Canon PIXMA MX860 series User manual

MX860 / MX868
Service Manual
Revision 0
COPYRIGHTc2009CANONINC.CANONMX860012009XX0.00-0
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Scope
This manual has been issued by Canon Inc., to provide the service technicians of this product with the information
necessary for qualified persons to learn technical theory, installation, maintenance, and repair of products. The manual
covers information applicable in all regions where the product is sold. For this reason, it may contain information that is
not applicable to your region.
This manual does not provide sufficient information for disassembly and reassembly procedures.
Refer to the graphics in the separate Parts Catalog.
Revision
This manual could include technical inaccuracies or typographical errors due to improvements or changes made to the
product. When changes are made to the contents of the manual, Canon will release technical information when necessary.
When substantial changes are made to the contents of the manual, Canon will issue a revised edition.
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Copyright
All 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.
Copyright © 2009 by Canon Inc.
CANON INC.
Inkjet Device Market Support Management Div.
451, Tsukagoshi 3-chome, Saiwai-ku, Kawasaki-shi, Kanagawa 212-8530, Japan

TABLE OF CONTENTS
1. MAINTENANCE
1-1. Adjustment, Periodic Maintenance, Periodic Replacement Parts, and Replacement
Consumables by Service Engineer
1-2. Customer Maintenance
1-3. Special Tools
1-4. Sensors
1-5. Serial Number Location
2. LIST OF ERROR DISPLAY / INDICATION
2-1. Operator Call Errors
2-2. Service Call Errors
2-3. FAX Errors
2-4. Troubleshooting by Symptom
3. REPAIR
3-1. Major Replacement Parts
3-2. Part Replacement Procedures
(1) External housing, scanner unit, and document cover removal
(2) Operation panel and document feed unit removal
(3) Printer unit removal, and ink absorber replacement
(4) Carriage unlocking
(5) ASF unit removal
(6) Carriage unit removal
(7) Spur unit and platen unit removal
(8) Purge drive system unit (right plate) and switch system unit (left plate) removal
MX860 / MX868

4. ADJUSTMENT / SETTINGS
4-1. User Mode
4-2. Service Mode
(1) Service mode operation procedures
(2) Service Tool functions
(3) LF / Eject correction
(4) Button and LCD test
(5) Ink absorber counter setting
4-3. PTT Parameter Mode
4-4. Grease Application
4-5. Special Notes on Servicing
(1) Print head problem
(2) Paper feed motor adjustment
(3) Carriage unit replacement
(4) Document pressure sheet (sponge sheet) replacement
(5) Ink absorber counter setting
(6) Power supply unit and modular board replacement
(7) Rating label on the bottom case (for the models other than Japan)
(8) PTT label on the bottom case (for New Zealand only)
(9) NAL label on the bottom case (for China only)
4-6. Verification After Repair
(1) Standard inspection flow
(2) Service test print
(3) Ink absorber counter value print
5. MACHINE TRANSPORTATION
<TABLE OF CONTENTS>

1. MAINTENANCE
1-1. Adjustment, Periodic Maintenance, Periodic Replacement Parts, and Replacement
Consumables by Service Engineer
(1) Adjustment
MX860 / MX868 TABLE OF CONTENTS
Adjustment Timing Purpose Tool Approx.
time
EEPROM
initialization - At logic board replacement To initialize settings Service Tool*1
Perform in the service
mode.
1 min.
Destination
settings
(EEPROM
settings)
- At logic board replacement To set destination. Service Tool*1
Perform in the service
mode.
1 min.
Ink absorber
counter resetting
(EEPROM
settings)
- At logic board replacement
- At ink absorber replacement To reset the ink absorber counter. Service Tool*1
Perform in the service
mode.
1 min.
Ink absorber
counter value
setting
(EEPROM
settings)
- At logic board replacement To set the ink amount data in
the ink absorber to the ink
absorber counter.
Service Tool*1
Perform in the service
mode.
1 min.
Ink absorber
replacement - When the ink absorber becomes full To replace the ink absorber with a new one. Screwdriver, a pair of tweezers, etc. 15 min.
Paper feed motor
position
adjustment
- At paper feed motor
replacement To adjust the belt tension. (Position the paper feed motor
so that the belt is stretched
tight.)
None. 5 min.
Manual print head
alignment - At print head replacement - At logic board replacement
- When print quality is not
satisfying
To secure the dot placement
accuracy. None. Perform in the user
mode.
10 min.
Grease application - At carriage unit replacement To maintain sliding properties
of the carriage rail. FLOIL KG-107A 1 min.
Ink system
function check - At logic board replacement - At spur unit replacement
- At carriage unit replacement
To maintain detection
functionality for presence of
the ink tanks and each ink tank
position.
Service Tool*1
Perform in the service
mode.
1 min.
LCD language
settings - At logic board replacement To set the language to be displayed on the LCD. None. Perform in the user
mode.
1 min.
Platen glass
protection sheet
(document
pressure sheet)
position
adjustment
- At protection sheet
replacement
- At document bottom cover
replacement
- At scanner unit replacement
To maintain scanning
accuracy, hold the sheet with
the long side down, then fit its
upper left corner to the platen
glass reference mark (back
left).
None. 1 min.
LF / Eject - At logic board replacement To correct line feeding (LF Service Tool*1 5 min.
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N: New adjustment item
*1: Install the Service Tool version 1.030 or later to a pre-registered computer.
(2) Periodic maintenance
No periodic maintenance is necessary.
(3) Periodic replacement parts
There are no parts in this machine that require periodic replacement by a service engineer.
(4) Replacement consumables
There are no consumables that require replacement by a service engineer.
correction - At paper feed roller
replacement roller diameter). Perform in the service mode. (LF correction
and Eject
correction
is
performed
at the same
time.)
- At logic board replacement
- At platen unit replacement To correct line feeding (eject roller diameter). Service Tool*1
Perform in the service
mode.
Carriage rail
position
adjustment
- At carriage unit replacement
- At carriage unit removal To set the carriage rail to the original position prior to
removal or replacement of the
carriage unit, put a mark on the
main chassis before removal of
the carriage unit.
None. 1 min.
LAN resetting - At logic board replacement
- At WLAN board
replacement
To initialize the network
setting. None. Perform in the user
mode.
- Machine buttons
- Computer (IJ
Network Tool)
1 min.
Wired / Wireless
LAN setting
information
display
- At confirmation of the
network setting To confirm the network setting. None. Perform in the user
mode.
- Machine buttons
- Computer (IJ
Network Tool)
1 min.
NFAX user data
settings - At logic board replacement - At modular board
replacement
To confirm the FAX user data
settings. None. Perform in the user
mode.
2 min.
- The screws securing the paper feed motor may be loosened only at replacement of the paper feed motor
unit.
- For print head alignment, perform manual print head alignment using plain paper.
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1-2. Customer Maintenance
Adjustment Timing Purpose Tool Approx.
time
Manual print head
alignment - At print head replacement - When print quality is not satisfying
(uneven printing, etc.)
To ensure accurate dot
placement. - Machine buttons
- Computer
(MP driver)
10 min.
Print head cleaning When print quality is not satisfying. To improve nozzle
conditions. - Machine buttons
- Computer
(MP driver)
1 min.
Print head deep
cleaning When print quality is not satisfying, and not improved by print head cleaning. To improve nozzle conditions. - Machine buttons
- Computer
(MP driver)
2 min.
Ink tank replacement When an ink tank becomes empty. ("No
ink error" displayed on the monitor or on
the machine LCD, or short flashing of an
ink tank LED)
To replace the empty ink
tank. --- 1 min.
Paper feed roller
cleaning - When paper does not feed properly. - When the front side of the paper is
smeared.
To clean the paper feed
rollers of the selected paper
source (rear tray or
cassette).
- Machine
buttons
- Computer
(MP driver)
2 min.
Bottom plate cleaning When the back side of the paper is
smeared. To clean the platen ribs. (Feed the paper from the
rear tray.)
- Machine
buttons
- Computer
(MP driver)
1 min.
Scanning area
cleaning When the platen glass or document pressure sheet is dirty. To clean the platen glass and pressure sheet. Soft, dry, and clean lint-free
cloth.
1 min.
Exterior cleaning When necessary To clean the machine
exterior, or to wipe off
dusts.
Soft, dry, and
clean lint-free
cloth.
1 min.
LAN resetting When changing the network setting, etc. To return the LAN setting to
its original state. - Machine buttons
- Computer (IJ
Network
Tool)
1 min.
Wired / Wireless
LAN setting
information display
When changing the network setting, etc. To confirm the LAN setting
information. - Machine buttons
- Host
computer (IJ
Network
Tool)
1 min.
FAX user data
settings When changing the telephone line type, etc. To confirm the FAX user data settings. - Machine buttons 2 min.
FAX number data When the printer is repaired, etc. To confirm that the
registered FAX numbers are
retained.
- Machine
buttons 2 min.
3 / 64

1-3. Special Tools
1-4. Sensors
Name Tool No. Application Remarks
FLOIL KG-107A QY9-0057-000 To the carriage rail sliding portions. In common with the MP610, etc.
No. Sensor Function Possible problems
1DES sensor Detects paper ejection from the ADF. - Paper jam in the ADF
2DS sensor Detects paper feeding from the ADF. - No paper in the ADF
3ADF cover sensor Detects opening and closing of the
document feeder cover. - Although the document feeder cover is closed, the machine indicates that the cover is open.
4DF open sensor Detects opening and closing of the ADF. - The machine stays in the sleep mode even when the
document cover is opened.
5SCN open sensor Detects opening and closing of the
scanning unit (cover). - The carriage does not move to the center.
6PE sensor Detects paper feeding and ejection. - No paper
- Paper jam
7ASF sensor Controls paper feeding from the rear
tray. - Paper feed problem - ASF sensor error
8APP sensor Controls paper feeding and purging
operation. - APP sensor error
9LF encoder sensor Detects rotation of the LF encoder, and
controls its drive. - Uneven printing - LF position error
10 Carriage encoder
sensor Detects the position of the timing slit film, and controls printing. - Printing shifts from the correct position. - Carriage position error
11 Temperature sensor Detects the temperature of the inside of
the machine. - Internal temperature error
12 Ink sensor Detects the position of an ink tank. - No recognition of an ink tank
- Wrong position of an ink tank
13 Valve cam sensor Controls purging operation. - Valve cam sensor error
14 Pump roller sensor Detects the position of the pump roller - Pump roller sensor error
15 Purge cam sensor Controls purging operation. - PG cam sensor error
4 / 64

5 / 64

1-5. Serial Number Location
On the inner guide over the upper portion of the spur holder (visible when the scanning unit (cover) is opened)
When the machine power is OFF. When the machine power is ON.
<1. MAINTENANCE>
6 / 64

2. LIST OF ERROR DISPLAY / INDICATION
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 MP 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.
2-1. Operator Call Errors (by Alarm LED Lit in Orange)
MX860 / MX868 TABLE OF CONTENTS
Error Error
code U No. Message on the LCD Solution Parts that are likely to be faulty
No paper in the
rear tray. [1000] --- Rear tray. There is no paper. Load
paper and press [OK].
Confirm that the rear tray is
selected as the paper source.
Set the paper in the rear tray,
and press the OK button.
- ASF unit
- Pressure roller unit
- Switch system unit
- Paper feed motor
No paper in the
cassette. [1003] --- Cassette. There is no paper. Load
paper and press [OK].
Confirm that the cassette is
selected as the paper source.
Set the paper in the cassette,
and press the OK button.
- Pick-up arm unit
- Pressure roller unit
- Switch system unit
- Paper feed motor
Paper jam. [1300] --- The paper is jammed.
Clear the paper and press
[OK].
Remove the jammed paper or
foreign material causing a
paper jam (paper remainings,
clips, pens, etc.), and press the
OK button.
- ASF unit
- Pick-up arm unit
- Cassette unit
- Pressure roller unit
Paper jam in the
rear guide. [1303] ---
Paper jam in the
under guide. [1304] ---
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
- Spur unit
- Logic board
Ink tank not
installed. [1660] U043 The following ink tank cannot be recognized.
(Applicable ink tank
icon)
Install the applicable ink tank
(s) properly, and confirm that
the LED's of all the ink tanks
light red.
- Ink tank
- Carriage unit
- Logic board
Print head not
installed, or not
properly
installed.
[1401] U051 Print head is not
installed. Install the print
head.
Install the print head properly. - Print head
- Carriage unit
- Logic board
Faulty print head
ID. U052 The type of print head is incorrect. Install the Re-set the print head. If the error is not cleared, the print - Print head - Logic board
7 / 64