Canon Pixma iP5200 Service Manual

PIXMA iP5200 PIXMA iP5200R

SER VICE MANUAL

Canon

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.

ll 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.

I. MANUAL OUTLINE

This manual consists of the following three parts to provide information necessary to service the PIXMA iP5200:

Part 1: Maintenance Information on maintenance and troubleshooting of the PIXMA iP5200

Part 2: Technical Reference New technology and technical information such as FAQ's (Frequently Asked Questions) of the PIXMA iP5200

Part 3: Appendix Block diagrams and pin layouts of the PIXMA iP5200

Reference: This manual does not provide sufficient information for disassembly and reassembly procedures. Refer to the graphics in the separate Parts Catalog.

II. TABLE OF CONTENTS

Part 1: MAINTENANCE

1. MAINTENANCE

-1. Adjustment, Periodic Maintenance, Periodic Replacement Parts, and Replacement Consumables by

Service Engineer

-2. Customer Maintenance

-3. Product Life

-4. Special Tools

-5. Serial Number Location

2. LIST OF ERROR DISPLAY / INDICATION

-1. Operator Call Errors

-2. Service Call Errors

-3. Warnings

-4. Troubleshooting by Symptom

3. REPAIR 3-1. Notes on Service Part Replacement (and Disassembling / Reassembling)

-2. Special Notes on Repair Servicing

-3. Adjustment / Settings

(1) Paper feed motor adjustment (2) Grease application (3) Waste ink counter setting (4) User mode (5) Service mode

-4. Verification Items

(1) Service test print (2) EEPROM information print

4. PRINTER TRANSPORTATION

Destination settings LF correction

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Part 2: TECHNICAL REFERENCE

1. NEW TECHNOLOGIES

2. CLEANING MODE AND AMOUNT OF INK PURGED

3. PRINT MODE

4. FAQ (Problems Specific to the iP5200 and Corrective Actions)

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Part 3: APPENDIX

1. BLOCK DIAGRAM

2. CONNECTOR LOCATION AND PIN LAYOUT

-1. Logic Board Ass'y

-2. Carriage Board (Print Head Connector)

PIXMA iP5200 Specifications

Part 1

MAINTENANCE

1. MAINTENANCE

1-1

1-1. Adjustment, Periodic Maintenance, Periodic Replacement Parts, and

Replacement Consumables by Service Engineer

(1) Adjustment

Adjustment Timing Purpose Tool

Destination settings (EEPROM settings)

Waste ink counter resetting (EEPROM settings)

Paper feed motor position

adjustment

CD / DVD detection sensor light volume

correction Grease

application

At logic board replacement

- At logic board replacement

- At waste ink absorber replacement

At paper feed motor replacement

- At logic board replacement

- At carriage unit replacement

- At PR shaft ass'y replacement

- At CL base / gear replacement

To set the destination.

To reset the waste ink counter.

To adjust the belt tension. (Position the paper feed motor so that the belt is stretched

tight.) To correct the light volume for

the CD / DVD detection sensor.

- To maintain sliding properties

- To protect the printer's

of the carriage shaft and the lift cam shaft.

sliding portions (gears).

None. Perform in the

service mode.

None. Perform in the

service mode.

None.

None. Perform in the

service mode.

FLOIL KG-107A 1 min.

Approx.

time

1 min.

5 min.

2 min.

Ink system function check

LF correction

- At logic board replacement

- At platen unit replacement

- At carriage unit replacement

- At feed roller replacement

- At logic board replacement

To maintain detection functionality for presence of the ink tanks and each ink tank position.

To correct the line feed accuracy

None. Perform in the

service mode.

None. Perform in the

service mode.

1 min.

3 min.

󲩷 󲩷

Note: DO NOT loosen the red screws at both ends of the carriage shaft, securing the print head position, as

they are not re-adjustable. The red screws securing the paper feed motor may be loosened only at replacement of the paper

feed motor unit.

*1: Only for CD / DVD printing supported regions.

(2) Periodic maintenance

No periodic maintenance is necessary.

(3) Periodic replacement parts

There are no parts in this printer that require periodic replacement by a service engineer.

(4) Replacement consumables

There are no consumables that require replacement by a service engineer.

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1-2

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1-2. Customer Maintenance

Adjustment Timing Purpose Tool

Print head alignment

Print head cleaning

Print head deep cleaning

Ink tank replacement

Paper feed roller cleaning

At print head replacement. To ensure accurate dot

When print quality is not satisfying.

When print quality is not satisfying, and not improved by print head cleaning.

When an ink tank becomes empty. ("No ink error" via the computer, or ink tank LED flashing fast in red)

When necessary

- Printer buttons

placement.

To improve nozzle conditions.

----- -----

- Computer (automatic settings via the

printer driver)

- Printer buttons

- Computer (settings via the printer driver)

Computer (settings via the printer driver)

To clean the paper feed rollers.

Printer buttons

Approx.

time

3 min.

1 min.

2 min.

1 min.

2 min.

CD / DVD print position

adjustment Bottom plate

cleaning

ASF sub- roller cleaning

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At CD / DVD printing, when necessary

When the back side of the paper is smeared

When the paper fed from the ASF is smeared due to ink mist attached to the ASF sub-

rollers.

1-3. Product Life

To correct CD / DVD print position.

To clean the platen ribs.

To clean the ASF subrollers.

Computer (application software)

- Plain paper

- Computer (settings via the printer

driver)

- Plain paper

- Printer buttons

[See Part 2, 4. FAQ,

How to make and set the ASF subroller cleaning

sheet, for details]

5 min.

1 min.

(1) Printer

Specified print volume (I) or the years of use (II), whichever comes first. (I) Print volume : 18,000 pages

Black

1,500 character pattern 8,300 pages

Color

1-3

A4, 7.5% duty per color pattern 5,400 pages

(II) Years of use

󲩷󲩷󲩷󲩷󲩷󲩷󲩷󲩷 5 years of use

(2) Print head

Print volume : 18,000 pages

(3) Ink tank (target value)

Black Color

A4, photo, borderless printing 400 pages

4 x 6, photo, borderless printing 3,200 pages

Postcard, photo, borderless printing 700 pages

1,500 character pattern 8,300 pages

A4, 7.5% duty per color pattern 5,400 pages

A4, photo, borderless printing 400 pages

4 x 6, photo, borderless printing 3,200 pages

Postcard, photo, borderless printing 700 pages

Pattern Ink tank used Print yield

Black text PGI-5BK Approx. 800 pages

PGI-5BK Approx. 1,250 pages CLI-8Y Approx. 480 pages

Color chart

CLI-8M Approx. 500 pages CLI-8C Approx. 710 pages CLI-8BK Approx. 1,100 pages CLI-8Y Approx. 280 pages

Photo chart

CLI-8M Approx. 250 pages

󲩷 󲩷

Black text: When printing the Canon standard pattern (1,500 characters per page) on A4 size plain

paper, with the default settings in the Windows XP driver, using Word 2003.

Color chart: When printing the ISO/JIS-SCID N5 pattern on A4 size plain paper in bordered printing, with

the default settings in the Windows XP driver, using Photoshop 7.0.

Photo chart: When printing the Canon standard pattern on 4" x 6" Photo Paper Plus Glossy in

borderless printing, with the default settings in the Windows XP driver, using Windows XP Photo Printing Wizard.

The print yield in the table above is an average value measured in continuous printing, using the ink tank

CLI-8C Approx. 390 pages

immediately after it is unsealed, until the ink is out. Ink yield may vary depending on texts and photos

1-4

printed, application software, print mode, and type of paper used.

1-4. Special Tools

Name Tool No. Application Remarks

Grease FLOIL KG-107A

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1-5. Serial Number Location

On the carriage flexible cable holder (visible on the right of the carriage after the printer is turned on, the access cover is opened, and the carriage moves to the center).

QY9-0057-000 To be applied to the sliding

portions of the carriage shaft and lift cam shaft.

In common with the S500 and S520.

To the top

2. LIST OF ERROR DISPLAY / INDICATION

1-5

Errors are indicated by the LED, and warnings are displayed on the monitor of the computer connected to the printer.

2-1. Operator Call Errors (by Alarm LED Blinking in Orange)

Alarm

LED

blinking

in orange 2 times

3 times

4 times No ink. [1600] Replace the empty ink tank(s), or press

No paper. (ASF) [1000]

No CD / DVD tray. [1001]

No paper in the cassette. [1003]

(No paper in the front paper feed cassette.)

No CD / DVD disc. [1002]

Paper jam. [1300] Remove the jammed paper, and press

Paper jam in the rear guide. [1303]

Paper jam in the under guide. [1304]

Front door close error. [1250] Open the paper output tray. The error is

Ink tank not installed. [1660] Install the applicable ink tank(s)

Error [Error code]

Set the paper in the ASF, and press the Resume/Cancel button.

Set the CD / DVD tray, and press the Resume/Cancel button.

Set the paper in the cassette, and press the Resume/Cancel button.

Set a CD or DVD in the CD / DVD tray (which is ejected at error occurrence), and insert the CD / DVD tray in the proper position. Then, press the Resume/Cancel button.

the Resume/Cancel button.

properly, and confirm that the LED's of all the ink tanks light red.

Solution Remarks

Error in paper feeding from the ASF.

Error in the duplex printing unit.

Error in paper feeding from the cassette.

indicated if the paper output tray is closed at start of a print job, or while a print job is being performed.

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 ,

or it is not properly installed.

Install the print head properly.

6 times

1-6

[1401]

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Print head temperature sensor error [1403]

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Faulty EEPROM data of the print head [1405]

Inner cover open. [1841]

Close the inner cover, and press the Resume/Cancel button.

7 times

Inner cover open during printing on paper. [1846]

Inner cover open (print continuable). [1851]

Inner cover open during printing on paper (print NOT

continuable). [1856]

Inner cover closed during CD / DVD printing (print

continuable). [1850]

Inner cover closed during CD / DVD printing (print NOT

continuable). [1855]

Multiple ink tanks of the same color installed. [1681]

Close the inner cover, and press the Resume/Cancel button to clear the error. The paper being printed at error occurrence will be ejected without printing the remaining data for the ejected paper, then printing will resume from the next page.

Close the inner cover, and press the Resume/Cancel button.

Open the inner cover which functions as the CD / DVD tray feeder, set the CD / DVD tray in the feeder, and press the Resume/Cancel button.

Open the inner cover, and press the Resume/Cancel button to clear the error. The CD or DVD being printed at error occurrence will be ejected without printing the remaining data for the ejected CD or DVD, then the next print

job will be done.

Replace the wrong ink tank(s) with the correct one(s).

Ink tank in a wrong position. [1680]

8 times Warning: The waste ink

absorber becomes almost full. [1700]

9 times The connected digital camera

or digital video camera does not support Camera Direct Printing. [2001]

10 times Automatic duplex printing

cannot be performed. [1310]

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

Pressing the Resume/Cancel button will exit the error, and enable printing.

Remove the cable between the camera and the printer.

The size of paper may not be compatible with automatic duplex printing. Press the Resume/Cancel

The service call error, indicating the waste ink absorber is full, is likely to occur soon.

Data which was to be printed on the back side of

11 times

1-7

Failed in automatic print head alignment. [2500]

button to eject the paper being used at error occurrence. Printing will resume from on the front side of the next page.

Press the Resume/Cancel button.

- If paper is being fed at error occurrence, the error is indicated after the paper is ejected.

- If the error occurs, the print head alignment values are not changed.

- After exit from the error by the Resume/Cancel button, the automatic print head alignment will not be redone.

paper at error occurrence is skipped (not printed).

The error is indicated when the pattern is not printed due to no ink or nonejection of ink, or when the sensor's AD value is incorrect.

13 times

14 times

15 times

No blinking

The remaining ink amount unknown. [1683]

Ink tank not recognized. [1684] A non-supported ink tank is installed

Ink tank not recognized. [1410 to 1419]

Access cover open. [1200]

An ink tank which has once been empty is installed. Replace the applicable ink tank with a new one.

(the ink tank LED is turned off). Install the supported ink tanks.

An error occurred in an ink tank (the ink tank LED is turned off). Replace the ink tank(s).

Close the access cover.

Printing with a once-empty or refilled ink tank can damage the print head.

If printing is continued without replacing the "nogood" ink tank, press the Resume/Cancel button for 5 sec. or longer to record the use of a refilled ink tank.

Note: After the above

operation, the function to detect the remaining ink amount is disabled.

*1: Only for models supporting CD / DVD printing *2: Only for models not supporting CD / DVD printing

󲩷

2-2. Service Call Errors (by Cyclic Blinking in Orange (Alarm LED) and Green

(Power LED), or Alarm LED Lit in Orange)

Cycles of

blinking in

orange (Alarm

LED) and

green (Power

Error [Error code]

(Replacement of listed parts, which are likely to be faulty)

Solution

LED)

1-8

2 times

Carriage error [5100]

- Carriage unit (QM2-2251)

- Timing slit strip film (QC1-6526)

- Logic board ass'y (QM2-2733)

- Carriage motor (QK1-1500)

3 times

4 times

5 times

6 times

7 times

8 times

9 times

11 times

Line feed error [6000]

Purge cam sensor error [5C00]

ASF (cam) sensor error [5700]

Internal temperature error [5400]

Waste ink absorber full [5B00]

Print head temperature rise error [5200]

EEPROM error [6800]

Carriage lift mechanism error [5110]

- Timing sensor unit (QM2-2683)

- Timing slit disk film (QC1-6229)

- Feed roller ass'y (QL2-0950)

- Platen unit (QM2-2248)

- Logic board ass'y (QM2-2733)

- PAPER FEED MOTOR (QK1-1502)

- Purge unit (QM2-2252)

- Logic board ass'y (QM2-2733)

- Sheet feed unit (QM2-2278)

- Logic board ass'y (QM2-2733)

- Ink absorber kit (QY5-0152)

- Print head (QY6-0059)

- Logic board ass'y (QM2-2733)

- PR lift shaft ass'y (QL2-0936)

- Sheet feed unit (QM2-2278)

- Logic board ass'y (QM2-2733)

- Carriage lift sensor unit (QM2-2678)

12 times

13 times

14 times

15 times

16 times

17 times

19 times Ink tank position sensor

20 times

AP position error [6A00]

Paper feed position error [6B00]

Paper feed cam sensor error [6B10]

USB Host Vbus over current [9000]

Valve sensor error [6C00]

Motor driver error [6D00]

error [6502]

Other hardware error

- Sheet feed unit (QM2-2278)

- Logic board ass'y (QM2-2733)

- Purge unit (QM2-2252)

- Sheet feed unit (QM2-2278)

- Logic board ass'y (QM2-2733)

- Sheet feed unit (QM2-2278)

- Logic board ass'y (QM2-2733)

- Purge unit (QM2-2252)

- Logic board ass'y (QM2-2733)

- Platen unit (QM2-2248)

- Logic board ass'y (QM2-2733)

[6500]

1-9

Continuous alternate blinking

Alarm LED lit RAM error

*1: Before replacement of the logic board ass'y, check the waste ink amount (by service test print or

EEPROM information print). If the waste ink amount is 7% or more, also replace the ink absorber kit (QY5-0152) when replacing the logic board ass'y.

[See Section 3

ROM error

-3. Adjustment / Settings, (5) Service mode, for details.]

- Logic board ass'y (QM2-2733)

2-3. Warnings

Printer (no LED indications):

Displayed warning Remarks

Low ink

Print head temperature rise

Protection of excess rise of the print head temperature

*1: If the warning is displayed, the carriage does not move to the ink tank replacement position when the

access cover is opened.

2-4. Troubleshooting by Symptom

Symptom Solution Remarks

- Status monitor indication.

- The ink tank lamp flashes slowly (at about a second interval).

The power does not turn on. The power turns off

immediately after power-on.

If the print head temperature is high when the access cover is opened, the warning is displayed

When the print head temperature falls, the warning is released.

If the print head temperature exceeds the specified limit, a Wait is inserted during printing,

Replace the

- AC adapter, or

- logic board ass'y*1.

Faulty operation

Paper feed

problems

A strange noise occurs. Remove foreign material, or attach a

removed part if any.

Printing stops mid-way.

Multiple sheets feed.

Paper does not feed.

Paper feeds at an angle. Remove foreign material, adjust the

Replace the logic board ass'y*1.

Replace the

- sheet feed unit, or

- cassette.

Remove foreign material, or replace the

- sheet feed unit, or

- cassette.

paper guide, or replace the

- sheet feed unit, or

1-10

- cassette.

No printing, or no color ejected. Replace the

- ink tank,

- print head*2, or

- logic board ass'y*1,

remove foreign material from the purge unit caps, if any, or

replace the purge unit.

Unsatisfactory

print quality

Printing is faint, or white lines appear on printouts even after print head cleaning.

Line(s) not included in the print data appears on printouts.

Paper gets smeared.

A part of a line is missing on printouts.

Color hue is incorrect.

Remove and re-install the print head, or replace the

- ink tank,

- print head*2,

- purge unit, or

- logic board ass'y*1.

Feed several sheets of paper, perform bottom plate cleaning, clean the paper path with cotton swab

or cloth, or clean the ASF sub-rollers. Replace the

- ink tank, or

- print head*2.

Replace the

- ink tank, or

- print head*2, or

perform print head alignment.

Printing is incorrect.

No ejection of black ink. Replace the

Graphic or text is enlarged on printouts.

Replace the logic board ass'y*1.

- ink tank, or

- print head*2, or

remove foreign material from the purge unit caps, if any, or

replace the purge unit.

When enlarged in the carriage movement direction, clean grease or oil off the timing slit strip film, or replace the

- timing slit strip film,

- carriage unit, or

- logic board ass'y*1.

When enlarged in the paper feed direction, clean grease or oil off the timing slit disk film, or replace the

- timing slit disk film,

1-11

- timing sensor unit, or

- logic board ass'y*1.

󲩷

Uneven printing due to line feeding

*1: Before replacement of the logic board ass'y, check the waste ink amount (by service test print or

EEPROM information print). If the waste ink amount is 7% or more, also replace the ink absorber kit (QY5-0152) when replacing the logic board ass'y.

[See Section 3

*2: Replace the print head only after the print head deep cleaning is performed 2 times, and when the

problem persists.

-3. Adjustment / Settings, (5) Service mode, for details.]

Perform LF correction adjustment.

To the top

3. REPAIR

1-12

3-1. Notes on Service Part Replacement (and Disassembling / Reassembling)

Service part

Logic board ass'y QM2-2733

Ink absorber kit QY5-0152

Carriage unit QM2-2251

Paper feed motor QK1-1502

Notes on replacement

- Before removal of the logic board ass'y, remove the power cord, and allow for approx. 1 minute (for discharge of capacitor's accumulated charges), to prevent damages to the logic board ass'y.

- Before replacement, check the waste ink amount (by service test print or EEPROM information print). If the waste ink amount is 7% or more, also replace the ink absorber kit when replacing the logic board ass'y.

[See 3-3. Adjustment / Settings, (5) Service mode, for details.]

- The red screws securing the paper feed motor are allowed to be loosened. (DO NOT loosen any

Adjustment / settings Operation check

After replacement:

1. Initialize the EEPROM.

2. Reset the waste ink counter.

3. Set the destination in the EEPROM.

4. Correct the CD / DVD and automatic print head alignment sensors.

5. Check the ink system function.

[See 3-3. Adjustment / Settings, (5) Service mode, for details of 1 to 5]

6. Perform the print head alignment in the user mode.

- EEPROM information print

- Service test print

- Printing via USB connection

- Direct printing from a digital camera

After replacement:

1. Reset the waste ink counter.

[See 3.3. Adjustment / Settings, (5) Service mode.]

At replacement:

1. Apply grease to the sliding portions.

[See 3 Settings, (2) Grease application.]

After replacement:

1. Correct the CD / DVD and automatic print head alignment sensors.

[See 3.3. Adjustment / Settings, (5) Service mode.]

2. Check the ink system function.

[See 3.3. Adjustment / Settings, (5) Service

mode.]

3. Perform the print head alignment in the user mode.

At replacement:

1. Adjust the paper feed

motor.

-3. Adjustment /

- Service test print

- EEPROM information print

- Service test print (Confirm CD / DVD and automatic print head alignment sensor correction, and ink

system function.)

Platen unit: QM2-

1-13

2248 Purge unit: QM2-

2252 Waste ink tube:

QC1-6458 Waste ink tube

holder: QC1-6460

Platen unit QM2-2248

PR lift shaft ass'y QL2-0936

󲩷

CL INPUT GEAR QC1-6213

Timing slit strip film QC1-6526

Timing slit disk film QC1-6229

other red screws.) [See 3-3. Adjustment /

Settings, (1) Paper feed motor adjustment.]

By attaching the tape at

the specified 2 locations, secure the waste ink tube to the waste ink tube holder.

- Upon contact with the film, wipe the film with ethanol.

- Confirm no grease is on the film. (Wipe off any grease thoroughly with ethanol.)

- Do not bend the film

At replacement:

1. To protect the waste ink tube from being pinched when reassembling the printer unit chassis into the bottom case unit, tape the tube (at 2 locations).

[See 3-2. Special Notes on Repair Servicing, (3) Printer unit and bottom case unit assembly.]

After replacement

1. Check the ink system function.

[See 3-3. Adjustment / Settings, (5) Service mode.]

At replacement:

1. Apply grease to the

[See 3.3. Adjustment / Settings, (2) Grease application.]

After replacement:

1. Perform the print head

sliding portions.

alignment in the user mode.

After the printer unit is assembled in the bottom case unit, the tube conditions are not visible. For confirmation of the tube conditions, perform the manual purging 3 or 4 times, and confirm that no strange noise is heard.

- Service test print

Print head QY6-0061

󲩷

*1: General notes:

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

-2. Special Notes on Repair Servicing, (2) Flexible cable and harness wiring, connection, for

[See 3 details.]

- Protect the waste ink tube from being pinched when assembling the printer unit chassis into the bottom case unit.

Since the tube conditions after assembly are not visible, perform the manual purging 3 or 4 times to confirm that no strange noise is heard.

[See 3 details.]

-2. Special Notes on Repair Servicing, (3) Printer unit and bottom case unit assembly, for

After replacement:

1. Perform the print head alignment in the user mode.

- Service test print

- Do not drop the ferrite core, which may cause damage.

1-14

- Protect electrical parts from damage due to static electricity.

- Before removing a unit, after removing the power cord, allow the printer 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 film. No grease or abrasion is allowed.

- Protect the units from soiled with ink.

- Protect the housing from scratches.

- Exercise caution with the red screws, as follows:

i. The red 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. DO NOT loosen the red screws on both sides of the main chassis, securing the carriage

shaft positioning (they are not adjustable in servicing).

󲩷

To the top

3-2. Special Notes on Repair Servicing

1-15

(1) External cover removal

󲩷

(I) With your fingers at the points indicated by the blue circle, raise and slide the left and right side

covers to remove them.

󲩷

(II) Release the 2 hooks on the rear side of the printer (indicated by the blue circles).

󲩷

(III) Slide the left and right panel cover units.

+ 44 hidden pages