Canon iX6500 Series User manual

iX6500 series
Service Manual
(iX6510 / iX6520 / iX6530 / iX6540 / iX6550 / iX6560 / iX6580)
Revision 0
QY8-13DG-000
COPYRIGHT©2011 CANON INC. CANON iX6500 series 032011 XX 0.00-0
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.
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.
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 © 2011 by Canon Inc.
CANON INC.
Inkjet Device Market Support Management Div.
451, Tsukagoshi 3-chome, Saiwai-ku, Kawasaki-shi, Kanagawa 212-8530, Japan

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.
This manual does not provide sufficient information for disassembly and reassembly procedures. Refer to the
graphics in the separate Parts Catalog.
iX6500 series
Troubleshooting Identify the problem, and handle it accordingly.
Repair When a part needs to be replaced, see this section.
Adjustment &
Settings After repair, perform the necessary adjustment and settings.
Verification At the end of the servicing, verify the printer following the inspection flow in this
section.
Appendix Information that will be necessary for maintenance and repair of the printer.
<INTRODUCTION>

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. Disassembly & Reassembly Procedures
(1) External housing removal
(2) Printer unit removal & Ink absorber replacement
(3) Board removal
(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
(9) Engine unit reassembly
(10) Cable wiring and connection
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
(4) Ink absorber counter 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) Ink absorber counter setting
(5) Preventive replacement of ink absorber
(6) Rating label on the bottom case (except China)
4. VERIFICATION AFTER REPAIR
4-1. Standard Inspection Flow
4-2. Integrated Inspection Pattern Print
4-3. Ink Absorber Counter Value Print
iX6500 series

5. APPENDIX
5-1. Customer Maintenance
5-2. Special Tools
5-3. Sensors
5-4. Serial Number Location
6. MACHINE TRANSPORTATION
<TABLE OF CONTENTS>

1. TROUBLESHOOTING
1-1. Troubleshooting by Symptom
iX6500 series TABLE OF CONTENTS
Symptom Solution
Faulty
operation The power does not turn on. The power turns off
immediately after power-on.
(1) Confirm cable connection:
- DC 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
- Panel cable
A strange noise occurs. (1) Examine and remove any foreign material from the drive
portions.
(2) Replace the following item(s):
- The part generating the strange noise
- Purge drive system unit
Paper feed problems (multi-
feeding, skewed feeding, no
feeding).
(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 cable connection:
- PE sensor cable
- Paper feed relay harness ass'y
=> No incomplete connection, cable breakage, or cable
caught in units
(4) Replace the following item(s):
- ASF unit
- PE sensor board ass'y
- Pressure roller unit
Printer not recognized by a
USB-connected computer. (1) Confirm the USB cable connection. (2) Connect the printer to another computer via the USB
cable, and check if the printer is recognized.
(3) Replace the following item(s):
- USB cable
- Logic board ass'y
Unsatisfactory
print quality No printing, or no color ejected.
Faint printing, or white lines on
See 3-5. Special Notes on Servicing, (1) For smeared
printing, uneven printing, or non-ejection of ink, for details.
(1) Confirm the ink tank conditions:
1 / 52

*1: Replace the print head only after the print head deep cleaning is performed 2 times, and when the
problem persists.
printouts.
Uneven printing.
Improper color hue.
- No remainder of the outer film (the air-through must be
opened)
- Whether the ink tank is Canon-genuine one or not
- Whether the ink tank is refilled one or not
- 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 printer.
(2) Perform bottom plate cleaning.
(3) Perform paper feed roller cleaning.
(4) Replace the following item(s):
- Pressure roller unit (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 printer. (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
Graphic or text is enlarged on
printouts in the carriage
movement direction.
(1) Confirm that the carriage slit film is free from 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
Graphic or text is enlarged on
printouts in the paper feed
direction.
(1) Confirm that the LF slit film is free from smearing or
scratches:
- Cleaning of the LF 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
2 / 52

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 messages are displayed on the
printer driver Status Monitor.
2. 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 printer off and on again.
2. Resume/Cancel button: To cancel the job at error occurrence, and to clear the error.
Cycles of
blinking
of Alarm
LED
Error
Error
code 1) Check points 2) Parts that are likely to be
faulty
2 times No paper in the
rear tray. [1000] Set the paper in the rear tray, and press the Resume/Cancel button.
If the error is not cleared,
confirm that no foreign material
is inside the paper feed slot.
- PE sensor board ass'y
- ASF unit
- Pressure roller unit
3 times Paper jam. [1300] Remove the jammed paper and
press the Resume/Cancel button. - ASF unit - Pressure roller unit
4 times Ink may have run
out. [1600] Replace the applicable ink tank, or press the Resume/Cancel
button to clear the error without
ink tank replacement. When the
error is cleared by pressing the
Resume/Cancel button, ink may
run out during printing.
- Spur unit
Ink tank not
installed. [1660] Install the applicable ink tank(s) properly, and confirm that the
LED's of all the ink tanks light
red.
- Ink tank
- Carriage unit
5 times Print head not
installed, or not
properly installed.
[1401] Install the print head properly.
If the error is not cleared,
confirm that the print head
contact pins of the carriage are
not bent.
- Print head
- Carriage unit
Faulty print head
ID. Re-set the print head. If the error is not cleared, the print head may
be defective. Replace the print
head. If the error is not cleared,
confirm that the print head
contact pins of the carriage are
not bent.
- Print head
- Carriage unit
Print head
temperature sensor
error.
[1403]
Faulty EEPROM
data of the print [1405]
3 / 52

head.
7 times Multiple ink tanks
of the same color
installed.
[1487] Replace the wrong ink tank(s)
with the correct one(s). - Ink tank
Ink tank in a
wrong position. [1680] Install the ink tank(s) in the correct position. - Ink tank
8 times Warning: The ink
absorber becomes
almost full.
[1700] Replace the ink absorber, and
reset its counter. [See 3-3,
Adjustment and Settings in
Service Mode.]
Pressing the Resume/Cancel
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.
- Absorber kit
11 times Failed in automatic
print head
alignment.
[2500] Press the Resume/Cancel button
to clear the error, then perform
the automatic print head
alignment again. (Use plain
paper.)
If the alignment pattern was not
printed properly (faint printing,
etc.), perform print head
cleaning, then perform the print
head alignment again.
- Carriage unit
- Print head
- Purge drive system unit
12 times Premium Contents
print error. [4100] Non-genuine ink tanks are installed. Install the supported
(Canon-genuine) ink tanks.
- Ink tank
13 times The remaining ink
amount unknown
(raw ink present).
[1683] An ink tank which has once been
empty is installed. Replace the
applicable ink tank with a new
one. Printing with a once-empty
ink tank can damage the printer.
To continue printing without
replacing the ink tank(s), press
the Resume/Cancel button for 5
sec. or longer to disable the
function to detect the remaining
ink amount. After the operation,
it is recorded in the printer
EEPROM that the function to
detect the remaining ink amount
was disabled.
- Ink tank
- Spur unit
4 / 52

14 times Ink tank not
recognized. [1684] An incompatible ink tank is installed (the ink tank LED is
turned off). Install the supported
ink tanks.
- Ink tank
[1750] A non-supported ink tank is
installed (the ink tank LED is
turned off). Install the supported
ink tanks.
- Ink tank
15 times Ink tank not
recognized. [1682] A hardware error occurred in an ink tank (the ink tank LED is
turned off). Replace the ink tank
(s).
- Ink tank
16 times No ink (no raw
ink). [1688] Replace the empty ink tank(s), and close the top cover.
Printing with an empty ink tank
can damage the printer.
To continue printing without
replacing the ink tank(s), press
the Resume/Cancel button for 5
sec. or longer to disable the
function to detect the remaining
ink amount. After the operation,
it is recorded in the printer that
the function to detect the
remaining ink amount was
disabled.
- Ink tank
- Spur unit
5 / 52

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.
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 that are
likely to be faulty" 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
blinking of
Alarm and
Power LEDs
Error Error
code 1) Check points & Solution
2) Parts that are
likely to be faulty
(listed in the order
of likeliness to be
faulty)
2 times Carriage error [5100] (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 (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.
- Timing slit strip film
- Carriage unit
- Logic board ass'y
- Carriage motor
3 times Line feed error [6000] (1) Smearing or scratches on the LF slit
film:
Clean the LF slit film using lint-
free paper.
(2) Foreign material in the LF drive:
Remove foreign material.
(3) Cable connection
Re-connect the cables.
If any damage or breakage of the
cable is found, replace the cable.
(4) LF lock arm spring:
Attach the spring properly.
- Timing slit disk feed
film
- Timing sensor unit
- Paper feed roller
unit
- Logic board ass'y
- Paper feed motor
4 times Purge cam
sensor error [5C00] (1) Foreign material around the purge drive system unit:
Remove foreign material.
(2) Cable connection:
- LF encoder cable
- Purge drive system
unit
- Logic board ass'y
6 / 52