Canon Pixma MG8120 Service Manual. Parts Catalog

PIXMA MG8120

SERVICE

MANUAL

Canon

Copyright © 2010, Canon U.S.A. This technical publication is the proprietary and confidential information of Canon U.S.A. which shall be retained for reference purposes by Authorized Service Facilities of Canon U.S.A. Its unauthorized use is prohibited.

MG8100 series

INTRODUCTION

[ How to use this Service Manual ]

This manual is intended to solve printer problems smoothly, with each section representing the typical service procedures, as shown below.

Troubleshooting

Repair

Adjustment &

Settings

Verification

Appendix

For reference:

Identify the problem, and handle it accordingly.

When a part needs to be replaced, see this section.

After repair, perform the necessary adjustment and settings.

At the end of the servicing, verify the machine following the inspection flow in this section.

Information that will be necessary for maintenance and repair of the machine

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

<INTRODUCTION>

MG8100 series

TABLE OF CONTENTS

1.TROUBLESHOOTING

1-1. Troubleshooting by Symptom

1-2. Operator Call Error Troubleshooting

1-3. Service Call Error Troubleshooting

2.REPAIR

2-1. Major Replacement Parts and Adjustment

2-2. Part Replacement Procedures

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

(2)Operation panel removal

(3)Cable wiring and connection

(4)Document window R removal

(5)Carriage unlocking

(6)ASF unit removal

(7)Carriage unit removal

(8)Spur unit and platen unit removal

(9)Purge drive system unit (right plate) and switch system unit (left plate) removal

(10)Engine unit reassembly

(11)Ink absorber replacement

3.ADJUSTMENT / SETTINGS

3-1. Adjustment

3-2. Adjustment and Maintenance in User Mode

3-3. Adjustment and Settings in Service Mode

(1)Service mode operation procedures

(2)Service Tool functions

(3)LF / Eject correction (automatic / manual)

(4)Button and LCD test

(5)Ink absorber counter setting

(6)N/A

(7)Capacitive sensor sensitivity setting

3-4. Grease Application

3-5. Special Notes on Servicing

(1)For smeared printing, uneven printing, or non-ejection of ink

(2)Paper feed motor adjustment

(3)Carriage unit replacement

(4)Document pressure sheet (sponge sheet) replacement

(5)Ink absorber counter setting

(6)Preventive replacement of ink absorber

4.VERIFICATION AFTER REPAIR

4-1. Standard Inspection Flow

4-2. Integrated Inspection Pattern Print

4-3. Ink Absorber Counter Value Print

5.APPENDIX

5-1. Customer Maintenance

5-2. Special Tools

5-3. Sensors

5-4. Serial Number Location

6.MACHINE TRANSPORTATION

<TABLE OF CONTENTS>

MG8100 series	TABLE OF CONTENTS

1. TROUBLESHOOTING

1-1. Troubleshooting by Symptom

		Symptom
Faulty operation		The power does not turn on.
		The power turns off
		immediately after power-on.

A strange noise occurs.

The LCD does not display properly.

A portion of the LCD is not displayed.

The display flickers.

Paper feed problems (multifeeding, skewed feeding, no feeding).

Solution

(1) Confirm cable connection:

-DC harness ass'y

-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

-Power switch harness ass'y

-Document top cover unit

(1)Examine and remove any foreign material from the drive portions.

(2)Replace the following item(s):

-The part generating the strange noise

-Logic board ass'y

(1) Confirm cable connection:

-LCD FFC

-Panel FFC

=> No incomplete connection, cable breakage, or cable caught in units

(2) Replace the following item(s):

-LCD viewer unit

-Panel cable

-Document top cover unit

-Logic board ass'y

(1) Examine and remove any foreign material from the following parts:

-ASF unit

-PE sensor

-Paper guide unit

-Pressure roller unit

-Spur unit

(2)Confirm that the paper guides are set properly.

(3)Confirm the PF rear cover and the cassette conditions.

(4)Confirm cable connection:

-PE sensor cable

-Paper feed relay harness ass'y

=> No incomplete connection, cable breakage, or cable caught in units

(5) Replace the following item(s):

1/70

- 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 unit

- PE sensor cable - Cassette unit

Faulty scanning (no scanning,	(1)	Confirm that the scanner lock switch is
strange noise).		unlocked.
	(2)	Confirm cable connection:
	- Scanner motor relay harness ass'y
	- CCD cable
	=> No incomplete connection, cable
		breakage, or cable caught in units
	(3)	Replace the following item(s):
	- Scanner unit
	- Logic board ass'y

Unsatisfactory print quality No printing, or no color ejected.	See 3-5. Special Notes on Servicing, (1)For
Faint printing, or white lines on	smeared printing, uneven printing, or non-
printouts.	ejection of ink, for details.
Uneven printing.	(1) Confirm the ink tank conditions:
Improper color hue.	- No remainder of the outer film (the air-
		through must be opened)
	- Re-setting of an ink tank
	- Whether the ink tank is Canon-genuine
		one or not
	- Whether the ink tank is refilled one or not
	(2)	Remove foreign material from the purge
		unit caps, if any.
	(3)	Perform cleaning or deep cleaning of the
		print head.
	(4)	Perform print head alignment.
	(5)	Replace the following item(s):
	- Print head*1, and ink tanks
	- Logic board ass'y
	- Purge drive system 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):
	- ressure roller unit (if smearing is heavy)

2/70

The back side of paper gets smeared.

Graphic or text is enlarged on printouts in the carriage movement direction.

Graphic or text is enlarged on printouts in the paper feed direction.

Faulty scanning

No scanning.

Streaks or smears on the scanned image.

Smearing or streaks in film scanning.

-Print head*1 (when smearing is caused by the print head)

(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

(1) Confirm that the carriage slit film is free from smearing or scratches:

-Cleaning of the timing slit film.

(2) Replace the following item(s):

-Timing slit strip film

-Carriage unit

-Logic board ass'y

-Scanner unit (for copying)

(1) Confirm that the LF / EJ slit film is free from smearing or scratches:

-Cleaning of the LF / EJ slit film..

(2) Replace the following item(s):

-Timing slit disk feed film, or timing slit disk eject film

-Timing sensor unit

-Platen unit

-Logic board ass'y

-Scanner unit (for copying)

(1)Confirm cable connection (CCD cable).

(2)Replace the following item(s):

-Scanner unit

-Logic board ass'y

(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) Confirm that the FAU lamp turns on, and the scanner operates properly.

3/70

No film scanning.	(2)	Confirm that the film is in good condition
		and it is properly set in the platen glass.
	(3)	Replace the following item(s):

-Document pressure plate unit (FAU)

-Film guide unit

-Logic board ass'y

-Scanner unit

Network connection problem No printing.

(1)Examine if printing is performed properly via USB connection.

(2)Confirm the network connection.

(3)Replace the following item(s):

-Logic board ass'y

-Wireless LAN 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 (by Alarm LED Lit in Orange) Troubleshooting

Errors and warnings are displayed by the following ways:

1.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.

2.Messages during printing from a computer are displayed on the printer driver Status Monitor.

3.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:

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

2.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.

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

		Error		U		Message on the				Parts that
Error		code		No.				Solution		are likely
						LCD				to be
										faulty

No paper in the	[1000]	--- Rear tray.
rear tray.		There is no paper.
		Load paper and press
		[OK].

Confirm that the rear tray is	- PE sensor
selected as the paper source. Set	board
the paper in the rear tray, and press	ass'y
the OK button.	- ASF unit
If the error is not cleared, confirm	- Pressure
that no foreign material is inside	roller
the paper feed slot.	unit

4/70

No paper in the	[1003]	--- Cassette.
cassette.		There is no paper.
		Load paper and press
		[OK].

Confirm that the cassette is	- Pick-up
selected as the paper source. Set	arm unit
the paper in the cassette, and press	- Pressure
the OK button.	roller
Note that the cassette is for plain	unit
paper only.	- Cassette
	unit

Paper jam.	[1300]	---	The paper is jammed.
			Clear the paper and
Paper jam in the	[1303]	---	press [OK].

rear guide.

Paper jam in the	[1304]	---
under guide.

Remove the jammed paper and	- Pick-up
press the OK button.	arm unit
For paper jam in the rear guide,	- ASF unit
confirm that the rear guide is not	- Pressure
dislocated.	roller
	unit
	- Cassette
	unit
	- Rear
	guide
	unit

Ink may have run	[1600]
out.

Ink tank not	[1660]
installed.

Print head not	[1401]
installed, or not
properly installed.
Faulty print head
ID.
Print head	[1403]
temperature
sensor error.
Faulty EEPROM	[1405]
data of the print
head.

U041 The ink may have run out. Replacing the ink tank is recommended.

Replace the applicable ink tank, or - Spur unit 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.

U043	The following ink	Install the applicable ink tank(s)	- Ink tank
	tank cannot be	properly, and confirm that the	- Carriage
	recognized.	LED's of all the ink tanks light red.	unit
	(Applicable ink tank
	icon)
U051	Print head is not	Install the print head properly.	- Print
	installed. Install the	If the error is not cleared, confirm	head
	print head.	that the print head contact pins of	- Carriage
		the carriage are not bent.	unit

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

Re-set the print head. If the error is	- Print
not cleared, the print head may be	head
defective. Replace the print head.	- Carriage
If the error is not cleared, confirm	unit
that the print head contact pins of
the carriage are not bent.

5/70

Inner cover error	[1841,
	1846]

Multiple ink tanks	[1487]
of the same color
installed.
Ink tank in a	[1680]
wrong position.
Warning: The ink	[1700]
absorber becomes
almost full.

---Inner cover is open. close the inner cover and press [OK].

U071 More than one ink tank of the following color is installed.

U072 Some ink tanks are not installed in place.

---The ink absorber is almost full. Press [OK] to continue printing. Contact the service center for replacement.

Close the inner cover, and press	- Spur unit
the OK button.	- Inner
If the error is not cleared, examine	cover
that the inner cover sensor is	unit
properly installed.

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

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

Replace the ink absorber, and reset - Absorber its counter. [See 3-3, Adjustment kit

and Settings in Service Mode.] Pressing the OK button will exit the 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 the	camera and the machine.
digital video		device.
camera does not
support Camera
Direct Printing.

Automatic duplex	[1310]	--- This paper is not
printing cannot be		compatible with two-
performed.		sided printing.
		Remove the paper and
		press [OK].

The paper length is not supported	- Duplex
for duplex printing.	paper
Press the OK button to eject the	feed
paper being used at error	roller
occurrence.	unit
Data which was to be printed on	- PE sensor
the back side of paper at error	board
occurrence is skipped (not	ass'y
printed).

Failed in	[2500]	--- Auto head align has	Press the OK button to clear the	- Carriage
		6/70

automatic print	failed. Press [OK] and	error, then perform the automatic	unit
head alignment.	repeat operation. <See	print head alignment again. (Use	- Print
	manual>	Matte Photo Paper MP-101.)	head
		If the alignment pattern was not	- Purge
		printed properly (faint printing,	drive
		etc.), perform print head cleaning,	system
		then perform the print head	unit
		alignment again.
The remaining ink	[1683] U130 (Applicable ink tank	An ink tank which has once been	- Ink tank
amount unknown	icon)	empty is installed. Replace the	- Spur unit
(raw ink present).	The remaining level	applicable ink tank with a new
	of the ink cannot be	one. Printing with a once-empty
	correctly detected.	ink tank 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]	U140	The following ink
recognized.			tank cannot be
			recognized.
			(Applicable ink tank
			icon)
Ink tank not	[1682]	U150	The following ink
recognized.			tank cannot be
			recognized.
			(Applicable ink tank
			icon)
No ink (no raw	[1688]	U163	The ink has run out.
ink).			Replace the ink tank.
			(Applicable ink tank
			icon)

A non-supported ink tank is	- Ink tank
installed (the ink tank LED is
turned off). Install the supported
ink tanks.
A hardware error occurred in an	- Ink tank
ink tank (the ink tank LED is
turned off). Replace the ink tank
(s).
Replace the empty ink tank(s), and	- Ink tank
close the scanning unit (cover).	- Spur unit
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	[2002]	--- An unsupported USB
hub.		hub is connected.
		Remove the hub.

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

7/70

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 Contents	[4100]	--- Cannot print the data.	Install the supported (Canon-	- Ink tank
print error.			genuine) ink tanks.

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.

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

2)When 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.

Cycles of				Error
blinking of		Error
Alarm and				code
Power LEDs
2 times		Carriage error [5100]

3 times

Line feed error [6000]

Check points & Solution

(1)Smearing or scratches on the carriage slit film:

Clean the film using lint-free paper.

(2)Foreign material that obstructs the carriage movement:

Remove foreign material.

(3)Ink tank conditions:

Re-set the ink tanks.

(4) Cable connection:

-CR FFC (CN401, CN402, CN403)

-Motor multi harness ass'y

Re-connect the cables.

If any damage or breakage of the cable is found, replace the cable.

(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.

Parts to be replaced (when no solution is effective)

-Logic board ass'y

-Carriage motor

-Carriage unit

-Motor multi harness ass'y

(1) Opening and closing of the paper output	- Timing slit disk
tray:	feed film
Remove obstacles from around the	- Timing slit disk

8/70

				paper output tray so that the tray	eject film
				opens and closes properly.	- Timing sensor
			(2)	Smearing or scratches on the LF / EJ slit	unit
				film:	- Paper feed roller
				Clean the LF / EJ slit film using lint-	unit
				free paper.	- Logic board
			(3)	Foreign material in the LF drive:	ass'y
				Remove foreign material.	- Paper feed
			(4)	Cable connection:	motor
			- LF encoder cable
			- PE sensor cable
			- Paper feed relay harness ass'y
			- Paper feed motor harness ass'y
				Re-connect the cables.
				If any damage or breakage of the
				cable is found, replace the cable.
			(5)	LF lock arm spring:
				Attach the spring properly.
4 times	Purge cam	[5C00]	(1)	Foreign material around the purge drive	- Purge drive
	sensor error			system unit:	system unit
				Remove foreign material.	- Logic board
			(2)	Cable connection:	ass'y
			- Valve cam harness (CN700)
				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		- PE sensor board
				Re-connect the cable.	ass'y
				If any damage or breakage of the	- Logic board
				cable is found, replace the cable.	ass'y
6 times	Internal	[5400]	(1)	Cable connection:	- Spur unit
	temperature		- Ink absorber multi harness (CN701)		- Logic board
	error			Re-connect the cable.	ass'y
				If any damage or breakage of the	- Print head
				cable is found, replace the spur unit.
7 times	Ink absorber	[5B00]	(1)	Ink absorber condition:
	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 rise			mold):	- Logic board
	error			If a burn mark or heat deformation is	ass'y
				seen on the face surface or the mold,	- Carriage unit
				replace the print head.
			(2)	Head contact pin condition of the carriage
				unit:

If the pin is bent or deformed, replace the carriage unit.

9/70

(3) Cable connection:

			- CR FFC (CN401, CN402, CN403)
			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:
		[6801]	Replace the logic board ass'y.
10 times	VH monitor	[B200]	(1) Print head condition (face surface and	- AC adapter
	error		mold):	- Carriage unit
			If a burn mark or heat deformation is

seen on the face surface or the mold, replace the print head and the logic board in set. (Be sure to replace 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 (CN401, CN402, CN403) Re-connect the cable.

If any damage or breakage of the cable is found, replace the carriage unit.

11 times	Carriage lift	[5110]
	mechanism
	error
12 times	APP position	[6A80]
	error

APP position

[6A81]

error during initial purging

(1)	Foreign material that obstructs the	- Switch system
	carriage movement:	unit
	Remove foreign material.	- Carriage unit
(1)	Cap absorber and wiper blade:	- Timing slit disk
	If the cap absorber contacts the wiper	APP film
	blade, lower the cap absorber so that	- PE sensor board
	it will not contact the wiper blade.	ass'y
(2)	Foreign material around the purge drive	- Purge drive
	system unit:	system unit
	Remove foreign material.	- Logic board
(3)	Ink absorber right beneath the purge drive	ass'y
	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)APP slit film condition:

10/70

14 times	APP sensor	[6A90]		Clean the APP slit film using lint-free
	error			paper.
			(6)	APP code wheel gear condition:
				If the gear wears, replace the gear.
			(7)	Cable connection:
			- PE sensor cable
			- Motor multi harness ass'y
				Re-connect the cables.
				If any damage or breakage of the
				cable is found, replace the cable.
	Paper feed cam	[6B10]	(1)	Ink absorber counter value:	- Pick-up arm
	sensor error			If the value exceeds 60%, replace the	unit
				ink absorber. Follow the "Guideline	- Duplex paper
				for Preventive Replacement of the Ink	feed roller unit
				Absorber."
			(2)	Jammed paper or foreign material in the
				under guide:
				Remove the jammed paper and
				foreign material.
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
	sensor error		- Valve cam harness (CN700)		system unit
				Re-connect the cable.
17 times	Paper eject	[6010]	(1)	Smearing on the LF / EJ slit film:	- Timing sensor
	encoder error			Clean the LF / EJ slit film using lint-	unit
				free paper.	- Platen unit
			(2)	Foreign material in the paper path:	- Logic board
				Remove foreign material.	ass'y
			(3)	Cable connection:	- Paper feed
			- LF encoder cable		motor
			- PE sensor cable
				Re-connect the cable.
				If any damage or breakage of the
				cable is found, replace the cable.
			(4)	Scratches on the LF / EJ slit film:
				Replace the timing slit disk feed film
				or the timing slit disk eject film.
19 times	Ink tank	[6502]	(1)	Ink tank position:	- Spur unit
	position sensor			Confirm the ink tank position.	- Logic board
	error		(2)	Re-set or replacement of ink tanks:	ass'y
				If the error persists, replace the ink
				tanks.
			(3)	Cable connection:
			- Ink absorber multi harness (CN701)
				Re-connect the cable.
20 times	Other errors	[6500]	(1)	Cable connection:	- Logic board
			- Wireless LAN cable		ass'y

11/70

				Re-connect the cable.	- Wireless LAN
				If any damage or breakage of the	board ass'y
				cable is found, replace the cable.
21 times	Drive switch	[C000]	(1)	Foreign material in the drive switch area	- Purge drive
	error			of the purge drive system unit:	system 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.
22 times	Scanner home	[5000]	(1)	Cable connection:	- Scanner unit
	position sensor		- CCD FFC (CN1100)		- Logic board
	error		- Scanner motor relay harness ass'y		ass'y
				Re-connect the cables.
	Scanner error	[5011]	(1)	Cable connection:	- Scanner unit
			- CCD FFC (CN1100)		- Logic board
			- Lamp harness ass'y		ass'y
			- Scanner motor relay harness ass'y		- Scanner motor
				Re-connect the cables.	relay harness
			(2)	Document pressure sheet conditions:	- Lamp harness
				Re-attach the document pressure	ass'y
				sheet, or replace it.
	Error during	[5021]	(1)	Scanner lock switch:	- Scanner unit
	scanning			Unlock the switch,	- Logic board
	operation			and power off and on the machine	ass'y
				again.
			(2)	Cable connection:
			- CCD FFC (CN1100)
			- Lamp harness ass'y
			- Scanner motor relay harness ass'y
				Re-connect the cables.
	Scanner light	[5030]	(1)	Cable connection:	- Scanner unit
	source not		- CCD FFC (CN1100)		- Logic board
	turned on		- Lamp harness ass'y		ass'y
				Re-connect the cables.
			(2)	Document pressure sheet conditions:
				Re-attach the document pressure
				sheet, or replace it.
	Scanner electric	[5050]	(1)	Cable connection:	- Scanner unit
	circuit error		- CCD FFC (CN1100)
			- Lamp harness ass'y
			- Scanner motor relay harness ass'y
				Re-connect the cables.
23 times	Valve cam	[6C10]	(1)	Foreign material around the purge drive	- Purge drive
	sensor error			system unit:	system unit
				Remove foreign material.	- Logic board
			(2)	Cable connection:	ass'y
			- Valve cam harness (CN700)

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			Re-connect the cable.
Alarm and	Scanner lock	[5020] (1)	Scanner lock switch:	- Scanner unit
Power LED's	error		Unlock the switch,
lit			and power off and on the machine
			again.
		(2)	Cable connection:
		- CCD FFC (CN1100)
			Re-connect the cables.

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 "Guideline for Preventive Replacement of Ink Absorber," replace the ink absorber. [See 3. ADJUSTMENT / SETTINGS, 3-3. Adjustment and Settings in Service Mode, for details.]

<1. TROUBLESHOOTING>

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MG8100 series	TABLE OF CONTENTS

2. REPAIR

2-1. Major Replacement Parts and Adjustment

Service part

Logic board ass'y

Absorber kit

Carriage unit

Recommended removal procedure*1 / Notes on replacement

(1)Cassette unit

(2)Left and right side covers

(3)Document pressure plate unit (FAU)

(4)Scanner unit

(5)Main case

(6)Rear cover

(7)Logic board ass'y

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

-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.

(1)Cassette unit

(2)Left and right side covers

(3)Document pressure plate unit (FAU)

(4)Scanner unit

(5)Main case

(6)Rear cover

(7)Print unit

(8)Ink absorber

-See 2-2. Part Replacement Procedures, (11) Ink absorber replacement, for details.

(1)Cassette unit

(2)Left and right side covers

(3)Document pressure plate unit (FAU)

Adjustment / settings / operation check

In the service mode:

1.Set the ink absorber counter value.

2.Set the destination.

3.Print the integrated inspection pattern.

4.Perform LF / Eject correction (only when streaks or uneven printing occurs).

5.Set the sensitivity of the capacitive sensors.

[See 3-3. Adjustment and Settings in Service Mode, (7) Capacitive sensor sensitivity setting, for details.]

6.Print the EEPROM information. [See 3-3. Adjustment and Settings in Service Mode, for details.]

In the user mode:

7.Set the language displayed on the LCD.

8.Reset the LAN settings.

9.Perform print head alignment.

10.Print via USB connection.

11.Copy.

12.Perform direct printing from a digital camera (PictBridge).

In the service mode:

1.Reset the ink absorber counter. [See 3-3. Adjustment and Settings in Service Mode, for details.]

After the ink absorber counter is reset, the counter value is printed automatically.

1.Apply grease to the sliding portions of the carriage rail. [See 3-4. Grease Application, for

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(4)Scanner unit

(5)Main case

(6)Rear cover

(7)Timing slit strap

-Before removal of the carriage rail, put a mark of the carriage rail position.

(8)Carriage upper rail

(9)Carriage unit

-Keep the timing slit strap (carriage encoder film) free from stain or damage. When returning the strap, make sure of its orientation (left and right, front and back).

-See 2-2. Part Replacement Procedures, (7) Carriage unit removal, for details.

details.]

In the service mode:

2.Print the integrated inspection pattern.

[See 3-3. Adjustment and Settings in Service Mode, for details.]

In the user mode:

3.Perform automatic print head alignment.

Switch system	(1)	Cassette unit	1.	Adjust the paper feed motor.
unit	(2)	Left and right side covers		[See 3-5. Special Notes on
	(3)	Document pressure plate unit (FAU)		Servicing, (2) Paper feed motor
	(4)	Scanner unit		adjustment, for details.]
	(5)	Main case
	(6)	Rear cover	In the service mode:
	(7)	Print unit	2.	Print the integrated inspection
	(8)	See 2-2. Part Replacement Procedures.		pattern.

Paper feed	- The screws securing the paper feed motor are
motor	allowed to be loosened only for paper feed motor
	replacement. (DO NOT loosen them in any other
	cases.)
	- See 2-2. Part Replacement Procedures, (9) Purge
	drive system unit (right plate) and switch system
	unit (left plate) removal, for details.
	- See 2-2. Part Replacement Procedures, (10) Engine
	unit reassembly, for details.
Platen unit	(1)	Cassette unit
	(2)	Left and right side covers
	(3)	Document pressure plate unit (FAU)
	(4)	Scanner unit
	(5)	Main case
	(6)	Rear cover
	(7)	Print unit
	(8)	See 2-2. Part Replacement Procedures, from this
		step.

In the service mode:

1.Perform LF / Eject correction (only when uneven printing or streaks appear on printouts after replacement).

[See 3-3. Adjustment and Settings in Service Mode, for details.]

2.Print the integrated inspection pattern.

Spur unit	(1)	Cassette unit	In the service mode:
	(2)	Left and right side covers	1.	Print the integrated inspection
	(3)	Document pressure plate unit (FAU)		pattern.
	(4)	Scanner unit	2.	Perform LF / Eject correction
	(5)	Main case		(only when uneven printing or
	(6)	Rear cover		streaks appear on printouts after

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	(7)	Print unit	replacement).
	(8)	See 2-2. Part Replacement Procedures.	[See 3-3. Adjustment and
	- DO NOT contact the spur edges.		Settings in Service Mode, for
			details.]
Purge drive	(1)	Cassette unit	In the service mode:
system unit	(2)	Left and right side covers	1. Print the integrated inspection
	(3)	Document pressure plate unit (FAU)	pattern.

(4)Scanner unit

(5)Main case

(6)Rear cover

(7)Print unit

(8)See 2-2. Part Replacement Procedures.

-See 2-2. Part Replacement Procedures, (9) Purge drive system unit (right plate) and switch system unit (left plate) removal, for details.

-See 2-2. Part Replacement Procedures, (10) Engine unit reassembly, for details.

Carriage rail	See 2-2. Part Replacement Procedures, and Parts		1.	Apply grease to the sliding
and main	Catalog.			portions.
chassis				[See 3-4. Grease Application, for
Idler pulley				details.]
parallel pin			In the service mode:
APP code
			2.	Print the integrated inspection
wheel gear				pattern.
shaft
Document	(1)	Cassette unit	1.	Confirm the document pressure
pressure sheet	(2)	Left and right side covers		plate sheet position.
	(3)	Document pressure plate unit (FAU)		[See 3-5. Special Notes on
	(4)	Scanner unit		Servicing, (4) Document pressure
				sheet replacement, for details.]
Scanner unit			In the service mode:
			2.	Print the integrated inspection
				pattern.

Document pressure plate unit

Document top cover unit

LCD viewer unit

(1)Right side cover

(2)Document pressure plate unit (FAU)

(3)Document top cover unit

(4)LCD viewer

-Be cautious not to scratch or damage the LCD cable.

-To protect the external housing of the machine from scratches, spread a soft cloth and disassemble / reassemble the machine on it.

In the service mode:

1.Perform button and LCD test. [See 3-3. Adjustment and Settings in Service Mode, for details.]

2.Set the sensitivity of the capacitive sensors.

[See 3-3. Adjustment and Settings in Service Mode, (7)

Capacitive sensor sensitivity setting, for details.]

3.Print the integrated inspection pattern.

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Timing slit strip film

Timing slit disk feed film

Timing slit disk eject film

Print head

Wireless LAN board ass'y

See 2-2. Part Replacement Procedures, and Parts

Catalog.

-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.

(1)Cassette unit

(2)Left and right side covers

(3)Document pressure plate unit (FAU)

(4)Scanner unit

(5)Main case

(6)WLAN board

Bottom case (1)	Cassette unit
(2)	Left and right side covers
(3)	Document pressure plate unit (FAU)
(4)	Scanner unit
(5)	Main case
(6)	Front door / bottom case

In the user mode:

1. Perform print head alignment.

In the service mode:

2.Print the nozzle check pattern.

3.Perform LF / Eject correction (only when uneven printing or streaks appear on printouts after replacement).

[See 3-3. Adjustment and Settings in Service Mode, for details.]

In the user mode:

1. Perform print head alignment.

In the service mode:

2.Print the integrated inspection pattern.

In the user mode:

1. Reset the LAN settings.

In the service mode:

2.Print the integrated inspection pattern, and confirm that the WLAN MAC address is properly updated.

In the service mode:

1.Print the integrated inspection pattern.

*1: To reassemble the unit after replacement, follow the procedures in the reverse order.

General notes:

-Make sure that the flexible cables and wires in the harness are in the proper position and connected correctly. See 2-2. Part Replacement Procedures or the Parts Catalog for details.

-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, timing slit disk feed film, and timing slit disk eject film. No grease or abrasion is allowed.

-Protect the units from soiled with ink.

-Protect the housing from scratches.

-For automatic print head alignment, use Matte Photo Paper MP-101 to maintain the alignment accuracy.

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-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 original position. [See 2-2. Part Replacement Procedures, (7) Carriage unit removal, for details.]

<2-1. Major Replacement Parts and Adjustment>

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MG8100 series --- 2. REPAIR	TABLE OF CONTENTS

2-2. Part Replacement Procedures

Be sure to protect the machine from static electricity in repair servicing, especially for the LCD, document top cover, scanner unit, logic board, card board, IrDA board, PE sensor board, and WLAN board.

Some of the photos are of the iP4700, iP4800, MP640, MP990, and MG6100 series since their structures are same.

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

1)Remove the cassette.

2)Open the front door and scanner unit, then remove the side cover R (2 screws).

3)Remove the scanner FFC, panel cable, FAU lamp cable, and FB motor cable. <Be cautious of the core location and wiring layout.>

Disconnect the red-circled cables.

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4) Remove the side cover L, scanner unit, then document pressure plate unit (2 screws).

<While holding the scanner unit, sliding it to the right and disengage it from the scanner support arm.>

Remove 2 screws at the center of the side cover L.

[1] Lift the back of the scanner unit.

[2] Slide it to the right to disengage from the support arm.

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5) Remove the main case (no screws).

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