannot be detected.

[6502] None of the ink tank position is detected.

[6500] An unidentified error occurred.

[C000] Drive was not switched properly.

[5011] An error occurred in the scanner.

1) Part replacement:

- Logic board

1) Cable connection

2) Part replacement:

- Purge drive system unit

1) Ink tank position;

confirm the ink tank position.

2) Re-set or replacement of ink tanks

3) Cable connection

4) Part replacement:

- Spur unit

- Logic board

1) Part replacement:

- Logic board

1) Foreign material or paper debris in the drive switch area;

remove foreign material.

2) Part replacement:

- Purge drive system unit

- ASF unit

1) Document pressure sheet conditions

2) Cable connection

3) Part replacement:

- Document pressure sheet (sponge sheet)

- Scanner unit

- Logic board

23 times

Flatbed motor error

Valve cam sensor error

[5012] An error occurred in the scanner flatbed motor.

[6C10] The valve cam sensor was faulty at power-on or when purging was attempted.

1) Cable connection

2) Part replacement

- Scanner unit

1) Foreign material or paper debris around the purge drive system unit;

remove foreign material.

2) Cable connection

3) Part replacement:

- Purge drive system unit

- Logic board

Note: Before replacement of the logic board ass'y, check the ink absorber counter value (by service test print or EEPROM information print). If the counter value is 7% or more, also replace the ink absorber kit when replacing the logic board ass'y. If the counter value is less than 7%, register the current ink absorber counter value to the replaced new logic board.

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1-3. Warnings

Warning Message on the LCD Solution

Low ink

Print head temperature rise If the print head temperature does not fall, the print head error will occur.

Protection of excess rise of the print head temperature

Restrictions on paper

"!" is indicated for an applicable ink tank icon in the Status Monitor.

If the print head temperature does not fall, the print head error will occur.

The current paper cannot be set.

Change the size and type.

USB cable not connected Set the PC to start scan.

Cancellation of image select Reset the selected photo information? information Yes No

Do you want to clear the image scanned from the photo?

Yes No

Do you want to clear the scanned image and rescan?

Yes No

Since the ink will be used up soon, prepare for a new ink tank.

When the print head temperature falls, the error is automatically cleared. If the print head error is indicated, repair servicing is required.

If the print head temperature exceeds the specified limit, an intermission is inserted during printing.

Re-select the supported paper type and size.

Connect the USB cable, then turn on the computer.

- Select Yes, and press the OK button.

=> The image selection is cancelled, and the LCD returns to the display before the message was displayed.

- Select No, and press the OK button.

=> The LCD returns to the display immediately before the message was displayed.

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2. ADJUSTMENT / SETTINGS

< Service mode operation procedures >

Use the Service Tool on the connected computer.

1) Start the machine in the service mode. i. With the machine power turned off, while pressing the Stop button, press and hold the ON button. (DO NOT release the buttons). ii. When the Power LED lights in green, while holding the ON button, release the Stop button.

(DO NOT release the ON button.) iii. While holding the ON button, press the Stop button 2 times, and then release both the ON and Stop buttons. (Each time the Stop button is pressed, the Alarm and Power LEDs light alternately, Alarm in orange and Power in green, starting with Alarm LED.) iv. When the Power LED lights in green, the machine is ready for the service mode operation.

- LCD ready for the service mode operation:

2) Start the Service Tool on the connected computer. i. When a button is clicked in the Service Tool dialog box, that function is performed. During operation of the selected function, all the Service Tool buttons are dimmed and inactive. ii When the operation is completed, "A function was finished." is displayed, and another function can be selected. iii If a non-supported function is selected, "Error!" is displayed. Click OK in the error message dialog box to exit the error.

< Service Tool Functions >

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No. Name

(1) Test Print

Function

Service test print

Remarks

Paper will feed from the rear tray.

Service test print:

- Model name

- ROM version

- Ink absorber counter value (ink amount in the ink absorber)

- USB serial number

- Destination

- EEPROM information

- Process inspection information

- Barcode (model name + destination)

- Ink system function check result

(2) EEPROM

(3) CD-R

(4) LF / Eject

(5) Left

(7) Main

(8) Platen

EEPROM information print The dialog box opens to select the paper source.

Select Rear tray or Cassette, and click OK.

EEPROM information print:

- Model name

- ROM version

- Ink absorber counter value (ink amount in the ink absorber)

- Print information

- Error information, etc.

CD-R check pattern print

Not used.

LF / Eject correction pattern print

See “LF / Eject correction” below.

Left margin pattern print Not used.

Print head deep cleaning

Cleaning of both Black and Color at the same time.

Main ink absorber counter resetting

Set a sheet of A4 or Letter sized plain paper. After the ink absorber counter is reset, the counter value is printed automatically.

Platen ink absorber counter resetting

Not used.

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No. Name

(9) EEPROM

Function

EEPROM initialization

Remarks

The following items are NOT initialized, and the shipment arrival flag is not on:

- USB serial number

- Destination settings

- Record of ink absorber counter resetting and setting

- Record of repair at the production site

- LF / Eject correction values

- Left margin correction value

- Production site E-MIP correction value and enabling of it

- Endurance correction value and enabling of it

- Record of disabling the function to detect the remaining ink amount

- Ink absorber counter value (ink amount in the ink absorber)

(10) Panel Check Button and LCD test See "Button and LCD test" below.

(11) Set Destination Destination settings Select the destination, and click OK.

ASA, AUS, BRA, CHN, CND, EUR, JPN, KOR,

LTN, TWN, USA

(12) CD-R Correction

(13) LF / EJECT

Correction

CD / DVD print position correction (X and Y direction)

LF / Eject correction value setting

(14) Left Margin Correction

Left margin correction value setting

(15) Ink Absorber Counter

Ink absorber counter setting

Not used.

See " LF / Eject correction " below.

Not used.

See " Ink absorber counter setting " below.

< LF / Eject correction >

After replacement of the feed roller, platen unit, LF / Eject encoder, encoder film, or logic board in repair servicing or in refurbishment operation, perform the adjustment to maintain the optimal print image quality.

1) Print the LF / Eject correction pattern. paper type, and print the pattern. 5 sheets of paper will be used for the pattern printing.

- Paper source: Select either Rear tray or Cassette.

- Media type: Select one from HR-101, GF-500/Office Planner, HP Bright White, and

Canon Extra/STEINBEIS.

2) When printing is finished, the machine returns to be ready for selection of another function

("Service Mode Idle" is displayed on the LCD).

3) In the printout, determine the Pattern No. in which streaks or lines are the least noticeable for the

LF check pattern and the Eject check pattern respectively. (LF Pattern No. 0 to 4, Eject Pattern

No. 0 to 4)

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4) In the LF/EJECT Correction section of the Service Tool, select the Pattern No. (from 0 to 4) determined in step 3) for LF and EJECT respectively, and click Set.

5) The selected LF and Eject correction values are written to the EEPROM, making the E-MIP correction value (which was set at shipment from the production site) invalid.

Note: At the production site, the E-MIP correction, which is equivalent to the LF / Eject correction, is performed using the special tool, and the E-MIP correction value is written to the EEPROM as the valid data.

When LF / Eject correction is performed, the LF / Eject correction values become valid instead of the E-MIP correction value (thus, in the initial EEPROM information print, "LF = *" and "EJ = *" are printed, but the selected values are printed after the LF / Eject correction).

< Button and LCD test >

Confirm the operation after replacement of the operation panel unit, board, or LCD unit.

1) Click Panel Check of the Service Tool on the connected computer. The machine LCD turns blue, waiting for a button to be pressed.

2) Press each button of the operation panel.

3) Only one button should be pressed at one time. If 2 or more buttons are pressed at the same time, only one of them is considered to be pressed, and the other buttons are ignored.

The LCD is divided into 16 segments, representing each button. The color of a segment corresponding to the pressed button changes to red.

1: ON button

2: Back button

9: Color button

10: Stop button

3: OK button

4: Up cursor button

11: NAVI button

12: HOME button

5: Down cursor button 13: Left function button

6: Left cursor button 14: Right function button

7: Right cursor button 15: [+] button

8: Black button 16: [-] button

4) Rotate the Easy-Scroll Wheel clockwise and counterclockwise 1 round (16 steps) each, as follows:

4-1) Rotate the Easy-Scroll Wheel clockwise step by step. The LCD is divided into 16 segments, representing each step. The color of a segment corresponding to the step changes from red to green.

If the wheel is rotated counterclockwise before clockwise round completes, the color of segment(s) corresponding to the number of steps the wheel is rotated counterclockwise returns to red.

If the wheel keeps rotated clockwise over 1 round (16 steps), the color of segment(s) corresponding to the extra number of steps returns to red, starting with the "Start" segment in the figure below.

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4-2) When the Easy-Scroll Wheel is rotated clockwise 1 round (16 steps), press the OK button.

4-3) Rotate the Easy-Scroll Wheel counterclockwise step by step. The LCD is divided into 16 segments, representing each step. The color of a segment corresponding to the step changes from green to blue.

If the wheel is rotated clockwise before counterclockwise round completes, the color of segment(s) corresponding to the number of steps the wheel is rotated clockwise returns to green.

If the wheel keeps rotated counterclockwise over 1 round (16 steps), the color of segment(s) corresponding to the extra number of steps returns to green, starting with the

"Start" segment in the figure below.

4-4) When the Easy-Scroll Wheel is rotated counterclockwise 1 round (16 steps, and all the segments are in blue), press the OK button. The color pattern is displayed on the LCD.

If there is any segment that is not in blue when the OK button is pressed, the display remains unchanged.

5) Adjust the transparent color, as follows:

5-1) Press the OK button. "OK1" in white is displayed on the black background.

If the result is not good, "NG1" in black is displayed on the white background (transparent color) immediately after "OK1."

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5-2) Press the OK button. "OK2" in black is displayed on the white background.

If the result is not good, "NG2" in white is displayed on the black background (transparent color) immediately after "OK2."

6) Adjust the LCD flicker, as follows:

6-1) Press the OK button. The screen is displayed as below for LCD flicker adjustment.

6-2) If the screen flickers, press the left or right cursor button until the flickering disappears. By pressing the left or right cursor, the VrefPWM value displayed at the bottom of the LCD changes from 36 to 3D (in hexadecimal).

6-3) Press the OK button. The machine returns to be ready for selection of another function

("Service Mode Idle" is displayed on the LCD).

< Ink absorber counter setting >

Set the ink absorber counter value to a new EEPROM after the logic board is replaced in servicing.

1) Before replacement of the logic board, check the ink absorber counter value in EEPROM information print.

2) After replacement of the logic board, the ink absorber counter value should be set in the service mode using the Service Tool. pull-down menu. closest to the actual counter value confirmed before replacement of the logic board, and click Set.

3) Print EEPROM information to confirm that the value is properly set to the EEPROM.

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Function Procedures Remarks

Nozzle check pattern printing

Print head manual cleaning

Print head deep cleaning

Manual print head alignment

Print head alignment value printing

Paper feed roller cleaning

Bottom plate cleaning

Perform via the machine operation panel, or from the MP driver

Maintenance tab.

Set a sheet of plain paper (A4 or Letter) in the cassette, or the rear tray if selected.

- Cleaning both Black and Color:

Perform via the machine operation panel, or from the MP driver Maintenance tab.

- Cleaning Black or Color separately:

Perform from the MP driver

Maintenance tab.

Unclogging of the print head nozzles, and maintenance to keep the print head conditions good.

If there is a missing portion or white streaks in the nozzle check pattern printout, perform this cleaning.

Perform via the machine operation panel, or from the MP driver

Maintenance tab.

If print head cleaning is not effective, perform this cleaning. Since the deep cleaning consumes more ink than regular cleaning, it is recommended to perform deep cleaning only when necessary.

Set 3 sheets of plain paper (A4 or Letter) in the cassette, or the rear tray if selected.

Perform via the machine operation panel, or from the MP driver

Maintenance tab.

Perform via the machine operation panel, or from the MP driver

Maintenance tab.

Confirmation of the current print head alignment values.

Perform via the machine operation panel, or from the MP driver

Maintenance tab.

Perform via the machine operation panel, or from the MP driver

Maintenance tab.

The paper feed rollers of the selected paper source (the rear tray or the cassette) rotate while being pushed to the paper lifting plate. Since the rollers will wear out in this cleaning, it is recommended that you perform this only when necessary.

Cleaning of the platen ribs when the back side of paper gets smeared.

Fold a sheet of plain paper (A4 or Letter) in half crosswise, then unfold and set it in the rear tray with the folded ridge facing down.

(No paper feeding from the cassette)

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2-3. Special Notes on Assembling

(1) External housing, scanner unit, and document cover removal

1) Remove the cassette, and open the front door.

2) Pull up the document cover to remove it, then remove the rear top cover and the middle frame

(4 screws).

3) Remove the side cover R (2 screws).

< The scanner unit hinges are fitted in the right and left side covers. >

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4) Remove the scanner cable, panel cable, FB encoder cable, and core.

< The core is fixed on the rib of the sub-case (back of the main case). >

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5) Remove the side cover L and scanner unit (2 screws).

< While holding the scanner unit, separate the scanner stay from the

side cover L. >

6) Remove the operation panel unit (11 screws).

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7) Remove the main case and sub-case (1 screw).

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(2) Notes on Service Part Replacement (and Disassembling / Reassembling)

Service part Notes on replacement

*1

Adjustment / settings Operation check

Logic board ass'y - Before removal of the logic After replacement: board ass'y, remove the power cord, and allow for

1) Initialize the EEPROM.

2) Set the ink absorber counter approx. 1 minute (for discharge of capacitor's accumulated charges), to prevent damages to the value.

3) Set the destination in the

EEPROM.

4) Check the ink system function. logic board ass'y.

- Before replacement, check the ink absorber counter value (by service test print or EEPROM information print).

5) Perform LF / Eject correction.

6) Perform button and LCD test.

Perform 1 to 6 in the service mode.

7) Perform print head alignment and LCD language setting in the user mode.

Absorber kit

Carriage unit

Switch system unit

Paper feed motor

- The red screws securing the paper feed motor are allowed to be loosened only for paper feed motor replacement. (DO NOT loosen them in any other cases.)

- EEPROM information print

- Service test print

- Printing via USB connection

- Copying

- Direct printing from a digital camera (PictBridge)

After replacement:

1) Reset the ink absorber counter.

- Ink absorber counter value print (After the ink absorber counter is reset, the counter value is printed automatically.)

At replacement:

1) Before removal of the carriage

- Service test print (Confirm ink system function.) rail, mark the carriage rail position.

2) Apply grease to the sliding portions of the carriage rail.

3) Check the ink system function.

4) Perform print head alignment in the user mode.

At replacement:

1) Adjust the paper feed motor.

- EEPROM information print

- Service test print

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Service part Notes on replacement

*1

Adjustment / settings Operation check

Platen unit

Spur unit

Purge drive system unit

- DO NOT contact the spur edges.

After replacement: - EEPROM information print

1) Perform LF / Eject correction in - Service test print the service mode.

After replacement:

1) Check the ink system function.

2) Perform LF / Eject correction in

- EEPROM information print

- Service test print the service mode.

After replacement:

1) Confirm the purging operation and the machine operation.

At replacement:

1) Apply grease to the sliding portions.

- Service test print

- Service test print Carriage rail and main chassis

Idler pulley parallel pin

Easy-Scroll

Wheel base

APP code wheel gear shaft

Document cover unit

Scanner unit

Panel board ass'y

At replacement:

1) Confirm the document pressure sheet position.

- Be cautious not to scratch

At replacement: or damage the LCD cable.

1) Perform button and LCD test.

- Service test print

- Service test print

LCD unit

Timing slit strip film

- Upon contact with the film,

After replacement: wipe the film with ethanol. 1) Perform print head alignment in

- EEPROM information print

- Service test print

- Confirm no grease is on the film. (Wipe off any the user mode.

2) Perform LF / Eject correction in

Timing slit disk feed film grease thoroughly with ethanol.)

- Do not bend the film the service mode.

Print head After replacement:

1) Perform print head alignment in

- Service test print the user mode.

*1: General notes:

- Make sure that the flexible cables and wires in the harness are in the proper position and connected correctly.

- 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 machine 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 feed film. No grease or abrasion is allowed.

- Protect the units from soiled with ink.

- Protect the housing from scratches.

- Exercise caution with the screws, as follows: i. The 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. Before loosening the 3 screws that fix the carriage rail to the main chassis, mark the screw positions so that the carriage rail will be re-attached to the main chassis in its

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original position.

(3) Paper feed motor adjustment

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 photo 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.

Caution: The screws securing the paper feed motor may be loosened only at replacement of the paper feed motor unit. DO NOT loosen them in other cases.

(4) Document pressure sheet (sponge sheet) replacement

1) Peel off the cover sheet from the double-sided adhesive tape on the back of the document pressure sheet.

With the long-side down, position the upper-left corner of the document pressure sheet at the scanning reference point on the platen glass (back left where the red lines cross in the photo above).

2) Slowly close the document pressure plate while maintaining the hinge position. The document pressure sheet will attach to the plate.

3) Open the plate to confirm the following:

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- No extension of the sponge edges over the mold part of the upper scanner cover.

- No gap between the platen glass reference edges and the corresponding sponge edges.

- No shades or streaks in monochrome test printing without a document on the platen glass.

(5) Ink absorber counter setting

Before replacement of the logic board, check the ink absorber counter value, and register it to the replaced new logic board. (The value can be set in 10% increments.)

In addition, according to the ink absorber counter value, replace the ink absorber (ink absorber kit).

When the ink absorber is replaced, reset the applicable ink absorber counter (to 0%).

(23/58)

(1) Printer unit

No. Part name Where to apply grease / oil

1 Carriage rail

2 Carriage rail

3 Carriage rail

4 Carriage rail

The surface where the carriage unit slides

The surface where the carriage unit slides

The surface where the carriage unit slides

The surface where the carriage unit slides

5 Main chassis The surface where the carriage unit slides

6 Parallel pin The pin surface which contacts the idler pulley hole

7 APP code wheel APP code wheel gear sliding portion (the entire gear shaft surface)

*1: Drawing No.

*2: Number of drops (1 drop = 9 to 18 mg) x locations

*1

Grease

(1) Floil KG107A 270 to 330

(2) Floil KG107A

(3) Floil KG107A 360 to 440

(4) Floil KG107A 360 to 440

(6) Floil KG107A

Grease amount (mg)

18 to 36

(5) Floil KG107A 230 to 290

9 to 18

*2

---

1 x 2

---

---

---

1 x 1

(7) Floil KG107A 9 to 18 1 x 1

(24/58)

(2) Operation panel, Easy-Scroll Wheel

No. Part name Where to apply grease / oil

8 Easy-Scroll Wheel base Easy-Scroll Wheel sliding portions

Drawing

No.

Grease

(8) Floil KG107A

Grease amount (mg)

9 to 18

(25/58)

2-5. Notes on Transportation

This section describes the procedures for transporting the machine for returning after repair, etc.

1) In the service mode, press the ON button to finish the mode, and confirm that the paper lifting plate of the rear tray is raised.

2) Keep the print head and ink tanks installed in the carriage. See Caution (a) below.

3) Turn off the machine to securely lock the carriage in the home position. (When the machine is turned off, the carriage is automatically locked in place.) See Caution (b) below.

Caution: a. If the print head is removed from the machine and left alone by itself, ink (the pigment-based black ink in particular) is likely to dry. For this reason, keep the print head installed in the machine even during transportation. b. Securely lock the carriage in the home position, to prevent the carriage from moving and applying stress to the carriage flexible cable, or causing ink leakage, during transportation.

Note: - If the print head must be removed from the machine and transported alone, attach the protective cap (used when the packing was opened) to the print head (to protect the print head face from damage due to shocks).

- If the packing material that fixed the carriage from the factory is still available, re-use it to fix the carriage (to prevent the carriage unlocked during transportation).

(26/58)

3. EXTERNAL VIEW / PARTS LIST

FIGURE 1 PACKING CONTENTS & PRINT HEAD

(27/58)

LIST OF FIGURE 1

FIGURE &

KEY No.

PART NUMBER RANK QTY

11 QM3-3685-000

2 QY6-0073-000

1

1

DESCRIPTION

CASSETTE UNIT

PRINT HEAD

3 QH2-2716-000

3 QH2-2719-000

3 QK1-0776-000

3 QK1-2017-000

3 QK1-3048-000

3 QK1-3761-000

3 WT3-5156-000

3 WT3-5160-000

4 QC2-7932-000

1 CORD, POWER

1 CORD, POWER

1 CORD, POWER

1 CORD, POWER

1 CORD, POWER

1 CORD, POWER

1 CORD, POWER

1 CORD, POWER

1 LABEL, PANEL

REMARKS

220V-240V(EUM, EMB, ASA,

MY)

100V-120V

220V-240V(AU)

100V-120V(TW)

120V-240V(LAM, CHN)

100V(JP)

220V-240V(GB, HK)

220V-240V(KR)

CA

(28/58)

FIGURE 2 AC ADAPTER

(29/58)

LIST OF FIGURE 2

FIGURE &

KEY No.

PART NUMBER RANK QTY

21 QK1-4965-000

DESCRIPTION

1 AC ADAPTER: 100V-240V 50/60HZ

REMARKS

(30/58)

FIGURE 3 EXTERNAL COVERS & SCANNER UNIT

(31/58)

LIST OF FIGURE 3

FIGURE &

KEY No.

PART NUMBER RANK QTY

31 QC1-9023-000 1 EMBLEM

DESCRIPTION

1

2

3

4

5

6

7

7

7

7

7

7

8

9

10

QC1-9024-000

QM3-3689-000

QM3-3684-000

QM3-3682-000

QM3-3683-000

QC2-7841-000

QL2-2602-000

QL2-2603-000

QL2-2604-000

QL2-2605-000

QL2-2606-000

QL2-2607-000

QC2-7872-000

QC2-7871-000

QC2-7874-000

REMARKS

1 EMBLEM

1 SCANNER UNIT

1 ASF COVER UNIT

1 SIDE COVER R UNIT

1 SIDE COVER L UNIT

1 STAY, SCANNER

1 COVER, OPERATION PANEL

1 COVER, OPERATION PANEL

FOR JAPAN

FOR OTHER

REGIONS

CA, AU, ASA

JP

1 COVER, OPERATION PANEL

LAM, GB, EUM,

EMB

1 COVER, OPERATION PANEL

1 COVER, OPERATION PANEL

1 COVER, OPERATION PANEL

1 EDGE PANEL, OPERATION

1 TOP COVER, OPERATION REAR

HK, TW

CN

KR

1

MIDDLE FRAME, OPERATION

REAR

(32/58)

FIGURE 4 DOCUMENT PRESSURE PLATE UNIT

(33/58)

LIST OF FIGURE 4

FIGURE &

KEY No.

PART NUMBER RANK QTY

41 QM3-3692-000

2 QC2-7863-000

1

2

DESCRIPTION

DOCUMENT COVER UNIT

HINGE

3 QC2-9324-000 1

SHEET, DOCUMENT

PRESSURE

REMARKS

(34/58)

FIGURE 5 OPERATION PANEL UNIT

(35/58)

LIST OF FIGURE 5

FIGURE &

KEY No.

PART NUMBER RANK QTY

51 QC2-7873-000

2 QC2-7870-000

1

1

DESCRIPTION

GUIDE, LIGHT

FRAME, PANEL

3

4

5

6

7

8

QC2-7919-000

QC2-7878-000

QC2-7879-000

QC2-7877-000

QC2-7876-000

QC2-8026-000

1

1

1

1

1

1

KEY, ARROW

KEY, OK

JOG WHEEL

KEY, START

KEY, POWER

BASE, JOG WHEEL

9 QM3-3709-000

10 QM3-3696-000

11 QC2-9308-000

11 QC2-9309-000

12 QC2-7885-000

13 QC2-7882-000

14 QC2-7886-000

15 QC2-7887-000

16

17

18

QL2-2609-000

QC2-7883-000

QC2-7884-000

1 PANEL BOARD ASS'Y

1 LCD UNIT

1 LABEL, PRODUCT NAME

1 LABEL, PRODUCT NAME

1 WINDOW, LCD

1 COVER, LCD FRONT

1 HINGE, LCD L

1 HINGE, LCD R

1

1

1

LCD CABLE ASS'Y

COVER, LCD TOP

EDGE PANEL, LCD

REMARKS

MP540

MP545

(36/58)

FIGURE 6 MAIN CASE & FRONT DOOR UNIT

(37/58)

LIST OF FIGURE 6

FIGURE &

KEY No.

PART NUMBER RANK QTY

61 QM3-3641-000

2 QC2-7844-000

1

1

DESCRIPTION

REAR GUIDE UNIT

CASE, MAIN

3

4

5

QM3-3681-000

QM3-3694-000

QC2-7925-000

1

1

1

FRONT DOOR UNIT

SUB CASE UNIT

SHEET, PE BIND

REMARKS

(38/58)

FIGURE 7 BOTTOM CASE & INK ABSORBER

(39/58)

LIST OF FIGURE 7

FIGURE &

KEY No.

PART NUMBER RANK QTY

71 QM3-3711-000

2 QM3-4278-000

1

1

DESCRIPTION

FRONT DOOR LINK UNIT

DC HARNESS ASS'Y

3

4

5

6

QC2-7654-000

QM3-3644-000

QY5-0239-000

QC2-7908-000

1

1

1

1

GEAR, PICK UP SHAFT

PICK UP ARM UNIT

ABSORBER KIT

CASE, BOTTOM

REMARKS

(40/58)

FIGURE 8 LOGIC BOARD ASS’Y & PE SENSOR BOARD ASS’Y

(41/58)

LIST OF FIGURE 8

FIGURE &

KEY No.

PART NUMBER RANK QTY

81 QK1-4512-000

2 QK1-5002-000

1

1

DESCRIPTION

CABLE, CARD SLOT

CABLE, PICTBRIDGE

3

4

5

6

7

8

QC2-8523-000

QC2-7850-000

QM3-3708-000

QM3-4467-000

QM3-3707-000

QM3-4451-000

1

1

1

1

1

1

HOLDER, CORE

PANEL, CARD

CARD BOARD ASS'Y

LOGIC BOARD ASS'Y

PICTBRIDGE BOARD UNIT

PE SENSOR BOARD ASS'Y

9 QK1-4835-000

10 QK1-5034-000

11 QK1-4815-000

12 QC2-7921-000

1 CABLE, PE SENSOR

1 CABLE, LF ENCODER

1 CABLE, PANEL

1 FRONT COVER, MIDDLE

REMARKS

(42/58)

FIGURE 9 SHEET FEED UNIT

(43/58)

LIST OF FIGURE 9

FIGURE &

KEY No.

PART NUMBER RANK QTY

91 QM3-3633-000

2 QL2-2529-000

1

DESCRIPTION

ASF UNIT

1 PAPER FEED ROLLER ASS'Y

3 QM3-3610-000

4 QM3-4757-000

1 CASSETTE FEED GUID UNIT

1 PAPER GUIDE UNIT

REMARKS

(44/58)

FIGURE 10 CARRIAGE UNIT & PRESSURE ROLLER UNIT

(45/58)

LIST OF FIGURE 10

FIGURE &

KEY No.

PART NUMBER RANK QTY

101 QC2-7783-000

2 QM3-3598-000

1

1

DESCRIPTION

FILM, TIMING SLIT STRIP

CARRIAGE UNIT

3

4

5

QL2-2528-000

QK1-1500-000

QM3-3614-000

1

1

1

PULLEY HOLDER UNIT

MOTOR, CARRIAGE

PRESSURE ROLLER ASS'Y

REMARKS

(46/58)

FIGURE 11 PLATEN UNIT & SPUR UNIT

(47/58)

LIST OF FIGURE 11

FIGURE &

KEY No.

PART NUMBER RANK QTY

111 QC2-7526-000

2 QL2-2525-000

3

4

QC2-7667-000

QC2-7765-000

1

1

DESCRIPTION

BELT, PAPER FEED

LF ROLLER ASS'Y

1 BUSHING, PAPER FEED ROLLER

1 FILM, TIMING SLIT DISK FEED

5

6

7

QM3-3618-000

QC2-7671-000

QM3-3617-000

1

1

1

PLATEN/EJECT ROLLER UNIT

ABSORBER, INK

SPUR UNIT

REMARKS

(48/58)

FIGURE 12 PURGE DRIVE SYSTEM UNIT & SWITCH SYSTEM UNIT

(49/58)

LIST OF FIGURE 12

FIGURE &

KEY No.

PART NUMBER RANK QTY

121 QM3-3619-000

2 QM3-3651-000

3 QM3-4449-000

1

1

1

DESCRIPTION

PURGE DRIVE SYSTEM UNIT

PURGE MOTOR UNIT

MOTOR MULTI HARNESS ASS'Y

4

5

6

7

8

QM3-4453-000

QM3-5094-000

QK1-3849-000

QM3-4445-000

QC2-7682-000

1

PAPER FEED RELAY HANESS

ASS'Y

1 SWITCH SYSTEM UNIT

1 MOTOR, PAPER FEED

1 LF MOTOR HARNESS ASS'Y

1 GEAR, IDLER

REMARKS

(50/58)

FIGURE 13 OPTION & CONSUMABLES

(51/58)

LIST OF FIGURE 13

3

4

FIGURE &

KEY No.

PART NUMBER RANK QTY

131 NPN

NPN

1

1

DESCRIPTION

BLACK INK TANK CLI-221BK

MAGENTA INK TANK CLI-221M

REMARKS

CONSUMABLES

CONSUMABLES

2

NPN

NPN

NPN

NPN

NPN

NPN

1

1

1

1

1

1

YELLOW INK TANK CLI-221Y

BLACK INK TANK PGI-220BK

CYAN INK TANK CLI-221C

BLACK INK TANK CLI-821BK

YELLOW INK TANK CLI-821Y

MAGENTA INK TANK CLI-821M

CONSUMABLES

CONSUMABLES

CONSUMABLES

CONSUMABLES

CONSUMABLES

CONSUMABLES

NPN

NPN

NPN

NPN

NPN

NPN

NPN

NPN

NPN

NPN

NPN

NPN

1 BLACK INK TANK PGI-820BK CONSUMABLES

1 CYAN INK TANK CLI-821C

1 CYAN INK TANK CLI-521C

1

1

1

1

MAGENTA INK TANK BCI-321M

YELLOW INK TANK BCI-321Y

CYAN INK TANK BCI-321C

CONSUMABLES

1 BLACK INK TANK CLI-521BK CONSUMABLES

1 MAGENTA INK TANK CLI-521M CONSUMABLES

1 YELLOW INK TANK CLI-521Y CONSUMABLES

1 BLACK INK TANK PGI-520BK CONSUMABLES

CONSUMABLES

1 BLACK INK TANK BCI-321BK CONSUMABLES

CONSUMABLES

CONSUMABLES

BLACK INK TANK BCI-320PGBK CONSUMABLES

CONSUMABLES

(52/58)

FIGURE 14 TOOL

(53/58)

LIST OF FIGURE 14

FIGURE &

KEY No.

PART NUMBER RANK QTY

T1 QY9-0057-000

DESCRIPTION

1 LUBE, FLOIL KG107A, OIL

REMARKS

(54/58)

REFERENCE PRINTER UNIT

(55/58)

SCREW & WASHER LIST

FIGURE &

PART NUMBER RANK QTY

KEY No.

S- 1 XB4-7300-809

2 XA9-1756-000

DESCRIPTION

SCREW, TAP, BINDING HEAD, M3X8

SCREW, TP, M3X8

REMARKS

3

4

5

6

XB4-7300-805

XB1-2300-405

XA9-1752-000

XB1-2300-605

SCREW, TP, BH3X8

SCREW, MACH.BH, M3X4

SCREW, TAP, WASHER HEAD, M3X12

SCREW, MACHINE, M3X6

7 XA9-1915-000

8 XB6-7300-605

9 XB4-7300-605

10 XA9-1783-000

SCREW, SPRING W WASHER M3X10

SCREW, MACHINE, TP, M3X6

SCREW, BH M3X6

SCREW, BINDING HEAD M2.6X3.5

(56/58)

NUMERICAL INDEX

PART NUMBER

FIGURE

&

KEY No.

DESCRIPTION

QC1-9023-000 3- 1 EMBLEM

QC1-9024-000 3- 1 EMBLEM

QC2-7526-000 11- 1 BELT, PAPER FEED

QC2-7654-000 7- 3 GEAR, PICK UP SHAFT

QC2-7667-000 11- 3 BUSHING, PAPER FEED ROLLER

QC2-7765-000 11- 4 FILM, TIMING SLIT DISK FEED

QC2-7783-000 10- 1 FILM, TIMING SLIT STRIP

QC2-7863-000 4- 2 HINGE

QC2-7871-000 3- 9 TOP COVER, OPERATION REAR

QC2-7872-000 3- 8 EDGE PANEL, OPERATION

MIDDLE FRAME, OPERATION

QC2-7874-000 3- 10

REAR

QC2-7882-000 5- 13 COVER, LCD FRONT

QC2-7883-000 5- 17 COVER, LCD TOP

QC2-7884-000 5- 18 EDGE PANEL, LCD

QC2-7886-000 5- 14 HINGE, LCD L

QC2-7887-000 5- 15 HINGE, LCD R

QC2-7921-000 8- 12 FRONT COVER, MIDDLE

QC2-7925-000 6- 5 SHEET, PE BIND

QC2-8026-000 5- 8 BASE, JOG WHEEL

QC2-9308-000 5- 11 LABEL, PRODUCT NAME

QC2-9309-000 5- 11 LABEL, PRODUCT NAME

QC2-9324-000 4- 3 SHEET, DOCUMENT PRESSURE

QH2-2716-000 1- 3 CORD, POWER

PART

NUMBER

FIGURE

&

KEY No.

DESCRIPTION

QK1-0776-000 1- 3 POWER

QK1-1500-000 104 MOTOR,

QK1-2017-000 1- 3 POWER

QK1-3048-000 1- 3 POWER

QK1-3761-000 1- 3 POWER

QK1-3849-000 126 MOTOR, PAPER FEED

QK1-4512-000 8- 1 CABLE, CARD SLOT

QK1-4815-000 8- 11 PANEL

QK1-4835-000 8- 9 CABLE, PE SENSOR

QK1-4965-000 2- 1 AC ADAPTER: 100V-240V 50/60HZ

QK1-5002-000 8- 2 PICTBRIDGE

QK1-5034-000 8- 10 CABLE, LF ENCODER

QL2-2525-000 112 LF ROLLER ASS'Y

QL2-2528-000 103 PULLEY HOLDER UNIT

QL2-2529-000 9- 2 PAPER FEED ROLLER ASS'Y

QL2-2602-000 3- 7 COVER, OPERATION PANEL

QL2-2603-000 3- 7 COVER, OPERATION PANEL

QL2-2604-000 3- 7 COVER, OPERATION PANEL

QL2-2605-000 3- 7 COVER, OPERATION PANEL

QL2-2606-000 3- 7 COVER, OPERATION PANEL

QL2-2607-000 3- 7 COVER, OPERATION PANEL

QL2-2609-000 5- 16 LCD CABLE ASS'Y

QM3-3598-000 102 CARRIAGE

QM3-3610-000 9- 3 CASSETTE FEED GUID UNIT

QM3-3614-000 105 PRESSURE ROLLER ASS'Y

QM3-3617-000 117 SPUR

QM3-3618-000 115 PLATEN/EJECT ROLLER UNIT

QM3-3619-000 121 PURGE

QM3-3633-000 9- 1 UNIT

QM3-3641-000 6- 1 REAR GUIDE UNIT

QM3-3644-000 7- 4 PICK UP ARM UNIT

QM3-3651-000 122 PURGE MOTOR UNIT

QM3-3681-000 6- 3 FRONT DOOR UNIT

QM3-3682-000 3- 4 SIDE COVER R UNIT

QM3-3683-000 3- 5 SIDE COVER L UNIT

QM3-3684-000 3- 3 ASF COVER UNIT

QM3-3685-000 1- 1 UNIT

QM3-3689-000 3- 2 UNIT

QM3-3692-000 4- 1

QM3-3694-000 64 SUB CASE UNIT

(57/58)

PART NUMBER

FIGURE

&

KEY No.

DESCRIPTION

QM3-3707-000 8- 7 LOGIC BOARD ASS'Y

QM3-3708-000 8- 5 CARD BOARD ASS'Y

QM3-3709-000 5- 9 PANEL BOARD ASS'Y

QM3-3711-000 7- 1 FRONT DOOR LINK UNIT

QM3-4278-000 7- 2 DC HARNESS ASS'Y

QM3-4445-000 12- 7 LF MOTOR HARNESS ASS'Y

QM3-4449-000 12- 3 MOTOR MULTI HARNESS ASS'Y

PAPER FEED RELAY HANESS

QM3-4453-000 12- 4

ASS'Y

QM3-4467-000 8- 6 PICTBRIDGE BOARD UNIT

QM3-4757-000 9- 4 PAPER GUIDE UNIT

QM3-5094-000 12- 5 SWITCH SYSTEM UNIT

QM3-3696-000 5- 10 UNIT

PART

NUMBER

FIGURE

&

KEY No.

DESCRIPTION

WT3-5156-000 1- 3 POWER

WT3-5160-000 1- 3 POWER

SCREW, TAP, WASHER HEAD,

XA9-1752-000 S- 5

M3X12

XA9-1756-000 S- 2 SCREW, TP, M3X8

XA9-1783-000 S- 10 SCREW, BINDING HEAD M2.6X3.5

SCREW, SPRING W WASHER

XA9-1915-000 S- 7

M3X10

XB1-2300-405 S- 4 SCREW, MACH.BH, M3X4

XB1-2300-605 S- 6 SCREW, MACHINE, M3X6

XB4-7300-605 S- 9 SCREW, BH M3X6

XB4-7300-805 S- 3 SCREW, TP, BH3X8

SCREW, TAP, BINDING HEAD,

XB4-7300-809 S- 1

M3X8

XB6-7300-605 S- 8 SCREW, MACHINE, TP, M3X6

QY9-0057-000 T- 1 LUBE, FLOIL KG107A, OIL

(58/58)

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