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Canon iX6500 Series Service Manual

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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

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  Summary of Contents for Canon iX6500 Series

  • Page 1 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.
  • Page 2 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 Identify the problem, and handle it accordingly. Repair When a part needs to be replaced, see this section.
  • Page 3: Table Of Contents

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

    TABLE OF CONTENTS 1. TROUBLESHOOTING 1-1. Troubleshooting by Symptom Symptom Solution Faulty The power does not turn on. (1) Confirm cable connection: operation The power turns off - DC harness ass'y immediately after power-on. => No incomplete connection, cable breakage, or cable...
  • Page 6 Uneven printing. opened) Improper color hue. - 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.
  • Page 7: Operator Call Error Troubleshooting

    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.
  • Page 8 12 times Premium Contents [4100] Non-genuine ink tanks are - Ink tank print error. installed. Install the supported (Canon-genuine) ink tanks. 13 times The remaining ink [1683] An ink tank which has once been - Ink tank amount unknown empty is installed. Replace the - Spur unit (raw ink present).
  • Page 9 14 times Ink tank not [1684] An incompatible ink tank is - Ink tank recognized. installed (the ink tank LED is turned off). Install the supported ink tanks. [1750] A non-supported ink tank is - Ink tank installed (the ink tank LED is turned off).
  • Page 10: Service Call Error Troubleshooting

    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 &...
  • Page 11 - PE sensor cable - Paper feed motor harness ass'y 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.
  • Page 12 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.
  • Page 13 (2) Foreign material in the paper path: - Platen unit Remove foreign material. - Logic board ass'y (3) Cable connection: - Paper feed motor - LF encoder cable - PE sensor cable Re-connect the cable. (4) Scratches on the LF slit film: Replace the timing slit disk feed film.
  • Page 14: Repair

    TABLE OF CONTENTS 2. REPAIR 2-1. Major Replacement Parts and Adjustment Service Adjustment / settings / operation Recommended removal procedure part check Logic board (1) Front panel cover L In the service mode: ass'y (2) Main case unit 1.
  • Page 15 system unit (2) Main case unit [See 3-5. Special Notes on Servicing, (3) Print unit (2) Paper feed motor adjustment, for (4) See 2-2. Disassembly & Reassembly details.] Procedures. In the service mode: - See 2-2. Disassembly & Reassembly Procedures, 2.
  • Page 16 upper rail details.] APP code In the service mode: wheel gear 2. Print the integrated inspection pattern. shaft Paper guide Timing slit 2-2. Disassembly & Reassembly Procedures, and In the user mode: strip film Parts Catalog. 1. Perform print head alignment. In the service mode: 2.
  • Page 17 Be sure to protect the machine from static electricity in repair servicing, especially for the logic board, panel cover unit, and PE sensor board. Some of the photos below are from the MG5200 series, since their structure is similar to that of the iX6500 series. (1) External housing removal 1) Remove the access cover and the paper support (no screws).
  • Page 18 3) Remove the front panel cover L (no screws). <Slide the cover toward you from the front of the printer.> 4) Remove the main case (2 screws). <Lift the main case upward to separate it from the printer.> 14 / 52...
  • Page 19 5) Remove the panel cover unit R (1 screw). 15 / 52...
  • Page 20 (2) Printer unit removal & Ink absorber replacement 1) Remove the protective sheet from the bottom case. 2) Disconnect the front cover switch and DC harnesses from the logic board, and release the front cover switch harness from the holder. 3) Release the ink sensor harness and the temperature &...
  • Page 21 4) Remove the printer unit. (6 screws) <Lift the printer unit.> Specific screw location: 17 / 52...
  • Page 22 When the printer unit is separated from the bottom case, ink absorbers can be replaced. When the ink absorbers are replaced, confirm that the replaced new absorbers fit in place securely, and they do not lift. After replacement of the ink absorbers, reset the ink absorber counter value to zero in the service mode.
  • Page 23 (3) Board removal 1) Remove the logic board and main PCB chassis (5 screws). 2) Remove the PE sensor board (4 screws). 19 / 52...
  • Page 24 (4) Carriage unlocking 1) Rotate the drive unit gear toward the back of the printer to unlock the carriage. Slide the carriage to the left (the opposite of the home position). (5) ASF unit removal 1) Remove 1 screw from the left plate, and 2 screws from the right plate. 20 / 52...
  • Page 25 (6) Carriage unit removal 1) Remove the front chassis. (From the left side, release the spring and remove 3 screws, then pull the chassis frontward). 2) Remove the carriage cable cover and holder from the front chassis. 3) On the main chassis, mark the position of the carriage upper rail (the positions of the left and right edges of the rail).
  • Page 26 4) Remove the carriage upper rail (3 screws). 5) On the main chassis, mark the positions of the screws that fix the carriage rail to the main chassis (3 points for each screw: the left, right, and center). 6) Remove the timing slit film. Be cautious to keep it free from any grease or damage. 22 / 52...
  • Page 27 7) Using a pair of pliers, etc., release the left end of the pulley holder spring, then remove the carriage belt. Be cautious to keep it free from any grease. 8) Remove 3 screws that fix the carriage rail to the main chassis, and slowly put down the carriage rail.
  • Page 28 (7) Spur unit and platen unit removal 1) Remove the ink sensor from the front chassis (1 screw). 2) From the left and right sides of the spur unit, release the springs (one spring each). 3) On the both ends of the spur unit, pull the hooks outward to release them from the platen unit, and lift the spur unit to separate it from the platen unit.
  • Page 29 4) Unlock the paper eject roller gear. While raising the front of the platen unit, remove the platen unit from the printer unit. 25 / 52...
  • Page 30 (8) Purge drive system unit (right plate) and switch system unit (left plate) removal 1) Remove the carriage motor cable, and 4 screws from the purge drive system unit. 2) Remove 3 screws from the switch system unit. 3) Separate the main chassis from the switch system unit and the purge drive system unit. 26 / 52...
  • Page 31 (9) Engine unit reassembly After repair, reassemble each unit of the printer engine on the bottom case in the procedures listed below. Depending on the replaced unit, some steps can be omitted. For specific part names and locations, refer to the Parts Catalog.
  • Page 32 (10) Cable wiring and connection 1) Logic board and spur unit: 28 / 52...
  • Page 33 2) Switch system unit and PE sensor board: 3) Bottom case and DC harness: <2-2. Disassembly & Reassembly Procedures> 29 / 52...
  • Page 34 TABLE OF CONTENTS 3. ADJUSTMENT / SETTINGS 3-1. Adjustment Approx. Adjustment Purpose Method time Destination settings To set the printer destination. 1 min. Service Tool (EEPROM settings) - At logic board replacement Set Destination section Ink absorber counter To reset the ink absorber counter.
  • Page 35 LF / Eject correction To correct line feeding when 5 min. Service Tool necessary. (1) In the LF/EJECT - At paper feed roller replacement Correction section, - At platen unit replacement click Print to print the - At logic board replacement LF/EJ correction pattern.
  • Page 36 3-2. Adjustment and Maintenance in User Mode Function Procedures Remarks Nozzle Perform from the printer driver Set a sheet of plain paper (A4 or Letter) in the rear check Maintenance tab, or via the tray. pattern Resume/Cancel button. printing Print head - Cleaning both Black and Color: Unclogging of the print head nozzles, and manual...
  • Page 37 3-3. Adjustment and Settings in Service Mode (1) Service mode operation procedures Use the Service Tool on the connected computer. 1) Start the printer in the service mode. i. With the printer power turned off, while pressing the Resume/Cancel button, press and hold the ON button. (DO NOT release the buttons.) ii.
  • Page 38 (2) Service Tool functions Service Tool screen: Version 2.000 34 / 52...
  • Page 39 35 / 52...
  • Page 40 - Barcode (model name + destination + printer serial number) - Ink system function check result - DVD / CD sensor check result (not applicable to the iX6500 series) 2 EEPROM EEPROM information print The dialog box opens to select the paper source.
  • Page 41 (same as the one in the user mode) 7 Main Main ink absorber counter Set a sheet of A4 or Letter sized plain paper. After (Clear Ink resetting the ink absorber counter is reset, the counter value Counter) is printed automatically. Platen Platen ink absorber counter Not used.
  • Page 42 5 sheets of A4 paper will be used for the pattern printing. - Paper source: Select either Rear tray. - Media type: Select one from HR-101, GF-500/Office Planner, HP Bright White, and Canon Extra/STEINBEIS. 2) When printing is finished, the printer returns to be ready for selection of another function ("A function was finished"...
  • Page 43 (4) Ink absorber counter setting Set the ink absorber counter value to a new EEPROM after the logic board is replaced in servicing. 1) Before replacement of the logic board, check the ink absorber counter value in EEPROM information print. 2) After replacement of the logic board, the ink absorber counter value should be set in the service mode using the Service Tool.
  • Page 44 --- 3. ADJUSTMENT / SETTINGS TABLE OF CONTENTS 3-4. Grease Application Grease Number Drawing Part name Where to apply grease / oil Grease amount of drops x (mg) Location The surface where the carriage unit 1 Carriage rail...
  • Page 45 - Is the outer film completely removed to open the air-through? - Re-install the ink tanks. - Is the ink tank Canon-genuine or not? - Is the ink tank refilled one or not? 2) Remove and clean any foreign material from the caps of the purge unit.
  • Page 46 (3) Carriage unit replacement In the iX6500 series, the carriage upper rail and carriage rail need to be removed from the main chassis. Before removing the screws from the carriage upper rail and carriage rail, put a mark on the main chassis to indicate the rail position.
  • Page 47 (4) Ink absorber counter setting 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. When the ink absorber is replaced, reset the applicable ink absorber counter (to 0%).
  • Page 48 (6) Rating label on the bottom case (except China*) When the bottom case is replaced, be sure to remove the rating label from the original bottom case and attach it to the replaced new one. The rating label is given to each printer unit respectively, thus the label of one unit is valid only for that unit.
  • Page 49 TABLE OF CONTENTS 4. VERIFICATION AFTER REPAIR 4-1. Standard Inspection Flow In each step below, confirm that printing is performed properly and the printer operates properly without any strange noise. EEPROM information print <Check point> - The information must be printed properly.
  • Page 50 4-2. Integrated Inspection Pattern Print < Print sample > 46 / 52...
  • Page 51 4-3. Ink Absorber Counter Value Print <Print sample> <4. VERIFICATION AFTER REPAIR> 47 / 52...
  • Page 52 TABLE OF CONTENTS 5. APPENDIX 5-1. Customer Maintenance Approx. Adjustment Timing Purpose Tool time Automatic print - At print head replacement To ensure accurate - 1 sheet of A4 or Letter 5 min. head alignment - When print quality is not satisfying dot placement.
  • Page 53 5-2. Special Tools Name Tool No. Application Remarks To the carriage rail sliding In common with other products on the FLOIL KG-107A QY9-0057-000 portions. market 5-3. Sensors Sensor Function Possible problems detected by the sensor Access cover Detects opening and closing of the - The carriage does not move to the center even sensor access cover (top cover).
  • Page 54 50 / 52...
  • Page 55 5-4. Serial Number Location On the inner guide over the upper portion of the spur holder (visible when the top cover is opened). When the printer power is OFF. When the printer power is ON. <5. APPENDIX> 51 / 52...
  • Page 56 TABLE OF CONTENTS 6. PRINTER TRANSPORTATION This section describes the procedures for transporting the printer for returning after repair, etc. 1) In the service mode, press the ON button to finish the mode, and confirm that the paper lifting plate of the rear tray is raised.

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