Canon Pixma MG5100 Simplified Service Manual

MG5100 series SIMPLIFIED SERVICE MANUAL

(MG5120 / MG5140 / MG5150 / MG5170 / MG5180)

QY8-13CX-000

Rev.00

July 2010

Canon Inc.

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Table of Contents

1. LIST OF ERROR DISPLAY / TROUBLESHOOTING....................................................		3
1-1.	Troubleshooting by Symptom..........................................................................................	3
1-2. Operator Call Error (Alarm LED Lit In Orange) Troubleshooting.....................................		5
1-3. Service Call Error (by Cyclic Blinking of Alarm and Power LEDs) Troubleshooting........		8
2. REPAIR / ADJUSTMENT / SETTINGS .......................................................................		13
2-1. Major Replacement Parts and Adjustment....................................................................		13
2-2. Adjustment and Settings in Service Mode ....................................................................		23
2-3.	Adjustment and Maintenance in User Mode .................................................................	30
2-4.	Grease Application........................................................................................................	31
2-5.	Special Notes on Servicing ...........................................................................................	32

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1.LIST OF ERROR DISPLAY / TROUBLESHOOTING

1-1. Troubleshooting by Symptom

operation Faulty

	Symptom		Solution
	The power does not turn on.		Confirm cable connection.
		(1)
	The power turns off immediately after		- DC harness ass'y
	power-on.		- Power switch harness ass'y
		=> No incomplete connection, cable breakage, or
			cable caught in units
		(2)	Replace the following item(s):
			- Logic board ass'y
			- AC adapter
			- DC harness ass'y
	A strange noise occurs.	(1)	Examine and remove any foreign material from the
			drive portions.
		(2)	Replace the following item(s):
			- Purge drive system unit
	The LCD does not display properly.	(1)	Confirm cable connection (LCD cable ass'y and
	A portion of the LCD is not displayed.		panel cable ass'y):
	The display flickers.		- LCD cable ass'y
			- Panel cable ass'y
		=> No incomplete connection, cable breakage, or
			cable caught in units
		(2)	Replace the following item(s):
			- LCD unit
			- LCD cable ass'y
			- Panel cable ass'y
			- Operation panel unit
			- Logic board ass'y
	Paper feed problems (multi-feeding, skewed	(1)	Examine and remove any foreign material from the
	feeding, no feeding).		following parts:
			- ASF unit
			- PE sensor
			- Paper guide unit
			- Pressure roller unit
			- Spur unit
		(2)	Confirm the PF rear cover and the cassette
			conditions.
		(3)	Confirm cable connection.
			- PE sensor cable
			- Paper feed motor harness ass'y
		=> No incomplete connection, cable breakage, or
			cable caught in units
		(4)	Replace the following item(s):
			- ASF unit (for paper feeding error from the rear
			tray)
			- Pick-up arm unit (for paper feeding error from
			the cassette)
			- PE sensor board ass'y
			- Pressure roller ass'y
			- Cassette unit
			- PE sensor cable

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Symptom

Solution

	Faulty scanning (no scanning, strange noise).	(1)	Confirm cable connection:
			- Scanner motor relay harness ass'y
			- Scanner encoder relay harness ass'y
			- CIS FFC
		=> No incomplete connection, cable breakage, or
			cable caught in units
		=> Nothing strange under the platen glass (such as
			improper position of the FFC damper)
		(2)	Replace the following item(s):
			- Scanner unit
			- Logic board ass'y
	Machine not recognized by a USB-connected	(1)	Confirm the USB cable connection.
	computer.	(2)	Connect the machine to another computer via the
			USB cable, and check if the machine is recognized.
		(3)	Replace the following item(s):
			- USB cable
			- Logic board ass'y
Unsatisfactory	No printing, or no color ejected.	See 2-5. Special Notes on Servicing, (1) For smeared
	Faint printing, or white lines on printouts.		not
		printing, uneven printing, or non-ejection of ink.
	Uneven printing.	(1)	Confirm the ink tank conditions:
print	Improper color hue.		- Whether the ink tank is Canon-genuine one or
			- Whether the ink tank is refilled one or not
quality			- No remainder of the outer film (the air-through
			must be opened)
			- Re-setting of an ink tank
		(2)	Remove foreign material from the purge unit caps, if
			any.
		(3)	Confirm the conditions of the carriage head contact
			pins
		(4)	Perform cleaning or deep cleaning of the print head.
		(5)	Perform print head alignment.
		(6)	Replace the following item(s):
			- Print head*1, and ink tanks
			- Logic board ass'y
			- Purge drive system unit
			- Carriage unit
	Paper gets smeared.	(1)	Clean the inside of the machine.
		(2)	Perform bottom plate cleaning.
		(3)	Perform paper feed roller cleaning.
		(4)	Replace the following item(s):
			- Pressure roller ass'y (if smearing is heavy)
			- Print head*1 (when smearing is caused by the
			print head)
	The back side of paper gets smeared.	(1)	Clean the inside of the machine.
		(2)	Perform bottom plate cleaning.
		(3)	Examine the platen ink absorber.
		(4)	Examine the paper eject roller.
		(5)	Replace the following item(s):
			- The part in the paper path causing the
			smearing

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			Symptom		Solution
			Graphic or text is enlarged on printouts in the	(1)	Confirm that the carriage slit film is free from
			carriage movement direction.		smearing or scratches:
					- Cleaning of the timing slit strip film.
				(2)	Replace the following item(s):
					- Timing slit strip film
					- Carriage unit
					- Logic board ass'y
					- Scanner unit (for copying)
			Graphic or text is enlarged on printouts in the	(1)	Confirm that the LF / EJ slit film is free from
			paper feed direction.		smearing or scratches:
					- Cleaning of the LF / EJ slit film.
				(2)	Replace the following item(s):
					- Timing slit disk feed film
					- Timing slit disk eject film
					- Timing sensor unit
					- Platen unit
					- Logic board ass'y
					- Scanner unit (for copying)
		Faulty	No scanning.	(1)	Replace the following item(s):
					- Scanner unit
		scanning			- Logic board ass'y
			Streaks or smears on the scanned image.	(1)	Clean the platen glass and the document pressure
					sheet.
				(2)	Confirm the position of the document pressure
					sheet.
				(3)	Replace the following item(s):
					- Scanner unit
					- Document pressure sheet
					- Logic board ass'y

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

1-2. Operator Call Error (Alarm LED Lit In Orange) Troubleshooting

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 printer 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.

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	Error	Error	U No.	Message on the LCD	Solution	Parts that are
		code				likely to be faulty
	No paper in the	[1000]	---	Rear tray.	Confirm that the rear tray is	-PE sensor
	rear tray.			There is no paper.	selected as the paper source.	board ass'y
				Load paper	Set the paper in the rear tray, and	-ASF unit
				and press [OK].	press the OK button.	-Pressure roller
					If the error is not cleared, confirm	ass'y
					that no foreign material is inside
					the paper feed slot.
	No paper in the	[1003]	---	Cassette.	Confirm that the cassette is	-Pick-up arm
	cassette.			There is no paper.	selected as the paper source.	unit
				Load paper and	Set the paper in the cassette, and	-Pressure roller
				press [OK].	press the OK button.	ass'y
					Note that the cassette is for plain	-Cassette unit
					paper only.
	Paper jam.	[1300]	---	The paper is	Remove the jammed paper and	-Pick-up arm
	Paper jam in the	[1303]	---	jammed. Clear the	press the OK button.	unit
	rear guide.			paper and press	For paper jam in the rear guide,	-ASF unit
	Paper jam in the	[1304]	---	[OK].	confirm that the rear guide is not	-Pressure roller
	under guide.				dislocated.	ass'y
						-Cassette unit
						-Rear guide unit
	Ink may have run	[1600]	U04	The ink may have	Replace the applicable ink tank, or	-Spur unit
	out.		1	run out. Replacing	press the Stop button to clear the
				the ink tank is	error without ink tank replacement.
				recommended.	When the error is cleared by
					pressing the Stop button, ink may
					run out during printing.
	Ink tank not	[1660]	U04	The following ink	Install the applicable ink tank(s)	-Ink tank
	installed.		3	tank cannot be	properly, and confirm that the	-Carriage unit
				recognized.	LED's of all the ink tanks light red.
				(Applicable ink tank
				icon)
	Print head not	[1401]	U05	Print head is not	Install the print head properly.	-Print head
	installed, or not		1	installed. Install the	If the error is not cleared, confirm	-Carriage unit
	properly			print head.	that the print head contact pins of
	installed.				the carriage are not bent.
	Faulty print head		U05	The type of print	Re-set the print head. If the error is	-Print head
	ID.		2	head is incorrect.	not cleared, the print head may be	-Carriage unit
	Print head	[1403]		Install the correct	defective. Replace the print head.
	temperature			print head.	If the error still occurs, confirm that
	sensor error.				the print head contact pins of the
	Faulty EEPROM	[1405]			carriage are not bent.
	data of the print
	head.
	Multiple ink tanks	[1487]	U07	More than one ink	Replace the wrong ink tank(s) with	-Ink tank
	of the same color		1	tank of the following	the correct one(s).
	installed.			color is installed.
	Ink tank in a	[1680]	U07	Some ink tanks are	Install the ink tank(s) in the correct	-Ink tank
	wrong position.		2	not installed in place.	position.

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	Error	Error	U No.	Message on the LCD	Solution	Parts that are
		code				likely to be faulty
	Warning: The	[1700]	---	The ink absorber is	Replace the ink absorber, and
	ink absorber			almost full. Press	reset its counter. See 2-2.
	becomes almost			[OK] to continue	Adjustment and Settings in Service
	full.			printing. Contact the	Mode for details.
				service center for	Pressing the OK button will exit the
				replacement.	error, and enable printing without
					replacing the ink absorber.
					However, when the ink absorber
					becomes full, no further printing
					can be performed unless the
					applicable ink absorber is
					replaced.
	The connected	[2001]	---	Incompatible device	Remove the cable between the
	digital camera or			detected. Remove	camera and the machine.
	digital video			the device.
	camera does not
	support Camera
	Direct Printing.
	Automatic duplex	[1310]	---	This paper is not	The paper length is not supported	-Duplex paper
	printing cannot be			compatible with	for duplex printing.	feed roller unit
	performed.			two-sided printing.	Press the OK button to eject the	-PE sensor
				Remove the paper	paper being used at error	board ass'y
				and press [OK].	occurrence.
					Data which was to be printed on
					the back side of paper at error
					occurrence is skipped (not
					printed).
	The remaining ink	[1683]	U13	(Applicable ink tank	An ink tank which has once been	-Ink tank
	amount unknown		0	icon)	empty is installed. Replace the	-Spur unit
	(raw ink present).			The remaining level	applicable ink tank with a new one.
				of the ink cannot be	Printing with a once-empty ink tank
				correctly detected.	can damage the machine.
				Replace the ink tank.	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.
	Ink tank not	[1684]	U14	The following ink	A non-supported ink tank is	-Ink tank
	recognized.		0	tank cannot be	installed (the ink tank LED is
				recognized.	turned off). Install the supported
				(Applicable ink tank	ink tanks.
				icon)
	Ink tank not	[1682]	U15	The following ink	A hardware error occurred in an	-Ink tank
	recognized.		0	tank cannot be	ink tank (the ink tank LED is turned
				recognized.	off). Replace the ink tank(s).
				(Applicable ink tank
				icon)

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	Error	Error	U No.	Message on the LCD	Solution	Parts that are
		code				likely to be faulty
	No ink (no raw	[1688]	U16	The ink has run out.	Replace the empty ink tank(s), and	-Ink tank
	ink).		3	Replace the ink tank.	close the scanning unit (cover).	-Spur unit
				(Applicable ink tank	Printing with an empty ink tank can
				icon)	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	[2002]	---	An unsupported USB	Remove the applicable USB hub
	hub.			hub is connected.	from the PictBridge (USB)
				Remove the hub.	connector.
	Time-out for the	[2700]	---	Timeout error has	The buffer became full in the
	scanner device.			occurred. Press [OK].	middle of scanning operation, and
					60 minutes have elapsed since
					then, making re-scanning unstable.
					Press the OK button to clear the
					error.
	Premium	[4100]	---	Cannot print the	Install the supported
	Contents print			data.	(Canon-genuine) ink tanks.
	error.

1-3. Service Call Error (by Cyclic Blinking of Alarm and Power LEDs) Troubleshooting

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.

yCheck each point in "Check points & Solution," and perform the solution if it applies.

yWhen no solution in "Check points & Solution" is effective, then replace the part listed under "Parts to be replaced" one by one from the one most likely to be faulty. The parts are listed in the order of likeliness to be faulty.

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	Cycles of					Parts that are likely
	blinking of	Error	Error		Check points & Solution	to be faulty (in the
	Alarm and		code			order of likeliness to
	Power LEDs					be faulty)
	2 times	Carriage error	[5100]	(1) Smearing or scratches on the carriage		-Timing slit strip film
					slit film:	-Carriage unit
					-> Clean the film using lint-free paper.	-Logic board ass'y
				(2)	Foreign material that obstructs the	-Carriage motor
					carriage movement:
					-> Remove foreign material.
				(3)	Ink tank conditions:
					-> Re-set the ink tanks.
				(4)	Cable connection (CR FFC J500, J501,
					J502, etc.):
					-> Re-connect the cables.
				(5)	Scratches or damages to the carriage slit
					film:
					-> Replace the timing slit strip film.
				(6)	Black debris around the carriage rail or
					pressure roller:
					-> Replace the carriage unit.
	3 times	Line feed error	[6000]	(1) Opening and closing of the paper output		-Timing slit disk feed
					tray:	film
					-> Remove obstacles from around the	-Timing sensor unit
					paper output tray so that the tray	-Paper feed roller
					opens and closes properly.	unit
				(2)	Smearing or scratches on the LF / EJ slit	-Logic board ass'y
					film:	-Paper feed motor
					-> Clean the LF / EJ slit film using
					lint-free paper.
				(3)	Foreign material in the LF drive:
					-> Remove foreign material.
				(4)	Cable connection:
					-> Re-connect the cables.
				(5)	LF lock arm spring:
					-> Attach the spring properly.
					If it is scratched or damaged, replace
					it.
	4 times	Purge cam	[5C00]	(1) Foreign material around the purge drive		-Purge drive system
		sensor error			system unit:	unit
					-> Remove foreign material.	-Logic board ass'y
				(2)	Cable connection:
					- Logic board J702 connector
					-> Re-connect the cable.
				(3)	Strange sound at power-on:
					-> Replace the purge drive system unit.
	5 times	ASF (cam)	[5700]	(1) Cable connection:		-ASF unit
		sensor error			- PE sensor cable, etc.	-PE sensor board
					-> Re-connect the cable.	ass'y
						-Logic board ass'y

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	Cycles of				Parts that are likely
	blinking of	Error	Error	Check points & Solution	to be faulty (in the
	Alarm and		code		order of likeliness to
	Power LEDs				be faulty)
	6 times	Internal	[5400]	(1) Cable connection:	-Spur unit
		temperature		- Between the spur unit and the logic	-Logic board ass'y
		error		board, J703 connector, etc.	-Print head
				-> Re-connect the cable.
	7 times	Ink absorber	[5B00]	(1) Ink absorber condition:	-Absorber kit
		full	[5B01]	-> Replace the ink absorber, and reset
				the ink absorber counter value in the
				EEPROM.
	8 times	Print head	[5200]	(1) Print head condition (face surface and	-Print head
		temperature		mold):	-Carriage unit
		rise error		-> If a burn mark or heat deformation is
				seen on the face surface or the mold,
				replace the print head.
				(2) Head contact pin condition of the
				carriage unit:
				-> If the pin is bent or deformed, replace
				the carriage unit.
				(3) Cable connection:
				- CR FFC (J500, J501, J502)
				-> Re-connect the cable.
				If any damage or breakage of the
				cable is found, replace the carriage
				unit.
	9 times	EEPROM error	[6800]	(1) Part replacement:	-Logic board ass'y
			[6801]	-> Replace the logic board ass'y.
	10 times	VH monitor	[B200]	(1) Print head condition (face surface and	-Print head and logic
		error		mold):	board ass'y
				-> If a burn mark or heat deformation is	(replace them at the
				seen on the face surface or the mold,	same time)
				replace the print head and the logic	-AC adapter
				board in set. (Be sure to replace	-Carriage unit
				them at the same time.)
				(2) Burn mark or heat deformation of the
				logic board:
				-> If a burn mark or heat deformation is
				seen on the logic board, replace the
				print head and the logic board in set.
				(Be sure to replace them at the same
				time.)
				(3) Head contact pin condition of the
				carriage unit:
				-> If the pin is bent or deformed, replace
				the carriage unit.
				(4) Cable connection:
				- CR FFC J502, J501, J500
				-> Re-connect the cable.
				If any damage or breakage of the
				cable is found, replace the carriage
				unit.

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		Cycles of					Parts that are likely
		blinking of	Error	Error		Check points & Solution	to be faulty (in the
		Alarm and		code			order of likeliness to
		Power LEDs					be faulty)
		11 times	Carriage lift	[5110]	(1) Foreign material that obstructs the		-Switch system unit
			mechanism			carriage movement:	-Carriage unit
			error			-> Remove foreign material.
		12 times	APP position	[6A80]	(1)	Cap absorber and wiper blade of the	-Purge drive system
			error			purge drive system unit:	unit
			APP position	[6A81]		-> If the cap absorber contacts the	-Logic board ass'y
			error during			wiper blade, lower the cap absorber
			initial purging			so that it will not contact the wiper
		14 times	APP sensor	[6A90]		blade.
			error		(2)	Foreign material around the purge drive
						system unit:
						-> Remove foreign material.
					(3)	Ink absorber right beneath the purge
						drive system unit:
						-> Confirm that the absorber stays in
						place and does not contact the unit.
					(4)	Foreign material around the ASF unit:
						-> Remove foreign material.
					(5)	Cable connection:
						- J702, PE sensor cable
						-> Re-connect the cables.
			Paper feed cam	[6B10]	(1)	Ink absorber counter value:	-Pick-up arm unit
			sensor error			-> If the value exceeds 60%, replace	-Duplex paper feed
						the ink absorber. Follow the	roller unit
						"Guideline for Preventive
						Replacement of the Ink Absorber."
					(2)	Jammed paper in the under guide:
						-> Remove the jammed paper.
		15 times	USB host Vbus	[9000]	(1)	Part replacement:
			overcurrent			-> Replace the logic board ass'y.
		16 times	Pump roller	[5C20]	(1)	Cable connection:	-Purge drive system
			sensor error			-> Re-connect the cable.	unit
		19 times	Ink tank	[6502]	(1)	Ink tank position:	-Spur unit
			position sensor			-> Confirm the ink tanks are installed in	-Logic board ass'y
			error			the correct slots.
					(2)	Re-set or replacement of ink tanks:
						-> If the error persists, replace the ink
						tanks.
					(3)	Cable connection:
						-> Re-connect the cable.
		20 times	Other errors	[6500]	(1)	Cable connection:	-Logic board ass'y
						-> Re-connect the cable.
		21 times	Drive switch	[C000]	(1)	Foreign material in the drive switch area	-Purge drive system
			error			of the purge drive system unit:	unit
						-> Remove foreign material.	-ASF unit
					(2)	Ink tank conditions:	-Carriage unit
						-> Confirm that the ink tanks are seated
						properly and they do not interfere
						with the carriage movement.

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