MP540 / MP545

SIMPLIFIED SERVICE MANUAL

1. LIST OF ERROR DISPLAY

2. ADJUSTMENT / SETTINGS
3. EXTERNAL VIEW / PARTS LIST

QY8-13CA-000
Rev.00

July 31, 2008

Canon Inc.

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1. LIST OF ERROR DISPLAY
Errors and warnings are displayed by the following ways:
- 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.
- Messages during printing from a computer are displayed on the MP driver Status Monitor.
- 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:
- ON button: To turn the machine off and on again.
- 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.
- Stop button: To cancel the job at error occurrence, and to clear the error.

1-1. Operator Call Errors (Alarm LED Lit In Orange)

Error
Error U No. Message on the LCD Solution
code
No paper in the rear [1000] --- Rear tray. Confirm that the rear tray is selected as
tray. There is no paper. Load the paper source. Set the paper in the
paper and press [OK]. rear tray, and press the OK button.
No paper in the [1003] --- Cassette. Confirm that the cassette is selected as
cassette. There is no paper. Load the paper source. Set the paper in the
paper and press [OK]. cassette, and press the OK button.
Note: Only plain paper can feed from
the cassette.
Paper jam. [1300] --- The paper is jammed. Clear Remove the jammed paper, and press
Paper jam in the rear [1303] --- the paper and press [OK]. the OK button.
guide.
Ink may have run [1600] U041 The following ink may have Replace the applicable ink tank, or press
out. run out. Replacing the ink the OK button to clear the error without
tank is recommended. ink tank replacement. When the error is
cleared by pressing the OK button, ink
may run out during printing.
Ink tank not installed. [1660] U043 The following ink tank cannot Install the applicable ink tank(s) properly,
be recognized. and confirm that the LED's of all the ink
(Applicable ink tank icon) tanks light red.
Print head not [1401] U051 Print head is not installed. Install the print head properly.
installed, or not Install the print head.
properly installed.
Faulty print head ID. U052 The type of print head is Re-set the print head. If the error is not
Print head [1403] incorrect. Install the correct cleared, the print head may be defective.
temperature sensor print head. Replace the print head.
error.
Faulty EEPROM data [1405]
of the print head.
Multiple ink tanks of [1681] U071 More than one ink tank of the Replace the wrong ink tank(s) with the
the same color following color is installed. correct one(s).
installed.
Ink tank in a wrong [1680] U072 Some ink tanks are not Install the ink tank(s) in the correct
position. installed in place. position.

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 Error
Error U No. Message on the LCD Solution
code
Warning: The ink [1700, --- Contact the support center or Replace the ink absorber, and reset its
absorber becomes 1701] service center for ink counter. Pressing the OK button will exit
almost full. absorber replacement. Press the error, and enable printing without
[OK] to continue printing. 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 digital [2001] --- The device may be Remove the cable between the camera
camera or digital incompatible. Remove the and the machine.
video camera does device and check the manual
not support Camera supplied with the connected
Direct Printing. device.
The remaining ink [1683] U130 (Applicable ink tank icon) An ink tank which has once been empty
amount unknown. The remaining level of the is installed. Replace the applicable ink
following ink cannot be tank with a new one. Printing with a
correctly detected. Replace once-empty ink tank can damage the
the ink tank. 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 not [1684] U140 The following ink tank cannot A non-supported ink tank (an ink tank
recognized. be recognized. that is sold in a different region from
(Applicable ink tank icon) where the machine was purchased) is
installed (the ink tank LED is turned off).
Install the supported ink tanks.
Ink tank not [1410 U150 The following ink tank cannot A hardware error occurred in an ink tank
recognized. to be recognized. (the ink tank LED is turned off). Replace
1419] (Applicable ink tank icon) the ink tank(s).
No ink (no raw ink). [1688] U163 Printer detected ink out Replace the empty ink tank(s), and close
condition of the following ink. the scanning unit (cover).
Replace the ink tank. Printing with an empty ink tank can
(Applicable ink tank icon) 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 hub [2002] --- An unsupported USB hub is Remove the applicable USB hub from
connected. Remove the hub. the PictBridge (USB) connector.

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 Error
Error U No. Message on the LCD Solution
code
Time-out for the [2700] --- Timeout error has occurred. The buffer became full in the middle of
scanner device Press [OK]. scanning operation, and 60 minutes
have elapsed since then, making
re-scanning unstable. Press the OK
button to clear the error.

1-2. 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, 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.
Cycles of
blinking of Error Solution
Error Conditions
Alarm and code (Check points and replacement items)
Power LEDs
2 times Carriage error [5100] An error occurred in the 1) Smearing or scratches on the carriage
carriage encoder signal. 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 1) Smearing or scratches on the LF slit
encoder signal. film;
clean the LF slit film.
2) Foreign material or paper debris in the
LF drive;
remove foreign material.
3) Cable connection
4) Part replacement:
- LF slit film
- LF timing sensor unit
- Paper feed roller unit
- Logic board
- Paper feed motor
4 times Purge cam [5C00] An error occurred in the 1) Foreign material or paper debris
sensor error purge unit. around the purge drive system unit;
remove foreign material.
2) Cable connection
3) Part replacement:
- Purge drive system unit
- Logic board

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 Cycles of
blinking of Error Solution
Error Conditions
Alarm and code (Check points and replacement items)
Power LEDs
5 times ASF (cam) [5700] An error occurred in the 1) Cable connection
sensor error ASF cam sensor. 2) Part replacement:
- ASF unit
- PE sensor board unit
- Logic board
6 times Internal [5400] The internal temperature is 1) Cable connection
temperature not normal. 2) Part replacement:
error - Carriage unit
- Logic board
- Print head
7 times Ink absorber full [5B00] The ink absorber is 1) Ink absorber condition
[5B01] supposed to be full. 2) Part replacement:
Message on the LCD: - Ink absorber kit
Ink absorber full. Service 3) Ink absorber counter value in the
required. EEPROM;
Error codes: reset the ink absorber counter.
5B00: Main ink absorber
is full (non-Japan).
5B01: Main ink absorber
is full (Japan).
8 times Print head [5200] The print head temperature 1) Print head condition
temperature rise exceeded the specified 2) Cable connection
error value. 3) Part replacement:
- Print head
- Logic board
9 times EEPROM error [6800] A problem occurred in 1) Part replacement:
[6801] reading from or writing to - Logic board
the EEPROM.
10 times VH monitor error [B200] The internal temperature 1) Part replacement:
exceeded the specified - Print head and logic board
value. (Replace them at the same time.)
- Power supply unit
11 times Carriage lift [5110] The carriage did not move 1) Foreign material or paper debris that
mechanism up or down properly. obstructs the carriage movement;
error remove foreign material.
2) Part replacement:
- Switch system unit
- Carriage unit
12 times APP position [6A80] An error occurred in the 1) Foreign material or paper debris
error APP motor. around the purge drive system unit;
14 times APP sensor [6A90] An error occurred during remove foreign material.
error paper feeding or purging. 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

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 Cycles of
blinking of Error Solution
Error Conditions
Alarm and code (Check points and replacement items)
Power LEDs
15 times USB Host VBUS [9000] The USB Host VBUS is 1) Part replacement:
overcurrent overloaded. - Logic board
16 times Pump roller [5C20] The pump roller position 1) Cable connection
sensor error cannot be detected. 2) Part replacement:
- Purge drive system unit
19 times Ink tank position [6502] None of the ink tank 1) Ink tank position;
sensor error position is detected. 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 1) Part replacement:
occurred. - Logic board
21 times Drive switch [C000] Drive was not switched 1) Foreign material or paper debris in the
error properly. drive switch area;
remove foreign material.
2) Part replacement:
- Purge drive system unit
- ASF unit
22 times Scanner error [5011] An error occurred in the 1) Document pressure sheet conditions
scanner. 2) Cable connection
3) Part replacement:
- Document pressure sheet (sponge
sheet)
- Scanner unit
- Logic board
Flatbed motor [5012] An error occurred in the 1) Cable connection
error scanner flatbed motor. 2) Part replacement
- Scanner unit
23 times Valve cam [6C10] The valve cam sensor was 1) Foreign material or paper debris
sensor error faulty at power-on or when around the purge drive system unit;
purging was attempted. remove foreign material.
2) Cable connection
3) Part replacement:
- Purge drive system unit
- Logic board
Note: 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.

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1-3. Warnings
Warning Message on the LCD Solution
Low ink "!" is indicated for an applicable ink Since the ink will be used up soon,
tank icon in the Status Monitor. prepare for a new ink tank.
Print head temperature rise If the print head temperature does not When the print head temperature falls,
fall, the print head error will occur. the error is automatically cleared. If the
print head error is indicated, repair
servicing is required.
Protection of excess rise of If the print head temperature does not If the print head temperature exceeds the
the print head temperature fall, the print head error will occur. specified limit, an intermission is inserted
during printing.
Restrictions on paper The current paper cannot be set. Re-select the supported paper type and
Change the size and type. size.
USB cable not connected Set the PC to start scan. Connect the USB cable, then turn on the
computer.
Cancellation of image select Reset the selected photo information? - Select Yes, and press the OK button.
information Yes No => The image selection is cancelled,
Do you want to clear the image and the LCD returns to the display
scanned from the photo? before the message was displayed.
Yes No - Select No, and press the OK button.
Do you want to clear the scanned => The LCD returns to the display
image and rescan? immediately before the message
Yes No was displayed.

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2. ADJUSTMENT / SETTINGS
2-1. Service Mode
< Service mode operation procedures >
Use the Service Tool on the connected computer.
1) Start the machine in the service mode.
i. With the machine power turned off, while pressing the Stop button, press and hold the ON
button. (DO NOT release the buttons).
ii. When the Power LED lights in green, while holding the ON button, release the Stop button.
(DO NOT release the ON button.)
iii. While holding the ON button, press the Stop button 2 times, and then release both the ON
and Stop buttons. (Each time the Stop button is pressed, the Alarm and Power LEDs light
alternately, Alarm in orange and Power in green, starting with Alarm LED.)
iv. When the Power LED lights in green, the machine is ready for the service mode operation.
- LCD ready for the service mode operation:

2) Start the Service Tool on the connected computer.

i. When a button is clicked in the Service Tool dialog box, that function is performed. During
operation of the selected function, all the Service Tool buttons are dimmed and inactive.
ii When the operation is completed, "A function was finished." is displayed, and another
function can be selected.
iii If a non-supported function is selected, "Error!" is displayed. Click OK in the error message
dialog box to exit the error.

< Service Tool Functions >

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No. Name Function Remarks
(1) Test Print Service test print Paper will feed from the rear tray.
Service test print:
- Model name
- ROM version
- Ink absorber counter value (ink amount in the ink
absorber)
- USB serial number
- Destination
- EEPROM information
- Process inspection information
- Barcode (model name + destination)
- Ink system function check result
(2) EEPROM EEPROM information print The dialog box opens to select the paper source.
Select Rear tray or Cassette, and click OK.
EEPROM information print:
- Model name
- ROM version
- Ink absorber counter value (ink amount in the ink
absorber)
- Print information
- Error information, etc.
(3) CD-R CD-R check pattern print Not used.
(4) LF / Eject LF / Eject correction See “LF / Eject correction” below.
pattern print
(5) Left Margin Left margin pattern print Not used.
(6) Deep Cleaning Print head deep cleaning Cleaning of both Black and Color at the same
time.
(7) Main Main ink absorber counter Set a sheet of A4 or Letter sized plain paper. After
resetting the ink absorber counter is reset, the counter value
is printed automatically.
(8) Platen Platen ink absorber Not used.
counter resetting

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 No. Name Function Remarks
(9) EEPROM Clear EEPROM initialization The following items are NOT initialized, and the
shipment arrival flag is not on:
- USB serial number
- Destination settings
- Record of ink absorber counter resetting and
setting
- Record of repair at the production site
- LF / Eject correction values
- Left margin correction value
- Production site E-MIP correction value and
enabling of it
- Endurance correction value and enabling of it
- Record of disabling the function to detect the
remaining ink amount
- Ink absorber counter value (ink amount in the ink
absorber)
(10) Panel Check Button and LCD test See "Button and LCD test" below.
(11) Set Destination Destination settings Select the destination, and click OK.
ASA, AUS, BRA, CHN, CND, EUR, JPN, KOR,
LTN, TWN, USA
(12) CD-R Correction CD / DVD print position Not used.
correction (X and Y
direction)
(13) LF / EJECT LF / Eject correction value See " LF / Eject correction " below.
Correction setting
(14) Left Margin Correction Left margin correction Not used.
value setting
(15) Ink Absorber Counter Ink absorber counter See " Ink absorber counter setting " below.
setting

< LF / Eject correction >

After replacement of the feed roller, platen unit, LF / Eject encoder, encoder film, or logic board in
repair servicing or in refurbishment operation, perform the adjustment to maintain the optimal print
image quality.
1) Print the LF / Eject correction pattern.
Click LF/EJECT of the Service Tool on the connected computer, select the paper source and the
paper type, and print the pattern. 5 sheets of paper will be used for the pattern printing.
- Paper source: Select either Rear tray or Cassette.
- Media type: Select one from HR-101, GF-500/Office Planner, HP Bright White, and
Canon Extra/STEINBEIS.
2) When printing is finished, the machine returns to be ready for selection of another function
("Service Mode Idle" is displayed on the LCD).
3) In the printout, determine the Pattern No. in which streaks or lines are the least noticeable for the
LF check pattern and the Eject check pattern respectively. (LF Pattern No. 0 to 4, Eject Pattern
No. 0 to 4)

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 4) In the LF/EJECT Correction section of the Service Tool, select the Pattern No. (from 0 to 4)
determined in step 3) for LF and EJECT respectively, and click Set.
5) The selected LF and Eject correction values are written to the EEPROM, making the E-MIP
correction value (which was set at shipment from the production site) invalid.

Note: At the production site, the E-MIP correction, which is equivalent to the LF / Eject correction,
is performed using the special tool, and the E-MIP correction value is written to the EEPROM
as the valid data.
When LF / Eject correction is performed, the LF / Eject correction values become valid
instead of the E-MIP correction value (thus, in the initial EEPROM information print, "LF = *"
and "EJ = *" are printed, but the selected values are printed after the LF / Eject correction).

< Button and LCD test >

Confirm the operation after replacement of the operation panel unit, board, or LCD unit.
1) Click Panel Check of the Service Tool on the connected computer. The machine LCD turns blue,
waiting for a button to be pressed.
2) Press each button of the operation panel.
3) Only one button should be pressed at one time. If 2 or more buttons are pressed at the same time,
only one of them is considered to be pressed, and the other buttons are ignored.
The LCD is divided into 16 segments, representing each button. The color of a segment
corresponding to the pressed button changes to red.
1: ON button 9: Color button
2: Back button 10: Stop button
3: OK button 11: NAVI button
4: Up cursor button 12: HOME button
5: Down cursor button 13: Left function button
6: Left cursor button 14: Right function button
7: Right cursor button 15: [+] button
8: Black button 16: [-] button

4) Rotate the Easy-Scroll Wheel clockwise and counterclockwise 1 round (16 steps) each, as
follows:
4-1) Rotate the Easy-Scroll Wheel clockwise step by step. The LCD is divided into 16 segments,
representing each step. The color of a segment corresponding to the step changes from red
to green.
If the wheel is rotated counterclockwise before clockwise round completes, the color of
segment(s) corresponding to the number of steps the wheel is rotated counterclockwise
returns to red.
If the wheel keeps rotated clockwise over 1 round (16 steps), the color of segment(s)
corresponding to the extra number of steps returns to red, starting with the "Start" segment
in the figure below.

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 4-2) When the Easy-Scroll Wheel is rotated clockwise 1 round (16 steps), press the OK button.
4-3) Rotate the Easy-Scroll Wheel counterclockwise step by step. The LCD is divided into 16
segments, representing each step. The color of a segment corresponding to the step
changes from green to blue.
If the wheel is rotated clockwise before counterclockwise round completes, the color of
segment(s) corresponding to the number of steps the wheel is rotated clockwise returns to
green.
If the wheel keeps rotated counterclockwise over 1 round (16 steps), the color of
segment(s) corresponding to the extra number of steps returns to green, starting with the
"Start" segment in the figure below.

4-4) When the Easy-Scroll Wheel is rotated counterclockwise 1 round (16 steps, and all the
segments are in blue), press the OK button. The color pattern is displayed on the LCD.
If there is any segment that is not in blue when the OK button is pressed, the display
remains unchanged.

5) Adjust the transparent color, as follows:

5-1) Press the OK button. "OK1" in white is displayed on the black background.
If the result is not good, "NG1" in black is displayed on the white background (transparent
color) immediately after "OK1."

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 5-2) Press the OK button. "OK2" in black is displayed on the white background.
If the result is not good, "NG2" in white is displayed on the black background (transparent
color) immediately after "OK2."

6) Adjust the LCD flicker, as follows:

6-1) Press the OK button. The screen is displayed as below for LCD flicker adjustment.

6-2) If the screen flickers, press the left or right cursor button until the flickering disappears. By
pressing the left or right cursor, the VrefPWM value displayed at the bottom of the LCD
changes from 36 to 3D (in hexadecimal).
6-3) Press the OK button. The machine returns to be ready for selection of another function
("Service Mode Idle" is displayed on the LCD).

< 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.
In the Ink Absorber Counter section of the Service Tool, select Main from the Absorber
pull-down menu.
From the Counter Value(%) pull-down menu, select the value (in 10% increments) which is the
closest to the actual counter value confirmed before replacement of the logic board, and click Set.
3) Print EEPROM information to confirm that the value is properly set to the EEPROM.

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2-2. User Mode
Function Procedures Remarks

Nozzle check pattern Perform via the machine operation Set a sheet of plain paper (A4 or Letter) in
printing panel, or from the MP driver the cassette, or the rear tray if selected.
Maintenance tab.
Print head manual - Cleaning both Black and Color: Unclogging of the print head nozzles, and
cleaning Perform via the machine maintenance to keep the print head
operation panel, or from the MP conditions good.
driver Maintenance tab. If there is a missing portion or white streaks
- Cleaning Black or Color separately: in the nozzle check pattern printout,
Perform from the MP driver perform this cleaning.
Maintenance tab.
Print head deep Perform via the machine operation If print head cleaning is not effective,
cleaning panel, or from the MP driver perform this cleaning. Since the deep
Maintenance tab. cleaning consumes more ink than regular
cleaning, it is recommended to perform
deep cleaning only when necessary.
Manual print head Perform via the machine operation Set 3 sheets of plain paper (A4 or Letter) in
alignment panel, or from the MP driver the cassette, or the rear tray if selected.
Maintenance tab.
Print head alignment Perform via the machine operation Confirmation of the current print head
value printing panel, or from the MP driver alignment values.
Maintenance tab.
Paper feed roller Perform via the machine operation The paper feed rollers of the selected
cleaning panel, or from the MP driver paper source (the rear tray or the cassette)
Maintenance tab. rotate while being pushed to the paper
lifting plate. Since the rollers will wear out in
this cleaning, it is recommended that you
perform this only when necessary.
Bottom plate cleaning Perform via the machine operation Cleaning of the platen ribs when the back
panel, or from the MP driver side of paper gets smeared.
Maintenance tab. Fold a sheet of plain paper (A4 or Letter) in
half crosswise, then unfold and set it in the
rear tray with the folded ridge facing down.
(No paper feeding from the cassette)

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2-3. Special Notes on Assembling
(1) External housing, scanner unit, and document cover removal
1) Remove the cassette, and open the front door.
2) Pull up the document cover to remove it, then remove the rear top cover and the middle frame
(4 screws).

3) Remove the side cover R (2 screws).

< The scanner unit hinges are fitted in the right and left side covers. >

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4) Remove the scanner cable, panel cable, FB encoder cable, and core.
< The core is fixed on the rib of the sub-case (back of the main case). >

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5) Remove the side cover L and scanner unit (2 screws).
< While holding the scanner unit, separate the scanner stay from the side cover L. >

6) Remove the operation panel unit (11 screws).

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7) Remove the main case and sub-case (1 screw).

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(2) Notes on Service Part Replacement (and Disassembling / Reassembling)
Service part Notes on replacement*1 Adjustment / settings Operation check
Logic board ass'y - Before removal of the logic After replacement: - EEPROM information print
board ass'y, remove the 1) Initialize the EEPROM. - Service test print
power cord, and allow for 2) Set the ink absorber counter - Printing via USB connection
approx. 1 minute (for value. - Copying
discharge of capacitor's 3) Set the destination in the - Direct printing from a digital
accumulated charges), to EEPROM. camera (PictBridge)
prevent damages to the 4) Check the ink system function.
logic board ass'y. 5) Perform LF / Eject correction.
- Before replacement, 6) Perform button and LCD test.
check the ink absorber Perform 1 to 6 in the service
counter value (by service mode.
test print or EEPROM 7) Perform print head alignment
information print). and LCD language setting in
the user mode.
Absorber kit After replacement: - Ink absorber counter value
1) Reset the ink absorber counter. print (After the ink absorber
counter is reset, the counter
value is printed
automatically.)
Carriage unit At replacement: - Service test print (Confirm
1) Before removal of the carriage ink system function.)
rail, mark the carriage rail
position.
2) Apply grease to the sliding
portions of the carriage rail.
3) Check the ink system function.
4) Perform print head alignment in
the user mode.
Switch system - The red screws securing At replacement: - EEPROM information print
unit the paper feed motor are 1) Adjust the paper feed motor. - Service test print
allowed to be loosened
Paper feed motor only for paper feed motor
replacement. (DO NOT
loosen them in any other
cases.)

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 Service part Notes on replacement*1 Adjustment / settings Operation check
Platen unit After replacement: - EEPROM information print
1) Perform LF / Eject correction in - Service test print
the service mode.
Spur unit - DO NOT contact the spur After replacement: - EEPROM information print
edges. 1) Check the ink system function. - Service test print
2) Perform LF / Eject correction in
the service mode.
Purge drive After replacement: - Service test print
system unit 1) Confirm the purging operation
and the machine operation.
Carriage rail and At replacement: - Service test print
main chassis 1) Apply grease to the sliding
Idler pulley portions.
parallel pin
Easy-Scroll
Wheel base
APP code wheel
gear shaft
Document cover At replacement: - Service test print
unit 1) Confirm the document pressure
Scanner unit sheet position.
Panel board - Be cautious not to scratch At replacement: - Service test print
ass'y or damage the LCD cable. 1) Perform button and LCD test.
LCD unit
Timing slit strip - Upon contact with the film, After replacement: - EEPROM information print
film wipe the film with ethanol. 1) Perform print head alignment in - Service test print
- Confirm no grease is on the user mode.
Timing slit disk the film. (Wipe off any 2) Perform LF / Eject correction in
feed film grease thoroughly with the service mode.
ethanol.)
- Do not bend the film
Print head After replacement: - Service test print
1) Perform print head alignment in
the user mode.
*1: General notes:
- Make sure that the flexible cables and wires in the harness are in the proper position and
connected correctly.
- 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, and timing slit disk feed film. No grease or abrasion is
allowed.
- Protect the units from soiled with ink.
- Protect the housing from scratches.
- 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

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 original position.

(3) Paper feed motor adjustment

1) When attaching the motor, fasten the screws so that the belt is properly stretched (in the
direction indicated by the blue arrow in the photo below).
2) After replacement, be sure to perform the service test print, and confirm that no strange noise or
faulty print operation (due to dislocation of the belt or gear, or out-of-phase motor, etc.) occurs.

Caution: The screws securing the paper feed motor may be loosened only at replacement of the
paper feed motor unit. DO NOT loosen them in other cases.

(4) Document pressure sheet (sponge sheet) replacement

1) Peel off the cover sheet from the double-sided adhesive tape on the back of the document
pressure sheet.
With the long-side down, position the upper-left corner of the document pressure sheet at the
scanning reference point on the platen glass (back left where the red lines cross in the photo
above).
2) Slowly close the document pressure plate while maintaining the hinge position. The document
pressure sheet will attach to the plate.
3) Open the plate to confirm the following:

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 - No extension of the sponge edges over the mold part of the upper scanner cover.
- No gap between the platen glass reference edges and the corresponding sponge edges.
- No shades or streaks in monochrome test printing without a document on the platen glass.

(5) 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 ink absorber counter value, replace the ink absorber (ink absorber kit).
When the ink absorber is replaced, reset the applicable ink absorber counter (to 0%).

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2-4. Grease application
(1) Printer unit
Grease
No. Part name Where to apply grease / oil *1 Grease *2
amount (mg)

1 Carriage rail The surface where the carriage unit slides (1) Floil KG107A 270 to 330 ---
2 Carriage rail The surface where the carriage unit slides (2) Floil KG107A 18 to 36 1x2
3 Carriage rail The surface where the carriage unit slides (3) Floil KG107A 360 to 440 ---
4 Carriage rail The surface where the carriage unit slides (4) Floil KG107A 360 to 440 ---
5 Main chassis The surface where the carriage unit slides (5) Floil KG107A 230 to 290 ---
6 Parallel pin The pin surface which contacts the idler pulley (6) Floil KG107A 9 to 18 1x1
hole
7 APP code wheel APP code wheel gear sliding portion (the entire (7) Floil KG107A 9 to 18 1x1
gear shaft surface)
*1: Drawing No.
*2: Number of drops (1 drop = 9 to 18 mg) x locations

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(2) Operation panel, Easy-Scroll Wheel
Drawing Grease
No. Part name Where to apply grease / oil Grease
No. amount (mg)

8 Easy-Scroll Wheel base Easy-Scroll Wheel sliding portions (8) Floil KG107A 9 to 18

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2-5. Notes on Transportation
This section describes the procedures for transporting the machine 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.
2) Keep the print head and ink tanks installed in the carriage. See Caution (a) below.
3) Turn off the machine to securely lock the carriage in the home position. (When the machine is
turned off, the carriage is automatically locked in place.) See Caution (b) below.

Caution: a. If the print head is removed from the machine and left alone by itself, ink (the
pigment-based black ink in particular) is likely to dry. For this reason, keep the print
head installed in the machine even during transportation.
b. Securely lock the carriage in the home position, to prevent the carriage from moving
and applying stress to the carriage flexible cable, or causing ink leakage, during
transportation.

Note: - If the print head must be removed from the machine and transported alone, attach the
protective cap (used when the packing was opened) to the print head (to protect the print
head face from damage due to shocks).
- If the packing material that fixed the carriage from the factory is still available, re-use it to fix
the carriage (to prevent the carriage unlocked during transportation).

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3. EXTERNAL VIEW / PARTS LIST

FIGURE 1 PACKING CONTENTS & PRINT HEAD

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LIST OF FIGURE 1

FIGURE &
PART NUMBER RANK QTY DESCRIPTION REMARKS
KEY No.
1- 1 QM3-3685-000 1 CASSETTE UNIT
2 QY6-0073-000 1 PRINT HEAD
220V-240V(EUM, EMB, ASA,
3 QH2-2716-000 1 CORD, POWER
MY)
3 QH2-2719-000 1 CORD, POWER 100V-120V
3 QK1-0776-000 1 CORD, POWER 220V-240V(AU)
3 QK1-2017-000 1 CORD, POWER 100V-120V(TW)
3 QK1-3048-000 1 CORD, POWER 120V-240V(LAM, CHN)
3 QK1-3761-000 1 CORD, POWER 100V(JP)
3 WT3-5156-000 1 CORD, POWER 220V-240V(GB, HK)
3 WT3-5160-000 1 CORD, POWER 220V-240V(KR)
4 QC2-7932-000 1 LABEL, PANEL CA

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FIGURE 2 AC ADAPTER

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LIST OF FIGURE 2

FIGURE &
PART NUMBER RANK QTY DESCRIPTION REMARKS
KEY No.
2- 1 QK1-4965-000 1 AC ADAPTER: 100V-240V 50/60HZ

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FIGURE 3 EXTERNAL COVERS & SCANNER UNIT

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LIST OF FIGURE 3

FIGURE &
PART NUMBER RANK QTY DESCRIPTION REMARKS
KEY No.
3- 1 QC1-9023-000 1 EMBLEM FOR JAPAN
FOR OTHER
1 QC1-9024-000 1 EMBLEM
REGIONS
2 QM3-3689-000 1 SCANNER UNIT
3 QM3-3684-000 1 ASF COVER UNIT
4 QM3-3682-000 1 SIDE COVER R UNIT
5 QM3-3683-000 1 SIDE COVER L UNIT
6 QC2-7841-000 1 STAY, SCANNER
7 QL2-2602-000 1 COVER, OPERATION PANEL CA, AU, ASA
7 QL2-2603-000 1 COVER, OPERATION PANEL JP
LAM, GB, EUM,
7 QL2-2604-000 1 COVER, OPERATION PANEL
EMB
7 QL2-2605-000 1 COVER, OPERATION PANEL HK, TW
7 QL2-2606-000 1 COVER, OPERATION PANEL CN
7 QL2-2607-000 1 COVER, OPERATION PANEL KR
8 QC2-7872-000 1 EDGE PANEL, OPERATION
9 QC2-7871-000 1 TOP COVER, OPERATION REAR
MIDDLE FRAME, OPERATION
10 QC2-7874-000 1
REAR

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FIGURE 4 DOCUMENT PRESSURE PLATE UNIT

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LIST OF FIGURE 4

FIGURE &
PART NUMBER RANK QTY DESCRIPTION REMARKS
KEY No.
4- 1 QM3-3692-000 1 DOCUMENT COVER UNIT
2 QC2-7863-000 2 HINGE
SHEET, DOCUMENT
3 QC2-9324-000 1
PRESSURE

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FIGURE 5 OPERATION PANEL UNIT

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LIST OF FIGURE 5

FIGURE &
PART NUMBER RANK QTY DESCRIPTION REMARKS
KEY No.
5- 1 QC2-7873-000 1 GUIDE, LIGHT
2 QC2-7870-000 1 FRAME, PANEL
3 QC2-7919-000 1 KEY, ARROW
4 QC2-7878-000 1 KEY, OK
5 QC2-7879-000 1 JOG WHEEL
6 QC2-7877-000 1 KEY, POWER
7 QC2-7876-000 1 KEY, START
8 QC2-8026-000 1 BASE, JOG WHEEL
9 QM3-3709-000 1 PANEL BOARD ASS'Y
10 QM3-3696-000 1 LCD UNIT
11 QC2-9308-000 1 LABEL, PRODUCT NAME MP540
11 QC2-9309-000 1 LABEL, PRODUCT NAME MP545
12 QC2-7885-000 1 WINDOW, LCD
13 QC2-7882-000 1 COVER, LCD FRONT
14 QC2-7886-000 1 HINGE, LCD L
15 QC2-7887-000 1 HINGE, LCD R
16 QL2-2609-000 1 LCD CABLE ASS'Y
17 QC2-7883-000 1 COVER, LCD TOP
18 QC2-7884-000 1 EDGE PANEL, LCD

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FIGURE 6 MAIN CASE & FRONT DOOR UNIT

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LIST OF FIGURE 6

FIGURE &
PART NUMBER RANK QTY DESCRIPTION REMARKS
KEY No.
6- 1 QM3-3641-000 1 REAR GUIDE UNIT
2 QC2-7844-000 1 CASE, MAIN
3 QM3-3681-000 1 FRONT DOOR UNIT
4 QM3-3694-000 1 SUB CASE UNIT
5 QC2-7925-000 1 SHEET, PE BIND

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FIGURE 7 BOTTOM CASE & INK ABSORBER

(39/58)
LIST OF FIGURE 7

FIGURE &
PART NUMBER RANK QTY DESCRIPTION REMARKS
KEY No.
7- 1 QM3-3711-000 1 FRONT DOOR LINK UNIT
2 QM3-4278-000 1 DC HARNESS ASS'Y
3 QC2-7654-000 1 GEAR, PICK UP SHAFT
4 QM3-3644-000 1 PICK UP ARM UNIT
5 QY5-0239-000 1 ABSORBER KIT
6 QC2-7908-000 1 CASE, BOTTOM

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FIGURE 8 LOGIC BOARD ASS’Y & PE SENSOR BOARD ASS’Y

(41/58)
LIST OF FIGURE 8

FIGURE &
PART NUMBER RANK QTY DESCRIPTION REMARKS
KEY No.
8- 1 QK1-4512-000 1 CABLE, CARD SLOT
2 QK1-5002-000 1 CABLE, PICTBRIDGE
3 QC2-8523-000 1 HOLDER, CORE
4 QC2-7850-000 1 PANEL, CARD
5 QM3-3708-000 1 CARD BOARD ASS'Y
6 QM3-4467-000 1 PICTBRIDGE BOARD UNIT
7 QM3-3707-000 1 LOGIC BOARD ASS'Y
8 QM3-4451-000 1 PE SENSOR BOARD ASS'Y
9 QK1-4835-000 1 CABLE, PE SENSOR
10 QK1-5034-000 1 CABLE, LF ENCODER
11 QK1-4815-000 1 CABLE, PANEL
12 QC2-7921-000 1 FRONT COVER, MIDDLE

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FIGURE 9 SHEET FEED UNIT

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LIST OF FIGURE 9

FIGURE &
PART NUMBER RANK QTY DESCRIPTION REMARKS
KEY No.
9- 1 QM3-3633-000 1 ASF UNIT
2 QL2-2529-000 1 PAPER FEED ROLLER ASS'Y
3 QM3-3610-000 1 CASSETTE FEED GUID UNIT
4 QM3-4757-000 1 PAPER GUIDE UNIT

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FIGURE 10 CARRIAGE UNIT & PRESSURE ROLLER UNIT

(45/58)
LIST OF FIGURE 10

FIGURE &
PART NUMBER RANK QTY DESCRIPTION REMARKS
KEY No.
10- 1 QC2-7783-000 1 FILM, TIMING SLIT STRIP
2 QM3-3598-000 1 CARRIAGE UNIT
3 QL2-2528-000 1 PULLEY HOLDER UNIT
4 QK1-1500-000 1 MOTOR, CARRIAGE
5 QM3-3614-000 1 PRESSURE ROLLER ASS'Y

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FIGURE 11 PLATEN UNIT & SPUR UNIT

(47/58)
LIST OF FIGURE 11

FIGURE &
PART NUMBER RANK QTY DESCRIPTION REMARKS
KEY No.
11- 1 QC2-7526-000 1 BELT, PAPER FEED
2 QL2-2525-000 1 LF ROLLER ASS'Y
3 QC2-7667-000 1 BUSHING, PAPER FEED ROLLER
4 QC2-7765-000 1 FILM, TIMING SLIT DISK FEED
5 QM3-3618-000 1 PLATEN/EJECT ROLLER UNIT
6 QC2-7671-000 1 ABSORBER, INK
7 QM3-3617-000 1 SPUR UNIT

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FIGURE 12 PURGE DRIVE SYSTEM UNIT & SWITCH SYSTEM UNIT

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LIST OF FIGURE 12

FIGURE &
PART NUMBER RANK QTY DESCRIPTION REMARKS
KEY No.
12- 1 QM3-3619-000 1 PURGE DRIVE SYSTEM UNIT
2 QM3-3651-000 1 PURGE MOTOR UNIT
3 QM3-4449-000 1 MOTOR MULTI HARNESS ASS'Y
PAPER FEED RELAY HANESS
4 QM3-4453-000 1
ASS'Y
5 QM3-5094-000 1 SWITCH SYSTEM UNIT
6 QK1-3849-000 1 MOTOR, PAPER FEED
7 QM3-4445-000 1 LF MOTOR HARNESS ASS'Y
8 QC2-7682-000 1 GEAR, IDLER

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FIGURE 13 OPTION & CONSUMABLES

(51/58)
LIST OF FIGURE 13

FIGURE &
PART NUMBER RANK QTY DESCRIPTION REMARKS
KEY No.
13- 1 NPN 1 BLACK INK TANK CLI-221BK CONSUMABLES
NPN 1 MAGENTA INK TANK CLI-221M CONSUMABLES
NPN 1 YELLOW INK TANK CLI-221Y CONSUMABLES
NPN 1 BLACK INK TANK PGI-220BK CONSUMABLES
NPN 1 CYAN INK TANK CLI-221C CONSUMABLES
2 NPN 1 BLACK INK TANK CLI-821BK CONSUMABLES
NPN 1 MAGENTA INK TANK CLI-821M CONSUMABLES
NPN 1 YELLOW INK TANK CLI-821Y CONSUMABLES
NPN 1 BLACK INK TANK PGI-820BK CONSUMABLES
NPN 1 CYAN INK TANK CLI-821C CONSUMABLES
3 NPN 1 BLACK INK TANK CLI-521BK CONSUMABLES
NPN 1 MAGENTA INK TANK CLI-521M CONSUMABLES
NPN 1 YELLOW INK TANK CLI-521Y CONSUMABLES
NPN 1 BLACK INK TANK PGI-520BK CONSUMABLES
NPN 1 CYAN INK TANK CLI-521C CONSUMABLES
4 NPN 1 BLACK INK TANK BCI-321BK CONSUMABLES
NPN 1 MAGENTA INK TANK BCI-321M CONSUMABLES
NPN 1 YELLOW INK TANK BCI-321Y CONSUMABLES
NPN 1 BLACK INK TANK BCI-320PGBK CONSUMABLES
NPN 1 CYAN INK TANK BCI-321C CONSUMABLES

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FIGURE 14 TOOL

(53/58)
LIST OF FIGURE 14

FIGURE &
PART NUMBER RANK QTY DESCRIPTION REMARKS
KEY No.
T- 1 QY9-0057-000 1 LUBE, FLOIL KG107A, OIL

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REFERENCE PRINTER UNIT

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 SCREW & WASHER LIST

FIGURE &
PART NUMBER RANK QTY DESCRIPTION REMARKS
KEY No.
S- 1 XB4-7300-809 SCREW, TAP, BINDING HEAD, M3X8
2 XA9-1756-000 SCREW, TP, M3X8
3 XB4-7300-805 SCREW, TP, BH3X8
4 XB1-2300-405 SCREW, MACH.BH, M3X4
5 XA9-1752-000 SCREW, TAP, WASHER HEAD, M3X12
6 XB1-2300-605 SCREW, MACHINE, M3X6
7 XA9-1915-000 SCREW, SPRING W WASHER M3X10
8 XB6-7300-605 SCREW, MACHINE, TP, M3X6
9 XB4-7300-605 SCREW, BH M3X6
10 XA9-1783-000 SCREW, BINDING HEAD M2.6X3.5

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 NUMERICAL INDEX

FIGURE FIGURE
PART
PART NUMBER & DESCRIPTION & DESCRIPTION
NUMBER
KEY No. KEY No.
QC1-9023-000 3- 1 EMBLEM QK1-0776-000 1- 3 CORD, POWER
QC1-9024-000 3- 1 EMBLEM QK1-1500-000 10- 4 MOTOR, CARRIAGE
QC2-7526-000 11- 1 BELT, PAPER FEED QK1-2017-000 1- 3 CORD, POWER
QC2-7654-000 7- 3 GEAR, PICK UP SHAFT QK1-3048-000 1- 3 CORD, POWER
QC2-7667-000 11- 3 BUSHING, PAPER FEED ROLLER QK1-3761-000 1- 3 CORD, POWER
QC2-7671-000 11- 6 ABSORBER, INK QK1-3849-000 12- 6 MOTOR, PAPER FEED
QC2-7682-000 12- 8 GEAR, IDLER QK1-4512-000 8- 1 CABLE, CARD SLOT
QC2-7765-000 11- 4 FILM, TIMING SLIT DISK FEED QK1-4815-000 8- 11 CABLE, PANEL
QC2-7783-000 10- 1 FILM, TIMING SLIT STRIP QK1-4835-000 8- 9 CABLE, PE SENSOR
QC2-7841-000 3- 6 STAY, SCANNER QK1-4965-000 2- 1 AC ADAPTER: 100V-240V 50/60HZ
QC2-7844-000 6- 2 CASE, MAIN QK1-5002-000 8- 2 CABLE, PICTBRIDGE
QC2-7850-000 8- 4 PANEL, CARD QK1-5034-000 8- 10 CABLE, LF ENCODER
QC2-7863-000 4- 2 HINGE QL2-2525-000 11- 2 LF ROLLER ASS'Y
QC2-7870-000 5- 2 FRAME, PANEL QL2-2528-000 10- 3 PULLEY HOLDER UNIT
QC2-7871-000 3- 9 TOP COVER, OPERATION REAR QL2-2529-000 9- 2 PAPER FEED ROLLER ASS'Y
QC2-7872-000 3- 8 EDGE PANEL, OPERATION QL2-2602-000 3- 7 COVER, OPERATION PANEL
QC2-7873-000 5- 1 GUIDE, LIGHT QL2-2603-000 3- 7 COVER, OPERATION PANEL
MIDDLE FRAME, OPERATION QL2-2604-000 3- 7 COVER, OPERATION PANEL
QC2-7874-000 3- 10
REAR QL2-2605-000 3- 7 COVER, OPERATION PANEL
QC2-7876-000 5- 7 KEY, START QL2-2606-000 3- 7 COVER, OPERATION PANEL
QC2-7877-000 5- 6 KEY, POWER QL2-2607-000 3- 7 COVER, OPERATION PANEL
QC2-7878-000 5- 4 KEY, OK QL2-2609-000 5- 16 LCD CABLE ASS'Y
QC2-7879-000 5- 5 JOG WHEEL QM3-3598-000 10- 2 CARRIAGE UNIT
QC2-7882-000 5- 13 COVER, LCD FRONT QM3-3610-000 9- 3 CASSETTE FEED GUID UNIT
QC2-7883-000 5- 17 COVER, LCD TOP QM3-3614-000 10- 5 PRESSURE ROLLER ASS'Y
QC2-7884-000 5- 18 EDGE PANEL, LCD QM3-3617-000 11- 7 SPUR UNIT
QC2-7885-000 5- 12 WINDOW, LCD QM3-3618-000 11- 5 PLATEN/EJECT ROLLER UNIT
QC2-7886-000 5- 14 HINGE, LCD L QM3-3619-000 12- 1 PURGE DRIVE SYSTEM UNIT
QC2-7887-000 5- 15 HINGE, LCD R QM3-3633-000 9- 1 ASF UNIT
QC2-7908-000 7- 6 CASE, BOTTOM QM3-3641-000 6- 1 REAR GUIDE UNIT
QC2-7919-000 5- 3 KEY, ARROW QM3-3644-000 7- 4 PICK UP ARM UNIT
QC2-7921-000 8- 12 FRONT COVER, MIDDLE QM3-3651-000 12- 2 PURGE MOTOR UNIT
QC2-7925-000 6- 5 SHEET, PE BIND QM3-3681-000 6- 3 FRONT DOOR UNIT
QC2-7932-000 1- 4 LABEL, PANEL QM3-3682-000 3- 4 SIDE COVER R UNIT
QC2-8026-000 5- 8 BASE, JOG WHEEL QM3-3683-000 3- 5 SIDE COVER L UNIT
QC2-8523-000 8- 3 HOLDER, CORE QM3-3684-000 3- 3 ASF COVER UNIT
QC2-9308-000 5- 11 LABEL, PRODUCT NAME QM3-3685-000 1- 1 CASSETTE UNIT
QC2-9309-000 5- 11 LABEL, PRODUCT NAME QM3-3689-000 3- 2 SCANNER UNIT
QC2-9324-000 4- 3 SHEET, DOCUMENT PRESSURE QM3-3692-000 4- 1 DOCUMENT COVER UNIT
QH2-2716-000 1- 3 CORD, POWER QM3-3694-000 6- 4 SUB CASE UNIT

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QH2-2719-000 1- 3 CORD, POWER QM3-3696-000 5- 10 LCD UNIT

FIGURE FIGURE
PART
PART NUMBER & DESCRIPTION & DESCRIPTION
NUMBER
KEY No. KEY No.
QM3-3707-000 8- 7 LOGIC BOARD ASS'Y WT3-5156-000 1- 3 CORD, POWER
QM3-3708-000 8- 5 CARD BOARD ASS'Y WT3-5160-000 1- 3 CORD, POWER
QM3-3709-000 5- 9 PANEL BOARD ASS'Y SCREW, TAP, WASHER HEAD,
XA9-1752-000 S- 5
QM3-3711-000 7- 1 FRONT DOOR LINK UNIT M3X12

QM3-4278-000 7- 2 DC HARNESS ASS'Y XA9-1756-000 S- 2 SCREW, TP, M3X8

QM3-4445-000 12- 7 LF MOTOR HARNESS ASS'Y XA9-1783-000 S- 10 SCREW, BINDING HEAD M2.6X3.5

QM3-4449-000 12- 3 MOTOR MULTI HARNESS ASS'Y SCREW, SPRING W WASHER

XA9-1915-000 S- 7
QM3-4451-000 8- 8 PE SENSOR BOARD ASS'Y M3X10

PAPER FEED RELAY HANESS XB1-2300-405 S- 4 SCREW, MACH.BH, M3X4

QM3-4453-000 12- 4
ASS'Y XB1-2300-605 S- 6 SCREW, MACHINE, M3X6

QM3-4467-000 8- 6 PICTBRIDGE BOARD UNIT XB4-7300-605 S- 9 SCREW, BH M3X6

QM3-4757-000 9- 4 PAPER GUIDE UNIT XB4-7300-805 S- 3 SCREW, TP, BH3X8

QM3-5094-000 12- 5 SWITCH SYSTEM UNIT SCREW, TAP, BINDING HEAD,

XB4-7300-809 S- 1
QY5-0239-000 7- 5 ABSORBER KIT M3X8

QY6-0073-000 1- 2 PRINT HEAD XB6-7300-605 S- 8 SCREW, MACHINE, TP, M3X6

QY9-0057-000 T- 1 LUBE, FLOIL KG107A, OIL

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