Canon MP560 - PIXMA Color Inkjet User manual

PIXMA MP560
SERVICE
MANUAL
Canon
Copyright 2009, 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 byAuthorized Service Facilities of Canon U.S.A. Its unauthorized use is prohibited.

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 / TROUBLESHOOTING
2-1. Operator Call Errors
2-2. Service Call Errors
2-3. Troubleshooting by Symptom
3. REPAIR
3-1. Major Replacement Parts
3-2. Part Replacement Procedures
(1) External housing removal
(2) Cable wiring and connection
(3) Emblem removal
(4) Carriage unlocking
(5) ASF unit removal
(6) Right chassis 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
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
MP560

4-3. Grease Application
4-4. 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
4-5. 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
MP560TABLE 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.
N
Automatic
print head
alignment
- At print head
replacement
- At logic board
replacement
- When print quality is
not satisfying
To secure the dot
placement accuracy. None (plain paper). Perform in the user
mode.
6 min.
Manual print
head alignment 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
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.
1 / 64

N: New adjustment item
*1: Install the Service Tool 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.
- At carriage unit
replacement
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
correction - At logic board replacement
- At paper feed roller
replacement
To correct line feeding
(LF roller diameter). Service Tool*1
Perform in the
service mode.
5 min.
(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).
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.
- The screws securing the paper feed motor may be loosened only at replacement of the
paper feed motor unit.
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1-2. Customer Maintenance
Adjustment Timing Purpose Tool Approx.
time
Automatic print
head alignment - At print head replacement - When print quality is not
satisfying (uneven printing, etc.)
To ensure accurate dot
placement. - 1 sheet of plain paper
- Machine
buttons
- Computer
(MP driver)
6 min.
Manual print
head alignment - 3 sheets of plain paper
- 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.
Exterior
cleaning When necessary To clean the machine exterior, or to wipe off
dusts.
Soft, dry, and
clean lint-free
cloth.
1 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
1Scanner unit open
sensor Detects opening and closing of the scanning unit (cover). - The carriage does not move to the center.
2PE sensor Detects the position of the leading
and trailing edges of paper. - No paper - Paper jam
3ASF cam sensor Detects the position of the ASF
cam (for paper feeding from the
rear tray)
- ASF cam sensor error
- Paper feed problem
4APP encoder
sensor Detects the amount of rotation of the APP encoder. (Controls paper
feeding and purging operation.)
- APP sensor error
- APP position error
5Carriage encoder
sensor Detects the position of the carriage. - Carriage position error - Printing shifts from the correct position.
- Uneven printing
- Strange noise
6Temperature &
Ink amount
sensor
Detects the temperature of the
inside of the machine and the
remaining ink amount.
- Internal temperature error
- Low-ink or out-of-ink warning
7 Ink sensor Detects the position of an ink
tank. - Wrong position of an ink tank - An error indicating that multiple ink tanks
of the same color are installed
- No recognition of an ink tank
8LF encoder
sensor Detects rotation of the LF encoder. (Controls paper feeding.) - LF position error - Uneven printing
9Valve cam sensor Detects the position of the purge
valve cam. (Controls purging
operation.)
- Valve cam sensor error
10 Pump roller
sensor Detects the position of the purge pump roller. (Controls purging
operation.)
- Pump roller sensor error
11 Purge cam sensor Detects the position of the purge
main cam. (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 / 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 messages are
displayed by the MP 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 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)
MP560 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
- PE sensor board
unit
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.
Note that the cassette is
for plain paper only.
- Pick-up arm unit
- Pressure roller unit
- Cassette unit
Paper jam. [1300] --- The paper is
jammed. Clear the
paper and press
[OK].
Remove the jammed
paper and press the OK
button.
- Pick-up arm unit
- ASF unit
- Pressure roller unit
- Cassette unit
- Rear guide unit
Paper jam in the
rear guide. [1303] ---
Paper jam in the
under guide. [1304] ---
Paper size not
supported for
automatic duplex
printing (MP560 /
MP568 only)
[1310] --- This paper is not
compatible with
duplex printing.
Remove the paper
and press [OK].
Set paper with a
supported size and press
the OK button.
Data which was to be
printed on the back side
7 / 64

of paper at error
occurrence is skipped
(not printed).
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
Stop button to clear the
error without ink tank
replacement. When the
error is cleared by
pressing the Stop
button, ink may run out
during printing.
- Spur unit
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
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
Faulty print head
ID. U052 The type of print head is incorrect.
Install the correct
print head.
Re-set the print head. If
the error is not cleared,
the print head may be
defective. Replace the
print head.
- Print head
- Carriage unit
Print head
temperature sensor
error.
[1403]
Faulty EEPROM
data of the print
head.
[1405]
Multiple ink tanks
of the same color
installed.
[1487] U071 More than one ink
tank of the
following color is
installed.
Replace the wrong ink
tank(s) with the correct
one(s).
- Ink tank
Ink tank in a wrong
position. [1680] U072 Some ink tanks are not installed in
place.
Install the ink tank(s) in
the correct position. - Ink tank
Warning: The ink
absorber becomes
almost full.
[1700] --- The ink absorber is
almost full. Press
[OK] to continue
printing. Contact the
service center for
replacement.
Replace the ink
absorber, and reset its
counter. [See 4-2.
Service Mode.]
Pressing the OK button
will exit the error, and
enable printing without
replacing the ink
absorber. However,
when the ink absorber
The ink absorber
will become full
soon (service call
error).
8 / 64

becomes full, no further
printing can be
performed unless the
applicable ink absorber
is replaced.
The connected
digital camera or
digital video
camera does not
support Camera
Direct Printing.
[2001] --- The device may be
incompatible.
Remove the device
and check the
manual supplied
with the connected
device.
Remove the cable
between the camera and
the machine.
The remaining ink
amount unknown
(raw ink present).
[1683] U130 The remaining level
of the following ink
cannot be correctly
detected. Replace
the ink tank.
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
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
EEPROM that the
function to detect the
remaining ink amount
was disabled.
- Ink tank
- Spur unit
Ink tank not
recognized. [1684] U140 The following ink tank cannot be
recognized.
(Applicable ink tank
icon)
A non-supported ink
tank (an ink tank that is
sold in a different
region from where the
machine was
purchased) is installed
(the ink tank LED is
turned off). Install the
supported ink tanks.
- Ink tank
Ink tank not
recognized. [1682] U150 The following ink tank cannot be
recognized.
(Applicable ink tank
icon)
A hardware error
occurred in an ink tank
(the ink tank LED is
turned off). Replace the
ink tank(s).
- Ink tank
9 / 64

No ink (no raw
ink). [1688] U163 The following ink has run out. Replace
the ink tank
(Applicable ink tank
icon)
Replace the empty ink
tank(s), and close the
scanning unit (cover).
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.
- Ink tank
- Spur unit
Non-supported
hub. [2002] --- An unsupported USB hub is
connected. Remove
the hub.
Remove the applicable
USB hub from the
PictBridge (USB)
connector.
10 / 64

2-2. Service Call Errors (by Cyclic Blinking of Alarm and Power LEDs)
Service call errors are indicated by the number of cycles the Alarm and Power LEDs blink.
Cycles of
blinking of
Alarm and
Power LEDs
Error Error
code Conditions Solution
(Check points and
replacement items)
2 times Carriage error [5100] An error occurred in the
carriage encoder signal. (1) Smearing or scratches on the carriage slit film;
clean the timing slit film.
(2) Foreign material or paper
debris that obstructs the
carriage movement;
remove foreign material.
(3) Ink tank conditions;
re-set the ink tanks.
(4) Cable connection
(5) Part replacement:
- Timing slit disk film
- Carriage unit
- Logic board
- Carriage motor
3 times Line feed error [6000] An error occurred in the
LF encoder signal. (1) Smearing or scratches on the LF / EJ slit film;
clean the LF / EJ slit film.
(2) Foreign material or paper
debris in the LF drive;
remove foreign material.
(3) Cable connection
(4) Part replacement:
- LF / EJ slit film
- LF / EJ timing sensor unit
- Paper feed roller unit
- Logic board
- Paper feed motor
4 times Purge cam
sensor error [5C00] An error occurred in the purge unit. (1) Foreign material or paper debris around the purge drive
system unit;
remove foreign material.
(2) Cable connection
(3) Part replacement:
- Purge drive system unit
- Logic board
5 times ASF (cam)
sensor error [5700] An error occurred in the ASF cam sensor (during
paper feeding from the
rear tray).
(1) Cable connection
(2) Part replacement:
- ASF unit
- PE sensor board unit
- Logic board
11 / 64

6 times Internal
temperature
error
[5400] The internal temperature
is not normal. (1) Cable connection (2) Part replacement:
- Spur unit
- Logic board
- Print head
7 times Ink absorber
full [5B00, 5B01] The ink absorber is supposed to be full.
Error codes:
5B00: Main ink
absorber is full
(overseas).
5B01: Main ink
absorber is full
(Japan).
(1) Ink absorber condition
(2) Part replacement:
- Ink absorber kit and
double-sided adhesive
tape
(3) Ink absorber counter value in
the EEPROM;
reset the ink absorber
counter.
8 times Print head
temperature
rise error
[5200] The print head
temperature exceeded
the specified value.
(1) Print head condition
(2) Head contact pin condition of
the carriage unit
(2) Cable connection
(3) Part replacement:
- Print head
- Carriage unit
9 times EEPROM
error [6800, 6801] A problem occurred in reading from or writing
to the EEPROM.
(1) Part replacement:
- Logic board
10 times VH monitor
error [B200] The internal temperature exceeded the specified
value.
(1) Head contact pin condition of
the carriage unit
(2) Cable connection (especially
the carriage FFC)
(3) Part replacement:
- Print head and logic
board (Replace them at
the same time.)
- Power supply unit
- Carriage unit
11 times Carriage lift
mechanism
error
[5110] The carriage did not
move up or down
properly.
(1) Foreign material or paper
debris that obstructs the
carriage movement;
remove foreign material.
(2) Part replacement:
- Switch system unit
- Carriage unit
12 times APP position
error [6A80] An error occurred in the APP motor. (1) Foreign material or paper debris around the purge drive
system unit;
remove foreign material,
and
confirm that the ink
12 / 64

14 times APP sensor
error [6A90] An error occurred during paper feeding or
purging.
absorber right beneath the
purge drive system unit
stays in place and does not
contact the unit.
(2) Foreign material or paper
debris around the ASF unit;
remove foreign material.
(3) Cable connection
(4) Part replacement:
- Purge drive system unit
- Logic board
15 times USB host
Vbus
overcurrent
[9000] The USB host Vbus
overloaded. (1) Part replacement: - Logic board
16 times Pump roller
sensor error [5C20] The pump roller position cannot be detected. (1) Cable connection (2) Part replacement:
- Purge drive system unit
19 times Ink tank
position sensor
error
[6502] None of the ink tank
position is detected. (1) Ink tank position; confirm the ink tank
position.
(2) Re-set or replacement of ink
tanks
(3) Cable connection
(4) Part replacement:
- Spur unit
- Logic board
20 times Other errors [6500] An unidentified error or
a network error
occurred.
(1) Part replacement:
- Logic board
21 times Drive switch
error [C000] Drive was not switched properly. (1) Foreign material or paper debris in the drive switch area;
remove foreign material.
(2) Ink tank conditions;
confirm that the ink tanks
are seated properly, or re-
set the ink tanks properly.
(3) Part replacement:
- Purge drive system unit
- ASF unit
- Carriage unit
22 times Scanner error [5011] An error occurred in the
scanner. (1) Document pressure sheet conditions
(2) Cable connection
(3) Part replacement:
- Document pressure sheet
- Scanner unit
- Logic board
13 / 64

23 times Valve cam
sensor error [6C10] The valve cam sensor was faulty at power-on
or when purging was
attempted.
(1) Foreign material or paper
debris around the purge drive
system unit;
remove foreign material.
(2) Cable connection
(3) Part replacement:
- Purge drive system unit
- Logic board
Before replacement of the logic board ass'y, check the ink absorber counter value (by
service test print or EEPROM information print). If the counter value is 7% or more,
also replace the ink absorber kit when replacing the logic board ass'y. If the counter
value is less than 7%, register the current ink absorber counter value to the replaced new
logic board instead. [See 4-2. Service Mode, for details.]
14 / 64

2-3. Troubleshooting by Symptom
Symptom Solution
Faulty operation The power does not turn on.
The power turns off
immediately after power-on.
(1) Confirm connection of the power supply
unit:
- Harness and connector conditions
(2) Replace the following item(s):
- Logic board
- Power supply unit
A strange noise occurs. (1) Examine and remove any foreign
material or paper debris.
(2) Replace the following item(s):
- The part generating the strange noise
- Logic board
The LCD does not display
properly.
A portion of the LCD is not
displayed.
The display flickers.
(1) Confirm cable connection (LCD FFC
and panel harness):
- Harness and connector conditions
- No cable breakage, etc.
(2) Replace the following item(s):
- LCD FFC
- LCD unit
- Panel board
- Logic board
Paper feed problems (multi-
feeding, skewed feeding, no
feeding).
(1) Examine and remove any foreign
material or paper debris.
(2) Confirm that the paper is supported and
that the paper guides are set properly.
(3) Confirm the PF rear cover and the
cassette conditions.
(4) Confirm cable connection.
(5) Replace the following item(s):
- ASF unit (for paper feeding error from
the rear tray)
- PF pick-up unit (for paper feeding error
from the cassette)
- PE sensor board
- Pressure roller unit
- Cassette unit
Faulty scanning (no
scanning, strange noise). (1) Confirm cable connection (scanner motor cable and CIS FFC):
- Harness and connector conditions
- No cable breakage, etc.
(2) Confirm the conditions of the inside of
the platen glass:
- FCC damper condition, etc.
(3) Replace the following item(s):
- Scanner unit
15 / 64

- Logic board
Machine not recognized by
a USB-connected PC (1) Confirm USB cable connection. (2) Connect the machine to another PC to
see if the machine is recognized.
(3) Replace the following item(s):
- USB cable
- Logic board
Unsatisfactory print quality No printing, or no color
ejected.
Faint printing, or white lines
on printouts.
Uneven printing.
Improper color hue.
(1) Confirm the ink tank conditions:
- Confirmation of the air-through of an
ink tank
- Re-setting of an ink tank
(2) Remove foreign material from the purge
unit caps, if any.
(3) Confirm the head contact pin condition
of the carriage unit.
(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
- 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 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 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
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 film.
(2) Replace the following item(s):
- Timing slit film
- Carriage unit
- Logic board
- Scanner unit (for copying)
Graphic or text is enlarged (1) Confirm that the LF slit film is free from
16 / 64

*1: Replace the print head only after the print head deep cleaning is performed 2 times, and when the
problem persists.
*2: For the MP560 only.
on printouts in the paper
feed direction. smearing or scratches: - Cleaning of the LF slit film..
(2) Replace the following item(s):
- LF slit film
- LF timing sensor unit
- Platen unit
- Logic board
- Scanner unit (for copying)
Faulty scanning No scanning. (1) Replace the following item(s):
- Scanner unit
- Logic board
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
Network connection problem No printing. (1) Examine if printing is performed
properly via USB connection.
(2) Confirm the network settings.
(3) Replace the following item(s):
- Logic board (for wireless LAN*2)
- WLAN board (for wireless LAN*2)
<2. LIST OF ERROR DISPLAY / INDICATION>
17 / 64